Linkbelt 235X3 A.LOWER OPERATOR'S MANUAL - PDF DOWNLOAD

A. LOWER

A. LOWER TABLE OF CONTENTS

Main Equipment Table...........................................................................................................................2-5 235X3.....................................................................................................................................................2-5 235X3 (Blade)........................................................................................................................................2-6 Main Equipment Structure and Operation Explanation......................................................................2-9 Travel Motor...........................................................................................................................................2-9 Port Diagram.........................................................................................................................................2-24 Travel Motor.........................................................................................................................................2-24 Center Joint..........................................................................................................................................2-24 Basic Functions...................................................................................................................................2-25 Travel Speed Selection........................................................................................................................2-25 Travel Alarm.........................................................................................................................................2-26 Removal and Installation of Track......................................................................................................2-29 Removal and Installation of Shoe Assembly.....................................................................................2-30 Removal of Shoe Assembly.................................................................................................................2-30 Installation of Shoe Assembly..............................................................................................................2-32 Removal and Installation of Shoe Plate.............................................................................................2-34 Removal of Shoe Plate........................................................................................................................2-34 Installation of Shoe Plate.....................................................................................................................2-34 Removal and Installation of Roller.....................................................................................................2-35 Removal and Installation of Upper Roller..........................................................................................2-36 Removal of Upper Roller......................................................................................................................2-36 Installation of Upper Roller..................................................................................................................2-37 Assembly and Disassembly of Upper Roller.....................................................................................2-38 Configuration Diagram.........................................................................................................................2-38 Dimension Diagram.............................................................................................................................2-39 Jig Dimension Diagram........................................................................................................................2-39 Disassembly Procedures.....................................................................................................................2-40 Assembly Procedures..........................................................................................................................2-42 Removal and Installation of Lower Roller..........................................................................................2-45 Removal of Lower Roller......................................................................................................................2-45 Installation of Lower Roller..................................................................................................................2-46 Assembly and Disassembly of Lower Roller.....................................................................................2-47 Configuration Diagram.........................................................................................................................2-47 Dimension Diagram.............................................................................................................................2-48 Jig Dimension Diagram........................................................................................................................2-48 Disassembly Procedures.....................................................................................................................2-48 Assembly Procedures..........................................................................................................................2-51 Removal and Installation of the Sprocket..........................................................................................2-54 Removal of Sprocket............................................................................................................................2-54 Installation of Sprocket........................................................................................................................2-55 Removal and Installation of Take-up Roller......................................................................................2-56 Removal of Take-up Roller..................................................................................................................2-56

2-1

A. LOWER

Specifications.........................................................................................................................................2-4 235X3.....................................................................................................................................................2-4 235X3 (Blade)........................................................................................................................................2-4

A. LOWER Installation of Take-up Roller...............................................................................................................2-57 Assembly and Disassembly of Take-up Roller.................................................................................2-58 Configuration Diagram.........................................................................................................................2-58 Dimension Diagram.............................................................................................................................2-59 Jig Dimension Diagram........................................................................................................................2-59 Disassembly Procedures.....................................................................................................................2-59 Assembly Procedures..........................................................................................................................2-62 Removal and Installation of Grease Cylinder....................................................................................2-66 Removal of grease cylinder.................................................................................................................2-66 Installation of grease cylinder..............................................................................................................2-67 Assembly and Disassembly of Tension Shock Absorber................................................................2-68 Configuration diagram.........................................................................................................................2-68 Dimension diagram..............................................................................................................................2-68 Jig dimension diagram.........................................................................................................................2-69 Disassembly procedures......................................................................................................................2-69 Assembly procedures..........................................................................................................................2-69 Removal and Installation of Center Joint..........................................................................................2-72 Removal of Center Joint......................................................................................................................2-72 Installation of Center Joint...................................................................................................................2-74 Assembly and Disassembly of Center Joint.....................................................................................2-76 Configuration Diagram.........................................................................................................................2-77 Dimension Diagram.............................................................................................................................2-78 Jig Dimension Diagram........................................................................................................................2-79 Disassembly Procedures.....................................................................................................................2-79 Assembly Procedures..........................................................................................................................2-80 Removal and Installation of Travel Motor..........................................................................................2-83 Removal of Travel Motor......................................................................................................................2-83 Installation of Travel Motor...................................................................................................................2-85 Assembly and Disassembly of Travel Motor.....................................................................................2-88 Tools for Assembly and Disassembly..................................................................................................2-88 Motor Disassembly Procedures...........................................................................................................2-91 Maintenance Standards.....................................................................................................................2-101 Motor Assembly Procedures..............................................................................................................2-106 Troubleshooting.................................................................................................................................2-123 Structural Diagram.............................................................................................................................2-131 Maintenance Standards.....................................................................................................................2-137 Drive Sprocket...................................................................................................................................2-137 Take-up Roller...................................................................................................................................2-138 Upper Roller.......................................................................................................................................2-139 Lower Roller.......................................................................................................................................2-140 Track Shoe (grouser shoe) ...............................................................................................................2-141 Inspection Gauge...............................................................................................................................2-142 Pressure Measurement and Adjustment Procedures.....................................................................2-144 Main Pressure Measurement.............................................................................................................2-144 Drain Volume Measurement Procedures.........................................................................................2-145 Preparations.......................................................................................................................................2-145 Travel Motor Drain Volume Measurement.........................................................................................2-145 Air Bleed Procedure...........................................................................................................................2-147 2-2

