Hyundai Excavator R450LC-7. Service and repair manual

7-1

SECTION 7 MAINTENANCE STANDARD

GROUP 1 OPERATIONAL PERFORMANCE TEST

1. PURPOSE

Performance tests are used to check:

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.

OPERATIONAL PERFORMANCE OF A
WORKING MACHINE
With the passage of time, the machine's
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).

OPERATIONAL PERFORMANCE OF A
REPAIRED MACHINE
After the machine is repaired or serviced, it
must be tested to confirm that its
operational performance was restored by
the repair and/or service work done.

Working
condition

Operating

Maintenance
record

21077MS01

7-3

Observe the following rules in order to carry
out performance tests accurately and
safely.

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

Test area

Select a hard, flat surface.
Secure enough space to allow the
machine to run straight more than 20m,
and to make a full swing with the front
attachment extended.
If required, rope off the test area and
provide signboards to keep unauthorized
personnel away.

Precautions

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.
Operate the machine carefully and
always give first priority to safety.
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.
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.

Make precise measurements

Accurately calibrate test instruments in
advance to obtain correct data.
Carry out tests under the exact test
conditions prescribed for each test item.
Repeat the same test and confirm that
the test data obtained can be procured
repeatedly. Use mean values of
measurements if necessary.

(1)

(2)

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(

(4)

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③

7-3 (210-7)

3. OPERATION FOR PERFORMANCE TESTS

7-4

ENGINE SPEED

Measure the engine speed at each power
mode
The engine speed at each power mode
must meet standard RPM; if not, all other
operational performance data will be
unreliable. It is essential to perform this
test first.

Preparation

Warm up the machine, until the engine
coolant temperature reaches 50

。

C or

more, and the hydraulic oil is 50

。

Set the accel dial at 10(Max) position.
Push the H-mode switch and confirm that
the fuel injection pump governor lever
comes into contact with the high-idle
stopper.
Measure the engine RPM.

easurement

Start the engine. The engine will run at
start idle speed. Measure engine speed
with a tachometer.
Measure and record the engine speed at
each mode(H, S).
Select the H-mode.
Lightly operate the bucket control lever a
few times, then return the control lever to
neutral; The engine will automatically
enter the auto-idle speed after 4
seconds.
Measure and record the auto deceleration
speed.

(1)

※

(2)

(3)

①

②

③
④

⑤

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②
③

④

valuation

The measured speeds should meet the following specifications.

(4)

Model

R450LC-7

Engine speed

Start idle

M mode

H mode

S mode

Auto decel

Standard

800

100

1950

1850

1750

1000

100

Remarks

Unit : rpm

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

7-5

TRAVEL SPEED

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

Preparation

Adjust the tension of both tracks to be
equal.
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.
Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Keep the hydraulic oil temperature at
50

。

easurement

Measure both the low and high speeds of
the machine.
Before starting either the low or high
speed tests, adjust the travel mode
switch to the speed to be tested, then
select the following switch positions.
Mode selector : H mode
Start traveling the machine in the
acceleration zone with the travel levers at
full stroke.
Measure the time required to travel 20m.
After measuring the forward travel speed,
turn the upperstructure 180

。

and

measure the reverse travel speed.
Repeat steps

④

and

⑤

three times in

each direction and calculate the average
values.

valuation

0.3~0.5m

3 ~ 5m

20m

3 ~ 5m

(1)

(2)

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②

③

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(

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·
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⑤

⑥

The average measured time should meet the following specifications.

(

Unit : Seconds / 20m

Model

R450LC-7

Travel speed

1 Speed

2 Speed

Standard

22.5

2.0

13.6

1.0

Maximum allowable

28.0

17.0

Remarks

290LC7MS01

290LC7MS02

7-6

TRACK REVOLUTION SPEED

Measure the track revolution cycle time
with the track raised off ground.

Preparation

Adjust the tension of both side tracks to
be equal.
On the track to be measured, mark one
shoe with chalk.
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.
Keep the hydraulic oil temperature at
50

。

easurement

Select the following switch positions.
Travel mode switch : 1 or 2 speed
Mode selector : M mode
Auto decel switch : OFF
Operate the travel control lever of the
raised track in full forward and reverse.
Rotate 1 turn, then measure time taken
for next 3 revolutions.
Raise the other side of machine and
repeat the procedure.
Repeat steps

③

and

④

three times and

calculate the average values.

valuation

Mark

90~110

(1)

(2)

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②

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(

①
·
·
·
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④

⑤

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

Model

R450LC-7

Travel speed

1 Speed

2 Speed

Standard

38.5

2.0

Maximum allowable

Unit : Seconds / 3 revolutions

(

21077MS06

7-7

TRAVEL DEVIATION

Measure the deviation by the tracks from
a 20m straight line.

Preparation

Adjust the tension of both tracks to be
equal.
Provide a flat, solid test yard 20m in
length, with extra length of 3 to 5m on
both ends for machine acceleration and
deceleration.
Hold the bucket 0.3 to 0.5m above the
ground with the arm and bucket rolled in.
Keep the hydraulic oil temperature at
50

。

easurement

Measure the amount of mistracking at
high and low travel speeds.
Before beginning each test, select the
following switch positions.
Mode selector : M mode
Start traveling the machine in the
acceleration zone with the travel levers at
full stroke.
Measure the distance between a straight
20m line and the track made by the
machine.(Dimension a)
After measuring the tracking in forward
travel, turn the upperstructure 180

。

and

measure that in reverse travel.
Repeat steps

④

and

⑤

three times and

calculate the average values.

valuation

0.3~0.5m

(1)

(2)

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(

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·
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Unit : mm / 20m

Mistrack should be within the following specifications.

