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BBM PIN : D6BD2045

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.
RAPH12CEX1320AA 1

Specified tightening torque chart

Bolt Hexagon T Bolt,
diameter Wrench Size Wrench Size Socket bolt
M8 13 6 29.5 N·m
M10 17 8 64 N·m
M12 19 10 108 N·m
M14 22 12 175 N·m
M16 24 14 265 N·m
M18 27 14 390 N·m
M20 30 17 540 N·m
M22 32 17 740 N·m
M24 36 19 930 N·m
M27 41 19 1370 N·m
M30 46 22 1910 N·m
M33 50 24 2550 N·m
M36 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.

2
B. Tighten diagonally. RAPH12CEX1321EA

C. Tighten from center and diagonally.

47454079-DRAFT 06/11/2012
4
 INTRODUCTION

Service recommendations for split flange

1. Be sure to clean and inspect sealing surfaces.
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. RAPH12CEX1322AA 3

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. RAPH12CEX1323AA 4

Nut and bolt lockings

Lock plate
NOTICE: Do not reuse lock plates. Do not try to bend the
same point twice.

Cotter pin
RAPH12CEX1324AA 5
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

RAPH12CEX1325AA 6

RAPH12CEX1326AA 7
47454079-DRAFT 06/11/2012
5
 INTRODUCTION

Piping joint

Pipe thread connection / union joint tighten-

ing torque specifications

Union joint
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. RAPH12CEX1327AA 8

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.

Wrench size Tightening

Type
Union nut Joint body Torque
37 ° 19 17 29 N·m
22 19 39 N·m
27 22 78.5 N·m
36 30, 32 157 N·m
41 36 205 N·m
50 46 323.6 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 Tightening

Union nun Joint body Torque
19 17 29.4 N·m
22 19 68.6 N·m
27 22 93 N·m
30 27 137.3 N·m
36 30 175 N·m
41 36 205 N·m
50 46 320 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 49 N·m A Male tapered thread
27 93 N·m B Male straight thread
36,32 157 N·m
50 320 N·m
60 410 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
RAPH12CEX1517AA 10
• Confirm the thread surface is clean, and free of dirt or
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

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.
RAPH12CEX1520AA 13

• 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.

RAPH12CEX1522AA 14

• DO NOT allow hoses to come into contact with moving

parts or sharp objects.

RAPH12CEX1521AA 15

RAPH12CEX1523AA 16

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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.

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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
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.
RAPH12CEX0329BA 1
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 RAPH12CEX0330BA 2
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.

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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-

tor cover. Swing the swing frame through 90° as shown
in Figure and make the crawler on one side take off the
ground, using the attachment. RAPH12CEX0331BA 1

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

Reference
Measurement Standard
value for Service limit
item value
remedy
H mode
1st
RH& speed RAPH12CEX0332BA 2
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
RAPH12CEX0333BA 3
1. Straight course more than 30 m (98 ft).
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
Reference
Measuring Standard
value for Service limit
position value
remedy
RAPH12CEX0334BA 4
240 mm
480 mm 720 mm
A (9.45 in) or
(18.9 in) (28.3 in)
less

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

makes an angle more than 15 degree. Hang a perpendic-
ular in parallel with the guide frame rib on the track frame
and put a mark (matching mark) on the shoe plate. RAPH12CEX0335BA 5

MEASUREMENT

Five minutes after the engine stops, measure the move-

ment distance of the matching mark.

Parking brake
Reference
Measuring Standard
value for Service limit
position value
remedy
1 mm (0.04 2 mm (0.08
C 0
in) in)

RAPH12CEX0336BA 6

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.

2. Stop the engine and release pressure from the hy- RAPH12CEX0337AA 7
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.
RAPH12CEX0338AA 8

Drain rate of travel motor

Reference
Measuring Standard
value for Service limit
position value
remedy
5 l (1.3 US 13 l (3.4 US 15 l (4.0 US
Drain rate
gal) gal) 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
bucket cylinder fully. And the machine becomes a posi-
tion of minimum reach. RAPH12CEX0339BA 1

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.

