SECTION 4

OPERATIONAL
PERFORMANCE TEST

CONTENTS
Group 1 Introduction Control Lever Operating Force .............. T4-4-14
Operational Performance Tests ............. T4-1-1 Control Lever Stroke ............................. T4-4-15
Preparation for Performance Boom Raise/Swing Combined
Test ..................................................... T4-1-2 Operation Check.................................. T4-4-16

Group 2 Standard
Operational Performance Group 5 Component Test
Standard Table .................................... T4-2-1 Primary Pilot Pressure........................... T4-5-1
Main Pump P-Q Diagram....................... T4-2-4 Secondary Pilot Pressure ...................... T4-5-3
Sensor Activating Range ....................... T4-2-5 Main Relief Valve Set Pressure ............. T4-5-4
Overload Relief Valve Set Pressure....... T4-5-10
Group 3 Engine Test Main Pump Flow Rate Measurement ..... T4-5-14
Engine Speed........................................ T4-3-1 Swing Motor Drainage ........................... T4-5-18
Engine Compression Pressure .............. T4-3-2 Travel Motor Drainage ........................... T4-5-20
Valve Clearance .................................... T4-3-4
Nozzle Check ........................................ T4-3-6 Group 6 Adjustment
Injection Timing ..................................... T4-3-8 Engine Speed Adjustment and
Engine Learning .................................. T4-6-1
Group 4 Excavator Test Boom Lowering Method
Travel Speed......................................... T4-4-1 when Engine Stalling ........................... T4-6-2
Track Revolution Speed ........................ T4-4-2 Check of Governor Lever and
Mistrack Check...................................... T4-4-3 Fuel Cut Lever Position ....................... T4-6-4
Travel Motor Leakage............................ T4-4-4 Assembly and Adjustment of Link for
Swing Speed ......................................... T4-4-5 Arm Angle Sensor (EX75UR-5) ............ T4-6-6
Swing Function Drift Check ................... T4-4-6 Initial Setting of the Angle Sensor .......... T4-6-7
Swing Motor Leakage ............................ T4-4-7 Initializing the Depth Limit Control
Maximum Swingable System (EX75UR-5) ............................. T4-6-8
Slant Angle .......................................... T4-4-8
Swing Bearing Play ............................... T4-4-9
Hydraulic Cylinder Cycle Time............... T4-4-10
Dig Function Drift Check........................ T4-4-12

197T-4-1
(Blank)

197T-4-2
 OPERATIONAL PERFORMANCE TEST / Introduction
OPERATIONAL PERFORMANCE TESTS
Use operational performance test procedures to quan-
titatively check all systems and functions on the ma-
chine.

Purpose of Performance Tests Precautions for Evaluation of Test Data

1. To evaluate not only that the test data are correct,
1. To comprehensively evaluate each operational but also in what range the test data are.
function by comparing the performance test data
with the standard values. 2. Be sure to evaluate the test data based on the
machine operation hours, kinds and state of work
2. According to the evaluation results, repair, adjust, loads, and machine maintenance conditions.
or replace parts or components as necessary to
restore the machine's performance to the desired The machine performance does not always deteriorate
standard. as the working hours increase. However, the machine
performance is normally considered to reduce in pro-
3. To economically operate the machine under opti- portion to the increase of the operation hours.
mal conditions. Accordingly, restoring the machine performance by
repair, adjustment, or replacement shall consider the
Kinds of Tests number of the machine's working hours.

1. Base machine performance test is to check the Definition of “Performance Standards”

operational performance of each system such as
engine, travel, swing, and hydraulic cylinders.
1. Operation speed values and dimensions of the
2. Hydraulic component unit test is to check the op- new machine.
erational performance of each component such as
hydraulic pump, motor, and various kinds of 2. Operational performance of new components ad-
valves. justed to specification. Allowable errors will be in-
dicated as necessary.
Performance Standards

“Performance Standards” is shown in tables to evalu-

ate the performance test data.

T4-1-1
 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 oil
or water leaks, loose bolts, cracks and so on, be-
fore 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.
(3) If required, rope off the test area and provide
signboards to keep unauthorized personnel
away. T105-06-01-003

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 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 acci-
dents 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 escap-
ing oil. Pay special attention to this when re-
moving hydraulic pipings.
T105-06-01-004

4. MAKE PRECISE MEASUREMENTS

(1) Accurately calibrate test instruments in ad-
vance to obtain correct data.
(2) Carry out tests under the exact test condi-
tions prescribed for each test item.
(3) Repeat the same test and confirm that the
test data obtained can be procured repeat-
edly.
Use mean values of measurements if neces-
sary.

T4-1-2
 OPERATIONAL PERFORMANCE TEST / Standard
OPERATIONAL PERFORMANCE
STANDARD TABLE
The standard Performance values are listed in the
table below. Refer to the Group T4-3 to T4-5 for
performance test procedures. Values indicated in
parentheses are reference values.
* The following switch positions shall be selected:
Engine Control Dial: Fast Idle
E Mode Switch: OFF
Oil Temperature: 50±5 °C(122±9°F)

EX75UR-5 EX75US-5
Reference
PERFORMANCE TEST DESIGNATION (Performance (Performance Remarks
Page
Standard) Standard)
ENGINE SPEED min-1 T4-3-1
Fast Idle(Normal) 1920±100 ←
E mode switch:
Fast Idle(When relieving) 1950±100 ←
Off
E mode switch:
Fast Idle(E Mode) 1800±50 ←
Off
Slow Idle +100
1050 -50 ←
Auto-Idle 1200±100 ←
ENGINE COMPRESSION PRESSURE 3.0 or more
← T-4-3-3
(After warming up) MPa (kgf/cm2) (30 or more)
With the engine
VALVE CLEARANCE(IN, EX) mm 0.4 ← T4-3-4
cold
NOZZULE INJECTION PRESSUREMPa (kgf/cm2) 18.1(185) ← T4-3-6
INJECTION TIMING(Degrees before TDC) deg. 13° ← T4-3-8
TRAVEL SPEED sec/20 m T4-4-1
Fast Speed 22.6±2.0 ←
Slow Speed 24.8±2.5 ←
TRACK REVOLUTION SPEED sec/3 rev ← T4-4-2
Fast Speed 14.6±1.0 ←
Slow Speed 22.6±2.0 ←
MISTRACK(in fast and slow speed mode)
200 or less ← T4-4-3
mm/20 m
TRAVEL MOTOR LEAKAGE mm/5 min 0 ← T4-4-4
SWING SPEED sec/3 rev 19.0±1.5 ← T4-4-5
SWING FUNCTION DRIFT CHECK mm /180° 250 or less ← T4-4-6
SWING MOTOR LEAKAGE mm/5 min 0 ← T4-4-7
18.5 or possibly
MAXIMUM SWINGABLE SLANT ANGLE deg. ← T4-4-8
more
Allowable Limit:
SWING BEARING PLAY mm (0.8 to 1.0) ← T4-4-9
(2.0)

T4-2-1
 OPERATIONAL PERFORMANCE TEST / Standard

EX75UR-3 EX75US-3
PERFORMANCE TEST Reference
(Performance (Performance Remarks
DESIGNATION Page
Standard) Standard)
HYDRAULIC CYLINDER CYCLE 1.81 m Arm 1.62 m Arm 0.28 m3 (PCSA heaped) T4-4-10
TIME sec Bucket
Boom Raise 3.8±0.4 3.4±0.4
Boom Lower 2.9±0.4 2.5±0.4
Arm Roll-In 3.5±0.4 3.0±0.4
Arm Roll-Out 3.1±0.4 2.7±0.4
Bucket Roll-In 3.5±0.4 ←
Bucket Roll-Out 2.2±0.4 ←
Offset Left 3.9±0.5
(Switch Control) (4.5±0.5)
Offset Right 3.9±0.5
(Switch Control) (4.5±1.1)
Blade Raise 2.1±0.4 ←
Blade Lower 2.5±0.4 ←
DIG FUNCTION DRIFT CHECK 1.81 m Arm 1.62 m Arm 0.28 m3 (PCSA heaped) T4-4-12
mm/5 min Bucket
Boom Cylinder 10 or less ←
Arm Cylinder 20 or less ←
Bucket Cylinder 10 or less ←
Bucket Bottom 100 or less ←
Offset Cylinder 10 or less ←
Blade Cylinder 5 or less ←
CONTROL LEVER OPERATING ← HITACHI Lever Pattern T4-4-14
FORCE N (kgf)
Boom Lever 19.6 (2.0) ←
or less
Arm Lever 16.7 (1.7) ←
or less
Bucket Lever 16.7 (1.7) ←
or less
Swing Lever 19.6(2.0) ←
20.or less
Travel Lever 24.5 (2.5) ←
24.6 or less
Blade Lever 33.3 (3.4) ←
or less
Offset Pedal (Right/Left) 147.1 (15.0) ←
or less
CONTROL LEVER STROKE mm HITACHI Lever Pattern T4-4-15
Boom Lever 105±10 ←
Arm Lever 83±10 ←
Bucket Lever 83±10 ←
Swing Lever 105±10 ←
Travel Lever 115±10 ←
Blade Lever 60±10 ←
Offset Pedal (Right/Left) 14±10 ←

