Operational Performance Test: Section 4

SECTION 4
OPERATIONAL
PERFORMANCE TEST
CONTENTS
Group 1 Introduction Dig Function Drift Check.........................T4-3-12
Operational Performance Tests ................T4-1-1 Control Lever Operating Force ...............T4-3-14
Preparation for Performance Tests ...........T4-1-2 Control Lever Stroke ..............................T4-3-15
Combined Boom Raise/Swing
Group 2 Engine Test
Function Check.....................................T4-3-16
Engine Speed...........................................T4-2-1
Engine Compression Pressure .................T4-2-3 Group 4 Component Test
Valve Clearance Adjustment.....................T4-2-4 Primary Pilot Pressure ..............................T4-4-1
Nozzle Check ...........................................T4-2-6 Secondary Pilot Pressure .........................T4-4-3
Injection Timing ......................................T4-2-10 Solenoid Valve Set Pressure ....................T4-4-4
Main Pump Deliuery Pressure ..................T4-4-6
Group 3 Excavator Test
Main Relief Valve Set Pressure.................T4-4-8
Travel Speed ............................................T4-3-1
Overload Relief Valve Set Pressure ........T4-4-12
Track Revolution Speed ...........................T4-3-2
Main Pump Flow Rate Measurement ......T4-4-14
Mistrack Check ........................................T4-3-3
Swing Motor Drainage ............................T4-4-20
Travel Parking Function Check .................T4-3-4
Travel Motor Drainage ............................T4-4-22
Swing Speed ............................................T4-3-5
Swing Function Drift Check ......................T4-3-6 Group 5 Standard
Swing Motor Leakage ...............................T4-3-7 Operational Performance
Maximum Swingable Slant Angle..............T4-3-8 Standard Table .......................................T4-5-1
Swing Bearing Play ..................................T4-3-9 Main Pump P-Q Curve..............................T4-5-4
Hydraulic Cylinder Cycle Time ................T4-3-10 Dr.EX Monitor Indicating Values................T4-5-6
1HHT-4-1
(Blank)
1HHT-4-2
OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to

quantitatively check all systems and functions on the
machine.
Purpose of Performance Tests Precautions for Evaluation of Test Data
1. To comprehensively evaluate each operational 1. To evaluate not only that the test data are correct,
function by comparing the performance test data but also in what range the test data are.
with the standard values.
2. Be sure to evaluate the test data based on the
2. According to the evaluation results, repair, adjust, machine operation hours, kinds and state of work
or replace parts or components as necessary to loads, and machine maintenance conditions.
restore the machine's performance to the desired
standard. The machine performance does not always
deteriorate as the working hours increase. However,
3. To economically operate the machine under the machine performance is normally considered to
optimal conditions. reduce in proportion to the increase of the operation
hours.
Kinds of Tests Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
1. Base machine performance test is to check the number of the machine's working hours.
operational performance of each system such as
engine, travel, swing, and hydraulic cylinders. Definition of “Performance Standards”
2. Hydraulic component unit test is to check the 1. Operation speed values and dimensions of the
operational performance of each component such new machine.
as hydraulic pump, motor, and various kinds of
valves. 2. Operational performance of new components
adjusted to specification. Allowable errors will be
Performance Standards indicated as necessary.
“Performance Standards” is shown in tables to

evaluate the performance test data.
T4-1-1
OPERATIONAL PERFORMANCE TEST / Introduction
PREPARATION FOR PERFORMANCE
TESTS
Observe the following rules in order to carry out

performance tests accurately and safely.
1. THE MACHINE
Repair any defects and damage found, such as oil
or water leaks, loose bolts, cracks and so on,
before starting to test.
2. TEST AREA
(1) Select a hard, flat surface.
(2) Secure enough space to allow the machine
to run straight more than 20 m (65 ft 7 inch),
and to make a full swing with the front
attachment extended.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away.
3. PRECAUTIONS
(1) Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is started,
be sure to communicate with each other T105-06-01-003
using these signals, and to follow them
without fail.
(2) Operate the machine carefully and always
give first priority to safety.
(3) While testing, always take care to avoid
accidents due to landslides or contact with
high-voltage power lines. Always confirm
that there is sufficient space for full swings.
(4) Avoid polluting the machine and the ground
with leaking oil. Use oil pans to catch
escaping oil. Pay special attention to this
when removing hydraulic pipings.
4. MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate test instruments in
advance to obtain correct data. T105-06-01-004
(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 procured
repeatedly.
Use mean values of measurements if
necessary.
T4-1-2
OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. Measure the engine speed using the built-in diag- 1
nosing system (refer to TROUBLESHOOT-
ING/General group.) or Dr. EX. If the built-in diag- 2
nosing system or Dr. EX is not available, use an
engine speed meter.
2. Measure the engine speeds in each mode.
NOTE: Measure the engine speed before perform-

ing all other tests to check that the engine
speed meets specification. Because, if the
engine speed is not adjusted correctly, all
other performance data will be unreliable. 3 T107-06-02-002
Preparation:
1. Select the monitor function of the built-in diagnos-
ing system (or Dr.EX). When using an engine
speed meter, install speed pickup (1) to injection
pipe (2).
2. Warm up the machine until the engine coolant

temperature reaches 50 °C (122 °F) or more, and
hydraulic oil is 50±5 °C (122±9 °F).
IMPORTANT: Never attempt to the readjust stop-

per (3) of the governor lever.
T1HH-04-02-002
T4-2-1
Measurement: Evaluation:
1. Check engine speeds for auto-warm up (when Refer to T4-5 Operational Performance Standard.
starting the engine), auto-idle, slow idle, fast idle
(when normal), fast idle (when the ECO is deacti- Remedy:
vated), fast idle (in the E mode), and fast idle (in Refer to T5-4 Troubleshooting B.
the HP mode).
2. Select the switch positions and the test conditions
corresponding to the engine speed to be meas- NOTE: ECO stands for the auto engine speed re-
-1
ured as shown in the table below. duction system by 100 min .
Engine Power Ӹ Auto-Idle/ Auto- Work
Control Ӹ Mode Ӹ Acceleration Mode Test Conditions
Dial Switch Selector Switch
Digging
Slow Idle Min. Speed P OFF
Mode
Fast Idle Digging
Max. Speed P OFF
(Normal) Mode
Fast Idle Check in the Dr. EX special
Digging
(With ECO deac- Max. Speed P OFF functions with ECO deacti-
Mode
tivated) vated.
Fast Idle (Relief Digging Check the engine speed while
Max. Speed P OFF
operation) Mode relieving the boom raise circuit.
Fast Idle Digging
Max. Speed E Mode OFF
(E mode) Mode
Fast Idle Digging Check the engine speed while
Max. Speed HP Mode OFF
(HP mode) Mode relieving the boom raise circuit.
Check engine speed 4 seconds
Digging
Auto-Idle Max. Speed P Auto-Idle after returning all control levers
Mode
to neutral.
Check reduced engine speed
Auto- Digging
Max. Speed P Auto-Acceleration within 3 seconds after returning
Acceleration Mode
all control levers to neutral.
Digging Check only when oil tempera-
Warming Up Max. Speed P OFF
Mode ture is lower than 0 °C (32 °F).
Monitor Panel Switch Panel
Engine Con-
trol Dial
Auto-Idle/
Acceleration Selector
Power Mode
Switch
Work Mode
Switch
T178-01-01-003 T178-01-01-004
T4-2-2
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.
2. Check exhaust gas color and the amount of blow-

by gas from the crankcase. Keep track of engine
oil consumption.
3. Check for abnormalities in the intake system, in-

cluding the air filter.
Preparation:
1. Confirm that valve clearances are correct.
2. Confirm that the batteries are charged properly.
3. Run the engine until the coolant temperature

gauge reaches the operating range.
T1HH-04-02-003
4. Stop the engine. Remove glow plugs from each
cylinder.
NOTE: Unless the fuel delivery pipes are discon-

nected, fuel will ignite in the cylinders so
that pressure in the cylinders will increase.
5. Install an adapter (Isuzu 5-8840-2622-0) and

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adapter and compression gauge to prevent air
leakage.)
Measurement:
1. Turn the starter to crank the engine. Record the
compression pressure of each cylinder.
2. Repeat measurement three times for each cylin-

der and calculate the mean values.
Evaluation:
Refer to Group-5 in this section.
RemedyȚ Ț
Refer to engine shop manual.
T4-2-3
VALVE CLEARANCE ADJUSTMENT
Summary:
Perform the measurement when the engine is cool.
Pointer
Before starting work, clean the head cover mounting
area to avoid contaminating the engine.
Preparation:
1. Locate top dead center (TDC) in the compression
stroke.
While turning the crank shaft clockwise, align the
matching mark on the crank pulley with the pointer
located on the flywheel housing as illustrated.
When the S mark on the driving side flange of the
injection pump coupling aligns with the pointer,
piston No.1 (or piston No.6) is positioned at TDC
in the compression stroke.
2. Remove the head cover.