Reference
Measuring Standard
value for Service limit
position value
remedy
Swing speed 4.6 - 6.2 s
3.7 - 4.9 s 6.4~ 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 Boom foot pin
so that the arm top pin is positioned at same height 2 Arm top pin
with boom foot 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

Reference
Measuring Standard No. Item
value for Service limit
position value 1 Matching marks on outer race
remedy
Swing 180° 75° 85° 90° 2 Matching marks on inner race

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.

Reference
Measuring Standard
value for Service limit
position value
remedy
1 mm (0.04 2 mm (0.08
B 0 in) / 5 in) / 5
minutes minutes

RAPH12CEX0341BA 5

No. Item
1 Matching marks on outer race
2 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.

Reference
Measuring Standard
value for Service limit
position value
remedy
2.1 l (0.55 5.2 l (1.37 6.2 l (1.64
Drain rate 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.

Reference
Standard
Measuring value for Service limit
value
position remedy (Seconds)
(Seconds)
(Seconds)
1 3.5 - 4.1 s 4.4 - 5.2 s 5.4~ s
2 2.1 - 2.7 s 2.7 - 3.4 s 3.5~ s
7 3.6 - 4.2 s 4.4 - 5.2 s 5.6~ s
8 2.4 - 3.0 s 3.0 - 3.8 s 4.0~ s
9 3.0 - 3.6 s 4.0 - 4.7 s 4.9~ s
10 4.9 - 5.5 s 6.6 - 7.4 s 7.8~ 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
remedy
A 6 mm (0.24 8 mm (0.31 10 mm (0.39
in) in) in)
B 10 mm (0.39 13 mm (0.51 18 mm (0.71
in) in) in)
C – – –
D 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
remedy
A 6 mm (0.24 8 mm (0.31 10 mm (0.39
in) in) in)
B 10 mm (0.39 13 mm (0.51 18 mm (0.71 RAPH12CEX0345AA 2
in) in) in)
C – – – No. Item
D 90 mm (3.54 150 mm 225 mm 1 Arm top pin
in) (5.91 in) (8.86 in) 2 Boom foot pin

47454079-DRAFT 06/11/2012
21
 INTRODUCTION

Basic instructions Measuring Performances of Swing Bearing

[49362376]
SK170-9 LA

PURPOSE

Measure the gap between the lower frame and the bottom
face of the swing bearing and estimate the degree of wear
of the swing bearing.

CONDITIONS

Firm, level ground The swing bearing mounting bolts are

not loosened. The swing bearing is lubricated well, not
making abnormal sound during turning.

47454079-DRAFT 06/11/2012
22
 INTRODUCTION

PREPARATION

1. Install a dial indicator to the magnetic base and fix it to

the lower frame.
2. Direct the upper swing body and the lower frame to-
ward the travel direction, bring the probe of the dial in-
dicator in contact with the bottom surface of the outer
race on the swing body side and set the reading at
zero.

MEASUREMENT
Measuring position 1 and 2

Measure the displacement of the outer race in the axial di-

rection in position 1 [The arm at 90°~110° and the crawler
front is lifted by attachment about 30cm (1ft)] and in posi- RAPH12CEX0346BA 1
tion 2, using a dial indicator.
No. Description
Axial play of swing bearing 1 Lower frame
Measuring Standard Reference Service limit 2 Dial indicator
position value value for 3 Swing bearing
remedy 4 Location of bearing mounting bolts
A 0.8 - 1.8 mm 2.3 - 3.3 mm 3.6 mm
(0.03 - 0.07 (0.09 - 0.13 (0.14 in)
in) in)

RAPH12CEX0347BA 2

RAPH12CEX0340AA 3

No. Description
1 Arm top pin
2 Boom foot pin

47454079-DRAFT 06/11/2012
23
 INTRODUCTION

Measuring position 3

Retract the arm cylinder fully and extend the bucket cylin-
der fully. And move the boom so that the arm top pin is
positioned at same height with boom foot pin. Then swing
the bucket right and left by man power. But in this case,
the gap of the attachment is included.

