INTRODUCTION TO THE READER ‘© This manual is written for an experienced technician to provide technical information needed to maintain ‘and repair this machine. ~ Be sure to thoroughly read this manual for correct product information and service procedures. - If you have any questions or comments, at if you found any errors regarding the contents of this manual. please contact using "Service Manual Revision Request Form” at the end of this manual. (NOTE: Do not tear off the form. Copy it for usage.): Publications Marketing & Product Support Hitachi Construction Machinery Co. Ltd. TEL: 81-298-82-7173 FAX: 81-298-31-1162 ADDITIONAL REFERENCES © Please refer to the materials listed below in addition to this manual. The Operator's Manual - The Parts Catalog - Operation Manual of the Engine + Parts Catalog of the Engine - Hitachi Training Material MANUAL COMPOSITION This manual consists of three portions: the Tech- nical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Man- val, NOTE: Use W157E-00 for Workshop Manval. “Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems. Information included in the Technical Manual (Troubleshooting): technical information needed for operational per- formance 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 stan- dards, and removalfinstallation, and assem- ble/disassemble procedures. PAGE NUMBER Each page has @ number, located on the center lower part of the page, and each number contains the following information: Example: T_ 01-03-05 '—> Group Number '—— Section Number T: Technical Manual De consecutive Page Number for Each Group W: Workshop Manual IN-01INTRODUCTION SAFETY ALERT SYMBOL AND HEAD- LINE NOTATIONS In this manual, the following safety alert symbol and signal words are used to alert the reader to the poten- tial for personal injury or machine damage. Ai Tris is the safety alert symbol. When you see this symbol, be alert to the potential for personal in- jury. Never fal to follow the safety instructions prescribed along withthe safety alert symbol. The safety alert symbol is also used to draw attention to componeni/part weights To avoid injury and damage, be sure to use appropr- ate liting techniques and equipment when liting heavy parts. ¢ & caution: incicated a potentially hazardous situation which could, if not avoided, resutt in per- sonal injury or death. ‘© IMPORTANT: indicates a situation which, if not ‘conformed to the instructions, could result in dam- age to the machine. © NOTE: indicates supplementary technical informa- tion or know-how. UNITS USED ‘© SI Units (Intemational System of Units) are used in this manual. MKSA system units and English units are also in- dicated in parentheses just behind SI units. Example: 24.5 MPa (250 kaffom?, 3 560 psi) A table for conversion from SI units to other system Units is shown below for reference purposes. To Convert Maliply To Conver, Multiply Quantity | From Into By | arty | From Into. th ram in 0038.37, MPa__| —kaffent — mm ft 0.003 267] Pressure MPa psi US gal | 0.2642 kW. PS. Volume t Us qt [1.087] ower kW HP me ya 1.308, Temperature [°C SF Went ka ib 2205, kmh mph Fore N af 0.107 a7 eee min rpm aw ait ozs [Fon ale Umin | US gpm rad im | 1.0197 mijrev| — ocfrev Tore Nem. Ibf 07375, IN-02SAFETY RECOGNIZE SAFETY INFORMATION © This is the SAFETY ALERT SYMBOL. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. ooreoragnon2 sot UNDERSTAND SIGNAL WORDS © On machine safety signs, signal words designating the degree or level of hazard - DANGER, WARNING, DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or ate A WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death seats A CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor ‘or moderate injury. - DANGER or WARNING safety signs are located IM PORTANT near specific hazards. General precautions are isted on CAUTION safety signs. this manual. To avoid confusing machine protection with personal safety messages, a signal word IMPORTANT indi- ees cates a situation which, if not avoided, could result in damage to the machine. ‘@ NOTE indicates an additional explanation for an ele- ment of information. SA-1SAFETY FOLLOW SAFETY INSTRUCTIONS © Carefully read and follow all safety signs on the machine and all safety messages in this manual ‘© Safety signs should be installed, maintained and replaced when necessary. It @ safety sign or this manual is damaged or missing, replace it with new one. ‘® Learn how to operate the machine and its controls correctly and safely. ‘© Allow only trained, qualified, authorized personnel to operate the machine. Keep your machine in proper working condition, “Unauthorized modifications to the machine may impair the function andjor safety and affect machine lite. © The safety messages in this SAFETY chapter are intended to illustrate basic safety procedures of machines. However it is impossible for these safety messages to cover every hazardous situation you may encounter. If you have any questions, you should first consult your supervisor before operating performing maintenance work on the machine. PREPARE FOR EMERGENCIES ‘© Be prepared if fire starts or if an accident occurs. 