SECTION 6 MAINTENANCE STANDARD

Group 1 Operational Performance Test ----------------------------------------------------------------------- 6-1

Group 2 Major Components ----------------------------------------------------------------------------------------- 6-20
Group 3 Track and Work Equipment ---------------------------------------------------------------------------- 6-31
 SECTION 6 MAINTENANCE STANDARD
GROUP 1 OPERATIONAL PERFORMANCE TEST

1. PURPOSE
Performance tests are used to check:
1) OPERATIONAL PERFORMANCE OF A
NEW MACHINE
Whenever a new machine is delivered in
parts and reassembled at a customer's
site, it must be tested to confirm that the
operational performance of the machine
meets Hyundai spec.
2) OPERATIONAL PERFORMANCE OF A Maintenance
record
WORKING MACHINE Operating

With the passage of time, the machine's Working

condition
operational performance deteriorates, so
that the machine needs to be serviced
periodically to restore it to its original
performance level.
Before servicing the machine, conduct
performance tests to check the extent of
deterioration, and to decide what kind of
service needs to be done (by referring to
the "Service Limits" in this manual).
1696MS01
3) OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confir m that its
operational performance was restored by
the repair and/or service work done.

6-1
2. TERMINOLOGY
1) STANDARD
Specifications applied to the brand-new
machine, components and parts.

1696MS02

2) SERVICE LIMIT
The lowest acceptable performance level.
When the perfor mance level of the
machine falls below this level, the machine
must be removed from work and repaired.
Necessary parts and components must be
replaced.

1696MS03

6-2
3. OPERATION FOR PERFORMANCE
TESTS
1) 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
Η Select a hard, flat surface.
Θ Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
Ι If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.
(3) Precautions
Η Before starting to test, agree upon the
signals to be employed for communication
among coworkers. Once the test is
7-3 (140-7)
started, be sure to communicate with
each other using these signals, and to
follow them without fail.
Θ Operate the machine carefully and
always give first priority to safety.
Ι 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.
Κ 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
Η Accurately calibrate test instruments in
advance to obtain correct data.
Θ Carry out tests under the exact test
conditions prescribed for each test item.
Ι Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.

6-3
2) ENGINE SPEED
(1) Measure the engine speed at the
maximum RPM.
ö The engine speed must meet standard
RPM; if not, all other operational
performance data will be unreliable. It is
essential to perform this test first.
(2) Preparation and measurement
Η Warm up the machine, until the engine
coolant temperature reaches 50°C or
more, and the hydraulic oil is 50Ü5°C.
Θ Set the accel lever at the maximum
stroke.
Ι Measure the engine RPM.

(3) Evaluation
The measured speeds should meet the
following specifications.
Unit : rpm
Model Engine speed Standard Remarks
Low idle 1600Ü100
R16-9
High idle 2500Ü50

6-4
3) TRAVEL SPEED
(1) Measure the time required for the
excavator to travel a 20m test track.
(2) Preparation
Η Adjust the tension of both tracks to be
equal.
Θ Prepare a flat and solid test track 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration. 0.3~0.5m
Ι Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Κ Keep the hydraulic oil temperature at
1696MS04
50Ü5°C.
(3) Measurement
Η Measure both the low and high speeds
of the machine.
Θ Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested.
Ι Star t traveling the machine in the
acceleration zone with the travel levers at
full stroke.
Κ Measure the time required to travel 20m.
3 ~ 5m 20m 3 ~ 5m
Λ After measuring the forward travel
speed, turn the upperstructure 180Á
and measure the reverse travel speed.
Μ Repeat steps Κ and Λ three times in 1696MS05

each direction and calculate the average

values.
(4) Evaluation
The average measured time should meet the following specifications. Unit : Seconds / 20m
Model Travel speed Standard Maximum allowable Remarks
1 Speed 32.7Ü2.0 40.8
R16-9
2 Speed 17.6Ü1.0 22.0

6-5
4) TRACK REVOLUTION SPEED
(1) Measure the track revolution cycle time
with the track raised off ground.
(2) Preparation
Η Adjust the tension of both side tracks to
be equal.
Θ On the track to be measured, mark one
shoe with chalk.
Ι Swing the upperstructure 90° and lower
the bucket to raise the track off ground.
Keep the boom-arm angle between 90 to
110° as shown. Place blocks under
machine frame. 90~110
Κ Keep the hydraulic oil temperature at
50Ü5°C.
(3) Measurement Mark
Η Select the following switch positions.
1696MS06
 Travel mode switch : 1 or 2 speed
Θ Operate the travel control lever of the
raised track in full forward and reverse.
Ι Rotate 1 turn, then measure time taken
for next 3 revolutions.
Κ Raise the other side of machine and
repeat the procedure.
Λ Repeat steps Ι and Κ three times and
calculate the average values.
(4) Evaluation
The revolution cycle time of each track should meet the following specifications.
Unit : Seconds / 3 revolutions
Model Travel speed Standard Maximum allowable
1 Speed 16.5Ü2.0 20.6
R16-9
2 Speed 8.9Ü2.0 11.1