Right and left movement of the tip of bucket

Measuring Standard Reference Service limit
position value value for RAPH12CEX0340AA 4
remedy
Bucket 30 - 50 mm 80 mm (3.15 120 mm No. Description
(1.18 - 1.97 in) (4.72 in) 1 Arm top pin
in) 2 Boom foot pin

47454079-DRAFT 06/11/2012
24
 INTRODUCTION

Basic instructions PRECAUTIONS FOR DISASSEMBLY AND

ASSEMBLY [51294741]
SK170-9 LA

PREPARATIONS FOR DISASSEMBLY

- Thoroughly wash the machine before bringing it into the shop. Bringing a dirty machine into the shop may cause
machine components to be contaminated during disassembling/assembling, resulting in damage to machine compo-
nents, as well as decreased efficiency in service work.
- Be sure to thoroughly understand all disassembling/assembling procedures beforehand, to help avoid incorrect dis-
assembling of components as well as personal injury.
- Check and record the items listed below to prevent problems from occurring in the future.
1. The machine model, machine serial number, and hour meter reading.
2. Reason for disassembly (symptoms, failed parts, and causes).
3. Clogging of filters and oil, water or air leaks, if any.
4. Capacities and condition of lubricants.
5. Loose or damaged parts.
- Prepare the necessary tools to be used and the area for disassembling work.
- Wear appropriate clothing, safety shoes, safety helmet, goggles, and clothes with long sleeves.
- Confirm the position of first-aid kit and fire extinguisher, and also where to make contact for emergency measure
and ambulance to prepare for accidents and fire.
- Attach "Don’t operate" tag to control lever, and begin a meeting before starting the work.

DISASSEMBLING AND ASSEMBLING HYDRAULIC EQUIPMENT

- Before removing pipes, release the pressure of hydraulic oil tank, or open the cover on the return side to tank, and
take out the filter.
- Drain the oil in the removed pipes into pan to prevent the oil from spilling on the ground.
- Pipes with plugs or caps to prevent oil leaking, entry of dust, etc.
- Clean the outside surface of equipment, etc. before disassembling, and drain hydraulic oil and gear oil before putting
them on working.

DISASSEMBLING HYDRAULIC EQUIPMENT

- Since performance and function of hydraulic equipment after disassembly and assembly results in immunity from
responsibility on the manufacture’s side, disassembly, assembly and modification without permission are strictly pro-
hibited.
- If it is unavoidably necessary to disassemble and modify, it should be carried out by experts or personnel qualified
through service training.
- Make match mark on parts for reassembling.
- Before disassembling, read Disassembling Instruction in advance, and determine if the disassembly and assembly
are permitted or not.
- For parts which are required to use jig and tools, don’t fail to use the specified jig and tools.
- For parts which can not be removed in the specified procedure, never force removal. First check for the cause.
- Inspecting parts. Measure the wear of parts and clearance, and record the measured values.
- If an abnormality is detected, repair or replace the parts.
- The removed parts should be put in order and tagged so as to install on proper places without confusion.
- For common parts, pay attention to the quantity and places.

REASSEMBLING HYDRAULIC EQUIPMENT

- During the parts cleaning, ventilate the room.
- Remove adhering oil by compressed air, and apply hydraulic oil or gear oil, and then assemble them.
- Replace the removed O-ring, back-up rings and oil seal with new ones, and apply gear oil on them before assembling.
- Removes dirt and water on the surface on which liquid sealant are applied, decrease them, and apply liquid sealant
on them.
- Before assembling, remove rust preventives on new parts.
- Use special tools to fit bearings, bushing and oil seal.
- Assemble parts matching to the marks.
- After completion, check that there is no omission of parts.

47454079-DRAFT 06/11/2012
25
 INTRODUCTION

Basic instructions INSTALLING HYDRAULIC EQUIPMENT

[51298009]
SK170-9 LA

Confirm level of hydraulic oil and lubrication oil

Bleeding air from hydraulic system

Air bleeding is required in the following cases:
1. When hydraulic oil is changed.
2. After replacement of parts on suction pipe side.
3. After removing and attaching hydraulic pump.
4. After removing and attaching swing motor.
5. After removing and attaching travel motor.
6. After removing and attaching a hydraulic cylinder.
NOTICE: If hydraulic oil and lubricating oil are not filled and also air bleed is not performed, the hydraulic equipment
may be damaged.

