SECTION 4 OPERATIONAL PERFORMANCE TEST

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2 SECTION 4 OPERATIONAL PERFORMANCE TEST CONTENTS Group 1 Introduction Group 5 Component Test Operational Performance Test... T4-1-1 Primary Pilot Pressure...T4-5-1 Preparation for Performance Tests... T4-1-2 Secondary Pilot Pressure...T4-5-2 Main Relief Valve Set Pressure...T4-5-3 Group 2 Standard Overload Relief Valve Set Pressure...T4-5-6 Operational Performance Standard... T4-2-1 Swing Motor Drainage...T4-5-8 Main Pump P-Q Diagram... T4-2-5 Travel Motor Drainage...T Group 3 Engine Test Revolution Sensing Valve Engine Speed... T4-3-1 Output Pressure...T Engine Compression Pressure... T4-3-2 Pump Delivery Pressure...T Valve Clearance... T4-3-4 Pump Driving Torque...T Nozzle Check... T4-3-6 Auxiliary Flow Selector Valve Injection Timing... T4-3-8 Pressure (Optional)...T Group 4 Excavator Test Travel Speed... T4-4-1 Track Revolution Speed... T4-4-2 Mistrack Check... T4-4-3 Travel Motor Leakage... T4-4-4 Swing Speed... T4-4-5 Swing Function Drift Check... T4-4-6 Swing Motor Leakage... T4-4-7 Maximum Swingable Slant Angle... T4-4-8 Swing Bearing Play... T4-4-9 Hydraulic Cylinder Cycle Time... T Dig Function Drift... T Control Lever Operating Force... T Control Lever Stroke... T Combined Boom Raise/Swing Function Check... T Group 6 Adjustment Governor Adjustment...T M9T-4-1

3 (Blank) 1M9T-4-2

4 OPERATIONAL PERFORMANCE TEST / Introduction OPERATIONAL PERFORMANCE TEST 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. Definition of Allowable Limit 1. Normal machine performance cannot be accomplished after exceeding this limit. 2. Repair or adjustment is impossible after exceeding this limit. 3. Therefore, in consideration of operation efficiency and maintenance expense, proper maintenance shall be carried out before reaching the Allowable Limit. 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. T4-1-1

5 OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION FOR PERFORMANCE TESTS Observe the following rules in order to carry out performance tests accurately and safely. THE MACHINE 1. Repair any defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. TEST AREA 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 in), and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide signboards to keep unauthorized personnel away. PRECAUTIONS 1. Before starting to test, agree upon the signals to be employed for communication among coworkers. Once the test is started, be sure to communicate with each other using these signals, and to follow them without fail. 2. Operate the machine carefully and always give first priority to safety. 3. While testing, always take care to avoid accidents due to landslides or contact with high-voltage power lines. Always confirm that there is sufficient space for full swings. 4. Avoid polluting the machine and the ground with leaking oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. 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. T T T4-1-2

6 OPERATIONAL PERFORMANCE TEST / Standard OPERATIONAL PERFORMANCE STAN- DARD This Operational Performance Standard values are listed below. Refer to the correspondence section in T4-3 and after for the details of measurement method. The value in ( ) is shown for reference only. * The standard measurement condition is as follows; Engine Speed Control Lever: Full Stroke Hydraulic Oil Temperature: 50±5 C (122±9 F) Item ZAXIS40U-2 ZAXIS50U-2 Remarks ENGINE SPEED min -1 Refer to T4-3-1 Slow Idle Speed 1150±50 Fast Idle Speed 2650±50 Fast Idle Speed (Bucket Relief Operation) 2250±50 Fast Idle Speed (Boom Relief Operation) 2250±50 ENGINE COMPRESSION PRESSURE MPa (kgf/cm 2, psi) 3.43±0.1 (35±1, 499±14.5) VALVE CLEARANCE (IN, EX) mm 0.2±0.05 ZZLE INJECTION PRESSURE MPa (kgf/cm 2, psi) INJECTION TIMING (Fuel Pump Mounting Standard Angle) deg ( , ) 25 After engine warm-up Refer to T4-3-2 With engine cold Refer to T4-3-4 Refer to T4-3-6 Refer to T4-3-8 TRAVEL SPEED sec/20 m Refer to T4-4-1 Fast Speed Mode (Rubber Crawler/Steel Crawler) Slow Speed Mode (Rubber Crawler/Steel Crawler) 16.0±1.5 / 17.2± ±1.5 / 27.6±1.5 TRACK REVOLUTION SPEED sec/3 rev. Refer to T4-4-2 Fast Speed Mode (Rubber Crawler/Steel Crawler) Slow Speed Mode (Rubber Crawler/Steel Crawler) 11.3±1.5 / 11.9± ±1.5 / 20.7±1.5 MISTRACK Refer to T or less (Fast Speed Slow Speed) mm/20 m TRAVEL MOTOR LEAKAGE mm/3 min 0 Refer to T4-4-4 SWING SPEED sec/3 rev. 19.3±1.5 Refer to T4-4-5 SWING FUNCTION DRIFT mm/ or less Refer to T4-4-6 SWING MOTOR LEAKAGE mm/5 min 0 Bucket loaded Refer to T4-4-7 MAXIMUM SWINGABLE Bucket loaded 21 or more 20 or more SLANT ANGLE deg. Refer to T4-4-8 SWING BEARING PLAY mm 0.4 or less Refer to T4-4-9 T4-2-1

