DOWNLOAD PDF : Hitachi ZX 300LC-7 300LCN-7 Hydraulic Excavator Troubleshooting Technical Manual PNTT

PART NO.

TTDD650-EN-00

ZX300LC-7 • 300LCN-7 HYDRAULIC EXCAVATOR

Technical Manual Troubleshooting

TECHNICAL MANUAL TROUBLESHOOTING

ZX

300LC-7 300LCN-7

Hydraulic Excavator

URL:http://www.hitachi-c-m.com

TTDD650-EN-00

PRINTED IN JAPAN (K) 2019, 11

Service Manual consists of the following separate Part No. Technical Manual (Operational Principle) : Vol. No.TODD650-EN Technical Manual (Troubleshooting) : Vol. No.TTDD650-EN Workshop Manual : Vol. No.WDD650-EN Engine Manual : Vol. No.ETDD750-EN, EWDD750-EN

COPYRIGHT(C)2019 Hitachi Construction Machinery Co., Ltd. Tokyo, Japan All rights reserved

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. ● Be sure to thoroughly read this manual for correct product information and service procedures. ● If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy this form for usage.)

•

Service Material Development Center Hitach Construction Machinery Co., Ltd.

•

TEL: 81-29-832-9673

•

FAX: 81-29-831-1162

• E-mail: HCM-TIC-GES@hitachi-kenki.com 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.

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, the Workshop Manual and the Engine Manual. ● 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.

● 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 Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine •

Operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures

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

Technical Manual

1

Section Number

3

Group Number

5

Consecutive Page Number for Each Group

● Workshop Manual: W 1-3-2-5 W

Workshop Manual

1

Section Number

3

Group Number

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IN-1

INTRODUCTION 2

Sub Group Number

5

Consecutive Page Number for Each Group

Trademark AdBlue® is a registered trademark of the Verband der Automobilindustrie e.V. (VDA).

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.

WARNING This is the safety alert symbol. When you see this symbol, be alert to the potential for personal injury. Never fail to follow the safety instructions prescribed along with the safety alert symbol. The safety alert symbol is also used to draw attention to component/part weights. To avoid injury and damage, be sure to use appropriate lifting techniques and equipment when lifting heavy parts.

CAUTION Indicates potentially hazardous situation which could, if not avoided, result in personal injury or death. This is also provided before the indication of mass to draw attention to safety during handling of the machine.

IMPORTANT Indicates a situation which, if not conformed to the instructions, could result in damage to the machine. This header is given to matters that are important in terms of operation and management.

NOTE Indicates supplementary technical information or know-how.

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 Length

To Convert From

Into

Multiply By

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

0.10197

Pressure

MPa

kgf/cm2

10.197

MPa

psi

145.0

Volume

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IN-2

INTRODUCTION Quantity Power

To Convert From

Into

Multiply By

kW

PS

1.360

kW

HP

1.341

Temperature

°C

°F

°C×1.8+32

Velocity

km/h

mph

0.6214

min-1

rpm

1.0

L/min

US gpm

0.2642

mL/rev

cc/rev

1.0

Flow rate

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IN-3

INTRODUCTION MEMO

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IN-4

SYMBOL AND ABBREVIATION Symbol and Abbreviation Symbol/Abbreviation

Name

Meaning

TO

Technical manual (Operational Technical manual (Operational principle). principle)

TT

Technical manual (Trouble­ shooting)

Technical manual (Troubleshooting).

T/M

Technical manual

Technical manual.

W, W/M

Workshop manual

Workshop Manual (Mounting/dismounting, disassembly and assembly of devices).

MC

Main Controller

Main Controller. MC controls the engine, pumps, and valves ac­ cording to the machine operation condition.

ECM

Engine Control Module

Engine Controller. ECM controls the fuel injection amount and others according to the machine operation condition.

VGS

Variable Geometry System con­ Variable Turbocharger Controller. VGS is a system for efficiently troller supercharging even when the engine speed is low and the ex­ haust energy is low. Through adjustment of the nozzle open­ ing of the turbine housing, the turbine rotation speed is opti­ mized, the low-speed torque and acceleration are improved, and the power consumption and PM are reduced.

GSM

Global System for Mobile com­ Communication Controller. GSM is one of wireless communica­ munications controller tion methods and is used in over 100 countries centering around Europe and Asia and serves as the de facto global standard for mobile phones.

GPS

Global Positioning System

Global Positioning System.

CAN

Controller Area Network

CAN communication. CAN is ISO Standards of the serial com­ munication protocol (rules).

A/C

Air Conditioner

Air conditioner.

OP, OPT

Option

Optional item.

MPDr.

Maintenance Pro Dr.

MPDr. is software for conducting troubleshooting, monitoring, and adjustment.

A/I

Auto-Idle

Auto-Idle.

WU

Warming-Up

Warming up.

Li

Low (Slow) Idle

Slow Idle Engine Speed

ATT

Attachment

Attachment. In this document, it refers to an optional part such as breaker, pulverizer, and crusher.

HI, Hi

High

Travel fast speed position.

LO, Lo

Low

Travel slow speed position.

DPF

Diesel Particulate Filter

DPF (Diesel Particulate Filter) is a filter to remove fine particles including harmful substances in the exhaust gas of the diesel engine. Exhaust fine particle removing device.

DPD

Diesel Particulate Diffuser

DPD (Diesel Particulate Diffuser) is an exhaust gas purifying device (one type of DPF) that removes PM (particulate matter) in the exhaust gas of the diesel engine. DPD collects and filters PM in the exhaust gas using a ceramic filter and, when the PM accumulation amount has become large, incinerates the accu­ mulated PM at once and regenerates the filter.

DOC

Diesel Oxidation Catalyst

Oxidation catalyst for diesel. DOC oxidizes the unburnt fuel and raises the exhaust temperature.

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SY-1

SYMBOL AND ABBREVIATION Symbol/Abbreviation

Name

Meaning

CSF

Catalyzed Soot Filter

Filter. The filter collects PM, and removes it by burning it by means of high-temperature exhaust gas whose temperature has been raised by oxidation catalyst. The catalyst is also ap­ plied on the filter, thus accelerating burning of PM.

PM

Particulate Matter

Particulate matter.

EGR

Exhaust Gas Recirculation

The EGR re-circulates a part of exhaust gas into intake mani­ fold and mixes it with intake-air to lower the burn temperature and suppress the generation of NOx (nitrogen oxide).

ML

Moment Limiter

ML crane.

HRV

Hose Rupture Valve

Hose rupture valve.

LLC

Long Life Coolant

Coolant.

SCR

Selective Catalytic Reduction

The urea SCR system injects DEF to NOx in the exhaust of en­ gine to remove NOx.

DCU

Dosing Control Unit

Urea SCR System Controller. DCU controls the DEF injection amount and others according to the machine operation condi­ tion.

S/M

Supply Module

DEF supply module. The DEF supply module supplies the pres­ surized DEF to dosing module (D/M). When the key switch is set to the OFF position, it sucks DEF from DEF circuit to return it.

D/M

Dosing Module

Dosing Module. The dosing module (D/M) injects DEF into the exhaust piping according to the signal from DCU.

NOx

Nitrogen Oxide

Nitrogen oxide.

DEF

Diesel Exhaust Fluid

Urea water. This is urea water with a concentration of 32.5% that is specified in ISO 22241.

PLCU

Performance Level Control Unit PLCU is a controller to control AFL.

PBLI

Push Button Low Idle

Push button low idle. PBLI is described as audio mute/onetouch idle switch in this manual.

AFL

Auxiliary Function Lever

AUX function lever.

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SY-2

CONTRASTING LIST OF PART NAME Contrasting List of Part Name between Technical Manual and Parts Catalog Part name in technical manual

Part name in parts catalog

Part No.

Fuel Sensor (float)

FLOAT

4660782

Hydraulic Oil Temperature Sensor

SENSOR

4697482

MAF/Intake-Air Temperature Sensor

SENSOR

4664861

Ambient Temperature Sensor

SENSOR

4405815

Coolant Temperature Sensor

SENSOR;THERMO

YA00010305

Common Rail Pressure Sensor

RAIL ASM; COMMON

8982446690

Fuel Temperature Sensor

SENSOR;FUEL TEMP

8980235810

Crank Speed Sensor

SENSOR

YA00010304

Engine Oil Pressure Sensor

SENSOR;PRES

4657942

EGR Cooler Outlet Temperature Sensor

SENSOR;THERMO

YA00001667

Intake Manifold Temperature Sensor

SENSOR;THERMO

YA00011515

Boost Pressure/Temperature Sensor

SENSOR;PRES

YA00001668

EGR Cooler Inlet Temperature Sensor

SENSOR;THERMO

YA00001666

Cam Angle Sensor

SENSOR;ANGLE

YA00011513

Differential Pressure Sensor

SENSOR;PRESSURE

YA00054794

Upstream NOx Sensor

SENSOR;NOX

YA00001705

Downstream NOx Sensor

SENSOR;NOX

YA00001705

DOC Outlet Exhaust Temperature Sensor

SENSOR;THERMO

YA00009436

DOC Inlet Exhaust Temperature Sensor

SENSOR;THERMO

YA00009435

SCR Exhaust Temperature Sensor

SENSOR;THERMO

YA00001706

Pump 1 Delivery Pressure Sensor

SENSOR;PRESSURE

4436271

Pump 2 Delivery Pressure Sensor

SENSOR;PRESSURE

4436271

Pump 3 Delivery Pressure Sensor

SENSOR;PRESSURE

4436271

Pump 1 Control Pressure Sensor

SENSOR;PRES.

4436536

Pump 2 Control Pressure Sensor

SENSOR;PRES.

4436536

Pump 3 Control Pressure Sensor

SENSOR;PRES.

4436536

Arm 1 Roll-In Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Arm 2 Roll-In Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Arm Roll-Out Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Bucket Roll-In Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Bucket Roll-Out Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Boom Raise Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Auxiliary 1 Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Auxiliary 2 Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Swing Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Travel Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

Front Pilot Pressure Sensor

SENSOR;PRESSURE

4436535

DEF Quality Sensor

UNIT;UREA

YA00050269

DEF Tank Level Sensor

UNIT;UREA

YA00050269

DEF Tank Temperature Sensor

UNIT;UREA

YA00050269

TTDD650-EN-00(18/11/2019)

CO-1

CONTRASTING LIST OF PART NAME Part name in technical manual

Part name in parts catalog

Part No.

Engine Oil Monitoring Sensor

SENSOR;OIL

YA00046690

Hydraulic Oil Monitoring Sensor

SENSOR;OIL

YA00052887

TTDD650-EN-00(18/11/2019)

CO-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 injury to persons.

•

Follow recommended precautions and safe operating practices.

SA-2644 ja

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.

● CAUTION also calls attention to safety message in this manual. ● 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. ●

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

TTDD650-EN-00(18/11/2019)

SA-1

SAFETY

SA-632 en_GB

Follow Safety Instructions ● Carefully read and follow all safety instructions on the machine and in this manual. ● Safety signs should be readable 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. ● Only trained, qualified and authorized personnel should operate the machine.

SA-003 ja

● 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 machine and will void Hitachi Warranty.

•

Never attempt to modify or disassemble the inlet/exhaust parts of the engine and the aftertreatment device. Avoid shocks to the aftertreatment device, such as striking or dropping objects onto the device. Failure to do so may affect the exhaust gas purifying function, possibly damaging it or lowering its performance.

● Attachments and/or optional parts or equipment not matching machine characteristics and -capacities may cause injuries to persons, machine trouble and/or damage to material. If you are not sure of the suitability of attachments, optional parts, and/or equipment, contact your authorized Hitachi dealer. The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures when working with machines. However, it is impossible to cover every hazardous situation you may encounter in these safety messages. Adequate measures resulting from job site risk assessment allow safe operation of machines. 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.

TTDD650-EN-00(18/11/2019)

SA-2

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 ja

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

SA-438 ja

• Respirator or filter mask Be sure to wear the correct equipment and clothing for the job.

•

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.

TTDD650-EN-00(18/11/2019)

SA-3

SAFETY Protect Against Noise ● Prolonged exposure to loud noise can cause, stress, fatigue and impairment or loss of hearing.

•

Wear a suitable hearing protective device such as earmuffs or earplugs to protect against noise.

SA-434 ja

Inspect Machine ● Inspect your machine carefully each day or shift before you start operating it to ensure the machine is in full working order.

•

During the inspection be sure to cover all points described in the "Inspect Machine Daily Before Starting" section in the operator's manual.

SA-435 ja

TTDD650-EN-00(18/11/2019)

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 a control such as a pedal is operated with dirt and/or oil on the soles of the operator's work boots, the operator's foot may slip off the pedal, potentially resulting in a personal accident. ● Keep your cabin clean. Parts, tools, soil, stones, cans or lunch box or other obstacles may fold up or turn over, potentially blocking control levers or pedals which may result in unintended movement of the machine with the risk of accidents. 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. ● After using the ashtray, always cover it to extinguish the match and/or tobacco. ● Do not leave cigarette lighters in the cab. When the temperature in the cab increases, the lighter may explode. ● If a floor mat is used, use an original Hitachi floor mat specific to the machine model. If a floor mat other than original Hitachi mat is used, it may be displaced and interfere with pedal movement during operation, potentially resulting in serious injury or death.

Use Handrail and Steps ● Falling is one of the major causes of injury.

•

When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails.

•

Do not use any controls as hand-holds.

•

Never jump on or off the machine. Never mount or dismount a moving machine.

•

Before getting on or off the machine, check the condition of the steps and handrails for sticking of slippery material like grease or mud. Thoroughly remove such material if stuck.

•

Repair any damage to the steps and/or handrails before using the machine. Retighten loose bolts.

•

Never get on and off the machine with tools or other items in your hands.

TTDD650-EN-00(18/11/2019)

SA-439 ja

SA-5

SAFETY 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 loss of focus and maloperation.

•

The seat should be adjusted whenever the operator of the machine changes.

•

The operator should be able to fully depress the pedals in any direction and to operate the control levers in any direction while his back remains against the seat back.

•

If not, adjust the seat and check again.

•

Depending on the work, the seat may need to be moved forward or backward to improve visibility into the working area. Do not stand up from your seat while operating the machine.

•

Adjust the mirrors to maximize visibility into areas without direct visibility, in particular areas close to the machine.

For mirror adjustment, refer to the mirror adjustment section of this manual.

SA-378 ja

Ensure Safety Before Rising from or Leaving Operator's Seat ● Before rising from the operator's seat to e. g. open or close a window or to adjust the seat position, be sure to first lower the front attachment to the ground and move the pilot 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, potentially resulting in serious injury or death. ● Before leaving the machine, be sure to first lower the front attachment to the ground and move the pilot shut-off lever to the LOCK position. Turn the key switch OFF to stop the engine. ● Before leaving the machine, close all windows, doors, and access covers and lock them.

Fasten Your Seat Belt ● 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.

•

If the machine should overturn, the seat belt keeps the operator within the safe zone provided by the cabin- or canopy structure. Failure to use the seat belt may result in the operator being injured, thrown from the cab and subsequently crushed by the overturning machine, potentially 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.

•

We recommend that the seat belt is replaced every three years regardless of its apparent condition.

SA-237 ja

TTDD650-EN-00(18/11/2019)

SA-6

SAFETY Move and Operate Machine Safely ● Be aware of bystanders.

•

Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine.

•

Always keep the travel alarm and horn in working condition (if equipped). It allows you to warn people when you plan to start moving the machine.

•

Use a signal person when moving, swinging, or operating the machine in confined areas. Coordinate hand signals before starting the machine.

•

Use appropriate illumination. Check that all lights are functioning correctly before operating the machine. If any faulty illumination is present, immediately repair it.

•

Ensure the cab door, windows, doors and covers are closed and securely locked.

•

Check the mirrors and the monitor in the cab for visibility.

Keep mirrors, camera lenses and the monitor display clean. Repair or replace any defective part(s).

Refer to Rear View Monitor section for information on cleaning the camera lenses and the monitor display.

SA-426 ja

Start the Engine Only from Operator's Seat ● Inappropriate engine starting procedures may cause the machine to run away, possibly resulting in serious injury or death.

•

Start the engine only while seated in the operator's seat.

•

Never start the engine while standing on the track or ground.

•

Do not start engine by shorting across starter terminals.

•

Before starting the engine, confirm that all control levers are in neutral position and the pilot shut-off lever in the LOCK position.

•

Before starting the engine, confirm the safety around the machine and sound the horn to alert bystanders.

SA-444 ja

TTDD650-EN-00(18/11/2019)

SA-7

SAFETY 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.

•

If battery is frozen, warm and defrost before use.

•

Failure to follow correct jump starting procedures could result in a battery explosion or a runaway machine.

SA-032 ja

Keep Riders off Machine ● Riders on machine are subject to injury such as being struck by foreign objects or being thrown off the machine.

•

Only the operator should be on the machine. Keep riders off.

•

Riders also distract the operator and obstruct the operator's view, resulting in the machine being operated in an unsafe manner.

SA-379 ja

TTDD650-EN-00(18/11/2019)

SA-8

SAFETY Precautions for Operations ● Perform job site risk assessment before starting operations.

•

Be sure to wear close fitting clothing and safety equipment appropriate for the job, when operating the machine.

•

Keep bystanders and obstacles clear of the area of machine operation.

Keep bystanders away from areas where there is danger, such as from flying objects.

Always be aware of the surroundings while operating.

When working in a confined 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 ja

TTDD650-EN-00(18/11/2019)

SA-9

SAFETY Perform Job Site Risk Assessment Beforehand ● Make a work plan. Use machines appropriate to the work and job site. ● 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. ● When working at the edge of an excavation or on a road shoulder, the machine could fall, possibly resulting in serious injury or death.

•

Reinforce ground, edges and road shoulders as necessary. Keep the machine well back from the edges of excavations and road shoulders.

SA-380 ja

● When working on an incline or on a road shoulder, employ a signal person as required. ● Confirm that your machine is equipped with a FOPS cab before working in areas where the possibility of falling stones or debris exist. ● 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. ● 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.

In case of a risk of cliff or bank collapsing, do not work In the area.

•

Soft ground may collapse when the machine is operated on it, possibly causing the machine to fall.

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. To reduce the risk of tipping over: •

Reduce the engine speed.

•

Select slow travel speed mode.

•

Operate the machine slowly and be cautious with machine movements.

TTDD650-EN-00(18/11/2019)

SA-10

M104-05-016 ja

SAFETY Install OPG Guard In case the machine is operated in areas where the possibility of falling stones or debris exist, equip the cabin with Hitachi OPG guards.

Consult your authorized dealer for installing the OPG guards.

In order not to impair operator protection: Replace damaged OPG guards. Never attempt to repair or modify a guard.

OPG

:

Operator Protective Guard

SA-490 ja

Restriction of Attachment Installation Do not install an attachment which exceeds the permissible weight for the concerning machine configuration. Take into account the additional weight of any payload.

Provide Signals for Jobs Involving Multiple Machines ● For jobs involving multiple machines, provide signals known and understood by all personnel involved. Also, appoint a signal person to coordinate the work. Make sure that all personnel obey the signal person's directions.

SA-481 ja

TTDD650-EN-00(18/11/2019)

SA-11

SAFETY Confirm Direction of Machine Travel ● Incorrect travel pedal/lever operation may result in serious injury or death.

•

Before travelling with the machine, confirm the position of the undercarriage in relation to the operator's station. Arrows on the inner side of the trackframe indicated the forward position of the undercarriage. If the travel motors are visible in front of the cab, the machine will move in opposite direction compared to lever/pedal movement.

SA-491 ja

TTDD650-EN-00(18/11/2019)

SA-12

SAFETY Drive Machine Safely ● Before driving the machine, always confirm that the travel levers/pedals direction corresponds to the direction you wish to drive.

•

Avoid traveling over obstructions. Soil, fragments of rocks, and/or metal pieces may scatter around the machine. Do not allow bystanders near the machine while traveling.

● Travelling on a slope may cause the machine to slip or overturn, possibly resulting in serious injury or death.

•

Never attempt to ascend or descend slopes steeper than 35 degrees.

•

Always fasten the seat belt.

•

When driving up or down a slope, keep the bucket facing the direction of travel, approximately 0.2 to 0.3 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.

SA-387 ja

SA-388 ja

SA-441 ja

SA-442 ja

TTDD650-EN-00(18/11/2019)

SA-13

SAFETY ● Avoid swinging the upperstructure on slopes. The machine may tip over. Before swinging, preferably travel to level ground before swinging the upperstructure. If swinging 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. ● Warm up the machine, including the hydraulic oil, before ascending steep slopes. If hydraulic oil has not warmed up sufficiently, necessary performance may not be available. ● Use a signal person when moving, swinging or operating the machine in confined spaces. Ensure mutual understanding of 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 (M) are in the rear, pushing down on the front of the travel pedals or pushing the levers forward moves the machine forward. An arrow-mark (1) is affixed on the inside surface of the side frame to indicate the machine forward direction.

M

● Select a travel route that is as flat as possible. Steer the machine as straight as possible, making small gradual changes in direction. ● Before traveling on them, confirm the strength of bridges and road shoulders, and reinforce if necessary.

M104-05-008-2 ja

● Use wood plates in order not to damage the road surface. Be careful of steering when operating on asphalt roads in summer. ● When crossing rail road tracks, use wood plates in order not to damage them. ● 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.

1

M178-03-001-2 ja

● When traveling on rough terrain, reduce engine speed.

Select slow travel speed. Slower speed will reduce the possiblility of damage to the machine. ● Avoid operations that may damage the track and undercarriage components. ● In winter time, always clean snow and ice from track shoes before loading and unloading the machine, to prevent the machine from slipping.

TTDD650-EN-00(18/11/2019)

SA-14

SAFETY Avoid Injury from Rollaway Accidents ● Do not try to enter a moving machine. Serious injury or death may result if you attempt to mount or stop a moving machine. ● To avoid rollaways: •

Park the machine on a level ground.

•

Position the machine to prevent rolling.

•

Park at a reasonable distance from other machines.

•

Lower the bucket or work tool to the ground. Thrust the bucket teeth into the ground if you must park on a slope.

•

Set the pilot shut-off lever to LOCK position.

•

Block both tracks.

SA-391 ja

SA-2273 ja

TTDD650-EN-00(18/11/2019)

SA-15

SAFETY Avoid Accidents from Reversing and Swing Operation ● If any person is present near the machine when reversing the machine or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death.

To avoid accidents: •

Before you reverse or swing the machine, be sure that no bystanders are IN THE WORK AREA. Always be alert for bystanders moving into the work area. Use the horn to warn bystanders before moving machine.

•

Use a signal person during reversing if your view is obstructed. Always keep the signal person in view.

•

Keep windows, mirrors, and lights clean and functional.

•

Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, adapt machine movements accordingly to maintain safe operation and use proper lighting.

SA-383 ja

SA-384 ja

TTDD650-EN-00(18/11/2019)

SA-16

SAFETY Keep People Clear from Working Area ● Bystanders in the vicinity of an operating machine may be hit severely by the swinging front attachment or counterweight, be caught by other objects, and/or be struck by flying objects, resulting in serious injury or death.

•

Set up barriers to keep bystanders away from areas where risk exist. Use appropriate measures to prevent anyone from entering the machine’s work area, e.g. setting up barriers.

•

Follow instructions and respect local regulations concerning segregation of persons and machines.

SA-386 ja

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 ja

TTDD650-EN-00(18/11/2019)

SA-17

SAFETY Avoid Undercutting ● Ensure stability of the ground before starting work. Keep sufficient clearance from the excavation to avoid change in stability of the ground, potentially causing it to slide away.

•

In order to be able to move the machine away from the edge of an excavation if the ground should collapse despite the precautions taken, always position the undercarriage perpendicular to the edge of the excavation with the travel motors at the rear.

•

If the ground starts to collapse and moving the machine away from the edge is not possible, lower the front attachment in such cases to minimize the risk of tip-over.

SA-488 ja

Avoid Tipping Fasten your seat belt Do not attempt to jump clear of a machine tipping over.

Machine will tip over faster than you can jump free --- Serious or fatal crushing injuries will result ● The danger of tipping is always present when operating on a slope, possibly resulting in serious injury or death.

To avoid tipping: •

Be extra careful before operating on a slope.

•

Prepare the operating area, allowing the machine to work on flat, level ground.

•

Keep the bucket low to the ground and close to the machine.

•

Reduce operating speeds and movements.

•

Avoid changing direction when traveling on slopes.

•

NEVER attempt to travel across a slope steeper than 15 degrees if crossing the slope is unavoidable.

SA-012 ja

● Be careful when working on frozen ground.

•

Temperature increases will cause the ground to become soft and make ground travel unstable.

SA-440 ja

TTDD650-EN-00(18/11/2019)

SA-18

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

SA-489 ja

Dig with Caution ● Accidental damaging of underground cables or gas lines may cause an electric shock, explosion and/or fire, possibly resulting in serious injury or death.

•

Before digging confirm the location of cables, gas lines, and water lines.

•

Respect the minimum distance required from cables, gas lines, and water lines.

•

If a fiber optic cable should be accidentally damaged, do not look into the end. Doing so may result in serious eye injury.

SA-382 ja

TTDD650-EN-00(18/11/2019)

SA-19

SAFETY Caution with an Overhead Obstacle ● If the front attachment or any other part of the machine hits an overhead obstacle, such as a bridge both the machine and the overhead obstacle may be damaged, and injury may result as well.

•

Take care to avoid hitting overhead obstacles with the attachment, boom, arm or cabin.

SA-389 ja

Avoid Power Lines ● Serious injury or death can result if the machine or front attachments are not kept at a safe distance from electric overhead lines.

•

When operating near an electric overhead 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 ja

TTDD650-EN-00(18/11/2019)

SA-20

SAFETY 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-2715 ja

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 lifting operations, be sure to comply with all local regulations.

•

Do not use damaged chains or frayed cables, slings, or ropes.

•

Before lifting, 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.

TTDD650-EN-00(18/11/2019)

SA-21

SA-014 ja

SAFETY Protect Against Flying Debris ● During hammer operation, debris from earth, rock or metal may fly in all directions, resulting in a serious injury or death.

•

When driving the connecting pins in or out, wear hard hat and face shield, goggle or safety glasses.

SA-432 ja

● During machine operation, debris from earth, rock or metal may fly off from the track and bucket, potentially resulting in a serious injury or death.

•

Ensure nobody is present in or around the work area while machine is operating.

SA-344 ja

● Falling of accumulated earth or dirt onto people may result in a serious injury or death.

•

Before performing maintenance or inspection under carriage, remove accumulated debris.

SA-527 ja

TTDD650-EN-00(18/11/2019)

SA-22

SAFETY Park Machine Safely •

To avoid accidents: •

Park machine on a firm, level surface.

•

Lower bucket to the ground.

•

Set pilot shut-off lever to the LOCK position.

•

Turn auto-idle switch OFF.

•

Run engine at slow idle speed without load for 5 minutes.

•

Turn key switch to OFF to stop engine.

•

Remove the key from the key switch.

•

Close windows, roof vent, and cab door.

•

Lock all access doors and compartments.

SA-2590 ja

SA-390 ja

TTDD650-EN-00(18/11/2019)

SA-23

SAFETY 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.

•

Discharge static electricity before fueling.

● All fuels, most lubricants, and some coolants are flammable.

•

Store flammable fluids well away from fire hazards.

•

Do not incinerate or puncture pressurized containers.

•

Do not store oily rags on the machine; they can ignite and burn spontaneously.

•

Securely tighten the fuel and oil filler caps.

SA-018 ja

SA-019 ja

TTDD650-EN-00(18/11/2019)

SA-24

SAFETY Transport Safely •

Take extra care when loading or unloading the machine onto or from a truck or trailer as the machine may turn over.

•

Observe the related regulations and rules for safe transportation.

•

Confirm length, width, height and weight of the machine and select an appropriate truck or trailer for the machine to be transported.

