Kobelco SK170-9 Excavator Workshop Manual

SERVICE MANUAL SK170-9 47454079-DRAFT 06/11/2012 EN

Contents INTRODUCTION Engine....................................................................................... 10 Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202 Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216 Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500 Hydraulic systems....................................................................... 35 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000 Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106 Charge pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.105 Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300 Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.322 Hydraulic swing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.352 Hydraulic travel system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.353 Hydraulic central joint. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.354 Pilot system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.357 Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359 Frames and ballasting ................................................................. 39 Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.100 Ballasts and supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.140 Tracks and track suspension ........................................................ 48 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.100 Track frame and driving wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.130 Track tension units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.134 Track rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48.138 47454079-DRAFT 06/11/2012

Cab climate control ..................................................................... 50 Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200 Electrical systems ....................................................................... 55 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.000 Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.512 Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.640 FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC Booms, dippers, and buckets ....................................................... 84 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.100 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.910 Dipper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.912 Platform, cab, bodywork, and decals ............................................. 90 Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105 Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150 47454079-DRAFT 06/11/2012

47454079-DRAFT 06/11/2012

INTRODUCTION 47454079-DRAFT 06/11/2012 1

Contents INTRODUCTION Personal safety and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SK170-9 LA Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SK170-9 LA Basic instructions – How to use the maintenance standard and precautions . . . . . . . . . . . . . . . . . . 9 SK170-9 LA Basic instructions – PREPARATION FOR PERFORMANCE TESTS . . . . . . . . . . . . . . . . . . . . . . . . 11 SK170-9 LA Basic instructions – Measuring Travel Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SK170-9 LA Basic instructions Measuring Swing Performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 SK170-9 LA Basic instructions - MEASURING ATTACHMENT OPERATING PERFORMANCES . . . . . . . . 20 SK170-9 LA Basic instructions Measuring Performances of Swing Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SK170-9 LA Basic instructions PRECAUTIONS FOR DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . 25 SK170-9 LA Basic instructions INSTALLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SK170-9 LA Basic instructions Floating seal precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 SK170-9 LA Basic instructions Electrical Equipment Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SK170-9 LA Basic instructions – Measurement of Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SK170-9 LA Basic instructions – Measurement of Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 SK170-9 LA Basic instructions – Preparation for Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 SK170-9 LA Capacities FLUIDS AND LUBRICANTS SK170-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SK170-9 LA General specification Performance inspection standard table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SK170-9 LA 47454079-DRAFT 06/11/2012 2

INTRODUCTION Personal safety and signal word definitions [50090504] SK170-9 LA Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW. FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety. Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage. 47454079-DRAFT 06/11/2012 3

INTRODUCTION Torque [45206476] SK170-9 LA Bolt types Tighten nuts or bolts to torque specifications. There are two kinds of bolts; hexagon T bolts (1) and socket bolts (2). The two types of bolts are made from different mate- rials. The correct type of bolt must be used when assem- bling the machine and/or components. Specified tightening torque chart RAPH12CEX1320AA 1 RAPH12CEX1321EA 2 Bolt Hexagon T Bolt, diameter M8 Wrench Size Wrench Size Socket bolt M10 M12 13 6 29.5 N·m M14 M16 17 8 64 N·m M18 M20 19 10 108 N·m M22 M24 22 12 175 N·m M27 M30 24 14 265 N·m M33 M36 27 14 390 N·m 30 17 540 N·m 32 17 740 N·m 36 19 930 N·m 41 19 1370 N·m 46 22 1910 N·m 50 24 2550 N·m 55 27 3140 N·m 1. Apply lubricant (i.e., white zinc B dissolved into spin- dle oil) to nuts and bolts to stabilize their friction coef- ficients. 2. Torque tolerance is ± 10 % 3. Be sure to use bolts of correct length. Bolts that are too long cannot be tightened, as the bolt tip comes into contact with the bottom of the bolt hole. Bolts that are too short cannot develop sufficient tightening force. 4. The torques given in the chart are for general use only. Do not use these torques if a different torque is given for a specific application. 5. Make sure that the nut and bolt threads are clean be- fore installing. Remove dirt or corrosion, if any. Bolt tightening order When tightening two or more bolts, tighten them alter- nately, as shown, to ensure even tightening. A. Equally lighten upper and lower alternately. B. Tighten diagonally. C. Tighten from center and diagonally. 47454079-DRAFT 06/11/2012 4