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. 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.SAFETY WEAR PROTECTIVE CLOTHING ‘© Wear close fitting clothing and safety equipment appropriate to the job. You may need: Ahard hat Safety shoes Safety glasses, goggles, or face shield Heavy gloves Hearing protection Reflective clothing Wet weather gear oe Respirator or filter mask. Be sure to wear the correct equipment and clothing for the job. Do not take any chances. 98 «3D Pate ‘Avoid wearing loose ciothing, jewelry, or other items that can catch on control levers or other parts of the machine. ‘© Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. PROTECT AGAINST NOISE @ Prolonged exposure to loud noise can cause Impairment or loss of hearing, Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortably loud noises. walking around it before you start it to avoid personal injury. INSPECT MACHINE «npc jour mace ey each dy fs gS In the walk-around inspection be sure to cover all points described in the "PRE-START INSPECTION" chapter in the operator's manual. Socom nio52 sass SA-3SAFETY USE HANDHOLDS AND STEPS ¢¢ Falling is one of the major causes of personal injury. ‘When you get on and off the machine, always face the machine and maintain a three-point contact with the steps and handrails. Do not use any controls as handholds. + Never jump on or off the machine. Never mount or dismount a moving machine. Be careful of slippery conditions on piatforms, steps, and handrails when leaving the machine. es ADJUST THE OPERATOR’S SEAT © A poorly adjusted seat for either the operator or for the work at hand may quickly fatigue the operator leading to misoperations. The seat should be adjusted whenever changing the ‘operator for the machine. ‘The operator should be able to fully depress the pedals and to correctly operate the control levers with his back against the seat back. Ht not, move the seat forward or backward, and ‘check again. SA-4SAFETY FASTEN YOUR SEAT BELT @ If the machine should overturn, the operator may become injured and/or thrown from the cab. Additionally the operator may be crushed by the overturning machine, resulting in serious injury or death. Prior to operating the machine, thoroughly examine ‘webbing, buckle and attaching hardware. if any item is damaged or worn, replace the seat belt or ‘component before operating the machine. Be sure to remain seated with the seat belt securely fastened at all times when the machine is in operation to minimize the chance of injury from an accident. We recommend that the seat belt be replaced every three years regardless of its apparent condition. MOVE AND OPERATE MACHINE SAFELY © Bystanders can be run over. Take extra care not to run over bystanders. Confirm the location of bystanders before moving, swinging, or operating the machine. Always keep the travel alarm and hor in working condition (if equipped). It warns people when the machine starts to move. Use a signal person when moving, swinging, or operating the machine in congested areas. Coordinate hand signals before starting the machine. SASSAFETY OPERATE ONLY FROM OPERATOR’S SEAT ‘¢ Inappropriate engine starting procedures may cause the machine to runaway, possibly resulting in serious injury or death. Start the engine only from the operator's seat. NEVER start the engine while standing on the track ‘or on ground. Do not start engine by shorting across starter terminals. Before starting the engine, confirm that all control levers are in neutral. JUMP STARTING «Battery gas can explode, resulting in serious injury. If the engine must be jump started, be sure to follow the instructions shown in the "OPERATING THE ENGINE® chapter in the operator's manual. The operator must be in the operator's seat so that the machine will be under control when the engine starts. Jump starting is a two-person operation. Never use a frozen battery. Failure to follow correct jump starting procedures could result in @ battery explosion or a runaway machine. KEEP RIDERS OFF MACHINE © Riders on machine are subject to injury such as being struck by foreign objects and being thrown off the machine. + Only allow the operator on the machine. Keep riders off. Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner. SAGSAFETY PROVIDE SIGNALS FOR JOBS INVOLVING MULTIPLE NUMBERS OF MACHINES © For jobs involving multiple numbers of machines, provide signals commonly known by all personnel involved. Also, appoint a signal person to coordinate the job site. Make sure that all personnel obey the signal person’s directions. CONFIRM DIRECTION OF MACHINE TO BE DRIVEN © Incorrect travel pedalflever operation may result in serious injury or death. Before driving the machine, confirm the position of the undercarriage in relation to the operator's, position. If the travel motors are located in front of the cab, the machine will move in reverse when travel pedalsjlevers are operated to the front orneoraouan2 sao SA7SAFETY DRIVE MACHINE SAFELY ‘© Before moving the machine, confirm which way to move travel pedals/levers for the corresponding direction you wish to go. Pushing down on the front of the travel pedals or pushing the levers forward moves the machine towards the idlers. (Refer to the Steering the Machine Using Pedals/Levers section in the operator's manual for correct travel operation.) © Traveling on a grade may cause the machine to slip a or to overturn, possibly resulting in serious injury or death, When traveling up or down a grade, keep the bucket in the direction of travel, approximately 200 to 300 mm (approximately 8 to 12 in) ® above the ‘ground. If machine starts to skid or becomes unstable, lower the bucket immediately. Traveling across the face of a slope may cause the machine to skid or to turnover. When traveling (ascending/descending) on a slope, be sure to point the tracks uphilidownhill saat Turning on an incline may cause the machine to tip over. If turning on an incline is absolutely unavoidable, do so at a place where the slope is gentle and the surface is firm. SABSAFETY AVOID INJURY FROM ROLLAWAY ACCI- DENTS © Death or serious injury may result if you attempt to mount or stop a moving machine. To avoid rollaways: + Select level ground when possible to park machine. Do not park the machine on a grade. Lower the bucket andjor other work tools to the ground. + Turn the auto-idle switch off + Run the engine at slow idle speed without load for 5 ‘minutes to coot down the engine. + Stop the engine and remove the key from the key switch, + Pull the pilot control shut-off lever to LOCK position, Block both tracks and lower the bucket to the ground. Thrust the bucket teeth into the ground if you must park on a grade. Position the machine to prevent raling. Park a reasonable distance from other machines. SA-9SAFETY AVOID INJURY FROM BACK-OVER AND SWING ACCIDENTS If any person is present near the machine when backing or swinging the upperstructure, the machine may hit or run over that person, resulting in serious injury or death, To avoid back-over and swing accidents: Always look around BEFORE YOU BACK UP AND. SWING THE MACHINE. BE SURE THAT ALL BYSTANDERS ARE CLEAR, Keep the travel alarm in working condition (if equipped). ALWAYS BE ALERT FOR BYSTANDERS MOVING INTO THE WORK AREA. USE THE HORN OR. OTHER SIGNAL TO WARN BYSTANDERS BEFORE MOVING MACHINE, USE A SIGNAL PERSON WHEN BACKING UP IF YOUR VIEW IS OBSTRUCTED. ALWAYS KEEP ‘THE SIGNAL PERSON IN VIEW. Use hand signals, which conform to your local regulations, when work conditions require a signal person. No machine motions shall be made unless signals are clearly understood by both signalman and operator. Lear the meanings of all flags, signs, and markings used on the job and confirm who has the responsibilty for signaling. Keep windows, mirrors, and lights clean and in good condition, Dust, heavy rain, fog, etc., can reduce visibility. As visibility decreases, reduce speed and use proper lighting. Read and understand all operating instructions in the operator's manual. = « oa ND SA-10SAFETY AVOID TIPPING ‘® The danger of tipping is always present when operating on a grade, possibly resulting in serious injury or death, To avoid tipping: © Be extra careful before operating on a grade. - Prepare machine operating area flat. Keep the bucket low to the ground and close to the machine. “Reduce operating speeds to avoid tipping or slipping. ‘Avoid changing direction when traveling on grades. - NEVER attempt to travel across a grade steeper than 15 degrees if crossing the grade is unavoidable. “Reduce swing speed as necessary when swinging loads. ‘* Be careful when working on frozen ground. - Temperature increases will cause the ground to become soft and make ground travel unstable. saaeo SA-11SAFETY AVOID POWER LINES © Serious injury or