Crank Pulley Matching Mark
T1HH-04-02-004
3. Move the intake and exhaust valve push rods on
cylinder No.1 up and down by hand.
If any clearance is present on both ends of the Pointer S Mark
push rods, piston No.1 is positioned at TDC in the
compression stroke.
Start measurement from cylinder (No.1 or No.6)
positioned at TDC in the compression stroke.
Measurement:
1. Insert a feeler gauge into the clearance between
the rocker arm and the valve stem end to meas-
ure the valve clearance.
T173-04-02-007
NOTE: Cylinder Nos. are designated from No.1 to
No.6 as viewed from the fan side.
T4-2-4
2. When the measurement is started from cylinder
No.1, perform the same measurement to all
valves indicated with the mark “{” in the table be-
low. (When the measurement is started from cyl-
inder No.6, perform the measurement on the
valves shown with the mark “×”.)
Cylinder NO. No.1 No.2 No.3 No.4 No.5 No.6

Valve I E I E I E I E I E I E
When starting meas-
urement from cylinder { { { { { {
No.1
When starting meas-
urement from cylinder × × × × × ×
No.6
3. Turn the crankshaft 360°. Align the TC mark with

the pointer. Then, continue measurement of the
Adjusting
other valves in the same way. Screw (A)
Evaluation: Rocker Arm

Refer to the Performance Standard Table in Group
T4-5. Adjusting
Screw (B)
Adjustment:
• If the measurement results are out of specification, Valve Stem
adjust the valve clearance in the same order of
measurement.
1. Loosen the adjusting screws (A) and (B) lock nuts

on the rocker arms.
T1HH-04-02-005
2. Insert the feeler gauge set at the specified dimen-

sion between the rocker arms and the valve stem,
turn the adjusting screws (A).
3. After adjusting, retighten the lock nuts on adjust-

ing screws (A) to the specification.
: 22 N⋅m (2.2 kgf⋅m 16 lbf⋅ft)
4. Tighten adjusting screws (B) completely with the

feeler gauge inserted.
5. Loosen gradually adjusting screws (B) until the

feeler gauge moves smoothly
6. After adjusting, retighten the lock nuts on adjust-

ing screws (B).
: 22 N⋅m (2.2 kgf⋅m 16 lbf⋅ft)
T4-2-5
NOZZLE CHECK
Summary:
1. Check the injection pressures and the spray pat-
terns at the first and second stages with a nozzle
tester.
Nozzle Nozzle
Holder
2. Before starting work, clean the nozzle holder
Retaining
mounting area to avoid contaminating the engine Nut
system.
Preparation:
1. Injection Pressure at First Stage:
1-1. Remove the nozzle holder, the fuel injection Injection Pressures T1HH-04-02-007
at First and Second
pipings and so on. Stages:
Retaining
1-2. Remove the retaining nut from the nozzle Nut (Tool) Nozzle
holder. Install the gasket (tool) and retaining
nut (tool) on the nozzle.
Gasket
Gasket (Tool) :157892-1500 (Bosch Automo- (Tool)
tive)
Retaining Nut (Tool) :157892-4000 (Bosch
Automotive)
: 34 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)
1-3. Install the nozzle holder to the nozzle tester.

T1HH-04-02-008
2. Injection Pressure at Second Stage: Injection Pressures at Second Stage:
2-1. Remove the retaining nut from the nozzle
holder. Install the gasket (tool) and the retain- Plug (Tool)
ing nut (tool) to the nozzle.
Retaining Nut
2-2. Install the gasket (tool) and the plug (tools) to (Tool) Gasket (Tool)
the retaining nut (tool).
Gasket (Tool) :026508-1140 (Bosch Automo-
tive)
Plug (Tool) :157892-1600(Bosch Automotive)
2-3. Install the holder (tools) to the nozzle holder.

Holder (Tool) :157892-4400(Bosch Automo-
tive) Injection Pressures at Second Stage:
Holder (Tool) T1HH-04-02-009
Nozzle Holder
T1HH-04-02-010
T4-2-6
2-4. Install the nut (tool) to the holder (tool).
Nut (Tool): 157892-1000 (Bosch Automotive) Nut (Tool)
Holder (Tool)
2-5. Install the pin (tool) to the dial gauge (tool).
Dial Gauge (Tool): 157892-3800 (Bosch
Automotive)
Pin (Tool) (Length: 60 mm): 157892-5300
(Bosch Automotive)
2-6. Install the dial gauge assembly to the nozzle

holder so that the pin on the dial gauge comes
in contact with the first spring seat, and then
secure it with the nut.
T1HH-04-02-011
NOTE: Secure the dial gauge to measure the

stroke of 2 mm.
Dial Gauge
Check if the shaft of the dial gauge can (Tool)
move smoothly. Dial
Gauge
2-7. Install the nozzle holder to the nozzle tester Assembly Nut (Tool)
Pin (Tool)
and calibrate the dial gauge to zero.
2-8. Loosen the plug of the retaining nut to bleed

any air from inside the retaining nut. After that,
check any for fuel leaks.
Fast Spring
Seat
T1HH-04-02-012
Retaining Nozzle
Nut Tester
Plug
T1HH-04-02-013
T4-2-7
Measurement
CAUTION: Never allow skin to contact the Injection Pressure at First Stage:
spray directly. The fuel spray from the nozzle
may penetrate the skin,
resulting in serious injury. If the fuel pene-
trates into the blood stream, it may cause
blood toxication. Nozzle Tester
IMPORTANT: Be sure to use clean diesel oil for the
test.
1. Injection Pressure at First Stage:

Operate the nozzle tester and make several
strong strokes of the tester to inject the fuel. Then,
T1HH-04-02-006
while operating the tester at approx. 60 strokes a
minute, measure the fuel injection pressure. Injection Pressure at Second Stage:
Dial Gauge
2. Injection Pressure at Second Stage:
2-1. Operate the nozzle tester in order to increase
the pressure inside the nozzle holder to 34.3 to
2
44.1 MPa (350 to 450 kgf/cm , 4980 to 6400
psi). The nozzle’s needle valve should move
through its full stroke. Record full stroke (L). Nozzle Tester
2-2. With the needle valve at full stroke, release the

nozzle tester handle.(The pressure inside the
nozzle holder will decrease and the needle
valve stroke as indicated on the dial gauge will T1HH-04-02-016
fall.)
2-3. Read needle valve stroke (M) from the dial Stroke of Needle Valve
gauge indication (once the needle valve has
descended). Refer to the set value as below. L
2
Set Value :18.1+1 MPa (185+10 kgf/cm ,
2630+142 psi)
NOTE: The valve indicated on the dial gauge M+0.05 mm

means pre-life value (M). M
2-4. Operate the nozzle tester again in order to in-

crease the pressure inside the nozzle holder to
2
34.3 to 44.1 MPa (350 to 450 kgf/cm , 4980 to Pressure
6400 psi). Release the nozzle tester handle.
Holder will decrease (and the needle valve
stroke as indicated on the dial will fall. Injection Pressure Insertion Pressure 34.3 to 44.1 MPa
at First Stage at Second Stage (350 to 450 kgf/cm 2 ,
4980 to 6400 psi)
2-5. Read the pressure at the moment when the
value indicated on the dial gauge points the set
value as below.
Set Value: Pre-lift value (M)+0.05 mm
T4-2-8
3. Spray Pattern
Attach the nozzle holder to the nozzle tester.
Make several strong strokes of the tester and
check the fuel spray pattern. Be sure not to oper-
ate the pressure gauge.
4. Leak Condition
Be sure to keep the pressure as that just before Normal
the injection. Then, check for any oil leakage
around the nozzle.
Evaluation
1. Standard Injection Pressure:
Refer to T4-5 Operational Performance Standard
Table.
2. Spray Pattern T1HH-04-02-014

• Large-size spray should not be visible to the na- Abnormal
ked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be

fine injected intermittently.
• There should be no drips found.
• Injection spray angle must be normal.
3. Oil Tight Condition

• No fuel leaks.
T1HH-04-02-015
Adjustment
1. Injection pressure at the first stage can be
changed in response to the first nozzle opening
pressure shim thickness.
Second Nozzle
2. Injection pressure at the second stage can be Opening
changed in response to the second nozzle open- Pressure Shim
ing pressure shim thickness.
3. When adjusting the injection pressures at the first

and the second stages, it’s easier to adjust them
referring to the record of shim thickness and the
pressure.
NOTE: Use a micrometer to measure shim thick-

ness.
First Nozzle
Opening
Pressure
Shim
T1HH-04-02-007
T4-2-9
INJECTION TIMING
Pointer
Inspection/Adjustment:
1. Position piston No.1 at TDC. Turn the crank shaft
clockwise to align the matching mark on the crank
pulley with the pointer on the housing.
2. Check if the mark on the coupling of the injection T1HH-04-02-004

pump aligns with the pointer on the housing side. Crank Pulley Matching Mark
Injection Coupling Pointer

NOTE: When the matching mark on the crank pul- Pump
ley aligns with the pointer on the housing
and the matching mark on the coupling
aligns with the pointer on the housing, the
injection timing is equal to the position at 9 °
before TDC.
3. If not, align them by loosening the adjusting bolt

on the coupling.
4. With the matching mark on the crank pulley

aligned with the pointer on the housing, the mark T1HH-04-02-017
on the coupling of the injection pump aligns with Adjusting

Coupling Bolt
the pointer on the housing, and then tighten the
adjusting bolt.
2
: 88 N⋅m (91 kgf/cm , 65 lbf⋅ft)
T1HH-04-02-017
Coupling
Adjusting
Bolt
T1HH-04-02-018
T4-2-10
OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
Measure the time required for the excavator to travel
a 20 m (65.6 ft) test track.
Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 20 m (65.6 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
Arm Rolled-In, Bucket Rolled-In
both ends for machine acceleration and decelera- End
tion. Bucket Height: 0.3 to 0.5 m
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in. Start
20 m Deceleration
4. Maintain hydraulic oil temperature at 50±5 °C Zone
(122±9 °F). 3 to 5 m
Acceleration
Measurement: Zone
3 to 5 m
1. Measure both the slow and fast speeds of the
machine. T105-06-03-001
2. Select the following switch positions:
Travel Engine Power Work Auto-Idle/
Mode Control Mode Mode Acceleration
Switch Dial Switch Switch Selector
Slow Digging
Fast Idle P Mode OFF
Mode Mode
Fast Digging
Mode Mode
3. Start traveling the machine in the acceleration

zone with the travel levers to full stroke.
4. Measure the time required to travel 20 m (65.6 ft).
5. After measuring the forward travel speed, turn the
upperstructure 180° and measure the reverse
travel speed.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.
Evaluation:
T4-5.
Remedy:
Refer to the Troubleshooting B in Group T5-4.
T4-3-1
TRACK REVOLUTION SPEED
Summary: Evaluation:
Measure the track revolution cycle time with the track Refer to the Performance Standard Table in Group
raised off ground. T4-5.
Preparation: NOTE: The measurement data obtained through

1. Adjust the track sag of both side tracks to be the raised track revolution test may have
equal. wide variations. Therefore, the evaluation
2. On the track to be measured, mark one shoe with based on the results obtained from the 20
chalk. m travel speed check described before is
3. Swing the upperstructure 90° and lower the more recommendable.
bucket to raise the track off ground. Keep the
boom-arm angle between 90 to 110° as shown. Remedy:
Place blocks under the machine frame. Refer to the Troubleshooting B in Group T5-4.
CAUTION: Securely support the raised track

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

(122±9 °F).
90 to 110°
Measurement:
NOTE: When jacking up one side track and rotat-
ing it, the track doesn’t rotate at fast speed
though the travel made switch is turned to
Fast Mode. M104-07-067
(Refer to the “Travel Motor Swash Angle Mark
Control” of the SYSTEM / Control System
group in the T/M (Operational Principle).)