7 OPERATIONAL PERFORMANCE TEST / Standard Item ZAXIS40U-2 ZAXIS50U-2 Remarks HYDRAULIC CYLINDER Refer to T CYCLE TIME sec Boom Raise (Canopy Version) 2.0± ±0.3 Boom Lower (Canopy Version) 2.6± ±0.3 Arm Roll-In 2.6± ±0.5 Arm Roll-Out 2.1± ±0.3 Bucket Roll-In 2.3± ±0.3 Bucket Roll-Out 1.7± ±0.3 Right Boom Swing 7.0±0.5 Left Boom Swing 7.0±0.5 Blade Raise 2.5± ± 0.6 Blade Lower 3.1± ± 0.6 DIG FUNCTION DRIFT mm/5 min Boom Cylinder 5 or less Arm Cylinder 8 or less Bucket Cylinder 5 or less Bucket Bottom 100 or less Blade Cylinder 3 or less Blade Cylinder (When jacked up) 15 or less Boom Swing Cylinder 3 or less CONTROL LEVER/PEDAL OPERATING FORCE Boom Lever N (kgf, lbf) Arm Lever (ISO Lever Pattern: Swing) Bucket Lever Swing Lever (ISO Lever Pattern: Arm) Travel Lever Blade Lever Boom Swing Pedal 11.0 or less (1.1, 2.5 or less) 11.0 or less (1.1, 2.5 or less) 11.0 or less (1.1, 2.5 or less) 11.0 or less (1.1, 2.5 or less) 17.0 or less (1.7, 3.8 or less) 19.0 or less (1.9, 4.3 or less) 54.0 or less (5.5, 12.2 or less) Bucket loaded Refer to T HITACHI Lever Pattern Refer to T T4-2-2

8 OPERATIONAL PERFORMANCE TEST / Standard CONTROL LEVER/PEDAL STROKE Item ZAXIS40U-2 ZAXIS50U-2 Remarks mm (in) Boom Lever 100±10 (3.9±0.4) Arm Lever (ISO Lever Pattern: Swing) 95±10 (3.7±0.4) Bucket Lever 95±10 (3.7±0.4) Swing Lever (ISO Lever Pattern: Arm) 100±10 (3.9±0.4) Travel Lever 100±10 (3.9±0.4) Blade Lever 55±10 (2.2±0.4) Boom Swing Pedal 18±5 (0.7±0.2) BOOM RAISE/SWING (Bucket Empty) Height mm 3000 or more Time sec 2.3±0.3 PRIMARY PILOT PRESSURE SECONDARY PILOT PRESSURE MAIN RELIEF VALVE SET PRESSURE Main Pumps P1 Travel Swing MPa (kgf/cm 2, psi) MPa (kgf/cm 2, psi) MPa (kgf/cm 2, psi) OVERLOAD RELIEF VALVE SET PRESSURE MPa (kgf/cm 2, psi) 6.6±0.5 (67±5, 960±73) 2.9±0.5 (30±5, 422±73) 25.3±1.0 (258±10, 3678±145) 25.5±1.0 (260±10, 3707±145) 21.6±1.0 (220±10, 3140±145) HITACHI Lever Pattern Refer to T Refer to T Refer to T4-5-1 Refer to T4-5-2 Measure at Machine Refer to T4-5-3 Measure at Bench Refer to T ±1(270±10, Boom, Arm, Bucket 3852±145) SWING MOTOR DRAINAGE L/min (gal) Refer to T or less at constant speed (0.1 or less) TRAVEL MOTOR DRAINAGE L/min (gal) Refer to T or less / at constant speed 0.2 or less (Fast/Slow) (0.08 or less / 0.05 or less) T4-2-3

9 OPERATIONAL PERFORMANCE TEST / Standard Item ZAXIS40U-2 ZAXIS50U-2 Remarks REVOLUTION SENSING VALVE OUTPUT PRESSURE (Pressure PGR) MPa (kgf/cm 2, psi) Measure at bench Refer to T Fast Idle 1.96 (20, 285) Reference Slow Idle 0.49 (5.0, 71) Reference PUMP DELIVERY PRESSURE (Lever in Neutral) MPa (kgf/cm 2, psi) Refer to T Fast Idle 3.1 (31.8, 451) Reference Slow Idle 2.3 (23.3, 334) Reference T4-2-4

10 MAIN PUMP P-Q DIAGRAM P-Q control (Torque control) OPERATIONAL PERFORMANCE TEST / Standard (Reference: Calculated Valve) Rated Pump Speed: 2500 min -1 (rpm) Hydraulic Oil Temperature: 50±5 C (122±41 F) Pilot Pump Pressure: 5.9 MPa (60 kgf/cm 2, 858psi) P-Q Point (Air conditioner: OFF (PC Pressure = 0 MPa)) Delivery Pressure MPa (kgf/cm 2, psi) Flow Rate L/min (GPM) A 1.96 (20, 285) 126 (33.2) B 4.6 (47, 669) 125 (33) C 6.67 (68, 970) [121.5] [(32)] D 8.7 (88.7, 1265) (30.7) E (170, 2473) [70] [(18.5)] F 24.5 (250, 3562) 47.5 (12.5) The valve indicated in [ ] is only a reference valve. P-Q Point (Air conditioner: ON (PC pressure = 3.9 MPa (40 kgf/cm 2, 567 psi)) Delivery Pressure MPa (kgf/cm 2, psi) Flow Rate L/min (GPM) A 1.96 (20, 285) 126 (33.2) B 4.6 (47, 669) 125 (33) C 6.67 (68, 970) [121.5] [(32)] G 15 (153, 2181) [69] [(18.2)] H 24.5 (250, 3562) [40] [(10.6)] The valve indicated in [ ] is only a reference valve. L/min A B C D Flow Rate G E F H Delivery Pressure MPa (kgf/cm 2 ) T1M T4-2-5

11 OPERATIONAL PERFORMANCE TEST / Standard (Blank) T4-2-6

12 ENGINE SPEED OPERATIONAL PERFORMANCE TEST / Engine Test Summary: 1. Be sure to check the engine speed before performing all other tests, since it always affects test results. Engine Control Dial Preparation: 1. Warm up the machine, until the engine coolant temperature reaches 50 C (122 F) or more, and hydraulic oil temperature is 50±5 C (122±9 F). 2. Move the engine control dial from slow idle to fast idle. Confirm that the fuel injection pump governor lever comes into contact with the slow-idle and fast-idle stoppers. 3. Connect an engine tachometer to the fuel injection line. Measurement: 1. Depending upon the engine speed measured, make measurement as per the following table. Engine Control Dial Auto Idle Switch Slow Idle (No-load) Slow Idle OFF Fast Idle (No-load) Fast Idle OFF 2. Repeat measurement three times and calculate the mean value. Evaluation: Refer to T4-2 Operational Performance Standard. Governor Lever T1M Stopper T1M T4-3-1

