SECTION 3 TESTING AND ADJUSTING

Group 1 Operational Performance Test 3-1

Group 2 Testing and Adjusting Hydraulic Pressure 3-21

3-1

SECTION 3 TESTING AND ADJUSTINGGROUP 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.

1)

2)

3)

R55NN7MA01

3-2

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)

R55NN7MA02A

R55NN7MA02B

3-3

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

7-3 (140-7)

3-4

ENGINE SPEED

Measure the engine speed at themaximum RPM.The engine speed must meet standardRPM; if not, all other operationalperformance data will be unreliable. It isessential to perform this test first.

Preparation and measurementWarm up the machine, until the enginecoolant temperature reaches 50。C ormore, and the hydraulic oil is 50±5。C.Set the accel lever at the maximumstroke.Measure the engine RPM.

EvaluationThe measured speeds should meet thefollowing specifications.

2)

(1)

※

(2)

(3)

①

②

③

Model

R55-3

Engine speed

Low idle

High idle

Standard

1100±50

2560±50

Remark

Unit : t / rpm

3-5

TRAVEL SPEED

Measure the time required for theexcavator to travel a 20m test track.

Preparation Adjust the tension of both tracks to beequal.Prepare a flat and solid test track 20m inlength, with extra length of 3 to 5m onboth ends for machine acceleration anddeceleration.Hold the bucket 0.3 to 0.5m above theground with the arm and bucket rolled in.Keep the hydraulic oil temperature at 50±5。C.

Measurement Measure both the low and high speedsof the machine.Before starting either the low or highspeed tests, adjust the travel modeswitch to the speed to be tested.Start traveling the machine in theacceleration zone with the travel levers atfull stroke.Measure the time required to travel 20m.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

3)

(1)

(2)①

②

③

④

(3)①

②

③

④⑤

⑥

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

Unit : Seconds / 20m

Model

R55-3

Travel speed

1 Speed

2 Speed

Standard

32.7±2.0

18.0±1.0

Maximum allowable

39.2

21.6

Remarks

R55NN7MA03

R55NN7MA04

3-6

TRACK REVOLUTION SPEED

Measure the track revolution cycle timewith the track raised off ground.

PreparationAdjust the tension of both side tracks tobe equal.On the track to be measured, mark oneshoe with chalk.Swing the upperstructure 90。and lowerthe bucket to raise the track off ground.Keep the boom-arm angle between 90 to110。as shown. Place blocks undermachine frame.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.Travel mode switch : 1 or 2 speedOperate the travel control lever of theraised track in full forward and reverse.Rotate 1 turn, then measure time takenfor next 3 revolutions.Raise the other side of machine andrepeat the procedure.Repeat steps ③ and ④ three times andcalculate the average values.

Evaluation

4)

(1)

(2)①

②

③

④

(3)①·②

③

④

⑤

The revolution cycle time of each track should meet the following specifications.

Model

R55-3

Travel speed

1 Speed

2 Speed

Standard

27.6±2.0

15.5±2.0

Maximum allowable

33.1

18.6

Unit : Seconds / 3 revolutions

(4)

R55NN7MA05

3-7

TRAVEL DEVIATION

Measure the deviation by the tracks froma 20m straight line.

PreparationAdjust the tension of both tracks to beequal.Provide a flat, solid test yard 20m inlength, with extra length of 3 to 5m onboth ends for machine acceleration anddeceleration.Hold the bucket 0.3 to 0.5m above theground with the arm and bucket rolled in.Keep the hydraulic oil temperature at 50±5。C.

MeasurementMeasure the amount of mistracking athigh and low travel speeds.Start traveling the machine in theacceleration zone with the travel levers atfull stroke.Measure the distance between a straight20m line and the track made by themachine.(Dimension a)After measuring the tracking in forwardtravel, turn the upperstructure 180。andmeasure that in reverse travel.Repeat steps ③ and ④ three times andcalculate the average values.