Slow Digging
Mode Mode
Fast Digging
Mode Mode
2. Operate the travel control lever of the raised track
to full stroke.
3. Measure the time required for 3 revolutions in
both directions after a constant track revolution
speed is obtained.
4. Raise the other side and repeat the above proce-
dures.
5. Repeat steps 2. to 4. three times and calculate the
average values.
T4-3-2
MISTRACK CHECK
Summary:
1. Allow the machine to travel 20 m (65.6 ft). Meas-
ure the maximum tread deviation from the tread
chord line drawn between the travel start and end Maximum Distance
points to check the performance equilibrium be-
tween both sides of the travel device systems
(from the main pump to the travel motor). Acceleration
2. If measured on a concrete surface, the tread de- Zone:
viation has a trend to decrease. 3 to 5 m
20 m
Preparation:
1. Adjust the track sag of both tracks to be equal.
2. Provide a flat, solid test yard 20 m (65.6 ft) in
length, with extra length of 3 to 5 m (9.8 to 16 ft)
on both ends for machine acceleration and decel- T105-06-03-022
eration.
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above
the ground with the arm and bucket rolled in.
(122±9 °F).
Measurement:
1. Measure the amount of mistracking in both fast,
and slow travel speeds.
Slow Digging
Mode Mode
Fast Digging
Mode Mode
3. Start traveling the machine in the acceleration

zone with the travel levers at full stroke.
4. Measure the maximum distance between a
straight 20 m (65.6 ft) tread chord line and the
tread made by the machine.
5. After measuring the tracking in forward travel, turn
the upperstructure 180° and measure in reverse
travel.
average values.
Evaluation:
T4-5.
Remedy:
T4-3-3
TRAVEL PARKING FUNCTION CHECK
Summary:
To measure the parking brake function on a specified
slope.
Preparation:
1. The surface of the test slope shall be even with a
gradient of 20 % (11.31°).
0.2 to 0.3 m
2. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket fully rolled in.
(122±9 °F).
Measurement: T105-06-03-004
1. Measure the travel parking brake slip amount
while parked.
1-1. Climb the slope and place the travel levers in
neutral.
1-2. Stop the engine.
1-3. After the machine stops, put matching marks
on a track link or shoe, and the track side
frame.
1-4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the
track side frame.
Evaluation:
T4-5.
Matching marks on the track
side frame and shoe when the
machine comes to a stop.
Displacement measured
after 5 minutes.
T105-06-03-006
T4-3-4
SWING SPEED
Summary:
Measure the time required to swing three complete
turns.
Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on
slopes.
3. With the arm rolled out and bucket rolled in, hold The same height as the
the bucket so that the height of the bucket pin is boom foot pin height
the same as the boom foot pin. The bucket must
be empty. T105-06-03-013
NOTE: In case a sufficient space for the measure-

ment is difficult to find, carry out the meas-
urement with the boom fully raised and the
arm fully rolled-in.

(122±9 °F).
CAUTION: Prevent personal injury. Always

make sure that the area is clear and that co-
workers are out of the swing area before
starting the measurement.
Measurement:
Auto-Idle/
Engine Con- Power Mode Work Mode T178-04-03-001
Acceleration
trol Dial Switch Switch
Selector
Digging
Mode
2. Operate swing control lever fully.

3. Measure the time required to swing 3 turns in one
direction.
4. Operate swing control lever fully in the opposite
direction and measure the time required for 3
turns.
average values.
Evaluation:
T4-5.
Remedy:
T4-3-5
SWING FUNCTION DRIFT CHECK
Summary:
Measure the swing drift on the bearing outer circum-
ference when stopping after a 180° full-speed swing.
Preparation:
bearing.
2. Place the machine on flat, solid ground with ample
space for swinging. Do not conduct this test on a
slope. Two Check Marks
3. With the arm rolled out and bucket rolled in, hold
T105-06-03-008
the bucket so that the height of the bucket pin is
the same as the boom foot pin. The bucket must
be empty.
4. Make two chalk marks: one on the swing bearing
and one directly below it on the track frame.
5. Swing the upperstructure 180°.
(122±9 °F).

workers are out of the swing area before T105-06-03-009
Measurement: Measure Difference Between Marks

Auto-Idle/
Engine Con- Power Mode Work Mode
Acceleration
Selector
Digging
Mode
Marking on the Track Frame
2. Operate the swing control lever fully and return it Marking on the Swing Bearing
to the neutral position when the mark on the up-
perstructure aligns with that on the track frame af- T105-06-03-010
ter swinging 180° .
3. Measure the distance between the two marks.
4. Align the marks again, swing 180°, then test in the
opposite direction.
5. Repeat steps 3. to 5. three times each and calcu-
late the average values.
Evaluation:
T4-5.
Remedy:
T4-3-6
SWING MOTOR LEAKAGE
Summary:
Check for upperstructure drift while suspending a
load on a slope.
Preparation:
bearing.
2. Park the machine on a smooth slope with a gradi-
ent of 26.8 % (15°).
3. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=1800 kg (3970 lb)
4. With the arm rolled out, and bucket rolled in, posi- T105-06-03-011
tion the arm top pin height to be level with the
boom foot pin.
5. Swing the upperstructure to position it 90° to the
slope. Make aligning marks on the swing bearing
periphery and track frame using tape, as illus-
trated.
(122±9 °F).
Measurement:
1. Select the following switch position:
Auto-Idle/ Measure Difference Between Marks
Power Mode Work Mode
Acceleration
Switch Switch
Selector
P Mode Digging Mode OFF
2. Maintain the engine at slow idle. After five minutes,

measure the difference between the marks along Marking on the Track Frame
the swing bearing periphery and the track frame. Marking on the Swing Bearing
3. Perform the measurement in both right and left
swing directions.
T105-06-03-010
4. Perform the measurement three times in each di-
rection and calculate the average values.
Evaluation:
T4-5.
Remedy:
T4-3-7
MAXIMUM SWINGABLE SLANT ANGLE
Summary:
With the upperstructure swung 90° to the slope,
check the maximum slant angle on which the upper-
structure can swing to the uphill side.
Preparation:
1. Check that the swing gear and bearing are well
lubricated.
used.
W=1800 kg (3970 lb)
3. With the arm cylinder fully retracted and the
bucket cylinder fully extended, hold the arm top
pin to the position flush with the boom foot pin T105-06-03-011
height.
4. Climb a slope and swing the upperstructure 90° to
the slope.
(122±9 °F).
Measurement:
Engine Auto-Idle/
Control Acceleration
Switch Switch
Dial Selector
Fast Idle P Mode Digging Mode OFF
2. Operate the swing lever to full stroke to swing the

upperstructure to the uphill side.
3. If the machine can swing, measure the cab floor
slant angle.
4. Increase the slope angle and repeat steps 2. and
3. Check both clockwise and counterclockwise.
5. Perform the measurement three times.
Evaluation:
T4-5.
Remedy:
T4-3-8
SWING BEARING PLAY
Summary:
Measure the swing bearing play using a dial gauge to
check the wear of bearing races and balls.
Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con-
firm that bearing rotation is smooth and without
noise.
3. Install a dial gauge on the track frame as shown, Magnetic Dial
using a magnetic base. Base Gauge
T105-06-03-014
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.
NOTE: The measured value will vary depending on Round Trunk

where the magnet base is secured. Se-
cure the magnet base onto the round trunk
or in a position as close to the round trunk
as possible.
T105-06-03-015
Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket so that the height of the bucket pin is
the same as the boom foot pin. Record the dial
gauge reading (h1).
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 (h2).
3. Calculate bearing play (H) from this data (h1 and
h2) as follows:
H=h2-h1
Measurement: (h1) Measurement: (h2)
The same height

as the boom foot
pin height
T105-06-03-017
T105-06-03-007
Evaluation:
T4-5.
T4-3-9
HYDRAULIC CYLINDER CYCLE TIME
1. Measure the cycle time of the boom, arm, and

bucket cylinders.
2. Be sure that the bucket is empty.
Preparation:
1. Keep the condition on measuring as below.
1-1. To measure the cycle time of the boom cylin-
ders: With the arm rolled out and the empty
bucket rolled in, lower the bucket to the ground,
as shown. T105-06-03-018
1-2. To measure the cycle time of the arm cylinder:

With the empty bucket rolled in, position the
arm so that it is vertical to the ground. Lower
the boom until the bucket is 0.5 m (20 in)
above the ground.
1-3. To measure the cycle time of the bucket cylin-
der: The empty bucket should be positioned at
mid-stroke between roll-in and roll-out, so that
0.5 m
the sideplate edges are vertical to the ground.
T105-06-03-019
(122±9 °F).
Measurement:
Engine Auto-Idle/
Switch Switch
Dial Selector
2. To measure cylinder cycle times:

(Cylinder full stroke includes cylinder cushioning
zone.)
2-1. Boom cylinders:
Measure the time it takes to raise the boom, T105-06-03-020
and the time it takes to lower the boom. To do

so, position the boom at one stroke end, then
move the control lever to the other stroke end
as quickly as possible.
2-2. Arm cylinder:
Measure the time it takes to roll in the arm, and
the time it takes to roll out the arm. To do so, Evaluation:
position the arm at one stroke end, then move Refer to the Performance Standard Table in Group
the control lever to the other stroke end as T4-5.
quickly as possible.
2-3. Bucket cylinder: Remedy:
Measure the time it takes to roll in the bucket, Refer to the Troubleshooting B in Group T5-4.
and the time it takes to roll out the bucket. To
do so, position the bucket at one stroke end,
then move the control lever to the other stroke
end as quickly as possible.
3. Repeat each measurement three times and calcu-