- When air bleeding hydraulic pump and swing motor, loosen drain plug on the upper part, start engine, and run in low
idling, then bleed air until hydraulic oil is comes out. After completion of air bleeding, tighten the plug securely.

- When air bleeding travel motor and hydraulic cylinders, start the engine and operate it for 10 minutes or more at
no-load and low speed.
NOTICE: When operating cylinders during this procedure, do not move the rod to the stroke end at the beginning.

- Air in the pilot circuit can be bled out only by operating the digging, swinging, and travelling motions thoroughly.

- Check hydraulic oil level.

Move attachments to hydraulic oil check position, as indicated in the figure below.

RAPH12CEX0378BA 1

- Open the hydraulic pump compartment door, then check the oil level on visual indicator (1) located on the hydraulic
oil reservoir. If the indicator is within level marks, the oil quantity is acceptable.

47454079-DRAFT 06/11/2012
26
 INTRODUCTION

RAPH12CEX0379BA 2

47454079-DRAFT 06/11/2012
27
 INTRODUCTION

Basic instructions Floating seal precautions [51302493]

SK170-9 LA

In general, replace the floating seal with a new one. If the floating is to be reused, follow these procedures:
1. Keep seal rings together as a matched set with seal ring faces together. Insert a piece of cardboard to protect
surfaces.
2. Check the seal ring face (1) for scuffing, scoring, corrosion, deformation or uneven wear.

RAPH12CEX0380BA 1

3. Check O-Ring (2) for tears, breaks, deformation or hardening.

If incorrectly assembled, oil leakage or damage will occur. Be sure to do the following, to prevent trouble.
1. Clean the floating seal and seal mounting bores with cleaning solvent.
Use a wire brush to remove mud, rust or dirt.
After cleaning, thoroughly dry parts with compressed air.
2. Clean the floating seal and seal mounting bores, as dust on them tends to enter the floating seal when installing it.
3. Check that the O-Ring is not twisted (2) , and that it is installed correctly (1)on the seal ring .

RAPH12CEX0381BA 2

4. After installing the floating seal, check that seal ring surface (3) is parallel with mating face (1) by measuring the
distances (a) and (b), as illustrated.
If these distances differ, correct the O-Ring (2) seating.

47454079-DRAFT 06/11/2012
28
 INTRODUCTION

RAPH12CEX0382BA 3

47454079-DRAFT 06/11/2012
29
 INTRODUCTION

Basic instructions Electrical Equipment Precautions [51309750]

SK170-9 LA

WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A

- The disassembly of electrical equipment is not allowed.

- Handle equipment with care so as not to drop it or bump it.

- Connector should be removed by unlocking while holding the connector.

- Never stress in tension to the caulked section by pulling wire.

- Check that connector is connected and locked completely.

- Engine key off before removing and connecting connector.

- Engine key off before touching terminals of starter and alternator.

- Wash machine with care so as not to splash water on electrical equipment and connector.

- When water has entered in the waterproofed connector, the removing of water is not easy. So check the removed
waterproofed connector with care to protect it from entry of water. If moisture adheres on it, dry it completely before
connecting.

- Remove battery grounding terminal before beginning work close to battery and battery relay with tools.

47454079-DRAFT 06/11/2012
30
 INTRODUCTION

Basic instructions – Measurement of Engine Speed [60644565]

SK170-9 LA

Warming up of engine
Start engine to raise the coolant temperature of the engine
to 60 - 90 °C (140 - 194 °F) at surface of radiator upper
tank.
The E/G coolant temperature gauge is used to measure
this.
The range in white shows the temperature of approxi-
mately 65 - 105 °C (149 - 221 °F) , so confirm that the
pointer indicates the temperature is within this white
range. RAPH12CEX1229AA 1

Engine speed measured value through ser-

vice diagnosis
1. Turn “ON” the starter switch with the buzzer stop
switch (1) pressed.
2. A program No. and an actual engine revolution are
displayed as the No. 2 item.
3. The screen advances like No. 2, No. 3...each time the
“Wiper switch” on the gauge cluster is pushed.
4. The screen returns like No. 45, No. 44...each time the
“Washer switch” is pushed.
5. The display does not disappear unless the starter
switch is turned to “OFF”.