INTRODUCTION RAPH12CEX1322AA 3 RAPH12CEX1323AA 4 Service recommendations for split flange RAPH12CEX1324AA 5 1. Be sure to clean and inspect sealing surfaces. RAPH12CEX1325AA 6 Scratches / roughness cause leaks and seal wear. Unevenness causes seal extrusion. If defects cannot be polished out, replace the component. 2. Be sure to use only specified O-rings. Inspect O-rings for any damage. Take care not to file O-ring surfaces. when installing an O-ring into a groove, use grease to hold it in place. 3. Loosely assemble split flange halves. Make sure that the split is centrally located and perpendicular to the port. Hand-tighten the bolts to hold the parts in place. Take care not to pinch the O-ring. 4. Tighten bolts alternately and diagonally, as shown, to ensure even tightening. 5. Do not use air wrenches. Using an air wrench often causes tightening of one bolt fully before the other bolts are tightened. This results in damage to the O-rings and/or uneven tightening of the bolts. Nut and bolt lockings Lock plate NOTICE: Do not reuse lock plates. Do not try to bend the same point twice. Cotter pin NOTICE: Do not reuse cotter pins. Match the holes in the bolt and nut while tightening, not while loosening. Lock wire NOTICE: Apply wire to bolts in the bolt tightening direc- tion, not in the bolt-loosening direction. A Wrong B Right C Bend along edge sharply D Do not bend it round E Tighten F Loosen RAPH12CEX1326AA 7 47454079-DRAFT 06/11/2012 5

INTRODUCTION Piping joint Pipe thread connection / union joint tighten- ing torque specifications Union joint RAPH12CEX1327AA 8 Metal sealing faces (4) and (5) of adaptor (1) and hose (2) fit together to form a seal. Union joints are used to join small-diameter lines. 1. Do not over tighten the union nut (3) . Excessive force will be applied to metal sealing surfaces (4) and (5), possibly crack the adaptor (1). Be sure to tighten the union nut to specifications (3). 2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting. Type Wrench size Tightening 37 ° Union nut Joint body Torque 19 17 22 19 29 N·m 27 22 39 N·m 36 30, 32 78.5 N·m 41 36 157 N·m 50 46 205 N·m 323.6 N·m NOTE: Tightening torque for the non union type 37 ° O-ring seal joint O-ring seats against the end face adaptor to form a seal. O-ring procedures: 1. Be sure to replace the O-ring with a new one when reconnecting 2. Before tightening the union nut, confirm that the O-ring is seated correctly in the O-ring groove. Tightening the union nut with the O-ring displaced will damage the O-ring, resulting in oil leakage. 3. Take care not the damage the O-ring groove or sealing face. Damage to the O-ring will cause leakage. 4. If the union nut is found to be loose, causing oil leak- age, do not tighten it to stop the leak. Instead, replace the O-ring with a new O-ring. Then tighten the union nut after confirming that the O-ring is securely seated in place. Wrench size Joint body Tightening Union nun 17 Torque 19 19 22 22 29.4 N·m 27 27 68.6 N·m 30 30 93 N·m 36 36 137.3 N·m 41 46 175 N·m 50 205 N·m 320 N·m 47454079-DRAFT 06/11/2012 6

