Perform Test
Perform Test
Perform Test
New Solar V
▣ Effective Models
- S140W-V, S180W-V, S210W-V, S175LC-V, S225LC-V, S255LC-V
- S300LC-V, S340LC-V, S420LC-V, S470LC-V
▣ Contents
I. Engine Control Cable & Speed XV. Cycle Times
II. Auto Idle Engine Speed XVI. Specification
III. Standard Mode Engine Speed XVII. Test & Adjustment record Chart
IV. Pilot Pressure XVIII. Test Tools
V. Main Relief & Pressure Up
VI. Power Shift Current & Pressure
VII. Speed Sensor
VIII. Working Mode
IX. Negacon Pressure
X. Px (PA) and Py(PT) Pressure
XI. High Travel Speed Signal
XII. Travel Motor Pressure
XIII. Swing Motor Pressure
XIV. Rock Breaker Flow Control Signal
I. Engine Control Cable & Speed DHIM C/S
Max
A
Min
1. Key Switch “On”, Auto Idle “Off” and Engine Control Dial Max position.
2. Adjust A point till the injection pump throttle lever contacts maximum speed stopp
er. Next have the cable stretched more by 1mm for the cable to have tension by its s
pring.
3. Turn the engine control dial to Min. position.
4. Check if the throttle lever contacts the minimum speed stopper screw.
5. If the lever doesn’t contact the stopper, move the cable to the next hole on the lever
at adjusting point B.
6. Repeat the above step 1 ~ 5.
II. Auto Idle Engine Speed DHIM C/S
Max
Min
1. At normal working temperature, start the engine and turn the dial to max position.
2. Auto Idle “On”.
3. Observing the engine speed on monitor panel, adjust “VR1” so that the engine speed is t
he specified value of auto idle speed as per each model.
Note) When adjusting the “VR1” or other VR’s, you need a very small flat blade “NON
CONDUCTIVE” screw driver.
III. Standard mode Engine Speed DHIM C/S
Max
Min
1. At normal working temperature, start the engine and turn the dial to max position.
2. Auto Idle “Off”.
3. Observing the engine speed on monitor panel, adjust “VR2” so that the engine speed is th
e specified value of Standard mode as per each model.
Note) When adjusting the “VR2” or other VR’s, you need a very small flat blade “NON
CONDUCTIVE” screw driver.
IV-1. Pilot Pressure – Tandem Pump DHIM C/S
Relief Pressure
@ Min. engine speed Above 35 bar
@ Max. engine speed Low pressure value + 8 bar, max.
IV-2. Pilot Pressure – Parallel Pump DHIM C/S
Relief Pressure
@ Min. engine speed Above 35 bar
@ Max. engine speed Low pressure value + 8 bar, max.
V-1. Main Relief &Pressure Up : DX Control Valve DHIM C/S
1 2
1. Loosen the upper jam nut and turn #1 clockwise till it is fully seated.
2. Loosen the lower jam nut and adjust #2 till the “Pressure – Up value” is obtained.
3. Tighten the lower jam nut with #2 fixed.
4. Trun out #1 till the “Main relief pressure value” is obtained.
5. Tighten the upper jam nut with #1 fixed.
6. Recheck if both pressures are correct and if necessary, make final adjustment.
V-2. Main Relief &Pressure Up : KVMG Control Valve DHIM C/S
1 2
1. Loosen the upper jam nut and turn #1 clockwise till it is fully seated.
2. Loosen the lower jam nut and adjust #2 till the “Pressure – Up value” is obtained.
3. Tighten the lower jam nut with #2 fixed.
4. Trun out #1 till the “Main relief pressure value” is obtained.
5. Tighten the upper jam nut with #1 fixed.
6. Recheck if both pressures are correct and if necessary, make final adjustment.
VI. Power Shift Current & Pressure DHIM C/S
Caution.
The test meter goes “IN SERIES” between
male and female bullet connector!!
Note.
To check the power shift current,
use the “Special Menu” of monitor panel.