RAPH12CEX1230AA 2

RAPH12CEX1231AA 3

47454079-DRAFT 06/11/2012
31
 INTRODUCTION

Basic instructions – Measurement of Hydraulic Pressure [60650951]

SK170-9 LA

Preparing to measure hydraulic pressure

HYDRAULIC EQUIPMENT

6.9 MPa (1001 psi) pressure gauge: 1 unit

49 MPa (7107 psi) pressure gauge: 2 units
Pressure measuring equipment and instrument for analy-
sis: 1 set

MEASURING CLEANLINESS OF HYDRAULIC OIL

NOTE: After releasing air in the hydraulic oil tank, open
the cover and sample the oil inside the tank using an in-
strument for analysis. If the measured value is higher than
the standard value, replace the return filter or change the
hydraulic oil.

Place to install pressure gauge

RAPH12CEX1232AA 1
MAIN CIRCUIT

After releasing the pressure in the hydraulic oil tank and

system, replace plugs PF1/4 of main pump gauge ports
A1 (1), and A2 (2), with plugs for pressure measurement.
Then attach pressure gauge rated for 49 MPa (7107 psi).

PILOT CIRCUIT

Replace the pilot gauge plug A5 (3), with a plug PF1/4 for
pressure measurement. Then attach a pressure gauge
rated for 6.9 MPa (1001 psi).

47454079-DRAFT 06/11/2012
32
 INTRODUCTION

Pressure adjustment position

MAIN CONTROL VALVE

Relief valve position on main control valve.

RAPH12CEX1233FA 2

47454079-DRAFT 06/11/2012
33
 INTRODUCTION

RAPH12CEX1234FA 3

47454079-DRAFT 06/11/2012
34
 INTRODUCTION

PILOT RELIEF VALVE

The pilot relief valve PR1 is located on the gear pump that
is attached to the main pump.

RAPH12CEX1235AA 4

SWING OVERLOAD RELIEF

The swing motor is equipped with plugs PA, PB for pres-

sure measurement, but the measurement is carried out
using gauge ports A1 and A2.

RAPH12CEX1236AA 5

RAPH12CEX1237AA 6

47454079-DRAFT 06/11/2012
35
 INTRODUCTION

Procedure for adjusting relief valve

PILOT RELIEF VALVE

Adjust it with adjust screw (311).

No. of turns of adjusting Pressure change MPa (psi)

screw
1 turn Approximately 2.1 MPa
(305 psi)

2–STAGE MAIN RELIEF VALVE

(Common for travel and ATT sections)

Start from the boosting side, first. Loosen nut (1), adjust
the pressure with adjusting screw (2) and tighten nut (1) RAPH12CEX1238AA 7

after completion of the adjustment on the boosting side.

Then, loosen nut (3), adjust the pressure on the standard
side with adjusting screw (4) and tighten nut (3) after com-
pletion of the adjustment.

No. of turns of adjusting Pressure change MPa (psi)

screw
Boosting side 1 turn
STD side 1 turn
Approximately 17.6 MPa
(2553 psi)
Approximately 17.6 MPa
(2553 psi)

RAPH12CEX1239AA 8

OVERLOAD RELIEF VALVE

(Boom, bucket, arm sections)

Loosen lock nut (1) and adjust it with adjusting screw (2).

No. of turns of adjusting Pressure change MPa (psi)

screw
1 turn Approximately 17.6 MPa
(2553 psi)

RAPH12CEX1240AA 9

OVERLOAD RELIEF VALVE (SWING)

When the adjustment of pressure is required, loosen lock

nut (1) and adjust the pressure with cap (2).