6-6
5) TRAVEL DEVIATION
(1) Measure the deviation by the tracks from
a 20m straight line.
(2) Preparation
Η Adjust the tension of both tracks to be
equal.
Θ Provide a flat, solid test yard 20 m in
length, with extra length of 3 to 5 m on
both ends for machine acceleration and
deceleration. 0.3~0.5m
Ι Hold the bucket 0.3 to 0.5 m above the
ground with the arm and bucket rolled in.
Κ Keep the hydraulic oil temperature at 1696MS07

50Ü5°C.
(3) Measurement
Η Measure the amount of mistracking at
high and low travel speeds.
Θ Star t traveling the machine in the
acceleration zone with the travel levers at 3~5 m extra length
full stroke. a

M
20
Ι Measure the distance between a straight
20m line and the track made by the
machine. (Dimension a) 3~5 m extra length
Κ After measuring the tracking in forward
travel, turn the upperstructure 180°and
measure that in reverse travel.
Λ Repeat steps Ι and Κ three times and 7-7(2) 140-7

calculate the average values.

(4) Evaluation
Mistrack should be within the following specifications.
Unit : mm / 20 m
Model Standard Maximum allowable Remarks
R16-9 200 below 240

6-7
6) SWING SPEED
(1) Measure the time required to swing three
complete turns.
(2) Preparation
Η Check the lubrication of the swing gear
and swing bearing.
Θ Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
Ι 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. The bucket must be empty.
Κ Keep the hydraulic oil temperature at
50Ü5°C. 1696MS08

(3) Measurement
Η Operate swing control lever fully.
Θ Swing 1 turn and measure time taken to
swing next 2 revolutions.
Ι Repeat steps Η and Θ three time and
calculate the average values.
(4) Evaluation
The time required for 2 swings should meet the following specifications.
Unit : Seconds / 2 revolutions
Model Standard Maximum allowable Remarks
R16-9 12.9Ü1.0 16.1

6-8
7) SWING FUNCTION DRIFT CHECK
(1) Measure the swing drift on the bearing
outer circumference when stopping after
a 360° full speed swing.
(2) Preparation
Η Check the lubrication of the swing gear
and swing bearing.
Θ Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
Ι 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 1696MS09
foot pin. The bucket must be empty.
Κ Make two chalk marks: one on the swing
bearing and one directly below it on the
track frame.
Λ Swing the upperstructure 360°.
Μ Keep the hydraulic oil temperature at
50Ü5°C.
(3) Measurement
Η Operate the swing control lever fully and
return it to the neutral position when the
mark on the upperstructure aligns with
that on track frame after swinging 360Á
Θ Measure the distance between the two
marks.
Ι Align the marks again, swing 360Á, then
test the opposite direction.
Κ Repeat steps Θ and Ι three times each 360 swing
Swing start & stop
and calculate the average values.
Driftangle
Drift angle
(4) Evaluation 1696MS10

The measured drift angle should be within the following specifications.

Unit : Degree
Model Standard Maximum allowable Remarks
R16-9 40 below 50

6-9
8) SWING BEARING PLAY
(1) Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.
(2) Preparation
刮 Check swing bearing mounting cap
screws for loosening.
刯 Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
到 Install a dial gauge on the track frame as
shown, using a magnetic base.
刱 Position the upperstructure so that the 7-10(1) 140-7
boom aligns with the tracks facing
towards the front idlers.
刲 Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
刳 Bucket should be empty.
(3) Measurement Measurement : h1
Measurement:h1
刮 With the arm rolled out and bucket rolled
in, hold the bottom face of the bucket to
the same height of the boom foot pin.
Record the dial gauge reading (h1).
刯 Lower the bucket to the ground and use
it to raise the front idler 50 cm. 1696MS18

Record the dial gauge reading (h2). Measurement : h2

到 Calculate bearing play (H) from this data
(h1 and h2) as follows.
H=h2-h1

1696MS11

(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm
Model Standard Maximum allowable Remarks
R16-9 0.5 ~ 1.2 2.4

6-10
9) HYDRAULIC CYLINDER CYCLE TIME
Boom cylinder
(1) Measure the cycle time of the boom,
Raise
standard arm, and standard bucket
cylinders.
(2) Preparation Lower

Η To measure the cycle time of the boom

cylinders:
Arm cylinder
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown. Roll out Roll in
Θ To measure the cycle time of the arm 90
0.5m
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground. Bucket cylinder
Lower the boom until the bucket is 0.5m
above the ground.
Ι To measure the cycle time of the bucket Roll out Roll in
cylinder. 0.5m
The empty bucket should be positioned
1696MS12
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
Κ Keep the hydraulic oil temperature at
50Ü5°C.
(3) Measurement
Η To measure cylinder cycle times.
- Boom cylinders
Measure the time it takes to raise the
boom, 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.
- 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, position the bucket at one
stroke end, then move the control lever
to the other stroke end as quickly as
possible.

