SECTION 7 MAINTENANCE STANDARD

Group 1 Operational Performance Test 7-1

Group 2 Major Components 7-19

Group 3 Work Equipment 7-28

7-1

SECTION 7 MAINTENANCE STANDARDGROUP 1 OPERATIONAL PERFORMANCE TEST

1. PURPOSEPerformance tests are used to check:

OPERATIONAL PERFORMANCE OF A NEWMACHINEWhenever a new machine is delivered inparts and reassembled at a customer's site,it must be tested to confirm that theoperational performance of the machinemeets Hyundai spec.

OPERATIONAL PERFORMANCE OF AWORKING MACHINEWith the passage of time, the machine'soperational performance deteriorates, sothat the machine needs to be servicedperiodically to restore it to its originalperformance level.Before servicing the machine, conductperformance tests to check the extent ofdeterioration, and to decide what kind ofservice needs to be done(by referring to the"Service Limits" in this manual).

OPERATIONAL PERFORMANCE OF AREPAIRED MACHINEAfter the machine is repaired or serviced, itmust be tested to confirm that itsoperational performance was restored bythe repair and/or service work done.

Workingcondition

Operating

Maintenance record

1)

2)

3)

14W77MS01

7-2

2. TERMINOLOGY

STANDARDSpecifications applied to the brand-newmachine, components and parts.

1)

SERVICE LIMITThe lowest acceptable performance level.When the performance level of the machinefalls below this level, the machine must beremoved from work and repaired.Necessary parts and components must bereplaced.

2)

140W77MS02

140W77MS03

7-3

3. OPERATION FOR PERFORMANCE TESTS

Observe the following rules in order to carryout performance tests accurately andsafely.

The machineRepair any defects and damage found,such as oil or water leaks, loose bolts,cracks and so on, before starting to test.

Test areaSelect a hard, flat surface.Secure enough space to allow themachine to run straight more than 20m,and to make a full swing with the frontattachment extended.If required, rope off the test area andprovide signboards to keep unauthorizedpersonnel away.

PrecautionsBefore starting to test, agree upon thesignals to be employed for communicationamong coworkers. Once the test isstarted, be sure to communicate witheach other using these signals, and tofollow them without fail.Operate the machine carefully andalways give first priority to safety.While testing, always take care to avoidaccidents due to landslides or contactwith high voltage power lines. Alwaysconfirm that there is sufficient space forfull swings.Avoid polluting the machine and theground with leaking oil. Use oil pans tocatch escaping oil. Pay special attentionto this when removing hydraulic pipings.

Make precise measurementsAccurately calibrate test instruments inadvance to obtain correct data.Carry out tests under the exact testconditions prescribed for each test item.Repeat the same test and confirm thatthe test data obtained can be procuredrepeatedly. Use mean values ofmeasurements if necessary.

1)

(1)

(2)①②

③

(3)

(4)

①

②

③

④

①

②

③

(290-7TIER) 7-3

7-4

ENGINE SPEED

Measure the engine speed at each powermodeThe engine speed at each power modemust meet standard RPM; if not, all otheroperational performance data will beunreliable. It is essential to perform thistest first.

Preparation Warm up the machine, until the enginecoolant temperature reaches 50。C ormore, and the hydraulic oil is 50±5。C.Push the M-mode switch and confirmthat the fuel injection pump governorlever comes into the high-idle stopper.To measure engine RPM.

Measurement Start the engine. The engine will run atstart idle speed. Measure engine speedwith a tachometer.Measure and record the engine speed ateach mode(M, H, S).Select the M-mode.Lightly operate the bucket control lever afew times, then return the control lever toneutral; The engine will automaticallyenter the auto-idle speed after 4seconds.Measure and record the auto decelerationspeed.

2)

(1)

※

(2)

(3)①

②

③④

⑤

①

②

③

EvaluationThe measured speeds should meet the following specifications.

(4)

Model

R170W-7

Engine speed

Start idle

M mode

H mode

S mode

Auto decel

Standard

950±100

2200±50

2100±50

2000±50

1200±100

Remarks

Unit : rpm

Condition : Set the accel dial at 10(Max) position.

7-5

TRAVEL SPEED

Measure the time require for theexcavator to travel a 50m at high speedand a 20m at low speed test run.

PreparationPrepare a flat and solid test track 50m inlength, with extra length of 150m formachine acceleration.Set the traveling position as figure.Keep the hydraulic oil temperature at50±5。C.