13 OPERATIONAL PERFORMANCE TEST / Engine Test ENGINE COMPRESSION PRESSURE Summary: 1. Measure compression pressure in the cylinders to check for a reduction in engine power. 2. Check exhaust gas color. Keep track of engine oil consumption. 3. Check for abnormalities in the intake system, including the air cleaner. Compression Gauge Kit Preparation: 1. Warm up the engine. 2. Disconnect the negative terminal at the battery, and then remove engine stop solenoid connectors. 3. Reconnect the negative terminal to battery. 4. Remove the fuel injection valve of the cylinder to be measured, and attach a pressure gauge (compression gauge kit for YANMAR TNV88) TE: Attach the gasket to the end of the adaptor, and tighten it firmly. 4. Confirm that the batteries are charged. T1M Measurement: 1. Turn the starter to crank the engine. Record the compression pressure of each cylinder. 2. Repeat measurement three times and calculate the mean value. Evaluation: Refer to T4-2 Operational Performance Standard. TE: Engine speed and compression pressure. 4 Compression Pressure (kgf/cm 2 ) 3 Compression Pressure (MPa) 2 Engine Speed min -1 (rpm) T1M T4-3-2

14 OPERATIONAL PERFORMANCE TEST / Engine Test (Blank) T4-3-3

15 OPERATIONAL PERFORMANCE TEST / Engine Test VALVE CLEARANCE Summary: 1. Perform the measurement when the engine is cold. 2. Before removing the head cover, clean the area around the head cover to prevent the entry of dust into the engine. Preparation: 1. Remove the head cover. 2. Locate the top dead center (TDC) in the compression stroke of piston No.1 (on the flywheel side). Turn the crank pulley counterclockwise viewed from the flywheel, and have the mark groove coincide with the Mark-0 of the timing gear case cover. At this time, if both of the locker arms of the inlet and exhaust valves for cylinder No. 1 have play when operated manually, TDC for cylinder No. 1 is properly located. If not, turn the crank pulley 360 degrees, and check one more time. Flywheel Side Mark Groove Mark-0 Crank Pulley T1M TE: For turning the crank pulley, remove the fan guard, and turn the fan with one hand while holding the fan belt with the other. If the fuel injection valve of each cylinder is removed in advance, the crank pulley can be easily rotated with no compressive force. IMPORTANT: In case no play is felt for both of the locker arms of the inlet and exhaust valves for cylinder No. 1 even after turning the pulley 4 times, abnormal wear of the valve seats is suspected, and disassembled examination is necessary. T4-3-4

16 OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. Measure the valve clearance between the rocker arm and valve. 2. Measure the clearances of valves marked ( ) in the table below. Rocker Arm Adjust Screw Lock Nut Cylinder No Valve I E I E I E I E Cylinder No.1 at top dead center Cylinder No.1 at overlap 3. Turn flywheel 360, then measure the valve clearances marked ( ) in the above table. T1M Evaluation: Refer to T4-2 Operational Performance Standard. Adjustment 1. Loosen the lock nut and the adjusting screw of the locker arm. 2. Confirm that the valve cap has no tilting, dust ingress, or wear. 3. Insert a thickness gauge of 0.2 mm between the locker arm and the valve head, and tighten the lock nut after adjusting the valve clearance. Normal Abnormal T1M IMPORTANT: The valve clearances marked with are adjustable when piston No. 1 is at TDC, and those marked with are adjustable when Piston No. 4 is at TDC. In case no play is felt for the locker arm to have play, abnormal wear of the valve seat is suspected, and disassembled examination is necessary. T1M T4-3-5

17 ZZLE CHECK OPERATIONAL PERFORMANCE TEST / Engine Test Summary: 1. Check the injection pressure and the spray pattern with a nozzle tester. 2. Before starting work, clean the fuel injector mounting area to avoid contamination in the engine. Preparation: 1. Remove all fuel injector and fuel injection pipings from the engine. 2. Attach a fuel injector to nozzle tester. Measurement: CAUTION: Never touch spray directly. The fuel spray from the nozzle may penetrate the skin, resulting in serious injury. If fuel penetrates into the blood stream, it may cause blood toxication. Fuel Injector T1M Injection pressure After attaching the fuel injector to nozzle tester, strongly make several strokes of the tester to inject fuel. Then, while operating the tester at approx. 60 time strokes a minute, measure the fuel injection pressure. Use shims in the fuel injector to adjust the pressure. TE: If the shim is thickened by 0.1 mm, pressure rises by about 1.9 MPa (19 kgf/cm 2 ). Fuel Injector Over Flow Pipe Nozzle Holder 2. Spray pattern For this test, turn the pressure tester knob to bypass the pressure gauge. Attach the fuel injector to the nozzle tester. Strongly make several strokes of the tester and check the fuel spray pattern. Shim TE: Use clean diesel oil. 3. Oil tight condition Keep the pressure slightly below the injection pressure. Check for fuel leak from around the nozzle tip. T1M T4-3-6

18 OPERATIONAL PERFORMANCE TEST / Engine Test Evaluation: 1. Standard Injection Pressure: Refer to T4-2 Operational Performance Standard. 2. During Spray Injection 2-1. After injecting spray two to three times, gradually raise pressure, and halt it at slightly lower than 2 MPa (20 kgf/cm 2 ), and confirm that there is no fuel drop coming out of the nozzle end During injection with a nozzle tester, in case an extremely large amount of fuel leakage takes place out of the overflow connector, confirm by tightening it again. In case the situation is not bettered, replace the nozzle assembly Operate the nozzle tester lever at the speed of one or two strokes a second, and confirm that no abnormal spray takes place In case spray conditions shown below cannot be obtained, make readjustment or replacement of the parts. -Spray spread angles are similar. (θ) -Spray direction angles are similar. (α) -The whole spray is like fine mist. -Injection ends with no dripping. (Normal) (Abnormal) T1M T1M T4-3-7