A. LOWER

A. LOWER

Travel Motor.......................................................................................................................................2-147

2-3

A. LOWER Specifications 235X3 Travel Lower Body Travel hydraulic motor

Variable displacement piston motor x 2

Reduction gear

Planetary gear 2-stage reduction gear

Travel brake

Hydraulic lock

Parking brake

Mechanical lock (travel lever linkage type)

Track shoe Model

Assembly-type triple grouser shoe

No. of shoes (per side)

49

Shoe width

600 mm (23.622 in) [options 700 mm (27.559 in)、800 mm (31.496 in)]

Grouser height

26 mm (1.027 in)

Link pitch

190 mm (7.480 in)

Roller No. of upper rollers (per side)

2

No. of lower rollers (per side)

7

Track belt tension adjuster

Grease cylinder type (with cushion spring)

235X3 (Blade) Travel Lower Body Travel hydraulic motor

Variable displacement piston motor x 2

Reduction gear

Planetary gear 2-stage reduction gear

Travel brake

Hydraulic lock

Parking brake

Mechanical lock (travel lever linkage type)

Track shoe Model

Assembly-type triple grouser shoe

No. of shoes (per side)

49

Shoe width

600 mm (23.622 in) [options 700 mm (27.559 in)、800 mm (31.496 in)]

Grouser height

26 mm (1.027 in)

Link pitch

190 mm (7.480 in)

Roller No. of upper rollers (per side)

2

No. of lower rollers (per side)

7

Track belt tension adjuster

Grease cylinder type (with cushion spring)

2-4

A. LOWER Main Equipment Table 235X3 A. LOWER

Lower Component ￭Travel Unit Manufacturer

KYB Corporation

Motor type

Variable displacement piston motor Automatic 2-speed switchover with parking brake

Intake amount

181.3/112.6 cm3/rev

Operating pressure

34.3 MPa (4975.341 psi)

Operating flow

234.0 L/min (61.818 gpm)

Brake torque

25.1 kN・m (18515.98 lbf・ft) min. (including reduction gear)

Relief valve set pressure

35.3 MPa at 40 L/min (5120.395 psi at 10.567 gpm)

Automatic 2-speed switchover pressure

25.8 MPa (3742.385 psi)

Reduction gear Reduction gear type

Planetary gear 2-stage reduction gear

Reduction ratio

43.246

Dry weight

263 kg (579.819 lb)

￭Take-up Roller Weight

89.2 kg (196.6534 lb)

￭Upper Roller Weight

17.8 kg (39.2425 lb)

￭Lower Roller Weight

35.0 kg (77.1622 lb)

￭Recoil Spring Item

Weight [kg (lb)]

Q'ty

Yoke

23.9 (52.6908)

1

Sems B M16 x 50

0.5 (1.1023)

4

Threaded rod

24.3 (53.5726)

1

Groove height N M48

1.0 (2.2046)

1

SP pin 8 x 80

0.1 (0.2205)

1

Recoil spring

64.9 (143.081)

1

Grease cylinder assembly

30.0 (66.1390)

1

Sems B M16 x 60

0.3 (0.6614)

2

Assembly(Total)

145 (319.672)

Mounting length of spring

556 mm (21.890 in)

￭Shoe Weight or Q'ty 600 grouser

1343 kg (2960.805 lb)

2-5

A. LOWER Weight or Q'ty Link

1 set

Shoe

49

Bolt

196

Nut

196

700 grouser

1559 kg (3437.003 lb)

Link

1 set

Shoe

49

Bolt

196

Nut

196

800 grouser

1701 kg (3750.059 lb)

Link

1 set

Shoe

49

Bolt

196

Nut

196

900 grouser

1838 kg (4052.092 lb)

Link

1 set

Shoe

49

Bolt

196

Nut

196

￭Center Joint Operating pressure

High-pressure passage (ABCD)

34.3 MPa (4975.341 psi)

Drain port (E)

0.5 MPa (72.527 psi)

Pilot port (F)