•

Be sure to use a signal person.

Always follow the following precautions for loading or unloading: SA-395 ja 1. Place machine and truck or trailer on solid and level ground.

2. Always use a ramp or deck strong enough to support the machine weight to drive on or from a truck or trailer.

3. Fasten operator’s seat belt before starting driving the machine.

4. Turn auto-idle switch OFF. 5. Always select the slow speed mode with the travel mode switch.

6. To avoid instability, never load or unload the machine onto or off a truck or trailer using the front attachment functions when driving up or down the ramp.

7. Never steer the machine while on the ramp. If the traveling direction must be changed while on the ramp, unload the machine from the ramp, reposition the machine on the ground, then try loading again.

8. At the top end of the ramp where it meets the flatbed, there is a change in angle. Take care when traveling over it.The machine will tip forward or backward.

9. Place blocks in front of and behind the tires of the machine, if applicable. Securely fasten the machine to the truck or trailer deck with wire ropes.

Be sure to further follow the details described in the "TRANSPORTING" section.

•

TTDD650-EN-00(18/11/2019)

SA-25

SAFETY Practice Maintenance Safely ● 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 the engine is running.

•

Keep hands, feet and clothing away from moving 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 low idle speed without load for 5 minutes.

5. Turn the key switch to OFF to stop engine.

6. Relieve the pressure in the hydraulic system according to the pressure relief procedure.

(Refer to chapter-5 "Guide to Releasing Pressure in the Hydraulic Circuit".)

7. Remove the key from the key switch.

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

9. Set pilot shut-off lever to the LOCK position.

10. Allow the engine to cool.

SA-028 ja

● 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. ● Inspect the machine periodically in accordance with the "MAINTENANCE" chapter of this manual and repair or replace as necessary. ● 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 or gasoline to clean parts or surfaces.

SA-527 ja

● Turn the battery disconnect switch to OFF before maintaining the electrical systems or performing welding on the machine. ● 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 ja

TTDD650-EN-00(18/11/2019)

SA-26

SAFETY 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.

SS2045102-4 ja

TTDD650-EN-00(18/11/2019)

SA-27

SAFETY 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 ja

Stay Clear of Moving Parts ● Entanglement in moving parts can cause serious injury.

•

To prevent accidents, do not remove guards to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts.

SA-026 ja

SA-2294 ja

TTDD650-EN-00(18/11/2019)

SA-28

SAFETY 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.

•

Do not attempt to remove the valve stop plate.

•

As pieces may fly off, be sure to keep body and face away from valve.

•

Never attempt to disassemble the track adjuster.

Inadvertent disassembling of the track adjuster may cause the parts such as a spring to fly off, possibly resulting in severe injury or death.

SA-344 ja

● 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.

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 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 bystanders away from attachment storage areas.

SA-034 ja

TTDD650-EN-00(18/11/2019)

SA-29

SAFETY Prevent Burns Hot spraying fluids: ● After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, expansion 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 expansion tank cap until the engine is cooled down. When opening, turn the cap slowly to the first stop. Allow all pressure to be released before removing the cap.

SA-039 ja

The hydraulic oil tank is pressurized. Push the pressure release button on the tank cap to release pressure before carefully removing the cap. 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 down before starting any maintenance or inspection work.

SA-225 ja

TTDD650-EN-00(18/11/2019)

SA-30

SAFETY Replace Rubber Hoses Periodically ● Rubber hoses under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration of rubber hoses by inspection alone. Therefore: •

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, which may result in serious injury or death.

SA-019 ja

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 medical assistance immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result.

SA-031 ja

SA-292 ja

SA-044 ja

TTDD650-EN-00(18/11/2019)

SA-31

SAFETY Prevent Fires Check for Oil Leaks: ● Fuel, hydraulic oil and lubricant leaks can cause fires.

•

Check for oil leaks due to missing or loose clamps, kinked hoses, damaged 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.

SA-019 ja

Check for Short circuits: ● 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 damaged 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.

TTDD650-EN-00(18/11/2019)

SA-32

SAFETY Clean up Flammable Materials: ● Spilled fuel and oil, trash, grease, debris, accumulated dust (such as coal, wood, paper), and other flammable materials may cause fires.

•

Prevent fires by inspecting and cleaning the machine daily, in particular clean high temperature parts such as the exhaust outlet and muffler.

•

Do not wrap high temperature parts such as a muffler or exhaust pipe with oil absorbents.

•

Do not store oily cloths on the machine as they are vulnerable to catching fire.

•

Keep flammable materials away from sparks, hot surfaces, exhaust gases or open flames.

•

Wire screens may be provided for openings in the engine compartment covers to prevent larger flammable materials such as dead leaves from entering. However, small flammable materials which can pass through the wire screen may cause fires. Check and clean the machine every day and immediately remove accumulated flammable materials.

Check Key Switch: ● If a fire breaks out, failure to stop the engine will escalate the fire, hampering fire fighting.

•

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

2. Turn the key switch to the OFF position to confirm that the engine stops.

•

If any abnormalities are found, be sure to repair them before operating the machine.

Check Heat Shields: ● Damaged or missing heat shields may cause fires.

•

Damaged or missing heat shields must be repaired or replaced before operating the machine.

•

If hydraulic hoses break while the engine cover is open, splattered oil on the high temperature parts such as muffler may cause fire. Always keep the engine cover closed while operating the machine.

TTDD650-EN-00(18/11/2019)

SA-33

SAFETY Evacuating in Case of Fire ● In case of fire, evacuate the machine in the following way: •

Stop the engine by turning the key switch to the OFF position if there is time.

•

Leave the machine

•

Use a fire extinguisher if there is time.

● In an emergency, if the cab door or front window can not be opened, break the front or rear window pane with the emergency evacuation hammer to escape from the cab.

Read the explanation pages on the Emergency Evacuation Method for details.

SA-393 ja

SS-1510 ja

Beware of Exhaust Fumes ● Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

•

If you must operate the machine in a building, be sure there is adequate ventilation.

•

White smoke may be generated during the aftertreatment device regeneration. Do not perform aftertreatment device manual regeneration indoor.

SA-016 ja

TTDD650-EN-00(18/11/2019)

SA-34

SAFETY 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 disconnect 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.

SA-818 ja

● After finishing welding and grinding, recheck that there are no abnormalities such as the area surrounding the welded area still smoldering.

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 ja

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

TTDD650-EN-00(18/11/2019)

SA-35

SAFETY 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 or cut the unit. ● Avoid giving shocks to the unit. ● Respect the environment when disposing the unit. Consult your authorized dealer.

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.

•

Work outside 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 SA-029 ja 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.

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

Keep cabin door and windows closed and install additional filtration systems if necessary.

•

Depending on the work site conditions, the risk of inhaling asbestos fiber, silica dust or other contaminations may exist.

•

Keep bystanders out of the work site during operation.

SA-029 ja

TTDD650-EN-00(18/11/2019)

SA-36

SAFETY Prevent Battery Explosions ● Battery gas can explode.

•

Keep sparks, and flames away from the top of battery.

•

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

•

Do not charge a frozen battery; it may explode.

Gently 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 ja

● 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.

•

The air conditioning system must be maintained by qualified persons only. Refer to the instructions provided by the supplier when handling the refrigerant.

•

Use a recovery and recycling system to avoid leaking refrigerant into the atmosphere.

•

Never touch the refrigerant.

SA-405 ja

TTDD650-EN-00(18/11/2019)

SA-37

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, 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.

•

SA-2579 ja

See your authorized dealer for SDS's (available only in English) on chemical products used with your machine.

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, DEF/AdBlue®, 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 damage the Earth's atmosphere. Government regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants.

•

SA-226 ja

Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer.

TTDD650-EN-00(18/11/2019)

SA-38

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

Notes on Aftertreatment Device The aftertreatment device removes particulate matter (PM) and NOx (Nitrogen Oxide) from the exhaust gas. Do not make any modifications affecting the functionality of the aftertreatment device. In case of damage to the aftertreatment device, have its functionality checked by your authorized dealer.

Exhaust gas from the aftertreatment device, muffler, exhaust piping and tail piping becomes hot during and right after engine running and regeneration of aftertreatment device. Keep away from the exhaust system or hot gas from the exhaust piping during regeneration. Be careful to avoid skin contact with exhaust gas or hot sufaces. It may cause severe burns. ● White smoke may be generated during aftertreatment device regeneration. Do not attempt to perform aftertreatment device manual regeneration in a badly ventilated area. ● Do not touch water coming directly out of the aftertreatment device. The water is mildly-acidic by oxidation catalyst mounted in the aftertreatment device. If filter water spills on your skin, immediately flush with clean water.

Precautions for Communication Terminal ● Non-compliant radio communication equipment and associated parts, and/or improper installation of radio communication equipment may affect and disturb the machine's electronic parts, potentially causing involuntary movement of the machine. ● Improper installation of electrical equipment may cause machine failure and/or a fire on the machine. ● Be sure to consult your authorized dealer when installing radio communication equipment or additional electrical parts, or when replacing electrical parts.

Never attempt to disassemble or modify the electrical/electronic components. If replacement or modification of such components is required, contact your authorized dealer.

TTDD650-EN-00(18/11/2019)

SA-39

SAFETY Precautions for Communication Terminal Equipment This machine has a communication terminal equipment emitting electrical waves installed inside the rear tray situated at the back of the operator's seat. There is a possibility that a medical device, including an implantable device such as a cardiac pacemaker, could be affected and malfunction due to the electrical waves emitted from the communication terminal equipment.

Any person using a medical device such as mentioned 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 communication terminal equipment switched off, and confirm that it is not emitting electrical waves.

SA-2759-1 ja

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.

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 (as of March 2010). ● Do not attempt to disassemble, repair, modify or relocate the communication terminal, antenna and cables. This 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. This may cause damage or fire on the machine and the communication terminal due to short/broken circuit.

TTDD650-EN-00(18/11/2019)

SA-40

SAFETY Notes on Protection by Operator's Station when the Machine Rolls Over The cab incorporates a structure to protect the operator by absorbing impact energy when the machine rolls over (RollOver Protective Structure (ROPS)). However, when modifying the machine or installing a special attachment causing the machine mass to exceed the maximum operating mass indicated on the ROPS certification label, the cab cannot fulfill its protective function, possibly causing serious injury or death.

In order to safeguard the protective structure, follow the instructions below. ● Consult your authorized dealer before welding parts or drilling a hole on the cab. Modifications to the structure which possibly reduce the cab strength are not allowed.

SS-3636-1 ja

● Be sure to always fasten the seat belt when operating the machine. If the machine rolls over without operator having fastening the seat belt, the operator may be thrown out of the cab and/or may become crushed under the machine.

The ROPS certification is valid under the following conditions. ● The actual machine mass is lower than the maximum operating mass described in the ROPS certification. ● The ROPS is properly installed. ● No modification is made to the ROPS. ● The ROPS is free from damage.

1

1

Applicable Machine Model Number

2

2

Maximum operating mass assuring the ROPS

3

4

3

Certificate number of the ROPS

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.

TTDD650-EN-00(18/11/2019)

SA-41

4

SS-3671-2 ja ROPS Model Number

SAFETY

SA-435 ja

TTDD650-EN-00(18/11/2019)

SA-42

SECTION AND GROUP CONTENTS

SECTION4

OPERATIONAL PERFORMANCE TEST

Group1

Introduction

Group2

Standard

Group3

Engine Test

Group4

Machine Performance Test

TECHNICAL MANUAL

Group5

Component Test

( T r o u b l e s h o o t i n g )

Group6

Adjustment

SECTION5 TROUBLESHOOTING Group1

Diagnosing Procedure

Group2

Monitor

Group3

e-Service

Group4

Component Layout

Group5

Troubleshooting A

Group6

Troubleshooting B

Group7

Air Conditioner

MEMO

TTDD650-EN-00(18/11/2019)

4

OPERATIONAL PERFORMANCE TEST Introduction..............................................T4-1-1 Operational Performance Tests ...................................... T4-1-1 Preparation for Performance Tests ................................ T4-1-2

Standard....................................................T4-2-1 Operational Performance Standard Table .................. T4-2-1 Engine System Performance Standards ...................... T4-2-1 Travel System Performance Standards......................... T4-2-2 Swing System Performance Standards ........................ T4-2-3 Front Attachment System Performance Standards ............................................................................................... T4-2-3 Lever System Performance Standards.......................... T4-2-7 Combined Operation System Performance Standards .......................................................................... T4-2-7 Component System Performance Standards ............ T4-2-7 Main Pump P-Q Diagram (P1, P2) .................................. T4-2-8 Main Pump P-Q Diagram (P3)........................................T4-2-10 Engine Control Dial Activating Range........................T4-2-12 Pilot Pressure Sensor (4436535) Activating Range. .............................................................................................T4-2-12 Pump Control Pressure Sensor (4436536) Activating Range ..........................................................T4-2-13 Pump Delivery Pressure Sensor (4436271) Activating Range ..........................................................T4-2-14 Monitor Indicating Values of ECM ...............................T4-2-15 Monitor Indicating Values of MC..................................T4-2-17 Monitor Indicating Values of MC (Pressure Sensor) .............................................................................................T4-2-20 Monitor Indicating Values of MC (Solenoid Valve) . .............................................................................................T4-2-23 Monitor Indicating Values of Switch Box Controller ........................................................................T4-2-24

Engine Test ................................................T4-3-1 Engine Speed ........................................................................ T4-3-1 Lubricant Consumption .................................................... T4-3-3

Machine Performance Test ......................T4-4-1 Travel Speed .......................................................................... T4-4-1 Track Link Revolution Speed............................................ T4-4-1 Mistrack Check...................................................................... T4-4-2 Travel Parking Leakage ...................................................... T4-4-3 Swing Speed.......................................................................... T4-4-4 Swing Function Drift Check ............................................. T4-4-5 Swing Motor Leakage ........................................................ T4-4-7

TTDD650-EN-00(18/11/2019)

Maximum Swingable Slant Angle.................................. T4-4-8 Swing Bearing Play.............................................................. T4-4-9 Hydraulic Cylinder Cycle Time.......................................T4-4-11 Dig Function Drift Check (Maximum Reach Position)...........................................................................T4-4-12 Dig Function Drift Check (Arm Roll-In Position) .....T4-4-14 Control Lever Operating Force......................................T4-4-15 Control Lever Stroke .........................................................T4-4-16 Combined Operation of Boom Raise and Swing Function Check .............................................................T4-4-16 Combined Operation of Boom Raise and Arm Roll-In Function Check ...............................................T4-4-18 Clearance of Front Attachment Connecting Part.... .............................................................................................T4-4-19

Component Test........................................T4-5-1 Primary Pilot Pressure......................................................... T4-5-1 Secondary Pilot Pressure................................................... T4-5-2 5-Spool Solenoid Valve Unit Set Pressure ................... T4-5-3 3-Spool Solenoid Valve Unit Set Pressure ................... T4-5-6 2-Spool Solenoid Valve Unit (Aftertreatment Device Regeneration Control) Set Pressure.......... T4-5-8 Main Pump Delivery Pressure .......................................T4-5-11 Main Relief Set Pressure ..................................................T4-5-12 Main Relief Valve Pressure Adjustment Procedure. .............................................................................................T4-5-13 High-Pressure Side of Main Relief Pressure Adjustment Procedure ...............................................T4-5-14 Low-Pressure Side of Main Relief Pressure Adjustment Procedure ...............................................T4-5-16 Relief Pressure (When Relieving Swing) ....................T4-5-16 Overload Relief Valve Set Pressure ..............................T4-5-18 Overload Relief Valve Pressure Adjustment Procedure (Reference) ................................................T4-5-19 Main Pump Flow Rate Measurement (P-Q Control (Torque Control)) ..........................................................T4-5-20 Main Pump Flow Rate Measurement (Pilot Pressure Characteristics)............................................T4-5-22 Regulator Adjustment (P1, P2)......................................T4-5-27 Regulator Adjustment (P3).............................................T4-5-29 Swing Motor Drainage.....................................................T4-5-30 Travel Motor Drainage .....................................................T4-5-33

Adjustment ...............................................T4-6-1 Rewrite of Aftertreatment Device Serial No............... T4-6-1 How to Clear Fault Code.................................................... T4-6-1

Measuring Method of No-Load-Max Differential Pressure.............................................................................. T4-6-3 Differential Pressure Sensor Learning .......................... T4-6-4 Filter Maintenance............................................................... T4-6-5 Procedure after Replacing DCU and ECM ................... T4-6-5 Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping ........................................................... T4-6-6 How to Check Manual Regeneration Switch ............. T4-6-8 Remedy at DEF Pressure Decrease ................................ T4-6-9 Clean DEF Tank ...................................................................T4-6-11 Remedy when Mixing Oil in DEF Tank........................T4-6-13 Calibration of Aerial Angle .............................................T4-6-13 Oil Monitoring Sensor Setting ......................................T4-6-21 [A] Constant Change (Oil Monitoring Sensor Setting).............................................................................T4-6-22 [D] Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)..........................................T4-6-25 [B] Diagnosis of Engine Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check) ..................T4-6-28 [C] Diagnosis of Hydraulic Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check) ..........T4-6-31

TTDD650-EN-00(18/11/2019)

5

TROUBLESHOOTING Diagnosing Procedure .............................T5-1-1 Introduction........................................................................... T5-1-1 Diagnosis Procedure........................................................... T5-1-2 Electrical System Inspection ............................................ T5-1-5 Precautions for Inspection and Maintenance............ T5-1-5 Instructions for Disconnecting Connectors ............... T5-1-7 Instructions for Removing Relays .................................. T5-1-9 Fuse Inspection...................................................................T5-1-11 Fuse Connection Destination........................................T5-1-11 Fusible Link Inspection ....................................................T5-1-13 Battery Voltage Check......................................................T5-1-17 Alternator Check ................................................................T5-1-17 Continuity Check ...............................................................T5-1-19 Voltage and Current Measurement of 24-Volt Circuit................................................................................T5-1-20 Voltage and Current Measurement of 5-Volt Circuit................................................................................T5-1-26 Check by False Signal .......................................................T5-1-29 Test Wire Harness...............................................................T5-1-30 Removal of ECM .................................................................T5-1-31 Installation of ECM ............................................................T5-1-34 Removal of DCU .................................................................T5-1-36 Installation of DCU ............................................................T5-1-38 Removal of MC (Main Controller).................................T5-1-39 Installation of MC (Main Controller)............................T5-1-42 Removal of Monitor Controller .....................................T5-1-45 Installation of Monitor Controller ................................T5-1-48 Removal of GSM .................................................................T5-1-52 Installation of GSM ............................................................T5-1-55 Removal of PLCU (Option) ..............................................T5-1-59 Installation of PLCU (Option) .........................................T5-1-62 Removal of Aerial Angle Controller.............................T5-1-65 Installation of Aerial Angle Controller........................T5-1-68 Mounting Position of Pump Delivery Pressure Sensor...............................................................................T5-1-71 Mounting Position of Pump Control Pressure Sensor...............................................................................T5-1-72 Mounting Position of Boom Raise Pilot Pressure Sensor...............................................................................T5-1-73 Mounting Position of Arm Roll-Out Pilot Pressure Sensor...............................................................................T5-1-73 Mounting Position of Arm 2 Roll-In Pilot Pressure Sensor...............................................................................T5-1-74 Mounting Position of Bucket Roll-Out Pilot Pressure Sensor.............................................................T5-1-74 TTDD650-EN-00(18/11/2019)

Mounting Position of Bucket Roll-In Pilot Pressure Sensor...............................................................................T5-1-75 Mounting Position of Travel Pilot Pressure Sensor . .............................................................................................T5-1-75 Mounting Position of Arm 1 Roll-In Pilot Pressure Sensor...............................................................................T5-1-76 Mounting Position of Swing Pilot Pressure Sensor. .............................................................................................T5-1-76 Mounting Position of Front Pilot Pressure Sensor .. .............................................................................................T5-1-77 Mounting Position of Auxiliary 1 Pilot Pressure Sensor...............................................................................T5-1-77 Mounting Position of Auxiliary 2 Pilot Pressure Sensor...............................................................................T5-1-78 Mounting Position of Fuel Sensor................................T5-1-79 Mounting Position of Hydraulic Oil Temperature Sensor...............................................................................T5-1-79 Mounting Position of Differential Pressure Sensor. .............................................................................................T5-1-80 Mounting Position of Exhaust Temperature Sensor...............................................................................T5-1-80 Mounting Position of NOx Sensor ...............................T5-1-81 Mounting Position of Engine Oil Monitoring Sensor...............................................................................T5-1-81 Mounting Position of Hydraulic Oil Monitoring Sensor...............................................................................T5-1-82 Mounting Position of Ambient Temperature Sensor...............................................................................T5-1-83 Mounting Position of Re-circulated Air Temperature Sensor ....................................................T5-1-83 Mounting Position of Frost Sensor ..............................T5-1-84 Mounting Position of Solar Radiation Sensor..........T5-1-84

Monitor......................................................T5-2-1 Basic Screen of Monitor..................................................... T5-2-1 Operating Procedures of Service Menu....................... T5-2-1 How to Display Service Menu ......................................... T5-2-2 How to Display Troubleshooting Screen..................... T5-2-4 How to Display Monitoring.............................................. T5-2-7 Monitoring Items of Engine Controller (ECM) .........T5-2-11 Monitoring Items of Main Controller (MC) ...............T5-2-13 Monitoring Items of PLCU ..............................................T5-2-18 Monitoring Items of Monitor Controller (Information)..................................................................T5-2-18 Monitoring Items of Switch Box Controller..............T5-2-19 Monitoring Items of Air Conditioner Unit.................T5-2-20

How to Display Controller Version...............................T5-2-20 How to Display Operation ..............................................T5-2-21 How to Display Communication Terminal Status ... .............................................................................................T5-2-23 List of Communication Terminal Status.....................T5-2-24 Operating Procedures of Breaker Alarm....................T5-2-25 Operating Procedures of Machine Setting (Constant Change) .......................................................T5-2-27 List of Machine Setting Items........................................T5-2-30 Operating Procedures of Monitor Setting (Operation Permission) ..............................................T5-2-32 Operating Procedures of Monitor Setting (Maintenance Items) ...................................................T5-2-35 List of Monitor Setting Items .........................................T5-2-38 Operating Procedures of Attachment Setting (Constant Change) .......................................................T5-2-40 List of Attachment Setting Items .................................T5-2-43 Operating Procedures of Engine Setting ..................T5-2-46 How to Display Aftertreatment Device No...............T5-2-48 Attachment Adjustment .................................................T5-2-50 Operating Procedures of Breaker Relief Pressure.... .............................................................................................T5-2-50 Operating Procedures of Auxiliary Overload Relief Valve Pressure................................................................T5-2-54 Inspection of Engine Oil Level and Coolant Level... .............................................................................................T5-2-57 Inspection of Hour Meter and Fuel Gauge ...............T5-2-58 Fuel Gauge ...........................................................................T5-2-59 Coolant Temperature Gauge .........................................T5-2-60 DEF Gauge............................................................................T5-2-60 Hydraulic Oil Temperature Gauge ...............................T5-2-61

e-Service....................................................T5-3-1 Outline of e-Service ............................................................ T5-3-1 List of Operation Data ........................................................ T5-3-1 Communication System .................................................... T5-3-3

Component Layout...................................T5-4-1 Main Component (Upperstructure) .............................. T5-4-1 Main Component (Undercarriage) ................................ T5-4-3 Main Component (Front Attachment) ......................... T5-4-3 Electrical System (Overview) ........................................... T5-4-4 Electrical System (Rear Tray) ............................................ T5-4-5 Electrical System (Switches)............................................. T5-4-6 Electrical System (Utility Space) ..................................... T5-4-7 Electrical System (Relays).................................................. T5-4-8 Engine Oil Monitoring Sensor ......................................... T5-4-8 Hydraulic Oil Monitoring Sensor.................................... T5-4-9 Engine ....................................................................................T5-4-10 Aftertreatment Device .....................................................T5-4-11 Pump Device .......................................................................T5-4-12 Around Pump Device .......................................................T5-4-12 Control Valve .......................................................................T5-4-13 Signal Control Valve..........................................................T5-4-13 Swing Device.......................................................................T5-4-14 Travel Device .......................................................................T5-4-15

TTDD650-EN-00(18/11/2019)

5-Spool Solenoid Valve Unit ..........................................T5-4-15 3-Spool Solenoid Valve Unit ..........................................T5-4-16 2-Spool Solenoid Valve Unit (For Aftertreatment Device Regeneration Control) .................................T5-4-16 DEF Tank................................................................................T5-4-17 DEF Supply Module...........................................................T5-4-17 Layout of Attachment Spec. Parts ...............................T5-4-18 Around Control Valve .......................................................T5-4-18 Control Valve Lower Side ................................................T5-4-19 Utility Space.........................................................................T5-4-20 Components in Control Valve .......................................T5-4-21 Pilot Valve Side of Pilot Port ...........................................T5-4-40 Control Valve Side of Pilot Port .....................................T5-4-42 Port Layout of Control Valve (Main Circuit) ..............T5-4-44 Port Layout of Control Valve (Pilot Circuit) ...............T5-4-46 Cab Harness .........................................................................T5-4-49 Main Harness.......................................................................T5-4-59 Pump Harness .....................................................................T5-4-68 NOx Harness ........................................................................T5-4-69 Monitor Harness.................................................................T5-4-70 Console Harness.................................................................T5-4-71 Control Valve Harness ......................................................T5-4-73 Wiper Harness .....................................................................T5-4-75 Wiper Motor Harness........................................................T5-4-76 Pilot Shut-Off Solenoid Valve Harness .......................T5-4-77 Engine Stop Switch Harness ..........................................T5-4-78 Cigar Lighter Sub Harness ..............................................T5-4-79 Connector Layout of MC .................................................T5-4-79 Connector Layout of Monitor Controller...................T5-4-81 Connector Layout of ECM...............................................T5-4-82 Connector Layout of DCU...............................................T5-4-82 Connector Layout of GSM ..............................................T5-4-83 Connector Layout of Aerial Angle Controller ..........T5-4-83 Connector Layout of PLCU (Option) ...........................T5-4-84

Troubleshooting A....................................T5-5-1 Troubleshooting A (Base Machine Diagnosis by Using Fault Codes) Procedure.................................... T5-5-1 Contents of Troubleshooting A ...................................... T5-5-1 MC Fault Code 73000-3...................................................... T5-5-2 MC Fault Code 73000-4...................................................... T5-5-4 MC Fault Code 73001-3...................................................... T5-5-6 MC Fault Code 73001-4...................................................... T5-5-7 MC Fault Code 73002-3...................................................... T5-5-7 MC Fault Code 73003-2...................................................... T5-5-8 MC Fault Code 73004-2...................................................... T5-5-8 MC Fault Code 73005-2...................................................... T5-5-8 MC Fault Code 73006-2...................................................... T5-5-9 MC Fault Code 41000-2...................................................... T5-5-9 MC Fault Code 51000-3....................................................T5-5-10 MC Fault Code 51000-4....................................................T5-5-11 MC Fault Code 51001-3....................................................T5-5-12 MC Fault Code 51001-4....................................................T5-5-13 MC Fault Code 51002-3....................................................T5-5-13 MC Fault Code 51002-4....................................................T5-5-14 MC Fault Code 51003-3....................................................T5-5-15