NOTE: 1 kgf = 9.8 N

1 kgf/cm2 = 0.09807 MPa

T4-2-2
 OPERATIONAL PERFORMANCE TEST / Standard

EX75UR-5 EX75US-5
Reference
PERFORMANCE TEST DESIGNATION (Performance (Performance Remarks
Page
Standard) Standard)
COMBINED BOOM RAISE/SWING FUNCTION
T4-4-16
CHECK; With Bucket Empty sec
(Both Normal and Precise Swing) 0±0.3
Bucket Tooth Height (H) mm
(Both Normal and Precise Swing) 3600 or more
Bucket/Cab Collision Prevention System
Cab Front mm 200+100-30
Cab Side mm 220+50-40
HYDRAULIC COMPONENT PERFORMANCE
PRIMARY PILOT PRESSURE MPa (kgf/cm2) T4-5-1
+1.0 +1.0
3.73 -0.5 (38 -
Fast Idle
5 )
Slow Idle 3.43+1.0-0.5 (35+10-5)
SECONDARY PILOT PRESSURE MPa (kgf/cm ) 2
3.33 to 3.92
T4-5-3
(at both fast idle(normal)and slow idle speed) (34 to 40)
MAIN RELIEF VALVE SET PRESSURE
T4-5-4
MPa (kgf/cm2)
25.5±1.0
Front Attachment
(260±10)
31.4±1.0
Travel
(320±10)
22.6±1.0
Swing
(230±10)
22.6±1.0
Blade
(230±10)
MAIN PUMP FLOW RATE L/min - T4-5-14
SWING MOTOR DRAINAGE - Allowable
T4-5-18
(at constant speed) L/min 0.3 or less Limit: 1.0
Allowable
(at relief pressure) L/min 1.0 or less
Limit: 2.0
TRAVEL MOTOR DRAINAGE Allowable
T4-5-20
(while being raised off ground) L/min 0.5 to 1.5 Limit: 2.0
Allowable
(at relief pressure) L/min (2.0 to 4.0)
Limit: (5.0)

NOTE: 1 kgf = 9.8 N

1 kgf/cm2 = 0.09807 MPa

T4-2-3
 OPERATIONAL PERFORMANCE TEST / Standard
MAIN PUMP P-Q DIAGRAM

• Pump Model : AP2D36 P-Q Point

• Rated Pump Speed : 1900 min-1(rpm) MPa (kgf/cm2) L/min
• Hydraulic Oil Temperature : 50±5 °C (122±9°F) 9.8 (100) 64
31.4 (320) 7.5
*1 : Digging
*2 : Travel
NOTE: 1 kgf = 9.8 N
1 kgf/cm2 = 0.09807 MPa

80

70

2
60

50
L/min

40

30

20

10

0
50 100 150 200 250 300 350
T197-04-05-01
(P1+P2) / 2 kgf/cm2

T4-2-4
 OPERATIONAL PERFORMANCE TEST / Standard
SENSOR ACTIVATING RANGE
1. Checking Method

• Hydraulic Oil Temperature:

50±5 °C (122±9 °F)

• Unless specified:
Engine Control Dial: Fast Idle Position
E Mode Switch: OFF
Auto-Idle Switch: OFF

• Monitor using Dr. EX.

2. Sensor Activating Range

Item Engine Speed Specification

Slow Idle 0.3 to 1.0 V
Engine Control Dial (Sensor)
Fast Idle 4.0 to 4.7 V
Slow Idle 2.5 to 2.7 V
EC Sensor Fast Idle (Lever in neutral) 3.2 to 3.4 V
Fast Idle (Lever in the operating position) 3.3 to 3.5 V

T4-2-5
 OPERATIONAL PERFORMANCE TEST / Standard
(Blank)

T4-2-6
 OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE SPEED
Summary:
1. 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 performance data will be
unreliable.

Preparation:
1. Install the speed pickup to the injection pipe.

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

stopper.

Measurement:
1. No Load Engine Speed
1-1. Measure the slow idle speed, fast idle speed
(in normal mode), and fast idle speeds (in E
mode).
1-2. Select the switch positions as shown below.
Engine Control Auto-Idle
E Mode Switch
Dial Switch
Slow Idle OFF OFF
Fast Idle
OFF OFF
(Normal Mode)
Fast Idle
ON OFF
(E Mode)

2. No Load Auto-Idle Speed

2-1. Select the switch positions as shown below.
Engine Control Auto-Idle
E Mode Switch
Dial Switch
Fast Idle OFF ON

2-1. Start the engine and operate the bucket lever.

2-2. Return the lever to the neutral position. Wait
approx. 4 seconds until the engine speed is
automatically reduced. Then, measure the
reduced engine speed.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to the Troubleshooting B in Group T5-4.

T4-3-1
 OPERATIONAL PERFORMANCE TEST / Engine Test
ENGINE COMPRESSION PRESSURE
Summary:
1. Measure compression pressure in the cylinders to
check for a decline in engine power.

2. Check exhaust gas color. Keep track of engine oil

consumption.

3. Check for abnormalities in the intake system,

including the air filter.

Preparation:
1. Confirm that valve clearances are correct.

2. Confirm that the batteries are charged properly.

T105-06-02-001
3. Run the engine until the coolant temperature
gauge reaches the operating range.

4. Stop the engine. Remove glow plugs (4 used)

from each cylinder.

5. Install an adaptor (Isuzu: 5-8531-7001-0) and

compression gauge in place of the glow plug in
one cylinder. (Be sure to sufficiently tighten the
adaptor 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

cylinder and calculate the mean values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to engine shop manual.

T4-3-2
 OPERATIONAL PERFORMANCE TEST / Engine Test
(Blank)

T4-3-3
 OPERATIONAL PERFORMANCE TEST / Engine Test
VALVE CLEARANCE
Summary:
1. Perform the measurement when the engine is
cool.

2. Before starting work, clean the head cover

mounting area to avoid contamination in the
engine. TDC Mark Pointer

Preparation:
1. Locate the top dead center (TDC) in the
compression stroke.
Align the TDC mark on the crank pulley with the
pointer located on the timing gear case as
illustrated. Piston No.1(or piston No.4) is now
positioned at the TDC in its compression stroke.

2. Remove the head cover.

Crank Pulley T197-04-02-001

3. Move push rods for the intake and exhaust valves

on the No.1 cylinder up and down by hand. If any
clearances on the both ends of the push rods are
found, piston No.1 is positioned at TDC in the
compression stroke. (If the exhaust valve of
cylinder No.1 is pushed down, piston No.4 is
positioned at TDC in the compression stroke.
Start measurement from the cylinder (No.1 or
No.4) positioned at TDC in the compression
stroke.

Measurement:

1. Insert a thickness gauge into the clearance

between the rocker arm and the valve stem end to
measure the valve clearance.
T107-02-12-005

NOTE: The cylinders are aligned from No.1 to No.4

in that order, as viewed from the fan side .

T4-3-4
 OPERATIONAL PERFORMANCE TEST / Engine Test
2. When the measurement is started from No.1
cylinder, perform the same measurement to all
valves indicated with the mark “!” in the table
below. (When the measurement is started from
No.4 cylinder, perform the measurement in the
valves shown with mark “×”.)

Cylinder No. No.1 No.2 No.3 No.4

Valve locations I E I E I E I E
When the measurement is
! ! ! !
started from No.1 cylinder
When the measurement is
× × × ×
started from No.4 cylinder

3. Rotate the crankshaft 360°. Align the TDC mark

with the pointer. Then, continue measurement of
other valves in the same way.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Adjustment:
If the measurement results are out of specification,
adjust the valve clearance in the same order of
measurement.

1. Loosen the adjusting screw lock nuts for the

rocker arms. Insert the thickness gauge set at
0.35 mm (0.014 in), adjust the adjusting screws.

2. After adjusting, retighten the lock nuts to the

specification.
Recheck the valve clearance after the lock nuts
are tightened.

: 25.5±4.9 N·m
(2.6±0.5 kgf·m, 18.8±3.6 lbf·ft)

T4-3-5
 OPERATIONAL PERFORMANCE TEST / Engine Test
NOZZLE CHECK
Summary:
1. Check the injection pressure and the spray
pattern with a nozzle tester.

2. Before starting work, clean the nozzle holder

mounting area to avoid contamination in the
engine.

Preparation:
1. Remove the nozzle holders.
Remove all nozzle holders and fuel injection
pipings from the engine.

2. Attach a nozzle holder to the nozzle tester.

Measurement:

CAUTION: Never touch spray directly. The

fuel spray from the nozzle may penetrate the
skin, resulting in serious injury. If fuel
penetrates into the blood stream, it may
cause blood toxication.

1. Injection pressure
After attaching the nozzle holder to the nozzle
tester, strongly make several strokes of the tester
to inject fuel. Then, while operating the tester at
approx. 60 time strokes a minute, measure the T107-06-02-006

fuel injection pressure.

If adjustment is required, loosen the lock nuts and
adjust the adjusting screws. Turn clockwise to
increase the pressure, and counterclockwise to
decrease the pressure.

