Retightening torque table

1 Voltage Measurement Procedure

Items to prepare

[1] Use the service connector (female) (1) and the service connector (male) (2) for voltage measurement.

[2] Remove the connector (1) for voltage measurement.

•Service connectors •Tester

1

2

1

[3] Connect the service connector (male) (1) to the connector you have removed. Connect the tester (2) to connector terminals and measure the voltage.

[4] Also connect the service connector (1) into the other socket of the connector you have removed, and measure the voltage using a tester (2).

1

2

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2

1 Removal and Installation of Shoe Assembly

Warnings

•Gradually loosen the check valve when loosening it. •The hydraulic pressure inside the cylinder is very high. If the check valve is loosened too much, grease may come out or the plug may fly off. Never stand in front of the check valve when you adjust it.

Caution •Be sure to stop the engine before beginning work.

•Wrench (17 mm, 19 mm) •Bar hammer •Holding-up bar •Pinch bar •Rags

Items to prepare

[1] Loosen the check valve (1) using a 19-mm box wrench to release the grease, and release the track shoe tension.

[2] Remove the stopper (1) from the check valve using a 17-mm wrench. •The track shoe tension can easily be released with the check valve (2) removed. 1

1

2

[3] Straighten the S pin (1) mounted on the master pin by hammering, and pull it out using a pinch bar.

[4] Push the master pin (3) out using bar hammer (1) and holding-up bar (2).

[5] Remove the track shoe (1). 1

1 3

2

1

2 Removal and Installation of Shoe Plates

Caution •Be sure to stop the engine before beginning work.

•Wrench (30 mm) •Grease •Rags •Cleaning fluid

Items to prepare

[1] Remove 4 shoe bolts (1) using a 30-mm box wrench, and remove the shoe plate (2). 1

2

1 Removal and Installation of Travel Motor Assembly

Warning

Caution

•When loosening the check valve, loosen it gradually and stop loosening when grease appears. (The pressure inside the cylinder is very high. If the check valve is loosened too much, grease may come out or the plug may fly off.)

•Before removing the shoes, be sure to bleed off any air in the hydraulic circuits. •Be sure to inspect the wire rope and other suspended items before beginning work. •Do not stand or pass under the suspended load (travel motor).

•Box wrench (19 mm, 24 mm) •Wrench (17 mm, 19 mm, 27 mm, 36 mm) •Hammer (to remove the master pin) •Pipe (to remove the master pin) •Crane (that meets the lifting capacity) •Wire (with the required breaking load) •Crossties •Rags •Cleaning fluid

Items to prepare

[1] Allow the bucket (1) to touch the ground so as to elevate one shoe (2) as in the figure on the right.

[2] Slowly rotate the shoe until the shoe joint section (1) is aligned as in the figure on the right. [3] Place 2 crossties (2) under the shoe and bring the bucket to its original position. [4] Bleed off air from all parts, referring to the

Air Bleed Procedure.

1 2

1

2

[5] Use a 19-mm box wrench to rotate the grease cylinder check valve (1) and loosen the shoe tension. •Grease flows out, so provide rags. If the check valve is loosened too much at this time, it may fly off. Be careful not to stand in front of the check valve.

[6] Pull out the S pin (1) from the rear of the joint section.

[7] Place a pipe or similar object against the master pin (1) and hit with a hammer (2) to remove the master pin (1) to the outside.

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1

2

1

[8] Open the shoe (1) to the rear.

[9] Use a crane and wire to suspend the motor.

[10]Use a 19-mm wrench to remove the 4 bolts (1), and then remove the cover (2).

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2

1

[11]Use a wrench (27-mm for drain hose, 36mm for main hose) to remove the 3 drain and main hoses (1). •Be sure to use plugs on the removed drain and main hoses.

[12]Use a 17-mm wrench to remove the elbow joint (1) as in the figure on the right.

[13]Use a 24-mm box wrench to remove all 34 bolts (1).

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1 1

[14]Remove the motor.

2 Assembly and Disassembly of Travel Motor 1.Foreword

This manual provides instruction for maintenance of the swash plate-type piston motor with case rotation type reduction gear for the open circuit MAG-170VP-3800E series. This manual helps first-time users to understand maintenances issues as well as assists experienced users to review the swash plate-type piston motor with case rotation type reduction gear for the open circuit manufactured by KYB Co., Ltd. Read this maintenance procedures well and come to an understanding of its contents before beginning actual maintenance work. It is recommended that users keep this manual ready at hand during operation.