MC Fault Code 51003-4....................................................T5-5-16 MC Fault Code 51004-3....................................................T5-5-16 MC Fault Code 51004-4....................................................T5-5-17 MC Fault Code 51005-3....................................................T5-5-18 MC Fault Code 51005-4....................................................T5-5-19 MC Fault Code 53000-3....................................................T5-5-19 MC Fault Code 53000-4....................................................T5-5-20 MC Fault Code 53001-3....................................................T5-5-21 MC Fault Code 53001-4....................................................T5-5-22 MC Fault Code 53002-3....................................................T5-5-22 MC Fault Code 53002-4....................................................T5-5-23 MC Fault Code 53003-3....................................................T5-5-24 MC Fault Code 53003-4....................................................T5-5-25 MC Fault Code 53004-3....................................................T5-5-26 MC Fault Code 53004-4....................................................T5-5-27 MC Fault Code 53005-3....................................................T5-5-27 MC Fault Code 53005-4....................................................T5-5-28 MC Fault Code 53006-3....................................................T5-5-29 MC Fault Code 53006-4....................................................T5-5-30 MC Fault Code 53015-3....................................................T5-5-30 MC Fault Code 53015-4....................................................T5-5-31 MC Fault Code 53016-3....................................................T5-5-32 MC Fault Code 53016-4....................................................T5-5-33 MC Fault Code 51006-2....................................................T5-5-33 MC Fault Code 51006-6....................................................T5-5-34 MC Fault Code 51006-5....................................................T5-5-35 MC Fault Code 51007-2....................................................T5-5-35 MC Fault Code 51007-6....................................................T5-5-36 MC Fault Code 51007-5....................................................T5-5-37 MC Fault Code 51008-2....................................................T5-5-37 MC Fault Code 51008-6....................................................T5-5-38 MC Fault Code 51008-5....................................................T5-5-39 MC Fault Code 51009-2....................................................T5-5-39 MC Fault Code 51009-6....................................................T5-5-40 MC Fault Code 51009-5....................................................T5-5-41 MC Fault Code 51010-2....................................................T5-5-41 MC Fault Code 51010-6....................................................T5-5-42 MC Fault Code 51010-5....................................................T5-5-42 MC Fault Code 51011-2....................................................T5-5-43 MC Fault Code 51011-6....................................................T5-5-44 MC Fault Code 51011-5....................................................T5-5-44 MC Fault Code 51012-2....................................................T5-5-45 MC Fault Code 51012-6....................................................T5-5-46 MC Fault Code 51012-5....................................................T5-5-46 MC Fault Code 51013-2....................................................T5-5-47 MC Fault Code 51013-6....................................................T5-5-48 MC Fault Code 51013-5....................................................T5-5-48 MC Fault Code 51014-2....................................................T5-5-49 MC Fault Code 51014-6....................................................T5-5-50 MC Fault Code 51014-5....................................................T5-5-50 MC Fault Code 51015-2....................................................T5-5-51 MC Fault Code 51015-6....................................................T5-5-51 MC Fault Code 51015-5....................................................T5-5-52 MC Fault Code 51016-2....................................................T5-5-53 MC Fault Code 51016-6....................................................T5-5-53 MC Fault Code 51016-5....................................................T5-5-54 TTDD650-EN-00(18/11/2019)

MC Fault Code 51017-2....................................................T5-5-55 MC Fault Code 51017-6....................................................T5-5-55 MC Fault Code 51017-5....................................................T5-5-56 MC Fault Code 51018-2....................................................T5-5-56 MC Fault Code 51018-6....................................................T5-5-57 MC Fault Code 51018-5....................................................T5-5-57 MC Fault Code 51019-2....................................................T5-5-57 MC Fault Code 51019-6....................................................T5-5-58 MC Fault Code 51019-5....................................................T5-5-59 MC Fault Code 51020-2....................................................T5-5-59 MC Fault Code 51021-3....................................................T5-5-60 MC Fault Code 51021-4....................................................T5-5-61 MC Fault Code 51022-3....................................................T5-5-62 MC Fault Code 51022-4....................................................T5-5-62 MC Fault Code 51023-3....................................................T5-5-63 MC Fault Code 51023-4....................................................T5-5-64 MC Fault Code 51025-0....................................................T5-5-64 MC Fault Code 51026-14 .................................................T5-5-65 MC Fault Code 63000-2....................................................T5-5-65 MC Fault Code 73007-2....................................................T5-5-65 MC Fault Code 73008-2....................................................T5-5-66 MC Fault Code 73034-2....................................................T5-5-66 MC Fault Code 51029-2....................................................T5-5-66 MC Fault Code 51029-6....................................................T5-5-67 MC Fault Code 51029-5....................................................T5-5-68 MC Fault Code 51030-2....................................................T5-5-68 MC Fault Code 51030-6....................................................T5-5-69 MC Fault Code 51030-5....................................................T5-5-70 MC Fault Code 51031-2....................................................T5-5-70 MC Fault Code 51031-6....................................................T5-5-71 MC Fault Code 51031-5....................................................T5-5-72 MC Fault Code 73028-2....................................................T5-5-72 Monitor Controller (Information) Fault Code 41001-2 ............................................................................T5-5-73 Monitor Controller (Information) Fault Code 41002-3 ............................................................................T5-5-73 Monitor Controller (Information) Fault Code 41003-3 ............................................................................T5-5-74 Monitor Controller (Information) Fault Code 41003-4 ............................................................................T5-5-75 Monitor Controller (Information) Fault Code 73033-2 ............................................................................T5-5-76 Monitor Controller (Information) Fault Code 41004-14..........................................................................T5-5-77 Monitor Controller (Information) Fault Code 41005-14..........................................................................T5-5-77 Monitor Controller (Information) Fault Code 41006-14..........................................................................T5-5-78 Monitor Controller (Information) Fault Code 41007-14..........................................................................T5-5-78 Monitor Controller (Information) Fault Code 41008-14..........................................................................T5-5-78 Monitor Controller (Information) Fault Code 41004-20..........................................................................T5-5-79 Monitor Controller (Information) Fault Code 73013-2 ............................................................................T5-5-79

Monitor Controller (Information) Fault Code 73014-2 ............................................................................T5-5-80 Monitor Controller (Information) Fault Code 73015-2 ............................................................................T5-5-80 Monitor Controller (Information) Fault Code 73016-2 ............................................................................T5-5-80 Monitor Controller (Information) Fault Code 73017-2 ............................................................................T5-5-81 Monitor Controller (Information) Fault Code 73018-2 ............................................................................T5-5-81 Monitor Controller (Information) Fault Code 73019-2 ............................................................................T5-5-82 Monitor Controller (Information) Fault Code 73020-2 ............................................................................T5-5-82 Monitor Controller (Information) Fault Code 73021-2 ............................................................................T5-5-83 Monitor Controller (Information) Fault Code 68004-12..........................................................................T5-5-83 Monitor Controller (Information) Fault Code 68005-12..........................................................................T5-5-83 Monitor Controller (Information) Fault Code 68006-12..........................................................................T5-5-83 Monitor Controller (Information) Fault Code 68007-12..........................................................................T5-5-84 Monitor Controller (Information) Fault Code 68008-12..........................................................................T5-5-84 Monitor Controller (Information) Fault Code 68009-12..........................................................................T5-5-84 Monitor Controller (Information) Fault Code 41002-4 ............................................................................T5-5-84 Monitor Controller (Information) Fault Code 73029-2 ............................................................................T5-5-85 Monitor Controller (Monitor) Fault Code 73010-2.. .............................................................................................T5-5-85 Monitor Controller (Monitor) Fault Code 73011-2.. .............................................................................................T5-5-85 Monitor Controller (Monitor) Fault Code 73012-2.. .............................................................................................T5-5-86 Monitor Controller (Monitor) Fault Code 73030-2.. .............................................................................................T5-5-86 Monitor Controller (Monitor) Fault Code 13911-3.. .............................................................................................T5-5-87 Monitor Controller (Monitor) Fault Code 13912-4.. .............................................................................................T5-5-87 Monitor Controller (Monitor) Fault Code 13913-3.. .............................................................................................T5-5-88 Monitor Controller (Monitor) Fault Code 13914-4.. .............................................................................................T5-5-89 Monitor Controller (Monitor) Fault Code 13917-3.. .............................................................................................T5-5-89 Monitor Controller (Monitor) Fault Code 13918-4.. .............................................................................................T5-5-90 Monitor Controller (Monitor) Fault Code 13921-3.. .............................................................................................T5-5-90 Monitor Controller (Monitor) Fault Code 13922-4.. .............................................................................................T5-5-91 TTDD650-EN-00(18/11/2019)

Monitor Controller (Monitor) Fault Code 13943-2.. .............................................................................................T5-5-91 Monitor Controller (Monitor) Fault Code 13944-2.. .............................................................................................T5-5-92 Monitor Controller (Monitor) Fault Code 13951-2.. .............................................................................................T5-5-93 Monitor Controller (Monitor) Fault Code 13991-2.. .............................................................................................T5-5-93 Monitor Controller (Monitor) Fault Code 13992-2.. .............................................................................................T5-5-94 Switch Box Controller Fault Code 14504-3 ...............T5-5-94 Switch Box Controller Fault Code 14504-4 ...............T5-5-95 Aerial Angle Controller Fault Code 68000-2.............T5-5-95 Aerial Angle Controller Fault Code 68001-2.............T5-5-96 Aerial Angle Controller Fault Code 68002-2.............T5-5-96 Aerial Angle Controller Fault Code 73022-2.............T5-5-97 Aerial Angle Controller Fault Code 68003-2.............T5-5-98 PLCU Fault Code 53007-3................................................T5-5-98 PLCU Fault Code 53007-4................................................T5-5-99 PLCU Fault Code 53008-3................................................T5-5-99 PLCU Fault Code 53008-4............................................. T5-5-100 PLCU Fault Code 53009-12 .......................................... T5-5-101 PLCU Fault Code 53009-7............................................. T5-5-101 PLCU Fault Code 53010-12 .......................................... T5-5-101 PLCU Fault Code 53010-7............................................. T5-5-102 PLCU Fault Code 53011-2............................................. T5-5-102 PLCU Fault Code 53011-6............................................. T5-5-103 PLCU Fault Code 53011-5............................................. T5-5-103 PLCU Fault Code 53012-2............................................. T5-5-104 PLCU Fault Code 53012-6............................................. T5-5-104 PLCU Fault Code 53012-5............................................. T5-5-105 PLCU Fault Code 53013-2............................................. T5-5-106 PLCU Fault Code 53013-6............................................. T5-5-106 PLCU Fault Code 53013-5............................................. T5-5-107 PLCU Fault Code 53014-2............................................. T5-5-108 PLCU Fault Code 53014-6............................................. T5-5-108 PLCU Fault Code 53014-5............................................. T5-5-109 PLCU Fault Code 53017-2............................................. T5-5-109 PLCU Fault Code 53018-2............................................. T5-5-110 PLCU Fault Code 53019-2............................................. T5-5-110 PLCU Fault Code 53020-2............................................. T5-5-110 PLCU Fault Code 53021-2............................................. T5-5-111 PLCU Fault Code 53009-8............................................. T5-5-111 PLCU Fault Code 53010-8............................................. T5-5-111 PLCU Fault Code 53017-8............................................. T5-5-112 PLCU Fault Code 53020-8............................................. T5-5-112 PLCU Fault Code 53018-8............................................. T5-5-112 PLCU Fault Code 53021-8............................................. T5-5-112 PLCU Fault Code 63001-3............................................. T5-5-113 PLCU Fault Code 63001-4............................................. T5-5-114 PLCU Fault Code 73023-2............................................. T5-5-115 PLCU Fault Code 73024-2............................................. T5-5-115 PLCU Fault Code 73035-7............................................. T5-5-115 Power-CAN harness Check .......................................... T5-5-116 Body-CAN Harness Check............................................ T5-5-117 ISO-CAN (Engine) Harness Check ............................. T5-5-119

IF-CAN Harness Check................................................... T5-5-121 OPT-CAN Harness Check .............................................. T5-5-122 PL-CAN Harness Check ................................................. T5-5-123 ECM Fault Code List........................................................ T5-5-124 DCU Fault Code List ....................................................... T5-5-134

Troubleshooting B....................................T5-6-1 Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure.................................... T5-6-1 Contents of Troubleshooting B....................................... T5-6-1 Relationship between Machine Trouble Symptoms and Related Parts..................................... T5-6-3 When a Fault Occurs in MC (Main Controller)............ T5-6-3 When a Fault Occurs in Switch Box Controller .......... T5-6-3 When a Fault Occurs in Engine Control Dial .............. T5-6-3 When a Fault Occurs in Auto-Idle Switch .................... T5-6-4 When a Fault Occurs in Power Mode Switch (ECO Mode) ................................................................................. T5-6-4 When a Fault Occurs in Travel Mode Switch .............. T5-6-5 When a Fault Occurs in Power Digging Switch......... T5-6-5 When a Fault Occurs in Pilot Shut-Off Switch (Pilot Shut-Off Lever) ................................................................ T5-6-5 When a Fault Occurs in Manual Regeneration Switch ................................................................................. T5-6-6 When a Fault Occurs in Pilot Shut-Off Solenoid Valve.................................................................................... T5-6-6 When a Fault Occurs in Hydraulic Oil Temperature Sensor................................................................................. T5-6-7 When a Fault Occurs in Differential Pressure Sensor................................................................................. T5-6-7 When a Fault Occurs in DOC Inlet Exhaust Temperature Sensor ...................................................... T5-6-7 When a Fault Occurs in DOC Outlet Exhaust Temperature Sensor ...................................................... T5-6-8 When a Fault Occurs in SCR Exhaust Temperature Sensor................................................................................. T5-6-8 When a Fault Occurs in Pump 1 Delivery Pressure Sensor................................................................................. T5-6-8 When a Fault Occurs in Pump 2 Delivery Pressure Sensor................................................................................. T5-6-9 When a Fault Occurs in Pump 3 Delivery Pressure Sensor................................................................................. T5-6-9 When a Fault Occurs in Pump 1 Control Pressure Sensor................................................................................. T5-6-9 When a Fault Occurs in Pump 2 Control Pressure Sensor...............................................................................T5-6-10 When a Fault Occurs in Pump 3 Control Pressure Sensor...............................................................................T5-6-10 When a Fault Occurs Swing Pilot Pressure Sensor .. .............................................................................................T5-6-10 When a Fault Occurs in Boom Raise Pilot Pressure Sensor...............................................................................T5-6-11 When a Fault Occurs in Arm 2 Roll-In Pilot Pressure Sensor.............................................................T5-6-11 When a Fault Occurs in Arm 1 Roll-In Pilot Pressure Sensor.............................................................T5-6-11

TTDD650-EN-00(18/11/2019)

When a Fault Occurs in Travel Pilot Pressure Sensor...............................................................................T5-6-12 When a Fault Occurs in Front Pilot Pressure Sensor .............................................................................................T5-6-12 When a Fault Occurs in Bucket Roll-In Pilot Pressure Sensor.............................................................T5-6-12 When a Fault Occurs in Arm Roll-Out Pilot Pressure Sensor.............................................................T5-6-13 When a Fault Occurs in Bucket Roll-Out Pilot Pressure Sensor.............................................................T5-6-13 When a Fault Occurs in Auxiliary 1 Pilot Pressure Sensor (Option) .............................................................T5-6-13 When a Fault Occurs in Auxiliary 2 Pilot Pressure Sensor (Option) .............................................................T5-6-14 When a Fault Occurs in Pump 1 and 2 Torque Control Solenoid Valve ...............................................T5-6-14 When a Fault Occurs in Pump 3 Torque Control Solenoid Valve ...............................................................T5-6-15 When a Fault Occurs in Maximum Pump 1 Flow Rate Limit Control Solenoid Valve..........................T5-6-15 When a Fault Occurs in Maximum Pump 2 Flow Rate Limit Control Solenoid Valve..........................T5-6-15 When a Fault Occurs in Maximum Pump 3 Flow Rate Limit Control Solenoid Valve..........................T5-6-16 When a Fault Occurs in 5-Spool Solenoid Valve Unit (SI).............................................................................T5-6-16 When a Fault Occurs in 5-Spool Solenoid Valve Unit (SD)...........................................................................T5-6-17 When a Fault Occurs in 5-Spool Solenoid Valve Unit (SE) ...........................................................................T5-6-17 When a Fault Occurs in 5-Spool Solenoid Valve Unit (SF)............................................................................T5-6-18 When a Fault Occurs in 5-Spool Solenoid Valve Unit (SC)...........................................................................T5-6-18 When a Fault Occurs in 3-Spool Solenoid Valve Unit (SK1).........................................................................T5-6-18 When a Fault Occurs in 3-Spool Solenoid Valve Unit (SK2).........................................................................T5-6-19 When a Fault Occurs in 3-Spool Solenoid Valve Unit (SK3).........................................................................T5-6-19 When a Fault Occurs in 2-Spool Solenoid Valve Unit (SZ) ...........................................................................T5-6-20 When a Fault Occurs in 2-Spool Solenoid Valve Unit (SJ)............................................................................T5-6-20 When a Fault Occurs in Main Relief Valve (For P1, P2) ......................................................................................T5-6-21 When a Fault Occurs in Main Relief Valve (For P3) .. .............................................................................................T5-6-21 When a Fault Occurs in Overload Relief Valve.........T5-6-22 When a Fault Occurs in Boom Anti-Drift Valve........T5-6-22 When a Fault Occurs in Arm Rod Anti-Drift Valve ... .............................................................................................T5-6-22 When a Fault Occurs in Arm Bottom Anti-Drift Valve..................................................................................T5-6-23 When a Fault Occurs in Flow Combiner Valve.........T5-6-23

When a Fault Occurs in Boom Regenerative Valve. .............................................................................................T5-6-24 When a Fault Occurs in Arm Regenerative Valve .... .............................................................................................T5-6-24 When a Fault Occurs in Bucket Regenerative Valve .............................................................................................T5-6-24 When a Fault Occurs in Bucket Regeneration Cut Valve..................................................................................T5-6-25 When a Fault Occurs in Arm 1 Flow Rate Control Valve..................................................................................T5-6-25 When a Fault Occurs in Auxiliary Flow Rate Control Valve..................................................................T5-6-25 When a Fault Occurs in Auxiliary Flow Combiner Valve..................................................................................T5-6-26 When a Fault Occurs in Pump 1 Bypass Shut-Out Valve..................................................................................T5-6-26 When a Fault Occurs in Pump 3 Bypass Shut-Out Valve..................................................................................T5-6-27 When a Fault Occurs in Digging Regenerative Valve..................................................................................T5-6-27 When a Fault Occurs in Boom Lower Meter-In Cut Valve..................................................................................T5-6-28 When a Fault Occurs in Arm Roll-In Meter-Out Open Control Spool.....................................................T5-6-28 When a Fault Occurs in Travel Motor Displacement Angle Control Valve ........................T5-6-29 When a Fault Occurs in Pump 1 Flow Rate Control Valve..................................................................................T5-6-29 When a Fault Occurs in Pump 2 Flow Rate Control Valve..................................................................................T5-6-30 When a Fault Occurs in Pump 3 Flow Rate Control Valve..................................................................................T5-6-30 When a Fault Occurs in Swing Parking Brake Release Spool.................................................................T5-6-31 When a Fault Occurs in Flow Combiner Valve Control Spool.................................................................T5-6-31 When a Fault Occurs in Auxiliary Flow Combiner Control Solenoid Valve (Option) .............................T5-6-32 When a Fault Occurs in Auxiliary Flow Rate Control Solenoid Valve (Option) .............................T5-6-32 When a Fault Occurs in Selector Valve Control Solenoid Valve (Option) .............................................T5-6-32 When a Fault Occurs in Selector Valve (Option) .....T5-6-33 When a Fault Occurs in Accumulator Control Valve (Option) ................................................................T5-6-33 When a Fault Occurs in Breaker Relief Solenoid Valve (Option) ................................................................T5-6-33 When a Fault Occurs in Auxiliary Overload Relief Solenoid Valve (Option) .............................................T5-6-34 Identification Symbol of Troubleshooting B............T5-6-34 Correlation between Trouble Symptoms and Part Failures .............................................................................T5-6-35 Parts Related with "E-1 Starter does not rotate." ....T5-6-35 Parts Related with "E-2 Even if starter rotates, engine does not start."................................................T5-6-35

TTDD650-EN-00(18/11/2019)

Parts Related with "E-3 Even if power mode switch is operated, power mode is not shifted." .............................................................................................T5-6-35 Parts Related with "E-4 ECO mode is faulty." ............T5-6-36 Parts Related with "E-5 Travel HP mode is faulty."... .............................................................................................T5-6-36 Parts Related with "E-6 Auto-idle system is faulty." .............................................................................................T5-6-36 Parts Related with "E-7 Even if pilot shut-off lever is set to UNLOCK position with engine running at slow idle speed, engine speed does not increase."..........................................................................T5-6-37 Parts Related with "E-8 Engine speed does not increase when coolant temperature is low.".......T5-6-37 Parts Related with "E-9 Auto shut-down is not activated."........................................................................T5-6-37 Parts Related with "E-12 Engine speed does not decrease when audio mute/one-touch idle switch is pushed." .........................................................T5-6-38 Parts Related with "A-1 All actuators do not work." .............................................................................................T5-6-38 Parts Related with "A-2 All actuator speeds are slow." .................................................................................T5-6-38 Parts Related with "A-3 Actuator does not stop even if control lever is set to neutral." ...................T5-6-39 Parts Related with "A-4 Manual regeneration of aftertreatment device cannot be performed.".... .............................................................................................T5-6-39 Parts Related with "A-5 Travel (right) operation speed is slow when performing travel single operation. Bucket single operation speed is slow. (All problems occur at the same time.)"....T5-6-40 Parts Related with "A-6 Travel (left) operation speed is slow when performing travel single operation. Attachment single operation speed is slow. (All problems occur at the same time.)". .............................................................................................T5-6-40 Parts Related with "A-9 Swing single operation speed is slow. Boom speed is slightly slow when performing arm level crowding operation. (All problems occur at the same time.)" ...............................................................................T5-6-40 Parts Related with "F-1 All front attachment actuator powers are weak.".......................................T5-6-40 Parts Related with "F-2 Front attachment drifts remarkably."....................................................................T5-6-41 Parts Related with "F-3 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down."........................T5-6-41 Parts Related with "F-4 Even if power digging switch is pushed, power does not increase.

Boom raise power is weak when performing digging operation."......................................................T5-6-41 Parts Related with "F-5 Boom, arm, or bucket single operation is not operated. Boom, arm, or bucket single operation speed is slow." ...............T5-6-42

Parts Related with "F-6 Bucket roll-in speed is slow or power is weak when performing digging operation.".......................................................................T5-6-42 Parts Related with "F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation.

These troubles often occur when temperature is low." ...............................................................................T5-6-43 Parts Related with "F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation.".......................................................................T5-6-43 Parts Related with "F-9 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground."...........................T5-6-43 Parts Related with "F-10 Arm roll-in speed is slow when performing digging operation." .................T5-6-43 Parts Related with "F-11 Arm roll-in speed is fast when performing arm level crowding operation. Arm power is weak when performing digging operation."..............................T5-6-44 Parts Related with "F-12 Arm roll-out speed is slow when performing combined operation of boom raise, arm roll-out, and attachment."........T5-6-44 Parts Related with "F-14 Boom raise or attachment speed is slow when performing combined operation of boom raise and arm or attachment and arm." .................................................T5-6-45 Parts Related with "F-16 Boom raise speed is slow when performing combined operation of swing and boom raise." ..............................................T5-6-45 Parts Related with "F-22 Bucket speed is slow when performing combined operation of arm roll-in and bucket. Boom raise speed is slow when performing combined operation of swing, boom raise, and arm roll-in. Arm roll-in speed is slow." ................................................................T5-6-46 Parts Related with "F-23 Arm roll-out speed is slow." .................................................................................T5-6-46 Parts Related with "F-24 Arm roll-in speed is slow when performing combined operation of boom raise and arm roll-in." .....................................T5-6-46 Parts Related with "S-1 Swing speed is slow or is not operated." ................................................................T5-6-47 Parts Related with "S-2 When starting swing operation, swing speed is fast." ...............................T5-6-47 Parts Related with "T-1 Both of right and left travels are not operated or travel speed is slow." .................................................................................T5-6-48 Parts Related with "T-2 One side travel is not operated or travel speed is slow. Machine mistracks."........................................................................T5-6-48

TTDD650-EN-00(18/11/2019)

Parts Related with "T-3 Machine mistracks when performing combined operation of travel and front attachment." ........................................................T5-6-48 Parts Related with "T-4 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode."................T5-6-48 Parts Related with "T-5 Occasionally, machine may mistrack when traveling with engine running at slow speed." ...............................................................T5-6-49 Parts Related with "T-6 Attachment speed is slow when performing attachment single operation.

Travel speed is slow when performing combined operation of attachment and travel." .............................................................................................T5-6-49 Parts Related with "O-1 Work light does not light." .............................................................................................T5-6-50 Parts Related with "O-2 Cab light does not light."... .............................................................................................T5-6-50 Parts Related with "O-3 Wiper is not operated." .....T5-6-50 Parts Related with "O-4 Washer is not operated." ... .............................................................................................T5-6-50 Parts Related with "O-5 Boom light does not light." .................................................................................T5-6-51 E-1 Starter does not rotate. ............................................T5-6-51 E-2 Even if starter rotates, engine does not start. ... .............................................................................................T5-6-52 E-3 Even if power mode switch is operated, power mode is not shifted......................................................T5-6-53 E-4 ECO mode is faulty. ....................................................T5-6-53 E-5 Travel HP mode is faulty...........................................T5-6-54 E-6 Auto-idle system is faulty. .......................................T5-6-54 E-7 Even if pilot shut-off lever is set to UNLOCK position with engine running at slow idle speed, engine speed does not increase...............T5-6-55 E-8 Engine speed does not increase when coolant temperature is low. ......................................................T5-6-55 E-9 Auto shut-down is not activated. .........................T5-6-55 E-12 Engine speed does not decrease when audio mute/one-touch idle switch is pushed. ...............T5-6-56 A-1 All actuators do not work........................................T5-6-57 A-2 All actuator speed are slow. ...................................T5-6-58 A-3 Actuator does not stop even if control lever is set to neutral. .................................................................T5-6-59 A-4 Manual regeneration of aftertreatment device cannot be performed..................................................T5-6-59 A-5 Travel (right) operation speed is slow when performing travel single operation. Bucket single operation speed is slow. (All problems occur at the same time.) ............................................T5-6-60 A-6 Travel (left) operation speed is slow when performing travel single operation.

Attachment single operation speed is slow. (All problems occur at the same time.) ........................T5-6-60 A-9 Swing single operation speed is slow. Boom speed is slightly slow when performing arm

level crowding operation. (All problems occur at the same time.).........................................................T5-6-61 F-1 All front attachment actuator powers are weak..................................................................................T5-6-61 F-2 Front attachment drifts remarkably.....................T5-6-62 F-3 When boom raise or arm roll-out is operated, boom or arm starts to move after moving slightly down. ................................................................T5-6-63 F-4 Even if power digging switch is pushed, power does not increase. Boom raise power is weak when performing digging operation. .......T5-6-63 F-5 Boom, arm, or bucket single operation is not operated. Boom, arm, or bucket single operation speed is slow. ............................................T5-6-64 F-6 Bucket roll-in speed is slow or power is weak when performing digging operation....................T5-6-65 F-7 When performing combined operation, arm does not start to move smoothly. Arm starts to move slightly slow when performing arm single operation. These troubles often occur when temperature is low...........................................T5-6-65 F-8 When performing combined operation, boom does not start to move smoothly. Boom starts to move slightly slow when performing boom lower single operation. ..............................................T5-6-65 F-9 Boom lower speed above ground is faster than other actuators when performing combined operation. Machine cannot be raised off the ground. .................................................T5-6-66 F-10 Arm roll-in speed is slow when performing digging operation. .......................................................T5-6-66 F-11 Arm roll-in speed is fast when performing arm level crowding operation. Arm power is weak when performing digging operation. .......T5-6-67 F-12 Arm roll-out speed is slow when performing combined operation of boom raise, arm rollout, and attachment. ..................................................T5-6-67 F-14 Boom raise or attachment speed is slow when performing combined operation of boom raise and arm or attachment and arm.....T5-6-67 F-16 Boom raise speed is slow when performing combined operation of swing and boom raise.. .............................................................................................T5-6-68 F-22 Bucket speed is slow when performing combined operation of arm roll-in and bucket.