VI. Power Shift Current & Pressure DHIM C/S
S175LC-V, S180W-V,
S340LC-V, S420LC-V,
S470LC-V
S300LC-V
VI. Power Shift Current & Pressure DHIM C/S
1. Tools : 60 bar gauge, Tee type test adapter, Test meter, test harness.
2. Test Condition : 50 ℃ of hyd oil temp, Engine max speed
3. Procedure
1) Select Power Mode.
2) Measure the power shift pressure current and pressure and record the value.
3) Briefly operate boom up or arm dump, observe the pressure and current again.
4) Select Standard Mode.
5) Measure and record the power shift pressure and current.
VI. Power Shift Current & Pressure DHIM C/S
Adjustment
1. Procedure
1) Stop the engine.
2) Loosen the lock nut of speed sensor.
3) Turn in the speed sensor till it gently makes contact with the tooth of ring gear.
4) Turn out the speed sensor 1/4 ~ 1/2 turn from the contact position.
5) Tighten the lock nut.
Resistance(Ω) Remark
Resistance between two terminals 1,750 ~ 2,050 Out of range, failure
Resistance between on of terminal and body Infinite
VIII. Working Mode DHIM C/S
Px
Py
PT
PA
X. Px(PA) and Py(PT) Pressure DHIM C/S
1. Tools : 60 bar gauges, Tee type test adapter(Px), Straight type test adapter(Py).
2. Test Condition : 50 ℃ of hyd oil temp., max engine speed
3. Procedure
1) Start the engine and increas the engine speed to the max.
2) Operate any of front actuators gradually while observing Px(PA) and Py(PT). Record t
he values observed.
3) Operate any of travel motors gradually while doing Px(PA) and Py(PT). Record the va
lues.
Note ) Px(PA) and Py(PT) pressures should increase sharply just before the front or travel motors
begin to move. They are very sensitive to the touch of joysticks or pedal valve.
3. Procedures
1) Set the power mode to be Power Mode and work mode, Digging.
2) Set the Auto Travel Switch to be “Off”.
3) Set the engine speed to the maximum.
4) Begin travelling the machine in the “acceleration zone” making sure both travel lev
ers are in the full stroked position.
5) Begin timing the travel when the machine just passes the start line of the 20 meter t
est course.
6) End timing the travel when the machine just touches the end line of the 20 meter tes
t course.
7) Record the results fo the test.
8) Rotate the upper structure 180 degrees and repeat the procedure in reverse.
9) Perform travel speed measurements three times for each direction. Average the thre
e results for a performance data measurement value.
10) Set the Auto Travel Switch to be “On” and repeat the process.
XV. Cycle Times – Travel Deviation DHIM C/S
3. Procedures
1) Set the power mode to be Power Mode and work mode, Digging.
2) Set the Auto Travel Switch to be “Off”.
3) Set the engine speed to the maximum.
4) Begin travelling the machine in the “acceleration zone” making sure both travel lev
ers are in the full stroked position.
5) Begin timing the travel when the machine just passes the start line of the 20 meter t
est course.
6) Trace the path of the track over the 20 meter test course using a taught string or by t
racing a line with a stick.
7) Measure the distance off from a straight course and the machine’s actual course ove
r the 20 meter test course.
8) Record the results of the test.
9) Rotate the upper structure 180 degrees and repeat the procedure operating the tracks
in reverse.
10) Perform travel speed measurements three times for each direction. Average the thre
e results for a performance data measurement value.
11) Set the Auto Travel Switch to the “On” position and repeat the process.
XV. Cycle Times – Jack Up Travel Speed DHIM C/S
1. Objective : To measure the track operation speed with the track raised off the ground.
2. Preparation and test condition
1) On the track to be measured, mark one shoe with chalk or paint.
2) Equally adjusted track tension.
3) Warmed machine with hydraulic oil over 50 ℃.
4) Swing the upper structure 90 degrees and lift up the machine using fronts like as fig
ure.
XV. Cycle Times – Jack Up Travel Speed DHIM C/S
3. Procedures
1) Set the power mode to be Power Mode and work mode, Digging.
2) Set the Auto Travel Switch to be “Off”.
3) Set the engine speed to the maximum.
4) Operate the travel control lever of the raised track in either full forward or reverse.
After one revolution begin measuring the time required for the track to complete ex
actly three more revolutions.
5) Perform the procedure three times. Average the results to arrive at a performance da
ta value. Record the average value.