MeasurementMeasure both the low and high speed ofthe machine.Before starting either the low or highspeed tests, adjust the LH multifunctionswitch to the speed to be tested, thenselect the following switch position.·Mode selector : M modeStart traveling the machine in the extralength with the two speed switch at highor low speed.Measure the time required to travel 50mat high speed or 20m at low speed.After measuring the Forward travelspeed, turn the upperstructure 180。andmeasure the Reverse travel speed.Repeat steps ④ and ⑤ three times ineach direction and calculate the averagevalues.

Evaluation

100m 50m

Extra lengthTest runExtra length

High speed : 50mLow speed : 20m

3)

(1)

(2)①

②③

(3)①

②

③

④

⑤

⑥

The average measured time should meet the following specifications.(4)

Model

R170W-7

Travel speed

Low speed

High speed

Standard

7.6

6

Maximum allowable

9.5

7.5

Remarks

Seconds / 20m

Seconds / 50m

17W77MS04

17W77MS05

7-6

SWING SPEED

Measure the time required to swing threecomplete turns.

PreparationCheck the lubrication of the swing gearand swing bearing.Place the machine on flat, solid groundwith ample space for swinging. Do notconduct this test on slopes.Lower the dozer blade at ground.With the arm rolled out and bucket rolledin, hold the bucket so that the height ofthe bucket pin is the same as the boomfoot pin. The bucket must be empty.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.·Mode selector : M modeOperate swing control lever fully.Swing 1 turn, and measure time taken toswing next 3 revolutions.Repeat steps ② and ③ three times andcalculate the average values.

Evaluation

4)

(1)

(2)①

②

③④

⑤

(3)①

②③

④

The time required for swings should meet the following specifications.

Model

R170W-7

Power selector switch

M mode

Standard

15.7±1.5

Maximum allowable

19.6

Unit : Seconds / 3 revolutions

(4)

17W77MS06

7-7

SWING FUNCTION DRIFT CHECK

Measure the swing drift on the bearingouter circumference when stopping after a360。full speed swing.

PreparationCheck the lubrication of the swing gearand swing bearing.Place the machine on flat, solid groundwith ample spacer for swinging. Do notconduct this test on slopes.Lower the dozer blade at ground.With the arm rolled out and bucket rolledin, hold the bucket so that the height ofthe bucket pin is the same as the boomfoot pin. The bucekt must be empty.Make two chalk marks: One on the swingbearing and one directly below it on thelower frame.Swing the upperstructure 360。.Keep the hydraulic oil temperature at 50±5。C.

MeasurementConduct this test in the H mode.Select the following switch position.·Mode selector : M modeOperate the swing control lever fully andreturn it to the neutral position when themark on the upperstructure aligns withthat on lower frame after swinging 360。.Measure the distance between the twomarks.Align the marks again, swing 360°, thentest the opposite direction.Repeat steps ④ and ⑤ three times eachand calculate the average values.

Evaluation

5)

(1)

(2)①

②

③④

⑤

⑥⑦

(3)①②

③

④

⑤

⑥

Unit : Degree

The measured dirft angel should be within the following specifications.(4)

Model

R170W-7

Mode select switch

M mode

Standard

90

Maximum allowable

157.5

Remarks

Drift angle

Swing start and stop

360 swing

17W77MS06

20W77MS04

7-8

Unit : mm

SWING BEARING PLAY

Measure the swing bearing play using adial gauge to check the wear of bearingraces and balls.

PreparationCheck swing bearing mounting capscrews for loosening.Check the lubrication of the swingbearing. Confirm that bearing rotation issmooth and without noise.Install a dial gauge on the track frame asshown, using a magnetic base.Position the upperstructure so that theboom aligns with the tracks facingtowards the front idlers.Position the dial gauge so that its needlepoint comes into contact with the bottomface of the bearing outer race.Bucket should be empty.

MeasurementWith the arm rolled out and bucket rolledin, hold the bottom face of the bucket tothe same height of the boom foot pin.Record the dial gauge reading(h1).Lower the bucket to the ground and useit to raise the front idler 50cm.Record the dial gauge reading(h2).Calculate bearing play(H) from thisdata(h1 and h2) as follows.H=h2-h1

Evaluation

6)

(1)

(2)①

②

③

④

⑤

⑥

(3)①

②

③

The measured drift should be within the following specifications.(4)

Model

R170W-7

Standard

0.5 ~ 1.5

Maximum allowable

3.0

Remarks

7-10(1) 140-7

17W77MS08

Measurement : (h1)

Measurement : (h2)

7-9

90

0.5m

0.5m

Raise

Lower

Roll in Roll out

Roll in Roll out

HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the boom,standard arm, and standard bucketcylinders.