3.9 MPa (565.709 psi)

High-pressure passage (ABCD)

234 L/min (61.818 gpm)

Drain port (E)

10 L/min (2.642 gpm)

Pilot port (F)

21 L/min (5.548 gpm)

Port A

Forward right

G3/4

Port B

Forward left

G3/4

Port C

Backward right

G3/4

Port D

Backward left

G3/4

Port E

Drain port

G1/2

Port F

Pilot port

G1/4

Weight

30 kg (66.139 lb)

Flow

235X3 (Blade) Lower Component ￭Travel Unit Manufacturer

KYB Corporation

Motor type

Variable displacement piston motor Automatic 2-speed switchover with parking brake

Intake amount

181.3/112.6 cm3/rev

Operating pressure

34.3 MPa (4975.341 psi) 2-6

A. LOWER 234.0 L/min (61.818 gpm)

Brake torque

25.1 kN・m (18515.98 lbf・ft) min. (including reduction gear)

Relief valve set pressure

35.3 MPa at 40 L/min (5120.395 psi at 10.567 gpm)

Automatic 2-speed switchover pressure

25.8 MPa (3742.385 psi)

A. LOWER

Operating flow

Reduction gear Reduction gear type

Planetary gear 2-stage reduction gear

Reduction ratio

43.246

Dry weight

263 kg (579.819 lb)

￭Take-up Roller Weight

89.2 kg (196.6534 lb)

￭Upper Roller Weight

17.8 kg (39.2425 lb)

￭Lower Roller Weight

35.0 kg (77.1622 lb)

￭Recoil Spring Item

Weight [kg (lb)]

Q'ty

Yoke

23.9 (52.6908)

1

Sems B M16 x 50

0.5 (1.1023)

4

Threaded rod

24.3 (53.5726)

1

Groove height N M48

1.0 (2.2046)

1

SP pin 8 x 80

0.1 (0.2205)

1

Recoil spring

64.9 (143.081)

1

Grease cylinder assembly

30.0 (66.1390)

1

Sems B M16 x 60

0.3 (0.6614)

2

Assembly(Total)

145 (319.672)

Mounting length of spring

556 mm (21.890 in)

￭Shoe Weight or Q'ty 600 grouser

1335 kg (2943.187 lb)

Link

1 set

Shoe

46

Bolt

184

Nut

184

700 grouser

1463 kg (3225.380 lb)

Link

1 set

Shoe

46

Bolt

184

Nut

184

800 grouser

1597 kg (3520.801 lb)

2-7

A. LOWER Weight or Q'ty Link

1 set

Shoe

46

Bolt

184

Nut

184

￭Center Joint Operating pressure

High-pressure passage (ABCD)

34.3 MPa (4975.341 psi)

Blade port (EF)

30.9 MPa (4482.158 psi)

Drain port (G)

0.5 MPa (72.527 psi)

Pilot port (H)

3.9 MPa (565.709 psi)

High-pressure passage (ABCD)

210 L/min (55.477 gpm)

Blade port (EF)

80.5 L/min (21.266 gpm)

Drain port (G)

10 L/min (2.642 gpm)

Pilot port (H)

19.8 L/min (5.231 gpm)

Port A

Forward right

G3/4

Port B

Forward left

G3/4

Port C

Backward right

G3/4

Port D

Backward left

G3/4

Port E

Blade up

G1/2

Port F

Blade down

G1/2

Port G

Drain port

G1/2

Port H

Pilot port

G1/4

Weight

53.4 kg (117.727 lb)

Flow

2-8

A. LOWER Main Equipment Structure and Operation Explanation

Explanation of Component Device Operation

Travel motor operation explanation Double Counter Balance Valve The purpose of the "double counter balance valve" is to control the speed of the motor according to the feed flow.

Therefore, motor rotation getting away due to external load is prevented.

As the roles of the double counter balance valve, there are 1. The overrun prevention function that controls the piston motor speed to match feed quantity in the state of rotation at or higher than the speed determined by the flow feed from the piston motor for the external load (below, pumping action).

2. The brake function used together with the crossover relief valve to make up the brake circuit that gradually stops the rotation of the piston motor by applying braking force to the piston motor rotation.

3. The high-pressure selection shuttle valve function for releasing the parking brake through its own pressure.

Diagram 3 shows a structural diagram of the standard double counter balance valve.

This section explains the operations of each function using this standard double counter balance valve.