6) Repeat the same for the opposite direction of travel.
7) Turn the travel switch to the “On” position and repeat the above.
8) Repeat the entire process for the opposite track.
XV. Cycle Times – Swing Speed DHIM C/S
3. Procedures
1) Set the power mode to be Power Mode and work mode, Digging.
2) Set the engine speed to the maximum.
3) Operate the swing control lever fully. After completing the first revolution begin ti
ming the duration required to complete exactly three full additional revolutions.
4) Operate the swing control lever fully in the opposite direction in the manner describ
ed above.
5) Perform the test three times and average the results to arrive at performance data.
XV. Cycle Times – Swing Coa ㄴ ting Angle DHIM C/S
1. Objective : To measure the angle of travel on the
swing bearing outer race which the upper
structure travels after swing stop.
2. Preparation and test condition
1) A flat level surface with ample room to safely swing
the machine in a full 360 degree circle.
2) Warmed machine with hydraulic oil over 50 ℃.
3) Arm rolled out, bucket rolled in, empty bucket, buck
et pin height is the same as the one of boom foot pin
3. Procedure
1) Set the power mode to be Power Mode and work mo
de, Digging.
2) Make two chalk marks : one on the lower structure a
nd the other on the swing bearing.
3) Swing the upper structure 360 degrees.
4) Operate the swing control lever fully and release it w
hen the two marks align.
5) Measure the distance between the two marks.
6) Align the marks and repeat the process in the opposit
e direction.
XV. Cycle Times – Swing Motor Creep DHIM C/S
1. Objective : To check the superstructure for movement or drift when suspending a load
on a slope.
2. Preparation and test condition
1) Locate the machine on a smooth slope with a grade of 15 degree.
2) Warmed machine with hydraulic oil over 50 ℃.
3) With the are rolled out and the bucket rolled in, position the arm top pin height to b
e level with the boom foot pin.
4) Load bucket fully.
XV. Cycle Times – Swing Motor Creep DHIM C/S
3-1. Procedures – Swing Mechanical Brake “engaged”
1) Swing the upper structure to position it 90 degree to the slope.
2) Make an Alignment mark cross the lower structure and the swing bearing as shown.
3) Maintain the engine at low idle. After five minutes, measure the difference between
the alignment marks.
4) Performan the measurement in both directions.
Note ) With this procedure, we can measure the slipping amount between mechanical
brake discs built in swing motor.
3-2. Procedures – Swing Mechanical Brake “released”
1) Swing the upper structure to position it 90 degree to the slope.
2) Make an Alignment mark cross the lower structure and the swing bearing as shown.
3) Set the engine speed to be maximum and select the auto idle “On” then wait till the
engine speed drops to the auto idle set rpm.
4) Operate the arm dump slightly only utill the engine speed recovers and maintain it d
uring the measuring time of 5 minutes.
5) After five minutesnutes, measure the difference between the alignment marks.
6) Performan the measurement in both directions.
Note ) With this procedure, we can measure the slipping amount of swing motor caused
by internal oil leakage between swing motor, rotary parts, relief valve etc.
XV. Cycle Times – Swing Bearing Play DHIM C/S
1. Objective : To measure the swing bearing vertical play
using a dial indicator.
2. Preparation and test condition
1) Check the swing bearing fixing bolts for tightness
2) Check the lubrication of the bearing. Confirm that th
e bearing rotation is smooth and quiet.
3) Position the uper structure so that the boom aligns wi
th the tracks facing towards the front idlers. The buck
et should be empty.
4) Install a dial indicator with magnetic base on the trac
k frame as shown. The needle point should come in c
ontact with the bottom face of the swing bearing oute
r face.
XV. Cycle Times – Swing Bearing Play DHIM C/S
3. Procedures
1) With the arm rolled out and the bucket rolled in, position the bucket so that the heig
ht of the bucket is level with the boom foot pin.
2) Record the dial indicator reading (h1).
3) Lower the bucket to the ground and use it to raise the front idler 0.5 meter.
4) Record the dial indicator reading (h2).
5) Calculate the bearing vertical play (H) from this data : H = h2-h1.