2. Spray pattern
For this test, turn the pressure tester knob to
bypass the pressure gauge. Attach the nozzle
holder to the nozzle tester. Strongly make several
strokes of the tester and check the fuel spray
pattern.

NOTE: Use clean diesel oil.

T4-3-6
 OPERATIONAL PERFORMANCE TEST / Engine Test
Evaluation:
1. Refer to Performance Standard Table in Group
Normal
T4-2.

2. Spray Pattern
• Large-size spray should not be visible to the
naked eye.
• No stray sideways sprays should be seen.
• During initial injection stage, spray size should be
fine and injected intermittently.
• There should be no drips found.
• Injection spray angle must be normal.

T102-02-11-005
3. Oil Tight Condition
No fuel leaks.
Abnormal

T102-02-11-006

Adjustment: Shim
• Use the adfusting shims to adjust the pressure.
Increasing the number of shims increases the
pressure.
Decreasing the number of shims decreases the
pressure.

T152-04-02-001

T4-3-7
 OPERATIONAL PERFORMANCE TEST / Engine Test
INJECTION TIMING
Inspection:
1. Position No.1 piston to the top dead center. Turn
the crank pulley in the direction of rotation TDC Mark Pointer
(clockwise as seen from the front of the engine) to
set “TDC” mark on the crank pulley under the
“pointer”, located on the timing gear case.

2. Turn the crank pulley at approx. 30 degrees

counterclockwise.

3. Remove the injection piping from No.1 cylinder.

4. Remove the delivery valve holder for No.1

Crank Pulley T197-04-02-001
cylinder from the injection pump to pull the
delivery valve and the spring out. Reinstall the
delivery valve holder.
: 29 N⋅m Delivery Valve Spring
(3 kgf⋅m, 21.7 lbf⋅ft) Holder

5. While supplying fuel with the feed pump, turn the

Delivery Valve
crank pulley slowly clockwise just until fuel cannot
be seen from the top of the delivery valve hole.
This is the position where the injection starts.

Adjustment:
1. Turn the crank pulley so that the pointer comes
just above the correct timing position (13 degrees T105-02-12-006
before the TDC) on the crank pulley.
Injection Pump

2. Loosen the mounting nuts of the injection pump.

3. When advancing timing, tilt the injection pump

outward against the cylinder body.
When delaying timing, tilt the injection pump
inward against the cylinder body. Nut

NOTE: The angle changes 2 degrees when the

alignment mark separaters for 1 mm.

Alignment Mark T197-04-02-002

T4-3-8
 OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL SPEED
Summary:
To totally check the travel driving system perform-
ance (between the main pump and the travel motor)
by measuring the time required to travel a 10 m (32.8
ft) test track.

Preparation:
1. Adjust the track sag on both side tracks equally.
2. Prepare a flat and solid test track 10 m (32.8 ft) in
length with extra length of 3 to 5 m (9.8 to 16 ft) on
both ends for machine acceleration and decelera-
tion. Arm Rolled-In, Bucket Rolled-In
3. Hold the bucket 0.3 to 0.5 m (12 to 20 in) above End
Bucket Height: 0.3 to 0.5 m
the ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C
Start
(122±9 °F). Deceleration Zone
20 m
3 to 5 m
Measurement:
Acceleration
1. Measure in both slow and fast travel modes. Zone 3 to 5 m
2. Select the following switch positions:
Travel Mode Engine Control E Mode Auto-Idle
Switch Dial Switch Switch T105-06-03-001

Slow Mode Fast Idle OFF OFF

Fast Mode Fast Idle OFF OFF

3. Start traveling the machine in the acceleration

zone with the travel levers fully stroked.
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 in the same way.
6. Repeat steps 4. to 5. three times in each direction
and calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-1
 OPERATIONAL PERFORMANCE TEST / Excavator Test
TRACK REVOLUTION SPEED
Summary:
To totally check the travel driving system perform-
ance (between the main pump and the travel motor)
by measuring the track revolution cycle time with the
track raised off ground.

Preparation:
1. Adjust the track sag of both side tracks equally.
2. Mark one shoe with a piece of cloth or chalk on
the track to be measured.
CAUTION: Securely support the raised track
using wooden blocks.
3. Swing the upperstructure 90° and lower the
bucket to raise the track off the ground. Keep the
boom-arm angle between 90 to 110° as shown.
4. Maintain the hydraulic oil temperature at 50±5°C
(122±9°F).

Measurement:
1. Measure in both slow and fast travel modes.
2. Select the following switch positions:
Travel Mode Engine Control E Mode Auto-Idle
90 to 110°
Switch Dial Switch Switch
Slow Mode Fast Idle OFF OFF
Fast Mode Fast Idle OFF OFF

3. Operate the travel control lever of the raised track

to full stroke.
M104-07-067
4. After a constant track revolution speed is obtained,
measure the time required for 3 revolutions in
both directions.
5. Raise the other side and repeat the above proce-
dures.
6. Repeat steps 3. to 5. three times and calculate the
average values.

Evalution:
Refer to Performance Standard Table in Group T4-2.

NOTE: The measurement data obtained through

the raised track revolution test may vary.
Therefore, the evaluation based on the
results obtained from the 20 m (65.6 ft)
travel speed check described before is
recommended.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-2
 OPERATIONAL PERFORMANCE TEST / Excavator Test
MISTRACK CHECK
Summary
1. To check the performance equilibrium between
both sides of the travel device systems (between
the main pump and the travel motors) by measur-
ing the maximum tread deviation from the tread
chord line drawn between the travel start and end
points after traveling the machine 20 m (65.5 ft).
2. If measured on a concrete surface, the tread de-
viation has a tend to decrease.

Preparation: Maximum Distance

1. Adjust the track sag of both tracks equally.
2. Prepare a flat and solid test track 20 m (65.5 ft) in
length with an extra length of 3 to 5 m (9.8 to 16 ft)
Acceleration
on both ends for machine acceleration and decel- Zone:
eration. 20 m
3 to 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.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement: T105-06-03-002
1. Measure in both slow and fast travel modes.
2. Select the following switch positions:
Travel Mode Engine Control E Mode Auto-Idle
Switch Dial Switch Switch
Slow Mode Fast Idle OFF OFF
Fast Mode Fast Idle OFF OFF

3. Start traveling the machine in the acceleration

zone with the travel levers fully stroked.
4. Measure the maximum distance between a
straight 20 m (65.5 ft) tread chord line and the
tread made by the machine.
5. After measuring in forward travel, turn the upper-
structure 180° and measure in reverse travel in
the same method.
6. Repeat steps 3. to 5. three times in each direction
and calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-3
 OPERATIONAL PERFORMANCE TEST / Excavator Test
TRAVEL MOTOR LEAKAGE
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°).
2. Mark a white line on the travel device cover.
3. Hold the bucket 0.2 to 0.3 m (8 to 12 in) above the
ground with the arm and bucket rolled in.
4. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Measure in both slow and fast travel modes.
0.2 to 0.3 m
2. Select the following switch positions:
Travel Mode Engine Control E Mode Auto-Idle
Switch Dial Switch Switch
Slow Mode Fast Idle OFF OFF
Fast Mode Fast Idle OFF OFF
T105-06-03-004

3. Measure the displacement (revolution angle) of

the travel device cover until the parking brake is Position where the machine
comes to a stop.
applied.
3-1. Climb the slope and place the travel levers in Position when the travel
levers are in neutral.
neutral.
Displacement
3-2. Measure the displacement from the mark posi- (Revolution Angle)
tion on the travel device cover when the levers Mark
are placed in neutral to that position when the
machine stops moving.
4. Measure the travel parking brake slip amount
while parked.
4-1. Climb the slope and place the travel levers in
neutral. T107-06-03-002

4-2. Stop the engine.

4-3. After the machine stops, put alignment marks
on a track link or shoe, and the track side
frame.
4-4. After 5 minutes, measure the distance between
the marks on the track link or shoe and the
track side frame.
Alignment marks on the track
Evaluation: side frame and shoe when the
machine comes to a stop.
Refer to Performance Standard Table in Group T4-2. Displacement
measured after T105-06-03-006
5 minutes.

T4-4-4
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING SPEED
Summary:
To totally check the swing drive system (between the
main pump and the swing motor) by measuring the
time required to make three turns.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Secure enough space to allow the machine to
swing on a solid and flat surface. Avoid measuring
on a slope.
3. With the arm rolled out and bucket rolled in, hold
the bucket so that the bucket hinge pin height is
flush with the boom foot pin (with the bucket
empty). Hold the same level as
4. Maintain hydraulic oil temperature at 50±5 °C the boom foot pin height.
(122±9 °F).
T105-06-03-013

CAUTION: Always make sure that the area is

clear and that co-workers are out of the swing
area before starting the measurement.