19 INJECTION TIMING OPERATIONAL PERFORMANCE TEST / Engine Test Preparation Fuel Pump IMPORTANT: Measurement of injection timing is impossible in the case of an engine provided with the MP type fuel injection pump. Therefore, be sure to assemble the injection pump fully carefully in accordance with the descriptions given in the engine maintenance manual. Adjustment Explanation is made here about the procedure for replacing, mounting, or dismounting of the fuel injection pump. CAUTION: When dismounting the fuel pump, be sure not to loosen the four screws fixing the pump flange and the fuel pump driving gear. If they are loosened, adjustment of the injection timing becomes very difficult. 1. Before dismounting the fuel pump, put mating marks with a white felt pen on the respective contacting part of the fuel pump driving gear and the idle gear. Flange Bolt (Do not disassemble) Drive Gear Fixing Bolt Idle Gear Fuel Pump Drive Gear Crank gear T1M T4-3-8

20 OPERATIONAL PERFORMANCE TEST / Engine Test 2. Before dismounting the fuel pump, adhere to the gear case a injection angle adjustment sticker with its center line coinciding with the mark-off line on the fuel pump side. 3. Dismount the fuel pump, and read the injection angle marked on the fuel pump. 4. Read the injection angle marked on the fuel pump to be mounted, and figure out the difference from that of the dismounted fuel pump. Center Line TE: In case the same fuel pump is mounted again, the angle difference is zero. Injection angle difference (cam angle) = (injection angle of the mounted fuel pump) - (injection angle of the dismounted fuel pump) IMPORTANT: In case the injection angle of the fuel pump is difficult to read, consult the engine manufacturer for it by giving information on the fuel pump model and serial number. (Injection Angle Adjustment Sticker) Sticker T1M Attach the fuel pump temporarily to the gear case. Have the mating marks put in advance during disassembling coincide with each other, mount the driving gear to the camshaft, and tighten the nut. Tightening torque of fuel pump driving gear nut: 78 to 88 N m (8 to 9 kgf m, 564 to 637 lbf ft) 6. Read the injection angle difference figured out in procedure 5 with the adjustment sticker measure (minimum 0.5 degrees, cam angle), and adjust the mounting angle of the fuel pump. TE: For the injection angle difference of +1 degree, turn the fuel pump 1 degree outward in relation to the cylinder block, and for 1 degree, turn the fuel pump 1 degree toward the cylinder block. Mark-off Line Fuel Pump Mark-off Line Adjustment Sticker Center Line In case of +1 In case of (Adjustment of Injection Angle) Gear Case T1M T1M Tighten the nut for attaching the fuel pump. T4-3-9

21 OPERATIONAL PERFORMANCE TEST / Engine Test TE: The standard mounting angle for the fuel pump is 25 degrees. Cylinder Block Side (Fuel Pump Fixing Angle) T1M TE: For advancing or delaying the injection timing, change the mounting angle of the fuel pump. For example, in case the injection angle is advanced by 2 degrees, loosen the nut for fixing the fuel pump to the gear case, turn the fuel pump 1 degree outward in relation to the cylinder block, and tighten the nut for fixing the pump. For delaying the injection timing, mount the pump the other way around. Advance Delay Cylinder Block Side Fuel Pump Fixing Bolt (Adjustment of Injection Timing) T1M T4-3-10

22 TRAVEL SPEED OPERATIONAL PERFORMANCE TEST / Excavator Test Summary: 1. To check overall performance of travel drive system (between main pump and travel motor), measure the time required for the excavator to travel a test track. Preparation: 1. Adjust the track sag of both tracks to be equal. 2. Prepare a level and solid test track 20 m (65.5 ft) in length, with an extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground with the arm and bucket extended. 4. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Arm Roll-in, Bucket Roll-in Start Raise bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground. End 3 to 5 m (9.8 to 16 ft) extra length for acceleration / deceleration Measurement: 1. The test should be performed with each mode (slow and fast travel speeds) in the fast-idle speed with auto idle switch off. 2. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 3. Measure the time required to travel 20 m (65 ft 7 in). 4. After measuring the forward travel speed, turn the upperstructure 180 and measure the reverse travel speed. 5. Repeat steps (2) and (4) three times in each direction and calculate the mean values. 20 m (65.5 ft) 3 to 5 m (9.8 to 16 ft) extra length for acceleration / deceleration T Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". T4-4-1

23 OPERATIONAL PERFORMANCE TEST / Excavator Test TRACK REVOLUTION SPEED Summary: 1. With the track raised off ground, measure the track revolution cycle time to check the total track drive system (between main pump and travel motor). Preparation: 1. Adjust the track sag of both side tracks equally. 2. On the track to be measured, mark one shoe with chalk. CAUTION: Support the lifted track securely with wooden blocks. 3. Swing the upperstructure 90 and lower the bucket to raise the track off ground. Keep the boom-arm angle between 90 to 110 as shown. 90 to 110 Mark Measurement: 1. The test should be performed with each mode (slow and fast travel speeds) in the fast idle speed with auto idle switch off. 2. Operate the travel control lever of the raised track in the full forward or reverse stroke. 3. Measure the time required for 3 revolutions of shoe in both directions. 4. Raise the other track and repeat the procedures. 5. Repeat steps (2) and (4) three times for each track and calculate the mean values. T Evaluation: Refer to T4-2 Operational Performance Standard. TE: The measured values may vary widely. The evaluation based on the results obtained from the 20 m (65.5 ft) travel speed check is more recommendable. Remedy: Refer to T5-3 "Troubleshooting B". T4-4-2