8

8-1

f

8-2 g a h

b c

i

j

d

k 7-1 7-2

e 3

4-1

2-1

1

4-2

2-2

5-2 tjkkih-001

Diagram 3 Double counter balance valve structural diagram (stopped state) a

Oil path C1

e

Spring chamber 1

i

Damper chamber A2

b

Orifice D1

f

Oil path B

j

Orifice D4

c

Damper chamber A1

g

Oil path C2

k

Spring chamber 2

d

Orifice D2

h

Orifice D3

2-9

A. LOWER

Travel Motor

A. LOWER [1] Stopped state (Diagram 3) When the control valve is in neutral (the motor stopped), since pressure is generated at neither the P1 port nor the P2 port, the M1 and M2 ports are locked (hydraulically) with the spool (1) and the check valves (2-1) (2-2) and the piston motor does not rotate.

[2] Motor starting (Diagram 4) When the pressure oil discharged from the hydraulic pump is led to the double counter balance valve P1 port, the check valve (2-1) moves to the left against the spring (3), the oil path C1 (a) is opened, pressure oil flows from the M1 port into the piston motor and attempts to rotate the piston motor.

On the other hand, the return oil from the piston motor, flows from the M2 port into the double counter balance valve, but the flow is prevented by the check valve (2-2) and the hydraulic pump discharge pressure rises.

Therefore, the P1 port side goes to high pressure, the pressure oil operates through the orifice (b) (4-1) and the ball check (5-1) on the spring chamber 1 (e) and the damper chamber A1 (c), and that oil pressure moves the plunger (1) to the right against the opposite side spring (7-2) with force proportional to the pressure.

At this time, the M2 port return oil flows through the oil path B (f) in the circumferential notch section of the plunger (1) and into the P2 port while generating back pressure at the M2 port and this return oil returns to the tank through the control valve and the piston motor starts rotating.

[3] Counter balance function (Diagram 4) During piston motor rotation, if the piston motor is forced to rotate by the external load, pumping action occurs in the piston motor, and it runs wild.

In this case, since the P1 port section becomes the suction side of the pump action, that pressure drops.

At the same time, the pressure also drops in the spring chamber 1 (e) and the damper chamber A1 (c).

Therefore, the plunger (1) is moved to the left by the spring (7-2), oil path B (f) is closed, and when the return oil flow stops, the suction side flow stops at the same time.

When the flow of oil through oil path B (f) is stopped, in an instant, the P1 port side pressure rises again due to the hydraulic pump discharge oil and this moves the plunger (1) to the right.

2-10

In this way, the plunger (1) moves in small steps when there is pumping action due to the external load to hold the opening surface area of oil path B (f) in an appropriate state.

Therefore, rotation of the piston motor at a speed appropriate to the feed flow from the hydraulic pump is maintained and vacuum in the hydraulic circuit is prevented. This prevents the piston motor from running wild.

8

8-1

f

8-2 g a h

b c

i

j

d

k 7-1 7-2

e 3

4-1

2-1

1

4-2

2-2

5-2 tjkkih-002

Diagram 4 Double counter balance valve when motor rotating d

Orifice D2

h

Orifice D3

j

Orifice D4

g

Oil path C2

i

Damper chamber A2

k

Spring chamber 2

[4] Piston motor braking (Diagram 5) The double counter balance valve makes up the brake circuit together with the crossover relief valve.

When the control valve is returned to neutral, the pressure oil from the hydraulic pump is cut off and the P1 and P2 ports go to the same pressure.

Therefore, the plunger (1) moves to the neutral position, and the oil path B (f) opening surface area becomes small.

On the other hand, because the piston motor still attempts to rotate due to the inertial energy of the external load (piston motor pumping action), the M2 port pressure rises and acts as a braking force on the rotation of the piston motor.

2-11

A. LOWER

A. LOWER

A. LOWER At this time, when the M2 port side pressure reaches the set pressure for the relief valve (8), the M1 port side poppet (8-1) moves to the left against the spring (8-2) and the pressure oil escapes to the M1 port side.

In this way, the shock pressure due to the M2 port side inertial energy is controlled and at the same time the occurrence of a vacuum on the M1 port side is prevented.

8

8-1

f

8-2 g a h

b c

i

j

d

k 7-1 7-2

e 3

4-1

2-1

1

4-2

2-2

5-2 tjkkih-003

Diagram 5 Double counter balance valve and relief valve during piston motor braking a

Oil path C1

e

Spring chamber 1

j

Orifice D4

b

Orifice D1

g

Oil path C2

k

Spring chamber 2

c

Damper chamber A1

h

Orifice D3

d

Orifice D2

i

Damper chamber A2

[5] High-pressure selection shuttle valve function (Diagram 6 and Diagram 7) The double counter balance valve has a high-pressure selection shuttle valve function added for releasing the parking brake through its own pressure.

When pressure oil is fed from the P1 port, the plunger (1) moves to the right side creating the state in Diagram 6.