Measurement:
1. Select the following switch positions:
Engine Control Dial E Mode Switch Auto-Idle Switch
Fast Idle OFF OFF

2. Operate the swing control lever fully.

3. After a constant swing speed is obtained, meas-
ure the time required to swing 3 turns.
4. Measure in both right and left swing directions.
5. Repeat steps 2. to 4. three times in each direction
and calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-5
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING FUNCTION DRIFT CHECK
Summary:
To check the swing brake valve performance by
measuring the swing drift appeared on the bearing
outer circumference when stopping after a 180° full-
speed swing.

NOTE: The swing mechanical parking brake is

located in the swing motor.

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Secure enough space to allow the machine to
swing on a solid and flat surface. Avoid measuring
on a slope.
3. With the arm rolled out and bucket rolled in, hold
the bucket hinge pin flush with the boom foot pin Put alignment marks on the swing
bearing outer circumference and on
(with the bucket empty). the track frame T105-06-03-008
4. Put alignment marks on the swing bearing outer
circumference (on the upperstructure side) and on
the track frame with tape.
5. Swing the upperstructure 180°.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).

CAUTION: Always make sure that the area is

clear and that co-workers are out of the swing
area before starting the measurement. Start measurement after swinging
the upperstructure 180° T105-06-03-009

Measurement:
1. Select the following switch positions:
Engine Control Dial E Mode Switch Auto-Idle Switch
Fast Idle OFF OFF Measure difference along the swing
bearing outer circumference.

2. Operate the swing control lever fully and return it

to the neutral position when the mark on the swing
bearing aligns with that on the track frame after
swinging 180°.
3. After the upperstructure completely stops, meas-
Marking on the Track Frame
ure the distance between the two marks along the
swing bearing outer circumference.
Marking on the Swing Bearing
4. Measure in both right and left directions.
5. Repeat steps 2. to 3. three times in each direction T105-06-03-010

and calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-6
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING MOTOR LEAKAGE
Summary:
To check the swing brake valve performance by
measuring the swing drift appeared on the bearing
outer circumference due to the upperstructure weight
while parking the machine on a specified slope with
the upperstructure swung 90° to the slope. (The
swing mechanical parking brake is located in the
swing motor.)

Preparation:
1. Check the lubrication of the swing gear and swing
bearing.
2. Load the bucket with either soil or the weight of
the following specification:
W = 375 kg (825 lb)
3. With the arm rolled out and bucket rolled in, hold
the arm top pin flush with the boom foot pin
4. The test slope surface shall be even with a gradi-
ent of 15±1°.
5. After climbing the slope, swing the upperstructure
to position it 90° to the slope. Make aligning marks
on the swing bearing periphery and track frame
using tape, as illustrated.
6. Maintain hydraulic oil temperature at 50±5 °C
T105-06-03-011
(122±9 °F).

Measurement:
1. Select the following switch positions:
E Mode Switch Auto-Idle Switch
OFF OFF
Measure difference between marks.
2. Start the engine and maintain engine speed at
slow idle. After 5 minutes, measure the difference
between the marks along the swing bearing pe-
riphery and the track frame.
3. Measure in both right and left swing directions.
4. Measure three times in each direction and calcu- Marking on the Track Frame
late the average values.
Marking on the Swing Bearing
Evaluation:
Refer to Performance Standard Table in Group T4-2. T105-06-03-010

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-7
 OPERATIONAL PERFORMANCE TEST / Excavator Test
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 the lubrication of the swing gear and swing
bearing.
2. Load the bucket with either soil or the weight of
the following specification:
W = 375 kg (825 lb)
3. With the arm rolled out and bucket rolled in, hold
the arn top pin flush with the boom foot pin.
4. The test slope surface shall be even with a gradi-
ent of 15±1°.
5. After climbing the slope, swing the upperstructure
to position it 90° to the slope.
6. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
T105-06-03-011
Measurement:
1. Select the following switch positions:
Engine Control Dial E Mode Switch Auto-Idle Switch
Fast Idle OFF 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. to 3.
Check both clockwise and counterclockwise.
5. Perform the measurement three times.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-8
 OPERATIONAL PERFORMANCE TEST / Excavator Test
SWING BEARING PLAY
Summary:
To check the wear on the swing bearing races and
balls by measuring the swing bearing play between
the outer race and the inner race.

Preparation:
1. Check swing bearing mounting bolts for loose-
ness.
2. Check the lubrication of the swing bearing. Con- Dial Gauge
Magnetic
firm that bearing rotation is smooth and without Base T105-06-03-014
noise.
3. Install a dial gauge with a magnetic base on the
track frame as shown.
4. Position the upperstructure so that the boom
aligns with the tracks facing towards the front
idlers.
5. Position the dial gauge so that its needle point Round Frame Trunk
comes into contact with the bottom face of the
bearing outer race.
6. Bucket should be empty.

NOTE: The measured value may differ depending T105-06-03-015

on where the dial gauge magnetic base is Measurement of (h1)

located. Mount the magnetic base directly
onto the round frame trunk or ase close to
the round frame trunk as possible.

Measurement:
1. With the arm rolled out and bucket rolled in, hold
the bucket bottom flush with the boom fool pin.
Record the dial gauge reading (h1).
2. Lower the bucket to the ground and raise the front
side of the machine approx. 0.5 m (20 in) above
the ground. Record the dial gauge reading (h2). T105-06-03-007
3. Calculate bearing play (H) from this data (h1 and
Measurement of (h2)
h2) as follows:
(H) = (h2) — (h1)

Evaluation:
Refer to Performance Standard Table in Group T4-2.

T105-06-03-017

T4-4-9
 OPERATIONAL PERFORMANCE TEST / Excavator Test
HYDRAULIC CYLINDER CYCLE TIME
Boom Cylinder
Summary:
1. To totally check the front function performance by
measuring each cylinder cycle time.
2. Bucket should be empty.

Preparation:
1. Take the following machine position:
T191-04-03-010

1-1. When measuring the boom cylinder:

With the arm cylinder fully retracted and the Arm Cylinder
bucket cylinder fully extended, lower the
bucket to the ground.

1-2. When measuring the arm cylinder:

With the bucket cylinder fully extended, adjust
the boom and arm cylinder strokes so that
when the arm is moved half the full stroke, the
arm longitudinal center line perpendicularly 0.5 m
points to the ground and the bucket bottom
clearance above the ground is approx. 0.5 m T191-04-03-011

(20 in).
Bucket Cylinder
1-3. When measuring the bucket cylinder:
Adjust the boom and arm cylinder strokes so
that when the bucket is moved half the full
stroke, the bucket edge points to the ground
perpendicularly.

1-4. When measuring the offset cylinder (EX75UR-

5):
Set the offset cylinder in either the right or left
offset stroke end position. T105-06-03-020
Offset Cylinder
1-5. When measuring the blade cylinder:
Lower the bucket to the ground to raise the
machine front off the ground and secure the
space to allow the blade to move up-and-down
full stroke.

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

(122±9 °F).

M190-05-034

Blade Cylinder

T191-04-03-009

T4-4-10
 OPERATIONAL PERFORMANCE TEST / Excavator Test
Measurement:
1. Select the following switch positions:
Engine Con- E Mode Auto-Idle
trol Dial Switch Switch
All Cylinders Fast Idle OFF OFF

2. Operate each cylinder as follows:

(The cylinder stroke includes the cushion range.)

2-1. Measuring the boom cylinder.

Measure the time required to raise or lower the
boom while operating the boom control lever
full stroke.

2-2. Measuring the arm cylinder.

Measure the time required to roll in or out the
arm while operating the arm control lever full
stroke.

2-3. Measuring the bucket cylinder.

Measure the time required to roll in or out the
bucket while operating the bucket control lever
full stroke.

2-4. Measuring the offset cylinder (EX75UR-5)

Measure the time required to offset the front at-
tachment from right to left or vice versa while
operating the offset control pedal full stroke.

2-5. Measuring the blade cylinder

Measure the time required to raise or lower the
blade while operating the blade control lever
full stroke.

3. Repeat each measurement three times and calcu-

late the average values.

Evalution:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4.

T4-4-11
 OPERATIONAL PERFORMANCE TEST / Excavator Test
DIG FUNCTION DRIFT CHECK
Summary:
To check for internal oil leaks in the cylinders or con-
trol valve by measuring the cylinder drift (extension or
retraction) with the standard load in the bucket.

NOTE: When conducting the check soon after

cylinders were replaced, bleed any air
trapped in the cylinders by fully stroking the
cylinders before testing.
Extension
Retraction
Preparation:
1. Load the bucket with either soil or the weight of Retraction
the following specification:
W = 375 kg (825 lb)
2. With the arm rolled out and bucket rolled in, hold
the arm top pin flush with the boom foot pin Arm top pin height
3. Retract both the arm and bucket cylinders approx. should be flush with
boom foot pin.
50 mm (20 in) from the stroke end to avoid the
Bucket Bottom Height Drift
cushion range.
4. Maintain hydraulic oil temperature at 50±5 °C T105-06-03-021

(122±9 °F). Retraction of Boom or Bucket Cylinder

Mark Mark
Measurement:
1. Stop the engine.
2. Five minutes after the engine has been stopped,
measure the change in the height of the bucket
bottom, as well as the retraction or extension of
each cylinder.
3. Repeat step 2. three times and calculate the av-
erage values. T110-06-03-002

Evalution:
Refer to Performance Standard Table in Group T4-2. Extension of Arm or Blade
Cylinder

Remedy:
Refer to Troubleshooting B in Group T5-4.
Mark

T110-06-03-001

T4-4-12
 OPERATIONAL PERFORMANCE TEST / Excavator Test
Drift Check for Offset Cylinder (EX75UR-5)

Preparation:
1. Load bucket fully. In lieu of loading the bucket,
weight (W) of the following specification can be
used.
W=375 kg (825 lb)
2. With the arm rolled in and the bucket rolled in, po-
sition the offset cylinder with the rod 100 mm (4 in)
retracted from the fully extended position.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Stop the engine.
2. 1 hour after the engine has been stopped, meas-
ure the change in position of the offset cylinder.
3. Repeat step 2. three times and calculate the av-
erage value.