PreparationTo measure the cycle time of the boomcylinders. With the arm rolled out and the emptybucket rolled out, lower the bucket to theground, as figure.To measure the cycle time of the armcylinder.With the empty bucket rolled in, positionthe arm so that it is vertical to the ground.Lower the boom until the bucket is 0.5mabove the ground.To measure the cycle time of the bucketcylinder.The empty bucket should be positionedat midstroke between roll-in and roll-out,so that the sideplate edges are vertical tothe ground.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.·Mode selector : M modeTo measure cylinder cycle times.Boom cylinders.Measure the time it takes to raise theboom, and the time it takes to lower theboom. To do so, position the boom atone stroke end then move the controllever to the other stroke end as quicklyas possible.Arm cylinder.Measure the time it takes to roll in thearm, and the time it takes to roll out thearm. To do so, position the bucket at onestroke end, then move the control leverto the other stroke end as quickly aspossible.

7)

(1)

(2)①

②

③

④

(3)①

②-

-

17W77MS09

7-10

Bucket cylinders.Measure the time it takes to roll in thebucket, and the time it takes to roll outthe bucket. To do so, position thebucket at one stroke end, then move thecontrol lever to the other stroke end asquickly as possible.Repeat each measurement 3 times andcalculate the average values.

Evaluation

-

-

The average measured time should meet the following specifications.

Unit : Seconds

(4)

Model

R170W-7

Function

Boom raise

Boom lower

Arm in

Arm out

Bucket load

Bucket dump

Standard

3.2±0.4

2.6±0.4

2.9±0.4

3.3±0.4

2.8±0.3

3.8±0.4

2.1±0.3

Maximum allowable

3.8

3.2

3.5

3.9

3.4

4.5

2.6

Remarks

Heavy duty

General

7-11

DIG FUNCTION DRIFT CHECK

Measure dig function drift, which can becaused by oil leakage in the control valveand boom, standard arm, and standardbucket cylinders, with the loaded bucket.When testing the dig function drift justafter cylinder replacement, slowly operateeach cylinder to its stroke end to purge air.

PreparationLoad bucket fully. Instead of loading thebucket, weight(W) of the followingspecification can be used.W=M3×1.5Where :

M3 =Bucket heaped capacity(m3)1.5= Soil specific gravity

Position the arm cylinder with the rod 20to 30mm extended from the fully retractedposition.Position the bucket cylinder with the rod20 to 30mm retracted from the fullyextended position.With the arm rolled out and bucket rolledin, hold the bucket so that the height ofthe bucket pin is the same as the boomfoot pin.Keep the hydraulic oil temperature at 50±5。C.

MeasurementStop the engine.Five minutes after the engine has beenstopped, measure the changes in thepositions of the boom, arm and bucketcylinders.Repeat step ② three times and calculatethe average values.

Evaluation

8)

(1)

(2)①

·

②

③

④

⑤

(3)①②

③

The measured drift should be within the following specifications.Unit : mm / 5min

Model

R170W-7

Drift to be measured

Boom cylinder

Arm cylinder

Bucket cylinder

Standard

10 below

10 below

40 below

Maximum allowable

20

20

60

Remarks

(4)

17W77MS10

7-12

Unit : kgf

CONTROL LEVER OPERATING FORCE

Use a spring scale to measure themaximum resistance of each control leverat the middle of the grip.

PreparationKeep the hydraulic oil temperature at 50±5。C.

MeasurementStart the engine.Select the following switch positions.·Mode selector : M modeOperate each boom, arm, bucket andswing lever at full stroke and measurethe maximum operating force for each.Operate each boom, arm, bucket andswing lever at full stroke and measurethe maximum operating force for each.Repeat steps ③ three times andcalculate the average values.

Evaluation

9)

(1)

(2)①

(3)①②

③

④

⑤

The measured operating force should be within the following specifications.

Model

R170W-7

Kind of lever

Boom lever

Arm lever

Bucket lever

Swing lever

Standard

1.6 or below

1.6 or below

1.6 or below

1.6 or below

Maximum allowable

2.0

2.0

2.0

2.0

Remarks

(4)

7-13

Unit : mm

CONTROL LEVER STROKE

Measure each lever stroke at the lever topusing a ruler.When the lever has play, take a half of thisvalue and add it to the measured stroke.

PreparationKeep the hydraulic oil temperature at 50±5。C.

MeasurementStop the engine.Measure each lever stroke at the levertop from neutral to the stroke end using aruler.Repeat step ② three times and calculatethe average values.