24 MISTRACK CHECK OPERATIONAL PERFORMANCE TEST / Excavator Test Summary: 1. Allow the machine to travel 20 m (65.5 ft). Measure the maximum tread deviation from the tread chord line drawn between the travel start and end points to check the performance equilibrium between both sides of the travel device systems (between main pump and travel motor). 2. If measured on a concrete surface, the tread deviation has a trend to decrease. Preparation: 1. Adjust the track sag of both tracks to be equal. 2. Provide a flat, solid test yard 20 m (65.5 ft) in length, with extra length of 3 to 5 m (9.8 to 16 ft) on both ends for machine acceleration and deceleration. 3. Hold the bucket 0.3 to 0.5 m (1.0 to 1.6 ft) above the ground with the arm and bucket extended. 4. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Max Distance 20 m (65.5 ft) Measurement: 1. The test should be performed with each mode (slow and fast travel speeds) in the fast idle speed with auto idle switch off. 2. Start traveling the machine in the acceleration zone with the travel levers at full stroke. 3. Measure the distance between a straight 20 m (65.5 ft) line and the tread made by the machine. 4. After measuring the tracking in forward travel, swing the upperstructure 180 and measure that in reverse travel. 5. Repeat steps (3) and (4) three times in each direction and calculate the mean values. T Evaluation: Refer to T 4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". T4-4-3

25 OPERATIONAL PERFORMANCE TEST / Excavator Test TRAVEL MOTOR LEAKAGE Summary: 1. Measure the amount of travel motor slippage on a slope, which is due to travel motor inner oil leak. Preparation: 1. The surface of the test slope must be even, with a gradient of 20% (11.31 ). 2. Raise the bucket 0.2 to 0.3 m above the ground with the arm and bucket cylinders fully extended (rolled in) 3. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Measurement: 1. Measure the slip amount of travel motor at parking Climb the slope and place the travel levers in neutral Stop the engine After parking the machine, makes aligning marks on the side frame and a track link or shoe After 3 minutes, measure discrepancy between the marks. Evaluation: Refer to T4-2 Operational Performance Standard. Amount of slippage after 3 minutes T T T4-4-4

26 SWING SPEED OPERATIONAL PERFORMANCE TEST / Excavator Test Summary: 1. Measure the time required to swing three complete turns to check the total swing drive system (between the main pump and swing motor). Preparation: 1. Check the lubrication of swing gear and swing bearing. 2. Place the machine on level, solid ground with ample space for swinging. Do not conduct this test on slopes. 3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of arm top pin is even with the boom foot pin. The bucket must be empty. 4. Maintain the hydraulic oil temperature at 50±5 C (122±9 F) CAUTION: Before starting the measurement, make sure that there are no person or obstacles within the swing area. Measurement: 1. Run engine at fast idle speed with auto idle switch off. Operate swing control lever fully. 2. Measure the time required to swing 3 turns in one direction. 3. Operate swing control lever fully in the opposite direction and measure the time required for 3 turns. 4. Repeat steps (2) and (3) three times each and calculate the average values. Evaluation Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". Even with the Boom Foot Pin. T T4-4-5

27 OPERATIONAL PERFORMANCE TEST / Excavator Test SWING FUNCTION DRIFT CHECK Summary: 1. To check the valve unit performance, measure the swing drift on the bearing outer circumference when stopping after a 90 full speed swing. 2. Mechanical brake for swing parking is installed on swing motor. Preparation: 1. Check the lubrication of swing gear and swing bearing. 2. Place the machine on level, solid ground with ample space for swinging. Do not conduct this test on slopes. 3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of bucket pin is even with the boom foot pin. The bucket must be empty. 4. Make the marks on the swing bearing and track frame. 5. Swing the upperstructure Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Make aligning marks on the swing bearing outer circumference and track frame. T CAUTION: Before starting the measurement, make sure that there are no person or obstacles within the swing area. Measurement: 1. Start and run engine at fast idle speed with auto idle switch off. Operate the swing control lever fully to swing the upper-structure. When the marks on the swing bearing and track frame meet, return the swing lever to the neutral position. 2. After the swing movement stops, measure the arc length between two aligning marks along the circumference of the swing bearing. 3. Align the marks again, swing 90 then test in the opposite direction. 4. Repeat steps (1) and (2) three times each and calculate the mean values. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". Swing the upperstructure 90 to the test start position. T Measure the arc length along the circumference of swing bearing. Mark on the track frame Mark on the swing bearing T T4-4-6

28 OPERATIONAL PERFORMANCE TEST / Excavator Test SWING MOTOR LEAKAGE Summary: 1. To check swing parking brake performance, measure the upperstructure drift after parking the machine on a slope with the upperstructure positioned 90 to the slope. (Mechanical brake for swing parking is installed on swing device.) Preparation: 1. Check the lubrication of swing gear and swing bearing. 2. Load the bucket with either soil or a weight equivalent to the weight standard. Weight: ZAXIS40U-2: 210 kg (463 lb) ZAXIS50U-2: 240 kg (529 lb) 3. With the arm rolled out and bucket rolled in, hold the bucket so that the height of bucket pin is even with the boom foot pin. 4. Park the machine on a flat slope with a gradient of 15±1. 5. Climb the slope, then swing the upperstructure 90 toward the slope. Make aligning marks on the swing bearing circumference and track frame. 6. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Measurement: 1. Start the engine and maintain engine speed at idle speed. After 5 minutes, measure the difference between the marks on the swing bearing circumference and the track frame. 2. Perform the measurement under the following two conditions: When the brake is applied (with the pilot control shut-off lever in the LOCK position). When the brake is released (with the pilot control shut-off lever in the UNLOCK position). 3. Perform the measurement on both right and left swing directions. 4. Perform the measurement three times in each direction and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. T Measure the arc length along the swing bearing circumference. Mark on the track frame Mark on the swing bearing T Remedy: Refer to T5-3 "Troubleshooting B". T4-4-7