This maintenance procedures mainly consists of (1) the disassembling procedure, (2) maintenance standards (3) assembling procedure, and (4) post-assembly checking points for the MAG-170VP-3800E series, swash plate-type piston motor with case rotation type reduction gear for the open circuit.

MAG-170VP-3800E series, swash plate-type piston motor with case rotation type reduction gear for the open circuit produced by KYB Co., Ltd. is the actuator used in the hydraulic unit of the mother machine. Therefore, this maintenance procedures should be used along with the maintenance procedures of the mother machine. Always refer to the maintenance procedures of the mother machine when using this maintenance procedures.

2.For Safety Operation

Safety Cautions Be sure to follow the instructions below:

Warning

Never lift the motor by the tap on the base plate when transporting by crane. Doing so may cause the motor to fall, which may cause personal injury or damage to the machine.

Warning Always wear a helmet, safety shoes, gloves and protective goggles when disassembling the motor for transportation, installation, maintenance and inspection, etc.

Lifting prohibited Lifting recommended Eyebolt

Eyebolt Eyebolt

Safety Cautions Be sure to follow the instructions below:

Warning

Do not run the motor when the hydraulic oil level is low in the hydraulic tank (near the inlet), or when the hydraulic tank is empty. Doing so may cause air to enter the motor, and the motor may go out of control, which may cause personal injury or damage to the machine.

Inlet Hydraulic tank

Outlet

Warning

Do not run the motor when the pipe is empty.

Doing so may cause air to enter the motor, and the motor may go out of control, which may cause personal injury or damage to the machine.

Warning

Never remove the oil fill, oil discharge or oil check ports of the reduction gear lubricating oil within 1 hour after the motor has stopped. Doing so may cause high-temperature lubricating oil to squirt out and may cause burns. High-temperature lubricating oil will squirt out and may cause loss of eyesight if it gets into the eyes.

Safety Cautions Be sure to follow the instructions below:

Never remove the pressure detection port or oil drain port when the pipe is pressurized. Doing so may cause pressurized oil to squirt out and may cause loss of eyesight if it gets into the eyes. Always release the pressure inside the pipe to atmosphere level before removing.

Warning

Do not remove the cover from the reduction gear with the motor attached to the machine body. Doing so may cause your fingers or hands to get pinched causing injury.

Warning

Warning

Do not disassemble the motor with the motor attached to the machine body. Doing so may cause the machine to go out of control resulting in personal injury. Always remove the motor from the machine body before disassembling.

Safety Cautions Be sure to follow the instructions below:

Do not remove the spool from the double counter balance valve with the motor attached to the machine body. Doing so may cause the machine to go out of control causing personal injury or damage to the machine.

Warning

Never tamper with the relief valve adjuster. Doing so will change the set pressure of the relief valve, and the machine may go out of control causing personal injury or damage to the machine.

Warning

Safety Cautions Be sure to follow the instructions below:

Caution Do not run the motor beyond the specified range. Doing so may cause damage to the machine.

Never touch the motor within 1 hour after the motor has stopped. The motor surface is very hot as it has been operating. Touching the motor can cause burn injuries.

Caution

Never suddenly remove the oil fill, oil discharge or oil check port of the reduction gear. Doing so may cause the plug to pop out, causing injury. Align the ports to the specified positions, and slowly loosen the plugs, starting from the oil fill port on the top, to release the air inside the reduction gear.

Caution

Top Reduction gear lubricating oil Oil fill port

Reduction gear lubricating oil Oil check port Release air.

Loosen the oil fill port about 2 turns to release air inside the reduction gear.

Bottom Reduction gear lubricating oil Oil drain port Discharge oil.

Discharge oil while slowly loosening the discharge port plug.

Safety Cautions Be sure to follow the instructions below:

When connecting the pipe, make sure that the direction of hydraulic oil flow corresponds to that of the motor rotation. Failure to do so can reverse the motor rotation.

Caution Use specified hydraulic oil only. Otherwise, the machine may be damaged.

Caution Use specified hydraulic oil only. Otherwise, the machine may be damaged.

Caution Do not allow foreign matter to enter inside the motor. Otherwise, the machine will be damaged.

A direction (counterclockwise) C direction (clockwise)

Caution

Caution

Wait until the motor cools down before servicing or inspecting the motor.

3.Tools for Assembly and Disassembly

To disassemble or re-assemble a motor, user the tools listed below.

[1]Standard tools

Table 1 shows the standard tools required for the disassembly and assembly of this motor.