Boom raise speed is slow when performing combined operation of swing, boom raise, and arm roll-in. Arm roll-in speed is slow. ....................T5-6-68 F-23 Arm roll-out speed is slow. ...................................T5-6-68 F-24 Arm roll-in speed is slow when performing combined operation of boom raise and arm roll-in.................................................................................T5-6-69 S-1 Swing speed is slow or is not operated..............T5-6-69 S-2 When starting swing operation, swing speed is fast. ................................................................................T5-6-70

TTDD650-EN-00(18/11/2019)

T-1 Both of right and left travels are not operated or travel speed is slow.................................................T5-6-70 T-2 One side travel is not operated or travel speed is slow. Machine mistracks. .......................................T5-6-71 T-3 Machine mistracks when performing combined operation of travel and front attachment. ....................................................................T5-6-72 T-4 Fast travel can not be selected. Travel mode does not change from slow speed mode to fast speed mode....................................................................T5-6-72 T-5 Occasionally, machine may mistrack when traveling with engine running at slow speed. .... .............................................................................................T5-6-73 T-6 Attachment speed is slow when performing attachment single operation. Travel speed is slow when performing combined operation of attachment and travel. ...............................................T5-6-74 O-1 Work light does not light. .......................................T5-6-74 O-2 Cab light does not light...........................................T5-6-75 O-3 Wiper is not operated. .............................................T5-6-75 O-4 Washer is not operated. ..........................................T5-6-76 O-5 Boom light does not light. .....................................T5-6-77 Exchange Inspection ........................................................T5-6-77 How to Lower Boom in Case of Emergency and When Engine Stops without Hose Rupture Valve..................................................................................T5-6-81 How to Lowering Boom When Emergency and When Engine Stops with Hose Rupture Valve .... .............................................................................................T5-6-82 Attachment Circuit Pressure Release Procedure ....T5-6-82

Air Conditioner .........................................T5-7-1 Outline of Air Conditioner ................................................ T5-7-1 Component Layout of Air Conditioner ........................ T5-7-2 Functions of Main Electrical Parts.................................. T5-7-4 Troubleshooting of Air Conditioner.............................. T5-7-7 Monitor Controller (Monitor) Fault Code 13911-3.. ............................................................................................... T5-7-8 Monitor Controller (Monitor) Fault Code 13912-4.. ............................................................................................... T5-7-8 Monitor Controller (Monitor) Fault Code 13913-3.. ............................................................................................... T5-7-9 Monitor Controller (Monitor) Fault Code 13914-4.. .............................................................................................T5-7-10 Monitor Controller (Monitor) Fault Code 13917-3.. .............................................................................................T5-7-10 Monitor Controller (Monitor) Fault Code 13918-4.. .............................................................................................T5-7-11 Monitor Controller (Monitor) Fault Code 13921-3.. .............................................................................................T5-7-11 Monitor Controller (Monitor) Fault Code 13922-4.. .............................................................................................T5-7-12 Monitor Controller (Monitor) Fault Code 13943-2.. .............................................................................................T5-7-12 Monitor Controller (Monitor) Fault Code 13944-2.. .............................................................................................T5-7-13

Monitor Controller (Monitor) Fault Code 13951-2.. .............................................................................................T5-7-14 Monitor Controller (Monitor) Fault Code 13991-2.. .............................................................................................T5-7-14 Monitor Controller (Monitor) Fault Code 13992-2.. .............................................................................................T5-7-15 Faulty Cooling (1)...............................................................T5-7-16 Faulty Cooling (2)...............................................................T5-7-17 Faulty Cooling (3)...............................................................T5-7-18 Faulty Cooling (4)...............................................................T5-7-20 Faulty Cooling (5)...............................................................T5-7-21 Faulty Heating (1)...............................................................T5-7-23 Faulty Heating (2)...............................................................T5-7-24 Others ....................................................................................T5-7-24 Blower motor does not operate. ..................................T5-7-25 Compressor clutch does not operate. ........................T5-7-26 Cooling Circuit Check by Using Manifold Gauge .... .............................................................................................T5-7-28 Work after Replacing Components .............................T5-7-31 Refill compressor oil..........................................................T5-7-32 Necessity of Purging .........................................................T5-7-32 Procedures for Charging Air Conditioner with Refrigerant ......................................................................T5-7-34 Warm-Up Operation .........................................................T5-7-39 Hose and Pipe Tightening Torque ...............................T5-7-41

TTDD650-EN-00(18/11/2019)

MEMO

TTDD650-EN-00(18/11/2019)

4

OPERATIONAL PERFORMANCE TEST Introduction..............................................T4-1-1 Operational Performance Tests ...................................... T4-1-1 Preparation for Performance Tests ................................ T4-1-2

Standard....................................................T4-2-1 Operational Performance Standard Table .................. T4-2-1 Engine System Performance Standards ...................... T4-2-1 Travel System Performance Standards......................... T4-2-2 Swing System Performance Standards ........................ T4-2-3 Front Attachment System Performance Standards ............................................................................................... T4-2-3 Lever System Performance Standards.......................... T4-2-7 Combined Operation System Performance Standards .......................................................................... T4-2-7 Component System Performance Standards ............ T4-2-7 Main Pump P-Q Diagram (P1, P2) .................................. T4-2-8 Main Pump P-Q Diagram (P3)........................................T4-2-10 Engine Control Dial Activating Range........................T4-2-12 Pilot Pressure Sensor (4436535) Activating Range. .............................................................................................T4-2-12 Pump Control Pressure Sensor (4436536) Activating Range ..........................................................T4-2-13 Pump Delivery Pressure Sensor (4436271) Activating Range ..........................................................T4-2-14 Monitor Indicating Values of ECM ...............................T4-2-15 Monitor Indicating Values of MC..................................T4-2-17 Monitor Indicating Values of MC (Pressure Sensor) .............................................................................................T4-2-20 Monitor Indicating Values of MC (Solenoid Valve) . .............................................................................................T4-2-23 Monitor Indicating Values of Switch Box Controller ........................................................................T4-2-24

Engine Test ................................................T4-3-1 Engine Speed ........................................................................ T4-3-1 Lubricant Consumption .................................................... T4-3-3

Machine Performance Test ......................T4-4-1 Travel Speed .......................................................................... T4-4-1 Track Link Revolution Speed............................................ T4-4-1 Mistrack Check...................................................................... T4-4-2 Travel Parking Leakage ...................................................... T4-4-3 Swing Speed.......................................................................... T4-4-4 Swing Function Drift Check ............................................. T4-4-5 Swing Motor Leakage ........................................................ T4-4-7

TTDD650-EN-00(18/11/2019)

Maximum Swingable Slant Angle.................................. T4-4-8 Swing Bearing Play.............................................................. T4-4-9 Hydraulic Cylinder Cycle Time.......................................T4-4-11 Dig Function Drift Check (Maximum Reach Position)...........................................................................T4-4-12 Dig Function Drift Check (Arm Roll-In Position) .....T4-4-14 Control Lever Operating Force......................................T4-4-15 Control Lever Stroke .........................................................T4-4-16 Combined Operation of Boom Raise and Swing Function Check .............................................................T4-4-16 Combined Operation of Boom Raise and Arm Roll-In Function Check ...............................................T4-4-18 Clearance of Front Attachment Connecting Part.... .............................................................................................T4-4-19

Component Test........................................T4-5-1 Primary Pilot Pressure......................................................... T4-5-1 Secondary Pilot Pressure................................................... T4-5-2 5-Spool Solenoid Valve Unit Set Pressure ................... T4-5-3 3-Spool Solenoid Valve Unit Set Pressure ................... T4-5-6 2-Spool Solenoid Valve Unit (Aftertreatment Device Regeneration Control) Set Pressure.......... T4-5-8 Main Pump Delivery Pressure .......................................T4-5-11 Main Relief Set Pressure ..................................................T4-5-12 Main Relief Valve Pressure Adjustment Procedure. .............................................................................................T4-5-13 High-Pressure Side of Main Relief Pressure Adjustment Procedure ...............................................T4-5-14 Low-Pressure Side of Main Relief Pressure Adjustment Procedure ...............................................T4-5-16 Relief Pressure (When Relieving Swing) ....................T4-5-16 Overload Relief Valve Set Pressure ..............................T4-5-18 Overload Relief Valve Pressure Adjustment Procedure (Reference) ................................................T4-5-19 Main Pump Flow Rate Measurement (P-Q Control (Torque Control)) ..........................................................T4-5-20 Main Pump Flow Rate Measurement (Pilot Pressure Characteristics)............................................T4-5-22 Regulator Adjustment (P1, P2)......................................T4-5-27 Regulator Adjustment (P3).............................................T4-5-29 Swing Motor Drainage.....................................................T4-5-30 Travel Motor Drainage .....................................................T4-5-33

Adjustment ...............................................T4-6-1 Rewrite of Aftertreatment Device Serial No............... T4-6-1 How to Clear Fault Code.................................................... T4-6-1

Measuring Method of No-Load-Max Differential Pressure.............................................................................. T4-6-3 Differential Pressure Sensor Learning .......................... T4-6-4 Filter Maintenance............................................................... T4-6-5 Procedure after Replacing DCU and ECM ................... T4-6-5 Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping ........................................................... T4-6-6 How to Check Manual Regeneration Switch ............. T4-6-8 Remedy at DEF Pressure Decrease ................................ T4-6-9 Clean DEF Tank ...................................................................T4-6-11 Remedy when Mixing Oil in DEF Tank........................T4-6-13 Calibration of Aerial Angle .............................................T4-6-13 Oil Monitoring Sensor Setting ......................................T4-6-21 [A] Constant Change (Oil Monitoring Sensor Setting).............................................................................T4-6-22 [D] Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)..........................................T4-6-25 [B] Diagnosis of Engine Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check) ..................T4-6-28 [C] Diagnosis of Hydraulic Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check) ..........T4-6-31

TTDD650-EN-00(18/11/2019)

SECTION4 OPERATIONAL PERFORMANCE TEST Group1 Introduction Operational Performance Tests Use operational performance test procedure to quantitatively check all system and functions on the machine.

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.

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. 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.

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.

TTDD650-EN-00(18/11/2019)

T4-1-1

SECTION4 OPERATIONAL PERFORMANCE TEST Group1 Introduction Preparation for Performance Tests Observe the following rules in order to carry out performance tests accurately and safely.

The Machine 1. Be sure to check each part before measurement. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Be sure to check the implementation status of daily and monthly inspections before measurement.

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.

T105-06-01-003 ja

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. When removing hydraulic piping, use oil pans to prevent the ground and machine from being contaminated.

Completely remove and clean up after the work to prevent environmental pollution. (Bring back waste oil and waste cloths.)

T105-06-01-004 ja

TTDD650-EN-00(18/11/2019)

T4-1-2

SECTION4 OPERATIONAL PERFORMANCE TEST Group1 Introduction 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.

TTDD650-EN-00(18/11/2019)

T4-1-3

SECTION4 OPERATIONAL PERFORMANCE TEST Group1 Introduction MEMO

TTDD650-EN-00(18/11/2019)

T4-1-4

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Operational Performance Standard Table The standard Performance values are listed in the table below.

The detailed measurement procedures are explained in groups Engine Test to Component Test. Refer to the reference page.

Values indicated in parentheses [ ] are reference values.

The standard measurement conditions are as followings unless instructed in each performance test procedure: ● Engine control dial: Fast idle ● Power mode: PWR ● Auto-idle switch: OFF position ● Work mode: Bucket ● Coolant temperature: 80 °C or more ● Hydraulic oil temperature: 50 ± 5 °C ● The aftertreatment device regeneration control should not be activated.

Engine System Performance Standards Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Engine Speed

T4-3-1

Slow Idle Speed

min-1

800±50

Control lever: Neutral, Pi­ lot shut-off lever: LOCK position, Value indicated on MPDr.

Slow Idle Speed

min-1

900±50

Control lever: Neutral, Pi­ lot shut-off lever: UN­ LOCK position, Value in­ dicated on MPDr.

Fast Idle Speed (With ECO Deactivated)

min-1

1700±50

Control lever: Value indi­ cated on MPDr. during operation

Fast Idle Speed (Heater Control: OFF)

min-1

1600±50

Control lever: Neutral (when 1 second or more has passed after return­ ing to neutral), Pilot shutoff lever: UNLOCK posi­ tion, Value indicated on MPDr.

Fast Idle Speed (Heater Control: ON)

min-1

1900±50

Pilot shut-off lever: LOCK position, Coolant temper­ ature: Less than 5 °C, Val­ ue indicated on MPDr.

Fast Idle Speed (Relief Operation)

min-1

1700±50

Boom raise relief opera­ tion, Value indicated on MPDr.

Fast Idle Speed (ECO mode)

min-1

1500±50

Control lever: Neutral, ECO mode, Value indica­ ted on MPDr.

TTDD650-EN-00(18/11/2019)

Reference Page

T4-2-1

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Reference Page

Fast Idle Speed (Travel HP mode)

min-1

1800±50

Travel relief operation (both travel right and left), Value indicated on MPDr.

Auto-Idle Speed

min-1

1200±50

Control lever: Neutral (when 3.5 seconds or more have passed after returning to neutral), Val­ ue indicated on MPDr.

min-1

1400±50

Pilot shut-off lever: LOCK position, Coolant temper­ ature of 70 °C or higher, Value indicated on MPDr.

min-1

1400±50

Hydraulic oil temperature is 0 °C or less or coolant temperature is 23 °C or less, Value indicated on MPDr.

Engine Compression Pressure

MPa

3.02±0.2

Engine speed: When 200 Refer to En­ gine Man­ min-1 ual.

Valve Clearance (IN, EX)

mm

0.4

With the engine cold

Refer to En­ gine Man­ ual.

Lubricant Consumption (Rated output)

mL/h

30 or less

Hour meter: 2000 hours or less

T4-3-3

Perform­ ance Stand­ ard

Remarks

Manual Regeneration Engine Speed (Slow Idle Speed)

Warming Up Speed

Travel System Performance Standards Performance Test Designation

Unit

Travel Speed

Reference Page T4-4-1

Fast Mode

sec/10 m

6.9±0.6

Slow Mode

sec/10 m

[11.6±1.0]

Track Revolution Speed

With one side track raised T4-4-1 off the ground

Fast Mode

sec/3 rev

33.7±2.0

LC: 35.9±2.0

Slow Mode

LC: 35.9±2.0

sec/3 rev

33.7±2.0

Mistrack (Fast Speed and Slow Speed)

mm/20 m

200 or less

T4-4-2

Travel Parking Leakage

mm/5 min

0

T4-4-3

TTDD650-EN-00(18/11/2019)

T4-2-2

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Swing System Performance Standards Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Reference Page

Swing Speed

sec/3 rev

17.5±1.0

Bucket: empty

T4-4-4

Swing Function Drift Check

mm/180°

1437 or less Bucket: empty

T4-4-5

Swing Motor Leakage

mm/5 min

0

Maximum Swingable Slant Angle

deg

21 or more Bucket: Load, Prescribed T4-4-8 Weight: 1650 kg

Swing Bearing Play

mm

1.25 or less Allowable Limit: 3.05

T4-4-9

Perform­ ance Stand­ ard

Reference Page

Bucket: Load, Prescribed T4-4-7 Weight: 1650 kg

Front Attachment System Performance Standards Performance Test Designation

Unit

Hydraulic Cylinder Cycle Time (Mono Boom) (With­ out HRV)

3.11 m Arm, 1.1 m 3 (New T4-4-11 JIS) Bucket, Bucket: emp­ ty

Boom Raise

sec

3.7±0.3

Boom Lower

sec

2.5±0.3

Arm Roll-In

sec

3.7±0.3

Arm Roll-Out

sec

3.3±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Hydraulic Cylinder Cycle Time (2-Piece Boom) (Without HRV)

3.11 m Arm, 1.1 m 3 (New JIS) Bucket, Bucket: emp­ ty

Boom Raise

sec

4.6±0.3

Boom Lower

sec

3.6±0.3

Arm Roll-In

sec

3.7±0.3

Arm Roll-Out

sec

3.4±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Positioning Lower

sec

5.1±0.3

Positioning Raise

sec

4.3±0.3

Hydraulic Cylinder Cycle Time (Mono Boom) (With HRV)

3.11 m Arm, 1.1 m 3 (New T4-4-11 JIS) Bucket, Bucket: emp­ ty

Boom Raise

sec

3.7±0.3

Boom Lower

sec

2.5±0.3

Arm Roll-In

sec

3.7±0.3

Arm Roll-Out

sec

3.3±0.3

Bucket Roll-In

sec

3.4±0.3

TTDD650-EN-00(18/11/2019)

Remarks

T4-2-3

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Performance Test Designation

Bucket Roll-Out

Unit

sec

Perform­ ance Stand­ ard

Reference Page

2.5±0.3

Hydraulic Cylinder Cycle Time (2-Piece Boom) (With HRV)

3.11 m Arm, 1.1 m 3 (New JIS) Bucket, Bucket: emp­ ty

Boom Raise

sec

4.6±0.3

Boom Lower

sec

3.9±0.3

Arm Roll-In

sec

3.7±0.3

Arm Roll-Out

sec

3.4±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Positioning Lower

sec

5.1±0.3

Positioning Raise

sec

4.3±0.3

Hydraulic Cylinder Cycle Time (Mono Boom) (With­ out HRV)

3.11 m Arm, Without Bucket

Boom Raise

sec

3.2±0.3

Boom Lower

sec

3.0±0.3

Arm Roll-In

sec

4.0±0.3

Arm Roll-Out

sec

3.1±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Hydraulic Cylinder Cycle Time (2-Piece Boom) (Without HRV)

T4-4-11

3.11 m Arm, Without Bucket

Boom Raise

sec

4.1±0.3

Boom Lower

sec

4.7±0.3

Arm Roll-In

sec

4.0±0.3

Arm Roll-Out

sec

3.3±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Positioning Lower

sec

5.4±0.3

Positioning Raise

sec

4.3±0.3

Hydraulic Cylinder Cycle Time (Mono Boom) (With HRV)

3.11 m Arm, Without Bucket

Boom Raise

sec

3.2±0.3

Boom Lower

sec

3.0±0.3

Arm Roll-In

sec

4.0±0.3

Arm Roll-Out

sec

3.1±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Hydraulic Cylinder Cycle Time (2-Piece Boom) (With HRV)

3.11 m Arm, Without Bucket

Boom Raise

sec

4.1±0.3

Boom Lower

sec

4.7±0.3

TTDD650-EN-00(18/11/2019)

Remarks

T4-2-4

T4-4-11

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Performance Test Designation

Unit

Perform­ ance Stand­ ard

Arm Roll-In

sec

4.0±0.3

Arm Roll-Out

sec

3.3±0.3

Bucket Roll-In

sec

3.4±0.3

Bucket Roll-Out

sec

2.5±0.3

Positioning Lower

sec

5.4±0.3

Positioning Raise

sec

4.3±0.3

Hydraulic Cylinder Drift Check (Mono Boom) Boom Cylinder

Arm Cylinder

Bucket Cylinder

Bucket Bottom

Arm Cylinder

Bucket Cylinder

Positioning Cylinder

Bucket Bottom

(Maximum Reach Posi­ tion)

mm/5 min

20 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

5 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

20 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

10 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

20 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

10 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

150 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

90 or less

Bucket: empty 3.11 m Arm, 1.1 m3 (New JIS) Bucket

(Maximum Reach Posi­ tion)

mm/5 min

20 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

5 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

20 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

10 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

20 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

10 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

40 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

30 or less

Bucket: empty

(Maximum Reach Posi­ tion)

mm/5 min

200 or less

Bucket: Load, Prescribed Weight: 1650 kg

(Arm Roll-In Position)

mm/5 min

150 or less

Bucket: empty

TTDD650-EN-00(18/11/2019)

Reference Page

3.11 m Arm, 1.1 m3 (New T4-4-12 JIS) Bucket

Hydraulic Cylinder Drift Check (2-Piece Boom) Boom Cylinder

Remarks

T4-2-5

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Clearance of Front Attachment Connecting Part Main Frame and Boom Foot

T4-4-19 mm

1.0 or less

Main Frame max. 100.20 (including bushing) min. 100.05 (including bushing)

mm

1.0 or less

Boom Foot max. 100.25 (including bushing) min. 100.05 (including bushing)

mm

1.0 or less

Pin

max. 100.00 min. 99.91

Boom and Arm

mm

1.0 or less

Boom

max. 100.20 (including bushing) min. 100.05 (including bushing)

mm

1.0 or less

Arm

max. 100.25 (including bushing) min. 100.05 (including bushing)

mm

1.0 or less

Pin

max. 99.88 min. 99.79

First Boom and Second Boom (Only Machines With the 2-Piece Boom Attached)

mm

1.0 or less

First Boom

max. 100.20 (including bushing) min. 100.05 (including bushing)

mm

1.0 or less

Second Boom

max. 100.25 (including bushing) min. 100.05 (including bushing)

mm

1.0 or less

Pin

max. 99.88 min. 99.79

NOTE HRV: Hose Rupture Valve

TTDD650-EN-00(18/11/2019)

Reference Page

T4-2-6

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Lever System Performance Standards Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Control Lever Operating Force

Reference Page T4-4-15

Front and Rear at Right Side

N

14 or less

Right and Left at Left Side

N

12 or less

Right and Left at Right Side

N

12 or less

Front and Rear at Left Side

N

14 or less

Travel Control Lever

N

28 or less

Control Lever Stroke

T4-4-16

Front and Rear at Right Side

mm

96±10

Right and Left at Left Side

mm

81±10

Right and Left at Right Side

mm

81±10

Front and Rear at Left Side

mm

96±10

Travel Control Lever

mm

120±10

Combined Operation System Performance Standards Performance Test Designation

Unit

Perform­ ance Stand­ ard

Combined Operation of Boom Raise and Swing (Time Required to Swing 90 Degrees) (Mono Boom)

sec

4.0±0.4

Bucket Teeth Height:

mm

6700 or more

Combined Operation of Boom Raise and Swing (Time Required to Swing 90 Degrees) (2-Piece Boom)

sec

4.0±0.4

Bucket Teeth Height:

mm

6300 or more

Combined Operation of Boom Raise and Arm Roll- sec In (Time Required for Arm to Reach Stroke End)

[4.6±0.5]

Remarks

Reference Page

3.11 m Arm, 1.1 m 3 (New T4-4-16 JIS) Bucket, Bucket: emp­ ty

3.11 m Arm, 1.1 m 3 (New JIS) Bucket, Bucket: emp­ ty

3.11 m Arm, 1.1 m3 (New T4-4-18 JIS) Bucket

Component System Performance Standards Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Primary Pilot Pressure

T4-5-1

Engine: Fast Idle Speed

MPa

4.0+1.0-0.5

Value indicated on MPDr.

Engine: Slow Idle Speed

MPa

3.8+1.0-0.5

Value indicated on MPDr.

Secondary Pilot Pressure (Engine:Fast Idle Speed and Slow Idle Speed)

TTDD650-EN-00(18/11/2019)

Reference Page

T4-5-2 MPa

T4-2-7

3.4 to 4.0

Value indicated on MPDr. (Control Lever:Full stroke)

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Performance Test Designation

Unit

Perform­ ance Stand­ ard

Remarks

Reference Page

Solenoid Valve Set Pressure

MPa

Value indi­ cated on MPDr.±0.2

T4-5-3, T4-5-6, T4-5-8

Main Pump Delivery Pressure

MPa

0.3+1.2-0.3

Control Lever: Neutral, T4-5-11 Value indicated on MPDr.

Arm (Relief operation) (P1, P2)

MPa

34.3+2.0

-0.5

Value indicated on MPDr.

Boom raise (Relief operation) (P1, P2)

MPa

38.0+2.0-1.5

Value indicated on MPDr.

Boom raise (Relief operation) (P3)

MPa

38.5+2.0-0.5

Value indicated on MPDr.

Boom lower (Relief operation) (P1)

MPa

34.3+2.0-0.5

Value indicated on MPDr.

Bucket (Relief operation) (P1)

MPa

35.5+2.0-0.5

Value indicated on MPDr.

Positioning (Relief operation) (P3)

MPa

35.4+2.0-0.5

Value indicated on MPDr.

Power Digging (P1, P2)

MPa

38.0+2.0-0.5

Value indicated on MPDr.

Relief Combined Operation of Boom Raise and Arm MPa Roll-In (P3)

35.0+2.0-0.5

Value indicated on MPDr.

32.4+2.3-0.5

Value indicated on MPDr. T4-5-16

Main Relief Set Pressure

Relief Pressure (When Relieving Swing)

T4-5-12

MPa

Overload Relief Pressure

(Reference values at 50 L/ T4-5-18 min)

Boom Lower, Arm Roll-In, Bucket Roll-In

MPa

39.2+1.0-0

Boom Raise, Arm Roll-Out, Bucket Roll-Out

MPa

39.2+1.0-0

Main Pump Flow Rate

L/min

Refer to T4-2-8, T4-2-10.

Swing Motor Drainage

T4-5-30

With constant speed

L/min

0.2 to 0.5

With the motor relieved

L/min

[2 to 5]

Travel Motor Drainage

T4-5-33

With the track raised off the ground

L/min

Less than 10 Allowable Limit: 10

With the motor relieved

L/min

Less than 15 Allowable Limit: 15

Main Pump P-Q Diagram (P1, P2) ● P-Q Control (Torque Control) (Reference: Measured at Test Stand) •

Rated pump speed: 1700 min-1

•

Hydraulic oil temperature: 50 ± 5 °C

NOTE Refer to "Main Pump Flow Rate Measurement (P-Q Control (Torque Control))"T4-5-20.

TTDD650-EN-00(18/11/2019)

T4-5-20

T4-2-8

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Points on P-Q Line Delivery Pressure (P) MPa

Flow Rate (Q) L/min

A

4.9

236±3

B

17.6

[226]

C

19.6

220±6

D

23.5

[180]

E

27.4

160±6

F

34.3

120±10

Values indicated in brackets [ ] are reference values.

Q

A B

L/min

C

D

E

F

MPa P T178-04-05-001 ja

● Pilot Pressure Characteristics (Reference: Measured at Test Stand) •

Rated pump speed: 1700 min-1

•

Hydraulic oil temperature: 50 ± 5 °C

NOTE Refer to "Main Pump Flow Rate Measurement (Pilot Pressure Characteristics)"T4-5-22.

Points on Pi-Q Line Pump Control Pressure (Pi) MPa

Flow Rate (Q) L/min (P1, P2)

(P3)

A

0.98±0.05

67±4

63±4

B

1.96

[152]

[132]

TTDD650-EN-00(18/11/2019)

T4-2-9

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Pump Control Pressure (Pi) MPa

Flow Rate (Q) L/min (P1, P2)

(P3)

C

2.89+0.05

236±3

-

D

2.94+0.05-0.39

-

210±3

-0.39

Values indicated in brackets [ ] are reference values.

Q L/min

C D

B

A

MPa

Pi T178-04-05-002-2 ja

Main Pump P-Q Diagram (P3) ● P-Q Control (Torque Control) (Reference: Measured at Test Stand) •

Rated pump speed: 1700 min-1

•

Hydraulic oil temperature: 50 ± 5 °C

NOTE Refer to "Main Pump Flow Rate Measurement (P-Q Control (Torque Control))"T4-5-20.

Points on P-Q Line Delivery Pressure (P) MPa

Flow Rate (Q) L/min

A

4.9

210±3

B

18.6

[202]

C

26.5

190±6

D

34.3

[144]

E

-

-

F

-

-

TTDD650-EN-00(18/11/2019)

T4-2-10

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Values indicated in brackets [ ] are reference values.

Q

A B

L/min

C

D

E

F

MPa P T178-04-05-001 ja

● Pilot Pressure Characteristics (Reference: Measured at Test Stand) •

Rated pump speed: 1700 min-1

•

Hydraulic oil temperature: 50 ± 5 °C

NOTE Refer to "Main Pump Flow Rate Measurement (Pilot Pressure Characteristics)"T4-5-22.