29 OPERATIONAL PERFORMANCE TEST / Excavator Test MAXIMUM SWINGABLE SLANT ANGLE Summary: 1. To measure the maximum slope angle on which the upperstructure can swing, park the machine on a slope with the upperstructure positioned 90 to the slope. Preparation: 1. Check the lubrication of swing gear and swing bearing. 2. Load the bucket with either soil or a weight equivalent to the weight standard. Weight: ZAXIS40U-2: 210 kg (463 lb) ZAXIS50U-2: 240 kg (529 lb) 3. With the arm cylinder fully retracted and the bucket cylinder fully extended, hold the bucket so that the height of bucket pin is even with the boom foot pin. 4. Climb the slope, and then set the upperstructure 90 to the slope. 5. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). T Measurement: 1. Run engine at fast idle speed with auto idle switch off. Operate the swing control lever fully to swing the upperstructure to the uphill side of slope. 2. If swing is possible, measure the slant angle on the cab floor. 3. Increase the slope angle. Measure on both right and left swing directions. 4. Perform the measurement three times. Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". T4-4-8

30 OPERATIONAL PERFORMANCE TEST / Excavator Test SWING BEARING PLAY Summary: 1. Measure the swing play with a dial gauge to check the wear of bearing races and balls. Preparation: 1. Check the swing bearing mounting bolt for looseness. 2. Check the lubrication of swing bearing. Confirm that bearing rotation is smooth and noiseless. 3. Install a dial gauge with a magnetic base on the track frame as shown. 4. Position the upperstructure so that the boom aligns with the tracks facing towards the travel motors. 5. Position the dial gauge so that its needle point comes into contact with the bottom face of the bearing outer race as shown. 6. Bucket should be empty. Magnetic Base Dial Gauge Round Frame Trunk T TE: The measured value may differ depending on where the dial gauge magnetic base is located. Mount the magnetic base directly onto the round frame trunk or as close to the round frame trunk as possible. Measurement: [h 1 ] Magnetic Base T Measurement: 1. With the arm rolled out and bucket rolled in, hold the bucket so that the height of the bucket pin is even with the boom foot pin. Record the dial gauge reading (h 1 ). 2. Lower the bucket to the ground and use it to raise the front idler 0.5 m (20 in). Record the dial gauge reading (h 2 ). 3. Calculate bearing play (H) from this data (h 1 and h 2 ) as follows: H = h 2 h 1 Measurement: [h 2 ] Even with the Boom Foot Pin. T Evaluation: Refer to T4-2 Operational Performance Standard. 0.5 m (20 in) T T4-4-9

31 OPERATIONAL PERFORMANCE TEST / Excavator Test HYDRAULIC CYLINDER CYCLE TIME Summary: 1. To totally check the front attachment function performance (between the main pump and each cylinder) by measuring each cylinder cycle time. 2. Bucket should be empty. Preparation: 1. Take the following machine position: 1-1. When measuring the boom cylinder: With the arm cylinder fully retracted and the bucket cylinder fully extended, lower the bucket to the ground When measuring the arm cylinder: With the bucket cylinder fully extended, adjust the boom and arm cylinder strokes so that when the arm is moved half the full stroke, the arm longitudinal center line perpendicularly points to the ground and the bucket bottom clearance above the ground is approx. 0.5 m (20 in) When measuring the bucket cylinder: Adjust the boom and arm cylinder strokes so that when the bucket is moved half the full stroke, the bucket edge points to the ground perpendicularly When measuring the boom swing cylinder: Set the boom swing cylinder in either the right or left swing stroke end position When measuring the blade cylinder: Lower the bucket to the ground to raise the machine front off the ground and secure the height space to allow the blade to move up-and-down full stroke. 2. Maintain hydraulic oil temperature at 50±5 C (122±9 F). Boom Cylinder Arm Cylinder 0.5 m (20 in) Bucket Cylinder Boom Swing Cylinder T T T Blade Cylinder T T T4-4-10

32 OPERATIONAL PERFORMANCE TEST / Excavator Test Measurement: 1. Run engine at fast idle speed with auto idle switch off. Operate each cylinder as follows: (The cylinder stroke excludes the cushion range.) 1-1. Measure the boom cylinder. Measure the time required to raise or lower the boom while operating the boom control lever full stroke Measuring the arm cylinder. Measure the time required to roll in or out the arm while operating the arm control lever full stroke Measuring the bucket cylinder. Measure the time required to roll in or out the bucket while operating the bucket control lever full stroke Measuring the boom swing cylinder Measure the time required to swing the front attachment from right to left or vice versa while operating the boom swing pedal full stroke Measuring the blade cylinder Measure the time required to raise or lower the blade while operating the blade control lever full stroke. 2. Repeat each measurement three times and calculate the average values. Evaluation: Refer to T 4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". T4-4-11

33 OPERATIONAL PERFORMANCE TEST / Excavator Test DIG FUNCTION DRIFT Summary: 1. With the bucket loaded, measure dig function drift, which can be caused by oil leakage in the control valve and / or boom, arm, bucket, blade and boom swing cylinders. Retraction Extension Retraction 2. When testing the dig function drift just after cylinder replacement, slowly operate each cylinder to its stroke end to purge trapped air prior to testing. Arm Top Pin is even with Boom Foot Pin. Front Drift Preparation: 1. Load the bucket with either soil or a weight equivalent to the weight standard. Weight: ZAXIS40U-2: 210 kg (463 lb) ZAXIS50U-2: 240 kg (529 lb) 2. With the arm cylinder fully retracted and bucket cylinder fully extended, had the bucket pin height even with the boom foot pin. When measuring the boom swing cylinder, climb the slope with a gradient of 15±1 and set the upperstructure 90 to the slope. 3. Retract arm cylinder and bucket cylinder approx. 50 mm (2 in) to away from the cushion range. 4. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Measurement: 1. Stop the engine. 2. After five minutes, measure the boom, bucket and blade cylinder retraction, arm and boom swing cylinder extension, and amount of the bucket drift. 3. Repeat step 2. three times and calculate the mean values. Extension Boom, Bucket and Blade Cylinder Retraction Mark Mark T T T Evaluation: Refer to T4-2 Operational Performance Standard. Remedy: Refer to T5-3 "Troubleshooting B". Arm Cylinder Extension Mark Boom Swing Cylinder Extension T T T4-4-12