death can result if the machine or front attachments are not Kept a safe distance from electric ines. = When operating near an electric line, NEVER move any part of the machine or load closer than 3. m (10 X74 ft) plus twice the line insulator length. Check and comply with any local regulations that may apply. Wet ground will expand the area that could cause any person on it to be affected by electric shock. Keep all bystanders or co-workers away from the site, OBJECT HANDLING @ Ifa lifted load should fall, any person nearby may be struck by the falling load or may be crushed under- neath it, resulting in serious injury or death. = When using the machine for craning operations, be ‘sure to comply with al local regulations. Do not use damaged chains or frayed cables, sa- bles, slings, or ropes. Before craning, position the upperstructure with the travel motors at the rear. Move the load slowly and carefully. Never move it saan suddenly. Keep all persons well away from the load. Never move a load over a person's head. Do not allow anyone to approach the load until it is safely and securely situated on supporting blocks or (on the ground. Never attach a sling or chain to the bucket teeth. They may come off, causing the load to fall. SA-12SAFETY PROTECT AGAINST FLYING DEBRIS If tlying debris hit eyes or any other part of the body, serious injury may result, Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses. Keep bystanders away from the working area before striking any object. coveninoune sae PARK MACHINE SAFELY To avoid accidents: Park machine on a level surface. Lower bucket to the ground. Turn auto-idle switch off. Fun engine at siow idle speed without load for 5 minutes. ‘Tum key switch to OFF to stop engine. Remove the key from the key switch. Pull the pilot control shut-off lever to the LOCK position. Close windows, roof vent, and cab door. ad Lock all access doors and compartments. SA-13SAFETY HANDLE FLUIDS SAFELY — AVOID FIRES ‘© Handle fuel with care; it is highly flammable. If fuel ignites, an explosion and/or a fire may occur, possibly resulting in serious injury or death. Do not refuel the machine while smoking or when near open flame or sparks. Always stop the engine before refueling the machine, + Fill the fuel tank outdoors. © All fuels, most lubricants, and some coolants are flammable. + Store flammable fluids well away from fire hazards. Do not incinerate or puncture pressurized containers. Do not store oily rags; they can ignite and burn spontaneously. Li SA-14SAFETY PRACTICE SAFE MAINTENANCE To avoid accidents: Understand service procedures before doing work. Keep work area clean and dry. Do not spray water or steam inside cab. “Never lubricate or service the machine while it is moving. ~ Keep hands, feet and clothing away from power- driven parts. + Before servicing the machine: 1) Park the machine on a level surface. 2) Lower the bucket o the ground. 3) Turn the auto-idie switch off 4) Run the engine at slow idle speed without load for 5 minutes. ‘Tum the key switch to OFF to stop engine. Relieve the pressure in the hydraulic system by moving the control levers several times. Remove the key from the switch. ‘Attach a ‘Do Not Operate” tag on the control lever. Pull the pilot control shut-off lever to the LOCK Position, Allow the engine to cool. 5) 8) 7) 8) 9) 10) + If a maintenance procedure must be performed with the engine running, do not leave machine unattended. “If the machine must be raised, maintain a 90 to 110° angle between the boom and arm. Securely support any machine elements that must be raised for service work - Never work under a machine raised by the boom. + Inspect certain parts periodically and repair or replace as necessary. Refer to the section discussing that part in the “MAINTENANCE” chapter in the operator's manual. ~Keep all parts in good condition and properly installed. + Fix damage immediately. Replace worn or broken parts, Remove any buildup of grease, oil, or debris. + Disconnect battery ground cable (—) before making adjustments to electrical systems or before welding (on the machine. atk sscocoancnsr SA-15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. DO NOT OPERATE SUPPORT MACHINE PROPERLY © Never attempt to work on the machine without securing the machine first. Always lower the attachment to the ground before you work on the machine. + IF you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tires, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. STAY CLEAR OF MOVING PARTS ¢ Entanglements in moving parts can cause serious injury. To prevent accidents, care should be taken to ensure that hands, feet, clothing, jewelry