No. of turns of adjusting Pressure change MPa (psi)

screw
1 turn Approximately 10 MPa
(1451 psi)

RAPH12CEX1241AA 10

47454079-DRAFT 06/11/2012
36
 INTRODUCTION

OVERLOAD RELIEF VALVE (TRAVEL)

This valve was adjusted by the valve manufacturer. When

adjustment is required, loosen nut (1) and adjust the pres-
sure with adjusting screw (2).

RAPH12CEX1242AA 11

47454079-DRAFT 06/11/2012
37
 INTRODUCTION

Basic instructions – Preparation for Performance Tests [60724831]

SK170-9 LA

Observe the following rules in order to carry out perfor-

mance tests accurately and safely.

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

Test area
1. Select a hard and flat surface.
2. Secure enough space to allow the machine to run
straight more than 20 m, and to make a full swing with
the front attachment extended.
RAPH12CEX1271AA 1
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
2
swings. RAPH12CEX1272AA

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
38
 INTRODUCTION

Capacities FLUIDS AND LUBRICANTS SK170-9 [50853068]

SK170-9 LA

COMPONENT TO BE QUANTITY TUTELA MANUFACTURER INTERNATIONAL

FILLED SPECIFICATIONS SPECIFICATIONS
Engine 12 l (3.2 US gal) TUTELA AUTO
SUPREME™ ENGINE
OIL SAE 10W-30
Swing reduction unit 2.7 l (0.7 US gal) TUTELA HYPOIDE EP
Travel reduction units 4 l (1.1 US gal) GEAR LUBE SAE
(each) 80W-90
Radiator 6.6 l (1.7 US gal) CNH XHD HEAVY
DUTY COOLANT /
ANTI-FREEZE
Fuel tank 286 l (75.6 US gal)
DEF/ADBLUE® tank 79 l (20.9 US gal)
Hydraulic oil tank + 90.7 l (24.0 US gal)
Swing gear 8.6 kg (19.0 lb)
Windshield washer 1.5 l (0.4 US gal)
Pressure gauge
fittings

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 INTRODUCTION

General specification Performance inspection standard table

[60546611]
SK170-9 LA

NOTE: Unless otherwise specified, measure it on “H” mode.

Measuring Position
Standard Adjusting Measuring
Inspection Item Posi-
value point condition
tion Size Port
NAS 9 or
Cleanliness of hydraulic oil Hydraulic oil in tank - Sampling
less (Class)
50 °C (122 Atmo-
Hydraulic oil temperature Tank surface °F) ± 5 °C - spheric
(41 °F) temp 50 °C
75 °C (167 (122 °F) ~
Water temperature Radiator surface °F) ± 15 °C - -10 °C (14
(59 °F) °F)
1000 min-1
H mode Lo idle Low throttle
± 50
2200 min-1 Full throttle
H mode Hi idle
Measure the engine speed ± 50 (Hi idle)
Engine at multi display on the gauge 1050 min-1 Adjustment Perform all
Auto-Idle
speed cluster, or measure with diesel ± 50 not required measure-
speed meter 2000 min-1 ment with
S mode Hi idle
± 50 the air-con-
2000 min-1 ditioner
E mode Hi idle
± 50 "OFF"
5.0 MPa
G pump a5 +0.5/-0 PR1
Pilot primary pressure circuit HI idle
Main P1 a1 34.3 MPa
ATT travel +0.7/-0.5 MR1 Boom up
relief P2 a2
valve P1 a1
37.8 MPa
pres- Power boost MR1
P2 a2 +1.0/-0.5
sure
39.7 MPa
H +0/-5.9 OR3
Boom up
Boom a1
37.7 MPa
R +0/-4.0 OR4
Boom down
39.7 MPa Bucket
H +0/-5.9 OR1
digging
Bucket a1
37.7 MPa Bucket
High R +0/-4.0 OR2
PF 1/4 dump
pres- Main
37.7 MPa
sure H pump +0/-4.0 OR7
Arm in
circuit Arm a2
39.7 MPa
R +0/-5.9 OR8
Arm out
LH 29.0 MPa OR5 Swing LH
Swing a2 +4.0/-0
RH OR6 Swing RH
For-
ward 34.3 MPa
RH a1 +0.7/-0.5
Over Re- Simultane-
load verse ous Opera-
Travel
relief For- tion of travel
valve ward 34.3 MPa RH and LH
LH a2 +0.7/-0.5
pres- Re-
sure verse