T4-3-10
(Blank)
T4-3-11
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 loaded bucket.
2. When testing the dig function drift just after cylin-

der replacement, slowly operate each cylinder to
its stroke end for 10 minutes to purge air. Extended
Retracted
Distance
Distance
Retracted
Preparation: Distance
Same Height
used.
W=1800 kg (3970 lb)
2. Position the arm cylinder with the rod 50 mm (2 in) Bucket Bottom
extended from the fully retracted position.
3. Position the bucket cylinder with the rod 50 mm (2
in) retracted from the fully extended position. T105-06-03-021
4. With the arm rolled out and the bucket rolled in,
hold the bucket so that the height of the bucket
pin is the same as the boom foot pin.
Boom and Bucket Cylinder Retraction
(122±9 °F). Mark Mark
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the bucket, as well as the boom, arm and
bucket cylinders.
3. Repeat step 2. three times and calculate the av- T110-06-03-002
erage values.
Arm Cylinder Extension
Evaluation:
T4-5.
Remedy:
Mark
T110-06-03-001
T4-3-12
• 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. When testing the dig function drift just after cylin-

der replacement, slowly operate each cylinder to
its stroke end for 10 minutes to purge air.
Preparation:
1. The bucket must be empty.
2. Position the arm cylinder with the rod 50 mm (2 in)
retracted from the fully extended position.
3. Position the bucket cylinder with the rod 50 mm (2
in) retracted from the fully extended position.
4. With the arm rolled in and the bucket rolled in.
Lower the boom until the arm tip is 1 m (40 in)
above the ground. 1m
(122±9 °F). T173-04-03-001
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the position of the bottom
of the arm tip, as well as the boom, arm and
bucket cylinders.
3. Repeat step 2. three times and calculate the av- Cylinder Retraction
erage values.
Mark Mark
Evaluation:
T4-5.
Remedy:
T110-06-03-002
T4-3-13
CONTROL LEVER OPERATING FORCE
Summary:
1. Use a spring scale to measure the maximum re-
sistance of each control lever as illustrated.
2. Measure the maximum operating force of the front
attachment control lever.
3. Measure the operating force at the grip center of
each control lever.
Preparation:
Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Measurement:
T107-06-03-003
1. Measure each control lever.
Engine Auto-Idle/
Switch Switch
Dial Selector

3. Operate each boom (raise), arm, and bucket lever

and measure the maximum operating force when
each actuator is relieved. T107-06-03-004
4. Operate the boom (lower) lever in a safe area
while jacking up the machine, and measure the
maximum operating force when it is relieved.
5. Operate the swing lever after securing the bucket
teeth into the ground in order not to swing the ma-
chine, and measure the maximum operating force
when it is relieved.
6. Operate the travel lever after jacking up the track
to measure, and measure the maximum operating
force when operating it.
7. Repeat steps 3. to 6. Three times and calculate
the average values.
Evaluation:
T4-5.
T4-3-14
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.
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 each lever stroke at the lever top from
neutral to the stroke end using a ruler.
3. Repeat step 2. Three times and calculate the av-
erage values.
Evaluation:
T4-5.
T4-3-15
COMBINED BOOM RAISE/SWING FUNC-
TION CHECK
Summary:
Check boom raise and swing movement and speeds
while operating both functions simultaneously.
Preparation:
1. Start the engine and run it at fast idle. Operate the
boom raise function and check to be sure that the
cylinder movement is smooth, with out sticking.
T107-06-03-009
2. With the arm fully rolled out and bucket fully rolled
in, lower the bucket to the ground. The bucket
must be empty.
(122±9 °F).

Measurement:
Engine Auto-Idle/ T107-06-03-010
Switch Switch
Dial Selector
2. Raise the boom and swing simultaneously, both at

full stroke.
3. When the upperstructure rotates 90°, release the
control levers to stop both functions. Measure the
time required to swing 90 and the height(H) of the H
bucket teeth.
average values.
Evaluation: T107-06-03-011

T4-5.
Remedy:
T4-3-16
OPERATIONL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Properly shut down the engine.
2. Press the air release valve on top of the hydraulic
oil tank to release any remaining pressure.
3. Remove the plug from the pilot pump delivery port.
Install adapter (ST 6069) and pressure gauge (ST
6942) on the port.
: 6 mm
4. Start the engine. Confirm that no oil leakage is Plug

observed at the pressure gauge connection.
5. Maintain the hydraulic oil temperature at 50±5 °C T157-07-04-012
(122±9 °F).
Measurement:
Auto-Idle/
Acceleration
Selector
General
Fast Idle P Mode Purpose OFF
Mode
General
Slow Idle P Mode Purpose OFF
Mode
2. Measure the pilot pressure in each specified set-

ting above.
3. Repeat the measurement three times and calcu-
Evaluation:
T4-5.
T4-4-1
Primary Pilot Pressure Adjustment
1
Adjustment:
Adjust the set pressure of relief valve (1) as neces-
sary.
: 22 mm
T1HH-04-04-002
2 3
1. Remove plug (3).
2. Install the estimated necessary number of shims
(2).
3. Tighten plug (3).
: 24.5 N⋅m (2.5 kgf⋅m, 18 lbf⋅ft)
4. Check the relief pressure of relief valve (1).
Reference:Standard Change in Pressure

Change in Relief Pressure T157-05-04-007
Shim Thickness (mm)
kPa (kgf/cm2) (psi)
0.25 78 (0.8) (11)
0.5 147 (1.5) (21)
1.0 294 (3.0) (43)
T4-4-2
SECONDARY PILOT PRESSURE
1
Preparation:
3. Install pressure gauge (ST 6942) and tee (ST
6450) to the end of pilot line (1) at the respective
control valve spool end, as illustrated.
: 14 mm, 17 mm
4. Start the engine. Confirm that no oil leakage is

(122±9 °F).
Measurement:
T1HH-04-04-003
Auto-Idle/
Acceleration
Selector
Digging
Mode
Digging
Slow Idle P Mode OFF
Mode
2. While operating the corresponding control lever

full stroke of the function to be measured, meas-
ure the pilot oil pressure.
Evaluation:
Refer to Performance Standard Table in Group T4-5.
T157-05-04-011
Remedy:
Refer to Troubleshooting B in Group T5-4.
T4-4-3
SOLENOID VALVE SET PRESSURE
Measure the solenoid valve set pressure using both Dr.

EX and a pressure gauge.
Preparation:
3. Disconnect line (1) from the solenoid valve to be
measured. Install hose (Parts Number: 4216453),
tee (ST 6451), adapter (ST 6461), and pressure
gauge (ST 6942) to the disconnected end at the
solenoid valve side, as illustrated.
: 17 mm, 19 mm, 22 mm SC
Connect Dr. EX. Select the monitor function.

SI
SG
5. Maintain the hydraulic oil temperature at 50±5 °C T1HH-01-02-008
(122±9 °F).
Measurement:
Auto-Idle/ Pressure Gauge
Acceleration
Selector
Hose Piping
Digging
Mode
2. Pull the pilot control shut-off lever to LOCK posi-

tion.
3. Operate as instructed below for each measuring Tee Adapter
solenoid valve:
Solenoid Valve SG: Repeat pressing and releas-
ing of the power boost switch. T173-04-04-006
Solenoid Valve SC: Perform a combined opera-
tion of boom raise and arm roll-in. Solenoid Valve Unit
Solenoid Valve SI: Drive the machine, then stop
the machine at the fast mode.
4. Read the values on both Dr.EX and the pressure
gauge.
Evaluation:
The average value read on the pressure gauge shall
be within ±0.2 MPa (±2 kgf/cm2, ±28 psi) of the value
indicated on Dr.EX.
T4-4-4
Solenoid Valve Set Pressure Adjustment Proce-
dure
7
IMPORTANT: Do not loosen the adjusting screw
excessively. 8
The O-ring on the threads may come
off the sealing surface, causing oil
leakage.
Be sure to turn the adjusting screw
less than 2 turns to loosen. T107-06-04-020
The distance between the
lock nut end and screw end
should be 2.0 mm (0.079 in)
1. Mark the end of the adjusting screw with a white or less.
marker for the record of the original position.
(Take care not to touch any part of the screw
threads with the white marker.)
2. Loosen lock nut (7). Turn adjusting screw (8) to
adjust the set pressure of the solenoid valve. 8
3. Retighten lock nut (7).
: 10 mm
: 3 mm 7
: 5 N⋅m (0.5 kgf⋅m, 3.6 lbf⋅ft)
T107-06-05-001
4. Check the set pressure of the solenoid valve.
Reference:Standard Change in Pressure Adjusting Screw

Screw Turns 1/4 1/2 3/4 1
kPa 78 156 234 312
2
(kgf/cm ) (0.8) (1.6) (2.4) (3.2)
Pressure Pressure
(psi) (11) (22) (34) (45) Increase Decrease
W107-02-05-129
T4-4-5
MAIN PUMP DELIVERY PRESSURE
The main pump delivery pressure can also be meas-

ured with the built-in diagnosing system or Dr.EX.
1
Preparation:
1. Shut down the engine properly.
2. Press the air relief valve on top of the hydraulic oil
tank to release any remaining pressure.
3. Remove plug (1) from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Select the monitoring function of the built-in diag-

nostic system (or Dr. EX).
(122±9 °F).
T1HH-04-04-005
Measurement:
Auto-Idle /
Engine Power Mode Work Mode
Acceleration
Control Dial Switch Switch
Selector
Digging
Mode
2. Measure the pressure with the control levers in

neutral.
Evaluation:
T4-5.
Remedy:
T4-4-6
(Blank)
T4-4-7
MAIN RELIEF VALVE SET PRESSURE
Possible to measure with the built-in diagnosing sys-

tem or Dr. EX.
Summary:
Measure the main relief valve setting pressure at the
main pump delivery part. Pressure Check Ports
The main relief pressure can also be measured with
the built-in diagnosing system or Dr.EX.
Preparation:
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069), hose (ST 6943)
and pressure gauge (ST 6941) on the port.
: 6 mm
Select the monitoring function of the built-in diag-

nostic system (or Dr. EX).
(122±9 °F).
T1HH-04-04-005
Measurement:
Power Work Auto-Idle /
Engine Con-
Mode Mode Acceleration
trol Dial
Switch Switch Selector
Dipping
Fast Idle P Mode Mode OFF
2. Slowly operate bucket, arm, and boom control

levers to the stroke ends to relieve each function
one at a time.
3. As for the swing function, secure the upperstruc-
ture so it is immovable. Slowly operate the swing
lever to relieve the swing function.
4. As for the travel function, secure the tracks
against an immovable object. Slowly operate the
travel levers to relieve the travel function.
5. Which power boost switch depressed, then slowly
operate bucket, arm and boom control levers to
the stroke ends to relieve to relieve each function.
(Measure within 8 seconds.)
Evaluation:
T4-5.
T4-4-8
NOTE: If the measured pressures in all circuits is

lower than the specified range, a decrease
in the set pressure of the main relief valve
may be the probable cause. In cases where
the relief pressure of a particular circuit is Main Relief Valve
lower, the probable cause may be some-
thing other than the main relief valve.
Main Relief Set Pressure Adjustment
IMPORTANT: When the high pressure main relief

set pressure is adjusted, the lower
pressure main relief set pressure is
changed. Therefore, be sure to re-
adjust the lower pressure main relief
set pressure after adjusting the high
pressure main relief set pressure.
T1HH-01-02-005
• High Pressure Main Relief Set Pressure Adjustment