Evaluation

5)

(1)

(2)①

②

③

④

(3)①

②

③

④

⑤

Mistrack should be within the following specifications.

3~5m extra length

3~5m extra length

20Ma

Model

R55-3

Standard

200 below

Maximum allowable

240

Remarks

(4)

R55NN7MA03

7-7(2) 140-7

Unit : mm / 20m

3-8

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.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.

MeasurementOperate swing control lever fully.Swing 1 turn and measure time taken toswing next 2 revolutions.Repeat steps ① and ② three time andcalculate the average values.

Evaluation

6)

(1)

(2)①

②

③

④

(3)①②

③

Unit : Seconds / 2 revolutions

The time required for 2 swings should meet the following specifications.

Model

R55-3

Standard

12.0±1.0

Maximum allowable

15.6

Remark

(4)

R55NN7MA06A

3-9

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 space for swinging. Do notconduct this test on slopes.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.Make two chalk marks: one on the swingbearing and one directly below it on thetrack frame.Swing the upperstructure 360。.Keep the hydraulic oil temperature at 50±5。C.

MeasurementOperate the swing control lever fully andreturn it to the neutral position when themark on the upperstructure aligns withthat on track frame after swinging 360。Measure the distance between the twomarks.Align the marks again, swing 360。, thentest the opposite direction.Repeat steps ② and ③ three times eachand calculate the average values.

Evaluation

7)

(1)

(2)①

②

③

④

⑤⑥

(3)①

②

③

④

Unit : Degree

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

Model

R55-3

Standard

40 below

Maximum allowable

50

Remarks

R55NN7MA06A

R55NN7MA07

3-10

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

8)

(1)

(2)①

②

③

④

⑤

⑥

(3)①

②

③

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

Model

R55-3

Standard

0.5 ~ 1.2

Maximum allowable

2.4

Remarks

7-10(1) 140-7

R55NN7MA06

R55NN7MA08

Measurement : h1

Measurement : h2

3-11

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 shown.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.

MeasurementTo 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.

9)

(1)

(2)①

②

③

④

(3)①

-

-

R55NN7MA10

3-12

Bucket cylindersMeasure the time it takes to roll in thebucket, and the time it takes to roll outthe bucket. To do so, position the bucketat one stroke end, then move the controllever to the other stroke end as quicklyas possible.Repeat each measurement 3 times andcalculate the average values.

Evaluation

-

-

The average measured time should meet the following specifications.Unit : Seconds

(4)

Model

R55-3

Function

Boom raise

Boom lower

Arm in

Arm out

Bucket load

Bucket dump

Boom swing(LH)

Boom swing(RH)

Dozer up(Raise)

Dozer down(Lower)

Standard

2.4±0.4

2.8±0.4

2.9±0.4

2.5±0.4

3.5±0.4

2.4±0.4

6.8±0.4

5.6±0.4

1.2±0.3

1.2±0.3

Maximum allowable

3.1

3.6

3.8

3.2

4.6

3.1

8.8

7.3

1.6

1.6

Remarks

3-13

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.

10)

(1)

(2)①

·

②

③

④

⑤

(3)①②

③

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

Model

R55-3

Drift to be measured

Boom cylinder

Arm cylinder

Bucket cylinder

Standard

20 below

20 below

20 below

Maximum allowable

30

30

30

Remarks

(4)

R55NN7MA12

3-14

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.Operate each boom, arm, bucket andswing lever at full stroke and measurethe maximum operating force for each.Lower the bucket to the ground to raiseone track off the ground. Operate thetravel lever at full stroke and measure themaximum operating force required.When finished, lower the track and thenjack-up the other track.Repeat steps ② and ③ three times andcalculate the average values.

Evaluation

11)

(1)

(2)①

(3)①②

③

④

The measured operating force should be within the following specifications.