and hair do not become entangled when working around rotating parts. Or SA-16SAFETY PREVENT PARTS FROM FLYING OFF © Grease in the track adjuster is under high pressure. Failure to follow the precautions below may result in serious injury, blindness, or death ~Do not attempt to remove GREASE FITTING or VALVE ASSEMBLY. As pieces may fly off, be sure to keep body and face away from valve. © Travel reduction gears are under pressure. ‘As pieces may fly off, be sure to keep body and face away from AIR RELEASE PLUG to avoid injury. GEAR OIL is hot. Wait for gear oil to cool, then gradually loosen the air release plug to release Pressure. seoeoncaus ‘STORE ATTACHMENTS SAFELY ‘© Stored attachments such as buckets, hydraulic hammers, and blades can fall and cause serious injury or death. Securely store attachments and implements to prevent falling. Keep children and bystanders away from storage areas. SA-17SAFETY PREVENT BURNS Hot spraying fluids: © After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the ‘engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe bums, To prevent possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap, The hydraulic oll tank is pressurized. Again, be sure to release all pressure before 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 before starting any maintenance or inspection work. A206 REPLACE RUBBER HOSES PERIODICALLY @ Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone. Periodically replace the rubber hoses. Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death. Sh SA-18SAFETY AVOID HIGH-PRESSURE FLUIDS @ Fluids such as diesel fuel or hydraulic oil under Pressure can penetrate the skin or eyes causing serious injury, blindness or death. Avoid this hazard by relieving pressure before disconnecting hydraulic or other lines. Relieve the pressure by moving the control levers several times, Tighten all connections before applying pressure. Search for leaks with a piece of cardboard; take ‘are to protect hands and body from high-pressure fluids. Wear a face shield or goggles for eye protection. If an accident occurs, see a doctor familiar with this type of injury immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. B SA-19SAFETY PREVENT FIRES Check for Oil Leaks: © Fuel, hydraulic oil and lubricant leaks can lead to fires. Check for missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oll-cooler flange bolts for oil leaks. + 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. Check for Shorts: © Short circuits can cause fires. + Clean and tighten all electrical connections. Check before each shift or after eight (8) to ten (10) hours operation for loose, kinked, hardened or frayed electrical cables and wires. ‘Check before each shift or after eight (8) to ten (10) hours operation for missing or damaged terminal caps. + DO NOT OPERATE MACHINE if cable or wires are loose, kinked, etc.. Clean up Flammables: © Spilled fuel and oil, and trash, grease, debris, accumulated coal dust, and other flammables may cause fires. “Prevent fires by inspecting and cleaning the machine daily and by removing spilled or accumulated flammables immediately. Check Key Switch: © Ifa 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: 41) Start the engine and run it at slow idle. 2) Turn the key switch to the OFF position to ‘confirm that the engine stops. {ft any abnormalities are found, be sure to repair them before operating the machine. (S SA-20SAFETY Check Heat Shields: ‘© Damaged or missing heat shields may lead to fires. - Damaged or missing heat shields must be repaired or replaced before operating the machine. scacoonooie9 EVACUATING IN CASE OF FIRE © Ifa fire breaks out, evacuate the machine in the {following way: * Stop the engine by tuming the key switch to the OFF position if there is time. Use a fire extinguisher if there is time. + Exit the machine, sracoonoo2 cases BEWARE OF EXHAUST FUMES © Prevent asphyxiation. Engine exhaust fumes can cause sickness or death. If you must operate in a building, be sure there is adequate ventilation. Either use an exhaust pipe extension to remove the exhaust fumes or open. doors and windows to bring enough outside air into the area, SA-21SAFETY AVOID HEATING NEAR PRESSURIZED FLUID LINES ‘@ Flammable spray can be generated by heating near pressurized 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 when engaging in welding, soldering, ete AVOID APPLYING HEAT TO LINES CONTAINING FLAMMABLE FLUIDS Do not weld or flame cut pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting them. REMOVE PAINT BEFORE WELDING OR HEATING @ Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. If inhaled, these fumes may cause sickness. Avoid potentially toxic fumes and dust. Do all such work outside or in a well-ventilated area. Dispose of paint and solvent properly Remove paint before welding or heating: 4) If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. 