Drift Check for Blade Cylinder

Preparation:
1. Position the blade cylinder with fully retracted.
2. Measure the distance from the tip of the blade T197-04-03-001
edge to the ground.
3. Maintain the hydraulic oil temperature at 50±5 °C
(122±9 °F).
Offset Cylinder Extension

Measurement:
1. Stop the engine.
2. After 5 minutes, measure the distance from the tip
Mark
of the blade edge to the ground. Calculate the dif-
ference between the value measured during the
preparation.
3. Repeat step 2. three times and calculate the av-
erage value.

Evaluation:
Refer to Performance Standard Table in Group T4-2. T110-06-03-001

Blade Drift
Remedy:
Refer to Troubleshooting B in Group T5-4.

A B

T197-04-03-002

T4-4-13
 OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER OPERATING FORCE
Summary:
1. To measure each control lever operating force as
well as the lever stroke end play and operation
smoothness.
2. Attach the spring scale to the lever grip center.

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

Measurement:
CAUTION: Always make sure that the area is
clear and that co-workers are out of the swing
area before starting the measurement.
1. Measure each control lever.
2. Select the following switch positions:
Engine Control Dial E Mode Switch Auto-Idle Switch
Fast Idle OFF OFF
T107-06-03-003

3. When measuring the boom, arm, bucket, and

swing lever, operate each lever full stroke to
measure the maximum operating force.
4. When measuring the travel levers, raise the track
to be measured using the front function and
measure the maximum operating force.
5. Repeat steps 3. to 4. three times and calculate the
average values.

Evalution:
Refer to Performance Standard Table in Group T4-2.

T107-06-03-004

T4-4-14
 OPERATIONAL PERFORMANCE TEST / Excavator Test
CONTROL LEVER STROKE
Summary:
1. To measure each control lever stroke as well as
the lever stroke end play and operation smooth-
ness.
2. Measure the stroke at the lever grip center.
3. When the lever play is provided in the neutral po-
sition, divide the play equally to measure the
stroke.

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

Measurement:
1. Stop the engine. T107-06-03-005

2. Measure the operation strokes of the boom, arm,

bucket, swing, and travel levers at the lever grip
top from neutral to the stroke end using a ruler.
3. Measure the chord length from neutral to the
stroke end.
4. Repeat step 2. three times and calculate the av-
erage values.

Evalution:
Refer to Performance Standard Table in Group T4-2.

T4-4-15
 OPERATIONAL PERFORMANCE TEST / Excavator Test
BOOM RAISE/SWING COMBINED
OPERATION CHECK
Summary:
1. To check boom raise and swing movement and
speed while operating both functions simultane-
ously.
2. To check that no cylinder hesitation occurs during
operation with the engine running at full speed.

Preparastion:
1. With the arm rolled out and the bucket rolled in,
lower the bucket to the ground.(Bucket should be T107-06-03-009

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

CAUTION: Always make sure that the area is

clear and that co-workers are out of the swing
area before starting the measurement.

Measurement:
1. Select the following switch positions:
Engine Control Dial E Mode Switch Auto-Idle Switch
Fast Idle OFF OFF
T107-06-03-010

2. Raise the boom and swing simultaneously with

both control levers fully stroked. When the upper-
structure rotates 90°, release the control levers to
stop both functions. Measure the time required to
swing 90° and the height (H) of the bucket teeth
with the bucket empty.
3. Repeat steps 2. to 3. three times and calculate the
average values.
H

Evalution:
Refer to Performance Standard Table in Group T4-2.

Remedy:
Refer to Troubleshooting B in Group T5-4. T107-06-03-011

T4-4-16
 OPERATIONAL PERFORMANCE TEST / Component Test
PRIMARY PILOT PRESSURE
Preparation:
1. Stop the engine.
2. Press the air release valve on the filler cap to
release any remaining pressure.
3. Disconnect the hose from the solenoid valve unit
and install tee (ST 6477) and pressure gauge (ST
6942) between the solenoid valve unit and the
hose.
: 27 mm
4. Start the engine. Check the pressure gauge
connection for oil leaks.
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
1. Select the following switch positions:
Engine Control Auto-Idle Switch
Dial
Fast Idle OFF
Slow Idle OFF

2. Measure the pilot pressure at both fast and slow

idle engine speed.
3. Repeat the measurement three times and T1CC-04-04-001
calculate the average values.
Install tee and pressure
gauge between adapter
Evaluation: and hose.
Refer to Performane Standard Table in Group T4-2.

T4-5-1
 OPERATIONAL PERFORMANCE TEST / Component Test
Primary Pilot Pressure Adjustment Procedure
Solenoid Valve Unit
Adjust the set pressure of the pilot relief valve as
necessary. Plug

1. Remove the plug.

: 22 mm

2. Install the estimated necessary number of shims.

3. Tighten the plug.
: 25+5 N⋅m (2.5+0.5 kgf⋅m, 18+3.6 lbf⋅ft)

4. Check the set pressure of the relief valve.

NOTE: Standard Change in Pressure (Reference)

Pressure Change
Shim Thickness (mm)
kPa (kgf/cm2) (psi) T1CC-03-06-002

0.25 78 (0.8) (11)

Shim Plug
0.5 157 (1.6) (23)
1.0 304 (3.1) (44)

T157-05-04-007

T4-5-2
 OPERATIONAL PERFORMANCE TEST / Component Test
SECONDARY PILOT PRESSURE
Control Valve 1
Preparation: Pilot Port
1. Stop the engine.
2. Press the air release valve on the filler cap to
release any remaining pressure.
3. Install tee (ST 6451) and pressure gauge (ST
6942) to the control valve spool pilot port located
in the pilot circuit to be measured.
: 14 mm, 19 mm
4. Start the engine and check the pressure gauge
connection for oil leaks.
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
CAUTION: Before measuring, check that
there are no obstacles or personnel within
the swing radius. When measuring the boom
lower pilot pressure, raise the machine off
the ground while paying attention not to al-
low the base machine (counterweight) to
contact with the ground. Be careful not to
tip-over due to a loss of balance. T1CC-03-03-001

Control Valve 2
1. Select the following switch positions:
Pilot Port Pilot Port
Engine Control Auto-Idle Switch (EX75UR-5)
Dial
Fast Idle OFF
Slow Idle OFF

2. Measure the pilot pressure with the

corresponding control lever operated full stroke.

3. Repeat the measurement three times and

calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

Remedy: T197-03-03-005

Refer to Troubleshooting B in Groupe T5-4.

Tee

Pressure
Gauge

T157-05-04-011

T4-5-3
 OPERATIONAL PERFORMANCE TEST / Component Test
MAIN RELIEF VALVE SET PRESSURE
Summary:
To check the main relief valve set pressure at the
main pump delvery port.

Preparation: ST 6941
1. Stop the engine.
2. Press the air release valve on the filler cap to
release any remaining pressure.
3. Remove the plug from the pressure check port at
the main pump delivery port. Then, install adapter
(ST 6069), hose (ST 6943) and pressure gauge ST 6943
(ST 6941) to the port.
For measuring the main relief pressure of the
blade and swing circuit, install adapter (ST 6477),
adapter (ST 6069) and pressure gauge (ST 6941) ST 6069
at the hose.
: 6 mm
: 19 mm, 27 mm, 36 mm

4. Start the engine and check the pressure gauge

connection for oil leak. Hose
5. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).

Measurement:
T190-06-04-002
1. Select the following switch positions:
Engine Control Auto-Idle Switch
Dial
Fast Idle OFF

2. Relieve each cylinder circuit by gradually

operating the bucket, arm, and boom control lever
to extend or retract each cylinder full stroke.
3. When checking the swing circuit, secure the
upperstructure so it is immovable. Then, slowly
operate the swing lever to relieve the swing
function.
When checking the travel circuit, secure the
tracks against an immovable object. Then, slowly
operate the travel levers to relieve the travel
function.
In case of offset, grab the ground using the
bucket to relieve.
When lowering the blade, it becomes the jacked-
up position. Be careful that the machine does not
roll over.
4. Measure the relief oil pressure with the pressure
gauge.
5. Repeat the measurement three times and
caluculate the average values.