Model

R450LC-7

Standard

200 below

Maximum allowable

250

Remarks

((4)

290LC7MS01

7-7(2) 210-7

7-8

SWING SPEED

Measure the time required to swing three
complete turns.

Preparation

Check the lubrication of the swing gear
and swing bearing.
Place the machine on flat, solid ground
with ample space for swinging. Do not
conduct this test on slopes.
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.
Keep the hydraulic oil temperature at
50

。

easurement

Select the following switch positions.
Mode selector : Each mode
Operate swing control lever fully.
Swing 1 turn and measure time taken to
swing next 3 revolutions.
Repeat steps

②

and

③

three time and

calculate the average values.

valuation

(1)

(2)

①

②

③

④

(

①
·
②
③

④

Unit : Seconds / 3 revolutions

The time required for 3 swings should meet the following specifications.

Model

R450LC-7

Power selector switch

H mode

Standard

17.5

1.5

Maximum allowable

21.9

(

290LC7MS03

7-9

SWING FUNCTION DRIFT CHECK

Measure the swing drift on the bearing
outer circumference when stopping after a
360

。

full speed swing.

reparation

。

Keep the hydraulic oil temperature at
50

。

easurement

Conduct this test in the H mode.
Select the following switch positions.
Mode selector : H mode
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 360

。

Measure the distance between the two
marks.
Align the marks again, swing 360

。

, then

test the opposite direction.
Repeat steps

④

and

⑤

three times each

and calculate the average values.

valuation

Drift angle

Swing start & stop

360 swing

(1)

(2)

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(

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Unit : Degree

The measured drift angle should be within the following specifications.

(

Model

R450LC-7

Mode select switch

H mode

Standard

90 below

Maximum allowable

112.5

Remarks

290LC7MS03

21077MS08

7-10

Unit : mm

SWING BEARING PLAY

Measure the swing bearing play using a
dial gauge to check the wear of bearing
races and balls.

Preparation

Check swing bearing mounting cap
screws for loosening.
Check the lubrication of the swing
bearing. Confirm that bearing rotation is
smooth and without noise.
Install a dial gauge on the track frame as
shown, using a magnetic base.
Position the upperstructure so that the
boom aligns with the tracks facing
towards the front idlers.
Position the dial gauge so that its needle
point comes into contact with the bottom
face of the bearing outer race.
Bucket should be empty.

Measurement

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).
Lower the bucket to the ground and use it
to raise the front idler 50cm.
Record the dial gauge reading(h2).
Calculate bearing play(H) from this
data(h1 and h2) as follows.

H=h2-h1

Evaluation

Measurement : (h1)

Measurement : (h2)

(1)

(2)

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(

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The measured drift should be within the following specifications.

(

Model

R450LC-7

Standard

0.5 ~ 1.5

Maximum allowable

3.0

Remarks

7-10(1) 210-7

290LC7MS04

7-11

Raise

Lower

HYDRAULIC CYLINDER CYCLE TIME

Measure the cycle time of the boom,
standard arm, and standard bucket
cylinders.

Preparation

To measure the cycle time of the boom
cylinders:
With the arm rolled out and the empty
bucket rolled out, lower the bucket to the
ground, as shown.
To measure the cycle time of the arm
cylinder.
With the empty bucket rolled in, position
the arm so that it is vertical to the ground.
Lower the boom until the bucket is 0.5m
above the ground.
To measure the cycle time of the bucket
cylinder.
The empty bucket should be positioned
at midstroke between roll-in and roll-out,
so that the sideplate edges are vertical to
the ground.
Keep the hydraulic oil temperature at
50

。

easurement

Select the following switch positions.
Mode selector : H mode
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.

(1)

(2)

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②

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④

(

①

②

7-12

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.

Evaluation

The average measured time should meet the following specifications.

Unit : Seconds

(4)

Model

R450LC-7

Function

Boom raise

Boom lower

Arm in

Arm out

Bucket load

Bucket dump

Standard

3.7

0.3

3.3

0.4

4.0

0.4

3.5

0.3

2.7

0.4

2.6

0.3

Maximum allowable

4.6

4.1

5.3

4.3

2.9

3.1

Remarks

7-13

DIG FUNCTION DRIFT CHECK

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.

Preparation

Load bucket fully. Instead of loading the
bucket, weight(W) of the following
specification can be used.

W=M

1.5

Where :

= Bucket heaped capacity(m

)

1.5= Soil specific gravity

Position the arm cylinder with the rod 20
to 30mm extended from the fully retracted
position.
Position the bucket cylinder with the rod
20 to 30mm retracted from the fully
extended position.
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.
Keep the hydraulic oil temperature at
50

。

easurement

Stop the engine.
Five minutes after the engine has been
stopped, measure the changes in the
positions of the boom, arm and bucket
cylinders.
Repeat step

②

three times and calculate

the average values.

10)

(1)

(2)

①

②

③

④

⑤

(

①
②

③

The measured drift should be within the following specifications.

Unit : mm / 5min

Model

R450LC-7

Drift to be measured

Boom cylinder

Arm cylinder

Bucket cylinder

Standard

40 below

60 below

40 below

Maximum allowable

Remarks

(4)

290LC7MS05

Hyundai Excavator R450LC-7. Service and repair manual - page 21