INTRODUCTION Screwed in connection NOTICE: Many types of screwed in connections are used for hose connections Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw in connection. Male tapered thread Wrench Tightening torque Joint body RAPH12CEX1516AA 9 17,19 34 N·m 22 A Male tapered thread 27 49 N·m B Male straight thread 36,32 50 93 N·m 60 157 N·m 320 N·m 410 N·m Seal tape application Seal tape is used to seal clearances between male and female threads to prevent any leakage between threads. Apply the seal tape to fill the thread clearances, do not over wrap. Application procedure • Confirm the thread surface is clean, and free of dirt or RAPH12CEX1517AA 10 damage. A Clearance • Apply the seal tape around the threads as shown. Wrap B Internal thread the seal tape in the same direction as the threads. C External thread RAPH12CEX1518AA 11 Leave one to two pitch threads uncovered Low pressure hose clamp tightening torque Low pressure tightening torque vary depending on the type of clamp. f T-bolt type band clamp (1) tightening torque • 4.4 N·m (3.2 lb ft) Worm gear type band clamp (2) tightening torque • 5.9 - 6.9 N·m (4.4 - 5.1 lb ft) RAPH12CEX1519AA 12 47454079-DRAFT 06/11/2012 7

INTRODUCTION RAPH12CEX1520AA 13 RAPH12CEX1522AA 14 Connecting hoses Only use genuine parts. Using hoses other than genuine hoses may cause oil leakage, hose rupture, or separation of the fitting, possible resulting in a fire on the machine. • DO NOT install hoses that are twisted. Application of high oil pressure, vibration, or an impact to a twisted hose may result in oil leakage, hose rupture or separa- tion of the fitting. When installing the hoses, utilize the print marks on the hoses to prevent the hose from being installed twisted. • DO NOT allow hoses to rub against each other. Protect hoses from wear which will lead to hose rupture. • Take necessary measures to protect hoses from rub- bing against each other. Properly use hose clamps. • DO NOT allow hoses to come into contact with moving parts or sharp objects. RAPH12CEX1521AA 15 RAPH12CEX1523AA 16 47454079-DRAFT 06/11/2012 8

INTRODUCTION Basic instructions – How to use the maintenance standard and precautions [49037636] SK170-9 LA Application WHEN THE MACHINE IS NEW Confirm that the performances are in accordance with standard specifications as compared to the performance stan- dards. AT SPECIFIC SELF INSPECTION (RULE BY COUNTRY) Use the data for the criterion, for the purpose of correction, adjustment and replacement. WHEN PERFORMANCES ARE DETERIORATED Determine whether it is caused by a fault or end of service life after long hours of operation, to be used for safety and economical considerations. WHEN MAIN COMPONENTS ARE REPLACED For example, use data to restore performances of pumps and others Terminology STANDARD VALUES Values to be used to condition or assemble a new machine. Where special notes are not given, these values represent standard specifications (machine with standard attachments and standard shoes). REFERENCE VALUES FOR REMEDY Values at which readjustment is required. In order to ensure performance and safety it is strictly prohibited to use the machine over the specified values. SERVICE LIMIT This is the limit value at which reconditioning is impossible without replacement of parts. If the value is expected to exceed the service limit before next inspection and corrections are performed, replace the parts immediately. Cautions to be Exercised at Judgment EVALUATION OF MEASURED DATA Disagreement of measuring conditions, variations of data peculiar to a new machine, and measuring errors are to be evaluated. Determine generally at what levels measured values are located, instead of determining whether or not values fall within or run out of the reference values. DETERMINING CORRECTION, ADJUSTMENT OR REPLACEMENT Machine performances deteriorate with time as parts wear and some deteriorated performances may be restored to new levels. Therefore, determine correction, adjustment or replacement, depending upon the operating hours, kind of work and circumstances in which the machine is placed, and condition the machine performances to its most desirable levels. Other Cautions to be Exercised PARTS LIABLE TO DEGRADE Rubber products, such as, hydraulic hoses, O-rings, and oil seals deteriorate with time; replace them at regular inter- vals or at overhauls. 47454079-DRAFT 06/11/2012 9

INTRODUCTION PARTS REQUIRING REGULAR REPLACEMENT Out of critical hoses that are necessary to secure safety, we designate Very Important Parts (V.I.P) and recommend that they should be replaced regularly. INSPECTION AND REPLACEMENT OF OILS AND GREASES In performing maintenance, it is necessary for the user to familiarize himself with how to handle the machine safely, cautions to be exercised and inspection/lubrication procedures. Refer to the operators manuals as well. 47454079-DRAFT 06/11/2012 10