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 INTRODUCTION

Measuring
Inspection Item Standard value
condition
Sprocket 1st speed -
revolution (RH,
2nd speed -
LH)
In 3.6 - 4.2 s
Arm
Out 2.4 - 3.0 s
Operating time of Digging 3.5 - 4.1 s
Bucket (At no load)
Operating speeds cylinder Dumping 2.1 - 2.7 s
Up 3.0 - 3.6 s
Positioner
Down 4.9 - 5.5 s
3.7 - 4.9 s per 1
Swing speed RH - LH
revolution
1st speed Iron shoe seconds per 3
Travel speed
2nd speed Iron shoe revolutions
Amount of travel
2nd speed 0~240 mm / 20 m
deviation
Parking brake drift 15 ° Gradient 0 ° / 5 min
Performance of Neutral position after 180 ° full speed
55 - 75 °
Swing brake swing
Swing parking
Performance 15° Gradient 0 mm
brake drift
Tip of the bucket tooth 90 mmper 5 min
ATT amount of Boom cylinder 6 mmper 5 min
At no load
drift Arm cylinder 10 mmper 5 min
- -
Amount of horizontal play at the bucket tooth 30 - 50 mm
NOTE: Over load relief vales OR1~OR8 described in ad-
vance correspond to the following operations.

1. Bucket digging
2. Bucket dump
3. Boom up
4. Boom down
5. Swing left
6. Swing right
7. Arm in
8. Arm out
RAPH12CEX1319AA 1

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 CONSUMABLES INDEX

Consumable Reference PAGE

Tutela Auto Supreme™ Capacities FLUIDS AND LUBRICANTS SK170-9 39
Engine oil SAE 10W-30
Tutela Hypoide EP Gear lube Capacities FLUIDS AND LUBRICANTS SK170-9 39
SAE 80W-90
CNH XHD Heavy Duty Coolant Capacities FLUIDS AND LUBRICANTS SK170-9 39
/ Anti-freeze
DEF/AdBlue® Capacities FLUIDS AND LUBRICANTS SK170-9 39

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SERVICE MANUAL
Engine

SK170-9

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10
 Contents

Engine - 10

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

SK170-9

Air cleaners and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.202

SK170-9

Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216

SK170-9

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254

SK170-9

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400

SK170-9

Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.500

SK170-9

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 CONSUMABLES INDEX

Consumable Reference PAGE

DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 4
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 5
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 6
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 7
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 8
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 9
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 9
DEF/AdBlue® Engine - Overview Selective Catalytic Reduction 10.001 / 9
Loctite® 262 Fuel tank - Install – Fuel Tank 10.216 / 5
Loctite® 262 Radiator - Install 10.400 / 5
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 4
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 4
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 4
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 5
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 5
DEF/AdBlue® Diesel Exhaust Fluid 10.500 / 5
DEF/AdBlue® Coolant control valve - Remove – Removal of DEF/AdBlue® 10.500 / 6
Supply Module, Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Remove – Removal of DEF/AdBlue® 10.500 / 7
Supply Module, Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Remove – Removal of DEF/AdBlue® 10.500 / 7
Supply Module, Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Remove – Removal of DEF/AdBlue® 10.500 / 7
Supply Module, Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Remove – Removal of DEF/AdBlue® 10.500 / 7
Supply Module, Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Install – DEF/AdBlue® Supply Module, 10.500 / 8
Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Install – DEF/AdBlue® Supply Module, 10.500 / 8
Filter and Shut-Off Valve

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 Consumable Reference PAGE
DEF/AdBlue® Coolant control valve - Install – DEF/AdBlue® Supply Module, 10.500 / 8
Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Install – DEF/AdBlue® Supply Module, 10.500 / 8
Filter and Shut-Off Valve
DEF/AdBlue® Coolant control valve - Install – DEF/AdBlue® Supply Module, 10.500 / 9
Filter and Shut-Off Valve

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10
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