2-12

Therefore, the motor case drain oil path F (m) is closed, the oil path D (l) to the parking brake cylinder chamber E (p) is opened, the pressure oil is led into oil path G (o) via the orifice (n) and flows into the parking brake cylinder chamber E (p), releasing the parking brake.

Also, when the piston motor stops, the plunger (1) returns to the neutral state of diagram 7, the oil path D (l) closes, and the motor case drain oil path F (m) opens, so the oil in the parking brake cylinder chamber E (p) is led to the motor case drain and the parking brake operates.

1

l

m

l tjkkih-004

n o

Diagram 6 High-pressure selection function High-pressure selection

2-13

p

A. LOWER

A. LOWER

A. LOWER

l

m

n

o

p

tjkkih-005

Diagram 7 High-pressure selection function Release to motor case drain

Crossover Relief Valve The purpose of the "crossover relief valve" is to determine the motor drive force and braking force.

Therefore, this valve has a shockless function to soften the shock of motor starting and stopping in order to provide good operability.

Diagram 8 shows the structure of the relief valve.

This relief valve has a shockless function for reducing the shock that occurs at the start of startup and braking of the differential surface area type direct action relief valve.

3n89za-001

Diagram 8 Structure of relief valve

2-14

1. Relief valve operation and functions When the control valve moves and the piston motor is started up or braked, when the poppet (2-9-2) front surface pressure rises above the set pressure, this pressure wins out over the spring (2-9-5), the poppet (2-9-2) moves to the right and separates from the poppet seat (2-9-3), and the high-pressure oil at the poppet (2-9-2) front surface bypasses to the low-pressure oil path.

In this way, by allowing the high-pressure oil to bypass to the low-pressure oil path, the shock pressure due to the inertial energy of the high-pressure oil path is controlled and at the same time the occurrence of a vacuum in the low-pressure oil path is prevented.

2-9-2

2-9-5

2-9-3 3n89za-002

Diagram 9 Shockless function operation

2. Shockless function (Diagram 10) When the relief valve starts to operate, the shockless piston (2-9-9) moves to the left.

Therefore, inside the spring chamber D, the pressure is held low.

Therefore, the surface of the poppet (2-9-2) pressurized area becomes S1, a quite large pressurized area compared to the pressurized area S1 - S2 for the normal relief valve setting.

Therefore, while the shockless piston (2-9-9) movement is completing, the relief valve operating pressure is held to about 1/3 of the normal set pressure, absorbing the shock pressure due to the inertial energy of the high-pressure oil path.

When the shockless piston movement is complete, the pressure inside the spring chamber D rises, the pressure in front and behind the poppet (2-9-2) become equal, and the relief valve operates with its normal set pressure.

2-9-2

2-9-3

q

2-9-5

r

2-9-9

3n89za-003

2-15

s

A. LOWER

A. LOWER

Pressure

Pressure

A. LOWER

3n89za-004

3n89za-005

Time Time Conventional type Shockless type Diagram 10 Shockless function and pressure wave comparison q

Area S2

r

Area S1

s

Spring chamber D

Operating the relief valve in 2 stages in this way reduces the shock that occurs when the piston motor is started or braked and provides good operability.

Diagram 10 compares the pressure waveforms of the conventional type and the shockless type.

Automatic 2-speed Switchover Mechanism This motor has the automatic "2-speed switchover mechanism" that can switch the motor between 2 speeds, low speed and high speed.

1. Motor low-speed (high-capacity) position Diagram 11 shows the state with the motor capacity fixed to the low-speed (high-capacity) position. When the speed control switch is set to low speed and the pilot pressure acting on the Ps port is released to the tank, the motor capacity control valve built into the motor is fixed to the low-speed (high-capacity) position.

2. Automatic 2-speed position that selects the motor capacity according to the load pressure Diagram 12 shows the state of the automatic 2-speed position that selects the motor capacity according to the load pressure.

When the speed control switch is set to high speed and the regulation pressure is allowed to operate on the Ps port, the pressure oil operating on the Ps port operates on the front surface of the motor capacity control valve built into the motor and the position becomes the automatic 2speed position that switches the motor capacity according to the load pressure going to the motor.

3. High-speed motor state for automatic 2-speed position Diagram 13 shows the high-speed motor state for the automatic 2-speed position.

When the regulation pilot pressure is allowed to operate on the Ps port, the pilot pressure oil operates on the pilot hydraulic chamber on the motor capacity control valve front surface via oil path A and this pushes the motor capacity control valve to the right. Also, the load pressure Pin on the motor operates on the motor load pressure chamber via oil path B and pushes the motor capacity control valve to the left. When Pin is lower than the motor capacity control pressure P determined by the ratio of the pilot pressure pressurized area and the motor load pressure pressurized area, the motor capacity control valve is held in the state in Diagram 13 and the motor operates in high-speed (low-capacity) mode.

