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Figure 1
2 stage planetary gearbox
1. Track motor
2. No.1 planetary gear assembly
3. No.2 planetary gear assembly
4. Ring gear
Figure 2
Port connections
Rotational direction
Port connections
Figure 5
Track gearbox, torque flow
The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear (27) → spline of 1st
carrier (19) → 2nd sun gear (20) → 2nd planetary gear (12) → ring gear (8).
At this time, the reduction ratio of reduction gear is as follows:
Figure 1
2 stage planetary gearbox
1. Track motor
2. No.1 planetary gear assembly
3. No.2 planetary gear assembly
4. Ring gear
Figure 2
Port connections
Rotational direction
Port connections
Figure 5
Track gearbox, torque flow
The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear → spline of 1st carrier
→ 2nd sun gear → 2nd planetary gear → ring gear.
At this time, the reduction ratio of reduction gear is as follows:
Figure 1
Mounting location
Tightening torque
Tightening torque
NOTE!
The screws must be 10.9 KS strength classification or above.
Lubricating oil
NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
NOTE!
Gear oil specification
Use a gear oil equivalent to SAE 90 or 140, API classification GL4 or GL5.
Gear oil replacement period
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
NOTE!
Do not mix different types, classifications or brands of oil.
NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.
Rotate the gearbox until the drain plug and the fill plug are on the vertical axis.
Remove the 3 plugs on the cover and drain the oil into a suitable container.
Refill the gearbox through the fill port until oil exits from the level check port.
Ensure that the O-ring on each plug is not damaged, then install the plugs and torque to specification.
Figure 2
Oil replacement location
1. Fill port
2. Level check port
3. Drain port
NOTE!
Oil capacity: 5.8 Liter (1.5 US gal)
Operating checks
WARNING
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.
NOTE!
The temperature of the case must be lower than 90 °C, during continuous operation.
Service Information
Figure 1
Mounting location
Tightening torque
Tightening torque
NOTE!
The screws must be 10.9 KS strength classification or above.
Lubricating oil
NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
NOTE!
Gear oil specification
Use a gear oil equivalent to SAE 90 or 140, API classification GL4 or GL5.
Gear oil replacement period
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
NOTE!
Do not mix different types, classifications or brands of oil.
NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.
Rotate the gearbox until the drain plug and the level check plug are on the vertical axis.
Remove the 2 plugs on the cover and drain the oil into a suitable container.
Refill the gearbox through the level check port until oil exits from the level check port.
Ensure that the O-ring on each plug is not damaged, then install the plugs and torque to specification.
Figure 2
Oil replacement location
NOTE!
Oil capacity: 5.8 Liter (1.5 US gal)
Operating checks
WARNING
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.
NOTE!
The temperature of the case must be lower than 90 °C, during continuous operation.
Service Information
Oil leakage from mating joint Liquid gasket improperly applied. Disassembly and re-apply.
surfaces.
Floating seal leakage. Sliding surface worn. Replace the floating seal
assembly.
O-ring distorted.
Figure 1
Removal, cover
3. Place a wooden block on the track, and place the lower roller on the block to raise the sprocket off the track.
4. Disconnect the hydraulic hoses at the track motor.Plug the pipe ends and ports to prevent the outflow of oil and
the entry of contamination.
Figure 2
Removal, hydraulic hoses and screws
6. Pass a wire rope around the gearbox, and lift it.Remove the track motor as an assembly.Then, using screws in the
threaded holes of the undercarriage, force out the gearbox.
Figure 3
Removal, track gearbox
NOTE!
Lift the gearbox as close to the sprocket as possible to maintain balance.
NOTE!
The gearbox mounting screws may be used in the threaded frame holes.
NOTE!
Putting match-marks on the track frame and track gearbox will facilitate reassembly.
Service Information
NOTE!
Carefully check the mating surface of the undercarriage and the gearbox for burrs, dirt and rust scale.
1. Pass a wire rope around the gearbox, lift and install the gearbox to the undercarriage.
Figure 1
Install, track gearbox
2. Apply Loctite 277 to the gearbox mounting screws, and tighten them to the specified torque.
NOTE!
Tightening torque: 27 ± 3 kgf·m (195 ± 22 lbf·ft)
1. Check that the gearbox axis is horizontal. Rotate the gearbox housing until the drain plug is on the bottom of the
vertical axis of the end cover.
The gearbox is supplied with oil plugs (draining, filling and level) equipped with an hole that allows the air to bleed.
NOTE!
Remove the oil plugs with care. When the gearbox is warm, the air inside can be pressurized and this can cause
their strongly expulsion towards the worker.
NOTE!
Never mix mineral oils with synthetic oils and vice versa.
Do not dispose of the oil in the natural environment but be careful to eliminate it in compliance with the relative rules and
regulations that govern locally.
General tools
General tools
Special tools
Special tools
1. Park the machine in the service position B, see 091 Service positions.
Rotate the gearbox until the drain plug and level plug are on the vertical axis.
2. Remove the 2 plugs (1,2) on the cover and drain the oil into a suitable container.
Figure 1
Removal, plugs
Figure 2
Removal, gearbox cover
Figure 3
Applying, sealing compound
Figure 4
Installation, drain plug
8. Fill the oil through the level port until oil exits from the level check port.
9. Install the level check plug and tighten it to the specified torque.
Service Information
Precautions
1. Place the oil filling port and the oil drain port on the vertical axis. Remove plug (32) and drain the gear oil.
NOTE!
Drain oil into a clean container and check thoroughly for contamination.
NOTE!
Loosen the plug (1) for air extrusion before oil drain.
Figure 1
Removal, plug
1. Fill port
2. Level check port
3. Drain port
3. Remove No.1 planetary gear assembly (18) from No.2 planetary gear assembly (10).
Disassemble No.1 planetary gear assembly.
Figure 3
Removal, No. 1 planetary gear assembly
WARNING
The parts are heavy. Take appropriate safety precautions.
NOTE!
Match mark gears (22), pins (25) and carrier (19).
NOTE!
Do not mix the gears, bearings, thrust washers, and pin assemblies.
Figure 5
Removal, spring pins
NOTE!
Do not reuse spring pins (26).
NOTE!
If there are any flakes at the surface of No.1 pin, replace No.1 pin, No.1 carrier (28), No.1 planetary gear
(33) and needle bearing (34) simultaneously.
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 6
Removal, No.1 sun gear and coupling
Figure 7
Removal, No.2 planetary gear assembly
5. Remove No.2 planetary gear assembly (10) from spindle (302).
Disassembling No.2 planetary gear assembly
NOTE!
Match mark gears (12), pins (15) and carrier (11).
NOTE!
Do not mix the gears, bearing, thrust washers, and pin assemblies.
Figure 9
Removal, spring pins
NOTE!
Do not reuse spring pins (16).
6. Screw the eye bolts into ring gear (8), and remove ring gear.
Figure 10
Removal, ring gear
NOTE!
Do not reuse the screws.
Figure 11
Removal, screw, retainer and shim
8. Screw the eye bolts into housing (1), and remove housing (1), parallel pin (7), angular bearing (2) and seal (3) as an
assembly.
Figure 12
Removal, housing, pin, angular bearing and seal
WARNING
The parts are heavy. Take appropriate safety precautions.
NOTE!
When difficult to remove, lift the body vertically and tap lightly with a plastic hammer.
9. Remove seal (3) from housing (1). Remove seal (3) from motor casing (spindle 302).
NOTE!
Be careful not to damage the O-ring and seal surface.
Figure 13
Removal, angular bearing
Service Information
Precautions
1. Place the oil level port and the oil drain port on the vertical axis. Remove plug (32) and drain the gear oil.
NOTE!
Drain oil into a clean container and check thoroughly for contamination.
NOTE!
Loosen the plug (1) for air extrusion before oil drain.
Figure 1
Removal, plug
NOTE!
Install a screw (31) and carefully lift the cover off.
Figure 2
Removal, screw and cover
3. Remove No.1 planetary gear assembly (18) from No.2 planetary gear assembly (10).
Disassemble No.1 planetary gear assembly.
Figure 3
Removal, No. 1 planetary gear assembly
WARNING
The parts are heavy. Take appropriate safety precautions.
NOTE!
Match mark gears (22), pins (25) and carrier (19).
NOTE!
Do not mix the gears, bearings, thrust washers, and pin assemblies.
Figure 5
Removal, spring pins
NOTE!
Do not reuse spring pins (26).
NOTE!
If there are any flakes at the surface of No.1 pin, replace No.1 pin, No.1 carrier (28), No.1 planetary gear
(33) and needle bearing (34) simultaneously.
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 6
Removal, No.1 sun gear and coupling
Figure 7
Removal, No.2 planetary gear assembly
5. Remove No.2 planetary gear assembly (10) from spindle (302).
Disassembling No.2 planetary gear assembly
NOTE!
Match mark gears (12), pins (15) and carrier (11).
NOTE!
Do not mix the gears, bearing, thrust washers, and pin assemblies.
Figure 9
Removal, spring pins
NOTE!
Do not reuse spring pins (16).
6. Screw the eye bolts into ring gear (8), and remove ring gear.
Figure 10
Removal, ring gear
NOTE!
Do not reuse the screws.
Figure 11
Removal, screw, retainer and shim
8. Screw the eye bolts into housing (1), and remove housing (1), parallel pin (7), angular bearing (2) and seal (3) as an
assembly.
Figure 12
Removal, housing, pin, angular bearing and seal
WARNING
The parts are heavy. Take appropriate safety precautions.
NOTE!
When difficult to remove, lift the body vertically and tap lightly with a plastic hammer.
9. Remove seal (3) from housing (1). Remove seal (3) from motor casing (spindle 302).
NOTE!
Be careful not to damage the O-ring and seal surface.
Figure 13
Removal, angular bearing
Service Information
Preparation
Clean all parts with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts, bearings and gears with clean gear oil.
Replace the O-rings and seals.
Replace screws (6). DO NOT REUSE THESE SCREWS!
NOTE!
The outer races of the angular bearing must be properly aligned and fully seated.
NOTE!
Press–fit using a press or hammer.
Figure 1
Assembly, angular bearing
NOTE!
Take care not to damage the mating surface of the seal.
Figure 2
Assembly, seal
Tools: See the shim thickness measuring fixture of the special tools (part number: 8932-00290
Measuring plate).
NOTE!
Tightening torque: 0.8 kgf m (6 lbf ft)
Measure the dimension "A" from the top of the inner race of bearing to the motor as shown.
Measure the dimension "B" of retainer (5).
Shim thickness S = B – A + (0 ~ 0.05 mm)
Select a shim (4) of the appropriate thickness, align the retainer (5) correctly, and tighten screws (6) to the
specified torque.
NOTE!
Shim: 0.1, 0.9, 1.0, and 1.2 mm
NOTE!
Torque: 0.8 kgf·m (6 lbf·ft)
NOTE!
Apply loctite # 277 onto the thread of screws (6).
Figure 3
Adjustment, shim
4. Mount parallel pin (7) into housing (1), align ring gear (8) correctly, and screws.
NOTE!
Coat the mating surface of ring gear (8) with liquid gasket, loctite #5699.
NOTE!
Install 4 screws (30) temporarily.
Figure 4
Mount, pin
A. Applying, loctite
NOTE!
Check if No.2 planetary gears rotate smoothly.
NOTE!
Align the spring pin holes of the carrier and No.2 pins.
NOTE!