T4-5-4
 OPERATIONAL PERFORMANCE TEST / Component Test
Evaluation:
Refer to Performance Standard Table in Group T4-2.
Main Relief
NOTE: If the measured pressures for all functions Valve
are lower, a decrease in the main relief
valve set pressure may be the probable
cause.
If the relief pressure of a particular function
is lower, the probable cause may be other
than the main relief valve.

Adjusting Main Relief Valve Set Pressure:

• Control Valve 1
Ȁ After loosening lock nut (1), turn plug (3)(low pres-
sure), or plug (5)(high pressure) to adjust the relief
valve set pressure as necessary.

Adjusting High Pressure Main Relief Set Pressure:

1. Loosen lock nut (1). Lightly tighten plug (3) until it
comes in contact with piston (2). Tighten lock nut T1CC-03-03-001
(1).
: 27 mm 3
: Plug (3): 19.5 N⋅m (2 kgf⋅m, 14.5 lbf⋅ft)
Lock Nut (1): 68 to 78 N⋅m 1
(7 to 8 kgf⋅m, 50 to 58 lbf⋅ft)
2. Loosen lock nut (4). While holding the condition 5
set in step 1. , turn plug (5) until the desired pres-
sure is obtained. 4
: 27 mm, 32 mm
: Lock Nut (4): 78 to 88 N⋅m
(8 to 9 kgf⋅m, 58 to 65 lbf⋅ft)
2

Adjusting Low Pressure Main Relief Set Pressure:

3. Loosen lock nut (1). Turn plug (3) counter-
clockwise until the specified pressure is obtained.
Tighten lock nut (1).
: 27 mm
: Lock Nut (1): 59 to 69 N⋅m
(6 to 7 kgf⋅m, 43 to 50 lbf⋅ft) T157-05-04-009

4. Recheck the set pressure.

NOTE: Standard Change in Pressure (Reference) Plug 5 3

Plug Turns 1/4 1/2 3/4 1
Plug (5) MPa 7.1 14.2 21.3 28.4
2
(High (kgf/cm ) (72.5) (145) (217.5) (290) Pressure
Pressure) (psi) (1031) (2062) (3093) (4124) Pressure Decrease
Increase
Plug (3) MPa 5.3 10.7 16.0 21.3
2
(Low (kgf/cm ) (54) (109) (163) (217)
Pressure) (psi) (768) (1550) (2318) (3086)
W107-02-05-127

T4-5-5
 OPERATIONAL PERFORMANCE TEST / Component Test
• Control Valve 2
Main Relief Valve
1. Loosen the lock nut.
2. Turn the adjusting screw until the desired pres-
sure is obtained.
3. Tighten the lock nut.
: 14 mm
: 20+0.40 N⋅m (2+0.40 kgf⋅m, 28+40 psi)

4. Recheck the set pressure.

NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
MPa 2.9 5.9 8.8 11.8
Change in
(kgf/cm2) (30) (60) (90) (120)
Pressure
(psi) (430) (850) (1280) (1710) T197-03-03-005

Adjusting Screw
Lock Nut Adjusting Screw

Pressure Pressure
Increase Decrease
Lock Nut

T505-06-04-006
T563-02-04-002

T4-5-6
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjusting Swing Relief Valve Set Pressure: Swing Relief
Valve
Loosen the lock nut to adjust the set pressure.

1. Loosen the lock nut.

2. Turn the adjusting screw to adjust the set

pressure.

IMPORTANT: Turn the adjusting screw so that the

adjusting screw end face extends 2
to 5 mm (0.08 to 0.20 in) from the
lock nut end face.

3. Tighten the lock nut.

: 24 mm (Lock Nut)
T152-04-04-004
: 29 N⋅m (3 kgf⋅m, 22 lbf⋅ft)
Lock Nut
: 6 mm (Adjusting Screw)

4. Recheck the set pressure.

Adjusting
Screw
NOTE: Standard Change in Pressure (Reference)
Plug Turns 1/4 1/2 3/4 1 T152-03-02-005

Change in MPa 1.7 3.4 5.1 6.9

Relief (kgf/cm2) (17.5) (35) (52.5) (70)
Pressure (psi) (249) (498) (747) (995)
Lock Nut Adjusting Screw

Pressure Pressure
Increase Decrease

W107-02-05-129

T4-5-7
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjusting Travel Relief Valve Set Pressure:

1. Remove the travel relief valve assembly.

: 30 mm
2. Remove sleeve (1) and plug (4).
3. Provide shims (2) between spring (3) and spring
guide (5) to adjust the pressure setting.
4. Install the relief valve assembly. Travel Relief
Valve
: 314 N⋅m (32 kgf⋅m, 230 lbf⋅ft)
5. Recheck the set pressure.

T155-01-01-006
NOTE: Standard Change in Pressure (Reference)
Shim Change in Relief Pressure 1 3 4
2
Thickness Part No. 2
kPa (kgf/cm ) (psi)
(mm)
0.5 4305162 785 to (8 to 10) (114 to
980 142)

5
T135-06-04-001

T4-5-8
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-9
 OPERATIONAL PERFORMANCE TEST / Component Test
OVERLOAD RELIEF VALVE SET PRES-
SURE
Checking the pressure setting of the overload relief
valves on the machine is not recommended for the
following reasons:

1. With the return circuit from the control valve

blocked, the circuit pressure must be increased
by applying an external load. This checking
method is hazardous and the results obtained
with this method are unreliable.
2. Pressure setting of the overload relief valve must
be made at a specified oil flow rate normally far
smaller than the delivery flow rate of the main
pump. Accordingly, even if the engine speed is
reduced and the main relief valve pressure set-
ting can be reset higher than the setting pressure
of the overload relief valve, the main pump sup-
plies too much oil to correctly measure the setting
pressure of the overload valve.
The main relief valve has pre-leaking function.
Accordingly, the main relief valve pressure setting
may not be reset higher than the set pressure of
the overload relief valve plus the pressure at pre-
leaking.
Therefore, when the setting pressure of the over-
load relief valve must be checked correctly, re-
move the overload relief valve from the machine
and check the overload relief valve unit perform-
ance using the test stand and test block prepared
for this purpose.
If the poppet of overload relief valve seats to the
body of control valve, the test block requires pre-
cise machining.
Use other control valve unit for the measurement
instead of the test block.
3. As an easier method, however, measure the relief
pressure of each cylinders in the same method as
of main relief pressure setting in previous section.
Then, when each relief pressure meets its re-
spective specifications, judge that the setting
pressure of the overload relief valve is correct.

Measurement:
Repeat the measurement three times and calculate
the average values.

Evaluation:
Refer to T4-2 Standard.

T4-5-10
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjusting Overload Relief Valve Set Pressure:
Control Valve 1
NOTE: In principle, adjust the overload relief valve For Arm
set pressure on a specified test stand. For Boom

• Control Valve 1
1. Loosen the lock nut.
2. Turn the adjusting screw to adjust the set
pressure.
3. Tighten the lock nut.
: 17 mm (Lock nut)
: 27 to 31 N⋅m
For Bucket
(2.8 to 3.2 kgf⋅m, 20 to 23 lbf⋅ft)
: 6 mm (Adjusting screw)

4. Recheck the set pressure.

T1CC-03-03-004

Lock Nut

NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
Change in MPa 7.1 14.2 21.3 28.4
Relief (kgf/cm2) (72.5) (145) (217.5) (290)
Pressure (psi) (1031) (2062) (3093) (4124)
Adjusting Screw
T152-03-03-015

Lock Nut
Adjusting Screw

Pressure
Pressure Decrease
Increase

W107-02-05-129

T4-5-11
 OPERATIONAL PERFORMANCE TEST / Component Test
• Control Valve 2
Control Valve 2
1. Loosen the lock nut.
2. Turn the adjusting screw to adjust the set pres-
sure.
3. Tighten the lock nut.
: 14 mm (Lock Nut)
: 20+40 N⋅m (2+0.40 kgf⋅m, 28+40 psi)

4. Recheck the set pressure. For Blade

NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
MPa 2.9 5.9 8.8 11.8
Change in
(kgf/cm2) (30) (60) (90) (120)
Pressure
(psi) (430) (850) (1280) (1710)
T197-03-03-005

Adjusting Screw
Lock Nut Adjusting Screw

Pressure Pressure
Increase Decrease Lock Nut

T563-02-04-003

T505-06-04-006

T4-5-12
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-13
 OPERATIONAL PERFORMANCE TEST / Component Test
MAIN PUMP FLOW RATE MEASURE-
MENT
6. Disconnect the pressure sensor (Travel), connect
Summary: terminal #1 to #2 and select the travel mode
To check the main pump performance by measuring switch to the fast travel position to hold the pump
the pump flow rate with a hydraulic portable tester in- swash angle to the maximum.
stalled at the pump delivery port. Oil pressure should 7. Install the engine speed meter to the injection
also be measured using a pressure gauge at the pipe. Fully open the hydraulic tester loading
same time. valve.
8. Disconnect the vacuum pump. Loosed the plug
Preparation: on top of the pump casing. Start the engine and
1. Stop the engine and push the air release valve on bleed air until oil flows out of the clearance
top of the hydraulic oil tank to release any remain- around the plug. Check pipe connections for oil
ing pressure. Connect a vacuum pump. leaks at this time.
NOTE: Operate the vacuum pump while connect-
ing the hydraulic portable tester to the main Measurement:
pump. 1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F).
2. Remove the plug at the main pump delivery port. 2. Select the following switch positions:
Install adapter (ST 6069), hose (ST 6943) and Engine Control Auto-Idle
pressure gauge (ST 6941). (Fig. A) Dial Switch
: 6 mm Fast Idle OFF

3. Disconnect hoses A and B with adapters. Install 3. While gradually closing the hydraulic tester load-
plug (ST 6254) into the disconnected hose end. ing valve, measure the flow rates, and engine
: 32 mm speeds at the set oil pressures. (Refer to page
T4-2-3.)
4. Install adapters (ST 6025), test hoses (ST 6145) 4. Repeat the measurement three times and calcu-
(3 used), adapters (ST6012) (3 used), block (ST late the average values.
6289) (2 used), adapter (ST 6146) (2 used), hy-
draulic tester (ST 6299), test hoses (ST 6145) (2 Evaluation:
used), and adapter (ST 6003) (3 used) to the Convert the measured pump flow rate into the one
pump delivery ports. (Fig. B) for the rated pump speed. Then, refer to the Per-
: 32 mm, 36 mm, 41 mm formance Standard Table in Group T4-2.