XV. Cycle Times – Swing Bearing Backlash DHIM C/S
1. Objective : To measure the swing bearing backlash
using a dial indicator.
2. Preparation and test condition
1) Check the swing bearing fixing bolts for tightness
2) Check the lubrication of the bearing. Confirm that th
e bearing rotation is smooth and quiet.
3) Position the uper structure so that the boom aligns wi
th the tracks facing towards the front idlers. The buck
et should be empty.
4) Install a dial indicator with magnetic base on the trac
k frame as shown. The needle point should come in c
ontact with the head of one of the swing bearing mou
nting bolts.
XV. Cycle Times – Swing Bearing Backlash DHIM C/S
3. Procedures
1) With the arm and the bucket rolled out, position the bucket so that the height of the
bucket tooth point is above the ground about 10cm.
2) Rock the front implement left to right.
3) Record the dial indicator variation.
4) If a dial indicator is not available, measure the movement at the end of the bucket.
XV. Cycle Times – Cylinder Creep DHIM C/S
1. Objective : To measure cylinder creep which can
be caused by oil leakag
e in the control valve or cyli
nders.
2. Preparation and test condition
1) Warm the hydraulic oil over 50℃.
2) Load the bucket fully.
3. Procedure
1) Position the arm cylinder with the rod 50mm e
xtended from the fully retracted position.
2) Position the bucket cylinder with the rod retra
cted from the fully extended position.
3) With the arm rolled out and the bucket rolled i
n, position the bucket so that the height of the
bucket is equal to the boom foot pin.
4) Stop the engine and use a grease pencil or mar
ker to make marks on the cylinder rods.
5) After five minutes, measure and record the dis
tance the marks have moved.
6) Repeat all measurements three times and calcu
late the average values.
XV. Cycle Times – Front Implement Cycle Time DHIM C/S
1. Objective : To measure the cycle times of the boom,
arm and bucket cylinder functions.
2. Preparation and test condition
1) Warm the hydraulic oil over 50℃.
2) Power Mode, Diggine mode and max engine s
peed.
3. Procedure
1) To measure the boom cylinder cycle time, roll
out arm, roll in the empty bucket and lower th
e boom to the ground.
2) To measure the cycle time of the arm, roll in t
he bucket, the arm is placed vertical and the b
oom is lowered so the bucket is 0.5m above th
e ground.
3) To measure the bucket cylinder speed, have th
e side place edges are vertical as shown.
4) Measure the cycle time of each front impleme
nts.
5) Repeat the measurements three times and cauc
ulate the average values.
XV. Cycle Times – Combined Boom and Arm DHIM C/S
1. Objective : To check the combined boom
and arm crowd functions.
2. Preparation and test condition
1) Warm the hydraulic oil over 50℃.
2) Empty bucket
3) Power Mode
4) Digging Mode
5) Max engine speed
3. Procedure
1) With the arm fully rolled out and the bucket rolled in, lower the boom to the ground.
2) Raise the boom and crowd the arm simultaneously – both to full stroke.
3) Measure the time required for the boom cylinder to be fully extended.
4) Repeat 1), 2) procedure and time the arm cylinder full extension.
5) Repeat all measurements three times and calculate the average values.
