5.CAL (troubleshooting support) Screen

Replacement timing for the reduction gear lubricating oil Reduction gear lubricating oil deteriorates over time as it is used and as metal powder enters it due to the wear of the gear and sliding sections. Therefore, periodically replace the reduction gear lubricating oil according to the numerical indication shown in Table 20.

Table 20. Replacement Timing for the Reduction Gear Lubricating Oil

When replacing the lubricating oil, be careful not to leave the deteriorated oil or metal powder in the reduction gear. They can be contaminants to the new oil. Therefore, before replacing the lubricating oil, thoroughly flush the inside of the reduction gear to remove the residual oil and metal powder. Routine inspection of the reduction gear lubricating oil The degree of the deterioration of the reduction gear lubricating oil also depends on the operation environment and the operation frequency. Therefore, regularly inspect the lubricating oil in addition to the replacement described above. As a way of performing a routine inspection, it is recommended to ask the lubricating oil manufacturer or an analysis company to analyze the used lubricating oil and comprehensively judge from the measured results of viscosity, total oxidation, iron, etc.

Table 21. Replacement Indication from the Results of Analysis

4. Routine inspection of the motor

Using the motor for a long period of time will cause parts to wear and may result in performance degradation or failure. Keep logs about the routine inspection of the hydraulic oil and the reduction gear lubricating oil. If the property values of the oil indicate abnormal rise in the amount of foreign matter or if there is unusual foreign matter, disassemble and inspect the motor. In addition, disassemble and inspect the motor when the running time of it reaches 1000 hours or the number of start and stop times reaches 300000. Follow the maintenance procedures when disassembling and inspecting the motor. In particular, refer to the descriptions about wear of the parts including the parking brake disk in the maintenance procedures to replace the parts. The parking brake disk should be replaced when the number of action times reaches 300000.

Disassembly and inspection of the motor Follow the maintenance procedures when disassembling and inspecting the motor. Follow the maintenance standards described in the maintenance procedures when inspecting the motor during disassembly. Be sure to replace the seals when disassembling the motor.

Replacement Timing

Initial replacement 100 - 250 hours Second time replacement 1000 - 1500 hours

viscosity Change % Total Oxidation Heptane Insoluble Matter Iron % ±15 >2.0 >0.5 >0.1

Important

Follow the instructions for the machine main unit when removing the motor from the machine. Remove the pipes after stopping the operation of the hydraulic device and release the air pressure in the tank to make the pressure equal to the atmospheric pressure.

<Company that can conduct property test for your routine inspection of the hydraulic oil and the reduction gear lubricating oil> An affiliate of KYB Co., Ltd., Japan Analist Co., Ltd. conducts oil analysis.

Routine inspection and replacement timing

Pre-operation Inspection

Pipe looseness

Bolt looseness

Oil leaking

Hydraulic oil

Filter

Reduction gear lubricating oil

Motor

Initial replacement 500 hours

Routine inspection Appearance check Every 500 hours Property test Every 1000 hours

Initial replacement 50 hours Routine replacement Every 250 hours

Initial replacement 100 - 250 hours Routine inspection Every 1000 hours Routine replacement 1000 - 1500 hours

Routine inspection

Every 1000 hours Seal replacement During routine inspection When the cumulative running time at over 80°C has reached 100 hours Parking brake disk replacement After the brake has been operated 300000 times and depends on the maintenance procedures

Bearing replacement

Other parts Motor bearing Depends on the maintenance procedures

Needle bearing for the reduction gear

Depends on the maintenance procedures Angular bearing Depends on the maintenance procedures Depends on the maintenance procedures

15.Troubleshooting

If any kind of trouble occurs during a motor running, use the following troubleshooting information to investigate it and take countermeasure actions for it.

[1]Troubleshooting for piston motor

Trouble Description

Motor does not rotate. Possible Cause

Malfunction has occurred with equipment other than the piston motor and the reduction gear.

The rotation speed of the motor is not enough. The motor itself has a problem and the operation section is clogged up with dirt causing malfunction.

Pressure on the intake side of the motor is low.

The sliding section of the piston motor has abnormally worn and the pressurized oil is escaping.

The main part of the piston motor is damaged. In this case, abnormal noise comes from the piston motor.

Too much load on the piston motor causes the relief valve to operate.

Due to a problem with hydraulic pump, the pressure control valve, the flow control valve, or other parts, the specified amount of flow does not enter into the piston motor, resulting in the insufficient rotation speed.

Wear of the sliding section of the piston motor causes the pressurized oil to flow from high-pressure side to low-pressure side (reduce volume efficiency), resulting in the insufficient rotation speed.

A loosened tightening bolt on the base plate of the piston motor increases internal leakage and results in the insufficient rotation speed. Countermeasure and Solution

Check whether pressure has reached to the intake side of the motor and then inspect and repair the motor by identifying the causes of problems and countermeasures for it for each piece of equipment.

Disassemble and clean the unit to remove dirt and re-assemble it. If any part has been damaged by dirt, replace it.

Use the main relief of the circuit to rise the set pressure.

Disassemble the unit to replace the abnormally worn part. Remove any scratches or burr on the surface, clean the part, and re-assemble the unit.

Disassemble the unit to replace the damaged part. Clean the part, and reassemble the unit.

Investigate the load condition and adjust the load to the set pressure of the relief valve.

Check whether the specified amount of flow providos into the piston motor and then inspect and repair the motor by identifying the causes of problems and countermeasures for it for each piece of equipment.

Disassemble the piston motor to check the wear state of the sliding section and repair or replace it by following the maintenance procedures.

Retighten the tightening bolt on the base plate to the specified torque.