4. Low-speed motor state for automatic 2-speed position Diagram 14 shows the low-speed motor state for the automatic 2-speed position.

When the load pressure pin on the motor rises and becomes higher than the motor capacity control pressure P discussed above, the motor capacity control valve moves to the left, switching the motor to low-speed (high-capacity) mode, so the motor operates at low speed.

2-16

A. LOWER

A. LOWER

t

u u v

k3nqrh-001

Diagram 11 Motor high-speed (high-capacity) fixed mode

2-17

t

Pilot pressure

u

Pressure in motor

v

Motor load pressure

A. LOWER t

u u v

k3nqrh-002

Diagram 12 Automatic 2-speed control mode using load pressure

2-18

t

Pilot pressure

u

Pressure in motor

v

Motor load pressure

A. LOWER

A. LOWER

t w

y

x

f

u

u v

k3nqrh-003

Diagram 13 Motor high-speed (low-capacity) position for automatic 2-speed mode t

Pilot pressure

w

u

Pressure in motor

x

Oil path A

v

Motor load pressure

y

Motor load pressure chamber

2-19

Pilot oil pressure chamber

A. LOWER

t y

x

w

u

f

u v

k3nqrh-004

Diagram 14 Motor low-speed (high-capacity) position for automatic 2-speed mode t

Pilot pressure

w

Pilot oil pressure chamber

u

Pressure in motor

x

Oil path A

v

Motor load pressure

y

Motor load pressure chamber

Parking Brake Function The "parking brake function" is built into the piston motor. When the motor is stopped, the mechanical brake operates to prevent the motor from being rotated due to external load by locking the motor shaft.

Diagram 15 shows a structural diagram of the parking brake section.

The parking brake is made up of the disks (1) coupled with the cylinder block (z), the friction plate (2) mounted between the disks, the brake piston (3), and the spring (4) that applies force to the brake piston.

A. Releasing the parking brake (Diagram 15) When pressure oil is fed from the P1 port and attempts to start driving the piston motor, when the "High-pressure selection shuttle valve function" explained in Item E of "[1] Double Counter Balance Valve" leads pressure oil to the parking brake cylinder chamber E (ac) via oil path D, the hydraulic pressure force (aa) operates on the brake piston (3) and moves it to the left against the spring (4).As a result, the force pressing the disks (1) disappears, the disks (1) enter the free state, and the parking brake is released.

2-20

B. Operating the parking brake (Diagram 16) When the control valve is returned to the neutral position, the feed of pressure oil to the P1 port is cut off, and an attempt is made to stop the piston motor, because the "High-pressure selection shuttle valve function" explained in Item E of "[1] Double Counter Balance Valve" connects oil path D to motor case drain oil path F, the pressure oil in the parking brake cylinder chamber E (ac) is led to the motor case drain and the pressure drops.Therefore, the brake piston (3) is moved to the right side by the spring (4), the disks (1) are tightened with the force (ad) of the spring (4) by the brake piston (3) and motor case (ab), so the piston motor shaft is locked and the parking brake operates.

z

z ad

aa 1

1

ab

ab 2

4

3

2 4

ac

3

ac

lr8jra-001

Diagram 15 Parking brake released state

Diagram 16 Parking brake engaged state

Piston Motor The "piston motor" is a swash plate-type piston motor that converts the fluid energy of the pressure oil sent from the hydraulic pump into mechanical energy and outputs high-speed, low-torque power.

A swash plate-type piston motor is used as the piston motor.

Diagram 17 shows a structural diagram of the piston motor.

9 pistons (4-2) are incorporated in the cylinder block (4-1) and the end of the cylinder block (4-1) touches a valve plate (22) that has 2 sausage-shaped ports, B and C. The pressure oil discharged from the hydraulic pump flow in from the P1 port or the P2 port and while the piston motor rotates, flows out from the P2 port or P1 port.

Also, the drain oil in the case that has leaked from the sliding sections and the gap returns to the hydraulic tank from the base plate (2-1) T1 or T2 port.

1. The high-pressure oil from the P1 port enters the valve plate (22) sausage-shaped B port, the piston (4-2) is pressurized, and the top of the swash plate (5) rotates and moves from top dead center to bottom dead center.

2. The P2 port becomes the low-pressure side and while the piston (4-2) rotates and moves from bottom dead center to top dead center, the oil is discharged to the P2 port via the valve plate (22) sausage-shaped C port.

3. Accompanying the reciprocal movement of the piston (4-2), the cylinder block (4-1) and the shaft (3) spline coupled to it rotate in the counter-clockwise direction of the arrow in the diagram.