Table 1. Standard Tools for Disassembly and Assembly

No. Name of the Tool Standard No. Manufacturer Name Model or Dimensions Applicable Part

1 Preset-type torque wrench JIS B4650 Nominal size: 60 1-2-6-6, 1-2-17, -18, -19 2 Nominal size: 120 1-2-8 3 Nominal size: 230 1-2-6-5 4 Nominal size: 450 1-2-20 5 Nominal size: 900 24, 28 6 Nominal size: 1800 1-2-2-4, 1-2-6-3, 1-2-11, 1-214, 29

7 Nominal size: 2800 11

8 Nominal size: 4200 1-2-7

9 10 Socket wrench Ratchet handle 11 Hexagon bit for socket wrench 12 JIS B4641 Nominal size: 5600 8, 14

Width across flat: 2.5 1-2-6-6, 1-2-17, -18, -19 Width across flat: 4 1-2-8

13 Width across flat: 6 1-2-20

14 Width across flat: 8 28

15 Width across flat: 10 1-2-6-3, 1-2-11

16

Width across flat: 12 11, 29 17 Width across flat: 14 1-2-2-4, 1-2-6-5 18 T-shaped bit for torque wrench JASO F116-89 Size: T50 24 19 Size: T90 8, 14 20 Socket for socket wrench JIS B4636 Width across flat: 10 1-2-14 21 Width across flat: 27 1-2-7 22 Hexagon bar wrench JIS B4648 Width across flat: 2.5 1-2-6-6, 1-2-17, -18, -19 23 Width across flat: 4 1-2-8 24 Width across flat: 6 1-2-20 25 Width across flat: 8 28 26 Width across flat: 10 1-2-6-3, 1-2-11 27 Width across flat: 12 11, 29 28 Width across flat: 14 1-2-2-4, 1-2-6-5 29 Wrench JIS B4630 Width across flat: 10 1-2-14 30 Width across flat: 27 1-2-7 31 Needle-nose pliers JIS B4631 1-2-7 32 Snap ring pliers Model S-2 1-4-5 33 Flathead screwdriver JIS B4609 6x100 2, 1-27, 1-2, 1-21 34 Plastic hammer OF-50 Nominal size: No.3 35 Punch About 10 mm in length

36 Press No less than 200 kgf

37 Crane For 400-kilogram load

38 Eyebolt For M20

39 For M12 1-2

40 Chain string (wire)

[2]Auxiliary materials

Table 2 shows auxiliary materials required for the disassembly and assembly of this motor.

Table 2. Auxiliary Materials

No. Auxiliary Material Name

1 Sealing tape 2 Adhesive

3 Gear oil

4 Hydraulic oil

5 Grease

6 White kerosene

7 Liquid packing

8 Lapping plate

9 Lapping agent

10 Copper plate 11 Tube brush 12 Bamboo brush 13 Oil pan 14 Polyethylene container 15 Rags Standard No. Manufacturer Name Model or Dimensions Applicable Part

Locktite 271 Equivalent to GL-4#90 Equivalent to ISO VG46

Lithium-based

Class 2equivalent kerosene Three Bond 1211 For repairing sliding surfaces #1000 For repairing sliding surfaces 1-2-8 8, 14 1-1, 1-7, 1-6

1-2-1, 1-2-2, 1-2-9 1-4-1, 1-4-2, 1-21 1-4-4, 1-4-3 1-5, 1-4-2, 1-6 1-2-2-5, 1-2-6-2, 1-2-6-4, 1-2-12, 1-2-21, 1-2-24, 1-16, 1-17, 1-231-12, 1-15, 1-21

4, 27 1-4-1, 1-4-2, 1-5, 1-21

For washing 1-2-1, 1-4-1 For washing Oil catcher Grease container

[3]Special tools

Table 3 shows special tools required for the disassembly and assembly of this motor.

Table 3. Special Tools

No. Name of the Tool Standard No. Manufacturer Name Model or Dimensions Applicable Part

1 Pulley remover tool 2 Bearing press-fit jig 3 Bearing press-fit jig 4 Floating seal application jig 5 Drill rod 6 Angular bearing press-fit jig 7 Shim thickness adjusting jig 8 Drill rod 10 Thrust plate selection jig 11 Oil seal press-fit jig 12 Brake piston locating jig 13 Snap ring handling jig 1-8, 1-9 1-8 1-9 2 3 3 5 1-2-2 26 1-12 1-15 1-4-5

[4]Measurement device

Table 4 shows measurement devices required to assemble this motor.

Table 4. Measurement Devices

No. Name of the Tool Standard No. Manufacturer Name Model or Dimensions Applicable Part

1 Dial gauge 2 Micrometer JIS B7503 JIS B7502 5, 26 5, 26

4.Disassembly of the Motor

[1]Precautions for the disassembly of the motor

Read the following precautions carefully prior to starting disassembly of the motor.