5. Remove the plug on the return pipe from the oil Qc = (Np × Q) / (i × Ne)
cooler Connect test hose (ST 6145) to the return
pipe plug hole via adapter (ST 6025) (Fig. C) Qc : Converted Pump Flow Rate
: 36 mm Q : Measured Pump Flow Rate
i : Pump Transmission Gear Ratio (=1)
Np : Rated Pump Speed (1900 min-1)
Ne : Measured Engine Speed

T4-5-14
 OPERATIONAL PERFORMANCE TEST / Component Test
Fig. A
Pressure Gauge(ST 6941)

Hose A Hose(ST 6943)

Hose B

Adapter(ST 6069)

T190-06-04-002

Fig. B
Hose Hyd. Tester Test Hose
Adapter（ST 6025） （ST 6145） Adapter(ST 6012） （ST 6299） （ST 6145） Return Pipe

Front
Port

Rear
Port

Main Pump
T192-04-04-002
Block Test Hose Adapter Adapter Adapter
（ST 6289） （ST 6145） （ST 6146） （ST 6003） （ST 6025）

Fig. C

Plug (Return Pipe)

View A
T197-04-04-003

T4-5-15
 OPERATIONAL PERFORMANCE TEST / Component Test
Adjusting Pump Flow Rate

NOTE: The pump flow rate is adjusted by chang-

ing the swash plate set pressure.

Adjustment:
Loosen the lock nut and turn the adjusting screw as
necessary.
A 18.8 MPa (192 kgf/cm 2 )
1. Loosen the lock nut.
2. Turn the adjusting screw clockwise to increase ㈦
(Flow Rate)
pressure and counterclockwise to decrease pres-
sure.
3. Tighten the lock nut.
: 27 mm
: 8 mm
4. Recheck the flow rate after the set adjusting
pressure.

NOTE: Standard Change in Pressure (Reference)

Screw Turns 1/4 1/2 3/4 1
Change in MPa 1.35 2.70 4.05 5.39 Pump 1+Pump 2 (Pressure)
Set Pres- (kgf/cm2) (13.8) (27.5) (41.3) (55)
sure from (psi) (196) (391) (587) (782)
point A

Lock Nut

Adjusting Screw

T196-03-01-001

T4-5-16
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-17
 OPERATIONAL PERFORMANCE TEST / Component Test
SWING MOTOR DRAINAGE
Summary:
1. To check the swing motor performance by meas-
uring the oil drainage from the swing motor while
rotating the upperstructure.

NOTE: The amount of drain oil from the swing mo-

tor will change depending on hydraulic oil
temperature. Maintain hydraulic oil tem-
perature at 50±5 °C (122±9 °F) during the
measurement.

Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the swing motor to warm the
inside of the motor.
2. Stop the engine. Press the air release valve on
top of the hydraulic oil tank to release any remain-
ing pressure.
3. Disconnect the swing motor drain hose at the
swing motor end. Install a plug to the discon-
nected end on the hydraulic oil tank. Connect test
hose (9/16-18UNF) to the disconnected end on
T105-06-06-001
swing motor.
: 19 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft)
Drain Hose

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. Also, take care
not to fall off the machine while the meas-
urement.

Preconditions for Measurement:

1. Select the following switch positions:
Engine Control Auto-Idle Switch
Dial
Fast Idle OFF

T152-04-04-005

T4-5-18
 OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
1. Amount of Oil Drained While Swinging the Up-
perstructure
(1) With the arm cylinder fully retracted and the
bucket cylinder fully extended, raise the boom
so that the bucket hinge pin height is flush with
the boom foot pin height. Be sure that the
bucket is empty. Same Level as Boom
(2) Start the engine. Operate and hold the swing Foot Pin
lever full stroke. After the swing speed reaches
a constant maximum speed, start to receive the T105-06-03-013

amount of oil drained from the drain hose with a

container and measure the time.
(3) The measuring time should be more than 45
seconds.
(4) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.

2. Amount of Oil Drained While Relieving Swing Mo-

tor
(1) Securely thrust the bucket teeth into the ground
to prevent the upperstructure from rotating.
(2) Start the engine. Operate and hold the swing
lever full stroke. Receive the amount of oil T107-06-06-005

drained from the drain hose with a container

and measure the time.
(3) The measuring time should be more than 45
seconds.
(4) Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.
* Conversion of the amount of drain oil measured
into the per-minute value.
First measure the amount of the drain oil using a
calibrated container. The, convert the measured
drain oil into the per-minute value using the for-
mula below:

Qc = 60 × q / t

Where:
Qc: Amount of Drain Oil Per-Minute (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil (L)

T4-5-19
 OPERATIONAL PERFORMANCE TEST / Component Test
TRAVEL MOTOR DRAINAGE
Summary:
To check the travel motor performance by measuring
the oil drainage from the travel motor while rotating
the travel motor with the corresponding track raised
off the ground.

NOTE: The amount of drain oil from the swing mo-

tor will change depending on hydraulic oil
temperature. Maintain hydraulic oil tem-
perature at 50±5 °C (122±9 °F) during the
measurement.

Preparation:
1. Maintain hydraulic oil temperature at 50±5 °C
(122±9 °F). Rotate the travel motor to warm the
inside of the motor.
2. Stop the engine. Press the air release valve on
top of the hydraulic oil tank to release any remain-
ing pressure.
3. Disconnect the drain hose at the travel motor end.
Install a plug to the disconnected hose end. Con-
nect test hose (9/16-18UNF) to the disconnected
T105-06-06-001
end on the travel motor.
: 22 mm
: 39 N⋅m (4 kgf⋅m, 29 lbf⋅ft) Drain Hose

Preconditions for Measurement:

1. Select the following switch positions:
Engine Control Auto-Idle Switch
Dial
Fast Idle OFF

T155-05-04-004

T4-5-20
 OPERATIONAL PERFORMANCE TEST / Component Test
Measurement:
CAUTION: To prevent accidents, care
should be taken to ensure that hands, feet,
and clothing do not become entangled when
working around rotating parts.
Securely support the raised track with 90 to 110°
wooden blocks.

1. Start the engine. Raise the measuring side track

using the front attachment as illustrated.
M195-07-003
2. Rotate the raised track with the travel lever oper-
ated full stroke. Receive the drain oil from the test
hose and measure the time at the same time.
3. The measuring time should be more than 45 sec-
onds.
4. Repeat the measurement at least three times in
both clockwise and counterclockwise directions,
and calculate the average values.

Evaluation:
Refer to Performance Standard Table in Group T4-2.

NOTE: Operational performance of the travel mo-

tor should be totally evaluated taking test
results on the travel speed and mistrack
into consideration.

* Conversion of the amount of drain oil measured

into the per-minute value. T157-05-04-019
First measure the amount of the drain oil using a
calibrated container. The, convert the measured
drain oil into the per-minute value using the for-
mula below:

Qc = 60 × q / t

Where:
Qc: Amount of Drain Oil Per-Minute (L/min)
t : Measuring Time (sec)
q : Measured Drain Oil (L)

T4-5-21
 OPERATIONAL PERFORMANCE TEST / Component Test
(Blank)

T4-5-22
 OPERATIONAL PERFORMANCE TEST / Adjustment
ENGINE SPEED ADJUSTMENT AND
ENGINE LEARNING
When the following repair or inspection is made, or
when engine speeds deviate from the specifications,
perform the engine speed adjustment and engine
learning.

• When the engine, engine control cable, or EC

motor is removed.
• When MC is replaced.