4. When the piston motor rotates clockwise, the P1 port side becomes the low-pressure side and the P2 port side becomes the high-pressure side.

2-21

A. LOWER

A. LOWER

A. LOWER In this way, the piston motor converts the fluid energy of the pressure oil sent from the hydraulic pump into mechanical energy and outputs high-speed, low-torque rotation power. Also, the piston motor torque and speed are determined by the pressure and flow. Therefore, the larger the pressure and flow, the higher the piston motor torque and speed.

4-2

3

4-1

22

b a

5 9lxsu9-002

Diagram 17 Piston motor structural diagram a

C port

b

B port

Reduction Gear Diagram 18 shows a structural diagram of the reduction gear.

The reduction gear structure combines in two stages the simple planetary reduction gear system made up of the drive gear, sun gear, holder, planetary gear, and ring gear (with teeth cut in the inner diameter of the housing).

When pressure oil flows into the piston motor, the piston motor shaft rotates at high speed and power is input to the reduction gear section.In the reduction gear section, this high-speed rotation has its speed reduced in 2 stages by the simple planetary 2-stage reduction system. Low-speed, high-torque output is obtained from the rotation of the housing with ring gears (1-3) (2-3).

1. 1st stage reduction section operation The 1st stage reduction section comprises the drive gear (1-1), planetary gear A (1-2), ring gear (1-3), holder (1-4), needle bearing (1-5), and inner race (1-6).

The planetary gear A (1-2) meshes with the drive gear (1-1). When the drive gear (1-1) rotates clockwise, the planetary gear A (1-2) rotates counter-clockwise. On the other hand, since it meshes with the ring gear, it kicks the tooth of the ring gear and tries to revolve clockwise around the circumference of the drive gear (1-1).

Because the planetary gear (1-2) is fixed in a state in which it rotates freely on the holder (1-4) via the needle bearing (1-5), this clockwise revolution movement is transmitted to the holder (1-4) and the holder (1-4) starts to rotate in the clockwise direction.

Also, since the holder (1-4) is spline coupled with the 2nd stage sun gear (2-1), this holder (1-4) rotation is transmitted to the 2nd stage sun gear (2-1).

2. 2nd stage reduction section operation The 2nd stage reduction section comprises the sun gear (2-1), planetary gear B (2-2), ring gear (2-3), holder (2-4), needle bearing (2-5), and inner race (2-5).

The planetary gear B (2-2) meshes with the sun gear (2-1). When the sun gear (2-1) rotates clockwise, the planetary gear B (2-2) rotates counter-clockwise.

The planetary gear B (2-2) is fixed in a state in which it rotates freely on the holder (2-4) via the needle bearing (2-5). Furthermore, the holder (2-4) is coupled to the flange (5) by the bolts (3) (4) and the flange (5) is fastened to the frame of the machine main unit, so it cannot rotate.

2-22

Therefore, the planetary gear B (2-2) cannot revolve as in the 1st stage reduction section and rotates counter-clockwise at the position at which it was incorporated. Also, because the planetary gear B (2-2) is meshed with the ring gear, the counter-clockwise revolution of the planetary gear B (2-2) is transmitted to the ring gear and the ring gear is rotated counterclockwise.

Through the above action, the housings (1-3) (2-3) with the ring gear cut into their inner diameters receive the force of the planetary gears (2-2) (1-2) and rotate. This transmits power to the driven section of the machine main unit which is coupled with the housings (1-3) (2-3). b

c 4

5

2-1

1-4

1-3

a 1-5

1-6 1-2 1-1 3

2-4 2-3 2-2

2-6

2-5

e4izt1-002

Diagram 18 Reduction gear structural diagram

2-23

a

Piston motor shaft

b

Secured to machine main unit frame

c

Connected to driven section of machine

A. LOWER

A. LOWER

A. LOWER Port Diagram Travel Motor

P2 T

P2 T Pm2 P1 Pm1

P1

Ps

kjqptt-011

Port P1, P2

Port name

Port size

Main port

G1

T

Drain port

G1/2

Ps

Pilot port

G1/4

Pm1, Pm2 Pressure detection port

G1/4

Center Joint C

D E E B

A

E'

F'

F

A' F

B' C' D'

E

E

i7bypp-003

Port

2-24

Port name

Port size

A, A'

Main port (forward right)

G3/4

B, B'

Main port (forward left)

G3/4

C, C'

Main port (backward right)

G3/4

D, D'

Main port (backward left)

G3/4

E, E'

Drain port *E (2 locations), E' (1 location)

G1/2

F, F'

Pilot port *F (2 locations), F' (1 location)

G1/4

A. LOWER Basic Functions Purpose The travel motor tilting angle is changed by switching the travel speed between low speed and high speed with the switch. (Travel speed switchover) 4

3

2

2

nrmin

STOP

6

1 5

D6CF2E9D

1

Computer A

3

Travel motor

5

Travel 2-speed switchover solenoid

2

Travel 2-speed switchover solenoid

4

Monitor

6

Computer B

Operation explanation [1] When the key is turned ON, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the monitor goes to low speed.