6-11
 - Bucket cylinders
Measure the time it takes to roll in the
bucket, 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.
- Repeat each measurement 3 times and
calculate the average values.
(4) Evaluation
The average measured time should meet the following specifications.
Unit : Seconds
Model Function Standard Maximum allowable Remarks
Boom raise 2.4Ü0.4 3.0
Boom lower 2.4Ü0.4 3.0
Arm in 2.4Ü0.4 3.0
Arm out 1.7Ü0.4 2.3
Bucket load 3.0Ü0.4 3.7
R16-9
Bucket dump 2.2Ü0.4 2.8
Boom swing (LH) 4.8Ü0.4 5.9
Boom swing (RH) 3.5Ü0.4 4.3
Dozer up (raise) 1.6Ü0.3 1.9
Dozer down (lower) 1.9Ü0.3 2.2

6-12
10) DIG FUNCTION DRIFT CHECK
(1) Measure dig function drift, which can be
caused by oil leakage in the control valve
and boom, standard arm, and standard
bucket cylinders, with the loaded bucket.
When testing the dig function drift just
after cylinder replacement, slowly operate
each cylinder to its stroke end to purge air.
(2) Preparation
Η Load bucket fully. Instead of loading the
bucket, weight (W) of the following
specification can be used.
 W = M3Ý1.5
Where :
M3 = Bucket heaped capacity(m3)
1.5= Soil specific gravity
Θ Position the arm cylinder with the rod 20
to 30 mm extended from the fully retracted
1696MS13
position.
Ι Position the bucket cylinder with the rod
20 to 30 mm retracted from the fully
extended position.
Κ 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.
Λ Keep the hydraulic oil temperature at
50Ü5°C.
(3) Measurement
Η Stop the engine.
Θ Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
Ι Repeat step Θ three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : mm / 5 min
Model Drift to be measured Standard Maximum allowable Remarks
Boom cylinder 10 below 20
R16-9 Arm cylinder 20 below 30
Bucket cylinder 20 below 30

6-13
11) CONTROL LEVER OPERATING FORCE
(1) Use a spring scale to measure the
maximum resistance of each control lever
at the middle of the grip.
(2) Preparation
Η Keep the hydraulic oil temperature at
50Ü5°C.
(3) Measurement
Η Start the engine.
Θ Operate each boom, arm, bucket and
swing lever at full stroke and measure
the maximum operating force for each.
Ι Lower the bucket to the ground to raise
one track off the ground. Operate the
travel lever at full stroke and measure the
maximum operating force required.
When finished, lower the track and then
jack-up the other track.
Κ Repeat steps Θ and Ι three times and
calculate the average values.
(4) Evaluation
The measured operating force should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 1.4 or below 1.9
Arm lever 1.4 or below 1.9
R16-9 Bucket lever 1.4 or below 1.9
Swing lever 1.4 or below 1.9
Travel lever 2.0 or below 2.5

6-14
12) CONTROL LEVER STROKE
(1) Measure each lever stroke at the lever top
using a ruler.
ö When the lever has play, take a half of this
value and add it to the measured stroke.
(2) Preparation
Keep the hydraulic oil temperature at
50Ü5°C.
(3) Measurement
Η Stop the engine.
Θ Measure each lever stroke at the lever
top from neutral to the stroke end using a
ruler.
Ι Repeat step Θ three times and calculate
the average values.
(4) Evaluation
The measured drift should be within the following specifications.
Unit : kgf
Model Kind of lever Standard Maximum allowable Remarks
Boom lever 87Ü10 109
Arm lever 87Ü10 109
R16-9 Bucket lever 87Ü10 109
Swing lever 87Ü10 109
Travel lever 86Ü10 105

6-15
13) PILOT PRIMARY PRESSURE
(1) Preparation
Pressure gauge
Η Stop the engine.
Θ Loosen the cap of screw coupling at the
Screw coupling
fitting near pilot pump and connect
pressure gauge.
Ι Star t the engine and check for oil
leakage from the port. P4

Κ Keep the hydraulic oil temperature at

50Ü5˚C.
(2) Measurement
Η Measure the primary pilot pressure.
1696MS14
(3) Evaluation
The average measured pressure should meet the following specifications:
Unit : kgf / cm2
Model Standard Remarks
R16-9 30Ü5