Staking method:
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 5
No.2 planetary gear assembly
A. Stake
6. Fit No.2 planetary gear assembly (10) into the spline of the motor correctly.
Figure 6
Fitting, No.2 planetary gear assembly
7. Insert coupling (9), and then No.1 sun gear (27) onto the motor shaft.
Figure 7
Insertion, coupling
NOTE!
Align the spring pin holes of the carrier and No.1 pins.
NOTE!
Staking method:
NOTE!
Check if No.1 planetary gears rotate smoothly.
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 8
No.1 planetary gear assembly
A. Stake
9. Insert No.1 planetary gear assembly (18) into No.2 planetary gear assembly (10).
10. Install plugs (32) into cover (28) and tighten to specified torque.
Figure 10
Installation, plug
Service Information
Preparation
Clean all parts with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts, bearings and gears with clean gear oil.
Replace the O-rings and seals.
Replace screws (6). DO NOT REUSE THESE SCREWS!
Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
Tightening torque, unit: Nm (kgf m) (lbf ft)
NOTE!
The outer races of the angular bearing must be properly aligned and fully seated.
NOTE!
Press–fit using a press or hammer.
Figure 1
Assembly, angular bearing
NOTE!
Apply a thin coat of grease (NLGI #2) to the O-ring.
NOTE!
Take care not to damage the mating surface of the seal.
Figure 2
Assembly, seal
Tools: See the shim thickness measuring fixture of the special tools (part number: 8932-00290
Measuring plate).
NOTE!
Tightening torque: 7.85 Nm (0.8 kgf m) (6 lbf ft)
Measure the dimension "A" from the top of the inner race of bearing to the motor as shown.
Measure the dimension "B" of retainer (5).
Shim thickness S = B – A + (0 ~ 0.05 mm)
Select a shim (4) of the appropriate thickness, align the retainer (5) correctly, and tighten screws (6) to the
specified torque.
NOTE!
Shim: 0.1, 0.9, 1.0, and 1.2 mm
NOTE!
Torque: 7.85 Nm (0.8 kgf m) (6 lbf ft)
NOTE!
Apply loctite # 277 onto the thread of screws (6).
Figure 3
Adjustment, shim
4. Mount parallel pin (7) into housing (1), align ring gear (8) correctly, and screws.
NOTE!
Coat the mating surface of ring gear (8) with liquid gasket, loctite #5699.
NOTE!
Install 4 screws (30) temporarily.
Figure 4
Mount, pin
A. Applying, loctite
NOTE!
Check if No.2 planetary gears rotate smoothly.
NOTE!
Align the spring pin holes of the carrier and No.2 pins.
NOTE!
Staking method:
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 5
No.2 planetary gear assembly
A. Stake
6. Fit No.2 planetary gear assembly (10) into the spline of the motor correctly.
Figure 6
Fitting, No.2 planetary gear assembly
7. Insert coupling (9), and then No.1 sun gear (27) onto the motor shaft.
Figure 7
Insertion, coupling
NOTE!
Align the spring pin holes of the carrier and No.1 pins.
NOTE!
Staking method:
NOTE!
Check if No.1 planetary gears rotate smoothly.
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 8
No.1 planetary gear assembly
A. Stake
9. Insert No.1 planetary gear assembly (18) into No.2 planetary gear assembly (10).
10. Screw an eye bolt into the oil level port and install cover (28) on ring gear (8).Install screw (31), screws (30), and
tighten to specified torque.
Tools: Eye bolt (PT 1/2), L wrench 10 mm (M12), Torque wrench, Plastic hammer
NOTE!
Coat the mating surface of ring gear (8) with liquid gasket, loctite #5699.
NOTE!
Apply loctite #277 onto the threads of screws (30).
Figure 10
Installation, cover
11. Install plugs (32) into cover (28) and tighten to specified torque.
Figure 1
Model code
1. Serial No
2. Reduction ratio code
3. Size No. (Theoretical output torque
ex. 100 = 1000 kgf·m
4. Type No.
(ex. S = Slew gearbox)
Figure 3
Slew gearbox
A. Torque flow
Figure 1
Model code
1. Serial No
2. Reduction ratio code
3. Size No. (Theoretical output torque
ex. 100 = 1000 kgf·m
4. Type No.
(ex. S = Slew gearbox)
Figure 3
Slew gearbox
A. Torque flow
WARNING
The temperature of the case is high just after running. Do not touch directly by hand to prevent a burn injury. Check
the temperature with a surface thermometer.
The temperature of the case must be lower than the ambient temperature + 60 °C, during continuous operation.
Gear oil specification
Use a gear oil equivalent to SAE 90 or 140, API classification GL4 / GL5.
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
NOTE!
Do not mix different types, classifications or brands of oil.
Figure 1
Check, oil level
A. Level
* The level gauge also serves as an air breather for the gearbox.
Take out the level gauge, wipe it on a clean cloth, re-insert, take out, and then check if the oil is within the slanting
lines as shown.
Gear oil replacement
Figure 2
Replacing, gear oil
Open drain valve cap (D) from the drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into
a suitable container.
After completely draining, remove drain hose (E), then close drain valve cap (D).
After removing oil level gauge (A), refill the gearbox through the oil filling pipe using a funnel that allows the pipe
to breathe.
Service Information
WARNING
The temperature of the case is high just after running. Do not touch directly by hand to prevent a burn injury. Check
the temperature with a surface thermometer.
The temperature of the case must be lower than the ambient temperature +60 °C, during continuous operation.
Gear oil specification
Use a gear oil equivalent to SAE 90 or 140, API classification GL4 / GL5.
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
NOTE!
Do not mix different types, classifications or brands of oil.
Figure 1
Check, oil level
A. Level
* The level gauge also serves as an air breather for the gearbox.
Take out the level gauge, wipe it on a clean cloth, re-insert, take out, and then check if the oil is within the slanting
lines as shown.
Gear oil replacement
Figure 2
Replacing, gear oil
NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.
Open drain valve cap (D) from the drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into
a suitable container.
After completely draining, remove drain hose (E), then close drain valve cap (D).
After removing oil level gauge (A), refill the gearbox through the oil filling pipe using a funnel that allows the pipe
to breathe.
Service Information
Replace all parts that appear damaged or are not within the allowable value.
Replace some parts in sets, i.e. gears, bushings and thrust washers.
General tools
General tools
Special tools
8932-00600 Drift
Special tools
2
3 Oil seal assembly jig 8920-00550 1
Replace all parts that appear damaged or are not within the allowable value.
Replace some parts in sets, i.e. gears, bushings and thrust washers.
Wear limit
1. Install slew gearbox after coating the frame surface ("A") with liquid gasket, loctite # 5699.
2. Install slew gearbox (2) onto upper frame (4), then install screws (3 ).
NOTE!
Apply loctite #277 onto the threads of screws (3).
3. After tightening screw, seal it including head part of pin (1) at "B" with liquid gasket, loctite # 5699.
NOTE!
Be careful not to break oil drain pipe (5).
NOTE!
Prior to start up, purge the air from the circuit of the plumbing and the slew motor.
Figure 1
Slew gearbox, install
Service Information
1. Park the machine in the service position C. See 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
After disconnecting the hose, install a plug to prevent oil leakage and contamination.
4. Open the oil drain valve cap and install the oil drain hose. Drain the gearbox oil into a suitable container.
Figure 1
Draining, gearbox oil
Figure 2
Removal, hoses
1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses
9. Remove the swing gearbox mounting screws and remove the silicone from both back step holes.
Figure 3
Removal, mounting screws
1. Screws
2. Silicone
10. Install the back step screws to separate the swing gearbox from the superstructure.
NOTE!
The gearbox housing is not removed easily because of the dowel pin.
Figure 4
Installation, back step screw
11. Lift the swing unit with the sling, and lower to the workbench safely.
Figure 5
Removal, swing unit
1. Sling
2. Screws
12. Remove the screws, lift the swing motor with sling, and install it to a new swing gearbox.
NOTE!
Before installing the swing motor, thoroughly remove the sealing compound on the mounting surface.
NOTE!
Apply sealing compound to the mounting surface of the new swing gearbox and then install the swing motor.
13. Transfer drain pipe and dowel pin, to the new swing gearbox.
Figure 6
Transferring, drain pipe and dowel pin
1. Drain pipe
2. Dowel pin
14. Lift the swing unit with the hoist, and install it to the machine.
Figure 7
Installation, swing unit
1. Screws
2. Silicone
NOTE!
Before installing the swing unit, thoroughly remove the sealing compound on the seat surface of the
superstructure.
NOTE!
Apply sealing compound to the seat surface of the superstructure, and then install the swing unit.
NOTE!
Apply the loctite #277 to the mounting screws, and tighten them to the specified torque.
15. Fill the both back step holes, and cover the dowel pin with silicone.
Figure 8
Installation, hoses
1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses
21. Fill the gearbox oil through the oil filling pipe.
22. Bleed air from the hydraulic circuit at the swing motor before operating.
23. After completion of the work, start the engine and check for leaks.
Service Information
Special tools
Special tools
Figure 2
Jig for bearing assembly
Figure 4
Jig for oil seal assembly guide
Figure 5
Jig for oil seal assembly guide
Service Information
Gearbox does not rotate. The machine is overloaded. Reduce the load.
Oil leakage from mating joint Liquid gasket improperly applied. Disassemble and re-apply.
surfaces.
Leakage from the shaft. Oil seal damaged. Replace the oil seal.
Disassembly
1. Open drain valve cap (D) from drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into a
suitable container.
Figure 1
Removal, hydraulic motor
2. After completely draining, remove drain hose (E), then close drain valve cap (D).
3. Remove screws (24).
4. Lift the motor off the gearbox.
NOTE!
Make match marks (A) on hydraulic motor casing (301), plate (23), ring gear (20), and case (19).
Make sure match marks (A) are permanent and clearly visible.
Figure 3
Removal, 1st sun gear
8. Remove 1st planetary gear assembly (28) from ring gear (20).
Disassemble the 1st planetary gear assembly in the following order:
Figure 4
Removal, retaining ring
Remove retaining ring (35), and then thrust washer (34), planetary gear (30), needle bearing (32) and
thrust washer (33).
Remove thrust washer (27).
Remove spring pin (36) from carrier (29) to take out pin (31).
NOTE!
Match mark gears (30), pins (31) and carrier (29).
NOTE!
Do not remove pins (31) if not worn or damaged.
NOTE!
Do not reuse spring pins (36).
Figure 5
Removal, spring pin
9. Remove ring gear (20) and dowel pin (21).
Figure 6
Removal, 2nd sun gear
10. Remove 2nd sun gear (26) and thrust ring (25).
11. Remove 2nd planetary gear assembly (1) from shaft (10).
Disassemble the 2nd planetary gear assembly in the following order:
Figure 7
Removal, 2nd planetary gear
NOTE!
Match mark gears (3), pins (5), and carrier (2).
NOTE!
Do not mix the gears, thrust washers, bushings, and pin assemblies.
NOTE!
Do not reuse spring pins (9).
Figure 9
Removal, cover and oil seal
14. Remove cover (12).
15. Remove oil seal (14).
NOTE!
Do not reuse the oil seal
Figure 10
Removal, shaft
17. Press spherical bearing (16) and collar (11) from shaft (10).
Figure 11
Removal, spherical bearing
NOTE!
If it is difficult to remove spherical bearing (16) as illustrated, use a bearing puller.