2) If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating sac SA-22SAFETY PREVENT BATTERY EXPLOSIONS © Battery gas can explode. Keep sparks, lighted matches, and flame away from the top of battery. Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16 °C (60 °F). © Battery electrolyte is poisonous. If the battery should saver explode battery electrolyte may be splashed into eyes, possibly resulting in blindness. Be sure to wear eye protection when checking electrolyte specific gravity. SERVICE AIR CONDITIONING SYSTEM SAFELY ¢ If spilled onto skin, refrigerant may cause a cold contact burn, Refer to the freon container for proper use when ‘servicing the air conditioning system. Use a recovery and recycling system to avoid venting freon into the atmosphere. Never let the freon stream make contact with the skin, sos SA-23SAFETY DISPOSE OF WASTE PROPERLY ‘© Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with HITACHI equipment includes such items as oil, fuel, coolant, brake fluid, fiters, and batteries. + Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into drinking from them. = Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Goverment regulations may require a certified air conditioning service center to recover and recycle used air conditioning refrigerants. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your authorized dealer. BEFORE RETURNING THE MACHINE TO THE CUSTOMER © After maintenance or repair work is complete, confirm that: The machine is functioning properly, especially the safety systems. Worn or damaged parts have been repaired or replaced SA-24SECTION 05 OPERATIONAL PERFORMANCE TEST CONTENTS Group 01- Introduction Group 04- Component Test Operational Performance Tests ... TO5-01-01 Primary Pilot Pressure ...... T05-04-01 Preparation for Performance ‘Secondary Pilot pressure .. T05-04-03 Tests .. . T05-01-02 ‘Solenoid Valve Set Pressure ..... T05-04-04 Main Pump Delivery Pressure .... T05-04-07 Group 02- Engine Test Main Relief Valve Set Pressure ... T05-04-08 Engine Speed .........e.ceee-. TO5-02-01 Overload Relief Valve Set Engine Compression Pressure ... TO5-02-03 Pressure 05-04-12 Valve Clearance Adjustment .... 05-02-04 Main Pump Flow Test. 05-04-14 Nozzle Check 05-02-06 ‘Swing Motor Drainage 05-04-18 Injection Timing cece T05-02-08 Travel Motor Drainage . T05-04-20 Group 03- Excavator Test Group 05- Standard Travel Speed 05-03-01 Operational Performance Track Revolution Speed T05-03-02 Standard Table . T05-05-01 Mistrack Check ....... 05-03-03 Main Pump P-Q Diagram . TO5-05-04 Travel Parking Function Check .. 05-03-04 Injection Pump cesses T05-05-05 Swing Speed ....... T05-03-05 ‘Swing Function Drift Check .... TO5-03-06 ‘Swing Motor Leakage 705-03-07 ‘Swing Bearing Play .. T05-03-08 Maximum Swingable Slant Angle 05-03-08 Hydraulic Cylinder Cycle Time .. TO5-03-10 Dig Funetion Drift Check 705-03-11 Control Lever Operating Force .. 05-03-12 Control Lever Stroke ......... 7105-03-13 Combined Boom Raise / Swing Function Check ............ TOS-0814 160T-05-01160T-05-02OPERATIONAL PERFORMANCE TESTS / Introduction OPERATIONAL PERFORMANCE TESTS. Use operational performance test procedures to quantitatively check all systems and functions on the machine. Purpose of Performance Tests 1. To comprehensively evaluate each operational function by comparing the performance test da- ta with the standard values. 2. According to the evaluation results, repair, ad- just, or replace parts or components as neces- sary to restore the machine's performance to the desired standard. 3. To economically operate the machine under op- timal 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. cylin- ders. 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 F Performance Standards 4 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 cor- rect, 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 condi- tions. The machine performance does not always deterio- rate as the working hours increase. However, the machine performance is normally considered to re- duce 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 Standards 1. Operation speed values and dimensions of the new machine. 2. Operational performance of new components adjusted to specification. Allowable errors will be indicated as necessary. TO5-01-01OPERATIONAL PERFORMANCE TEST / Introduction PREPARATION FOR PERFORMANCE TESTS ‘Observe the following rules in order to carry out per- formance tests accurately and safely. 