6-16
14) FOR TRAVEL SPEED SELECTING PRESSURE
(1) Preparation
Η Stop the engine.
Θ To measure the speed selecting pressure: Pressure gauge
Install a connector and pressure gauge
Connector
assembly to turning joint P2 port as
shown.
Ι Star t the engine and check for on
leakage from the adapter. P2

Κ Keep the hydraulic oil temperature at

50Ü5°C.
(2) Measurement
Η Select the following switch positions. Turning joint
Travel mode switch : 1 speed
2 speed
Θ Measure the travel speed selecting R27Z96MC18
pressure in the Hi or Lo mode.
Ι Lower the bucket to the ground to raise
the track off the ground. Operate the
travel lever at full stroke and measure the
fast speed pressure.
Κ Repeat steps Θ and Ι three times and
calculate the average values.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Travel speed mode Standard Maximum allowable Remarks
1 Speed 0 -
R16-9
2 Speed 30Ü5 -

6-17
15) MAIN PUMP DELIVERY PRESSURE
(1) Preparation
Η Stop the engine. G1

Θ To measure the main pump pressure.

G2
Loosen the cap of screw coupling and
connect pressure gauge to the main
pump gauge port(G1, G2, G3) as shown.
A2 G3
Ι Star t the engine and check for oil A1

leakage from the port. A3

Κ Keep the hydraulic oil temperature at
50Ü5°C.
(2) Measurement
Η Measure the main pump deliver y
pressure at high idle. 1696MS15

(3) Evaluation
The average measured pressure should meet the following specifications.
Unit : kgf / cm2
Model Engine speed Standard Allowable limits Remarks
R16-9 High idle 20Ü5 -

6-18
16) SYSTEM PRESSURE REGULATOR RELIEF SETTING
(1) Preparation
Η Stop the engine.
Θ To measure the system relief pressure.
Loosen the cap of screw coupling and G1

connect pressure gauge to the main

G2
pump gauge port(G1, G2, G3) as shown.
Ι Star t the engine and check for oil
leakage from the port.
A2
Κ Keep the hydraulic oil temperature at A1
G3

50Ü5°C.
A3

(2) Measurement
Η Slowly operate each control lever of
boom, arm and bucket functions at full
stroke over relief and measure the
pressure.
Θ In the swing function, place bucket
against an immovable object and 1696MS15

measure the relief pressure.

Ι In the travel function, lock undercarriage
with an immovable object and measure
the relief pressure.
(3) Evaluation
The average measured pressure should be within the following specifications.
Unit : kgf / cm2
Model Function to be tested Standard
Boom, Arm, Bucket 210Ü10
R16-9 Travel 210Ü10
Swing 170Ü10

6-19
GROUP 2 MAJOR COMPONENT

1. MAIN PUMP
Before inspection, wash the parts well and dry them completely.
Inspect the principal parts with care and replace them with new parts when any abnormal wear
exceeding the allowable limit or damage considered harmful is found.
Replace the seal also when any remarkable deformation and damage are found.

1) INSPECTION POINTS WHEN DISASSEMBLED

Part Extent of the damage Inspection standard Action

Excessive wear on the Worn depth : 0.025 mm or more Replace the shaft.
Shaft (3)
seal surface.
Excessive wear or Worn depth : 0.020 mm or more Replace the cylinder barrel
Valve plate (5) damages on the sliding kit.
surface.
Excessive wear or Worn depth : 0.020 mm or more Replace the cylinder barrel
damages on the sliding kit.
surface.
Cylinder barrel (4)
Clearance between the 0.050 mm or more Replace the cylinder barrel
pistons. kit.

Wear of joint section Play between the shoe and the Replace the cylinder barrel
Piston (6),
piston. 0.2 mm or more by hand kit.
Shoe (7)
operation.
Seals Damage, excessive rust Replace each part.
(O-rings, gasket, -
etc.)

Piston assembly Cylinder barrel

Installation part of oil seal
d

Shoe

Piston
ɻ

R27Z96MC01

6-20
2) TROUBLESHOOTING AND COUNTERMEASURE

No. Trouble Possible cause Countermeasure

1 Overload to engine · Speed is higher than standard · Readjust it as standard

· Setting pressure is higher than · Readjust it as spec
specifications
· Damage of internal parts of pump · Repair or replace
2 Low pump flow or low · Speed down of engine · Readjust of engine speed
pressure · Wrong coupling · Repair or replace
· Damage of internal parts of pump · Repair or replace
3 Abnormal noise or · Air in the oil · Check piping
abnormal vibration Bleed the air in the hydraulic circuit
(cavitations)
· Water in the oil · Replace oil
· Clog of suction filter · Clean or replace
· High suction pressure · Correction
· Damage of piston shoe · Replace
· Installation condition is no good · Correction
· Wrong coupling · Replace
4 Oil leakage · Damage of O-ring or packing · Replace
· Loosened plug · Tight up
· Leaking from oil seal · Replace
Replace of oil seal