34 OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER OPERATING FORCE Summary: 1. Use a spring scale to measure the maximum force needed to move each control lever and pedal. 2. Measure the operating force at the center of each lever grip. Preparation: 1. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). CAUTION: Before the measurement, make sure there are no personnel or obstacles within the swing area. Measurement: 1. Start the engine. 2. Measure the maximum operating force with each boom raise, arm, bucket, swing lever, full stroke. 3. Measure the maximum operating force with the boom lower lever full stroke until the fully raised boom comes in contact with the ground. 4. Operate swing lever and measure the maximum operating force with swing relieved after securing the front attachment to prevent swinging. 5. Lower the bucket to the ground to raise one track off the ground. Operate the travel lever to full stroke and measure the maximum operating force. When finished, lower the track and then jack up the other track. 6. Repeat each measurement three times and calculate the mean values. T T Evaluation: Refer to T4-2 Operational Performance Standard. T4-4-13

35 OPERATIONAL PERFORMANCE TEST / Excavator Test CONTROL LEVER STROKE Summary: 1. Measure each lever stroke at the lever top using a ruler. 2. Measure the lever stroke at the grip center of each control lever. As for the boom swing pedal, measure the stroke from the center position to stopper. 3. In case lever stroke play is present in the neutral position, add half (1/2) the play present to both side lever strokes. Preparation: Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Measurement: 1. Stop the engine. 2. Measure the boom, arm, bucket, swing, travel and blade control lever strokes at the grip top center from the neutral position to the stroke end. On the boom swing pedal, measure the straight distance between the center and fully depressed positions at tip of the pedal. 3. Take the measurements by the straight stroke distances. 4. Conduct the measurement three times. Calculate the average values. T Evaluation: Refer to T4-2 Operational Performance Standard. T4-4-14

36 OPERATIONAL PERFORMANCE TEST / Excavator Test COMBINED BOOM RAISE/SWING FUNC- TION CHECK Summary: 1. Check boom raise and swing movement and speeds while operating both functions simultaneously to evaluate combined functions. 2. Confirm that no hesitation is found with the engine running at maximum speed. Preparation: 1. With the arm rolled out and the bucket rolled in, lower the bucket to the ground. The bucket should be empty. 2. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). M CAUTION: Always make sure that the area is clear and that co-workers are out of the swing area before starting the measurement. Measurement: 1. Run engine at fast idle speed with auto idle switch off. 2. Raise the boom and swing simultaneously, both at full stroke. When the upperstructure rotates 90, release the control levers to stop both functions. Measure the time required to swing 90 and the height (H) of the bucket teeth. 3. Perform the measurement three times and calculate the average values. T1M Evaluation: Refer to T4-2 Standard. Remedy: Refer to T5-3 "Troubleshooting B". H T1M T4-4-15

37 OPERATIONAL PERFORMANCE TEST / Excavator Test (Blank) T4-4-16

38 OPERATIONAL PERFORMANCE TEST / Component Test PRIMARY PILOT PRESSURE Preparation: 1. Stop the engine. 2. Turn the filling cap on hydraulic oil tank to bleed air. 3. Disconnect the hose (9/16-18 UNF) at the pilot filter. Install pressure gauge assembly (ST 6932) with tee (ST 6572) to the pilot filter. : 22 mm, 19 mm 4. Start the engine and check for oil leakage from the gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Measurement: 1. Run engine at fast idle speed with auto idle switch off. 2. Measure the pressure without load. 3. Perform the measurement three times and calculate the average value. Pilot Filter Adjusting Screw Hose (9/16-18 UNF) Lock Nut T1M Evaluation: Refer to T4-2 Operational Performance Standard. Adjustment: Adjustment the relief valve on 2-unit solenoid valve if necessary. 1. Loosen the lock nut. 2. Turn the adjusting screw to adjust the pressure. : 6 mm 3. Tighten the lock nut. : 17 mm : 15 to 20 N m (1.5 to 2.0 kgf m, 10.8 to 14.5 lbf ft) T1LA After completing the adjustment, recheck the set pressure. TE: Standard change in pressure. Screw Turns 1/4 1/2 3/4 1 Change in Relief Pressure kpa (kgf/cm 2 ) (1.85) (3.7) (5.55) (7.40) (psi) (13.4) (26.8) (40.1) (53.5) T4-5-1

39 OPERATIONAL PERFORMANCE TEST / Component Test SECONDARY PILOT PRESSURE Preparation: 1. Properly shut down the engine. 2. Turn the filling cap on hydraulic oil tank to bleed air. 3. Install pressure gauge (ST 6932) and tee (ST 6573) to the end of pilot hose (7/16-20 UNF) at the respective control valve spool end, as illustrated. : 19 mm, 17 mm 4. Start the engine and check for oil leakage at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). Measurement: Pressure Gauge (ST 6932) Tee (ST 6573) Pilot Hose CAUTION: Before measuring, check that there are no obstacles or personnel within the swing radius. When measuring the boom lower pilot pressure, raise the machine off the ground while paying attention not to allow the base machine (counterweight) to contact with the ground. Be careful not to tip-over due to a loss of balance. T Operate the lever to be measured. Measure the pilot pressure at its full stroke with the pressure gauge. 2. Perform the measurement three times and calculate the average valve. Evaluation: Refer to T4-2 Operational Performance Standard. T4-5-2

40 OPERATIONAL PERFORMANCE TEST / Component Test MAIN RELIEF VALVE SET PRESSURE Summary: Measure the main relief valve setting pressure at the main delivery port. Delivery Port in Main Pump (P1) Preparation: 1. Stop the engine. 2. Turn the filling cap on hydraulic oil tank to bleed air. 3. Disconnect the hose (1-1/16-12 UNF) onto the delivery port in main pump (P1). Install tee (ST 6652), adapter (ST 6069), and pressure gauge assembly (ST 6934). : 36 mm 4. Start the engine and check for oil leakage at the pressure gauge connection. 5. Maintain the hydraulic oil temperature at 50±5 C (122±9 F). T1M Measurement: 1. Run the engine at fast idle speed with auto idle switch off. 2. Slowly operate each control lever or pedal to fully extend or retract each cylinder to relieve the pressure. Measure the relief pressure at this time. 3. Repeat the measurement three times and calculate the average values. Evaluation: Refer to T4-2 Operational Performance Standard. T4-5-3