1. THE MACHINE Repair any defects and damage found, such as il or water leaks, loose bolts, cracks and so on, before starting to test. 2, TEST AREA (1) Select a hard, flat surface. (2) Secure enough space to allow the machine to run straight more than 20 m (65 ft 7 inch), and to make a full swing with the front at- tachment extended. (8) If required, rope off the test area and provide signboards to keep unauthorized personnel away. 3, PRECAUTIONS (1) Before starting to test, agree upon the sig- nals to be employed for communication ‘among coworkers. Once the test is started, be sure to communicate with each other us- ing these signals, and to follow them without fail. (2) Operate the machine carefully and always give first priority to safety. () While testing, always take care to avoid ac- cidents 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 cil. Use oil pans to catch escap- ing oil. Pay special attention to this when re- moving hydraulic pipings. 4, MAKE PRECISE MEASUREMENTS (1) Accurately calibrate test instruments vance to obtain correct data. (2) Carry out tests under the exact test condi- tions prescribed for each test item. (8) Repeat the same test and confirm that the test data obtained can be procured repeat- edly. Use mean values of measurements if neces- sary. ad- TO5-01-02OPERATIONAL PERFORMANCE TEST / Engine Test 2.1 ENGINE SPEED Summary: 1. Use Dr.EX. If Dr.EX is not available, use an engine tachometer. 2. Measure the engine speeds in each mode. NOTE: Measure the engine speed before performing all other tests to check that the engine speed meets specification. Because, if the engine speed is not adjusted correctly, all other perfor- mance data wil be unreliable. Preparation: 1. Connect Dr.£X to the diagnosing connector beside orae2.01 the fuse box located behind the operator's seat, and select the monitor function. When using an en- gine tachometer, install speed pickup (3) to injec- tion pipe (4) 2. Warm up the machine until the engine coolant tem- perature reaches 50 °C (122 °F) or more, and hy- draulic oll is 505 °C (12249 °F). NOTE: Never attempt to readjust stopper (1). TO5-02-01OPERATIONAL PERFORMANCE TEST / Engine Test Measurement: 1. No Load Engine Speed 1-1. Measure the engine start speed (Start Idle), slow idle speed, fast idle speed (in normal mode), and fast idle speeds (in both E and HP modes). 4-2. Select the switch positions as shown below. 1-3. Start measurement from the start idle speed. 1-4. Measure while changing the engine control E mode switch, and HP mode switch, Engine | EMode | HP Mode | Auto-idie] Work Control Dial | Switch | Switcn | Switch | Mode General star ide | oFF | OFF | OFF | Purpose Mode General Siow idle | OFF | OFF | OFF | Purpose Mode ‘wamet | ore | oFF | oFF | Purpose form: me Mode) Modo General Fast Idle fies | ON | OFF | OFF | Purpose General Fast idle (FENGR | OFF | ON | OFF | Purpose 2. No Load Auto-Idle Speed 2-1, Select the switch positions as shown below. Engine | & Mode | HP Mode | Auto-taie] Work Control Dial } Switch | “Switch | Switch | T05-05-05OPERATIONAL PERFORMANCE TEST / Standard T05-05-06MEMOMEMOSECTION 06 TROUBLESHOOTING CONTENTS Group 01- Diagnosing Procedure Group 04- Troubleshooting B Introduction... - 06-01-01 Troubleshooting B Procedure .... 06-04-01 Diagnosing Procedure T06-01-02 Relationship between Machine Trouble DrEX .. sees TO6-01-04 ‘Symptoms and Parts in Trouble .. T06-04-02 DLEX Start-Up Procedure... TO6-01-04 Correlation between Trouble List of Fault Code ............... TO6-01-05 ‘Symptoms and Part Failures ..... T06-04-14 Monitoring Function ............. T06-01-06 Engine Troubleshooting 06-04-20 ‘Actuator Control System Group 02- Component Layout Troubleshooting ... =. 706-0432 Main Components T06-02-01 Front Attachment Control system Electrical System Troubleshooting .... T06-04-40 (Overall System). 06-02-02 ‘Swing System Troubleshooting ... TO6-04-52 Electrical System (Relays) 06-02-03 Travel System Troubleshooting ... TO6-04-55 Electrical System Troubleshooting for Other (Monitor and Switch Panels)... 06-02-04 Functions 06-04-60 Pump and Related Parts 06-02-05 Engine Speed Adjustment and Control Valve T06-02-06 Engine Learning ... 06-04-62 Other Components 06-02-08 Pump Learining «2.2.2.2... TO6-0463 Exchange Inspection Method ..... 06-04-64 Group 03- Troubleshooting A Pump Contro| Line Direct Connection Troubleshooting A Procedure .... 06-03-01 Method = T06-04-66 List of Fault Code. 06-03-02 EC Sensor Installation and Voltage Fault Code 01, 02, 03 06-03-03 Adjustment 06-04-67 Fault Code 04 .........ceeeeese+ 706-0303 ‘A Sensor instalation and Voltage Fault Code 05... .eeseeeeee+ T06-08-04 Adjustment... 