XVI. Specifications (1/3) DHIM C/S
Machine Model S 130-V(98ps) S 175-V S 225-V S 255-V
Engine standard rpm 2000 ±50 1,950 ±50 1,950 ±60 2,000 ±50
Speed Power rpm 2000 ±50 2,100 ±60 2,080 ±60 2,150 ±50
No load
Low Idle rpm 1000 ±50 1,100 ±50 1,050 ±50 1,050 ±50
Auto Idle rpm 1400 ±50 1,400 ±50 1,400 ±50 1,400 ±50
1 pump relief rpm 1800 over 1,900 over 1,900 over 1,950 over
Loaded
2 pump relief rpm 1800 over 1,900 over 1,900 over 1,950 over
Relief M ain Kgf/㎠ 330 0~+10 330 0~+10 330 0~+10 330 0~+10
Front
Pressure Up pressure Kgf/㎠ 350 0~+10 350 0~+10 350 0~+10 350 0~+10
Swing @ motor Kgf/㎠ 275 0~+10 280 0~+5 280 0~+10 285 0~+10
Travel @ motor Kgf/㎠ 330 ±10 320 ±10 330 ±10 330 0~+10
Arti boom @ pump Kgf/㎠ ━ ━ ━ ━ ━ ━ ━ ━
Dozer @ pump Kgf/㎠ 300 0~+10 ━ ━ ━ ━ ━ ━
Front Up sec 3.1 ±0.4 3.1 ±0.4 3.0 ±0.4 3.0 ±0.4
Boom
Speed Down sec 2.5 ±0.4 2.7 ±0.4 2.5 ±0.4 3.1 ±0.4
Crowd sec 3.4 ±0.4 3.5 ±0.4 3.5 ±0.4 3.7 ±0.4
Arm
Dump sec 2.3 ±0.4 2.7 ±0.4 2.6 ±0.4 2.6 ±0.4
Crowd sec 3.8 ±0.5 2.9 ±0.5 3.6 ±0.5 2.8 ±0.5
Bucket
Dump sec 2.0 ±0.3 2.1 ±0.3 2.3 ±0.3 2.2 ±0.3
Up sec 4.5 ±0.5 ━ ━ ━ ━ ━ ━
Dozer
Down sec 4.2 ±0.5 ━ ━ ━ ━ ━ ━
Swing TSB:15.0
Swing 3 revolutions sec ±1.0 15.5 ±1.0 14.5 ±1.5 16.4 ±1.0
Speed KHI:15.4
Travel On ground Low speed sec 21.5 ±1.0 21.0 ±1.5 23.5 ±1.5 20.6 ±1.0
Speed (20m) High Speed sec 15.0 ±1.0 15.0 ±1.0 13.5 ±1.0 14.3 ±0.7
Jack up Low Speed sec 24.5 ±1.5 26.0 ±2.0 33.0 ±2.0 29.0 ±1.5
(3turns) High Speed sec 17.3 ±1.0 19.0 ±1.5 18.0 ±1.5 20.0 ±1.0
Swing Swing
After 360˚ swing mm 723(69˚) ±180(±17˚) 744(71˚) ±178(±17˚ ) 1055(91˚) ±250(±20˚) 850(83˚ ) ±200(±20˚)
Coasting Bearing
Cylinder Front Boom & Arm mm/5min 5 w ithin 5 w ithin 5 w ithin 5 w ithin
Creep Bucket mm/5min 20 w ithin 20 w ithin 20 w ithin 20 w ithin
Travel
20m travel High & Low mm 150 below 150 below 150 below 150 below
Deviation
XVI. Specifications (2/3) DHIM C/S
Sw ing 3 revolutions sec 16.5 ±1.5 20.3 ±1.5 19.4 ±1.5 17.5 ±1.5
Sw ing
Speed
Travel On ground Low Speed sec 22.5 ±1.5 23.7 ±1.5 22.6 ±1.5 23.5 ±1.5
Speed (20m) High Speed sec 14.4 ±1.0 15.8 ±1.0 13.5 ±1.0 14.5 ±1.0
Jack-up Low Speed sec 35.0 ±2.0 35.7 ±2.0 36.3 ±2.0 38.0 ±2.0
(3turns) High Speed sec 22.0 ±1.5 23.8 ±1.5 21.5 ±1.5 23.5 ±1.5
Sw ing Swing Bearing After 360˚ swing mm 1340(105˚) ±255(±20˚) 890(66˚) ±180(±13˚) 1000(75˚) ±200(±15˚) 1470(100˚) ±200(±15˚)
Coasting
Cylinder Front All mm/5min 20 20 20 20
w ithin within w ithin within
Creep
Boom up
Boom down
Arm crowd
Arm dump
Bucket crowd
Bucket dump
Left swing
Right swing
Travel forward
Travel backward
XVII. Test and Adjustment Record Chart DHIM C/S
4. Px (PA) and Py (PT) Pressure
Secondary pressure
Example
Tee adapter + Coupling
XVIII. Test tools DHIM C/S
4. Part number : 2181-2201D1
- PFO 1/4” adapter with M10x1.0
- Hydraulic motor pressure measure
Example
Adapter + Coupling
XVIII. Test tools DHIM C/S