1. Loosen lock nut (1). Turn adjusting plug (2) to ad-
1 2 3 4
just the set pressure. After adjusting, tighten lock
nut (1) so that adjusting plug (2) does not turn.
: 32 mm (Lock Nut (1))

: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 19 mm (Adjusting Plug (2))
• Low Pressure Main Relief Set Pressure Adjustment

2. Loosen lock nut (3). Turn adjusting screw (4) to T1HH-03-03-014
adjust the set pressure. After adjusting, tighten
lock nut (3) so that adjusting screw (3) does not
turn.
: 22 mm (Lock Nut (3))

: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
: 6 mm (Adjusting Screw (4)) Adjusting Plug
Adjusting Screw
3. Recheck the set pressure.
Reference:Standard Change in Pressure Pressure

Pressure
Adjusting Plug Increase Decrease
(2) and Adjust-
1/4 1/2 3/4 1
ing Screw (4)
Turns
MPa 4.4 8.8 13.2 17.7 W107-02-05-129
(kgf/cm2) (45) (90) (135) (180)

(psi) (640) (1280) (1920) (2560)
T4-4-9
Swing Relief Valve Set Pressure Adjustment
1. Loosen the lock nut to adjust the adjusting plug.
2. Loosen lock nut (2).

: 41 mm
3. Turn adjusting plug (1) to adjust.

: 27 mm Swing Relief Valve
4. Tighten lock nut (2).

: 41 mm
: 186 N⋅m(19 kgf⋅m, 137 lbf⋅ft)
5. Check the set pressure.
T1HH-01-02-004

Adjusting Plug
1/4 1/2 3/4 1 1 2
Turns
MPa 2.5 5.0 7.5 10.0
(kgf/cm2) (25.5) (51) (76.5) (102)
(psi) (363) (725) (1088) (1450)
T107-02-04-020
Adjusting Plug
Pressure Pressure
Increase Decrease
T157-05-04-023
T4-4-10
Travel Relief Valve Set Pressure Adjustment
ZAXIS330,ZAXIS350H:
1. Loosen the lock nut to adjust the adjusting plug.
2. Loosen lock not (2).

: 19 mm
3. Turn adjusting screw (1) to adjust.

: 6 mm
4. Tighten lock nut (2).

: 19 mm
: 49 N⋅m (5 kgf⋅m, 36 lbf⋅ft)
Travel Relief Valve T1HH-01-02-006
ZAXIS370MTH:
Travel Relief
Valve
NOTE: Standard Change in Pressure

(ZAXIS330, ZAXIS350H)
Adjusting Screw
1/4 1/2 3/4 1
Turns T183-01-02-012
MPa 2.9 5.9 8.8 11.5
(kgf/cm2) (30) (60) (90) (120)
(psi) (427) (853) (1280) (1706)
ZAXIS330,ZAXIS350H: 2 1

(ZAXIS370MTH)
Adjusting Screw
1/4 1/2 3/4 1
Turns
MPa 1.96 3.92 5.88 7.85
(kgf/cm2) (20) (40) (60) (80)
(psi) (284) (569) (853) (1138)
T157-05-04-008
2 1
Adjusting Screw ZAXIS370MTH:
Pressure Pressure
Increase Decrease
T142-05-04-007
W107-02-05-129
T4-4-11
OVERLOAD RELIEF VALVE SET PRES-
SURE
Summary:
1. The circuit pressure must be increased by apply- 4. Select the monitoring function of the built-in diag-
ing an external force while blocking the return cir- nosing system (or Dr.EX). Start the engine. Con-
cuit from the control valve. This measuring firm that no oil leakage is observed at the pres-
method is hazardous and the results obtained with sure gauge connection.
this method are unreliable. 5. Maintain the hydraulic oil temperature at 50±5 °C
2. The oil flow rate used to set the overload relief (122±9 °F).
pressure is far less than that used to set the main
relief pressure. Therefore, measuring the over- Measurement:
load pressure in the main circuit by increasing the 1. Select the following switch positions:
main relief set-pressure more than the overload Auto-Idle /
valve set-pressure is not a proper method. In Acceleration
addition, in case a main relief valve designed to Selector
leak a small quantity of oil before reliving is used, Digging
its pre-leaking start pressure must be increased Fast Idle P Mode OFF
Mode
more than the overload relief valve set-pressure.
However, the pre-leaking start pressure is not al- 2. Slowly operate bucket, arm, and boom control
ways increased more than the overload relief levers to the stroke ends to relieve each function
valve set-pressure as the adjustable upper limit of one at a time.
the main relief valve set-pressure is provided. Ac- 3. Read the pressures on the pressure gauge while
cordingly, the overload relief valve assembly releasing the front functions.
should be removed from the machine and 4. Perform the measurement for the bucket, arm,
checked on a specified test stand at a correct oil and boom, in that order.
flow rate. Some overload relief valves come in 5. Repeat the measurement three times and calcu-
contact with the control valve body to block the oil late the average value for each front function.
passage. When this type of overload relief valve is
checked, the control valve body must be precisely Evaluation:
finished as the test unit. Provide one control valve 1. Performance of the overload relief valves are
other than that on the machine as a test kit. normal if the measured main relief pressures are
3. If the overload relief valve performance must be within the specified value range.
checked on the machine, however, measure the
main relief pressure while releasing each front Refer to the Performance Standard Table in
function respective to the measuring overload re- Group T4-5.
lief valve. And, assume that the overload relief Pressure
valve is functioning correctly if the obtained main Check Ports
relief pressure is within the specified value range.
Measure the main pressure of the front functions
with the built-in diagnosing system or Dr.EX as fol-
lows:
Preparation:
1. Shut down the engine properly.
2. Press the air relief valve on top of the hydraulic oil
tank to release any remaining pressure.
3. Remove the plug from the main pump delivery
port. Install adapter (ST 6069) and pressure
gauge (ST 6934) on the port.
: 6 mm
T1HH-04-04-005
T4-4-12
Overload Relief Valve Set Pressure Adjusting
Procedure
NOTE: In principle, adjust the overload relief valve

set pressure on a test stand.
Adjustment:
Adjust the pressure setting of the overload relief valve
using adjusting screw (2) after loosening lock nut (1).
1. Loosen lock nut (1). 1 2
: 22 mm
2. Turn adjusting screw (2) to adjust the pressure.

: 6 mm
1. Retighten lock nut (1). T1HH-03-03-018
: 22 mm
: 29.5 N⋅m (30 kgf⋅m, 21.5 lbf⋅ft)

Adjusting Screw
4. Recheck the set pressures.
NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
Change MPa 4.4 8.8 13.2 17.7 Pressure Increase Pressure Decrease
2
in Relief (kgf/cm ) (45) (90) (135) (180)
Pressure (psi) (640) (1280) (1920) (2560) W107-02-05-129
T4-4-13
MAIN PUMP FLOW RATE MEASUREMENT
• P-Q Control (Torque Control) 9. Start the engine. Check for any oil leaks at con-
Summary: nections to the pressure gauge. Connect Dr. EX
Main pump performance is checked by measuring and select the monitoring function.
the pump flow rate with a hydraulic tester installed at
the main pump delivery port (one side) to be meas-
ured. Use Dr. EX and a pressure gauge at the same Measurement:
time. 1. Maintain the hydraulic oil temperature at 50±5 °C
(122 ± 9°F)
IMPORTANT: This measurement procedure is a 2. Measure the maximum flow rate.°
simple method. The measured data 3. Select each switch position as follows:
will be lower by approx. 5 % than the Auto-Idle /
accurately measured value. To Acceleration
measure accurately, disconnect the Selector
return circuit from the control valve Digging
and connect it to the hydraulic oil Fast Idle P Mode OFF
Mode
tank.
3. Slowly close the loading valve of the hydraulic
Preparation: tester while relieving the pressure. Measure the
1. Stop the engine. Push the air bleed valve to bleed flow rates and engine speeds at the pressure
air. Connect a vacuum pump to the oil filler port. points specified in the P-Q curve.
NOTE: Operate the vacuum pump while connect- 4. Repeat each measurement three times and calcu-
ing the pump flow rate test line. late the average values.
2. Disconnect the delivery hose from the main pump
(one side) to be measured. Connect pipe (1 or 2)
to the pump delivery port using the split flanges
and bolts which were used to connect the discon-
nected delivery hose.
: 41 mm : 10 mm
3. Connect hose (1 or 2) to hydraulic tester (5) using
test hose (3) and adapter (4). Connect adapter (6),
joint (7), test hose (8) and flange (9) to hydraulic
tester (5).
: 41 mm : 10 mm
4. Connect the delivery hose to flange (9) with split
flanges (10) and bolts (11).
: 10 mm
5. Install a pressure gauge to the main pump to be
measured. (Refer to T4-4-8 Main Relief Pressure
Check.)
: 6 mm
6. Remove regulator pipe (14).
Install hose (ST 6339) (13) to the port for regulator
pipe (14) to be measured.
Install plug (ST 6212) to the port for regulator pipe
(14) not to be measured.
7. Disconnect the vacuum pump. Loosen plug (12)
on the top of the pump casing to bleed the air
from the casing until oil comes out.
8. Fully open the loading valve located on the port-
able tester.
T4-4-14
Evaluation:
1. Convert the measured flow rates to those at the 2. Standard Flow Rate
specified pump speed using the following formu- Refer to T4-5 Operational Performance Standard.
las:
Qc = (Ns × Q) ⁄ Ne
Qc : Converted Flow Rate

Q: Measured Flow Rate
-1
Ns : Specified Pump Speed (1900 min )
Ne : Measured Engine Speed
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
T173-04-04-002
Signal Control Valve