Points on Pi-Q Line Pump Control Pressure (Pi) MPa

Flow Rate (Q) L/min (P1, P2)

(P3)

A

0.98±0.05

67±4

63±4

B

1.96

[152]

[132]

C

2.89+0.05-0.39

236±3

-

D

2.94+0.05-0.39

-

210±3

Values indicated in brackets [ ] are reference values.

TTDD650-EN-00(18/11/2019)

T4-2-11

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Q L/min

C D

B

A

MPa

Pi T178-04-05-002-2 ja

Engine Control Dial Activating Range 1. Checking Method •

Hydraulic oil temperature: 50 ± 5 °C

•

Unless specified: Power Mode

Work Mode

PWR

Auto-Idle Switch

Bucket

OFF Position

2. Operation Range How to Use Screens

Specification

Slow Idle

0.4 to 0.75 V

Fast Idle

4.25 to 4.6 V

Pilot Pressure Sensor (4436535) Activating Range 1. Checking Method •

Hydraulic oil temperature: 50 ± 5 °C

•

Unless specified: Engine Control Dial

Fast Idle

Power Mode PWR

Work Mode Bucket

2. Operation Range

TTDD650-EN-00(18/11/2019)

T4-2-12

Auto-Idle Switch OFF Position

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

How to Use Screens

Reference Value

Boom Raise Pilot Pressure Sensor, Arm Control lever: Neutral, Pilot shut-off 0 to 0.1 MPa 1 Roll-In Pilot Pressure Sensor, Arm 2 lever: LOCK Position Roll-In Pilot Pressure Sensor, Arm Roll- Control lever: Full stroke, Pilot shut-off 3.3 to 3.9 MPa Out Pilot Pressure Sensor, Bucket Roll- Lever: UNLOCK Position In Pilot Pressure Sensor, Bucket RollOut Pilot Pressure Sensor, Travel Pilot Pressure Sensor, Swing Pilot Pressure Sensor, Front Pilot Pressure Sensor, Auxiliary 1 Pilot Pressure Sensor, Auxil­ iary 2 Pilot Pressure Sensor 3. Output Characteristics Diagram •

Power voltage: 5.0 V

•

Ambient temperature: 25 °C ᨒ

a

᧱᧪᧬ ᧤᧰᧪᧱᧥ ᧰᧪᧬ ᧤᧯᧪᧳᧥ ᧯᧪᧬ ᧮᧪᧬ ᧤᧭᧪᧯᧥ ᧭᧪᧬ ᧤᧬᧪᧱᧥ ᧬

᧬

᧬᧪᧵᧴

᧭᧪᧵᧲

᧮᧪᧵᧰

᧯᧪᧵᧮

᧰᧪᧵᧬

ᨉᨌ᨝ TAEQ-04-02-001-1 ja

a- Calibration Point

Pump Control Pressure Sensor (4436536) Activating Range 1. Checking Method •

Hydraulic oil temperature: 50 ± 5 °C

•

Unless specified: Engine Control Dial

Fast Idle

Power Mode PWR

Work Mode Bucket

Auto-Idle Switch OFF Position

2. Operation Range Item Pump 1 Control Pressure Sensor, Pump 2 Control Pressure Sensor, Pump 3 Control Pressure Sensor

How to Use Screens Control lever: Neutral, Pilot shut-off lever: LOCK Position

Power voltage: 5.0 V

•

Ambient temperature: 25 °C

TTDD650-EN-00(18/11/2019)

0 to 0.1 MPa

Control lever: Full stroke, Pilot shut-off 3.3 to 4.3 MPa Lever: UNLOCK Position

3. Output Characteristics Diagram •

Reference Value

T4-2-13

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard 9

D

TDFY-04-02-001-1 ja

a- Calibration Point

Pump Delivery Pressure Sensor (4436271) Activating Range 1. Checking Method •

Hydraulic oil temperature: 50 ± 5 °C

•

Unless specified: Engine Control Dial

Fast Idle

Power Mode PWR

Work Mode Bucket

Auto-Idle Switch OFF Position

2. Operation Range Item

How to Use Screens

Pump 1 Delivery Pressure Sensor, Pump 2 Delivery Pressure Sensor, Pump 3 Delivery Pressure Sensor

Control lever: Neutral, Pilot shut-off lever: LOCK Position

Reference Value 0 to 1.5 MPa

Control lever: Full stroke, Pilot shut-off 34.3 to 49.0 MPa Lever: UNLOCK Position

3. Output Characteristics Diagram •

Power voltage: 5.0 V Y

03D

03D

Output Voltage Characteristics TDFY-04-02-002-1 ja

TTDD650-EN-00(18/11/2019)

T4-2-14

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard s 03D

03D

Pressure Deviation TDFY-04-02-003-1 ja

D

r&

E

Temperature Characteristics TDFY-04-02-004-1 ja

a- Magnification

b- Temperature

Monitor Indicating Values of ECM The standard measurement conditions are as followings unless instructed in each performance test procedure: ● Engine control dial: Fast idle ● Power mode: PWR ● Auto-idle switch: OFF position ● Work mode: Bucket ● Coolant temperature: 80 °C or more ● Hydraulic oil temperature: 50 ± 5 °C ● The aftertreatment device regeneration control should not be activated.

Item

Unit

Refer­ ence Value

Measured Value First

Actual Engine Speed No load

min-1 1600

When relieving arm roll-in

min-1 1700

Target Fuel Injection Qty No load

mm3/s 36.0 t

When relieving arm roll-in

mm3/s 100.7 t

Target Engine Speed No load

min-1 1600

When relieving arm roll-in

min-1 1700

Engine Torque

TTDD650-EN-00(18/11/2019)

T4-2-15

Second

Third

Remarks Aver­ age

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Unit

Refer­ ence Value

No load

%

25

When relieving arm roll-in

%

71

No load

kPa

152

When relieving arm roll-in

kPa

196

Measured Value First

Boost Pressure

Directed Engine Speed No load

min-1 1600

When relieving arm roll-in

min-1 1700

Common Rail Pressure DP No load

MPa

0

When relieving arm roll-in

MPa

0

No load

kPa

4

When relieving arm roll-in

kPa

4

No load

kPa

592

When relieving arm roll-in

kPa

608

No load

MPa

152

When relieving arm roll-in

MPa

177

No load

L/h

10.59

When relieving arm roll-in

L/h

30.89

No load

MPa

102

When relieving arm roll-in

MPa

102

No load

V

28

When relieving arm roll-in

V

28

No load

%

33

When relieving arm roll-in

%

33

No load

%

100

When relieving arm roll-in

%

100

No load

%

89

When relieving arm roll-in

%

60

hPa

9000

Supply Pump Inlet Pressure

Engine Oil Pressure

Common Rail Pressure

Fuel Flow Rate

Atmospheric Pressure

ECM Battery Voltage

EGR Opening Amount 1

ITH Opening Amount

Actual Turbo Opening Amt

DEF/AdBlue® Pressure No load

TTDD650-EN-00(18/11/2019)

T4-2-16

Second

Third

Remarks Aver­ age

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

When relieving arm roll-in

Unit

Refer­ ence Value

hPa

9000

No load

0 to 255

200

When relieving arm roll-in

0 to 255

205

No load

%

32.5

When relieving arm roll-in

%

32.5

No load

%

1.2

When relieving arm roll-in

%

1.2

No load

%

18.4

When relieving arm roll-in

%

20.8

Measured Value First

Second

Third

Remarks Aver­ age

Dosing Valve Status

DEF/AdBlue® Concentration

Dosing Valve Amount

DEF/AdBlue® S/M Pump Aperture

Monitor Indicating Values of MC The standard measurement conditions are as followings unless instructed in each performance test procedure: ● Engine control dial: Fast idle ● Power mode: PWR ● Auto-idle switch: OFF position ● Work mode: Bucket ● Coolant temperature: 80 °C or more ● Hydraulic oil temperature: 50 ± 5 °C ● The aftertreatment device regeneration control should not be activated.

Item

Unit

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

Demand Engine Speed Fast Idle Speed (No load)

min-1 1600

Fast Idle Speed (When operating a control lever)

min-1 1700

Relieve boom raise cir­ cuit.

Fast Idle Speed (Travel HP mode)

min-1 1800

Travel relief operation

Fast Idle Speed (ECO mode)

min-1 1500

Relieve boom raise cir­ cuit.

Auto-Idle Speed

min-1 1200

Slow Idle Speed

min-1 800

Pilot shut-off lever: LOCK position

Slow Idle Speed

min-1 900

Pilot shut-off lever: UN­ LOCK Position

TTDD650-EN-00(18/11/2019)

T4-2-17

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Manual Regeneration Engine Speed (Slow Idle Speed)

Unit

Refer­ ence Value

Measured Value First

min-1 1400

Second

Third

Remarks Aver­ age Coolant temperature: 70 °C or more, Pilot shut-off lever: LOCK Position

Actual Engine Speed Fast Idle Speed (No load)

min-1 1600

Fast Idle Speed (When operating a control lever)

min-1 1700

Relieve boom raise cir­ cuit.

Fast Idle Speed (Travel HP mode)

min-1 1800

Travel relief operation

Fast Idle Speed (ECO mode)

min-1 1500

Relieve boom raise cir­ cuit.

Auto-Idle Speed

min-1 1200

Slow Idle Speed

min-1 800

Pilot shut-off lever: LOCK position

Slow Idle Speed

min-1 900

Pilot shut-off lever: UN­ LOCK Position

Manual Regeneration Engine Speed (Slow Idle Speed)

min-1 1400

Coolant temperature: 70 °C or more, Pilot shut-off lever: LOCK Position

Tgt Pump 1 Flow Rate Control lever in neutral

L/min 30

Boom raise operation

L/min 25

Boom lower operation

L/min -

Arm roll-in operation

L/min 72

When relieving

Arm roll-out operation

L/min 72.5

When relieving

Bucket roll-out operation

L/min 141

When relieving

Bucket roll-in operation

L/min 141

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

L/min 25.5

When relieving

When relieving

Tgt Pump 2 Flow Rate Control lever in neutral

L/min 30

Boom raise operation

L/min 25

Boom lower operation

L/min -

Arm roll-in operation

L/min 72

When relieving

Arm roll-out operation

L/min 73

When relieving

Bucket roll-out operation

L/min 34

When relieving

Bucket roll-in operation

L/min 34

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

L/min 25.5

When relieving

When relieving

Tgt Pump 3 Flow Rate Control lever in neutral

L/min 28

Boom raise operation

L/min 112

Boom lower operation

L/min -

TTDD650-EN-00(18/11/2019)

When relieving

T4-2-18

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Unit

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

Arm roll-in operation

L/min 29.5

When relieving

Arm roll-out operation

L/min 30

When relieving

Bucket roll-out operation

L/min 29.5

When relieving

Bucket roll-in operation

L/min 29.5

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

L/min 128.5

When relieving

Tgt Pump 1 Displacement Control lever in neutral

cm3

18

Boom raise operation

cm3

15

Boom lower operation

cm3

-

Arm roll-in operation

cm3

42

When relieving

Arm roll-out operation

cm3

43

When relieving

Bucket roll-out operation

cm3

83

When relieving

Bucket roll-in operation

cm3

83

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

cm3

15

When relieving

Control lever in neutral

cm3

19

Boom raise operation

cm3

15

Boom lower operation

cm3

-

Arm roll-in operation

cm3

42

When relieving

Arm roll-out operation

cm3

43

When relieving

Bucket roll-out operation

cm3

20

When relieving

Bucket roll-in operation

cm3

20

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

cm3

15

When relieving

Control lever in neutral

cm3

17.5

Boom raise operation

cm3

66

Boom lower operation

cm3

-

Arm roll-in operation

cm3

17.5

When relieving

Arm roll-out operation

cm3

18

When relieving

Bucket roll-out operation

cm3

17.5

When relieving

Bucket roll-in operation

cm3

17.5

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

cm3

76

When relieving

Control lever in neutral

%

0

Boom raise operation

%

9

When relieving

Tgt Pump 2 Displacement When relieving

Tgt Pump 3 Displacement When relieving

Pump 1 Load Factor

TTDD650-EN-00(18/11/2019)

When relieving

T4-2-19

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Unit

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

Boom lower operation

%

-

Arm roll-in operation

%

25

When relieving

Arm roll-out operation

%

26

When relieving

Bucket roll-out operation

%

50

When relieving

Bucket roll-in operation

%

51

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

%

14.8

When relieving

Control lever in neutral

%

0

Boom raise operation

%

9

Boom lower operation

%

-

Arm roll-in operation

%

25

When relieving

Arm roll-out operation

%

26

When relieving

Bucket roll-out operation

%

0

When relieving

Bucket roll-in operation

%

0

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

%

8

When relieving

Control lever in neutral

%

0

Boom raise operation

%

82

Boom lower operation

%

-

Arm roll-in operation

%

0

When relieving

Arm roll-out operation

%

0

When relieving

Bucket roll-out operation

%

0

When relieving

Bucket roll-in operation

%

0

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

%

87

When relieving

Pump 2 Load Factor When relieving

Pump 3 Load Factor When relieving

Monitor Indicating Values of MC (Pressure Sensor) The standard measurement conditions are as followings unless instructed in each performance test procedure: ● Engine control dial: Fast idle ● Power mode: PWR ● Auto-idle switch: OFF position ● Work mode: Bucket ● Coolant temperature: 80 °C or more ● Hydraulic oil temperature: 50 ± 5 °C ● The aftertreatment device regeneration control should not be activated.

Item

Unit

Refer­ ence Value

Measured Value First

Pump 1 Delivery Pressure TTDD650-EN-00(18/11/2019)

T4-2-20

Second

Third

Remarks Aver­ age

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Unit

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

Control lever in neutral

MPa

0.3

Boom raise operation

MPa

38.8

Boom lower operation

MPa

-

Arm roll-in operation

MPa

35.8

When relieving

Arm roll-out operation

MPa

35.5

When relieving

Bucket roll-out operation

MPa

36

When relieving

Bucket roll-in operation

MPa

36

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

34.5

When relieving

Control lever in neutral

MPa

0.25

Boom raise operation

MPa

38.8

Boom lower operation

MPa

-

Arm roll-in operation

MPa

35.5

When relieving

Arm roll-out operation

MPa

35.3

When relieving

Bucket roll-out operation

MPa

0.5

When relieving

Bucket roll-in operation

MPa

0.5

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

34.5

When relieving

Control lever in neutral

MPa

0.25

Boom raise operation

MPa

39.3

Boom lower operation

MPa

-

Arm roll-in operation

MPa

0.5

When relieving

Arm roll-out operation

MPa

0.5

When relieving

Bucket roll-out operation

MPa

0.5

When relieving

Bucket roll-in operation

MPa

0.5

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

36.5

When relieving

Control lever in neutral

MPa

0

Boom raise operation

MPa

0

Boom lower operation

MPa

0

Arm roll-in operation

MPa

0

When relieving

Arm roll-out operation

MPa

0

When relieving

Bucket roll-out operation

MPa

0

When relieving

Bucket roll-in operation

MPa

0

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

0

When relieving

MPa

0.51

When relieving

Pump 2 Delivery Pressure When relieving

Pump 3 Delivery Pressure When relieving

ADD Pump Delivery Pressure When relieving

Pump 1 Control Pressure Control lever in neutral

TTDD650-EN-00(18/11/2019)

T4-2-21

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Unit

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

Boom raise operation

MPa

3.84

When relieving

Boom lower operation

MPa

-

Arm roll-in operation

MPa

3.9

When relieving

Arm roll-out operation

MPa

3.9

When relieving

Bucket roll-out operation

MPa

3.96

When relieving

Bucket roll-in operation

MPa

3.96

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

3.84

When relieving

Control lever in neutral

MPa

0.54

Boom raise operation

MPa

3.84

Boom lower operation

MPa

-

Arm roll-in operation

MPa

3.9

When relieving

Arm roll-out operation

MPa

3.9

When relieving

Bucket roll-out operation

MPa

0.54

When relieving

Bucket roll-in operation

MPa

0.54

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

3.84

When relieving

Control lever in neutral

MPa

0.54

Boom raise operation

MPa

3.84

Boom lower operation

MPa

-

Arm roll-in operation

MPa

0.54

When relieving

Arm roll-out operation

MPa

0.6

When relieving

Bucket roll-out operation

MPa

0.54

When relieving

Bucket roll-in operation

MPa

0.54

When relieving

Combined operation of boom raise, arm roll-in, and bucket roll-in

MPa

3.84

When relieving

Boom Cyl Bottom Pressure

MPa

0

Relieve boom raise cir­ cuit.

Boom Cyl Rod Pressure

MPa

0

When relieving boom lower

Boom Raise Pilot Pressure

MPa

3.96

Relieve boom raise cir­ cuit.

Arm 1 Roll-In Pilot Pressure

MPa

3.96

When relieving arm rollin

Arm 2 Roll-In Pilot Pressure

MPa

4.02

When relieving arm rollin

Arm Roll-Out Pilot Pressure

MPa

4.02

When relieving arm rollout

Bucket Digging Pilot Pressure

MPa

4.02

When relieving bucket roll-in

Pump 2 Control Pressure When relieving

Pump 3 Control Pressure

TTDD650-EN-00(18/11/2019)

When relieving

T4-2-22

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Unit

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

Bucket Roll-Out Pilot Pressure

MPa

4.02

When relieving bucket roll-out

Travel Pilot Pressure

MPa

4.02

Travel relief operation

Front ATT Pilot Pressure

MPa

3.96

Operate either of boom, arm, bucket, or swing.

Swing Pilot Pressure

MPa

3.99

When relieving swing

ATT 1 Pilot Pressure

MPa

3.0

When relieving attach­ ment

ATT 2 Pilot Pressure

MPa

3.0

When relieving attach­ ment

Monitor Indicating Values of MC (Solenoid Valve) The standard measurement conditions are as followings unless instructed in each performance test procedure: ● Engine control dial: Fast idle ● Power mode: PWR ● Auto-idle switch: OFF position ● Work mode: Bucket ● Coolant temperature: 80 °C or more ● Hydraulic oil temperature: 50 ± 5 °C ● The aftertreatment device regeneration control should not be activated.

Item

Pump 1, 2 Torque Control Solenoid Valve Output

Unit

Measured Value First

Second

Third

Remarks Aver­ age

0.99

When relieving arm rollin

Pump 3 Torque Control Solenoid Valve MPa Output

0

Relieve boom raise cir­ cuit.

Pump 2 Flow Rate Upper Limit Control MPa Solenoid Valve Output

1.56

Breaker mode, Attach­ ment pedal in full stroke, Pump 2 flow rate:

Arm Regeneration Control Solenoid Valve Output

MPa

1.71

Single arm roll-in opera­ tion above the ground

Digging Regeneration Control Sole­ noid Valve Output

MPa

3.18

When relieving arm rollin

Power Digging and Travel Motor Swash MPa Angle Switching Control Solenoid Valve Output

3

Power Digging Switch: ON

Pump 1 Flow Rate Increase Solenoid Valve Output

MPa

3.99

Aftertreatment Device Manual Regeneration

Pump 1 Center Bypass Cut Control Sol­ MPa enoid Valve Output

0.69

Aftertreatment Device Manual Regeneration

TTDD650-EN-00(18/11/2019)

MPa

Refer­ ence Value

T4-2-23

SECTION4 OPERATIONAL PERFORMANCE TEST Group2 Standard Item

Arm 1 Flow Rate Control Solenoid Valve Output

Unit

MPa

Refer­ ence Value

Measured Value First

Second

Third

Remarks Aver­ age

4.98

Breaker mode, Com­ bined operation of at­ tachment pedal and arm roll-in in full stroke

Pump 3 Center Bypass Cut Control Sol­ MPa enoid Valve Output

3

Relieve boom raise cir­ cuit.

Arm Roll-In Meter-Out Opening Amount Control Solenoid Valve Out­ put

MPa

2.82

When relieving arm rollin

Arm 2 Roll-In Pilot Pressure Control Solenoid Valve Output

MPa

3.99

Combined operation of bucket roll-in and arm roll-in in full stroke with the front attachment above the ground

Boom 3 Raise Pilot Pressure Control Solenoid Valve Output

MPa

0

Bucket roll-in relief, Arm roll-in relief

Auxiliary Flow Rate Control Solenoid Valve Output

MPa

4.98

Breaker mode, Priority (arm roll-in) max., Com­ bined operation of at­ tachment pedal and arm roll-in in full stroke

Aux. Overload Relief Solenoid Valve Output

MPa

27.4

Pulverizer mode, Attach­ ment pedal in full stroke

Breaker Relief Solenoid Valve Output

MPa

21

Breaker mode, Attach­ ment pedal in full stroke

Monitor Indicating Values of Switch Box Controller The standard measurement conditions are as followings unless instructed in each performance test procedure: ● Engine control dial: Fast idle ● Power mode: PWR ● Auto-idle switch: OFF position ● Work mode: Bucket ● Coolant temperature: 80 °C or more ● Hydraulic oil temperature: 50 ± 5 °C ● The aftertreatment device regeneration control should not be activated.

Item

Unit

Refer­ ence Value

Measured Value First

Engine Control Dial Fast Idle

V

4.42

Slow Idle

V

0.58

TTDD650-EN-00(18/11/2019)

T4-2-24

Second

Third

Remarks Aver­ age

SECTION4 OPERATIONAL PERFORMANCE TEST Group3 Engine Test Engine Speed Summary 1. Measure the engine speed by using the monitor unit or MPDr..

2. Measure the engine speeds in each mode.

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

Preparation 1. Select the service menu of the monitor or MPDr.. In case of MPDr., install MPDr. first.

2. Warm up the machine until the coolant temperature reaches 50 °C or more and the hydraulic oil temperature is 50±5 °C. Measurement 1. Measure the items as shown in the table.

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

Item

Engine Control Dial

Power Mode

Auto-Idle Switch Work Mode

Measurement Conditions

Slow idle speed

Slow Idle

PWR

OFF Position

Bucket

Control lever: Neutral, Pilot shut-off lever: LOCK position

Slow idle speed

Slow Idle

PWR

OFF Position

Bucket

Control lever: Neutral, Pilot shut-off lever: UNLOCK Position

Fast Idle Speed Fast Idle (With ECO Deac­ tivated)

PWR

OFF Position

Bucket

Deactivate ECO by MPDr., Control lever: auxiliary operation

Fast Idle Speed Fast Idle (Heater Control: OFF)

PWR

OFF Position

Bucket

Control lever: Neutral (1 second or more passed after returning to neutral), Pilot shut-off lever: UN­ LOCK Position

Fast Idle Speed Fast Idle (Heater Control: ON)

PWR

OFF Position

Bucket

Pilot shut-off lever: LOCK position, Coolant temperature: less than 5 °C

Fast Idle Speed (Relief Opera­ tion)

Fast Idle

PWR

OFF Position

Bucket

Boom raise relief operation

Fast Idle Speed (ECO Mode)

Fast Idle

ECO

OFF Position

Bucket

Control lever: Neutral

Fast Idle Speed Fast Idle (Travel HP Mode)

PWR

OFF Position

Bucket

Travel relief operation (both travel right and left)

Auto-Idle Speed Fast Idle

PWR

ON Position

Bucket

Control lever: Neutral (3.5 second or more passed after returning to neutral)

Manual Regener­ Slow Idle ation Engine Speed

PWR

OFF Position

Bucket

Pilot shut-off lever: LOCK position, Control lever: Neutral, Coolant tem­ perature is 70°C or more

TTDD650-EN-00(18/11/2019)

T4-3-1

SECTION4 OPERATIONAL PERFORMANCE TEST Group3 Engine Test Item Warming Up Speed

Engine Control Dial Slow Idle

Power Mode

Auto-Idle Switch Work Mode

PWR

OFF Position

Bucket

őŖŔʼn

Measurement Conditions Hydraulic oil temperature is 0 °C or less or coolant temperature is 23 °C or less

1

˩ˡ˪˱ Ŕņŕ

ůİŮŪůġ

˩˫ˠˡ

őŖŔʼn

2

䰙

信

˩˫ˠˡ

䩩

ŕŖŏņ

őŖŔʼn

ŔŐŖœńņ łŎİŇŎ őŖŔʼn

őŖŔʼn

ŗŐōİőŘœȁ

łŖŕŐ İŐŇŇ łŖŕŐ

ůİŮŪůġ ůİŮŪůġ

2 ŐŇŇ

3 Ŋŏŕ ŐŇŇ

Őŏ őŖŔʼnġ

3

ＯＦＦ

łń

ń Őŏ

Ŕŕł œŕ

1

2

3

4

5

6

7

8

9

0 Ŋŏŕ

Őŏ

ŐŇŇ őŖŔʼn

Switch Panel TDFY-02-05-018-5 ja 1-

Engine Control Dial

2-

Power Mode Switch

3-

Auto-Idle Switch

4 06 32PM 50.0 h

 ˫

81.3 MHz

Monitor TDFY-05-02-002-1 ja 4-

Work Mode

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

TTDD650-EN-00(18/11/2019)

T4-3-2

SECTION4 OPERATIONAL PERFORMANCE TEST Group3 Engine Test Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Lubricant Consumption Measuring Method 1. Place the machine on the level, firm ground and leave the machine for at least one hour in order to return the lubricant to the oil pan after the engine stops.

At this time, confirm that the machine is level by using a level.

2. Record read-out A (unit: hour) of the hour meter.

3. Replenish the lubricant up to the high-level gauge.

4. Operate the machine for at least 100 hours or until the oil level lowers to the low-level gauge.

5. Place the machine on the level, firm ground and leave the machine for at least one hour in order to return the lubricant to the oil pan after the engine stops.

At this time, confirm that the machine is level by using a level.

6. Record read-out B (unit: hour) of the hour meter.

7. Replenish the lubricant up to the high-level gauge while measuring the oil-replenishing volume C.

NOTE When measuring, use a high-precision measuring cylinder or the like.

8. The lubricant consumption can be determined from replenished oil amount (C) [mL]/operation hours (B-A) [hr].

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

TTDD650-EN-00(18/11/2019)

T4-3-3

SECTION4 OPERATIONAL PERFORMANCE TEST Group3 Engine Test MEMO

TTDD650-EN-00(18/11/2019)

T4-3-4

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 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 system (from the main pump to the travel motor).

Preparation 1. Adjust the track link sag of both tracks to the nominal dimension.

2. Provide a flat, solid test yard 10 m in length, with an extra length of 3 to 5 m at both ends for machine acceleration and deceleration.

3. With the arm and bucket cylinders fully extended, hold the bucket 0.3 to 0.5 m above the ground.

4. Maintain the hydraulic oil temperature at 50±5 °C. c a b e

d

d TDBC-04-04-001-1 ja

a- Bucket Height: 0.3 to 0.5 m b- Start Point c- End Point

d- Acceleration/Deceleration Zone: 3 to 5 m e- 10 m

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

2. Follow the test conditions specified below.

Travel Mode Switch

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Slow Mode

Fast Idle

PWR

OFF Position

Bucket

Fast Mode

Fast Idle

PWR

OFF Position

Bucket

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

4. Measure the time required to travel between the start and end.

5. After measuring the time when going, swing the upperstructure 180 degrees, and measure the time when coming back in the same way.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Track Link Revolution Speed Summary 1. Measure the track link revolution cycle time with the track raised off ground and check the performance of the travel systems (from the main pump to the travel motor).

TTDD650-EN-00(18/11/2019)

T4-4-1

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Preparation 1. Adjust the track link sag of both tracks to the nominal dimension.

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

3.

CAUTION Securely support the raised machine off the ground by using blocks.

Jack up the track link to be measured off the ground. Jack up the track to be measured as shown in Figure A.

a

A M104-07-067-1 ja

a- 90 to 110° 4. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Measure on both track links in slow and fast travel modes with forward and reverse travel.