6-21
2. MAIN CONTROL VALVE
Part name Inspection item Criteria & measure
Block ÂExistence of scratch, rusting or corrosion. Â
In case of damage in following section,
replace part.
- Sliding sections of casing fore and spool,
especially land sections applied with holded
pressure.
- Seal pocket section where spool is inserted.
- Seal section of port where O-ring contacts.
- Seal section of each relief valve for main,
travel, and port.
- Other damages that may damage normal
functions.
Spool Â
Existence of scratch, gnawing, rusting or Â
Replacement when its outside sliding section
corrosion. has scratch (Especially on seals-contacting
section).
ÂO-ring seal sections at both ends. Â
Replacement when its sliding section has
scratch.
Â
Insert spool in casing hole, rotate and Â
Correction or replacement when O-ring is
reciprocate it. damaged or when spool does not move
smoothly.
Poppet ÂDamage of poppet or spring Â
Correction or replacement when sealing is
incomplete.
ÂInsert poppet into casing and function it. Â
Normal when it can function lightly without
being caught.
Around spring Â
Rusting, corrosion, deformation or breaking ÂReplacement for significant damage.
of spring, spring seat, plug or cover.
Around seal ÂExternal oil leakage. ÂCorrection or replacement.
for spool
Â
Rusting, corrosion or deformation of seal ÂCorrection or replacement.
plate.
Main relief valve, ÂExternal rusting or damage. ÂReplacement.
port relief valve &
ÂContacting face of valve seat. ÂReplacement when damaged.
Anti cavitation valve
ÂContacting face of poppet. ÂReplacement when damaged.
ÂAbnormal spring. ÂReplacement.
Â100 replacement in general.
ÂO-rings, back up rings and seals.

6-22
3. SWING
SWING MOTOR
1) POSSIBLE REASONS FOR THE TROUBLE AND ITS COUNTERMEASURES

Trouble Possible reasons Countermeasure

Setting pressure is too low. Replace the relif valve

Relief valve
Faulty operation. assembly.

Motor does not move. Burned inner parts. Replace the hydraulic motor
The supplied pressure is Hydraulic motor
Too much internal leakage. assembly.
enough.
Replace the reduction gear
Reduction gear Damage to the gears.
assembly.
Overload - Remove the overload.
Setting pressure is too low. Replace the relief valve
Relief valve
Faulty operation. assembly.

Burned sliding parts. Replace the hydraulic motor

Insufficient torque Hydraulic motor
Too much internal leakage. assembly.

Damage to the gears. Replace the pinion kit, carrier

Reduction gear
Damage to bearings. kit.

Cavitation noise Insufficient flow. Adjust the piping.

Replace the hydraulic motor
Hydraulic motor Damage to sliding parts.
assembly.
Abnormal noise
Damage to the gears. Replace the pinion kit, carrier
Reduction gear
Damage to bearings kit.

Pinion gear Damage to the gear surface. Replace the pinion kit.
Damage to O-rings. Replace the O-ring
Body gasket
Oil leakage Loose bolts. Re-tighten the loose bolts.
Pinion gear Damage to oil seal. Replace the pinion kit.
Replace the relief valve
Delay in start up, or delay Relief valve Faulty operation.
assembly.
in stopping
Check valve Internal leakage. Replace the body H kit.
Burned or damaged sliding Replace the hydraulic motor
Hydraulic motor
parts. assembly.
Excessive heat generation
Damage to the gears. Replace the pinion kit, carrier
Reduction gear
Damage to bearings kit.

6-23
 2) STANDARD FOR PARTS INSPECTION
(1) Reduction
eduction gear section

Part Extent of the damage Inspection standard Action

Pitching
Excessive wear of the Pitching area 5% or more of Replace the pinion kit.
A internal gear surface the gear surface

Damage to spline By visual Replace the carrier kit.

Carrier 1 section
Pitching
Excessive wear of the Pitching area 5% or more of Replace the carrier kit.
surface the gear surface

S1 gear
b1 gear Excessive wear of the By visual pitching, flaking
bearing surface

Excessive wear of the By visual pitching, flaking Replace the carrier kit.
Ring bearing surface

Excessive wear of the By visual pitching, flaking Replace the carrier kit.
Roller bearing surface

Other (screw, Damage, excessive Replace each part.

rust -
etc.)

(2) Hydraulic
ydraulic motor section

Part Extent of the damage Inspection standard Action

Excessive wear of the Worn depth : 25μm or more Replace the hydraulic
Shaft spline section motor assembly.