41 OPERATIONAL PERFORMANCE TEST / Component Test Main Relief Valve Adjustment Procedure Adjustment: Adjust the main relief valves if necessary. The main relief valves are installed on the position as illustrated. A A TE: Before loosening the lock nut, make the alignment marks on the adjusting screw, lock nut and valve. Using these alignment marks, the number of turns of the adjusting screw can be checked easily. 1. Loosen the lock nut on main relief valve. : 17 mm IMPORTANT: Adjust the pressure so that it does not exceed the upper limit of standard. 2. Turn the adjusting screw to adjust the pressure. : 6 mm 3. Tighten the lock nut. : 17 mm : 34 to 39 N m (3.5 to 4 kgf m, 25 to 29 lbf ft) Section A-A Adjusting Screw T1M Lock Nut 4. After completing the adjustment, recheck the set pressure. TE: Standard change in pressure. Screw Turns 1/4 1/2 3/4 1 Change in MPa (8.9) Relief (kgf/cm 2 ) (22.4) (44.9) (69.4) (90.9) Pressure (psi) (319) (638) (986) (1290) Main Relief Valve T1M Lock Nut Adjusting Screw Pressure Increase Pressure Decrease W T4-5-4

42 OPERATIONAL PERFORMANCE TEST / Component Test Swing Relief Pressure Adjustment Procedure Adjustment: Adjust the pressure of swing relief valve with the adjusting screw after loosening the lock nut. Swing Relief Valve 1. Loosen the lock nut. : 17 mm 2. Turn the adjusting screw to adjust the pressure referring to the table below. : 4mm 3. Retighten the lock nut. : 17 mm : 15.7 ± 0.1 N m (16 ± 1 kgf m, 116 ± 7 lbf ft) 4. Recheck the set pressure. TE: Standard change in pressure. Change in Relief Pressure Screw Turns 1/4 1/2 3/4 1 MPa (kgf/cm 2 ) (25) (50) (75) (100) (psi) (360) (710) (1070) (1420) Lock Nut T Adjusting Screw Lock Nut Adjusting Screw T Pressure Increase Pressure Decrease W T4-5-5

43 OPERATIONAL PERFORMANCE TEST / Component Test OVERLOAD RELIEF VALVE SET PRES- SURE Summary: 1. With the return circuit from the control valve blocked, the circuit pressure must be increased by applying an external load. This checking method is hazardous and the results obtained with this method are unreliable. 2. Pressure setting of the overload relief valve must be made at a specified oil flow rate normally far smaller than the delivery flow rate of main relief valve. Accordingly, even if the main relief valve set pressure can be reset higher than the set pressure of overload relief valve, the main pump supplies too much oil to correctly measure the set pressure of overload relief valve. The main relief valve has pre-leaking function. In this case, the set pressure of main relief valve at pre-leaking function need to be set higher than that of overload relief valve. Accordingly, the main relief valve pressure setting may not be reset higher than the set pressure of overload relief valve plus the pressure at pre-leaking. Therefore, when the set pressure of overload relief valve must be checked correctly, remove the overload relief valve assembly from the machine and check the overload relief valve unit performance using the test stand and test block prepared for this purpose. If the poppet of overload relief valve seats to the body of control valve, the test block requires precise machining. Use other control valve unit for the measurement instead of the test block. 3. As an easier method, however, measure the relief pressure of each cylinder in the same method as of main relief pressure setting in previous section. Then, when each relief pressure meets its respective specifications, judge that the set pressure of overload relief valve is correct. T4-5-6

44 OPERATIONAL PERFORMANCE TEST / Component Test Adjustment: TE: Pressure of overload relief valve shall be adjusted with test device in principle. Lock Nut 1. Loosen the lock nut on overload relief valve. : 17 mm 2. Turn adjusting screw to adjust the set pressure. : 6 mm 3. Tighten the lock nut. : 17 mm : 34 to 39 N m (3.5 to 4 kgf m, 25 to 29 lbf ft) Adjusting Screw T After the adjustment, check the set pressure. Overload Relief Valves: TE: Standard Change in Pressure. Screw Turns 1/4 1/2 3/4 1 Change in MPa (11.0) Relief (kgf/cm 2 ) (27.5) (56.1) (84.7) (112) Pressure (psi) (392) (798) (1200) (1600) Lock Nut Pressure Increase Adjusting Screw Pressure Decrease W T4-5-7

45 OPERATIONAL PERFORMANCE TEST / Component Test SWING MOTOR DRAINAGE Summary: 1. To check the performance of swing motor, measure the amount of oil draining from the swing motor while swinging the upperstructure. 2. Always secure the test personnel s safe during the measurement. Before the measurement, make sure there are no person or obstacles within the test track. 3. The amount of drain oil will change depending on hydraulic oil temperature. Maintain hydraulic oil temperature at 50±5 C (122±9 F). Preparation: 1. Warm the hydraulic oil temperature to 50±5 C (122±9 F). Rotate the swing motor to warm up the inside of motor. 2. Stop the engine. Turn the filling cap to bleed air from the hydraulic oil tank. 3. Disconnect the drain hose at swing motor. Install a plug (9/16-18 UNF) to the disconnected hose end. Connect hose (ST 6627) onto the drain port of swing motor. : 22 mm, 19 mm : 39 N m (4 kgf m, 29 lbf ft) Make-Up Line Drain Hose (9/16-18 UNF) T1LD CAUTION: Before the measurement, make sure there are no person or obstacles within the swing area. Make sure not to fall off from machine during the measurement. 4. Disconnect the make-up line at swing motor. Install plugs on the disconnected line end and motor port. Measurement Condition: 1. Before the measurement, set the engine speed control dial to the fast idle position with auto idle switch off, and then measure it. T4-5-8