NOTE!
Be careful not to damage collar (11) by excessive force.
Figure 12
Removal, O-ring
NOTE!
Do not reuse the O-ring.
Figure 13
Removal, spherical bearing
NOTE!
Spherical bearing (17) can also be removed using a bench press.
Service Information
Disassembly
Op nbr 00000
Figure 1
Removal, hydraulic motor
Open drain valve cap (D) from the drain valve (C) and connect drain hose (E) to drain valve (C) and drain
the oil into a suitable container.
After completely draining, remove drain hose (E), then close drain valve cap (D).
Remove screws (24).
Lift the motor off the gearbox.
NOTE!
Match marks "A"
Make match marks on hydraulic motor casing (301), plate (23), ring gear (20), and case (19).
Make sure the match marks are permanent and clearly visible.
Figure 2
Removal, plate
Figure 3
Removal, 1st sun gear
Figure 4
Removal, retaining ring
Remove retaining ring (35), and then thrust washer (34), planetary gear (30), needle bearing (32) and
thrust washer (33).
Remove thrust washer (27).
Remove spring pin (36) from carrier (29) to take out pin (31).
NOTE!
Match mark gears (30), pins (31) and carrier (29).
Do not remove pins (31) if not worn or damaged.
Figure 5
Removal, spring pin
5. Ring gear
Figure 6
Removal, 2nd sun gear
Figure 7
Removal, 2nd planetary gear
NOTE!
Match mark gears (3), pins (5), and carrier (2).
Do not mix the gears, thrust washers, bushings, and pin assemblies.
8. Retaining ring
Figure 8
Removal, retaining
Figure 9
Removal, cover and oil seal
NOTE!
Do not reuse the oil seal
10. Shaft
Figure 10
Removal, shaft
11. Press spherical bearing (16) and collar (11) from shaft (10).
Figure 11
Removal, spherical bearing
NOTE!
If it is difficult to remove spherical bearing (16) as illustrated, use a bearing puller.
NOTE!
Be careful not to damage collar (11) by excessive force.
13. Bearing
Figure 13
Removal, spherical bearing
NOTE!
Spherical bearing (17) can also be removed using a bench press.
Service Information
When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain/fill ports are properly positioned.
Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
Use a torque wrench to tighten the mounting screws to the specified torque.
Clean all parts with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts, bearings and gears with clean gear oil.
Replace the O-ring and oil seal.
Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
NOTE!
Swing gearbox, sectional view and tightening torque. See 4312 Swing gearbox, description.
Assembly
1. Install O-ring (13) in collar (11), and then install it on shaft (10).
Figure 1
Installation, collar
NOTE!
Apply grease (NLGI 2) onto O-ring (13).
3. Press oil seal (14) into cover (12) using the seal pressing jigs.
Figure 3
Installation, oil seal
NOTE!
Apply loctite (#680) onto the outer diameter of the oil seal. Take care to get any loctite on the oil seal lip.
Figure 4
Apply, loctite
4. Install shaft (10) assembly into case (19) using an eye bolt (M8 × 1.25).
Figure 5
Installation, shaft
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
5. Install oil seal protector (A) onto the gear of shaft (10).
Figure 6
Installation, cover
6. Install cover assembly (12) on case (19) and install screws (15).
NOTE!
Coat the mating surface of cover (12) with liquid gasket, loctite # 5699.
9. Fully seat spherical bearing (17), and install retaining ring (18) onto shaft (10).
Figure 8
Installation, retaining ring
NOTE!
Check if casing (19) rotates smoothly after assembling the bearing and retaining ring.
Figure 9
Installation, 2nd planetary gear
Insert thrust washers (8) and 2nd planetary gear (3) into carrier (2).
Insert pin (5) and bushing (6).
Tap spring pin (9) into the pin hole of carrier (2). After inserting, stake the pin into both sides of spring
pins (9).
NOTE!
Align the spring pin holes in pin assembly (4) and carrier (2).
Install spring pin (9) with the slit facing the end of pin (5).
Figure 10
Installation, pin
A. Stake
Figure 11
Installation, 1st planetary gear
Press–fit pins (31) into carrier (29) and install spring pins (36). After inserting, stake both sides of spring
pins (36).
Put thrust washer (27) on the surface of carrier (29).
Onto pin (31) install thrust washer (33), gear (30) including bearing (32), thrust washer (34) and retaining
ring (35).
NOTE!
Check if planetary gears (30) rotate smoothly.
Figure 12
Checking, planetary gear
A. Stake
Figure 13
Installation, 2nd planetary gear
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
NOTE!
Coat the mating surface of case (19) with liquid gasket loctite #5699.
Support case (19).
Figure 14
Installation, 2nd planetary gear
13. 1st planetary gear assembly and 1st sun gear
Figure 15
Installation, 1st planetary gear
Install 1st planetary gear assembly (28) into ring gear (20).
Install retaining ring (38) into sun gear (37), and insert it into planetary (28).
NOTE!
Confirm that shaft (10) rotates smoothly by turning the 1st sun gear.
Figure 16
Installation, 1st planetary gear
14. Install plate (23) onto ring gear (20) then install screws (22).
Figure 17
Installation, plate
A. Tap hole
NOTE!
Align the match marks on casing (19) ring gear (20) and plate (23).
Coat the mating surface of ring gear (20) with liquid gasket loctite #5699.
Align the tap hole with the drain pipe mounting port.
Figure 18
Installation, plate
15. Install the motor onto plate (23) then install screws (24).
Figure 19
Installation, motor
NOTE!
Align match marks (A) of the motor and plate (23).
Coat the mating surface of plate (23) with liquid gasket loctite #5699.
16. Tighten drain valve (43) to pipe (44) and pipe (44) to case (19).
Figure 20
Installation, pipe
17. Install pipe (40) onto the motor, and insert level gauge (39).
NOTE!
Face the oil drain port of pipe sideward.
Coat with teflon tape or loctite #577 on the pipe and plug thread.
Service Information
When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain / fill ports are properly positioned.
Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
Use a torque wrench to tighten the mounting screws to the specified torque.
Clean all parts with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts, bearings and gears with clean gear oil.
Replace the O-ring and oil seal.
Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
Tightening torque, unit : kgf·m (lbf·ft)
Op nbr 00000
1. Shaft
Figure 1
Assembly, spherical bearing
Install o-ring (13) in collar (11), and then install it on shaft (10).
Press spherical bearing (16) onto shaft (10).
Figure 2
Assembly, spherical bearing
NOTE!
2. Cover
Figure 3
Assembly, oil seal
Press oil seal (14) into cover (12) using the seal pressing jigs.
Figure 4
Apply loctite
NOTE!
Apply loctite (#680) onto the outer diameter of the oil seal. Take care to get any loctite on the oil seal lip.
3. Case
Figure 5
Assembly, shaft
Install shaft (10) assembly into case (19) using an eye bolt (M8 × 1.25).
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
4. Cover assembly.
Figure 6
Assembly, cover
Install oil seal protector (A) onto the gear of shaft (10).
Install cover assembly (12) on case (19) and install screws (15).
NOTE!
Coat the mating surface of cover (12) with liquid gasket, loctite # 5699.
5. Bearing
Figure 7
Spherical bearing, assembly
NOTE!
Press–fit both inner and outer race simultaneously.
6. Retaining ring
Figure 8
Assembly, retaining ring
Fully seat spherical bearing (17), and install retaining ring (18) onto shaft (10).
NOTE!
Check if casing (19) rotates smoothly after assembling the bearing and retaining ring.
Figure 9
Assembly, 2nd planetary gear
Insert thrust washers (8) and planetary gear (3) into carrier (2).
Insert pin (5) and bushing (6).
Tap spring pin (9) into the pin hole of carrier (2). After inserting, stake the pin both sides of spring pin (9).
Figure 10
Assembly, pin
NOTE!
Align the spring pin holes in pin assembly (4) and carrier (2).
Install spring pin (9) with the slit facing the end of pin (5).
Figure 11
Assembly, 1st planetary gear
Press–fit pins (31) into carrier (29) and install spring pins (36). After inserting, stake both sides of spring
pins (36).
Put thrust washer (27) on the surface of carrier (29).
Onto pin (31) install thrust washer (33), gear (30) including bearing (32), thrust washer (34) and retaining
ring (35).
Figure 12
Checking, planetary gear
NOTE!
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
NOTE!
Coat the mating surface of case (19) with liquid gasket loctite #5699.
Support case (19).
Figure 14
Assembly, 2nd planetary gear
Install 1st planetary gear assembly (28) into ring gear (20).
Install retaining ring (38) into sun gear (37), and insert it into planetary (28).
Figure 16
Assembly, 1st planetary gear
NOTE!
Confirm that shaft (10) rotates smoothly by turning the 1st sun gear.
11. Plate
Figure 17
Assembly, plate
Install plate (23) onto ring gear (20) then install screws (22).
A : Tap hole
Figure 18
Assembly, plate
NOTE!
Align the match marks on casing (19) ring gear (20) and plate (23).
Coat the mating surface of ring gear (20) with liquid gasket loctite #5699.
Apply loctite #277 onto the threads of screw (22).
Align the tap hole with the drain pipe mounting port.
12. Motor
Figure 19
Installing motor
Install the motor onto plate (23) then install screws (24).
NOTE!
Align the match marks of the motor and plate (23).
Coat the mating surface of plate (23) with liquid gasket loctite #5699.
Apply loctite #277 onto the threads of screws (24).
Tighten drain valve (43) to pipe (44) and pipe (44) to case (19).
Install pipe (40) onto the motor, and insert level gauge (39).
NOTE!
Face the oil drain port of pipe sideward.
Coat with teflon tape or loctite #577 on the pipe and plug thread.
Service Information
Figure 1
Track motor, structure
1. Hydraulic motor
2. Brake valve
3. Parking brake
4. Displacement changeover valve
5. Control valve
6. Main pump
Hydraulic motor the hydraulic motor is a variable swash, axial piston design that includes the brake valve assembly
and parking brake. The rear flange contains the counterbalance valve, check valves, crossover relief valves and
displacement changeover valve.
Brake valve assembly the brake valve assembly consists of the following valves, each having a specific function as
described.
Check valves the check valves open/close according to supply oil pressure, and route oil flow to the counterbalance
spool. The check valves also prevent cavitation in the travel motor.
Counterbalance valve the counterbalance valve is used for smooth starting and stopping of the travel motor.It
blocks or throttles the circuit of the travel motor to control the travel speed according to the amount of oil
discharged by the pump to prevent machine run away on slopes.
Crossover relief valves the relief valves protect the motor and circuit from pressure spikes, maintaining the starting
pressure/bypass pressure of the hydraulic motor at a constant value.
High/low 2–speed travel the swash plate angle can be set in 2 positions: high speed/low torque or low speed/high
torque, according to the travel speed switch and the displacement changeover valve.
Parking brake assembly the travel parking brake is spring applied and hydraulically released. The brake is
automatically applied whenever the travel control valve spools are in neutral.
Figure 2
Construction, track motor
1. High speed
2. Low speed
Port connection
Rotational direction
Figure 3
Track motor, cylinder and piston kit
The pressurized oil delivered via the control valve from the hydraulic pump enters port on rear flange (201) and flows to half
the pistons in cylinder block (4) through valve plate (9).