Excessive wear to the Worn depth : 20μm or more Replace the cylinder
Cylinder barrel sliding surface of the barrel kit.
valve plate
Excessive wear to the Worn depth : 20μm or more Replace the cylinder
Valve plate sliding surface of the barrel kit.
cylinder barrel
Wear of joint section of Play of piston and shoe : 0.3 mm or more by Replace the cylinder
Piston shoe shoe hand operation barrel kit.

Excessive wear to the Worn depth : 0.1 mm or more Replace the swash
Swash plate sliding surface of the plate kit.
shoe
Damage, excessive Replace each part.
Other (screw,
rust -
etc.)

6-24
4. TRAVEL MOTOR
1) MAINTENANCE STANDARD FOR TRAVEL MOTOR
Travel motors basically don't require maintenance except changing the reducer lubricant. Don't
disassemble the motor unless there are problem with it. Refer to the following standards for parts
(kits) replacement.
(1) Reducer

No. Part name Point to be checked Standard Action

1 Body (internal Engaging tooth surface No pitching with 5% or greater (ratio Replace
gear) with B1 and B2 gears of engaging area to tooth surface)
No abnormal damage
2 Carrier 2 Spline tooth surface No abnormal damage, wear Replace whole
carrier 2 kit
Loose of B2 pins No loose by hand
3 B1 gears Tooth surface No pitching with 5% or greater (ratio Replace
of engaging area to tooth surface)
No abnormal damage
Needle rolling contact No flaking and pitching
surface
4 B2 gears Tooth surface No pitching with 5% or greater (ratio Replace whole
of engaging area to tooth surface) carrier 2 kit
No abnormal damage
Needle rolling contact No flaking and pitching
surface
5 S1 gear Tooth surface No pitching with 5% or greater (ratio Replace whole
of engaging area to tooth surface) carrier 2 kit
No abnormal damage
6 S2 gear Engaging tooth surface No pitching with 5% or greater (ratio Replace
with B2 gears of engaging area to tooth surface)
No abnormal damage
Spline tooth surface No abnormal damage, wear
7 B2 pins Needle rolling contact No flaking and pitching Replace whole
surface carrier 2 kit
8 Floating seals Seat surface No abnormal damage, wear Replace
O-ring surface No damage, deformation, and
hardening
9 Angular ball Rolling contact surface No abnormal damage, flaking Replace
bearings
10 Needles Rolling contact surface No flaking and pitching Replace whole
carrier 2 kit
11 O-rings Surface, hardness No damage, deformation, and Replace
hardening

6-25
(2) Hydraulic valve and motor
No. Part name Point to be checked Standard Action
12 Body 1 Spool sliding contact No abnormal damage, wear Relpace whole
surface body 1 kit
13 Counter valve Body 1 sliding contact No abnormal damage, wear Relpace whole
spool surface body 1 kit
Two-speed
spool
Shuttle spool
14 Body 2 Spline tooth surface No abnormal damage, wear Replace whole
body 2 kit
Control piston sliding No abnormal damage, wear
contact surface Clearance between piston and body
2 is 0.023 mm or smaller
Swash plate installaion No abnormal damage, wear
surface
Ball sliding contact No abnormal damage, wear
surface
15 Shaft Spline tooth surface No abnormal damage, wear Replace shaft kit
Oil seal sliding contact No abnormal damage, wear
surface (0.025 mm or greater)
16 Cylinder barrel Piston sliding contact No abnormal damage, wear Replace cylinder
surface Clearance between piston and barrel kit
cylinder barrel is 0.030 mm or
smaller
Valve place sliding No abnormal damage, wear Lap or replace
contact surface (0.020 mm or greater) cylicder barrel kit
17 Valve plate Cylinder barrel sliding No abnormal damage, wear Lap or replace
contact surface (0.020 mm or greater) cylicder barrel kit
18 Pistons Cylinder barrel sliding No abnormal damage, wear Replace cylinder
Shoes contact surface (0.020 mm or greater) barrel kit
Swash plate sliding No abnormal damage, wear Lap or replace
contact surface (0.020 mm or greater) cylicder barrel kit
Loose of shoe calking Loose is smaller than 0.3 mm Replace cylinder
part barrel kit
19 Shoe holder Barrel holder sliding No abnormal damage, wear Replace cylinder
contact surface barrel kit
20 Barrel holder Spline tooth surface No abnormal damage, wear Replace cylinder
barrel kit
Shoe holder sliding No abnormal damage, wear
contact surface
21 Swash plate Shoe sliding contact No abnormal damage, wear Lap or replace
surface (0.020 mm or greater)
Ball sliding contact No abnormal damage, wear Replace
surface
22 Control piston Body 2 sliding contact Clearance between piston and body Replace body 2 kit
surface 2 is 0.023 mm or smaller
23 Oil seal Lip surface No abnormal damage, wear and Replace
deformation
24 Ball bearing Rolling contact surface No abnormal damage, flaking Replace
25 Springs Surface No crack Replace
26 O-rings Surface and hardness No damage, deformation, and Replace
hardening