12
13
14
T1HH-01-02-003
T1HH-04-04-010
1- Pipe E (ST 6144) 5- Hydraulic Tester (ST 6299) 9- Flange (ST 6118) 12 - Plug
2- Pipe B (ST 6143) 6- Adapter PF1 × UNF1-7/8 10- Split Flange (ST 6130) 13 - Hose (ST 6339)
(ST 6146)
3- Test Hose (ST 6145) 7- Joint (ST 6330) 11- Bolt (ST 6409) (4 Used) 14- Pipe (2 Used)
4- Adapter PF1 × UNF1-7/8 8- Test Hose (ST 6320)
(ST 6146)
T4-4-15
• P-Q Control by Pump Control Pilot Pressure Signal

(Pilot Pressure Characteristics) Measurement:
Summary: 1. Measure the main pump flow rate controlled by
To check the main pump performance, measure the the pump control pilot pressure signal.
pump flow rate by connecting a portable tester at the
delivery port of the main pump of which the flow rate 2. Maintain the hydraulic oil temperature at 50±5 °C
is to be measured. Dr.EX or a pressure gauge is used (122±9 °F).
for pressure reading purpose in the measurement.
IMPORTANT: This measurement procedure is a Power Work Mode Auto-Idle/
Engine Con-
simple method. The measured data Mode Switch Acceleration
trol Dial
will be lower by approx. 5 % than the Switch Selector
accurately measured value. To Digging
measure accurately, disconnect the Fast Idle P Mode OFF
return circuit from the control valve
and connect it to the hydraulic oil
tank. 4. Adjust the reducing valve set pressure to the
specified pressure shown on the P-Q diagram of
Preparation: the main pump (Pilot Pressure Characteristics) on
1. Refer to steps 1 to 4 on page T4-4-14, connect a page T4-5-5.
portable tester to the main pump to be measured. Measure the flow rate and engine speed at each
specified pressure shown on the P-Q diagram.
2. Disconnect the hoses of port Pi at the regulator on
the main pump to be measured. 5. Repeat the measurement three times and calcu-
Attach plug (ST 6213) in the disconnected hose. late the average values.
: 6 mm, 19 mm
Evaluation:
3. Connect adapters (15) (3 used) to reducing valve
1. Convert the measured pump flow rate into the one
(16).
for the rated pump speed using the following for-
Disconnect hose M at port PC of the pilot filter.
mula.
Connect tee (17) to port PC of the pilot filter. Con-
nect hose M, adapter (13) and hose (14) to tee
(17). Connect hose (14) to port P1 on reducing
valve (16).
Ȁ Qc = Ns × Q / Ne
: 19 mm
Qc : Converted Flow Rate
4. Connect tee (17) to port P2 on reducing valve (16).
Q : Measured Flow Rate
Connect pressure gauge (18) and hose (14) to tee -1
Ns : Rated Pump Speed (1900 min )
(17). Connect hose (14) to the port Pi on the regu-
Ne : Measured Engine Speed
lator.
2. Specified Pump Flow Rate
5. Connect hose (19) and adapter (20) to port T on
Refer to the Performance Standard Table in
reducing valve (16). Connect hose (19) after re-
Group T4-5.
moving plug L from the return pipe .
: 19 mm, 22 mm
6. Disconnect the vacuum pump. Loosen plug (12)

on the pump casing to bleed air from the casing
until oil comes out.
7. Fully open the loading valve on the portable tester.
8. Start the engine. Check the pressure gauge con-

nections for any oil leakage.
T4-4-16
OPERATIONAL PERFORMANCE TEST / Component Test
1, 2 3 4 5 6 7 8 9 10 11
Delivery Hose
(To Control
Valve)
Port Pi
M T173-04-04-002
12
T1HH-04-04-002
T1HH-04-04-009
Reducing Valve Position

Reducing Valve
Return Piping
T
L
20
18
M
P1 P2 19
15 17
To Port Pi on Regulator
14 17 15 13 To Port PC on
16 15 14 Pilot Filter T1HH-04-04-008
1 - Pipe E (ST 6144) 6 - Adapter PF1 × UNF1-7/ 8 11 - Bolt (ST 6409) (4 used) 16 - Reducing Valve (4325439)
(ST 6146)
2 - Pipe B (ST 6143) 7 - Joint (ST 6330) 12 - Plug M 17 - Tee UNF7 / 16 × UNF 7 / 16
3 - Test Hose (ST 6145) 8 - Test Hose (ST 6320) 13 - Adapter UNF 7 / 16 × 18 - Pressure Gauge (ST 6931)
PF 1 / 4 (ST 6069)
4 - Adapter PF1 × UNF1-7 / 8 9 - Flange (ST 6118) 14 - Hose UNF7 / 16 × 19 - Hose UNF 7 / 16 ×
(ST 6146) UNF7 / 16 (4334309) UNF 7 / 16 (4334309)
5 - Potable Tester (ST 6299) 10 - Split Flange (ST 6130) 15 - Adapter PF3 / 8 × 20 - Adapter PF3 / 8 ×
UNF 7 / 16 (4200465) UNF 7 / 16 (4200465)
T4-4-17
Regulator Adjustment
6 5
1
3
2
4
10
T1HH-03-01-002
7 8
1 - Lock Nut (For Minimum 4 - Adjusting Screw(For Maxi- 7 - Lock Nut 9 - Lock Nut
Flow Adjustment) mum Flow Adjustment) (For P-Q Line Adjustment) For P-Q Line Adjustment)
2 - Adjusting Screw (For Mini- 5 - Lock Nut 8 - Adjusting Screw 10 - Adjusting Screw
mum Flow Adjustment) (For Pilot Pressure Char- (For P-Q Line Adjustment) (For P-Q Line Adjustment)
acteristic Adjustment)
3 - Lock Nut (For Maximum 6 - Adjusting Screw
Flow Adjustment) (For Pilot Pressure Char-
acteristic Adjustment)
T4-4-18
Adjustment Procedure Remarks

1. Minimum Flow Rate After loosening lock nut (1), turn 1) Do not tighten adjusting screw
Q adjusting screw (2). Tightening ad- (2) more than one and half
justing screw (2) 1/4 a turn in- turns.
creases the minimum pump flow 2) Securely retighten lock nut (1)
3
rate by 8.21 cm /rev. after adjustment.
Pi
2. Maximum Flow Rate After loosening lock nut (3), turn 1) Do not tighten adjusting screw
Q adjusting screw (4). Tightening ad- (2) more than two turns.
justing screw (4) 1/4 a turn de- 2) Do not attempt to increase the
creases the maximum pump flow maximum flow rate. (Do not turn
3
rate by 10.00 cm /rev. adjusting screw (4) counter-
clockwise.)
3) Securely retighten lock nut (3)
after adjustment.
Pd
3. Pilot Control Characteris- After loosening lock nut (5), turn 1) Do not tighten adjusting screw (6)
tics adjusting screw (6). Tightening ad- more than one turn.
(Pi-Q Line) justing screw (6) 1/4 a turn de- 2) When adjusting screw (6) is
creases the pump flow rate by tightened, the maximum flow rate
3
Q 17.11 cm /rev. decreases. Therefore, after tight-
ening adjusting screw (6), loosen
adjusting screw (4) by the ratio of
2 (adjusting screw (4) turn) to 1
(adjusting screw (6) turn) to main-
tain the maximum flow rate un-
changed. The loosening vs. tight-
ening ratio of 2 to 1 should always
Pi be kept constant.
3) Securely retighten lock nut (5)
after adjustment.
4. Pump Output Torque A. After loosening lock nut (7), turn 1) Do not tighten adjusting screw
(P-Q Line) adjusting screw (8). Tightening (8) more than one turn.
Q adjusting screw (8) 1/4 a turn in- 2) Increase or decrease the flow
creases the pump flow rate by rate. So that the engine is not
3
A 19.85 cm /rev. overloaded.
B. After loosening lock nut (9), turn 3) Securely retighten lock nut (3 or
Pd adjusting screw (10). Tightening 9) after adjustment.
Q adjusting screw (10) 1/4 a turn
increases the pump flow rate by
3
3.73 cm /rev.
B
Pd
NOTE: The change in the pump flow rate shown in

the above table means the change value
per one turn of the engine output shaft.
T4-4-19
SWING MOTOR DRAINAGE
Summary:
To check swing motor performance, measure the
amount of oil draining from the swing motor while
swinging the upperstructure.
NOTE: The amount of drain oil from the swing mo-

tor will change depending on hydraulic oil
temperature.
Maintain hydraulic oil temperature at 50±5 1
°C (122±9 °F).

Also, take care not to fall off the machine
while the measurement.
Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the T157-05-04-014
2
inside of the motor.
2. Properly shut down the engine. Press the air re-
lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the swing motor drain hose (2) at the
hydraulic oil tank end. Install plug (ST 6213) to the
disconnected end on the hydraulic oil tank.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
Preconditions for Measurement:

Power Work Mode Auto-Idle /
Engine Con-
Mode Switch Acceleration
trol Dial
Switch Selector
Digging T1HH-04-04-006
Mode
T4-4-20
Measurement:
1. Amount of Oil Drained While Swinging the Upper-
structure
(1) Fully retract the arm cylinder. Fully extend the
bucket cylinder. Raise the boom so that the
arm tip pin height is the same as the boom foot
pin height. Be sure that the bucket is empty.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start draining oil measure- The same height as
boom foot pin height
ment after the swing speed reaches a constant
maximum speed. The measuring time should
T105-06-03-013
be more than 45 seconds.
(3) Repeat the measurement at least three times
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
2. Amount of Oil Drained While Relieving Swing Mo-

tor Circuit
(1) Thrust the bucket teeth into the ground as il-
lustrated so that the upperstructure does not
rotate when the swing lever is operated full
stroke.
(2) Start the engine. Operate and hold the swing
lever full stroke. Start drain oil measurement
when drain oil starts coming out of the drain
hose end. The measuring time should be more T107-06-06-005
than 45 seconds.
in both clockwise and counterclockwise direc-
tions, and calculate the average values.
Evaluation:
Refer to the Performance Standard Table in group
T4-5.
∗ Conversion of the amount of drain oil measured into

the per-minute value
First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain
oil into the per-minute value using the formula be-
low:
Ȁ ∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds) T107-06-05-008
q : Total amount of drain oil (L)
T4-4-21
TRAVEL MOTOR DRAINAGE
Summary:
1
To check travel motor performance, measure the
amount of oil draining from the travel motor while ro-
tating the travel motor with the measuring side track
jacked up.
NOTE: The amount of drain oil from the travel mo-

tor will change depending on hydraulic oil
temperature.
Maintain hydraulic oil temperature at 50±5
°C (122±9 °F).
Preparation: T157-05-04-014
1. Main hydraulic oil temperature at 50±5 °C (122±9
°F). Rotate the travel motor to warm the inside of ZAXIS330, ZAXIS350H:
the motor.
2
2. Properly shut down the engine. Press the air re-
lease valve (1) on top of the hydraulic oil tank to
release any remaining pressure.
3. Disconnect the travel motor drain hose (2) at the
travel motor end. Install plug (ST 6637) to the dis-
connected end. Connect the drain hose (3/4-
16UN) to the travel motor.
: 22 mm, 27 mm
: 93 N⋅m (9.5 kgf⋅m, 69 lbf⋅ft)
Preconditions for Measurement:

Auto-Idle /
Engine Con- Power Mode Work Mode T1HH-04-04-007
Acceleration
trol Dial Switch Switch ZAXIS370MTH:
Selector
2
Fast Idle P Mode Digging OFF
M183-01-001
T4-4-22
Measurement:
Amount of Oil Drained While Rotating Travel Motor
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 raised track using 90 to 110°
wooden blocks.
(1) Start the engine. Jack up the measuring side

track using the front attachment as illustrated.
(2) Rotate the raised track with the travel lever M104-07-067
operated full stroke. Start measurement after
the track rotation speed reaches a constant
speed. Measure the drain oil amount and the
measuring time.
in both forward and reverse directions, and
calculate the average value.
(4) The measuring time should be more than 45
seconds.
Evaluation:
Refer to Performance Standard Table in group T4-5.
The total performance of the travel motor should be
evaluated by referring to the test results of travel
speed and mistrack.
T157-05-04-019
∗ Conversion of the amount of drain oil measured into
the per-minute value
First measure the amount of drain oil using a cali-

brated container. Then, convert the measured drain
oil into the per-minute value using the formula be-
low:
Ȁ ∆Q = 60 × q / t
Where:
∆Q : Amount of drain oil per minute (L/min)
t : Time measured (seconds)
q : Total amount of drain oil (L)
T4-4-23
(Blank)
T4-4-24
OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE STAN-
DARD TABLE
The standard performance values are listed in the ta- Engine Control Dial : Fast Idle
ble below. Refer to group T4-2 for performance test Power Mode Switch : P Mode
procedures. Values in parentheses are reference val- Auto-Idle / Acceleration Selector: OFF
ues. Work Mode Switch : Digging Mode
The following switch positions shall be selected and Hydraulic Oil Temperature
the hydraulic oil temperature shall be maintained as : 50±5 °C (122±9 °F)
indicated below when measuring performance unless
otherwise specified.
Performance
PERFORMANCE TEST DESIGNATION Remarks
Standard
ENGINE SPEED min -1
Slow Idle Speed 1000±150 Value indicated on Dr. EX.

Fast Idle (Normal) +90
2000 -75 ↑
Fast Idle (With ECO deactivated) +115
2100 -100 ↑
Fast Idle (Relief operation) Boom Raise relief operation
1850 to 2015
Value indicated on Dr. EX.
Fast Idle (E mode) 1900
+120
-100
Fast Idle (HP mode) Boom Raise / Arm Roll-In relief
1950 to 2200 operations.
Auto-idle Speed +135
1200 -100 Value indicated on Dr. EX.
Auto-Acceleration Speed +125
1650 -100 ↑
Warming Up Speed +150
1150 -100 ↑
ENGINE COMPRESSION PRESSURE 2.5 (26, 370) After engine warm up.
MPa (kgf/cm2, psi)
VALVE CLEARANCE (IN,EX) mm 0.4 With engine cold.
NOZZULE INJECTION PRESSURE
MPa (kgf/cm2, psi)
First stage :
18.1 (185, 2630)
Second stage : 22.1 (225, 3200)
INJECTION TIMING (Degrees before TDC) deg. 9°
TRVEL SPPED sec/20 m
Fast Mode ZAXIS330, ZAXIS350H: 13.1±1.0
ZAXIS370MTH : 13.7±1.0
Slow Mode ZAXIS330, ZAXIS350H: 19.0±2.0
ZAXIS370MTH : 22.0±2.0
TRACK REVOLUTION SPEED sec/3 rev
Fast Mode ZAXIS330, ZAXIS350H: 29.0±2.0 LC: 33.0±2.0
ZAXIS370MTH : 35.0±2.0
Slow Mode ZAXIS330, ZAXIS350H: 29.0±2.0 LC: 33.0±2.0
ZAXIS370MTH : 35.0±2.0
MISTRACK
(Both fast and slow travel speed modes) 200 or less
mm/20 m
TRAVEL MOTOR LEAK mm/5 min 0
SWING SPEED sec/3 rev 15.5±1.0
SWING FUNCTION DRIFT mm/180o 1706 or less
SWING MOTOR LEAKAGE mm/5 min 0
MAXIMUM SWINGABLE SLANT ANGLE deg. 21.2 or possibly
more
T4-5-1
Performance
Standard
SWING BEARING PLAY mm 0.2 to 1.25 Allowable Limit: 2.0 to 3.05
HYDRAULIC CYLINDER CYCLE TIME sec 3.2 m Arm
3
1.4 m (PCSA heaped) Bucket
Boom Raise ZAXIS330: 3.4±0.3
ZAXIS350H, ZAXIS370MTH: 3.6±0.3
Boom Lower ZAXIS330: 2.4±0.3
Arm Roll-In 4.4±0.3
Arm Roll-Out 3.2±0.3
Bucket Roll-In 4.0±0.3
Bucket Roll-Out 2.7±0.3
DIG FUNCTION DRIFT CHECK mm/5 min 3.2 m Arm
3
Boom Cylinder (Maximum Reach Position) 20 or less
(Arm Roll-In Position) 5 or less
Arm Cylinder (Maximum Reach Position) 30 or less
Bucket Cylinder (Maximum Reach Position) 20 or less
Bucket Bottom (Maximum Reach Position) 150 or less
CONTROL LEVER OPERATING FORCE HITACHI Lever Pattern
N (kgf, lbf)
Boom Lever 18 (1.8, 13.0)
or less
Arm Lever (ISO Lever Pattern: Swing Lever) 15 (1.5, 10.8)
or less
Bucket Lever 15 (1.5, 10.8)
or less
Swing Lever (ISO Lever Pattern: Arm Lever) 18 (1.8, 13.0)
or less
Travel Lever 28 (2.8, 20.3)
or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern
Boom Lever 105±10
Arm Lever (ISO Lever Pattern: Swing Lever) 84±10
Bucket Lever 84±10
Swing Lever (ISO Lever Pattern: Arm Lever) 105±10
Travel Lever 120±10
COMBINED BOOM RAISE/SWING FUNCTION 3.2 m Arm
3
Time to Swing 90° 1.4 m (PCSA heaped) Bucket
With bucket empty sec
ZAXIS330 : 4.0±0.4
Bucket Teeth Height When Swinging 90° mm
ZAXIS330 : 7200 or more
ZAXIS350H, ZAXIS370MTH: 6500 or more
Boom Raise / Arm Roll-In sec 5.5±0.5 3.2 m Arm
3
T4-5-2
Performance Stan-
dard
PRIMARY PILOT PRESSURE 2
MPa (kgf/cm , psi) +1.0
4.0 -0.5
Engine: Fast Idle +10
(40 -5 570 -71)
+142
Engine: Slow Idle +1.0

3.5 -0
+10 +142
(35 -0, 500 -0)
SECONDARY PILOT PRESSURE MPa (kgf/cm2, psi) 3.4 to 4.0 Value indicated on Dr.EX.
Engine: Fast (Standard Mode) and Slow Idle (34 to 40,483 to 570) (With control lever fully stroked)
SOLENOID VALVE SET PRESSURE Value indicated On
MPa (kgf/cm2, psi) Dr.EX±0.2 (2, 28)
MAIN PUMP PRESSURE MPa (kgf/cm2, psi) +1.5
2.0 -0.7 Value indicated on Dr.EX.
+15 +213
(20 -7 ,284 -100)
MAIN RELIEF VALVE SET PRESSURE
MPa (kgf/cm2, psi)
With Boom Lower / Arm / Bucket Circuit relieved +2.0
+20 +284
(320 -5, 4550 -71)
With Boom Raise Circuit relieved +2.0
+20 +284
(350 -10, 4980 -142)
With Swing Circuit relieved 31.4
+2.30
-0.5
Value indicated on Dr.EX.
+23 +327
(320 -5, 4550 -71)
With Travel Circuit relieved +2.0
+20 +284
(350 -5, 4980 -71)
With Power Boost Circuit relieved +2.0
+20 +284
(350 -10, 4980 -142)
OVERLOAD RELIEF VALVE SET PRESSURE (Reference Values at
MPa (kgf/cm2,, psi) 50L / min)
Boom (Raise/Lower), Arm (Roll-In), +1.0
37.3 -0
Bucket (Roll-In) +10
(380 -0, 5400 -0)
+142
Arm(Roll-Out), Bucket (Roll-Out) +1.0

39.2 -0
+10 +142
(400 -0, 5690 -0)
MAIN PUMP FLOW RATE L/min ҥ Refer to T4-5-4 and T4-5-5
Group.
SWING MOTOR DRAINAGE L/min
With constant maximum speed 0.2 to 0.3
With the motor relieved (2 to 5)
TRAVEL MOTOR DRAINAGE L/min
With the track jacked up 1.4 to 2.1 Allowable Limit :2.6
With the motor relieved 1.4 to 4.0 Allowable Limit :5.0
T4-5-3
MAIN PUMP P-Q CURVE
• Hydraulic P-Q Control (Torque Adjustment) Points on P-Q Line