INTRODUCTION Basic instructions – PREPARATION FOR PERFORMANCE TESTS [49050352] SK170-9 LA Observe the following rules in order to carry out performance tests accurately and safely. The machine 1. Repair and defects and damage found, such as oil or water leaks, loose bolts, cracks and so on, before starting to test. Test area RAPH12CEX0329BA 1 RAPH12CEX0330BA 2 1. Select a hard and flat surface. 2. Secure enough space to allow the machine to run straight more than 20 meters, and to make a full swing with the front attachment extended. 3. If required, rope off the test area and provide sign- boards to keep unauthorized personnel away. Precautions 1. 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. 2. Operate the machine carefully and always give first priority to safety. 3. 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. 4. Avoid polluting the machine and the ground with leak- ing oil. Use oil pans to catch escaping oil. Pay special attention to this when removing hydraulic pipings. Make precise measurements 1. Accurately calibrate test instruments in advance to ob- tain correct data. 2. Carry out tests under the exact test conditions pre- scribed for each test item. 3. Repeat the same test and confirm that the test data obtained can be produced repeatedly. Use mean val- ues of measurements if necessary. 47454079-DRAFT 06/11/2012 11

INTRODUCTION Basic instructions – Measuring Travel Performances [49094431] SK170-9 LA Travel Speed PURPOSES Measure the travel sprocket revolution and confirm the performances between the hydraulic pump and the travel motor of the travel drive system. CONDITIONS Hydraulic oil temperature 45 - 55 °C (113 - 131 °F); Crawler on the right and left sides are tensioned evenly. PREPARATION Attach the reflection panel with a magnet to the travel mo- RAPH12CEX0331BA 1 tor cover. Swing the swing frame through 90° as shown RAPH12CEX0332BA 2 in Figure and make the crawler on one side take off the ground, using the attachment. MEASUREMENT Engine revolution: Hi Idle 2–speed travel switch: 1st speed and 2nd speed Measuring points: right and left Method, example: Measure the revolutions per minute visually. SK170–9 Sprocket revolution Measurement Standard Reference Service limit item value value for remedy H mode 1st RH& speed LH H mode 2nd speed 47454079-DRAFT 06/11/2012 12

INTRODUCTION Deviation of travel PURPOSE Measure the amount of deviation at 20 m (66 ft) travel and confirm the horizontal balance between the hydraulic pump and the travel motor of the travel drive system. CONDITION Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) RH and LH crawler are tensioned evenly. Firm, level ground Engine revolution: Hi idle. PREPARATION 1. Straight course more than 30 m (98 ft). RAPH12CEX0333BA 3 RAPH12CEX0334BA 4 2. Travel position in which the bottom of the bucket is lifted by about 30 cm (12 in). MEASUREMENT 1. Measure the maximum. deviation distance of the cir- cular arc in the 20 m (66 ft) length, excluding the pre- liminary run of 3 - 5 m (10 - 16 ft) 3~5m (10~16ft). 2. Operate the travel lever at the same time. Travel deviation Measuring Standard Reference Service limit position value value for remedy 720 mm A 240 mm (28.3 in) (9.45 in) or 480 mm less (18.9 in) 47454079-DRAFT 06/11/2012 13

INTRODUCTION Performances of parking brake PURPOSE Confirm that the parking brake holds a stopped condition of the machine in a no-load travel position and on a 15 degree slope. CONDITION A slope with (Approx. 15 deg) gradient and a stopped condition in a no-load travel position. PREPARATION Place an angle meter on the shoe plate and confirm that it RAPH12CEX0335BA 5 makes an angle more than 15 degree. Hang a perpendic- RAPH12CEX0336BA 6 ular in parallel with the guide frame rib on the track frame and put a mark (matching mark) on the shoe plate. MEASUREMENT Five minutes after the engine stops, measure the move- ment distance of the matching mark. Parking brake Measuring Standard Reference Service limit value for position value remedy 2 mm (0.08 in) C0 1 mm (0.04 in) 47454079-DRAFT 06/11/2012 14