The pressurized oil in cylinder block (4) pushes half the pistons (5) out of the bores and force [F(kgf) = P(kgf/cm2 ) × A(cm2)]
is generated. This force is applied on swash plate (3) fixed to drive shaft (2) with angle (a°) so that it is divided into
components of force (F2 and F3).
Among the components of force, radial force (F3) generates the torque (T = F3 × ri) for (Y1) - (Y2), respectively.
The total of torque {T = Σ(F3 × ri)} is transmitted sequentially via pistons (5) to cylinder block (4) generating a rotational
force causing the cylinder block splined to output drive shaft (2) to rotate.
The top dead center port is the starting point of the high pressure rotational cycle ; for 180° the pistons move out of the
bores as they slide along the swash plate toward the bottom dead center port, then they begin moving into the bores
discharging low pressure oil to the return circuit.
Operation, brake valve
Figure 5
Brake valve released
When pressurized oil is supplied to port (A), it opens check valve (227) and the oil flows to inlet port (C) of the hydraulic
motor.
At the same time pressurized oil flows into chamber (b) through passage (a) via a small orifice in counterbalance spool (223).
As the pressure in chamber (b) increases spool (223) is moved to the left, connecting port (D) with outlet (B) allowing the
return oil from the motor to flow to tank, so that the hydraulic motor starts to rotate. And according to the movement of
spool (223), pressurized oil flows into port (P) and port (S). The oil flow through port (P) operates brake piston (12)
overcoming the brake spring force releasing the parking brake. If the supply port and the return port are interchanged the
travel motor rotates in the opposite direction.
Stopping or stalling (brake actuating)
Figure 6
Brake valve actuation
When the pressurized oil flow from the main control valve is blocked, the pressure in port (A) decreases rapidly. As this
happens the pressurized oil in chamber (b) escapes via passage (a) through the orifice in spool (223) to port (A) ; at the same
time spring (228) force acting on stopper (225) moves counterbalance spool (223) to the right (neutral position).
The return speed of spool (223) is controlled by the back pressure created by the throttling effect of the orifice at passage
(a). When the spool is completely returned to the neutral position, the passages to ports (A, B) are blocked, trapping the oil
in the motor to prevent rotation.
However inertia will tend to continue the motor rotation, creating a sharp rise in oil pressure at return port (D). (This referred
to as dynamic braking).
The pressurized oil flows through the orifice in the left relief valve piston (101) to chamber (f), then to chamber (g) and starts
to move piston (281) to the right. When the piston reaches the end of its stroke, the pressure in chambers (g & f) rise and
react on valve piston (101). At this time the opening pressure of the relief valve is higher than the normal relief setting
pressure. This sequence acts to cushion the pressure spike as the valve opens.
As the oil pressure at port (D) overcomes the combined force of the relief valve spring and pressurized oil in chambers (g &
f) the left relief valve opens, connecting ports (D & C) to prevent an abnormal pressure rise and cavitation.
When the oil pressure at port (D) drops the relief valve closes ; however if the pressure rises above the relief valve setting,
the relieving cycle is repeated. The 2 stage control of the relief valve stops the hydraulic motor smoothly.
Overspeed
Figure 7
Brake valve, overspeed
When travelling downhill the weight of the machine (inertia) tends to make the hydraulic motor rotate faster than the rate of
oil flow supplied by the hydraulic pump. This phenomenon is referred to as overspeed.
During this condition the hydraulic force of the motor decreases, and the counterbalance spool moves toward the neutral
position, blocking the return oil flow from port (D) to port (B). As the passage closes it creates a throttling action, causing a
back pressure at port (D), thereby decelerating the hydraulic motor until the pump flow begins applying force to the motor.
Operation, parking brake
When travelling
Figure 8
Parking brake, travelling
When the travel lever is operated pressurized oil from the pump actuates counterbalance spool (223), opening the circuit to
brake chamber (a) of brake piston (12).
When the oil pressure reaches approximately 6 kgf/cm2 (85psi) it starts to push brake piston (12) toward the rear flange (←)
overcoming the force of brake springs (13). As this happens the piston moves away from friction plates (15) and mating
plates (16) allowing the plates to separate, releasing the braking force holding cylinder block (4).
When stopping
Figure 9
Parking brake, stopping
When the travel lever is placed in neutral, the counterbalance spool returns to its neutral position closing the circuit to brake
chamber (a).
The pressurized oil in chamber (a) drains to tank through an orifice in the brake valve.
The throttling effect of the orifice slows the drain oil flow, preventing the brake springs from applying the brake abruptly.
As the pressure drops below 6 kgf/cm2 the force of brake springs (13) pushes brake piston (12) against (→) mating plates
(16) and friction plates (15), which are splined to gearbox spindle (302) and cylinder block (4).
When the plates are squeezed together the frictional force generated applies a brake torque of 40.6 kgf·m (293 lbf·ft) to the
motor output shaft (2).
Operation, displacement changeover valve
Low speed
When the travel solenoid valve is deactivated (ph) servo hydraulic flow to port (D) is cut off. The hydraulic pressure at (A, B)
port moves spool (263) upward overcoming the force of spring (266), and blocks port (C).
At the same time the pressurized oil in chamber (P) drains to the motor case. This allows the forces acting on the rotary
group to move swash plate (3) to maximum swash angle θ1, contacting y plane. Piston stroke is increased, cylinder
revolutions decrease, resulting in low speed with high torque.
Figure 10
Displacement changeover valve, low speed
High-speed
When the travel solenoid is energized (ph) servo hydraulic oil will flow to port (D).
The hydraulic pressure (40kgf/cm2) at port (D) combined with the force of spring (266) moves spool (263) downward
overcoming the force of the hydraulic oil pressure at port (A, B) and opens port (C).
The pressurized oil from port (C) flows into chamber (P) and pushes piston (61) moving swash plate (3) to minimum swash
angle θ2, contacting x plane. Piston stroke is decreased, cylinder revolutions increase, resulting in high speed with low
torque.
Figure 11
Displacement changeover valve, high speed
When the load (tractive effort) is increased during high speed travel the oil pressure at port (A, B) increases.
If the pressure is approximately 260kgf/cm2 it overcomes the combined force of spring (266) and (ph) servo hydraulic flow
40kgf/cm2 at port (D), and moves spool (263) upward, blocking port (C). At the same time the pressurized oil in chamber (P)
drains to the motor case, and swash plate (3) moves to maximum swash angle θ1, contacting Y plane, and the motor rotates
at low speed.
Figure 12
Displacement changeover valve, automatic speed shifting
Service Information
Figure 1
Mounting location
Installation
Tightening torque
NOTE!
The screws must be strength grade 10.9 (tensile strength: 100 kgf/mm2) or above.
Piping
Check that there is no contamination in the ports or plumbing before connecting to the motor.
Prior to start-up purge the air from the circuit plumbing and motor.
Prior to start-up fill the motor casing with the specified hydraulic oil.
NOTE!
Oil capacity : 1.7 liters.
Lubrication
NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
Service Information
General tools
Special tools
No. Description & Part No. Quanti No. Description & Part No. Quanti
ty ty
1 Retainer (I) 1 4 Lifter 1
Pressure is normal. Brake valve failure. Repair or replace the rear flange
(Counterbalance spool) assembly.
Oil leakage
Mating joint surfaces Mating surface is damaged. Remove burrs or nicks with fine
emery cloth.
Leakage from rear flange Loosened screws. Tighten to the specified torque.
Motor rotates. The volumetric efficiency of the motor Replace the hydraulic motor
is poor. assembly.
Parking brake does not operate. Springs are damaged. Replace all the springs.
Machine zigzags
Occurs at low pressure. Pump flow to left and right motor Check P1/P2 pump flow.
differs. Check flow through the center
passage.
Left and right motor drain quantity Replace the hydraulic motor
are different. assembly.
Occurs at high pressure. Pump flow to left and right motor Check P1/P2 pump flow.
differs. Check flow through the center
passage.
Left and right motor drain quantity Replace the hydraulic motor
are different. assembly.
Brake valve operation is different Replace the rear flange
between left/right motors. assembly.
Abnormal sound
Speed does not change from low to High pressure select shuttle valve Check, and repair or replace if
high. malfunction. necessary.
Speed does not change from high to Solenoid valve malfunction. Check if the spool is normal, and
low. repair or replace if necessary.
1. Park the machine in the service position F, see 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by the travel control lever smoothly for 3 ~ 4 times with ignition switch at "ON"
position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
Figure 1
Removal, motor cover
Figure 2
Removal, relief valve
6. Check relief valve pressure of the track motor, and adjust if necessary
7. Install the motor cover.
Service Information
Precautions
1. Prior to disassembly, install the motor on a rotary work stand. Drain the hydraulic oil & gear oil.
NOTE!
Oil pan size : 4 liter, 8 liter
Figure 1
Track motor
Figure 3
Screws, removal
Remove valve plate (9), parallel pin (241), brake springs (13) and bearing (50) from rear flange (201) and
hydraulic motor.
Remove O-rings (329) from spindle (302).
NOTE!
Do not reuse O-rings (329) after removal.
Figure 5
Bearing, removal
Brake valve
Figure 7
Plug, removal
Figure 8
Plug, removal
Remove springs (230) and check valves (227) from rear flange (201).
Figure 9
Check valve, removal
NOTE!
Be careful not to damage the seat sections of check valve (227) or rear flange (201).
Figure 11
Spool, removal
Remove spool (263) and spring (266) from rear flange (201).
Remove O-rings (295) from plugs (257).
NOTE!
Do not reuse O-ring (295) after removal.
Figure 12
Plug, removal
Figure 13
Piston, removal
Remove O-ring (296) from plug (280).
Remove piston (281) from rear flange (201).
NOTE!
Take care not to damage the piston hole.
NOTE!
Since rear flange (201) and piston (281) are of the selective fitting type, replace them together as a kit.
Figure 14
Plug, removal
NOTE!
Do not reuse O-ring after removal.
Figure 15
Steel ball, removal
Figure 17
Spring retainer, removal
Figure 18
Spring, removal
Figure 19
Shim, removal
Figure 20
Relief valve piston, removal
WARNING
Abrupt injection of compressed air may cause piston to pop out. To ensure your safety, apply a protective
cover over the piston.
Figure 21
Apply the compressed air
Remove brake piston (12) by injecting compressed air (pressure : 3~5 kgf/cm2) into the parking brake
access hole in spindle (302).
Figure 22
Brake piston, removal
Remove O-rings (35 and 39) from piston (12).
NOTE!
Do not reuse O-rings (35) (39) after removal.
Figure 23
Cylinder block, removal
NOTE!
Before removal, hold cylinder block (4) with both hands and turn it two to three times in a clockwise and
counterclockwise direction alternately, to detach shoes (6) from swash plate (3).
NOTE!
Be careful when removing the cylinder block that the pistons and needle rollers (51) do not fall into the
spindle.
Hold cylinder block (4) with both hands, and remove it from spindle (302).
Remove swash plate (3), steel balls (67) from spindle (302).
Remove the mating plates (16) and friction plates (15) that are mounted on the outer surface of cylinder
block (4).
Remove the piston assembly (5), shoe (6)], retainer plate (7), thrust ball (8), and needle rollers (51) from
cylinder block (4).
Figure 24
Needle roller, removal
Figure 25
Swash plate, removal
14. Remove the drive shaft (2) from spindle (302) by striking the front part lightly with a plastic hammer.
Figure 26
Drive shaft, removal
16. Remove the steel ball (67) and parallel pin (71) from spindle (302).
WARNING
Abrupt injection of compressed air may cause piston to pop out. To ensure your safety, apply a protective
cover over the piston.