1. When starting the disassembly operation, be sure to wear safety shoes and other protective gear. 2. When disassembling the motor, use the specified tools. 3. After detaching the motor from the mother machine, place the mother machine on a level place in order to prevent the machine from going out of control, and check that any external force will not work on the rotating section. Then, remove the piping from the motor and remove the motor from the mother machine. 4. In order to prevent the intrusion of foreign matter into the internal section of the piping and the motor when detaching the motor from the mother machine, carefully remove all soil and contamination off the section around the motor, and then remove the piping connected to the motor. 5. Removing the piping connected to the motor may induce a blow out of the hydraulic oil inside the piping. To prevent that, remove the pressure from the inside of the piping, prepare an oil catcher, and then detach the piping. In order to prevent injuries caused should the motor fall when transporting it by crane, lift the motor with an eyebolt installed in the position shown in the figure below. 6. The internal space of the motor is filled with hydraulic oil. Prior to disassembling the motor, prepare an oil catcher and drain hydraulic oil from the motor. 7. In order to prevent injury during the disassembly work, prepare a stable workbench that is about waist height, and perform the disassembly on the workbench. 8. The motor is comprised of precision components. As such, any attachment of foreign matter must be avoided. Disassemble the motor in a dust-free room to prevent the components from becoming contaminated with soil or dust. 9. Each of the components of the motor is a precision part. Any denting or damaging of their surfaces must be avoided. While handling motor components in the disassembly process, be fully attentive not to dent or damage them. 10.In order to prevent damage to any component and avoid injury, do not attempt to disassemble firmly engaged sections where disassembly cannot be performed without extreme force.

[2]Tightening torque

Table 4 shows tightening torques for respective joint sections.

Table 4. Tightening Torques

Reference Number Part Name

Screw Dimensions Width across Flat Tightening Torque

1-2-2-4 Plug 1-2-6-3 Socket head bolt M24 × 1.5 14 M12 × 1.75 × 40L 10

1-2-6-5 Plug 1-2-6-6 Orifice PF1/8

14 M5 × 0.8 × 5L 2.5 1-2-7 Relief valve assembly 1-5/6 12UNF 27 1-2-8 Plug NPTFR1/16 4

1-2-11 Plug 1-2-14 Plug 1-2-17 Orifice PF1/2 PF1/2

10 10 M5 × 0.8 × 5L 2.5

1-2-18 Orifice 1-2-19 Orifice M5 × 0.8 × 5L 2.5 M5 × 0.8 × 5L 2.5

1-2-20 Plug 1-11 Socket head bolt PF1/4

6 M14 × 2.0 × 35L 12 137±10 N•m 108±10 N•m 20.6±1.0 N•m 2.45±0.49 N•m 373±20 N•m 9.8±1.0 N•m 118±6 N•m 118±6 N•m 2.45±0.49 N•m 2.45±0.49 N•m 2.45±0.49 N•m 36.8±2.5 N•m 205±10 N•m

8 14 24 28 29 Bolt Bolt Screw Socket head bolt Plugs M20 × 2.0 × 70L Torques: T90 539±28 N•m M20 × 2.0 × 130L Torques: T90 539±28 N•m M10 × 1.5 Torques: T50 58.8±4.9 N•m M10 × 1.5 × 16L 8 73.4±3.63 N•m

PF3/4 12 157±8 N•m

[3]Disassembling procedure

Follow the procedure below to disassemble the motor, observing the precautions given in section 1.

1.)Removing the cap assembly (1-2-6)

Secure the motor in place on a stable workbench, loosen 8 socket head bolts (1-2-6-3), and remove the cap assembly (1-2-6). Next, remove the spring seat (1-2-5), spring (1-24) and spring seat (1-2-3). Next, remove the O-ring (1-2-24), spring (1-2-23) and check valve (1-2-24).

Note:

The spring (1-2-4) pushes out the cap assembly (1-2-6). Given that, the follow the instructions below. a.When loosening socket head bolts evenly (1-26-3). b.While holding down the cap assembly (1-2-6), loosen the socket head bolts (1-2-6-3).

2.)Removing the plunger assembly (1-2-2)

Lightly press the end section of the plunger assembly (1-2-2) and take part of the plunger assembly (1-2-2) out of the base plate (1-2-1).

Next, while rotating the plunger assembly (1-2-2) by capturing it by hand, pull the plunger assembly (1-2-2) out of the base plate (1-2-1).

Note:

The plunger assembly (1-2-2) and the base plate (1-2-1) are engaged with a very narrow clearance. Given that, follow the instructions below. a.When pulling out the plunger assembly (1-2-2), do not attempt to do so by imposing extra force on it if the operation does not go smoothly due to uneven force imposed on the assembly.