6-26
 2) FAILURE DIAGNOSIS OF TRAVEL MOTOR
Failure detail Major causes Countermeasure
Doesn't start Operating defect in hydraulic equipment except Inspect and repair or replace each
travel motors equipment. Check that normal work-
ing pressure is supplied to the motor
inlet port.
Defect in reducer
- Damage of inner parts Replace the damaged part (kit).
Defect in hydraulic motor
- Oil leakage due to abnormal wear of the slid- Replace the worn part (kit).
ing parts
- Damage of inner parts Replace the damaged part (kit).
Defect in hydraulic valve
- Spool doesn't move
Foreign object is caught in the spool sliding part. Remove the foreign object. In case of
much leakage, replace the body 1 kit.
Choke is clogged Remove the foreign object.
Doesn't stop or stop Defect in hydraulic valve
slowly - Spool doesn't return
Foreign object is caught in the spool sliding part. Remove the foreign object. In case of
much leakage, replace the body 1 kit.
Choke is clogged. Remove the foreign object.
Spring is damaged. Replace the body 1 kit.
- Check valve doesn't close due to foreign object Remove the foreign object. In case of
being caught on the seat. much leakage, replace the body 1 kit.
Rotating speed is Prescribed flow rate is not supplied to the motor Inspect and repair or replace the
slow due to operating defect in the pump. pump.
Volumetric efficiency declines due to defect in the
motor.
- Abnormal wear of sliding parts Replace the worn part (kit).
Volumetric efficiency declines due to defect in the
hydraulic valve.
- Abnormal wear of main spool and two speed Replace body 1 kit.
spool sliding part

6-27
 Failure detail Major causes Countermeasure
Doesn't change to Operating defect in hydraulic equipment except Inspect and repair or replace each
two speed travel motors equipment. Check that normal pres-
sure is supplied to the pilot port.
Defect in the hydraulic valve
- Two speed spool doesn't move due to foreign Remove the foreign object. In case of
object being caught in the spool sliding part. much leakage, replace the body 1 kit.
- Choke in the two speed pilot line is clogged. Remove the foreign object.
Defect in the hydraulic motor
- Control piston doesn't move.
Foreign object is caught in the piston sliding part. Remove the foreign object. In case of
much leakage, replace the body 2 kit.
Oil leakage due to abnormal wear of the sliding Replace the worn part (kit).
part.
Oil leakage due to damage of O-ring located be- Replace the O-ring.
tween body 1 and body 2.
Doesn't change to Operating defect in hydraulic equipment except Inspect and repair or replace each
one speed travel motors equipment. Check that normal pres-
sure is supplied to the pilot port.
Defect in the hydraulic valve
- Two speed spool doesn't move.
Foreign object is caught in the spool sliding Remove the foreign object. In case of
part. much leakage, replace the body 1 kit.
Damage of spring Replace the body 1 kit.
- Choke in the two speed pilot line is clogged. Remove the foreign object.
Tracking deviation Same as No.3, 4 and 5 -
Oil leakage Oil leakage due to damage of O-rings.
- Damage of O-ring located in the reducer cover. Replace the O-ring.
- Damage of O-rings located between body 1 Replace the O-ring.
and body 2.
Oil leakage from the floating seals
- Abnormal wear of the seat surface or damage Replace the floating seal.
of the O-ring.
- Pressure in the reducer casing rises due to Replace the oil seal.
damage of the oil seal.

6-28
5. TURNING JOINT
Parts Name Check Points Measures

Sliding surface with Plating worn or peeled due to seizure or contamination. Replace
sealing sections.
Sliding surface ÂWorn abnormality or damaged more than 0.1 mm Replace
between body and (0.0039 in) in depth due to seizure contamination.
stem other than
Body, ÂDamaged more than 0.1 mm (0.0039 in) in depth. Smooth with oilstone.
sealing section.
Stem
Sliding surface with ÂWorn more than 0.5 mm (0.02 in) or abnormality. Replace
thrust plate.
ÂWorn less than 0.5 mm (0.02 in). Smooth
Â
Damage due to seizure or contamination remediable Smooth
within wear limit (0.5 mm) (0.02 in).
Sliding surface with ÂWorn more than 0.5 mm (0.02 in) or abnormality. Replace
thrust plate.
ÂWorn less than 0.5 mm (0.02 in). Smooth
Cover
Â
Damage due to seizure or contamination remediable Replace
within wear limit (0.5 mm) (0.02 in).
ÂExtruded excessively from seal groove square ring. Replace

Extrusion
-
Square ring

Â
Slipper ring 1.5 mm (0.059 in) narrower than seal Replace

groove, or narrower than back ring.