INTRODUCTION Drain rate of travel motor PURPOSE To measure the drain rate of the travel motor and to con- firm the performances of the travel motor. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Engine revolution: Hi idle PREPARATION 1. Place a stopper under the RH and LH travel sprockets. RAPH12CEX0337AA 7 RAPH12CEX0338AA 8 2. Stop the engine and release pressure from the hy- draulic circuit. 3. Connect a hose with the drain port of the travel motor and take drain in a container. MEASUREMENT AT TRAVEL LOCK NOTICE: Unless you observe the rotary force direction at travel lock, rib \"A\" may be broken by stopper \"B\" in some cases. 1. Start the engine and relieve pressure at the full stroke of the travel lever. 2. Measure the drain rate for 30 seconds of relieving. Drain rate of travel motor Measuring Standard Reference Service limit position value value for remedy 15 l (4.0 US Drain rate 5 l (1.3 US gal) gal) 13 l (3.4 US gal) 47454079-DRAFT 06/11/2012 15

INTRODUCTION Basic instructions Measuring Swing Performances [49117989] SK170-9 LA Swing speed PARAGRAPH Measure the swing time and confirm the performances between the hydraulic pump and the swing motor of the swing drive system. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground Engine revolution: Hi idle PREPARATION Put the bucket empty and extend the boom, arm and RAPH12CEX0339BA 1 bucket cylinder fully. And the machine becomes a posi- tion of minimum reach. MEASUREMENT AT TRAVEL LOCK Swing the machine by bringing the swing lever to its full stroke. Measure the time required to make two turns after one turn of preliminary run and calculate the time required for one turn. Measuring Standard Reference Service limit value for 6.4~ s position value remedy Swing speed 3.7 - 4.9 s 4.6 - 6.2 s at min. reach /rev 47454079-DRAFT 06/11/2012 16

INTRODUCTION Performance of swing brake PURPOSE Confirm the braking torque performances by the swing relief valve. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground Engine revolution: Hi idle PREPARATION RAPH12CEX0340AA 2 1. Put the bucket empty, retract the arm cylinder fully and No. Item extend the bucket cylinders fully. And move the boom 1 so that the arm top pin is positioned at same height 2 Boom foot pin with boom foot pin. Arm top pin 2. Put a matching mark on the outer circumference of the swing bearing of the upper frame side and of the track frame side. Place two poles (flags) on the front and back of the extended line of the matching mark. MEASUREMENT AT TRAVEL LOCK 1. When operating in regular swing speed, by shifting lever to neutral position at pole position the swing op- eration stops. 2. Calculate the swing drift angle by the following equa- tion, after the upper swing body stops, using the amount of deflection (m) of the matching marks on the swing race and the length (m) of the circumference of the swing race: Swing drift angle = (Amount of deflection of matching marks [m (ft-in)] divided by circumferential length of swing race [m (ft-in)]) multiplied by 360. Swing brake performance RAPH12CEX0341BA 3 Measuring Standard Reference Service limit No. Item value for 90° 1 Matching marks on outer race position value remedy 2 Matching marks on inner race Swing 180° 75° 85° 47454079-DRAFT 06/11/2012 17

INTRODUCTION Performance of swing parking brake PURPOSE To confirm the mechanical performances of the swing parking brake that is fitted to the inside of the swing motor. CONDITIONS On a slope of 15 degree incline. Stop the machine at right angles with the slope. Put the bucket empty, retract the arm cylinder fully and extend the bucket cylinder fully. And move the boom so that the arm top pin is positioned at same height with boom foot pin. PREPARATION Put the angle meter on the shoe plate and make sure that RAPH12CEX0342BA 4 the angle is more than 15 degree. Put a matching mark on the outer race side and on the inner race side. MEASUREMENT AT TRAVEL LOCK When five minutes has passed after the engine stops, measure the length of the movement of the matching marks. Measuring Standard Reference Service limit value for position value remedy 2 mm (0.08 in) / 5 B0 1 mm (0.04 minutes in) / 5 minutes No. RAPH12CEX0341BA 5 1 2 Item Matching marks on outer race Matching marks on inner race 47454079-DRAFT 06/11/2012 18