Forcibly pulling out the assembly will damage the inside the hole of the base plate (1-2-1) and the side surface of the plunger assembly (1-22). If having trouble pulling out the assembly, follow the instructions below. b.Do not disassemble the plunger assembly (1-22) unnecessarily. The disassembly work may cause damage to the side surface of the plunger assembly. Contact us should you need to have the assembly disassembled.

Softly tap the end surface of the plunger assembly (1-22) with a plastic hammer to put the plunger assembly (12-2) into the inside of the base plate (1-2-1). Then check that the plunger assembly (1-2-2) moves smoothly, and then pull out the plunger assembly (1-2-2) again while rotating it.

3.)Removing relief valve assembly

Loosen the plug (1-2-7-6) and remove the relief valve assembly (1-2-7).

Then the poppet seat (1-2-7-3) will be found left inside the base plate (1-2-1).

Note:

Pressure is preset for the relief valve assembly (1-2-7).

The preset pressure determines the starting and braking force for the motor.

For that reason, refrain from carrying out the following actions. a.Loosen the nut (1-2-7-16), but do not tamper with the set screw (1-2-7-15). Tampering with this part will affect the set pressure for the relief valve, leading to failure of the design performance. b.Do not disassemble the relief valve assembly.

If disassembled, its set pressure will be affected, leading to failure of the design performance.

4.)Removing the poppet seat (1-2-7-3)

Remove the poppet seat (1-2-7-3) from the base plate (1-2-1), using the poppet seat (1-2-7-3) removal jig.

Note:

Do not undertake disassembly unnecessarily.

5.)Removing the valve assembly (1-2-9)

Loosen the plugs (1-2-11, 1-2-12) and remove the plugs (1-2-11, 1-2-12) and spring (1-2-10).

Lightly press the end section of the valve assembly (1-2-9) and take part of the valve assembly (1-2-9) out of the base plate (1-2-1).

Next, while rotating the valve assembly (1-2-9) by holding it by hand, pull it out of the base plate (12-1).

Note:

The valve assembly (1-2-9) and the base plate (1-2-1) are engaged with a very narrow clearance. Given that, follow the instructions below. a.When pulling out the valve assembly (1-2-9), do not attempt to do so by imposing extra force on it if the operation does not go easily due to uneven force imposed on the assembly.

Forcibly pulling out the assembly will damage the inside the hole of the base plate (1-2-1) and the side surface of the valve assembly (1-2-9).

If having trouble pulling out the assembly, follow the instructions below. b.Do not disassemble the valve assembly (1-2-9) unnecessarily. Contact us should you need to have the assembly disassembled.

Softly tap the end surface of the valve assembly (1-2-9) with a plastic hammer to put the valve assembly(1-2-9) into the inside of the base plate (1-2-1). Then check that the valve assembly (1-2-9) moves smoothly, and then pull out the valve assembly (1-2-9) again while rotating it.

6.)Do not remove the plug (1-2-8) unnecessarily.

Caulking is applied to the orifices (1-2-17, 2-18, 2-19) to prevent them from being loosened.

Do not attempt to disassemble them.

7.)Removing the base plate (1-2-1)

Loosen the socket head bolt (1-11) and remove the base plate (1-2-1).

Note:

When removing the base plate (1-2-1), follow the instructions below. a.The base plate (1-2-1) is pushed up by the spring (1-18). Given that, loosen socket head bolts (1-11) evenly.

b.Between the base plate (1-2-1) and the main body, knock pin (1-19) for positioning is provided. When removing the base plate (1-21), remove it so that the knock pin (1-19) may be removed straight along the shaft center without being blocked. Should the pin be in a blocked position, pat the base plate (1-2-1) softly, restore the knock pin (1-19) to the normal position, and then attempt to remove it again. c.When removing the base plate (1-2-1), the valve plate (1-21) accompanies the base plate (1-2-1). The sliding surface of the valve plate (1-21) is vulnerable to damage. Be careful not to allow the valve plate (1-21) to fall.

8.)Removing the valve plate (1-21)

Remove the valve plate (1-21) from the base plate (1-2-1).

Note:

When removing the valve plate (1-21), follow the instructions below. a.The sliding surface of the valve plate (1-21) is vulnerable to damage. Since damage on the sliding surface causes the design performance to fail, ensure that it is not damaged.

9.)Removing the O-rings, knock pin and spring

Remove the O-rings (1-22, 1-23), and knock pin (1-19). Also, remove the spring (1-18).