Figure 28
Steel ball and parallel pin, removal
17. Remove the speed selector piston assembly [piston (61) and shoe (62)] from spindle (302) by feeding compressed
air (pressure : 3 ~ 5 kgf/cm2) into the access hole in spindle (302).
Figure 29
Piston, removal
NOTE!
The rotary group parts must be replaced as a set. Reference the parts catalog for details.
18. Remove the seal (32) from spindle (302).
Figure 30
Bearing and seal, removal
Place cylinder block (4) on a press bench, then while pressing holding retainer (I) against washer (10),
remove snap ring (45).
NOTE!
Press load : 200 kg or over.
NOTE!
When removing the spring, press the axial centers of retainer (I) and washer to prevent the cylinder block
from being damaged by contact.
NOTE!
Protect the sliding surface of the cylinder block with a rubber sheet.
NOTE!
Remove spring (14) only if it is to be replaced.
WARNING
Do not release the press abruptly. The spring could pop out and cause an injury.
Figure 31
Snap ring, removal
Slowly release the press until the spring force is relaxed.
Remove washer (10), spring (14), and washer (10), in that order, from cylinder block (4).
Figure 32
Spring, removal
Service Information
Precautions
Clean all parts with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts, bearings and gears with clean gear oil.
Coat the motor assembly sliding parts and bearings with clean hydraulic oil.
Replace the O-rings, and seals.
Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
1. Check valves
NOTE!
Coat the thread section of plug (226) with loctite #577.
Figure 1
Plug, install
2. Counterbalance spool
NOTE!
Damage to the bore section of the rear flange or the surface of the spool may cause internal leakage to
occur after reassembling, and motor performance to deteriorate.
Figure 2
Counterbalance spool, install
Attach O-ring (236).
NOTE!
Apply grease to the O-ring.
Install stopper (225) and spring (228) into both plugs (224), and tighten plugs (224) into rear flange (201)
to the required torque (45 ± 9 kgf·m (325 ± 65 lbf·ft)).
NOTE!
If either the rear flange (201) or spool (223) is to be replaced, the entire assembly (kit) must be replaced.
Figure 3
Plug, install
3. Speed selector valve.
NOTE!
Apply hydraulic oil to spool (263) and insert it into rear flange (201).
NOTE!
Damage to the bore section of the rear flange or the surface of the spool may cause internal leakage to
occur after reassembling, and motor performance to deteriorate.
Figure 4
Spool, install
Tighten plugs (257) into rear flange (201) to the required torque (10 ± 2 kgf·m (72 ± 14 lbf·ft)).
Figure 5
Plug, install
Figure 7
Piston, install
Tighten plug (280) into rear flange (201) to the required torque (6 ± 1 kgf·m (43 ± 7 lbf·ft)).
Figure 8
Plug, install
5. Relief valves.
Mount O-ring (108, 109, 119) and back-up ring (111, 117) on sleeve (202).
NOTE!
Apply grease to O-ring (108), (109) and (110).
NOTE!
Apply grease to the shims to hold them to plug (104).
Mount piston seal (120) on piston (101).
NOTE!
Piston seal (120) consists of O-ring and teflon ring.
NOTE!
Apply grease to both sides of piston seal (120). Install O-ring and then teflon ring.
Install piston (101), spring (106), spring retainer (103) and shims (105) with plug (104) then tighten to the
required torque (10 ± 2 kgf·m (72 ± 14 lbf·ft)).
NOTE!
Coat piston (101) with hydraulic oil and install into sleeve (102).
NOTE!
The internal parts of the sleeve is comprised of a sleeve kit. Take care to assemble correctly.
Figure 9
Relief valve, install
Assemble the other relief valve in the same method.
6. Seal (32)
Fit seal (32) into the seal mounting hole of shaft (2).
NOTE!
Apply white petroleum jelly or lithium grease to the lip section of seal (32).
WARNING
When inserting ball bearing use leather gloves and take care not to get burned.
Figure 10
Assembly, seal
NOTE!
If ball bearing (49) has been removed from shaft (2) during disassembling replace the bearing with a new one and
then shrink-fit it onto shaft (2).
NOTE!
Shrinkage-fitting temperature : 100 ±10 °C
NOTE!
Take care not to heat (shaft (2) when shrink fitting ball bearing (49).
Figure 11
Assembly, bearing
Figure 12
Piston, assembly
Figure 13
Swash plate, mounting
Figure 14
Spring, assembly
Put the retainer on washer (10), and using the press force-fit spring (14), then mount snap ring (45).
NOTE!
When working on the cylinder block, protect its sliding face by covering it with a vinyl sheet.
NOTE!
Force to compress spring (14) : 200 kg or above.
NOTE!
Ensure that snap ring (45) is fully seated.
Figure 15
Retainer, install
Fit needle rollers (51) into cylinder block (4), and then, put collar (11) and thrust ball (8) on it.
Figure 16
Needles, install
Insert piston assembly (5), (6) into retainer plate (7).
Coat the piston assembly with hydraulic oil, and then fit to cylinder block (4).
NOTE!
Piston must be installed into the same bores because of wear pattern.
NOTE!
Align the match marks of the pistons and cylinder block made prior to disassembly.
Apply hydraulic oil on the sliding face of shoe (6) and the spherical section of thrust ball (8).
Figure 17
Piston, assembly
As shown in the diagram below, mount swash plate (3), thrust ball (8), collar, retaining plate (7), needle
roller (51), cylinder block (4), and piston assembly (5), (6), on shaft (2). Then install the lifter and turn the
shaft upright.
Figure 18
Cylinder block, assembly
Lift the motor assembly via lifter, and mount the guide inserting jig on the spline section of shaft (2).
NOTE!
Align steel ball (67) to the ball hole in swash plate (3).
13. Mount friction plate (15) and mating plate (16) alternately in that order on the cylindrical groove of cylinder block
(4).
NOTE!
Immerse friction plate (15) in hydraulic oil.
Figure 20
Brake, installing
NOTE!
Note the assembly order of friction plate and mating plate. If wrong, the parking brake force may be weakened.
14. Fit O-ring (35), (39) and assemble piston (12) into spindle (2).
Figure 21
Brake piston O-ring, installing
15. Fit brake piston (12) into spindle (302) by lightly tapping the sectional surface of piston (12) using a plastic hammer,
to prevent the piston from being distorted.
NOTE!
Apply grease on O-ring (35), (39).
Figure 22
Brake piston, installing
16. Mount ball bearing (50), valve plate (9), parallel pin (241), and springs (13) on rear flange (201).
NOTE!
Coat spring (13) and valve plate (9) with grease to hold it to rear flange (201).
NOTE!
Apply hydraulic oil on ball bearing (50).
Figure 23
Bearing, mounting
18. Insert O-ring (329), (327) and (342) into spindle (302), and mount rear flange (201).
NOTE!
Do not apply grease on O-ring (329) or mating surface. (Because the grease may be mistaken for oil leakage)
Figure 25
Rear flange, assembly
NOTE!
The rear flange (201) must be mounted so that the two parallel pin (342) mounted on spindle (302) and the pin
hole align.
20. Mount O-ring (295) on plug (257) and the drain port not pipe-connected
Figure 27
Relief valve mounting
Service Information
Swing unit Swash type axial piston hydraulic motor Mechanical brake
Relief valve
Anti-cavitation valve
Rotational direction
Relief valve
Anti-cavitation valve
Construction
Figure 2
Slew motor
1. Relief valve
2. Rebound damping valve
3. Lifting screw (2-M12)
Rotational direction
Figure 3
Slew motor
031 Delay valve 390 Name plate
031-1 Plug 391 Rivet
033 Screw 400 Rebound damping valve
051 Relief valve 400- O-ring
1
051-1 O-ring 400- Backup-ring
2
052 Rebound damping valve casing 401 Screw
100 Plug 437 Snap ring
101 Shaft 438 Snap ring
111 Cylinder 443 Roller bearing
113 Retainer 444 Roller bearing
114 Spring-Cylinder 451 Pin-dowel
116 Push rod 465 Plug
117 Spacer F 469 Plug
118 Spacer 471 O-ring
121 Piston 472 O-ring
122 Shoe 488 O-ring
123 Thrust plate 491 Oil seal
124 Shoe plate 702 Piston-brake
131 Valve plate 706 O-ring
151 Plug 707 O-ring
161 O-ring 712 Spring-brake
171 Screw 742 Friction plate
301 Casing 743 Mating plate
303 Valve casing 981 Plug
305 Seal cover 984 Plug
351 Spool 994 Level gauge and pipe
355 Spring
Service Information
Figure 1
Operation, slew motor
Figure 2
Circuit
1. Control valve
2. Return
The motor can be rotated faster than supplied oil flow because there is no counter-balancing valve to prevent overspeed. In
order to prevent cavitation of the motor due to insufficient flow, oil is drawn through the anti-cavitation check valve to
compensate insufficient flow.
Relief valve (type : KRD 20EK60)
Operation
When the port P begins to be under pressure by the tank, P & R port is shown in figure (1) as an initial tank pressure state.
When the force from the area (A1) and pressure (P) becomes the same as spring (321) plus the force generated by pressure
(Pg) in chamber (g), the relief valve starts working.
Piston (303) moves first, but the pressure in chamber (g) remains constant low pressure P2 until the piston stroke is end, as
shown figure(3). Then piston (302) starts moving but the spring (321) force is getting stronger and pressure (P) goes up
gradually.
In this procedure the relief pressure, P, is under control from P1 to Ps by pressure time, t1.
The following shows moving status of each components and relationships with relief pressure in figure (2)~(4).
Figure (2)
When P port is under pressure, chamber (g) is pressurized by orifice (m) in plunger (301). When the pressure applies to the
hydraulic pressurized area (A2-A3) in the piston (303), it overcomes the force of spring (322) and the piston acting to the
right. At that time the piston (303) moves to the right and relief valve start acting so that the plunger (301) moves to the
right.
At this moment the relationship is shown as,
P1 x A1 = Fsp1 + Pg1 x A2 [Fsp1: Initial spring (231) load]
As piston (303) moves to the right, the oil in chamber (h) is drained to port (R) via the slot in the piston.
Figure (3)
When piston (303) reaches its stroke end, the pressure of chamber (g) applies to pressurized area of piston (302), A4,
overcomes spring (321) force and piston (302) so that piston (302) starts moving.
When piston (302) starts moving, chamber (f) located in piston"s (302) sliding contact area of adjusting plug (401) and relief
slot acts like a damping seal so that the pressure of chamber (g) goes up gradually while the spring (321) load is increasing.
In this procedure, relief pressure P goes up gradually and smoothly from P2 to Ps.
Figure (4)
When piston (302) reaches the end of adjustment plug (401), chamber (g) goes to Ps in order to prevent moving left side
and the pressure equals to relief pressure. The steady state relief is applied at this condition.
From the (1) to (4) procedure, the relief pressure changes as shown in figure (5).
Figure 3
Operation, relief valve
Slew brake
The slew brake is spring applied and hydraulically released. Friction plates (742) are splined to and rotate with cylinder block
(111). Mating plates (743) are splined to motor casing (301). When the remote control valve pilot pressure to SH port is
blocked, the primary pilot oil pressure flow to brake piston (702) is cut off and the force of brake springs (712) acting on
piston (702) squeeze the mating and friction plates together, preventing output shaft (101) from rotating thereby stopping
the superstructure from slewing.