2. Follow the test conditions specified below.

Travel Mode Switch

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Slow Mode

Fast Idle

PWR

OFF Position

Bucket

Fast Mode

Fast Idle

PWR

OFF Position

Bucket

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

4. Measure the time required for 3 revolutions after a constant track link revolution speed is obtained.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

NOTE When the measurement data obtained through the track revolution test with the track raised off the ground has wide variations, the evaluation based on the results obtained from the 10 m travel speed check described before is more recommendable.

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Mistrack Check Summary 1. Allow the machine to travel 20 m. Measure the maximum tread deviation from the line drawn between the travel start and end points and check the performance of the travel system (from the main pump to the travel motor).

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

TTDD650-EN-00(18/11/2019)

T4-4-2

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Preparation 1. Adjust the track link sag of both tracks to the nominal dimension.

2. Provide a flat, solid test yard 20 m in length, with an extra length of 3 to 5 m at both ends for machine acceleration and deceleration.

3. With the arm and bucket cylinders fully extended, hold the bucket 0.3 to 0.5 m above the ground.

4. Maintain the hydraulic oil temperature at 50±5 °C. a

b c

T105-06-03-022-1 ja

a- Maximum Distance b- Acceleration/Deceleration Zone: 3 to 5 m

c- 20 m

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

2. Follow the test conditions specified below.

Travel Mode Switch

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Slow Mode

Fast Idle

PWR

OFF Position

Bucket

Fast Mode

Fast Idle

PWR

OFF Position

Bucket

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

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

5. After measuring maximum distance (a) when going, swing the upperstructure 180 degrees, and measure maximum distance (a) when coming back in the same way.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Travel Parking Leakage Summary 1. Measure the parking brake function on a specified slope.

2. The prescribed parking brake performance is that on a slope with a gradient of 20% (11.31°).

Preparation 1. Measure on a flat road with a gradient of 20% (11.31°).

TTDD650-EN-00(18/11/2019)

T4-4-3

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test 2. With the arm and bucket cylinders fully extended, hold the bucket 0.2 to 0.3 m above the ground.

3. Maintain the hydraulic oil temperature at 50±5 °C.

a

T105-06-03-004-1 ja

a- 0.2 to 0.3 m Measurement 1. Climb the slope and set the travel control lever in neutral.

2. Stop the engine.

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

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

b TDAA-04-04-001-1 ja

b- Distance Moved When 5 Minutes Passed Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Swing Speed Summary 1. Measure the time required to swing three complete turns and check the performance of the swing system (from the main pump to the swing motor).

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

2. Place the machine on flat and solid ground with an 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. (The bucket is empty.)

NOTE In case that 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.

TTDD650-EN-00(18/11/2019)

T4-4-4

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test

a

b TDFY-04-04-001-1 ja

a- The Same Height as the Boom Foot Pin

b- The Boom Fully Raised and the Arm Fully Rolled-in

Measurement

CAUTION Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

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

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

4. Measure in both the clockwise and counterclockwise directions.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

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.

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

2. Place the machine on flat and solid ground with an 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. (The bucket is empty.)

4. Put marks onto the swing bearing outer circumference (upperstructure side) and the track frame by using tapes or other means.

TTDD650-EN-00(18/11/2019)

T4-4-5

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test 5. Swing the upperstructure 180 degrees.

6. Maintain the hydraulic oil temperature at 50±5 °C.

a T105-06-03-008-1 ja

a- Put Marks onto the Swing Bearing Outer Circumference and the Track Frame

b T105-06-03-009-1 ja

b- Before Starting the Measurement, Swing the Upperstructure 180 Degrees Measurement

CAUTION Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode PWR

Auto-Idle Switch OFF Position

Work Mode Bucket

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

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

4. Measure in both the clockwise and counterclockwise directions.

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

TTDD650-EN-00(18/11/2019)

T4-4-6

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test

a

b c T105-06-03-010-1 ja

a- Measured Arc Length (Swing Bearing Outer Circumfer­ ence). b- Mark on the Track Frame

c- Mark on the Swing Bearing

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

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.

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

T105-06-03-011 ja

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

2. Load the bucket. (Refer to "Operational Performance Standard Table"T4-2-1 for the loading weight.)

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.

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

5. Climb a slope and swing the upperstructure 90 degrees to the slope. Put marks onto the swing bearing outer circumference (upperstructure side) and the track frame by using tapes or other means.

TTDD650-EN-00(18/11/2019)

T4-4-7

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test 6. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Power Mode PWR

Auto-Idle Switch OFF Position

Work Mode Bucket

2. Start the engine. When 5 minutes passed at idle speed, measure the arc length (swing bearing outer circumference) between the two marks on the swing bearing and track frame.

3. Measure in both the clockwise and counterclockwise directions.

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

a

b c T105-06-03-010-1 ja

a- Measured Arc Length (Swing Bearing Outer Circumfer­ ence). b- Mark on the Track Frame

c- Mark on the Swing Bearing

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Maximum Swingable Slant Angle Summary 1. With the upperstructure swung 90 degrees with respect to the slope, check the maximum slant angle on which the upperstructure can swing to the uphill side.

T105-06-03-011 ja

TTDD650-EN-00(18/11/2019)

T4-4-8

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Preparation 1. Check lubrication of the swing internal gear and the swing bearing.

2. Load the bucket. (Refer to "Operational Performance Standard Table"T4-2-1 for the loading weight.)

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.

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

5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

2. Operate the swing control lever to the full stroke position to swing the upperstructure toward the 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.

5. Repeat the measurement three times.

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Swing Bearing Play Summary 1. Measure the opening of the inner race and outer race to check the wear of the swing bearing races and the balls.

Preparation 1. Check the swing bearing mounting bolts for looseness.

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

3. Secure dial gauge (2) on the round trunk (3) side of the track frame by using magnetic base (1).

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

5. Position dial gauge (2) so that its needle point comes in contact with the lower surface of the swing bearing outer race.

6. The bucket should be empty.

NOTE The measured value will vary depending on where magnetic base (1) is secured. Secure magnetic base (1) on the round trunk as close to the swing bearing as possible.

TTDD650-EN-00(18/11/2019)

T4-4-9

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test

1

2 T105-06-03-014-1 ja

1-

Magnetic Base

2-

Dial Gauge

3

1 T105-06-03-015-1 ja 1-

Magnetic Base

3-

Round Trunk

Measurement 1. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket 100 mm above the ground. Record dial gauge reading (h1) of dial gauge (2).

2. Lower the bucket onto the ground and raise the front idler 0.5 m off the ground by using the front attachment. Record reading (h2) of dial gauge (2).

3. Calculate swing bearing play (H) from these data (h1 and h2) as follows: H = h2 - h1

a TDAA-04-04-002-1 ja

a- 100 mm

b T105-06-03-017-1 ja

b- 0.5 m

TTDD650-EN-00(18/11/2019)

T4-4-10

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Hydraulic Cylinder Cycle Time Summary 1. Measure the cycle time of the boom, arm, and bucket cylinders, and check the performance of the front attachment system (from the main pump to each cylinder).

2. The bucket should be empty.

Preparation 1. Measurement is made for the following positions.

•

Boom cylinder measurement: With the bucket cylinder fully extended and the arm cylinder fully retracted, lower the bucket onto the ground.

T105-06-03-018 ja

•

Arm cylinder measurement: Retract or extend the bucket cylinder so that the arm and the bucket teeth are vertical to the ground. Set the arm so that the center of arm operation is vertical. The bucket teeth clearance above the ground is 0.5 m.

a

T1V1-04-05-005-1 ja

a- 0.5 m •

Bucket cylinder measurement: Adjust the boom and arm cylinders so that the bucket oscillation center faces vertically to the ground.

TTDD650-EN-00(18/11/2019)

T4-4-11

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test

T105-06-03-020 ja

2. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

2. Measure as follows: (Cylinder full stroke includes cylinder cushioning zone.)

•

Boom cylinder measurement: Operate the boom control lever to full stroke. Measure the time to raise and lower the boom.

•

Arm cylinder measurement: Operate the arm control lever to full stroke. Measure the time to roll in and roll out the arm.

Bucket cylinder measurement: Operate the bucket control lever to full stroke. Measure the time to roll in and roll out the bucket.

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

•

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Dig Function Drift Check (Maximum Reach Position) Summary 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm, and bucket cylinders, with the bucket loaded.

2. Before measuring the drift just after cylinder replacement, slowly operate the cylinder for approximately 10 minutes and bleed air from the cylinder. b

a

a

d c T105-06-03-021-1 ja

TTDD650-EN-00(18/11/2019)

T4-4-12

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test a- Retracted Distance b- Extended Distance

c- Drift Amount d- The Arm End Pin at the Same Height as the Boom Foot Pin

Preparation 1. Load the bucket. (Refer to "Operational Performance Standard Table"T4-2-1 for the loading weight.)

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 approx. 50 mm away from the full stroke end position.

4. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Stop the engine.

2. When 5 minutes passed, measure the change in position of bottom of the bucket, as well as the boom, arm, and bucket cylinders.

•

Boom and bucket cylinder retracted distance: a (a=A-B)

• Arm cylinder extended distance: c (c=B-A) 3. Repeat the measurement three times and calculate the mean values. b

b

a T110-06-03-002-1 ja

a- Boom and Bucket Cylinders: Retracted Distance

b- Mark d

d

A

B

c TDC1-04-04-001-1 ja

c- Arm Cylinder: Extended Distance

d- Mark

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

TTDD650-EN-00(18/11/2019)

T4-4-13

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Dig Function Drift Check (Arm Roll-In Position) Summary 1. Measure dig function drift, which can be caused by oil leakage in the control valve and boom, arm, and bucket cylinders.

2. Before measuring the drift just after cylinder replacement, slowly operate the cylinder for approximately 10 minutes and bleed air from the cylinder.

Preparation 1. Empty the bucket.

2. With the arm and bucket cylinders fully extended, hold the arm end 1 m above the ground.

3. Position the arm cylinder and the bucket cylinder with the rod approx. 50 mm away from the full stroke end position.

4. Maintain the hydraulic oil temperature at 50±5 °C.

a T173-04-03-001-1 ja

a- 1 m Measurement 1. Stop the engine.

2. When 5 minutes passed, measure the change in position of the arm top, as well as the boom, arm and bucket cylinders.

• Cylinder retracted distance: b (b=A-B) 3. Repeat the measurement three times and calculate the mean values. c

c

b T110-06-03-002-2 ja

b- Cylinder Retracted Distance

c- Mark

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

TTDD650-EN-00(18/11/2019)

T4-4-14

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Control Lever Operating Force Summary 1. Check the play and operating condition of the control levers and measure the operating effort.

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

3. Measure the lever operating effort in the direction of control lever operation at the grip center of each control lever.

TABA50-04-04-001 ja

TABA50-04-04-003 ja

Preparation 1. Maintain the hydraulic oil temperature at 50±5 °C. Measurement

CAUTION Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

1. Measure the operating effort of each control lever.

2. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode PWR

Auto-Idle Switch OFF Position

Work Mode Bucket

3. In case of boom (raise), arm, and bucket control levers, measure the maximum operating effort for each with each actuator relieved.

TTDD650-EN-00(18/11/2019)

T4-4-15

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test 4. In case of boom (lower) control lever, measure the maximum operating effort with the boom (lower) relieved by raising the machine in a stable area.

5. In case of swing control lever, engage the bucket teeth with the ground and secure the upperstructure in order to prevent the machine from swinging. Operate the swing control lever and measure the maximum operating effort with the swing relieved.

6. In case of travel control lever, jack up the track link to be measured. Measure the maximum operating effort to be required.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Control Lever Stroke Summary 1. Check the play and operating condition of each control lever, and measure the 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.

T107-06-03-005 ja

Preparation 1. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Stop the engine.

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

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 Table"T4-2-1).

Combined Operation of Boom Raise and Swing Function Check Summary 1. Check the boom raise and swing movement while operating both functions simultaneously.

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

TTDD650-EN-00(18/11/2019)

T4-4-16

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Preparation 1. With the arm cylinder fully retracted and the bucket cylinder fully extended, lower the bucket onto the ground. (The bucket is empty.)

T107-06-03-009 ja

2. Maintain the hydraulic oil temperature at 50±5 °C. Measurement

CAUTION Always make sure that the area is clear and that coworkers are out of the swing area before starting the measurement.

1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

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

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

T107-06-03-010 ja

H

T107-06-03-011-1 ja

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

TTDD650-EN-00(18/11/2019)

T4-4-17

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Combined Operation of Boom Raise and Arm Roll-In Function Check Summary 1. Check boom raise and arm roll-in movement while operating both functions simultaneously.

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

Preparation 1. Retract the arm cylinder fully and extend the bucket cylinder so that the bucket teeth and arm mounting pin are on a straight line. Adjust the boom cylinder so that the height of the bucket teeth is 0.5 m above the ground. (The bucket is empty.) a

b T107-06-03-006-1 ja

a- Arm Mounting Pin

b- 0.5 m

2. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode PWR

Auto-Idle Switch OFF Position

Work Mode Bucket

2. Raise the boom and roll the arm in full stroke at the same time.

3. Measure the time required for the arm to reach the stroke end. (The bucket should be empty.)

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

T1V1-04-04-001 ja

TTDD650-EN-00(18/11/2019)

T4-4-18

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

Clearance of Front Attachment Connecting Part Summary 1. Measure the clearance of pin and pin hole, and check the clearance of pins bushings in each connecting part of main frame (5), boom (1), and arm (6).

1

2

5

4

3 TDCK-04-04-001-1 ja

12-

Boom Magnetic Base

34-

Dial Gauge Needle Point

1

5-

3

Main Frame

4 6

2 TDCK-04-04-002-1 ja 12-

Boom Magnetic Base

34-

Dial Gauge Needle Point

6-

Arm

Preparation 1. Secure dial gauge (3) on the side surface of boom (1) or arm (6) by using magnetic base (2).

2. Position the upperstructure so that the boom is aligned with the track frame facing towards the front idlers.

3. Position dial gauge (3) so that needle point (4) comes into contact with the upper surface of main frame (5) or the arm (6) connecting part of boom (1) tip.

Measurement 1. Set arm (6) so that the center of arm (6) operation is vertical. Hold the bucket 150 mm above the ground. Record reading (h1) of dial gauge (3).

2. Jack up the machine with arm (6) set in vertical position. Jack up the machine about 150 mm as illustrated. Record reading (h2) of dial gauge (3).

3. Calculate clearance (H) from these data (h1 and h2) below: TTDD650-EN-00(18/11/2019)

T4-4-19

SECTION4 OPERATIONAL PERFORMANCE TEST Group4 Machine Performance Test H = h2 - h1

a

Measurement of (h1) TDCK-04-04-003-1 ja

a- 150 mm

a

Measurement of (h2) TDCK-04-04-004-1 ja

a- 150 mm Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

TTDD650-EN-00(18/11/2019)

T4-4-20

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Primary Pilot Pressure Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Remove plug (1) from the pilot filter. Install the adapter (ST 6069) and the pressure gauge (ST 6942) to the pressure check port. : 19 mm

1 T178-03-07-001-4 ja 1-

Plug

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connecting part.

5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

PWR

OFF Position

Bucket

Slow Idle

PWR

OFF Position

Bucket

2. Measure the pilot pressure without load by using the pressure gauge under each test condition in the table.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Primary Pilot Pressure Adjustment Procedure Adjustment 1. Remove plug (2) from relief valve (1). : 42 mm

TTDD650-EN-00(18/11/2019)

T4-5-1

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test

1

T178-03-07-001-2 ja 1-

Relief Valve

2 3

T111-06-04-004-1 ja 2-

Plug

3-

Shim

2. Install the estimated quantity of shims (3).

3. After the adjustment, tighten plug (2). : 25+2 N·m 4. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Shim (3) Thickness Change in Pressure

mm kPa

0.25 78

0.5 157

1.0 304

Secondary Pilot Pressure Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Measure the pilot pressure between pilot valve (1) and signal control valve (2). Disconnect the signal control valve (2) side of pilot hose (3) of the circuit to be measured. Install hose (8), tee (5), adapter (4), adapter (7), and pressure gauge (6) between signal control valve (2) and pilot hose (3). : 19 mm, 22 mm

TTDD650-EN-00(18/11/2019)

T4-5-2

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1 8

2

7 6

5 4 3

TJAA-04-05-001-2 ja 123-

Pilot Valve Signal Control Valve Pilot Hose

456-

Adapter (ST 6460) Tee (4351843) Pressure Gauge (ST 6942)

78-

Adapter (ST 6069) Hose (9/16-18UNF, Length: approx. 400 mm)

4. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (6) connecting part.

5. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

PWR

OFF Position

Bucket

Slow Idle

PWR

OFF Position

Bucket

2. Operate the control lever to be measured. Measure the pilot pressure by using pressure gauge (6) with the control lever set to the full stroke.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

5-Spool Solenoid Valve Unit Set Pressure Use MPDr. and a pressure gauge at the same time.

Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Disconnect the hose from the solenoid valve to be measured. Install tee (4), hose (5), adapter (3), adapter (6), and pressure gauge (2) between the disconnected hose and solenoid valve unit (1). : 17 mm, 19 mm

TTDD650-EN-00(18/11/2019)

T4-5-3

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1 2

6

5

4

3 T157-05-04-002-1 ja

12-

Solenoid Valve Unit Pressure Gauge (ST 6942)

34-

Adapter (ST 6461) Tee (ST 6451)

56-

Hose (4216453) Adapter (ST 6069)

4. Connect MPDr. and select the monitoring function.

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (2) connecting part.

6. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

PWR

OFF Position

Bucket

Slow Idle

PWR

OFF Position

Bucket

2. Perform the following procedures for the solenoid valve to be measured.

•

Solenoid valve (SI): Turn ON and OFF the power digging switch.

•

Solenoid valve (SF): Conduct combined operation of boom raise and arm roll-in.

•

Solenoid valve (SC): Conduct relief combined operation of boom raise and arm roll-in.

•

Solenoid valve (SD): Conduct arm roll-in operation above the ground.

•

Solenoid valve (SE): Conduct combined operation of attachment and arm roll-in.

SC

SF

SE

SD

SI

TDAA-03-07-001-2 ja

3. Read the values on both MPDr. and the pressure gauge.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Solenoid Valve Adjustment Procedure

IMPORTANT If loosening adjusting screw (8) excessively, O-ring (9) is damaged and oil leakage may cause. Do not loosen adjusting screw (8) excessively. Do not loosen adjusting screw (8) more than 2 turns from fully tightened position.

1. Loosen lock nut (7). Turn adjusting screw (8) and adjust the set pressure.

TTDD650-EN-00(18/11/2019)

T4-5-4

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 9

7

8

a b TDAA-04-05-013-1 ja

a- 0.7 mm 7-

Lock Nut

b- 2.0 mm 8-

Adjusting Screw

9-

O-Ring

2. After the adjustment, tighten lock nut (7). : 13 mm : 5 N·m : 3 mm

7

8

TDAA-04-05-012-1 ja 7-

Lock Nut

8-

Adjusting Screw

3. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Adjusting Screw (8) Turns Change in Pressure

1/4 111

kPa

7

1/2 222

3/4 333

1 444

8

c

d

W107-02-05-129-1 ja

TTDD650-EN-00(18/11/2019)

T4-5-5

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test c- Pressure Increase 7-

Lock Nut

d- Pressure Decrease 8-

Adjusting Screw

3-Spool Solenoid Valve Unit Set Pressure Use MPDr. and a pressure gauge at the same time.

Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Disconnect the hose from the solenoid valve to be measured. Install tee (4), hose (5), adapter (3), adapter (6), and pressure gauge (2) between the disconnected hose and solenoid valve unit (1). : 17 mm, 19 mm 1 2

6

5

4

3 T157-05-04-002-1 ja

12-

Solenoid Valve Unit Pressure Gauge (ST 6942)

34-

Adapter (ST 6466) Tee (ST 6450)

56-

Hose (4334307) Adapter (ST 6069)

4. Connect MPDr. and select the monitoring function.

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (2) connecting part.

6. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

PWR

OFF Position

Bucket

Slow Idle

PWR

OFF Position

Bucket

2. Perform the following procedures for the solenoid valve to be measured.

•

Solenoid valve (SK1): Conduct relief combined operation of bucket roll-in and arm roll-in above the ground.

•

Solenoid valve (SK2): Conduct relief combined operation of bucket roll-in, arm roll-in, and boom raise.

•

Solenoid valve (SK3): Conduct boom raise relief operation.

TTDD650-EN-00(18/11/2019)

T4-5-6

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test SK1

SK2

SK3

TDFY-03-07-001-1 ja

3. Read the values on both MPDr. and the pressure gauge.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Solenoid Valve Adjustment Procedure

IMPORTANT If loosening adjusting screw (8) excessively, O-ring (9) is damaged and oil leakage may cause. Do not loosen adjusting screw (8) excessively. Do not loosen adjusting screw (8) more than 2 turns from fully tightened position.

1. Loosen lock nut (7). Turn adjusting screw (8) and adjust the set pressure.

9

7

8

a b TDAA-04-05-013-1 ja

a- 0.7 mm 7-

Lock Nut

b- 2.0 mm 8-

Adjusting Screw

9-

2. After the adjustment, tighten lock nut (7). : 13 mm : 5 N·m : 3 mm

TTDD650-EN-00(18/11/2019)

T4-5-7

O-Ring

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test

7

8

TDAA-04-05-012-1 ja 7-

Lock Nut

8-

Adjusting Screw

3. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Adjusting Screw (8) Turns Change in Pressure

1/4 111

kPa

7

1/2 222

3/4 333

1 444

8

c

d

W107-02-05-129-1 ja

c- Pressure Increase 7-

Lock Nut

d- Pressure Decrease 8-

Adjusting Screw

2-Spool Solenoid Valve Unit (Aftertreatment Device Regeneration Control) Set Pressure Use MPDr. and a pressure gauge at the same time.

Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. (Solenoid Valve (SJ)): Disconnect the hose from the solenoid valve. Install tee (4), hose (5), adapter (3), adapter (6), and pressure gauge (2) between the disconnected hose and solenoid valve unit (1). : 17 mm, 19 mm (Solenoid Valve (SZ)): Disconnect the hose from the solenoid valve. Install tee (4), hose (5), adapter (3), adapter (6), and pressure gauge (2) between the disconnected hose and solenoid valve unit (1). : 19 mm, 22 mm 4. Connect MPDr. and select the monitoring function.

TTDD650-EN-00(18/11/2019)

T4-5-8

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1 2

6

12-

Solenoid Valve Unit Pressure Gauge (ST 6942)

3-

5

4

Adapter (SJ): (ST 6461), (SZ): (ST 6466)

4-

3 Tee (SJ): (ST 6451), (SZ): (ST 6450)

56-

T157-05-04-002-1 ja Hose (SJ): (4216453), (SZ): (4334307) Adapter (ST 6069)

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge (2) connecting part.

6. Maintain the hydraulic oil temperature at 50±5 °C. SZ

SJ

TDAA-03-07-002-3 ja

Measurement 1. Follow the test conditions specified below.

Engine Control Dial

Power Mode

Auto-Idle Switch

Work Mode

Fast Idle

PWR

OFF Position

Bucket

Slow Idle

PWR

OFF Position

Bucket

2. Turn ON the manual regeneration by using MPDr..

3. Read the values on both MPDr. and the pressure gauge.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Solenoid Valve Adjustment Procedure

IMPORTANT If loosening adjusting screw (8) excessively, O-ring (9) is damaged and oil leakage may cause. Do not loosen adjusting screw (8) excessively. Do not loosen adjusting screw (8) more than 2 turns from fully tightened position.

1. Loosen lock nut (7). Turn adjusting screw (8) and adjust the set pressure.

TTDD650-EN-00(18/11/2019)

T4-5-9

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 9

7

8

a b TDAA-04-05-013-1 ja

a- 0.7 mm 7-

Lock Nut

b- 2.0 mm 8-

Adjusting Screw

9-

O-Ring

2. After the adjustment, tighten lock nut (7). : 13 mm : 5 N·m : 3 mm

7

8

TDAA-04-05-012-1 ja 7-

Lock Nut

8-

Adjusting Screw

3. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Adjusting Screw (8) Turns Change in Pressure

1/4 111

kPa

7

1/2 222

3/4 333

1 444

8

c

d

W107-02-05-129-1 ja

TTDD650-EN-00(18/11/2019)

T4-5-10

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test c- Pressure Increase 7-

Lock Nut

d- Pressure Decrease 8-

Adjusting Screw

Main Pump Delivery Pressure The main pump delivery pressure can be also measured by using MPDr..

Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Remove the plug from the delivery pressure check port of the main pump to be measured. Install adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) to the delivery pressure check port of the main pump to be measured. : 19 mm : 6 mm

1 2

3 TDDQ-01-02-008-3 ja 1-

Pump 1 Delivery Pressure Check Port

2-

Pump 3 Delivery Pressure Check Port

3-

Pump 2 Delivery Pressure Check Port

4. Connect MPDr. and select the monitoring function.

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connecting part.

6. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

2. Measure the pressure with the control lever set in neutral without load.

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

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Remedy Refer to ("Troubleshooting B (Machine Diagnosis by Using Trouble Symptom) Procedure"T5-6-1).

TTDD650-EN-00(18/11/2019)

T4-5-11

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Main Relief Set Pressure Summary Measure the main relief valve set pressure at the delivery port in the main pump. The main relief set pressure can be also measured by using MPDr..

Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Remove the plug from the delivery pressure check port of the main pump to be measured. Install adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) to the delivery pressure check port of the main pump to be measured. : 19 mm : 6 mm

1 2

3 TDDQ-01-02-008-3 ja 1-

Pump 1 Delivery Pressure Check Port

2-

Pump 3 Delivery Pressure Check Port

3-

Pump 2 Delivery Pressure Check Port

4. Connect MPDr. and select the monitoring function.

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connecting part.

6. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode PWR

Auto-Idle Switch OFF Position

Work Mode Bucket

Power Digging Switch ON Position OFF Position

2. (Measurement of main relief valve (for P1, P2) (2)): Perform bucket, arm, boom, or travel operation. Measure the set pressure of main relief valve (for P1, P2) (2). When measuring the pressure of bucket, arm, and boom, operate each control lever slowly. Operate each cylinder to the stroke end (extend, retract) and relieve the pressure. When measuring the pressure of travel, secure the tracks against an immovable object. Slowly operate the travel control lever and relieve the pressure.

3. (Measurement of main relief valve (for P3) (1)):

TTDD650-EN-00(18/11/2019)

T4-5-12

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Perform boom or swing operation. Measure the set pressure of main relief valve (for P3) (1). When measuring the pressure of boom, operate each control lever slowly. Operate each cylinder to the stroke end (extend, retract) 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.

4. When measuring the pressure during power digging operation, measure the pressure within 8 seconds after pushing the switch.

1

2

TDFY-04-05-001-1 ja 1-

Main Relief Valve (P3)

2-

Main Relief Valve (For P1, P2)

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Main Relief Valve Pressure Adjustment Procedure NOTE If the measured pressure for all functions are lower than the specified range, the probable cause is the set pressure decrease of main relief valves (1, 2).

If adjusting the pressure during power digging operation, adjust the high-pressure side of main relief pressure.

If adjusting the pressure in normal, adjust the low-pressure side of main relief pressure.

TTDD650-EN-00(18/11/2019)

T4-5-13

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1

2

TDFY-04-05-001-1 ja 1-

Main Relief Valve (P3)

2-

Main Relief Valve (For P1, P2)

High-Pressure Side of Main Relief Pressure Adjustment Procedure 1. Loosen lock nut (4). Lightly tighten plug (3) until plug (3) comes into contact with the end of piston (7). Tighten lock nut (4). : 27 mm (Plug (3)) : 20 N·m (Lock Nut (4)) : 70 to 80 N·m 3 4 5 6 7

TDAA-04-05-009-1 ja 34-

Plug Lock Nut

56-

Plug Lock Nut

7-

Piston

2. Loosen lock nut (6). Turn plug (5) and adjust the pressure until the specified pressure is obtained. : 27 mm, 32 mm (Lock Nut (6)) : 80 to 90 N·m TTDD650-EN-00(18/11/2019)

T4-5-14

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 3. After the adjustment, tighten lock nut (6).

4. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Plug (5) Turns Plug (5)

1/4 7.1

MPa

1/2 14.2

3/4 21.3

1 28.4

3Ŵ 5

a

b

W107-02-05-127-1 ja

a- Pressure Increase 3-

Plug

TTDD650-EN-00(18/11/2019)

b- Pressure Decrease 5-

Plug

T4-5-15

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Low-Pressure Side of Main Relief Pressure Adjustment Procedure 1. Loosen lock nut (4). Turn plug (3) and adjust the pressure until the specified pressure is obtained. After the adjustment, tighten lock nut (4). : 27 mm (Lock Nut (4)) : 60~70 N·m 3 4

TDAA-04-05-009-2 ja 3-

Plug

4-

Lock Nut

2. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Plug (3) Turns Plug (3)

1/4 5.3

MPa

1/2 10.7

3/4 16.0

1 21.3

3

b a

TDC1-04-05-002-1 ja

a- Pressure Increase 3-

b- Pressure Decrease

Plug

Relief Pressure (When Relieving Swing) Loosen lock nut (3) and adjust the set pressure of the swing relief valve (1) by using adjusting screw (2).

TTDD650-EN-00(18/11/2019)

T4-5-16

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1

TDAB-01-02-007-2 ja 1-

Swing Relief Valve

1. Loosen lock nut (3). : 24 mm, 32 mm 2. Turn adjusting screw (2) and adjust the set pressure.

3. Tighten lock nut (3). : 24 mm, 32 mm : 180 N･m 2

3

TDAB-04-05-003-1 ja 2-

Adjusting Screw

3-

Lock Nut

4. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Adjusting Screw (2) Turns Change in Pressure

TTDD650-EN-00(18/11/2019)

MPa

1/4 2.5

T4-5-17

1/2 5.0

3/4 7.5

1 10.0

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test

2

b a

T157-05-04-023-1 ja

a- Pressure Increase 2-

b- Pressure Decrease

Adjusting Screw

Overload Relief Valve Set Pressure Summary 1. 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 of the pressure on the machine is not recommended because of the reasons in 1 and 2 above. If the measurement on the machine is required, please substitute the measurement of the main relief pressure. The main relief set pressure can be also measured by using MPDr..

Preparation 1. Stop the engine.

2. Push the air bleed valve on top of the hydraulic oil tank and bleed air.

3. Remove the plug from the delivery pressure check port of the main pump to be measured. Install adapter (ST 6069), hose (ST 6943), and pressure gauge (ST 6941) to the delivery pressure check port of the main pump to be measured. : 19 mm : 6 mm

1 2

3 TDDQ-01-02-008-3 ja 1-

Pump 1 Delivery Pressure Check Port

TTDD650-EN-00(18/11/2019)

2-

Pump 3 Delivery Pressure Check Port

3-

T4-5-18

Pump 2 Delivery Pressure Check Port

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 4. Connect MPDr. and select the monitoring function.

5. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connecting part.

6. Maintain the hydraulic oil temperature at 50±5 °C. Measurement 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

2. Slowly operate the bucket, arm, or boom control levers. Operate each cylinder to the stroke end (extend, retract) and relieve the main relief valve.

3. Read the pressure on the pressure gauge at this time.

4. Perform the measurement for the bucket, arm, and boom in sequence.

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

Evaluation The overload relief valves are normal when each main relief set pressure in the measured circuits (bucket, arm, and boom) is within the specified value range.

Refer to ("Operational Performance Standard Table"T4-2-1).

Overload Relief Valve Pressure Adjustment Procedure (Reference) IMPORTANT Adjust the overload relief valve pressure on a test stand.

Loosen lock nut (1) and adjust the set pressure of the overload relief valve by using adjusting screw (2).

1. Loosen lock nut (1). : 17 mm 2. Turn adjusting screw (2) and adjust the set pressure. : 6 mm 3. Tighten lock nut (1). : 17 mm : 30 N·m 4. After the adjustment, check the set pressure.

NOTE Standard Change in Pressure (Reference) Adjusting Screw (2) Turns Change in Pressure

TTDD650-EN-00(18/11/2019)

MPa

1/4 5.2

T4-5-19

1/2 10.6

3/4 15.9

1 21.1

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1

2 TDAA-04-05-011-1 ja 1-

Lock Nut

2-

Adjusting Screw

2

a

b

W107-02-05-129-2 ja

a- Pressure Increase 2-

b- Pressure Decrease

Adjusting Screw

Main Pump Flow Rate Measurement (P-Q Control (Torque Control)) Summary Install hydraulic tester (5) to the delivery port of the main pump to be measured. Main pump performance is checked by measuring the pump flow rate. Use MPDr. and a pressure gauge at the same time.

IMPORTANT This measurement procedure is a simple method. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank.

Preparation 1. Stop the engine. Push the air bleed valve on top of the hydraulic oil tank and bleed air. Connect a vacuum pump to the oil filler port.

NOTE Operate the vacuum pump while connecting the pump flow rate test line.

2. Disconnect the delivery hose from the main pump to be measured. Connect pipe (1) or pipe (2) to the delivery port of the main pump with the split flange and bolt of the disconnected hose. : 19 mm

TTDD650-EN-00(18/11/2019)

T4-5-20

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 3. Install pipe (1) or pipe (2) to hydraulic tester (5) with test hose (3) and adapter (4). Install adapter (6), joint (7), test hose (8), and flange (9) to hydraulic tester (5). : 41 mm, 55 mm 4. Install flange (9) and the disconnected delivery hose with split flange (10) and bolt (11). : 10 mm 5. Install a pressure gauge to the main pump to be measured. (Refer to "Main Relief Set Pressure"T4-5-12.) : 6 mm 6. Disconnect hose (13) from the regulator. Remove elbows (2 used). Install the plug (G 1/4) to the hose (13) mounting hole of the regulator. : 17 mm 7. Remove the vacuum pump. Loosen plug (12) on top of the pump casing. Bleed air from the casing until oil comes out. : 27 mm 8. Fully open the loading valve of hydraulic tester (5).

9. Start the engine. Confirm that no oil leakage is observed at the pressure gauge connecting part. Connect MPDr. and select the monitoring function.

Measurement 1. Maintain the hydraulic oil temperature at 50±5 °C. 2. Measure the maximum flow rate.

3. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

4. Adjust the relief set pressure of main relief valve in control valve to each pressure point specified along the main pump P-Q curve. (Refer to"Main Pump P-Q Diagram (P1, P2)"T4-2-8, "Main Pump P-Q Diagram (P3)"T4-2-10.) Slowly restrict the loading valve of hydraulic tester (5) while relieving pressure in the arm roll-in 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 values.

Evaluation 1. Convert the measured flow rates to those at the specified engine speed.

Qc = Ns×Q/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 1700 min-1 Ne : Measured Engine Speed: Values indicated on MPDr. 2. Standard Flow Rate Refer to ("Operational Performance Standard Table"T4-2-1).

NOTE When actually measuring, connect pipe (1) or pipe (2) only to the pump to be measured.

TTDD650-EN-00(18/11/2019)

T4-5-21

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1,2

3

4

5

6

7

8

9

10

11

a T173-04-04-002-1 ja

a- Main Pump Delivery Hose (To Control Valve) 123-

Pipe E (ST 6144) Pipe B (ST 6143) Test Hose (ST 6145)

4-

Adapter G1×UNF1-7/8(ST 6603) Hydraulic Tester (ST 6299)

5-

678-

Adapter R1×UNF1-7/8(ST 6000) Joint (ST 6994) Test Hose (ST 6320)

91011-

Flange (ST 6118) Split Flange (ST 6130)×2 Bolt (ST 6409)×4

13 12

TDDQ-01-02-008-4 ja 12-

Plug

13-

Hose

Main Pump Flow Rate Measurement (Pilot Pressure Characteristics) Summary Install hydraulic tester (5) to the delivery port of the main pump to be measured. Main pump performance is checked by measuring the pump flow rate. Use MPDr. and pressure gauge (18) at the same time.

IMPORTANT This measurement procedure is a simple method. In order to measure accurately, disconnect the return circuit from the control valve and connect it to the hydraulic oil tank.

Preparation 1. "Main Pump Flow Rate Measurement (P-Q Control (Torque Control))"T4-5-20While referring to step 1 to step 4, install hydraulic tester (5) to the main pump to be measured.

2. Disconnect the hose from regulator port Pi (21) of the pump to be measured. Install the plug (ST 6214) to the disconnected hose. : 19 mm, 22 mm 3. Install adapters (15) (3 used) to reducing valve (16). Remove plug (23) from the pilot filter. Install adapter (13) and hose (14) to the pilot filter. Connect hose (14) to port P1 of reducing valve (16).

TTDD650-EN-00(18/11/2019)

T4-5-22

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test : 19 mm, 22 mm 4. Install tee (17) to port P2 of reducing valve (16). Connect adapter (24), pressure gauge (18) and hose (14) to tee (17).

Connect hose (14) to the regulator. : 19 mm, 22 mm 5. Connect hose (19) and adapter (20) to port T of reducing valve (16). Remove plug (L) from return pipe (22). Connect hose (19). : 19 mm, 22 mm 6. Remove the vacuum pump. Loosen plug (12) on top of the pump casing. Bleed air from the casing until oil comes out.

7. Fully open the loading valve of hydraulic tester (5).

8. Start the engine. Confirm that no oil leakage is observed at the pipe connecting part.

1,2

3

4

5

6

7

8

9

10

11

a T173-04-04-002-1 ja

a- Delivery Hose (To Control Valve) 123-

Pipe E (ST 6144) Pipe B (ST 6143) Test Hose (ST 6145)

4-

Adapter G1×UNF1-7/8(ST 6603) Hydraulic Tester (ST 6299)

5-

678-

Adapter R1×UNF1-7/8(ST 6000) Joint (ST 6994) Test Hose (ST 6320)

91011-

Flange (ST 6118) Split Flange (ST 6130)×2 Bolt (ST 6409)×4

21

12

TDDQ-01-02-008-5 ja 12-

Plug (Regulator)

TTDD650-EN-00(18/11/2019)

21-

Port Pi

T4-5-23

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test

23

T178-03-07-001-3 ja 23-

Plug (Pilot Filter)

22 16

T

L 20

18 P1

19

P2 d 24

15

c

b

14

17

15

16

15

14

13 TDC1-04-05-001-2 ja

b- To Pilot Filter c- To Regulator Port Pi (21) 131415-

Adapter UNF9/16×G1/4(A852123) Hose UNF9/16×UNF9/16(4334307) Adapter G3/8×UNF9/16(4200466)

d- Reducing Valve Port Position 1617-

18-

Reducing Valve (4325439) Tee UNF9/16×UNF9/16×G1/4(ST 6450) Pressure Gauge (ST 6934)

19202224-

Hose UNF9/16×UNF9/16(4334307) Adapter G3/8×UNF9/16(4200466) Return Pipe Adapter (ST 6069)

Measurement 1. Maintain the hydraulic oil temperature at 50±5 °C. 2. Measure pump flow rate in response to the external command pilot pressure.

3. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode PWR

Auto-Idle Switch OFF Position

Work Mode Bucket

4. Adjust the reducing valve set pressure to each pressure point specified along the main pump P-Q curve. (Refer to "Main Pump P-Q Diagram (P1, P2)"T4-2-8, "Main Pump P-Q Diagram (P3)"T4-2-10.)

Measure the flow rates and engine speed at the pressure points specified in the P-Q curve.

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

TTDD650-EN-00(18/11/2019)

T4-5-24

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Evaluation 1. Convert the measured flow rates to those at the specified engine speed.

Qc = Ns×Q/Ne Qc : Converted Flow Rate Q : Measured Flow Rate Ns : Specified Engine Speed: 1700 min-1 Ne : Measured Engine Speed: Values indicated on MPDr. 2. Standard Flow Rate Refer to ("Operational Performance Standard Table"T4-2-1).

NOTE When actually measuring, install pipe (1) (ST 6144) or pipe (2) (ST 6143) only to the pump to be measured.

1,2

3

4

5

6

7

8

9

10

11

a T173-04-04-002-1 ja

a- Delivery Hose (To Control Valve) 123-

Pipe E (ST 6144) Pipe B (ST 6143) Test Hose (ST 6145)

45-

Adapter G1×UNF1-7/8(ST 6603) Hydraulic Tester (ST 6299)

678-

Adapter R1×UNF1-7/8(ST 6000) Joint (ST 6994) Test Hose (ST 6320)

91011-

Flange (ST 6118) Split Flange (ST 6130)×2 Bolt (ST 6409)×4

21

12

TDDQ-01-02-008-5 ja 12-

Plug (Regulator)

TTDD650-EN-00(18/11/2019)

21-

Port Pi

T4-5-25

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test

23

T178-03-07-001-3 ja 23-

Plug (Pilot Filter)

22 16

T

L 20

18 P1

19

P2 d 24

15

c

b

14

17

15

16

15

14

13 TDC1-04-05-001-2 ja

b- To Pilot Filter c- To Regulator Port Pi (21) 131415-

Adapter UNF9/16×G1/4(A852123) Hose UNF9/16×UNF9/16(4334307) Adapter G3/8×UNF9/16(4200466)

TTDD650-EN-00(18/11/2019)

d- Reducing Valve Port Position 1617-

18-

Reducing Valve (4325439) Tee UNF9/16×UNF9/16×G1/4(ST 6450) Pressure Gauge (ST 6934)

19202224-

T4-5-26

Hose UNF9/16×UNF9/16(4334307) Adapter G3/8×UNF9/16(4200466) Return Pipe Adapter (ST 6069)

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Regulator Adjustment (P1, P2) 6

5

1 2

9 4

10

3

8

7 TDAB-04-05-001-1 ja 123-

Lock Nut (For Minimum Flow Rate) Adjusting Screw (For Mini­ mum Flow Rate) Lock Nut (For Maximum Flow Rate)

456-

Adjusting Screw (For Maxi­ mum Flow Rate) Lock Nut (For Pilot Pressure Characteristic) Adjusting Screw (For Pilot Pressure Characteristic)

Adjustment Item 1. Minimum Flow Rate

78910-

Lock Nut (For P-Q Control) Adjusting Screw (For P-Q Con­ trol) Lock Nut (For P-Q Control) Adjusting Screw (For P-Q Con­ trol)

Adjustment Procedure

Remark

Loosen lock nut (1) and adjust the mini­ Do not turn adjusting screw (2) more mum pump flow rate by using adjust­ than 1.5 turn. ing screw (2).

After the adjustment, securely tighten Turning adjusting screw (2) 1/4 turn lock nut (1). clockwise increases the minimum pump flow rate by 7.25 cm3/rev. : 17 mm : 20 N·m

᳋

TDAA-04-05-003 ja

2. Maximum Flow Rate

Loosen lock nut (3) and adjust the max­ Do not turn adjusting screw (4) more imum pump flow rate by using adjust­ than 1.5 turn. ing screw (4).

Do not increase the maximum flow rate Turning adjusting screw (4) 1/4 turn beyond the specified pump flow rate. clockwise decreases the maximum Do not turn the adjusting screw coun­ terclockwise. pump flow rate by 9.48 cm3/rev.

After the adjustment, securely tighten : 13 mm lock nut (3). : 10 N·m

᳋

TDFY-04-05-002 ja

TTDD650-EN-00(18/11/2019)

T4-5-27

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Adjustment Item

Adjustment Procedure

Remark

3. Pilot Pressure Characteristics Q

Loosen lock nut (5) and adjust the Do not turn adjusting screw (6) more pump flow rate of pilot pressure char­ than 1 turn. acteristics by using adjusting screw (6). Turning adjusting screw (6) clockwise Turning adjusting screw (6) 1/4 turn decreases the maximum pump flow clockwise decreases the pump flow rate. To maintain the pump flow rate unchanged, turn adjusting screw (4) rate by 13.7 cm3/rev. counterclockwise twice as much as ad­ : 30 mm justing screw (6) was turned clockwise. : 30 N·m This ratio of 2 (adjusting screw (4) counterclockwise turn) to 1 (adjusting Pi TDAA-04-05-005 ja screw (6) clockwise turn) is to counter­ balance.

After the adjustment, securely tighten lock nut (5).

4. P-Q Control (Torque Adjustment) Q

Loosen lock nut (7) and adjust the Do not turn adjusting screw (8) more pump flow rate of P-Q control by using than 1 turn. adjusting screw (8).

Adjust the pump flow rate of P-Q con­ Turning adjusting screw (8) 1/4 turn trol while watching the engine per­ clockwise increases the pump flow rate formance in order not to increase the pump driving torque excessively. by 19.3 cm3/rev.

After the adjustment, securely tighten : 30 mm lock nut (7). : 30 N·m

Pd TDAA-04-05-006 ja

5. P-Q Control (Torque Adjustment) Q

Loosen lock nut (9) and adjust the Do not turn adjusting screw (10) more pump flow rate of P-Q control by using than 1 turn. adjusting screw (10).

Adjust the pump flow rate of P-Q con­ Turning adjusting screw (10) 1/4 turn trol while watching the engine per­ clockwise increases the pump flow rate formance in order not to increase the pump driving torque excessively. by 8.45 cm3/rev.

After the adjustment, securely tighten : 13 mm lock nut (9). : 10 N·m

Pd TDAA-04-05-007 ja

TTDD650-EN-00(18/11/2019)

T4-5-28

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Regulator Adjustment (P3) 7

8 9

4 10

3 2 6

5

1 TDAB-04-05-002-1 ja

123-

Lock Nut (For Minimum Flow Rate) Adjusting Screw (For Mini­ mum Flow Rate) Lock Nut (For Maximum Flow Rate)

456-

Adjusting Screw (For Maxi­ mum Flow Rate) Lock Nut (For Pilot Pressure Characteristic) Adjusting Screw (For Pilot Pressure Characteristic)

Adjustment Item 1. Minimum Flow Rate

78910-

Lock Nut (For P-Q Control) Adjusting Screw (For P-Q Con­ trol) Lock Nut (For P-Q Control) Adjusting Screw (For P-Q Con­ trol)

Adjustment Procedure

Remark

Loosen lock nut (1) and adjust the mini­ Do not turn adjusting screw (2) more mum pump flow rate by using adjust­ than 1.5 turn. ing screw (2).

After the adjustment, securely tighten Turning adjusting screw (2) 1/4 turn lock nut (1). clockwise increases the minimum pump flow rate by 7.30 cm3/rev. : 17 mm : 20 N·m

᳋

TDAA-04-05-003 ja

2. Maximum Flow Rate

Loosen lock nut (3) and adjust the mini­ Do not turn adjusting screw (4) more mum pump flow rate by using adjust­ than 1.5 turn. ing screw (4).

Do not increase the maximum flow rate Turning adjusting screw (4) 1/4 turn beyond the specified pump flow rate. clockwise decreases the maximum Do not turn the adjusting screw coun­ 3 terclockwise. pump flow rate by 9.39 cm /rev.

After the adjustment, securely tighten : 13 mm lock nut (3). : 10 N·m

᳋

TDFY-04-05-002 ja

TTDD650-EN-00(18/11/2019)

T4-5-29

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Adjustment Item

Adjustment Procedure

Remark

3. Pilot Pressure Characteristics Q

Loosen lock nut (5) and adjust the Do not turn adjusting screw (6) more pump flow rate of pilot pressure char­ than 1 turn. acteristics by using adjusting screw (6). Turning adjusting screw (6) clockwise Turning adjusting screw (6) 1/4 turn decreases the maximum pump flow clockwise decreases the pump flow rate. To maintain the pump flow rate unchanged, turn adjusting screw (4) rate by 13.9 cm3/rev. counterclockwise twice as much as ad­ : 30 mm justing screw (6) was turned clockwise. : 30 N·m This ratio of 2 (adjusting screw (4) counterclockwise turn) to 1 (adjusting Pi TDAA-04-05-005 ja screw (6) clockwise turn) is to counter­ balance.

After the adjustment, securely tighten lock nut (5).

4. P-Q Control (Torque Adjustment) Q

Loosen lock nut (7) and adjust the Do not turn adjusting screw (8) more pump flow rate of P-Q control by using than 1 turn. adjusting screw (8).

Adjust the pump flow rate of P-Q con­ Turning adjusting screw (8) 1/4 turn trol while watching the engine per­ clockwise increases the pump flow rate formance in order not to increase the pump driving torque excessively. by 18.9 cm3/rev.

After the adjustment, securely tighten : 30 mm lock nut (7). : 30 N·m

Pd TDAA-04-05-006 ja

5. P-Q Control (Torque Adjustment) Q

Loosen lock nut (9) and adjust the Do not turn adjusting screw (10) more pump flow rate of P-Q control by using than 1 turn. adjusting screw (10).

Adjust the pump flow rate of P-Q con­ Turning adjusting screw (10) 1/4 turn trol while watching the engine per­ clockwise increases the pump flow rate formance in order not to increase the pump driving torque excessively. by 6.02 cm3/rev.

After the adjustment, securely tighten : 13 mm lock nut (9). : 10 N·m

Pd TDAA-04-05-007 ja

Swing Motor Drainage Summary 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 depending on the hydraulic oil temperature. Keep the hydraulic oil temperature.

Preparation 1. Maintain the hydraulic oil temperature at 50±5 °C. Rotate the swing motor and warm the inside of the motor.

2. Stop the engine. Push air bleed valve (1) on top of the hydraulic oil tank and bleed air.

TTDD650-EN-00(18/11/2019)

T4-5-30

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test 1

TDAA-04-05-008-1 ja 1-

Air Bleed Valve

3. Disconnect the drain hose of the swing motor at the return pipe side. Install the plug (ST 6491) to the return pipe. : 27 mm 2

TDAB-01-02-007-6 ja 2-

Drain Hose Connecting Hole

Measurement Conditions 1. Follow the test conditions specified below.

Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

Measurement

CAUTION Always make sure that the area is 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. Adjust and hold the boom so that the arm end pin height is the same as the boom foot pin height. (The bucket is empty.)

TTDD650-EN-00(18/11/2019)

T4-5-31

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test

a

T105-06-03-013-1 ja

a- The Same Height as the Boom Foot Pin 2. Start the engine. 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.

3. Measure in both the clockwise and counterclockwise directions.

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

5. The measuring time should be more than 45 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.

T107-06-06-005 ja

2. Start the engine. 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.

T107-06-05-008 ja

3. Measure in both the clockwise and counterclockwise directions.

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

5. The measuring time should be more than 45 seconds.

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Conversion of amount of measured drain oil 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 perminute value by using the following formula: ΔQ = 60 × q/t. ΔQ t q

: Amount of drain oil per minute (L/min) : Measured time (seconds) : Total amount of drain oil (L)

TTDD650-EN-00(18/11/2019)

T4-5-32

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Travel Motor Drainage Summary 1. While rotating the travel motor with the track link to be measured raised off the ground, measure the amount of oil draining from the travel motor and check the travel motor performance.

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 depending on the hydraulic oil temperature. Keep the hydraulic oil temperature.

Preparation 1. Adjust track link sag.

Track sag specification: 340 to 380 mm 2. Maintain the hydraulic oil temperature at 50±5 °C. Rotate the travel motor and warm the inside of the motor.

3. Stop the engine. Push air bleed valve (1) on top of the hydraulic oil tank and bleed air.

1

TDAA-04-05-008-1 ja 1-

Air Bleed Valve

4. Disconnect drain hose (2) of the travel motor at the travel motor side. Install the plug (ST 6637) to the disconnected hose. Connect the drain hose (3/4-16UN) to the travel motor. : 27 mm : 80 N·m 2

M178-07-047-1 ja 2-

Drain Hose

Measurement Conditions 1. Follow the test conditions specified below.

TTDD650-EN-00(18/11/2019)

T4-5-33

SECTION4 OPERATIONAL PERFORMANCE TEST Group5 Component Test Engine Control Dial Fast Idle

Power Mode

Auto-Idle Switch

PWR

OFF Position

Work Mode Bucket

Measurement

CAUTION When working around moving parts is unavoidable, pay special attention to ensure that hands, feet, and clothing do not become entangled. Securely support the machine raised off the ground by using blocks.

1. Start the engine. Jack up the track link to be measured off the ground.

a

M104-07-067-6 ja

a- 90 to 110° 2. Rotate the track link to be measured. Start drain oil measurement when drain oil starts coming out of the connected drain hose end.

T107-06-05-008 ja

3. Measure for both the left and right track links.

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

5. The measuring time should be more than 45 seconds.

Evaluation Refer to ("Operational Performance Standard Table"T4-2-1).

Conversion of amount of measured drain oil 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 perminute value by using the following formula: ΔQ = 60 × q/t. ΔQ t q

: Amount of drain oil per minute (L/min) : Measured time (seconds) : Total amount of drain oil (L)

TTDD650-EN-00(18/11/2019)

T4-5-34

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment Rewrite of Aftertreatment Device Serial No. When the aftertreatment device has been replaced, rewrite the serial No. of aftertreatment device and upload the data to e-Service.

Procedure 1. Connect MPDr..

2. Set the key switch to the ON position.

3. Select Functions-Engine-Aftertreatment Device No. with MPDr..

4. Input the serial No. after the replacement to the following items of Oxidation Catalyst (DOC), Filter (CSF) and SCR Catalyst.

•

ASM

•

SUB

• Serial No. 5. After inputting, select [[F5] Set].

6. Upload the input data to e-Service.

NOTE When the input data is uploaded to e-Service, the M-Find product specifications and history will be updated.

TDD7-04-06-001 en_GB

How to Clear Fault Code IMPORTANT When the DCU or ECM fault code is displayed, clear the DCU or ECM fault code.

How to Clear DCU and ECM Fault Codes 1. On the screen specific to the machine model on MPDr., click the [Hydraulic excavator (less than 6 to 40 tons)]. Then, select ZX-7- [MC/ECM] (1) and click [Connect] (2).

TTDD650-EN-00(18/11/2019)

T4-6-1

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

1

ZX-7

2 TDFY-04-06-014-1 en_GB

2. Next, select Functions-Engine-Data Setting from the Tool bar. Click [[C] Fault Code Clear] (3).

3

TDFY-04-06-015-1 en_GB

3. Click [Transmittance] (4).

4

TDFY-04-06-016-1 en_GB

TTDD650-EN-00(18/11/2019)

T4-6-2

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment 4. Click [OK] (5).

5 TDC1-04-06-004-2 en_GB

Measuring Method of No-Load-Max Differential Pressure When ECM fault code 10026 (filter trapped PM excessive) is displayed, measure the No-Load-Max differential pressure and check the filter condition. After the inspection, perform the remedy according to the results. During No-Load-Max differential pressure measurement, refer to the "No-Load-Max Differential Pressure Measurement" (Functions-EngineMuffler Filter) on MPDr. and measure the following items while monitoring. ● Actual engine speed (ECM) ● DOC outlet exhaust temperature (ECM) ● DPF exhaust differential pressure (ECM) Measurement Procedure Proce­ Contents dure

Condition

Monitoring Item

1

Warm up the machine until the coolant temperature is 70 °C or more.

-

-

2

Set engine control dial to the slow idle position.

Lever in neutral

Actual engine speed (ECM)

3

Under the condition of procedure 2, decrease CSF exhaust tem­ perature down to 140 °C.

Lever in neutral

DOC outlet exhaust temper­ ature (ECM)

4

Set engine control dial to the fast idle position.

Lever in neutral

Actual engine speed (ECM)

5

Under the condition of procedure 4, increase CSF exhaust tem­ perature and measure differential pressure (A) when the CSF ex­ haust temperature is 150 °C.