Evaluation

10)

(1)

※

(2)

(3)①②

③

The measured drift should be within the following specifications.(4)

Model

R170W-7

Kind of lever

Boom lever

Arm lever

Bucket lever

Swing lever

Standard

83±10

83±10

83±10

83±10

Maximum allowable

103

103

103

103

Remarks

7-14

PILOT PRIMARY PRESSURE

PreparationStop the engine.Remove the top cover of the hydraulictank oil supply port with a wrench.Loosen and remove plug on the pilotpump delivery port and connect pressuregauge.Start the engine and check for oilleakage from the port.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.·Mode selector : M mode·Auto decel switch : OFFMeasure the primary pilot pressure in theH mode.

Evaluation

11)

(1)

(2)①

②

①②

③

④

⑤

The average measured pressure should meet the following specifications.Unit : kgf / cm2

(3)

Model

R170W-7

Engine speed

M mode

Standard

40±5

Allowable limits

-

Remarks

17W77MS11

7-15

PreparationStop the engine.Push the pressure release button tobleed air.To measure the speed selecting pressure.Install a connector and pressure gaugeassembly to transmission P1, P2 port asfigure.Start the engine and check for onleakage from the adapter.Keep the hydraulic oil temperature at 50±5。C.

MeasurementLower the bucket and dozer blade to theground to raise the tires off the ground.Select the following switch position.·Parking switch : OFF·Mode selector : M modeOperate the travel speed switch turns tothe high or lower position and measurethe port P1 or P2 pressure.Repeat steps ③ three times andcalculate the average values.

Evaluation

FOR TRAVEL SPEED SELECTING PRESSURE

(1)①②

③

④

⑤

(2)①

②

③

④

The average measured pressure should be within the following specifications.

Unit : kgf / cm2

12)

(3)

Model

R170W-7

Travel speed mode

Low Speed

High Speed

Standard Allowable limits

P1 port

-

33+2

P2 port

33+2

-

P1 port

-

30~35

P2 port

30~35

-

Remarks

P2

Transmission

P1

Hose

Adapter

Pressuregauge

130W-3(7-14)

7-16

PreparationStop the engine.The pressure release L wrench to bleedair.Install a connector and pressure gaugeassembly to swing motor SH port, asfigure.Start the engine and check for oilleakage from the adapter.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.·Mode selector : M modeOperate the swing function or arm roll infunction and measure the swing brakecontrol pressure with the brakedisengaged. Release the control leverto return to neutral and measure thecontrol pressure when the brake isapplied.Repeat step ② three times and calculatethe average values.

Evaluation

SWING PARKING BRAKE RELEASING PRESSURE

(1)①②

③

④

⑤

(2)①

②

③

The average measured pressure should be within the following specifications.Unit : kgf / cm2

13)

(3)

Model

R170W-7

Description

Brake disengaged

Brake applied

Standard

40

0

Allowable limits

30~50

-

Remarks

SH

21077MS14

7-17

MAIN PUMP DELIVERY PRESSURE

PreparationStop the engine.Remove the top cover of the hydraulictank oil supply port with a wrench.Push the pressure release button tobleed air.To measure the main pump pressure.Install a connector and pressure gaugeassembly to main pump gauge port asfigure.Start the engine and check for oilleakage from the port.Keep the hydraulic oil temperature at 50 5 C.

MeasurementSelect the following switch positions.

Mode selector : M modeAuto decel switch : OFF

Measure the main pump deliverypressure in the M mode(High idle).

Evaluation

14)

(1)

(2)

The average measured pressure should meet the following specifications.Unit : kgf / cm2

Model

R170W-7

Engine speed

High idle

Allowable limits

-

Remarks

(3)

290LC7MS07

Standard

330 10

7-18

PreparationStop the engine.Remove the top cover of the hydraulictank oil supply port with a wrench.Push the pressure release button tobleed air.To measure the system relief pressure.Install a connector and pressure gaugeassembly to main pump gauge port, asfigure.Start the engine and check for oilleakage from the port.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.·Mode selector : M mode·Auto decel switch : OFFSlowly operate each control lever ofboom, arm and bucket functions at fullstroke over relief and measure thepressure.In the swing function, place bucketagainst an immovable object andmeasure the relief pressure.In the travel function, lock tires with animmovable object and measure the reliefpressure.

Evaluation

(1)①②

③

④

⑤

⑥

(2)①

②

③

④

The average measured pressure should be within the following specifications.

Unit : kgf / cm2

SYSTEM PRESSURE REGULATOR RELIEF SETTING15)

(3)

Model

R170W-7

Function to be tested

Boom, Arm, Bucket

Travel

Swing

Normal

330±10

360±10

240

Power boost

360±10

360±10

240

Overload

380

-

-

290LC7MS07