Model

R55-3

Kind of lever

Boom lever

Arm lever

Bucket lever

Swing lever

Travel lever

Standard

1.4 or below

1.4 or below

1.4 or below

1.4 or below

2.0 or below

Maximum allowable

1.9

1.9

1.9

1.9

2.5

Remarks

(4)

3-15

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

12)

(1)

※

(2)

(3)①②

③

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

Model

R55-3

Kind of lever

Boom lever

Arm lever

Bucket lever

Swing lever

Travel lever

Standard

87±10

87±10

87±10

87±10

86±10

Maximum allowable

109

109

109

109

105

Remarks

3-16

PILOT PRIMARY PRESSURE

PreparationStop the engine.Push the pressure release button tobleed air.Loosen and remove plug on the pilotpump delivery port(4G) and connectpressure gauge.Start the engine and check for oilleakage from the port.Keep the hydraulic oil temperature at 50±5。C.

MeasurementMeasure the primary pilot pressure in theH mode.

Evaluation

13)

(1)

(2)①

①②

③

④

⑤

The average measured pressure should meet the following specifications:

Unit : kgf / cm2

(3)

Model

R55-3

Standard

30±5

Remarks

R55NN7MA14

3-17

PreparationStop the engine.Push the pressure release button tobleed air.To measure the speed selecting pressure:Install a connector and pressure gaugeassembly to turning joint P port as shown.Start the engine and check for onleakage from the adapter.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSelect the following switch positions.Travel mode switch : 1 speed

2 speedMeasure the travel speed selectingpressure in the Hi or Lo mode.Lower the bucket to the ground to raisethe track off the ground. Operate thetravel lever at full stroke and measure thefast speed pressure.Repeat steps ② and 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

14)

(3)

Model

R55-3

Travel speed mode

1 Speed

2 Speed

Standard

0

30±5

Maximum allowable

-

-

Remarks

R55NN7MA15

3-18

PreparationStop the engine.Push the pressure release button tobleed air.Install a connector and pressure gaugeassembly to swing motor SH port, asshown.Start the engine and check for oilleakage from the adapter.Keep the hydraulic oil temperature at50±5。C.

MeasurementOperate the swing function or arm roll infunction and measure the swing brakecontrol pressure with the brakedisengaged. Release the control lever toreturn to neutral and measure the controlpressure when the brake is applied.Repeat three times and calculate theaverage values.

Evaluation

(1)①②

③

④

⑤

(2)①

②

The average measured pressure should be within the following specifications.

Unit : kgf / cm2

SWING PARKING BRAKE RELEASING PRESSURE15)

(3)

Model

R55-3

Description

Brake disengaged

Brake applied

Standard

30±5

0

Remarks

R55NN7MA16

3-19

MAIN PUMP DELIVERY PRESSURE

PreparationStop the engine.Push the pressure release button tobleed air.To measure the main pump pressure.Install a connector and pressure gaugeassembly main pump gauge port(1G,2G) as shown.Start the engine and check for oilleakage from the port.Keep the hydraulic oil temperature at 50±5。C.

MeasurementMeasure the main pump deliverypressure at high idle.

Evaluation

16)

(1)

(2)①

①②

③

④

⑤

The average measured pressure should meet the following specifications.

Unit : kgf / cm2

Model

R55-3

Engine speed

High ilde

Standard

20±5

Allowable limits

-

Remarks

(3)

R55NN7MA17

3-20

PreparationStop the engine.Push the pressure release button tobleed air.To measure the system relief pressure.Install a connector and pressure gaugeassembly main pump gauge port, asshown.Start the engine and check for oilleakage from the port.Keep the hydraulic oil temperature at 50±5。C.

MeasurementSlowly 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 undercarriagewith an immovable object and measurethe relief pressure.

Evaluation

(1)①②

③

④

⑤

(2)①

②

③

The average measured pressure should be within the following specifications.

Unit : kgf / cm2

SYSTEM PRESSURE REGULATOR RELIEF SETTING17)

(3)

Model

R55-3

Function to be tested

Boom, Arm, Bucket

Travel

Swing

Standard

210±10

210±10

180±10

R55NN7MA17