When the primary pilot oil pressure reacts on the opposite side of brake piston (702) it overcomes the force of springs (712)
and moves the piston creating clearance between the friction and mating plates, thereby releasing the brake.
Figure 5
Slew brake
1. Oil pressure
2. Spring force
3. Oil pressure chamber
Figure 6
Position, drain
Dr Drain port
Following the repair or replacement of the slew motor assembly it is necessary to prelubricate the internal
components to prevent scoring/scuffing of the bearings and sliding parts.
Remove the upper case drain port plug and fill the casing with the specified hydraulic oil.
Oil capacity : 900 cc
Prior to start up purge the air from the circuit plumbing and motor.
Check that there is no contamination in the ports or plumbing before connecting to the motor.
Check for oil leakage on the motor assembly.
Check if the direction of rotation according to the control lever is correct.
Check for abnormal sound or vibration while rotating.
Check for any abnormal temperature increase after operating for a short time.
Check if the hydraulic pressures are set to the specified values.
Figure 1
Operation, slew motor
Figure 2
Circuit, check valve
1. Control valve
2. Return
The motor can be rotated faster by inertia than supplied oil flow because there is no counter-balancing valve to prevent
overspeed. In order to prevent cavitation of the motor, oil compensating insufficient flow is drawn through the anti-
cavitation check valve.
Relief valve (Type : KRD22EK10C)
Operation
When ports (P & R) are pressurized by hydraulic tank pressure, the initial condition of the relief valve is closed as shown in
figure (1).
When port P is pressurized by hydraulic tank pressure, the relief valve begins to open at the point that the hydraulic force
[area (A1) of plunger (301) x pressure P] is equal to spring (321) force plus pushing force [area (A2) of plunger x pressure of
chamber g (Pg)]. And then, the force of spring (321) increases according to movement of piston (302) by the increasing
pressure of chamber g.
The relief pressure P is controlled with pressure-up timing t1 from P1 to Ps. For each step in figure (2) ~ (4), relations of the
movement and relief pressure is explained as follows.
Figure (2)
When port P of the relief valve is pressurized, chamber g is pressurized through orifice m, fitted into plunger (301). As
hydraulic force in plunger (301) increases and it reaches equal to spring (321) force, the relief valve operates with pressure
P1.
At this time, the relation is expressed in following formula.
P1 x A1 = Fsp1 + Pg1 x A2 [* Fsp1: the initial setting load of spring (321)]
Figure (3)
The pressure of chamber g acts on piston (302) area (A3 - A4). If this hydraulic force is greater than spring (321) force, the
piston begins moving to the left.
At this time, chamber h functions as a damping chamber because the oil in chamber h, which is between piston (302) and
adjustment plug (401), discharges through orifice n, which is installed at piston (302), and then it moves to the left. The relief
pressure P increases gradually because tensional load increases according to the compression of the spring until piston (302)
approaches the end of the adjustment plug.
Figure (4)
When the piston (302) contacts the end of adjustment plug (401), it does not move to the left any more, and it becomes
normal condition, then the relief pressure keeps as Ps.
By the above procedure, the relief pressure varies as figure (2).
As the oil pressure decreases, the pressure of port P and chamber g decreases to tank pressure. Therefore, the opening
plunger (301) is pushed to the left and contacts seat (341). Simultaneously, the piston (302) moves to the right by spring
(321) force as shown in figure (1).
Figure 3
Operation, relief valve
Rebound damping valve
The rebound damping valves allow, fast/responsive, but smooth/gentle acceleration and retardation of the superstructure
without jerking or impact, thereby greatly reducing mechanical stress on the slew mechanism and extending component
service life.
Operation
Figure (1) shows the damping valve in neutral condition in relation to normal slew operation.
Figure (2) shows the valve operating condition with brake pressure at port (A).
Oil pressure applied at port (A) flows through passage (l), the orifice in seat (313), and passage (m) of spool (311) to chamber
(n). When pressure (P) is more than set value of spring (321) force (Ps), it moves spool (311) left compressing spring (321),
pushing seat (313) to compress spring (322).
Figure (3) shows the valve condition when movement of the inertia load stops, [Y point in figure (4)], and the brake pressure
is lowered. When pressure (P) is less than spring (321) force (Ps), spool (311) moves right, then spring (322) starts to move
seat (311) right, but the seat return is delayed since the oil in chamber (p) exits via narrow passage (g) which causes a
damping function. The delay allows seat (t) to open and a passage is connected between port (A) & (B), by (l → t → r → k).
This rapidly equalizes the pressure at port (A) & (B), [Z point in figure (4)], which prevents the slew motor from over running.
Figure 4
Operation, rebound damping valve
Slew brake
The slew brake is spring applied and hydraulically released. Friction plates (742) are splined to and rotate with cylinder block
(111) which is splined to shaft (101). Mating plates (743) are held by arc grooves in motor casing (301). Brake springs (712)
force acting on brake piston (702) squeeze the mating and friction plates together, friction force is generated stopping
output shaft (101) from rotating, thereby halting the superstructure movement.
When primary oil pressure acts on the opposite side of brake piston (702) it overcomes brake springs (712) force and the
piston moves creating clearance between the plates, thereby releasing the brake.
Figure 5
Operation, slew brake
If the relief pressure can not be adjusted correctly, replace the relief valve assembly.
Figure 1
Position, pressure measuring
Figure 1
Position, drain
D Drain port
Following the repair or replacement of the swing motor assembly it is necessary to prelubricate the internal
components to prevent scoring/scuffing of the bearings and sliding parts.
Remove the upper case drain port plug and fill the casing with the specified hydraulic oil.
Oil capacity: 0.8 liters (0.21 US gal)
Prior to start up purge the air from the circuit plumbing and motor.
Check that there is no contamination in the ports or plumbing before connecting to the motor.
Check for oil leakage on the motor assembly.
Check if the direction of rotation according to the control lever is correct.
Check for abnormal sound or vibration while rotating.
Check for any abnormal temperature increase after operating for a short time.
Check if the hydraulic pressures are set to the specified values.
Gap between piston and caulked part of 0 0.3 Replace assembly of piston
shoe (α) (0.0118) and shoe.
If the relief pressure can not be adjusted correctly, replace the relief valve assembly.
Figure 2
Pressure adjustment
General tools
General tools
Special tool
Special tool
Tools
General tools
General tools
Special tools
Special tools
Description Size
Snap ring plier φ 52, φ 60 (φ 2.05, φ 2.36)
Driver (–) Medium (2)
Pry bar 10 × 8 × 200 mm (0.4 × 0.3 × 7.9 in)
Hammer Plastic and steel hammers
Torque wrench Tightening torque
100 ~ 450 kgf cm (80 ~ 400 lbf in)
400 ~ 1800 kgf cm (80 ~ 1600 lbf in)
1200 ~ 4800 kgf cm (1000 ~ 4200 lbf in)
Slide hammer bearing puller 14559282 Puller
Service Information
1. Park the machine in the service position C. See 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
After disconnecting the hose, install a plug to prevent oil leakage and contamination.
Figure 1
Removal, hoses
1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses
5. Screws
8. Lift swing motor with sling, and lower to the workbench safely.
Figure 2
Removal, swing motor
1. Sling
2. Oil filling pipe
3. Swing motor
9. Transfer oil filling pipe and the connectors to the new swing motor.
NOTE!
Before installing the drain port connector, fill the new swing motor casing with hydraulic fluid.
Figure 3
Applying, sealing compound
1. Swing gearbox
2. Sealing compound
17. Bleed air from the hydraulic circuit at the swing motor before operating.
18. After completion of the work, start the engine and check for leaks.
Service Information
1. Park the machine in the service position C, see 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at
"ON" position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
Figure 1
Replacing, relief valve
5. After completion of the work, start the engine and check for leaks.
6. Check relief valve pressure of the slew motor, and adjust if necessary.
Service Information
Figure 1
Removal, retaining rings
1. Retaining ring
2. Retaining ring
Figure 2
Removal, seal cover
1. Seal cover
1. Seal
Figure 4
Installation, seal cover
1. Seal cover
1. Retaining ring
2. Retaining ring
Service Information
14559282 Puller
1. Park the machine in the service position B. See 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
After disconnecting the hose, install a plug to prevent oil leakage and contamination.
Figure 1
Removal, hoses
1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
1. Valves
2. Screw
3. Swing motor cover
9. Remove the springs from the brake piston and remove the plate on the cylinder.
Figure 3
Removal, springs and plate
1. Springs
2. Plate
10. Fit the special tool to brake piston as shown and then tighten screws to the casing.
Pull the brake piston vertically by tightening the screws of special tool.
1. Special tool
2. Brake piston
3. Screws
Figure 5
Replacing, O-rings
1. O-ring
2. O-ring
12. Install the brake piston into the casing using the special tool.
1. Plate
2. Swing motor cover
17. Bleed air from the hydraulic circuit at the swing motor before operating.
Service Information
Op nbr 00000
1. Lift the motor assembly with a wire rope and crane. Clean with cleaning solvent, and dry with compressed air.
NOTE!
Clean the motor thoroughly before separating from the reduction gear.
2. Before disassembling make a match mark (A) on motor casing (301) and valve casing (303).
NOTE!
Select a clean place. Put a rubber sheet on the work bench to prevent the parts from being damaged.
Figure 1
Removal, drain plug
3. Remove screws (032) and delay valve (031) from casing (301).
Figure 2
Marking, A
Figure 3
Removal, delay valve
5. Remove screw (171) and rebound damping valve (052) from valve casing (303).
Figure 4
Removal, rebound damping valve
Figure 5
Removal, relief valve
NOTE!
Replace O-ring .
7. Remove Ro plug (469) and take out spring (355) and spool (351) from the valve casing.
Figure 6
Removal Ro plug
NOTE!
Be careful not to damage the spool seat.
8. Remove screws (401) and valve casing (303) from casing (301). When loosening the screws casing (303) will be
raised by brake springs (712). Remove valve plate (131) from the valve casing.
Figure 7
Removal screws
Figure 8
Removal, valve plate
NOTE!
Be careful not to drop the valve plate from the valve casing. (Sometimes the valve plate is adhered to the cylinder.)
Figure 9
Removal, brake springs
10. Disassemble brake piston (702) from casing (301) by using the special tool.
Figure 10
Disassembly, brake piston
NOTE!
Lift it straight, using the screw holes in the brake piston.
11. After placing the motor horizontally, take out cylinder (111) from drive shaft (101). Remove pistons (121), retainer
(123), spherical bushing (113), spacer (117) and swash plate (124).
Figure 11
Removal, cylinder
NOTE!
When taking out the cylinder, be careful not to pull out push rod (116). Piston must be installed into the same
bores because of wear pattern. Mark the pistons and respective cylinder bores.
12. Pull out friction plates (742) and mating plates (743) from casing (301).
Figure 12
Removal, friction and mating plates
Figure 13
Removal drive shaft
Figure 14
Removal, drive shaft
NOTE!
Tape drive shaft spline to prevent oil seal damage.
Figure 15
Remove the inner race
A. Press
B. Drive shaft
C. Bearing
D. Support the inner race
15. Remove snap ring (437) and pull out seal cover (305) from casing (301). Remove oil seal (491) from seal cover (305)
using a seal driver.
Figure 16
Removal, seal cover
16. Use a slide hammer and a bearing puller or a press to remove the outer race of bearing (443) from casing (301).
Figure 17
Removal, bearing outer race
NOTE!