Seal set -

1.5mm (max.)
(0.059in)

ÂWorn more than 0.5 mm (0.02 in) ~ 1.5 mm (MAX.) Replace

(0.059 in)

6-29
6. CYLINDER
Part name Inspecting section Inspection item Remedy

Piston rod ÂNeck of rod pin ÂPresence of crack ÂReplace

ÂWeld on rod hub ÂPresence of crack ÂReplace

Â
Stepped part to which piston ÂPresence of crack ÂReplace

is attached.
ÂThreads ÂPresence of crack ÂRecondition or replace

ÂPlated surface Â
Plating is not worn off to base ÂReplace or replate

metal.
ÂRust is not present on plating. ÂReplace or replate
ÂScratches are not present. Â
Recondition, replate or replace
ÂRod ÂWear of O.D. ÂRecondition, replate or replace

ÂBushing at mounting part ÂWear of I.D. ÂReplace

Cylinder tube ÂWeld on bottom ÂPresence of crack ÂReplace

ÂWeld on head ÂPresence of crack ÂReplace

ÂWeld on hub ÂPresence of crack ÂReplace

ÂTube interior ÂPresence of faults ÂReplace if oil leak is seen

ÂBushing at mounting part ÂWear on inner surface ÂReplace

Gland ÂBushing ÂFlaw on inner surface ÂReplace if flaw is deeper

than coating

6-30
GROUP 3 TRACK AND WORK EQUIPMENT

1. TRACK SHOE
1) RUBBER SHOE SPEC

1
B

A
B A SECTION B-B

3
2

SECTION A-A
R5576MC17

Unit : mm
Criteria
No Check item Remedy
Standard size Repair limit
1 Link pitch 48 50
2 Height of grouser 25 5 Replace
3 Width of link 30 40

6-31
2. IDLER

1
2

R27Z96MC23

Unit : mm
Criteria
No Check item Remedy
Standard size Repair limit
1 Outside diameter of flange Rubber 250 -
Rebuild
2 Outside diameter of thread Rubber 210 204
or replace
3 Width of flange 23 17

6-32
3. TRACK ROLLER

1
R35Z76MC19

Unit : mm
Criteria
No Check item Remedy
Standard size Repair limit
1 Outside diameter of flange Rubber 100 -
Rebuild
2 Outside diameter of thread Rubber 70 64
or replace
3 Width of flange 22 16

6-33
4. TENSION CYLINDER

1696MS16

Unit : mm
Criteria
No Check item Remedy
Standard size Repair limit
Track frame 51 53 Rebuild
1 Vertical width of idler guide
Idler support 50 48 Rebuild or replace
Track frame 151 155 Rebuild
2 Horizontal width of idler guide
Idler guide 150 146 Rebuild or replace
Standard size Repair limit
Free Installed Installed Free Installed Replace
3 Recoil spring length length load length load
261 223 880 kg - 700 kg

6-34
5. SPROCKET

3
4
1
2

R27Z96MC22

Unit : mm
Criteria
No Check item Remedy
Standard size Repair limit
Wear out of sprocket tooth
1 253 247
lower side diameter
Wear out of sprocket tooth
2 292 -
upper side diameter Rebuild or
Wear out of sprocket tooth Replace
3 16 -
upper side width
Wear out of sprocket tooth
4 22 16
lower side width

6-35
6. WORK EQUIPMENT

F E D C B A

G H I J K N O L M

1696MS17

Unit : mm
Pin Bushing
Remedy
Measuring point Normal Recomm. Recomm.
Mark Limit Limit &
(Pin and Bushing) value service service
of use of use Remark
limit limit
A Boom rear 35 34 33.5 35.5 36 Replace
B Boom cylinder head 30 29 28.5 30.5 31 Æ
C Boom cylinder rod 30 29 28.5 30.5 31 Æ
D Arm cylinder head 30 29 28.5 30.5 31 Æ
E Boom front 30 29 28.5 30.5 31 Æ
F Arm cylinder rod 30 29 28.5 30.5 31 Æ
G Bucket cylinder head 30 29 28.5 30.5 31 Æ
H Arm link 30 29 28.5 30.5 31 Æ
I Bucket and arm link 30 29 28.5 30.5 31 Æ
J Bucket cylinder rod 30 29 28.5 30.5 31 Æ
K Bucket link 30 29 28.5 30.5 31 Æ
L Boom swing post 45 44 43.5 45.5 46 Æ
M Boom swing cylinder 30 29 28.5 30.5 31 Æ
N Blade cylinder 30 29 28.5 30.5 31 Æ
O Blade and frame link 30 29 28.5 30.5 31 Æ

6-36