Engine Speed Adjustment: Bolt

1. Turn the key switch to START and run the engine.
(Note: Turn the air-conditioner switch OFF.) Control Lever
2. Turn the engine control dial to the minimum speed
position. (EC sensor voltage is set to 2.5 V.)
3. Loosen the bolt tightening the control lever to the
EC motor output axis.
4. While checking the engine actual speed with
Dr.EX or a tachometer, adjust the control lever to
conform the slow idle speed specification.
Specification: Refer to Operational Performance
Test section.
5. Tighten the bolt to secure the control lever to the
EC motor output axis.
: 13 N·m (1.3 kgf·m, 9.4 lbf·ft)

IMPORTANT: Take care not to allow oil or grease

to stick to the motor output axis.
T191-05-04-004
6. Perform engine learning.

Engine Learning:

1. Turn the key switch OFF.

NOTE: If the engine does not stop with the key

switch OFF, pull the fuel cut-off handle
under the operator's seat to stop the
engine.

2. Remove Dr.EX. Wait for 5 seconds.

3. Connect engine learning plug.
4. Turn the key switch ON. Wait for 5 seconds.
5. Turn the key switch OFF. Wait for 5 seconds.
6. Disconnect engine learning plug.
7. Check the engine speed.

T4-6-1
 OPERATIONAL PERFORMANCE TEST / Adjustment
BOOM LOWERING METHOD WHEN EN-
GINE STALLING

If the engine has stalled with the boom raised and is

difficult to restart due to some reason, lower the boom
in the following procedures:
Overload
Relief Valve
In case the bucket is empty: (Boom Raise)
1. Put an alignment mark on the overload relief valve
in the boom raise circuit and the control valve
housing.
CAUTION: If the overload relief valve is loos- Machine
ened rapidly, the boom may be lowered Front
Side
quickly. Be sure to loosen slowly.
In addition, if loosened approx. more than 3/4
turn, hydraulic oil may spout. Never loosen
further than 3/4 turn.
2. While watching the boom movement, slowly
loosen the overload relief valve.
: 24 mm T197-03-03-002

: 49 to 54 N·m
(5 to 5.5 kgf·m, 36 to 40 lbf·ft)

3. After checking that the boom has lowered com-

pletely, tighten the overload relief valve.
Adjusting
Lock Nut Screw
In case a load is in the bucket:
1. Put an alignment mark on the lock nut and the ad-
justing screw on the overload relief valve in the
boom raise circuit.
CAUTION: If the adjusting screw is loosened
rapidly, the boom may be lowered quickly. Be
sure to loosen slowly.
2. Loosen the lock nut. While watching the boom
movement, slowly loosen the adjusting screw.
: 17 mm
: 27 to 31 N·m
T152-05-04-003
(2.8 to 3.2 kgf·m, 20 to 23 lbf·ft)
: 6 mm

3. After checking that the boom has lowered com-

pletely, retighten the adjusting screw and lock nut
until the alignment marks align.

IMPORTANT: After retightening the overload relief

valve, check the overload relief valve
set pressure.

T4-6-2
 OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)

T4-6-3
 OPERATIONAL PERFORMANCE TEST / Adjustment
CHECK OF GOVERNOR LEVER AND
FUEL CUT LEVER POSITION
Check the fuel cut lever position during cranking in
case of below.

• Although starter rotates, engine doesn’t start.

• Governor Lever and Fuel Cut Lever

1 2 3 4

T105-07-04-003
1 - Governor Cable (From EC Mo-
tor)
2 - Fuel Cut-Off Cable
(Fuel Cut-Off Handle)
3 - Fuel Cut Lever
4 - Governor Lever

T4-6-4
 OPERATIONAL PERFORMANCE TEST / Adjustment
• Governor Lever Position

A - Key Switch OFF (Engine Stop Position)

B - Key Switch ON (Engine Start Position)

A B

STOP FULL

FULL

T105-07-04-003

STOP

• Fuel Cut Lever Position

A - Fuel Cut-Off Handle Pulled Position

B - Fuel Cut-Off Handle Returned Position

A
B

T105-07-04-003

T4-6-5
 OPERATIONAL PERFORMANCE TEST / Adjustment
ASSEMBLY AND ADJUSTMENT OF LINK
FOR ARM ANGLE SENSOR (EX75UR-5)
IMPORTANT: Compared to other angle sensors, it
is more difficult to assemble or ad-
just the link for the arm angle sensor.
When replacing the arm angle sen-
sor, follow the assembly and ad-
justment procedures below.

Assembling the Link

IMPORTANT: In the case of pressing – in of a bush,

vertically press the bush by using
protective plate so that the sur- T197-05-06-001

rounding areas are not damaged.

1. Press the bush into the lever.

2. Press the bush 2 into the end rod.

Bushing 2
IMPORTANT: Before attaching the link, apply
grease generously to sliding and ro-
End Rod
tating areas.
Lever
3. Attach the link to the front attachment as shown at
right. Bushing

T197-05-06-002
Adjusting the Link

1. With the arm rolled in fully, position the link so that

a parallelogram is formed with four points A, B, C
and D shown at right. At this time, turn the end rod
so that a distance between A to D becomes 330 330 mm
mm.
End Rod
2. Tighten the lock nuts to clamp the end rods.
C

A
D

End Rod T197-05-06-006

Lock Nut

T4-6-6
 OPERATIONAL PERFORMANCE TEST / Adjustment
INITIAL SETTING OF THE ANGLE SEN-
SOR (EX75UR-5)
Initial setting of the angle sensor is required when the
angle sensor or the front attachment (boom, arm) is
replaced.
Side Face of the Right Side Face of the
1. Set the front attachment in the following standard Side Cutter Operator's Cab
position.

Standard position:
Boom : Fully raised
(with the boom cylinder fully extended)
Arm : Fully rolled in
(with the arm cylinder fully extended)
Offset : Position the bucket so that the clearance be-
tween the side cutter of the bucket and the
operator's cab is 220 mm. T191-04-03-015

When equipped with an optional bucket, set

the offset position by referring to the below
table.

Clearance between the

side cutter of the
Bucket Type
bucket and the opera-
tor’s cab. (Unit: mm)
Standard 220
0.2 220
Slope finishing plate 1 220
Slope finishing plate 2 220
0.25 (Level finishing plate) 220
Left Console

2. Stop the engine and disconnect the initial setting

connector.
3. Start the engine and connect the initial setting
connector. Initial Setting Connector
4. Disconnect the initial setting connector again. The
setting is complete if the buzzer sounds a short
(beep).
5. Connect initial setting connector if setting is com-
plate.

NOTE: If the system failure indicator comes ON or

the buzzer sounds continuously, the initial
setting is failed. Check the angle sensor
system for abnormalities and repair if nec-
essary. Then, perform the initial setting
again.

T197-02-01-009

T4-6-7
 OPERATIONAL PERFORMANCE TEST / Adjustment
INITIALIZING THE DEPTH LIMIT CON-
TROL SYSTEM (EX75UR-5)
It is required to initialize the Depth Limit Control Sys-
tem in the following case:
• The front attachment, angle sensor, link for angle
sensor, 9-port solenoid valve or auto-MARCCINO
control unit is exchanged.

CAUTION: When initializing the depth limit

control system, the front attachment will be
automatically moved through the auto-
MARCCINO control unit. Therefore, the ini-
tialization must be carried out on firm level
ground in a wide space so that work crew is
not hit or injured by the moving front attach-
ment.

IMPORTANT: If initialization is interrupted, stop T197-05-01-001

the engine, and reset Dr. EX to re- Dr. EX Connector
start initialization. (Auto-MARCCINO
Control Unit)
Depth Limit Control System Initializing Proce-
dures

1. Connect Dr. EX to the auto-MARCCINO control

unit, and connect the service switch. Confirm that
hydraulic oil temperature is 20ºC or higher. (Refer
to T5-1-12.)
2. Choose the Target Digging Range Correction Left Console
from the Service Modes of Dr. EX. Follow the in-
structions on the window of Dr. EX.
3. Choose the Boom Metering Adjustment from the
Service Modes of Dr. EX. Follow the instructions Service Switch (Plug)
on the window of Dr. EX.
4. Choose the Arm Metering Adjustment from the
Service Modes of Dr. EX. Follow the instructions
on the window of Dr. EX.
5. Choose the Auto Adjustment Of Level Crowd Op-
eration (for Standard Monitor) from the Service
Modes of Dr. EX. (If an optional system monitor is
used, choose the Auto Adjustment Of Level
Crowd Operation (for Optional Monitor).) Follow
the instructions on the window of Dr. EX.
6. Stop the engine.

T197-02-01-009

T4-6-8
 OPERATIONAL PERFORMANCE TEST / Adjustment
Operational Check

1. With Dr. EX connected, start the engine.

NOTE: If Dr. EX is not connected to the auto-

MARCCINO control unit, or the service
switch is not connected, setting the depth to
plus side cannot be made.

2. Set the depth to ‘‘+0.1’’ m on the system monitor.

3. Align the bucket teeth with an extension straight-

line passing through the boom top pin and arm top
pin, and make full boom lowering and arm roll-in
at the same time.

Evaluation

Setting is OK when the bucket tooth tip can be level-

crowded at height of 0.1 m above the ground, without T197-05-06-005
touching the ground, in the above operation.

T4-6-9
 OPERATIONAL PERFORMANCE TEST / Adjustment
(Blank)

T4-6-10