Do not reuse the bearing.
17. Pull out roller bearing (444) from valve casing (303) with a sliding hammer and a bearing puller.
Figure 18
Removal, roller bearing
NOTE!
Do not reuse the bearing.
NOTE!
Disassembling is finished. Check each component thoroughly.
Op nbr 00000
1. Remove snap ring (437) and pull out seal cover (305) from casing (301).
Figure 19
Removal, snap ring
2. Remove oil seal (491) from casing (301) with a seal driver (M4 × 0.7 screws).
Figure 20
Removal, oil seal
3. Install new oil seal (491) to casing (301) and drive shaft (101) after assembling two screws (M4 × 0.7) on the oil seal.
Figure 21
Assembly, oil seal
NOTE!
Coat the lip of the oil seal with grease. Be careful not to damage the lip of the oil seal, tape the shaft splines. The
seal lip must face toward casing (301) – downward in the picture.
4. Insert seal cover (305) and install snap ring (437) to casing (301).
Figure 22
Assembly, seal cover
Service Information
2. Remove the drain plug and drain the oil from casing (301).
3. Put identification marks on the parts to indicate proper positioning during reassembly.
NOTE!
Prevent damage to disassembled parts, by keeping them protected and in a clean area.
Figure 1
Identification marks
4. Remove relief valves (051) from the valve casing (303).
NOTE!
Be sure to replace O-rings of relief valves because they are frequently damaged during disassembly.
Figure 2
Removal, relief valves
5. Remove plugs (469), spring (355) and spools (351) from the valve casing (303).
NOTE!
Handle carefully to prevent damage to the seat on spool (351).
Figure 3
Removal, plugs
6. Remove screws (401) and remove valve casing (303) from casing (301) then remove valve plate (131).
NOTE!
When the screws are loosened the valve casing is slightly lifted by the brake springs (712).
Be careful not to drop the valve plate from the valve casing. It is often adhered to the cylinder.
Figure 4
Removal, screws
7. Remove springs (712) from the brake piston (702).
Figure 5
Removal, springs
8. Remove brake piston (702) from casing (301) by using special tool.
– Tool part number: 14559282
NOTE!
Pull brake piston (702) vertically by using the special tool.
Figure 6
Removal, brake piston
9. Put the motor on its side as shown in the figure. Remove the rotation group from drive shaft (101).
NOTE!
During the removal of the rotation group from the swing motor, do not let the pistons fall out of the cylinder. All
pistons in the rotation group must be re-installed in their original locations.
Figure 7
Removal, rotation group
10. Disassemble the rotation group as follows:
Put identification marks on nine pistons (121), showing their location in plate (123) and cylinder (111). Remove nine
pistons (121) and plate (123) as a unit from the cylinder. Separate the piston assemblies from the plate.
NOTE!
Handle carefully so as not to damage the sliding face on the retainer or shoes (122).
11. Remove friction plates (742) and mating plates (743) from casing (301).
Figure 8
Removal, friction and mating plates
12. Turn the motor body over, and remove the shaft assembly from casing (301).
Figure 9
Removal, shaft assembly
13. Remove roller bearing (443) using a press if necessary.
NOTE!
Be careful not do damage the sliding face on the shaft. If the bearing is removed, a new bearing must be used
during reassembly.
Figure 10
Removal, bearing
14. Remove bearing (443) from casing (301) using a rod and hammer.
NOTE!
When hammering, be sure to use a soft metal bar to prevent damage to parts. Never hit directly with a hammer or
iron bar.
NOTE!
If the bearing is removed a new bearing must be used during reassembly.
15. Remove bearing (444) from the motor body using bearing pliers, only if necessary.
NOTE!
If the bearing is removed a new bearing must be used during reassembly.
Service Information
1. Place the motor in a vertical position with bell housing face down.
2. Heat bearing inner race (443) to 110 °C (230 °F) maximum and install onto drive shaft (101).
NOTE!
Do not exceed temperature 110 °C (230 °F).
Figure 1
Heating, bearing inner race
A. Output side
B. Bearing inner race
3. Heat bearing inner race (444) to 110 °C (230 °F) maximum and install onto drive shaft (101).
NOTE!
Do not exceed temperature 110 °C (230 °F).
4. Apply grease to seal (491) and install the seal to casing (301).
NOTE!
Be careful of direction of the oil seal. The seal lip must face toward casing (301).
NOTE!
Be careful not to damage the lip of the oil seal.
Figure 2
Installation, oil seal
5. Insert bearing (443) to casing (301).
Figure 3
Installation, bearing
6. Insert shaft (101) to casing (301).
NOTE!
Be careful not to damage the lip of the oil seal.
Figure 4
Installation, shaft
7. Install shoe plate (124) into casing (301).
NOTE!
The shoe plate lapped side must face outwards.
Figure 5
Installation, shoe plate
8. Put thrust plate (123) on plate spring (114) and install piston assembly (121, 122) into thrust plate (123).
Figure 6
Installation, piston assembly
9. Insert piston assemblies into cylinder (111).
Install the rotation group into casing (301).
Figure 7
Installation, rotation group
10. Place the motor in a vertical position with bell housing face down.
First, insert a mating plate (743), and then insert a friction plate (742) and mating plate (743) alternately.
NOTE!
Mating plate: 4 EA, Friction plate: 3 EA
Figure 8
Installation, friction and mating plates
11. Install O-ring (707) and O-ring (706) into casing (301).
NOTE!
Coat the O-rings with grease prior to installation.
Figure 9
Installation, O-ring
12. Install brake piston (702) into casing (301) by tapping the piston into position using a plastic hammer, and then
press firmly to ensure the brake piston is seated correctly.
Figure 10
Installation, brake piston
13. Install spring (712) into brake piston (702).
Figure 11
Installation, spring
14. Install bearing (444) into valve casing (303) using a hammer and steel rod.
NOTE!
Tap evenly at the periphery of bearing using a hammer and steel rod until it is fully seated.
Figure 12
Installation, bearing
15. Install valve plate (131) and O-ring (472) onto valve casing (303). Brass face must be upwards.
NOTE!
Coat the face of the valve casing lightly with grease to hold valve plate (131) in position.
Figure 13
Installation, valve plate and O-ring
16. Install valve casing (303) and four screws (401) into casing (301).
Figure 14
Installation, valve casing
17. Insert spool (351) and spring (355) into valve casing (303) and install plug (469) with O-ring (488) in valve casing
(303).
NOTE!
Check spool (351) to ensure it moves smoothly.
Figure 15
Installation, spool
18. Put the O-ring on relief valve (051) and install relief valve (051) into valve casing (303).
Figure 16
Installation, relief valve
Service Information
Preparation
Clean all part with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts and bearings with clean hydraulic oil.
Replace the o-rings and oil seal.
Use a torque wrench to tighten the screws and plugs, to the specified torque.
Assembly, slew motor
Op nbr 00000
1. Place casing (301) on the work bench with the valve casing side upward.
Figure 1
Casing
2. Heat the inner race of bearing (443) and press–fit to drive shaft (101).
Figure 2
Assembly, inner race collar
NOTE!
Pay attention to the direction of the inner race collar.
A. Output shaft
3. Heat the inner race of bearing (444) and press–fit to drive shaft (101).
Figure 3
Assembly, inner race bearing
4. Install snap ring (437) in casing (301) and seal cover (305). Install oil seal (491) in casing (301) using the oil seal
driver.
NOTE!
Pay attention the direction of oil seal. The seal lip must face toward casing (301) – upward in the drawing. Coat the
lip of the oil seal with grease.
Figure 4
Assembly, snap ring
5. Using a brass tap the outer race of roller bearing (443) until the bearing is fully seated in casing (301).
Figure 5
Assembly, roller bearing
7. Set the casing horizontally and assemble shoe plate (124) casing side.
Figure 7
Assembly, shoe plate
A. Casing side
NOTE!
Insert it with the larger chamfered side of the shoe plate toward the casing. Coat lightly with grease.
8. Insert push rods (116) and spacer F (117) to cylinder (111) and install spherical bushing (113) with the larger O.D.
toward the cylinder.
NOTE!
Be careful not to damage the sliding surface of the cylinder. Insert 2 push rods into each hole.
Figure 8
Assembly, push rods
Figure 9
Assembly, piston
10. Assemble the retainer with the piston sub assembly unit to the cylinder block and install it on drive shaft (101)
aligning the splines.
Figure 10
Assembly, piston sub
11. Set casing (301) with seal cover (305) downward and assemble three mating plates (743) and four friction plates
(742) in sequence.
NOTE!
Align 4 tangs to the notches as shown.
Figure 11
Assembly, plates
Figure 12
Assembly, o-rings
NOTE!
Coat the o-rings with grease.
Figure 13
Assembly, brake piston
Figure 14
Assembly, brake piston
NOTE!
Place 4 notches of the brake piston as shown below. The piston is difficult to assemble because of the restriction of
the o-ring; screw two M8 screws into the brake piston and tap them gently.
A. 2–M8
B. Brake piston
C. Screw hole
D. Mounting side
Figure 15
Assembly, brake springs
NOTE!
Confirm the springs are fitted to the brake piston completely.
Figure 16
Assembly, roller bearing
NOTE!
Tap evenly on the outer diameter of the outer race with a brass bar until it is fully seated.
16. Assemble valve plate (131) to valve casing (303) and fit o-ring (472).
NOTE!
Coat lightly with grease. Ensure dowel pins (451) are installed in the valve casing.
Figure 17
Assembly, valve plate
17. Mount valve casing (303) to casing (301) and tighten screws (401) to the specified torque.
Figure 18
Assembly, valve casing
NOTE!
Be careful to note the mounting direction of the valve casing. (See the drawing) Be careful not to drop the valve
plate or let the brake springs pop out. Tighten the screws evenly.
18. Insert spool (351) and spring (355) into the valve casing and install RO plug (469) with o-ring (488). Tighten the
plug to the specified torque.
Figure 19
Assembly, spool
NOTE!
Confirm the smooth movement of the spool before installing the plug.
Figure 20
Assembly, relief valve
Figure 21
Assembly, delay valve
21. Assemble o-ring (161) to rebound damping valve sub assembly (052) and install the valve with screw (171) to valve
casing (303).
Figure 22
Assembly, rebound damping valve
NOTE!
Be sure to install all the o-rings.
Figure 23
Assembly, plug
Service Information
Pressure rises.
1. Overload 1. Remove load.
2. Seizure of moving parts 2. Check and repair piston/shoes,
3. Brake is not applied with release cylinder, valve plate, etc.
of oil pressure. 3. a) Check and repair circuit.
4. Brake piston sticks. b) Check time delay valve for
5. Spool sticks. brake.
6. Friction plate is seized. 4. Disassemble and check it.
5. Disassemble and check it.
6. Disassemble and check it.
Replace seized plates.
Troubleshooting
Figure 1
Structure, coupling
1. Element
2. Hub
3. Insert A
4. Insert R
5. Screw (M18 × 60) Tightening torque: 304 ~ 324 Nm (31 ~ 33 kgf m) (224 ~ 238 lbf ft)
6. Screw (M16 × 55) Tightening torque: 304 ~ 324 Nm (31 ~ 33 kgf m) (224 ~ 238 lbf ft)
7. Clamping screw (M16 × 22) Tightening torque: 98 ~ 118 Nm (10 ~ 12 kgf m) (72 ~ 87 lbf ft)
8. Spring pin (φ5 × 10)
9. Coupling assembly weight: 6.5 kg (14.3 lbs)
1. Remove all hydraulic hoses, pipes and wire connectors from hydraulic pump, and then plug them.
2. Remove screws and hydraulic pump from the engine while keeping the pump shaft horizontal.
NOTE!