Lever in neutral, DOC outlet exhaust temper­ Coolant temper­ ature (ECM), DPF exhaust ature: 70 °C or differential pressure (ECM) more

1

2

3

4

5

b a c d

e f

g

h i

j

m

k p n A t

No-Load-Max Differential Pressure Timing Chart TDFY-04-06-001-1 ja

A- Measuring Point TTDD650-EN-00(18/11/2019)

h- Fast Idle

T4-6-3

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment a- Coolant Temperature b- 70 °C or more c- Normal Temperature d- Lever Operation e- Operation f- Non Operation g- Engine Speed 12-

Measurement Procedure 1 Measurement Procedure 2

i- Slow Idle j- CSF Exhaust Temperature k- 150 °C m- Filter Exhaust Differential Pressure n- No-Load-Max Differential Pressure p- 140 °C t- Time 34-

Measurement Procedure 3 Measurement Procedure 4

5-

Measurement Procedure 5

Differential Pressure Checking Condition •

Engine speed: 1900 min-1

• CSF temperature: 150°C Evaluation (Differential Pressure Specification) •

Filter Replacement Differential Pressure (Allowable Limit): 5.2 kPa

Remedy Proce­ Contents dure 1

Evaluation

Remedy

Measure the No-Load-Max differen­ Less than filter re­ Perform "Aftertreatment Device Manual Regeneration tial pressure and check filter re­ placement differen­ (Slow)" in Engine Setting of the monitor. Then, replace placement differential pressure. tial pressure engine oil.

Filter replacement Filter (CSF) replacement. differential pressure or more

NOTE Aftertreatment device manual regeneration (slow) performs regeneration for approx. 2 hours.

Differential Pressure Sensor Learning After making the following repairs and inspections, perform the Differential Pressure Sensor Learning. ● When the differential pressure sensor has been replaced ● When ECM has been replaced ● When the ECM software has been rewritten Learning Step 1. Connect MPDr..

2. Set the key switch to the ON position.

3. Select Functions/Engine/Muffler Filter/Muffler Filter Differential Pressure Sensor Learning with MPDr.. Select [Start Learning]. While the learning is being normally performed, [Learning] is displayed on MPDr..

4. Hold this state for 30 seconds.

NOTE When the key switch is operated in the process of learning, the learning stops. (Learning failed) 5. When the learning is successfully completed, [OK] is displayed on MPDr..

NOTE When the learning fails, [NG] is displayed on MPDr.. In this case, perform the operation from procedure 3 again.

6. Set the key switch to the OFF position.

TTDD650-EN-00(18/11/2019)

T4-6-4

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment 7. Hold this state for 60 seconds or more (until the ECM main relay is turned OFF).

Learning conditions: ● Exhaust temperature before filter (CSF): less than 100 °C ● Coolant temperature: less than 100 °C

IMPORTANT After the learning is successfully completed, download the ECM data with MPDr.. In addition, upload the downloaded data to e-Service.

Filter Maintenance IMPORTANT When the filter (CSF) is replaced or cleaned, do the ASH reset to reset the filter maintenance history on the monitor.

1. Connect MPDr..

2. Set the key switch to the ON position.

3. Select Functions/Engine/Muffler Filter/Muffler Filter Maintenance with MPDr..

4. Perform the work items in the table below.

Item

Description

Replacement of DOC

Setting of Aftertreatment Device Serial No.

Replacement of CSF or replacement of DOC with CSF

Setting of the aftertreatment device serial No. and the ASH reset

Cleaning

Checking of the aftertreatment device serial No. and the ASH reset

5. Set (or check) the serial No.. (Refer to ["Rewrite of Aftertreatment Device Serial No."T4-6-1].)

6. Do the [ASH reset].

IMPORTANT After setting the serial No. and doing the ASH reset, upload the set data to e-Service.

NOTE When the set data is uploaded to e-Service, the M-Find product specifications and history will be updated.

Procedure after Replacing DCU and ECM DCU and ECM retain the data of NH3 amount accumulated in SCR catalyst. When DCU and ECM are replaced, the NH3 accumulated amount data must be reset by performing the Aftertreatment Device Forcible Manual Regeneration Control function. When ECM is replaced, perform the Differential Pressure Sensor Learning. (Refer to ["Differential Pressure Sensor Learning"T4-6-4].)

Procedure 1. Start the engine.

2. Start MPDr., then select and perform the [Aftertreatment Device Forced Manual Regeneration Control] function.

TTDD650-EN-00(18/11/2019)

T4-6-5

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

TDFY-04-06-017 en_GB

3. The monitor will display the Manual Regeneration Request screen and the Manual Regeneration Switch (1) indicator starts blinking.

1 TDFY-04-06-002-1 ja

4. Turn the engine control dial to the slow idle position. Push the Manual Regeneration Switch (1) with setting the pilot control shut-off lever to the LOCK position.

5. The Manual Regeneration Switch (1) indicator is lit and the manual regeneration starts.

6. The Manual Regeneration completes after approximately 15 minutes.

7. Stop the engine and stop MPDr..

Air Bleeding from the Diesel Exhaust Fluid Defrosting Piping The DEF defrosting piping is equipped along with the DEF piping in order to prevent DEF from freezing. After performing the following procedures, bleed air from the DEF defrosting piping and fill the DEF defrosting piping with coolant.

•

When the DEF supply module, DEF sensor unit, coolant control valve, or coolant hose has been replaced

•

When coolant has been drained

Procedure 1. Turn ON the key switch with stopping the engine.

2. Start MPDr. Select the [D] Air Bleeding from the DEF/AdBlue® Defrosting Piping (1).

TTDD650-EN-00(18/11/2019)

T4-6-6

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

1

TDFY-04-06-018-1 en_GB

3. Push the [START] (2) button.

2

TDFY-04-06-019-1 en_GB

4. Ensure that the [Executing] icon (3) is displayed. Start the engine within 10 seconds.

3

TDFY-04-06-020-1 en_GB

TTDD650-EN-00(18/11/2019)

T4-6-7

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment 5. After starting the engine, set the engine control dial to the fast idle position.

6. When the [Executing] icon (3) disappears after 150 seconds have passed, the operation is completed.

7. Turn OFF the key switch.

How to Check Manual Regeneration Switch When manual regeneration switch (1) or the wire harness related to manual regeneration switch (1) is repaired or replaced, check that manual regeneration switch (1) operates normally.

Procedure 1. Start the engine.

2. Start MPDr., then select and perform the [Aftertreatment Device Forced Manual Regeneration Control] function.

TDFY-04-06-017 en_GB

3. The monitor will display the Manual Regeneration Request screen and the Manual Regeneration Switch (1) indicator starts blinking.

1 TDFY-04-06-002-1 ja

4. The Manual Regeneration Switch (1) indicator is lit and the manual regeneration starts.

5. When the Manual Regeneration starts, stop the Aftertreatment Device Forced Manual Regeneration control by using MPDr..

6. Stop the engine and stop MPDr..

TTDD650-EN-00(18/11/2019)

T4-6-8

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment Remedy at DEF Pressure Decrease When fault code 10520-12 (Abnormal DEF/AdBlue® Pressure (Low Pressure after Start-Up)) or fault code 10533-12 (Abnormal DEF/AdBlue® Pressure (Low Pressure in Normal Condition)) is displayed, perform the remedy as follows.

Procedure Pro­ ce­ dure

Contents

Condition

Monitoring Item

1

Check appearance of the machine and confirm that no DEF leakage is observed.

Key Switch: OFF Position

-

2

If DEF level is less than scale mark "2", add DEF beyond scale mark "2".

Key Switch: ON Position

DEF Gauge

3

Start the engine. Warm up the machine until the SCR exhaust temperature rises to the specified value (150℃).

When DEF pressure increases to 9000 hPa, continue warm up for 10 minutes. If DEF pressure does not decrease to 6500 hPa or less, stop the engine.

Warm up, Control lever: Neutral, Key Switch: OFF Posi­ tion, End of con­ firmation

4

If DEF pressure does not increase to 9000 hPa or it decrease to Key Switch: OFF 6500 hPa or less in procedure 3, remove DEF supply module Position main filter (d). Place a container to receive DEF (5 liter capacity) under the filter mounting port.

-

5

Start the engine and warm up the machine. When the SCR ex­ Warm up haust temperature exceeds the specified value (150℃), startup operation starts and DEF will be drained from the filter mounting port.

SCR Exhaust Temperature (En­ gine)

6

After confirmation of DEF drainage, stop the engine after 300 seconds while keeping the SCR exhaust temperature at the specified value (150℃).

7

Dispose drained DEF. If drained DEF is discolored or it contains Key Switch: OFF a mass of contamination, wash the DEF tank with using DEF. Position After draining DEF, install new main filter (d) and close cap (e).

(20±5 N･m)

8

Start the engine. Warm up the machine until the SCR exhaust temperature rises to the specified value (150℃).

When DEF pressure increases to 9000 hPa, continue warm up for 10 minutes. If DEF pressure does not decrease to 6500 hPa or less, stop the engine.

9

If DEF is not drained in procedure 5, DEF pressure does not in­ crease to 9000 hPa, or it decreases to 6500 hPa or less in proce­ dure 8, contamination may be clogging inside of piping or DEF supply module (c). Perform the remedy as follows.

-

10

Replace the DEF inlet adapter (f ). Perform step 8.

Key Switch: ON Position

-

11

If the problem does not resolve at step 10, remove DEF sensor Key Switch: OFF unit (a) from DEF tank (b) and check its appearance. Clean it if Position necessary.

-

12

If the problem does not resolve at step 11, replace DEF supply Key Switch: OFF module (c). After replacement, bleed air from the DEF defrost­ Position ing piping.

-

TTDD650-EN-00(18/11/2019)

T4-6-9

Warm up, Key Switch: OFF Posi­ tion -

Warm up, Control SCR Exhaust Temperature (En­ lever: Neutral, Key gine), DEF Pressure (Engine) Switch: OFF Posi­ tion, End of con­ firmation

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment a

b

TDFY-04-06-003-1 ja

a- DEF Sensor Unit

b- DEF Tank f

c

d

e

MDC1-07-004-1 ja

c- DEF Supply Module d- DEF Supply Module Main Filter

TTDD650-EN-00(18/11/2019)

e- Cap f- DEF Inlet Adapter

T4-6-10

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment Clean DEF Tank When impurity or liquid other than DEF is mixed in the DEF tank, fault code 10520-12 (Abnormal DEF Pressure (Low Pressure after Start-Up)), fault code 10533-12 (Abnormal DEF Pressure (Low Pressure in Normal Condition)), or fault code 10523-1 (Abnormal DEF Quality (Concentration Reduction)) will be displayed. When one of the above errors is displayed, the DEF tank must be cleaned. Clean the DEF tank as follows.

Procedure Pro­ ce­ dure

Contents

Condition

Monitoring Item

1

Remove the DEF tank. (*1)

2

Remove socket bolt (d). Remove filler port (e) and strain­ Key Switch: OFF Posi­ tion er (f ) from the DEF tank. (*2)

3

Tilt the DEF tank so that DEF is discharged from the filler Key Switch: OFF Posi­ port (e) mounting part. From the sensor unit mounting tion part, conduct high-pressure cleaning or insert a hose to clean the interior of the DEF tank.

4

Clean the area around the filler port (e) mounting part.

Key Switch: OFF Posi­ tion

5

Confirm that there is no impurity left in the DEF tank.

Key Switch: OFF Posi­ tion

6

Clean the sensor unit with DEF. (*3)

Key Switch: OFF Posi­ tion

7

Mount the sensor unit on the DEF tank.

Key Switch: OFF Posi­ tion

8

Clean strainer (f ) and filler port (e) with DEF.

Key Switch: OFF Posi­ tion

9

Install strainer (f ) and filler port (e) on the DEF tank with Key Switch: OFF Posi­ tion socket bolt (d). : 5 mm, : 12.5±2.5 N·m

10

Install drain plug (c) and mount the DEF tank on the ma­ Key Switch: OFF Posi­ tion chine body. (*4)

11

Supply DEF to the DEF tank.

12

Ensure that the DEF level is scale mark "2" or more on the Key Switch: ON Posi­ monitor. If the DEF level is below the scale mark "2", add tion DEF.

13

Install the removed handrail and covers. (*5)

*1 *2 *3 *4 *5

Refer to the section describing mounting/dismounting of DEF tank in the separate Workshop Manual.

Accumulation of dust on the strainer may cause hose clogging.

When the filter is dirty, replace it.

Refer to the section describing mounting/dismounting of DEF tank in the separate Workshop Manual.

Refer to the section describing mounting/dismounting of DEF tank in the separate Workshop Manual.

TTDD650-EN-00(18/11/2019)

Key Switch: OFF Posi­ tion

Key Switch: OFF Posi­ tion DEF Level

Key Switch: OFF Posi­ tion

T4-6-11

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment b

a MDC1-07-034-1 ja a-

Bolt

b-

Cover

c MDC1-07-028-1 ja c-

Drain Plug

d e, f TDC4-04-06-001-1 ja d-

Socket Bolt

TTDD650-EN-00(18/11/2019)

e-

Filler Port

f-

T4-6-12

Strainer

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment Remedy when Mixing Oil in DEF Tank When liquid other than DEF (such as oil) is mixed in the DEF tank, liquid in the DEF tank must be changed with new DEF. In particular, when oil is mixed in, perform the remedy as follows.

Procedure Pro­ ce­ dure

Contents

Condition

1

Identify the mixed liquid. If no oil is mixed, clean the DEF Key Switch: OFF Posi­ tank. If oil is mixed, the parts must be replaced. Check tion that the machine is operated or not after mixing the liq­ uid.

2

If the machine was not operated after mixing oil, replace Key Switch: OFF Posi­ the DEF tank and DEF sensor unit. tion If the machine was operated after mixing oil, oil may en­ ter the DEF piping or aftertreatment device and it may cause fire at worst. In this case, replace the DEF tank, DEF sensor unit, DEF supply module, DEF dosing module, af­ tertreatment device, and DEF piping.

Monitoring Item

Calibration of Aerial Angle When the camera position changes due to replacement of the camera or modification of the machine, perform calibration.

Preparation ● PC with "AA-Stationary-ZX-7 Service Tool.exe" installed

NOTE Download the service tools from Global e-Service Maintenance PRO and install the service tools to the PC. ● Calibration Sheet (ST 8411) (4 Used) ● Checking Line (ST 8412 or Equivalent) ● Kvaser (ST 8409), Connecting Cable (ST 8410)

NOTE • •

Space required for calibration depends on the machine model. Secure space with reference to the table below.

These are approximate dimensions of the standard specifications. The required space may depend on the machine specifications.

Machine front and rear sides Machine right and left sides

approx. 14 m approx. 9 m

Procedure 1. Push aerial angle switch (1) to change into the mode where composite image (2) is displayed in the full screen mode.

TTDD650-EN-00(18/11/2019)

T4-6-13

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

2

1

TDFY-04-06-004-1 ja

2. Place checking line (a) (ST 8412 or equivalent) on the ground. Place the machine so that the line closest to the rear of the machine overlaps checking line (a) on the ground on the monitor.

a TDFY-04-06-005-1 ja

a- Checking Line 3. Close the cab door and check the image on the monitor. It is OK when both right and left checking lines (b, c) are within the range from A to B. •

OK: The following procedures are not required:

•

NG: Go to Procedure No. 4. b

c A OK NG

A B

OK

B

NG

d c d

TDFY-04-06-006-1 ja

TTDD650-EN-00(18/11/2019)

T4-6-14

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment A- Icon Rear End Position B- Rear View Camera Checking Line Image (d) Rear End Position b- Camera Left Checking Line Image

c- Camera Right Checking Line Image d- Rear View Camera Checking Line Image

4. Place calibration sheets (ST 8411) around the machine in parallel with and symmetry to the machine.

NOTE Do not make boundary lines between shadows on the sheets.

e

f

g

g

ST 8411

h

h

h

h

h

ST 8411 h

i

TDFY-04-06-007-1 ja

e- Upperstructure Left End f- Upperstructure Right End g- Near Swing Center

h- Approx. 1 m i- Counterweight Rear End

5. Push the aerial angle switch to change into the screen on which 3 directions are displayed. Confirm that 2 calibration sheets appear on each camera. If not, move and adjust the calibration sheets. Place the rear calibration sheets to be visible in contact with the counterweight as illustrated.

j TDFY-04-06-008-1 ja

j- Rear Calibration Sheet Position 6. Remove the rear tray. Connect ST 8410, ST 8409, and PC to B_CAN.

TTDD650-EN-00(18/11/2019)

T4-6-15

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment B_CAN B_CAN

q

ST 8410 ST 8409

TDFY-04-06-012-1 ja

q- Connect to PC 7. Turn ON the key switch and start "Aerial Angle Stationary Mode Service Tool For ZX" on PC.

NOTE Download the service tools from Global e-Service Maintenance PRO and install the service tools to the PC.

TDC4-04-06-012 ja

8. Select [CAN (500)] (3) in ECU Connection and click [Connect] (4).

TTDD650-EN-00(18/11/2019)

T4-6-16

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment A

A

3

4

TDFY-04-06-009-1 ja

9. Select [Calibration] (5) and [Target Marker Calibration] (6), and click [Perform calibration] (7).

5 6 7

TDC4-04-06-015-1 ja

10. Wait until the progress bar reaches 100 %. (About 3 minutes)

TDC4-04-06-016 ja

11. The screen for selecting files appears. Open a file in [MODEL_default.calibin] (8).

Example: [ZX200-7_default.calibin], [ZX225US-7_default.calibin] 8

TDC4-04-06-017-1 ja

12. Click [Next] (9).

TTDD650-EN-00(18/11/2019)

T4-6-17

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

9 TDC4-04-06-018-1 ja

13. Click [Setting] (10) in [Right Camera]. The camera image viewed from above is displayed on the right side of the screen.

10

TDC4-04-06-019-1 ja

14. 2 markers are displayed. Click the 4 corners of the black square on each marker. After placing all points on one maker, click the 4 corners of the next marker in the same way. After placing the 8 points, click [Save] (13).

NOTE When placing any points in wrong positions, click and select the points, delete the points by using the Delete key, and properly place points again.

15. Click [Setting] (11) in [Left Camera] and perform procedure 14. Click [Setting] (12) in [Rear Camera] and perform procedure 14.

TTDD650-EN-00(18/11/2019)

T4-6-18

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

11

12

13 TDFY-04-06-010-1 ja

16. After [Save] is completed for the marker positions on all cameras, [Next] (14) can be clicked. Click [Next] (14).

14

TDC4-04-06-023-1 ja

17. Check that the composite image is displayed properly.

NOTE The composite image is displayed properly when boundary line (m) and white line (k) of the mat are in parallel with each other.

TTDD650-EN-00(18/11/2019)

T4-6-19

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment m

k

TDFY-04-06-011-1 ja

k- White Line

m- Boundary Line

18. When the boundary line and the white line are not in parallel with each other, adjust the tilt until the boundary line and the white line are in parallel with each other by gradually rotating the screen by using [Counterclockwise] (n) for the counterclockwise rotation or [Clockwise] (p) for the clockwise rotation. n

p

TDC4-04-06-026-1 ja

n- Counterclockwise rotation

p- Clockwise rotation

19. When the boundary line and the white line are in parallel with each other, click [Write ECU] (15).

15

TDC4-04-06-024-1 ja

20. Wait 10 to 15 minutes until the writing is completed.

TDC4-04-06-016 ja

21. After the completion of writing, click [No] (16).

TTDD650-EN-00(18/11/2019)

T4-6-20

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

16

TDC4-04-06-029-1 ja

22. Click [Disconnect](17) to exit the service tools and turn OFF the key switch.

17

TDC4-04-06-015-2 ja

23. Approx. 30 seconds after the battery relay is disconnected, turn ON the key switch again and check the monitor image. Perform procedures 2 and 3 again and check that the lines are not misaligned. When the lines are misaligned, perform the operation from procedure 4 again. When the lines are not misaligned, the operation is completed. Return the wires in the rear tray to their original position and install the rear tray. Then retry with MPDr. to clear the fault code.

Oil Monitoring Sensor Setting When the oil monitoring sensor is replaced, set the oil monitoring sensor with MPDr..

Procedure 1. Connect MPDr..

2. Set the key switch to the ON position.

3. Select Functions/Others/Sensors Related to Oil Monitoring with MPDr..

4. Select the item to perform.

A

B

C

D

TDFY-04-06-021-1 en_GB

A- Constant Change (Oil Monitoring Sensor Setting)

TTDD650-EN-00(18/11/2019)

C- To Hydraulic Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check)

T4-6-21

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment B- To Engine Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check)

D- To Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)

[A] Constant Change (Oil Monitoring Sensor Setting) When installing the oil monitoring sensor, set the corresponding items from OFF to ON. 1. Click [[A] Constant Change].

A

B

C

D

TDFY-04-06-021-1 en_GB

A- Constant Change (Oil Monitoring Sensor Setting) B- To Engine Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check)

C- To Hydraulic Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) D- To Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)

2. Select [Select] (1).

1

TDFY-04-06-022-1 en_GB

3. Click [[F4] Present Value] (2).

TTDD650-EN-00(18/11/2019)

T4-6-22

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

2 TDFY-04-06-023-1 en_GB

4. The setting is OFF (3). Therefore, select ON from the change value.

3

TDFY-04-06-024-1 en_GB

5. Click [[F5]Set] (5).

TTDD650-EN-00(18/11/2019)

T4-6-23

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

5 TDFY-04-06-025-1 en_GB

6. Click [YES] (6).

6 TDFY-04-06-026-1 en_GB

7. Click [OK] (7).

TTDD650-EN-00(18/11/2019)

T4-6-24

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

7 TDFY-04-06-027-1 en_GB

8. When the engine oil monitoring sensor setting and hydraulic oil monitoring sensor setting are ON (8), the setting work is completed. Go to [D] Sensor Batch Diagnosis. (Refer to "[D] Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)"T4-6-25.) When the setting is not ON, perform [A] Constant Change from procedure 1 again.

8

TDFY-04-06-028-1 en_GB

[D] Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check) 1. Click [[D] Sensor Collective Diagnosis].

TTDD650-EN-00(18/11/2019)

T4-6-25

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment A

B

C

D

TDFY-04-06-021-1 en_GB

A- Constant Change (Oil Monitoring Sensor Setting)

C- To Hydraulic Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) D- To Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)

B- To Engine Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) 2. Click [Execute] (1) in the sensor check.

1 TDFY-04-06-029-1 en_GB

3. When the sensor check is ON (2), [Diagnosis Request] (3) can be clicked. Click [Diagnosis Request] (3) to start diagnosis.

When the sensor check is OFF (4), [Diagnosis Request] (3) cannot be clicked. When the oil monitoring sensor is already installed and the sensor check is OFF (4), "Oil Monitoring Sensor Daily Report - Engine Oil" or "Oil Monitoring Sensor Daily Report - Hydraulic Oil" in the constant change may not be set to ON. Perform [A] Constant Change. (Refer to "[A] Constant Change (Oil Monitoring Sensor Setting)"T4-6-22)

NOTE It takes several minutes for the diagnosis result to be displayed after [Diagnosis Request] (3) is clicked.

TTDD650-EN-00(18/11/2019)

T4-6-26

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

2

3

Sensor check: ON TDFY-04-06-030-1 en_GB

4

Sensor check: OFF TDFY-04-06-031-1 en_GB

4. When the sensor diagnosis result is OK (5), it indicates that the engine oil monitoring sensor and hydraulic oil monitoring sensor are operating normally. When the diagnosis result is OK, the setting of the oil monitoring sensor is completed.

TTDD650-EN-00(18/11/2019)

T4-6-27

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

5 TDFY-04-06-032-1 en_GB

5. When the sensor diagnosis result is NG (6), scroll down to display the remedy. Check the connection between the wire harness and the oil monitoring sensor, and perform [D] Sensor Batch Diagnosis from procedure 1 again. When the sensor diagnosis result shows NG (6) again even after performing the remedy, replace the corresponding oil monitoring sensor.

a

6 TDFY-04-06-033-1 en_GB

a- Scroll

[B] Diagnosis of Engine Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check) 1. Click [[B] Engine Oil Monitoring Sensor].

TTDD650-EN-00(18/11/2019)

T4-6-28

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment A

B

C

D

TDFY-04-06-021-1 en_GB

A- Constant Change (Oil Monitoring Sensor Setting)

C- To Hydraulic Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) D- To Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)

B- To Engine Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) 2. Click [Execute] (1) in the sensor check.

1 TDFY-04-06-034-1 en_GB

3. When the sensor check is ON (2), [Diagnosis Request] (3) can be clicked. Click [Diagnosis Request] (3) to start diagnosis.

When the sensor check is OFF (4), Diagnosis Request (3) cannot be clicked. When the oil monitoring sensor is already installed and the sensor check is OFF (4), "Oil Monitoring Sensor Daily Report - Engine Oil" in the constant change may not be set to ON. Perform [A] Constant Change. (Refer to "[A] Constant Change (Oil Monitoring Sensor Setting)"T4-6-22)

NOTE It takes several minutes for the diagnosis result to be displayed after [Diagnosis Request] (3) is clicked.

TTDD650-EN-00(18/11/2019)

T4-6-29

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

2

3

Sensor check: ON TDFY-04-06-035-1 en_GB

4

Sensor check: OFF TDFY-04-06-036-1 en_GB

4. When the sensor diagnosis result is OK (5), it indicates that the engine oil monitoring sensor is operating normally.

When the diagnosis result is OK, the setting of the oil monitoring sensor is completed.

TTDD650-EN-00(18/11/2019)

T4-6-30

SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

5 TDFY-04-06-037-1 en_GB

5. When the sensor diagnosis result is NG (7), the remedy is displayed. Check the connection between the wire harness and the engine oil monitoring sensor, and perform [B] Engine Oil Monitoring Sensor Diagnosis from procedure 1 again. When the sensor diagnosis result shows NG (7) again even after performing the remedy, replace the engine oil monitoring sensor.

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[C] Diagnosis of Hydraulic Oil Monitoring Sensor (Oil Monitoring Sensor Functional Check) 1. Click [Hydraulic Oil Monitoring Sensor from [C]].

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SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment A

B

C

D

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A- Constant Change (Oil Monitoring Sensor Setting)

C- To Hydraulic Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) D- To Sensor Collective Diagnosis (Oil Monitoring Sensor Functional Check)

B- To Engine Oil Monitoring Sensor Diagnosis (Oil Moni­ toring Sensor Functional Check) 2. Click [Execute] (1) in the sensor check.

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3. When the sensor check is ON (2), [Diagnosis Request] (3) can be clicked. Click [Diagnosis Request] (3) to start diagnosis.

When the sensor check is OFF (4), [Diagnosis Request] (3) cannot be clicked. When the oil monitoring sensor is already installed and the sensor check is OFF (4), "Oil Monitoring Sensor Daily Report - Hydraulic Oil" in the constant change may not be set to ON. Perform [A] Constant Change. (Refer to "[A] Constant Change (Oil Monitoring Sensor Setting)"T4-6-22)

NOTE It takes several minutes for the diagnosis result to be displayed after [Diagnosis Request] (3) is clicked.

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SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

2

3

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4

Sensor check: OFF TDFY-04-06-041-1 en_GB

4. When the sensor diagnosis result is OK (5), it indicates that the hydraulic oil monitoring sensor is operating normally.

When the diagnosis result is OK, the setting of the oil monitoring sensor is completed.

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SECTION4 OPERATIONAL PERFORMANCE TEST Group6 Adjustment

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5. When the sensor diagnosis result is NG (7), the remedy is displayed. Check the connection between the wire harness and the hydraulic oil monitoring sensor, and perform [C] Hydraulic Oil Monitoring Sensor Diagnosis from procedure 1 again. When the sensor diagnosis result shows NG (7) again even after performing the remedy, replace the hydraulic oil monitoring sensor.

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