06-04-68 Fault Code 06... coceses T06-08-06 Fault Code 07... see eceeee 06-03-08 Fault Code 08,09... eee. 06-03-10 Fault Code 10,11. 06-03-12 Fault Code 12, 13 vos 706-038-414 Fault Code 14,15, 16, 17,18. 06-03-16 Fault Code 19... ve. 706-038-418 Sensor Operating Range List ..... 06-09-20 160T-06-01Group 05- Troubleshooting C Troubleshooting C Procedure .... Malfunction of Coolant Temperature Gauge . Malfunction of Fuel Gauge Malfunction of Indicator Light Check System Malfunction of Level Check Switch Malfunction of Engine Oil Level Indicator... Malfunction of Coolant Level Indicator Maltunction of Hydraulic Oi Level Indicator Maltunction of Alternator Indicator Malfunction of Engine Oil Pressure Indicator Maltunction of Overheat Indicator... eee eeeeeeeeeeee Malfunction of Fuel Level Indicator Mafluncton of Ait Filter Restriction Indicator ceseeeeeeee Malfunction of Buzzer .....2.2.++ Malfunction of Hour Meter Group 06- Electrical System Inspection r 06-05-01 Precautions for inspection and Maintenance cc + T06-05-02 Inspections for Disconnecting - T06-05-04 Connectors 6... .eeeeeeee Fuse Continuity Test so... ---.- 06-05-06 Inspection and Replacement o 7106-05-06 Fusible Links Battery Voltage Check 06-05-08 How to Troubleshoot Alternato Matfunctions .. ae 06-05-10 Continuity Check... Voltage and Current Check 7106-05-12 Replacement of Relay ....... T06-05-14 Group 07- Harness Check Circuit Check . 06-05-16 . 706-05-18 T06-05-20 - T06-05-22 06-05-24 06-05-26 = 706-06-01 «06-06-03 T06-06-04 . T06-06-05 . T06-08-06 06-06-07 - T06-06-08 - T06-06-10 T06-06-14 06-07-01 160T-06-02TROUBLESHOOTING / Diagnosing Procedure INTRODUCTION Each troubleshooting section group is presented in an orderty fashion so as to make the inspecting and troubleshooting procedures easy to follow. Use the troubleshooting section to guide you in locating the source of any problems that may arise. The troubleshooting section consists of 6 groups: the component layout, the troubleshooting A (using fault codes), troubleshooting B (starting with symp- toms), troubleshooting C (gauges and in-dicators), the electrical system inspection pro-cedures, and harness check groups. ‘Component Layout Drawing Troubleshooting A (using fault codes) Use these charts when the self-diagnosing func- tion of Dr.EX shows any fault codes. (The controller automatically diagnoses and memorizes malfunctions that have occurred in the signal sending system.) Example: Fault Code 08: EC Sensor Failure ‘Troubleshooting B (starting with symptoms) Use these charts when the machine is exhibiting ‘rouble and when Dr.EX does not indicate any fault codes. Example: Even if engine control dial is operated, engine speed does not change. + Troubleshooting C (Gauges and indicators) Use these charts when any gauges or indicators matfunetion.. Example: The fuel gauge does not operate. Electrical System Inspection Procedure Refer to this group for precautions and inspec- tion procedures of the electrical system when or before performing inspections on the electrical system. Example: Fuse Inspection Harness Check Refer to this group for information about the test hamesses. Example: ST 7129 ‘T06-01-01TROUBLESHOOTING / Diagnosing Procedure DIAGNOSING PROCEDURE ‘These six basic steps are essential for efficient trouble- shooting 4. Study the system ‘Study the machine's technical manuals. Know the sys- tem and how it works, and what the construction, func- tions and specifications of the system components are. 2. Ask the operator rrarenoon Before inspecting, get the full story of malfunctions from your star witness -- the operator. (a) How is the machine being used? ( Find out if the machine is being operated correctly) (b) When was the trouble noticed, and what types of work the machine doing at that time? (©) What are the details of the trouble? Is the trouble getting worse, or did it appear suddenly for the first time? (@) Did the machine have any other troubles pre- viously? If so, which parts were repaired before? 3. Inspect the machine Before starting the troubleshooting procedure, check the machine's daily maintenance points, as shown in the operator's manual. Also, check the electrical system, including the batter- jes, as troubles in the electrical system such as low bat- tery voltage, loose connections and blown fuses will re- sult in malfunction of the controllers, causing total oper- ational failure of the machine. Fuse failure is often caused by a fine crack in the fuse, and such fine cracks are very hard to detect by visual inspection. T06-01-02