INTRODUCTION Drain rate of swing motor PURPOSE Measure the drain rate of the swing motor and confirm the performances of the swing motor. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground Engine revolution: Hi idle PREPARATION 1. Stop the engine. 2. Release pressure from inside the hydraulic circuit. 3. Disconnect the swing motor drain hose from its end returning to the hydraulic oil tank and take oil in a con- tainer. 4. Put a plug to the tank side. MEASUREMENT AT SWING LOCK RAPH12CEX0343BA 6 1. Start the engine and put the side faces of bucket against the inside of the right or left shoe plates. 2. Relieve the swing motor at full stroke of the swing mo- tion. 3. Collect the amount of drained oil in a container for 30 seconds. Measuring Standard Reference Service limit position value value for remedy Drain rate 2.1 l (0.55 5.2 l (1.37 6.2 l (1.64 US gal) / 30 US gal) / 30 US gal) / 30 seconds seconds seconds 47454079-DRAFT 06/11/2012 19

INTRODUCTION Basic instructions - MEASURING ATTACHMENT OPERATING PERFORMANCES [49228069] SK170-9 LA Operating time of cylinders PURPOSE Measure the operating time of the arm, positioning and bucket and confirm the performances between the hy- draulic pump and the cylinder of the attachment drive sys- tem. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Engine revolution: Hi idle Operating time excluding the cushion stroke. PREPARATION Firm level ground with the bucket empty. MEASUREMENT Arm in and out, positioning in and out, bucket digging and dump In a position in which the tooth of the bucket rises to a level of about 30cm (1ft) above ground, measure the full stroke operating time required with the arm, the positioning and bucket operating levers at full stroke. Measuring Standard Reference Service limit position value value for (Seconds) (Seconds) remedy 1 (Seconds) 5.4~ s 2 3.5 - 4.1 s 3.5~ s 7 2.1 - 2.7 s 4.4 - 5.2 s 5.6~ s 8 3.6 - 4.2 s 2.7 - 3.4 s 4.0~ s 9 2.4 - 3.0 s 4.4 - 5.2 s 4.9~ s 10 3.0 - 3.6 s 3.0 - 3.8 s 7.8~ s 4.9 - 5.5 s 4.0 - 4.7 s 6.6 - 7.4 s RAPH12CEX0344CA 1 47454079-DRAFT 06/11/2012 20

INTRODUCTION Oil tightness of cylinders PURPOSE Confirm that the cylinder oil tight by checking the moving length of the cylinder rods. CONDITIONS Hydraulic oil temperature: 45 - 55 °C (113 - 131 °F) Firm, level ground After cylinders are replaced, bleed off air from the cylin- ders, before checking for oil tightness. Retract the arm cylinder rod 50 mm (2 in) from stroke end so that the pis- ton does not match a same range of the cushioning mech- anism. PREPARATION Put the bucket empty. Extend the arm cylinder rod 50 mm (2 in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin.Put the bucket empty. Extend the arm cylinder rod 50 mm (2 in) from the most retracted position. And extend the bucket cylinders fully. Then hold the boom so that the arm top pin is positioned at same height with boom foot pin. MEASUREMENT Measure the items five minutes after the engine is turned off. Measuring Standard Reference Service limit position value value for A remedy B 6 mm (0.24 8 mm (0.31 10 mm (0.39 C D in) in) in) 10 mm (0.39 13 mm (0.51 18 mm (0.71 in) in) in) ––– 90 mm (3.54 150 mm 225 mm in) (5.91 in) (8.86 in) MEASUREMENT Measure the items five minutes after the engine is turned off. Measuring Standard Reference Service limit position value value for A remedy B 6 mm (0.24 8 mm (0.31 10 mm (0.39 C D in) in) in) 10 mm (0.39 13 mm (0.51 18 mm (0.71 RAPH12CEX0345AA 2 in) in) in) ––– No. Item 1 Arm top pin 90 mm (3.54 150 mm 225 mm 2 Boom foot pin in) (5.91 in) (8.86 in) 47454079-DRAFT 06/11/2012 21