Before loosening screws take appropriate action to hold and support hydraulic pump.
Op nbr 00000
NOTE!
Take care not to enter dust and foreign materials around coupling assembled.
1. After inserting the spring pin, install the flexible coupling assembly to flywheel by using screws.
2. When assembling the hub spline onto the pump shaft, leave 3 mm (0.12 in) gap.
Adjust using two clamping screws on hub.
3. Install hydraulic pump to the engine while keeping the pump shaft horizontal by using screws.
1. Increase the engine rpm gradually to high rpm and operate boom, arm and bucket cylinder slowly.
2. Check for any abnormalities or leakage. Correct abnormal phenomena, if any.
Service Information
Figure 1
Center passage, section view and exploded view
Port connection
Main control valve port Center passage Port size Pressure Track motor Application
port kgf/cm2 (psi) port
– A PF 3/8″ 35 (498) Plug –
– B PF 3/8″ 35 (498) Ps Low/high speed
BL4 C PF 1″ 350 (4980) A Forward–left
BR3 D PF 1″ 350 (4980) B Forward–right
AL4 E PF 1″ 350 (4980) B Reverse–left
AR3 F PF 1″ 350 (4980) A Reverse–right
Track motor drain G PF 3/4″ 7 (100) D1, D2 Drain
Service Information
Figure 1
Center passage, mounting
1. Park the machine in the service position C, see 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with
ignition switch at "ON" position.
Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
NOTE!
After disconnecting the hose, install a plug to prevent oil leakage and contamination.
3. Remove screws (1) and protecting plates (2) in the middle of undercarriage.
Figure 1
Removal, protecting plates
Figure 2
Removal, hoses
5. Remove motor drain hoses (3).
Figure 3
Removal, hoses and fitting
Figure 4
Removal, plates and plugs
13. Install eye bolts (2) on center passage and hold the center passage with hoist (1).
Figure 5
Holding, center passage
14. Remove the center passage mounting screws (1) installed at the bottom.
Figure 6
Removal, screws
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
15. Lower the center passage with the hoist and move it to the workbench safely.
17. Install the new center passage in reverse order of the removal procedure.
Figure 7
Installation, stop screw
NOTE!
Turn the bolt (1) until the gap between bracket (2) and bolt (3) is 15 mm and then tighten the nut.
18. Remove the vacuum pump mounted on the hydraulic tank.
Service Information
1. Park the machine in the service position C, see 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at
"ON" position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
NOTE!
After disconnecting the hose, install a plug to prevent oil leakage and contamination.
Figure 1
Removal, cover
4. Remove the high pressure hose of main control valve port (1) and the high pressure hose of center passage port
(2).
Figure 2
Removal, hose
5. Install a new center passage hose in reverse order of the removal procedure.
Service Information
1. Park the machine in the service position C, see 091 Service positions.
2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at
"ON" position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
NOTE!
After disconnecting the hose, install a plug to prevent oil leakage and contamination.
Figure 1
Removal, motor cover
Figure 2
Removal, hose
5. Remove screws (1) and protecting plates (2) in the middle of undercarriage.
Figure 3
Removal, protecting plates
Figure 4
Removal, hose
7. Install a new center passage hose in reverse order of the removal procedure.
Service Information
No Tool Remark
1 Hammer
1. Steel hammer
2. Wooden or plastic hammer
6 Spatula
Apparatus
Hoist or crane
The lifting device should be capable of lifting the center passage assembly.
Work bench
The work bench should have an area of 1.2 m × 1.5 m (4 ft × 5 ft).
Others
Also prepare clean cloth, wooden block and oil pan.
Special tools
Dry bearing assembly jug
Special tools (unit : mm)
ØA ØB ØC ØD O N M L Part No.
129 104 100 30 Thru 25 33 45 103 8920-01520
Figure 1
Dimension, special tool
WARNING
The plate is heavy, take appropriate safety precautions.
NOTE!
Clean the outside of the center passage with hot water or steam.
NOTE!
Clean center passage with the ports plugged.
NOTE!
Mark each hose assembly to identify its location on the center passage.
NOTE!
Mark shaft (2) and hub (1) to aid in reassembly.
2. Remove hydraulic lines connected to the center passage hub, and plug each hose and oil port.
3. Remove hydraulic lines connected to the upper side of center passage shaft, and plug each hose and oil port.
5. Screw an eye bolt in the middle of the center passage shaft, attach a sling to the lifting equipment. (To prevent the
center passage from dropping when removing the mounting screws.)
7. Lower the sling slowly and take the center passage out through the bottom.
8. Dip the center passage into a cleaning solution to thoroughly clean the assembly.
Figure 1
Center passage, fixing
10. Remove screws (11), washer (12) and cover (3) from the center passage.
Figure 2
Cover, removal
11. Pull out o-ring (7), remove screws (9), washer (10) and spacer (8).
Figure 3
Spacer, removal
Figure 4
Shaft and hub, removal
14. Remove bushing (4) mounted in the hub using a bushing driver.
Replace only if necessary.
Take care not to damage the bushing / housing mounting surface.
Figure 6
Bearings, removal
15. Remove seals (5) assembled in the hub using a sharp pin.
NOTE!
Take care not to damage the seal grooves of hub (1).
Figure 7
Seals, removal
16. Inspect each part, and repair or replace the defective or worn parts.
17. Do not reuse o-ring or seals. Be sure to replace with new ones.
Service Information
WARNING
The plate is heavy, take appropriate safety precautions.
Figure 1
Cleaning with solvent and compressed air
1. Shaft
2. Hub
3. Cover
2. Coat the dry bearing outer diameter and hub section with loctite (#609) and press–fit using a jig.
NOTE!
Ensure the bearing is fully seated.
NOTE!
Wipe excess loctite off the hub and bearing surface.
Figure 2
Assembly, dry bearing
4. Before installing the seals (5) and o-ring (6), coat the seal grooves with hydraulic oil (2 ~ 3 times).
NOTE!
Take care not to twist or damage the seals.
NOTE!
Check the seal mounting condition.
NOTE!
Ensure the seals are not damaged or twisted, then by hand rubbing seat the seals inside of assembly section as
close as possible to a cylindrical condition.
Figure 3
Seal assembled in front
7. Fix hub to the stopper, and then operate the press slowly and insert the shaft.
Figure 5
Assembly, hub and shaft
After tightening plug 1/3 and applying loctite (#572), tighten completely.
Tightening torque : P/T 3/8 : 8 ± 0.8 kgf·m (58 ± 6 lbf·ft)
Figure 6
Assembly, plug
10. Fasten spacer (8) to the end of shaft (2) and tighten the screws (9) with lock washer (10) to specified torque.
NOTE!
The spacer must fully contact the shaft.
Figure 7
Assembly, spacer
11. Mount the o-ring (7) to the hub groove, then install cover (3) and tighten the screws (11) with lock washer (12) to
specified torque.
NOTE!
Apply a dab of grease on the surface of o-rings and install ensuring they are not twisted or damaged.
Figure 8
Assembly, cover
12. After the completion of assembly with shaft fixing jig (1) and hub fixing jig (2), check the hub, shaft and rotating
torque (X).
Starting torque : 25 kgf·m (181 lbf·ft)
Rotating torque : 20 kgf·m (144 lbf·ft)
Figure 9
Check of rotating torque and pressure
13. Connect adapter (3) to each port for internal/external leakage test.
Each port pressure
A, B : 35 kgf/cm2 (498 psi)
C, D, E, F : 350 kgf/cm2 (4980 psi)
G : 7 kgf/cm2 (100 psi)
Figure 10
Assembly, fittings
16. Install the four mounting screws, the clamping screw and tighten to specified torque.
18. Check for operating condition and leakage, and track motor functions
NOTE!
When assembling elbows (4) to center passage (5), take care that o-ring (1) and washer (2) are installed closely to
nut (3).
Figure 11
Elbows, install
Service Information
Wear limits
Shaft There is no damage or wear of New shaft external surface is The depth of damage is more than
external surface. finished as 1.5s. If the pitting of 0.1mm.
the shaft is slight, it is allowable.
Figure 1
Checking, high pressure port
Install a changeover valve and pressure gauge to the shaft port and hub port respectively, and while watching the pressure
gauge (for high pressure) installed on the hub and also by regulating high pressure relief valve (7), gradually increase the
pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) to trap the
hydraulic oil in the center passage. Keep stop valve (6) on the low pressure relief valve side closed at this time.
Low pressure port
(Drain port, return port, etc.)
Similar to the high pressure port, install a changeover valve and pressure gauge on each port of the shaft and hub.
Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure)
connected to the hub and also by regulating low relief valve (5), gradually increase the pressure and check for leakage with a
pressure of 10 kgf/cm2 (142 psi).
Checking, low pressure port
Troubleshooting
Troubleshooting
Figure 1
Slew ring gear, structure
A Filler plug (soft zone) "S" Soft zone 4 Filler plug 8 Name plate
B Grease port 1 Outer race 5 Ball 9 Rivet
C Pin holes 2 Inner race 6 Support 10
D Grease port 3 Taper pin 7 Seal 11
Service Information
Figure 1
Seal, removal
2. Scrape old adhesive from seal groove (B). Thoroughly clean seal groove and new seal using aerosol solvent.
4. Install seal with seal lip against outer race (A). Start about 76 mm (3 in) from end of seal using a blunt instrument to
force seal into groove. Push seal in direction of portion already installed to avoid stretching.
6. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together.
NOTE!
To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using slew function.
Figure 2
Adhesive, applying
Service Information
WARNING
Confirm the weight of slew ring gear, and take appropriate safety measures.
1. Remove superstructure.
Figure 1
Lifting, slew ring gear
3. Remove screws and lock washers and slew ring bearing (D).
A. Tooth
B. Loading plug
6. Install slew bearing on undercarriage so the tooth marked “S” or equivalent and bearing loading plug is the right
side of machine as shown.
Figure 3
Grease, applying
1 Pin 6 Cover 11 Screw
2 Pin 7 Screw, tightening torque : 2.3 ± 0.2 kgf·m (16.6 ± 1.4 lbf·ft) 12 Elbow
3 Pin 8 Screw, tightening torque : 2.3 ± 0.2 kgf·m (16.6 ± 1.4 lbf·ft) 13 Grease nipple
4 Soft zone filler plug 9 Screw, tightening torque : 52.2 ± 5.2 kgf·m (377 ± 38 lbf·ft)
5 Soft zone "S" 10 Screw, tightening torque : 52.2 ± 5.2 kgf·m (377 ± 38 lbf·ft)
NOTE!
The "E" hole (outer race) is not assembled screw, and seal it with liquid gasket, loctite # 5699.
Service Information
1. Park the machine in the service position B, see 091 Service positions.
NOTE!
Ring gear grease points are 3 points and 2 point type. See 173 Swing ring gear bearing, lubricate.
Figure 1
Ring gear grease 3 points (A) and 2 point (B)
Figure 2
Replacing, ring gear grease pipe
3. Install a new ring gear grease pipe in reverse order of the removal procedure.
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/12 9:26:42]