(Reference: Measured at Test Stand) Delivery Pressure Flow Rate
2
MPa (kgf/cm ) L/min
-1
• Rated Pump Speed: 1900 min (rpm) A 4.9 (50) 272±3
• Hydraulic Oil Temperature: 50±5 °C B 18.0 (184) (269)
C 20.4 (208) 234±6
NOTE: Refer to page T4-4-14. D 22.1 (225) (210)
E 26.4 (269) 180±6
F 34.3 (350) 127±6
The values in parentheses are reference only.
(L/min)
300
A B
250
C
D
200
E
Flow Rate
150
100
50
0
4.9 (50) 9.8 (100) 14.7 (150) 19.6 (200) 24.5 (250) 29.4 (300) 34.3 (350)
T173-04-05-001
Delivery Pressure MPa (kgf/cm 2 )
T4-5-4
• P-Q Control by Pump Control Pilot Pressure Signal
(Pilot Pressure Characteristics) Points on P-Q Line
(Reference: Measured at Test Stand) Pump Control Pressure Flow Rate
2
MPa (kgf/cm ) L/min
-1
• Rated Pump Speed: 1900 min (rpm) A − 73±3
• Hydraulic Oil Temperature: 50±5 °C B 0.78±0.05 (8.0±0.5) 93±3
C 2.94
+0.05
-0.29 (30
+0.5
-.3)
272±3
NOTE: Refer to page T4-4-16.
(L/min)
200
Flow Rate
B
100 A
MPa (kgf/cm 2 )
0 0.98(10) 1.96(20) 2.94(30)
Pump Control Pressure
T4-5-5
INJECTION PUMP
Test Conditions:
1. Injection pump: PE6P120/721LS3000
2. Governor: EP/RSV 200-1350
3. Nozzle and nozzle holder assembly: 105780-8140
(Bosch No. EF8511/9A)
4. Nozzle:Ȁ105780-0000 (Bosch No. DN12SD12T)
5. Nozzle holder: 105780-2080 (Bosch No.
EF8511/9)
6. Nozzle opening pressure:
2
17.2 MPa (175 kgf/cm , 2490 psi)
7. Test fuel: ISO 4113 or SAE J967d
8. Transfer pump pressure:
2
255 kPa (2.6 kgf/cm , 37 psi)
9. Injection pipe: Inner Dia. 3 mm×Outer Dia. 8 mmȍ
LengthȀ600 mm (0.118×0.315ȍ23.6 in)
10. Fuel temperature: 39 to 41 °C (109.2 to 114.8 °F)
11. Overflow valve opening pressure: 255 kPa (2.6
2
kgf/cm , 37.0 psi)
NOTE: The nozzle test injection pressure is 17.2

2
MPa (175 kgf/cm , 2490 psi). However, ac-
tual machine injection pressure at the first /
2
second stage are 18.1 MPa (185 kgf/cm ,
2
2630 psi) and 22.1 MPa (225 kgf/cm , 3200
psi) respectively.
Injection rate adjustment

Average Injection Maximum Variance
Adjusting Pump Speed Rack Position Boost
Rate Between Cylinders Remarks
Point (mm-1) (mm) Pressure (kPa)
(cm3/1000 Stroke) (%)
A 1000 12.8 133.5±1 ±3 More than 160 Basic
C 500 6.8 9.5±3.2 ±15
Governor adjustment
Rack limit
Idle-sub spring setting
Above
Boost Compensator Stroke; 0.7±0.1 mm
Governor spring setting
Pack Position
(mm)
Above
Pump Speed min-1 (rpm) T1HH-04-05-001
T4-5-6
DR. EX MONITOR INDICATING VALUES
Unless specified, test under the following conditions. ∗

NOTE: Items marked ( ) are measurable with the
Engine Speed: Fast Idle built-in diagnostic system.
Work Mode Switch: Digging Mode ∗∗
Items marked ( ) are measurable with the
Power Mode Switch: P mode
built-in diagnostic system. However, it may
Auto-Idle/Acceleration Selector: OFF
be difficult to read the measured value
while operating the machine.
Reference Measured Value

Item Remarks
Value First Second Third Average
PUMP 1 PRESSURE (MPa)
∗
Control Lever in Neutral 2.2
∗
Boom Raise 36.2 When relieving
∗
Boom Lower -
∗
Arm Roll-in 33.3 When relieving
∗
Arm Roll-Out 33.6 When relieving
∗
Bucket Roll-Out 33.3 When relieving
Bucket Roll-In* 35.0 When relieving
Boom Raise + Arm Roll-In +
Bucket Roll-In Combined 33.1 When relieving
∗
Operation
PUMP 2 PRESSURE (MPa)
∗
Control Lever in Neutral 2.0
∗
∗
Boom Lower -
∗
∗
∗
∗
Bucket Roll-In 2.2 When relieving
Bucket Roll-In Combined 32.6 When relieving
∗
Operation
T4-5-7

Item Remarks
PUMP 1 PUMP CONTROL
PRESSURE (MPa)
∗
Control Lever in Neutral 0
∗
∗
Boom Lower -
∗
∗
∗
∗
Bucket Roll-In 3.40 When relieving
Boom Raise + Arm Roll-In
+ Bucket Roll-In Combined 3.36 When relieving
∗
Operation
PUMP 2 PUMP CONTROL
PRESSURE (MPa)
∗
Control Lever in Neutral 0
∗
∗
Boom Lower -
∗
∗
∗
∗
Bucket Roll-In 0 When relieving
Bucket Roll-In Combined Op- 3.50 When relieving
∗
eration
T4-5-8

Item Remarks
TARGET ENGINE SPEED (min-1)
∗
Fast Idle 1850
Fast Idle
∗ 1950
(When operating a control lever)
∗
Fast Idle (HP Mode) 2050 With Boom
Raise relieved
∗
Fast Idle (E Mode) 1750
∗
Auto-Idle 1050
∗
Slow Idle 850
ACTUAL ENGINE SPEED (min-1)
∗
Fast Idle 2000
Fast Idle
∗ 1950
∗
Raise relieved
∗
∗
Auto-Idle 1220
∗
Slow Idle 1000
ENGINE SPEED DEVIATION
(min-1)
∗
Fast Idle 162
Fast Idle
∗ -4
∗
Raise relieved
∗
∗
Auto-Idle 170
∗
Slow Idle 152
EC ANGLE (Volt)
∗
Minimum 2.55
∗
Maximum 3.14
DIAL ANGLE (Volt)
∗
Minimum 0.37
∗
Maximum 4.17
T4-5-9

Item Remarks
BOOM RAISE PILOT
∗ 4.07 When relieving
CONTROL PRESSURE (MPa)
ARM ROLL-IN PILOT
∗ 4.07 When relieving
CONTROL PRESSURE (MPa)
SWING PILOT CONTROL
∗ -
PRESSURE (MPa)
TRAVEL PILOT CONTROL
∗ 3.40
PRESSURE (MPa)
FRONT ATTACHMENT “ON-OFF” is dis-
∗ -
CONTROL PRESSURE (MPa) played
PUMP 2 PROPORTIONAL
3.92
VALVE OUTPUT (MPa)
P TORQUE PROPORTION- Engine Slow
1.67
AL VALVE OUTP (MPa) Idle and Travel
ARE REGENERATIVE
PROPORTIONWAL VALVE
OUTPUT (MPa)
Lever in Neutral 1.64
Swing, Arm Roll-In and
Boom Raise Combined 2.72
Operation
POWER DIGGING CONTROL
PRESSURE (MPa)
During Operation 2.92
When Relieving Boom Raise
2.92
Circuit
TRAVEL MOTOR CONTROL Travel and Travel
2.92
PRESSURE (MPa) mode Switch (fast)
EC MOTOR POSITION With Arm Roll-In
332
relieved
T4-5-10

Operational Performance Test: Section 4

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Operational Performance Test: Section 4

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SECTION 4

Use operational performance test procedures to

Purpose of Performance Tests Precautions for Evaluation of Test Data

“Performance Standards” is shown in tables to

Observe the following rules in order to carry out

4. MAKE PRECISE MEASUREMENTS

2. Measure the engine speeds in each mode.

NOTE: Measure the engine speed before perform-

2. Warm up the machine until the engine coolant

IMPORTANT: Never attempt to the readjust stop-

2. Check exhaust gas color and the amount of blow-

3. Check for abnormalities in the intake system, in-

2. Confirm that the batteries are charged properly.

3. Run the engine until the coolant temperature

NOTE: Unless the fuel delivery pipes are discon-

5. Install an adapter (Isuzu 5-8840-2622-0) and

2. Repeat measurement three times for each cylin-

2. Remove the head cover.

Cylinder NO. No.1 No.2 No.3 No.4 No.5 No.6

3. Turn the crankshaft 360°. Align the TC mark with

Evaluation: Rocker Arm

1. Loosen the adjusting screws (A) and (B) lock nuts

2. Insert the feeler gauge set at the specified dimen-

3. After adjusting, retighten the lock nuts on adjust-

: 22 N⋅m (2.2 kgf⋅m 16 lbf⋅ft)

4. Tighten adjusting screws (B) completely with the

5. Loosen gradually adjusting screws (B) until the

6. After adjusting, retighten the lock nuts on adjust-

: 22 N⋅m (2.2 kgf⋅m 16 lbf⋅ft)

: 34 N⋅m (3.5 kgf⋅m, 25.5 lbf⋅ft)

1-3. Install the nozzle holder to the nozzle tester.

2-3. Install the holder (tools) to the nozzle holder.

2-6. Install the dial gauge assembly to the nozzle

NOTE: Secure the dial gauge to measure the

2-8. Loosen the plug of the retaining nut to bleed

1. Injection Pressure at First Stage:

2-2. With the needle valve at full stroke, release the

NOTE: The valve indicated on the dial gauge M+0.05 mm

2-4. Operate the nozzle tester again in order to in-

2. Spray Pattern T1HH-04-02-014

• No stray sideways sprays should be seen.

• During initial injection stage, spray size should be

• There should be no drips found.

• Injection spray angle must be normal.

3. Oil Tight Condition

3. When adjusting the injection pressures at the first

NOTE: Use a micrometer to measure shim thick-

2. Check if the mark on the coupling of the injection T1HH-04-02-004

Injection Coupling Pointer

3. If not, align them by loosening the adjusting bolt

4. With the matching mark on the crank pulley

on the coupling of the injection pump aligns with Adjusting

3. Start traveling the machine in the acceleration

Preparation: NOTE: The measurement data obtained through

CAUTION: Securely support the raised track

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

1. Select the following switch positions:

3. Start traveling the machine in the acceleration

NOTE: In case a sufficient space for the measure-

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

CAUTION: Prevent personal injury. Always

2. Operate swing control lever fully.