[2] When the travel speed switchover switch is pressed, the travel 2-switchover solenoid turns ON, and the travel mode icon on the monitor goes to high speed.

[3] When the travel speed switchover switch is pressed again, the travel 2-speed switchover solenoid turns OFF, and the travel mode icon on the monitor goes to low speed. * Even when the travel 2-speed switchover solenoid is ON, the tilting angle will automatically switch over to low speed due to a travel motor function if the travel motor drive pressure becomes high.

However, the travel 2-speed switchover solenoid is ON.

2-25

A. LOWER

Travel Speed Selection

A. LOWER Time chart

*1

START ON OFF

*2

ON OFF

*3

ON OFF

*6 *4

*7 *8

*5

*9 *10

F482E9CC

*1

Key switch

*5

Travel motor

*9

Low speed

*2

Travel speed switchover switch

*6

Hare

*10

Drive pressure rise

*3

Computer A output

*7

Tortoise

*11

Drive pressure fall

*4

Display monitor

*8

High speed

Travel Alarm Purpose The travel alarm sounds when a travel operation is performed.(Safety function)

2-26

*11

3 2 OFF 4

1

ON

*1

dzr2ya-001

1

Computer A

3

Travel alarm

2

Travel pressure sensor

4

Travel alarm select switch

[1] Operation conditions for travel alarm The operation starts under the following conditions. a. When a travel operation is being performed.(Travel pressure sensor ON) [2] End conditions for travel alarm The operation ends under the following conditions. a. When the travel operation is stopped. b. When the travel alarm select switch is turned OFF while a travel operation is being performed.

2-27

A. LOWER

A. LOWER

A. LOWER

c ON a

OFF ON

b

OFF ON

d

OFF [4]

[2]

*1

[3]

dzr2ya-002

*1

Mode switchover during travel

a

Travel alarm

c

10 sec.

b

Pressure sensor (travel)

d

Travel alarm select switch

2-28

A. LOWER

A. LOWER

Removal and Installation of Track

2-29

A. LOWER Removal and Installation of Shoe Assembly

2. Use a box wrench [ 19 mm ( 0.748 in ) ] to loosen the check valve (1) to release grease, and then loosen the track shoe tension.

Warning

･ When loosening the grease cylinder check valve, loosen it a little bit at a time. ･ The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off.

The check valve adjustment procedure should not be done in front of the check valve. ･ Do not get under the main unit when it is jacked up.

Make sure to place the main unit on crossties to prevent falling.

Warning

･ If the check valve (1) is too loose, it may fly off. ･ Do not place your body in front.

Do not loosen the check valve all at once.

Loosen it slowly while monitoring the grease output and shoe loosening.

Use a rag to catch grease that trickles out of the check valve.

Caution

･ Make sure to stop the engine for loosening shoes and when removing master pins.

Items to prepare ･ Wrenches [ 17 mm ( 0.669 in ), 19 mm ( 0.748 in ) ] ･ Box wrench [ 19 mm ( 0.748 in ) ] ･ Hammer ･ Wood planks, etc. ･ Striking jig ･ Crowbar ･ Rag ･ Lifting equipment (with the required breaking load) ･ Liftcrane (with the required lifting capacity)

1

1

Removal of Shoe Assembly 1. Rotate the shoe and align it so that the master pin (1) is next to the idler. zf29na-010

3. Use a wrench [ 17 mm ( 0.669 in ) ] to remove the bolt (1), and then remove the check valve (2) and stopper (3). ･ If the check valve (2) is removed, it is easier to loosen the track shoe tension.

1

zf29na-001

2-30

A. LOWER 6. Remove the track shoe (1).

At this time, support with a wood plank (2) so the bottom track shoe (1) does not fall.

1

A. LOWER

3 1 2

2

zf29na-008

4. Put wood planks (1) underneath the track shoe.

Straighten out the S-pin (3) attached to the master pin (2) by striking one side of it with a hammer, and use a crowbar, etc. to remove it.

2

zf29na-006

7. Start the engine, raise the lower side frame of the track shoe removal side about 20 cm ( 7.874 in ), slowly set the travel lever to backwards, and move the track shoe (1) to remove it from the lower frame.

3

1 1

zf29na-013

5. Use a hammer (2) and striking rod (3) to push the master pin (1) out.

zf29na-012

1 3

2

zf29na-005

2-31

A. LOWER Installation of Shoe Assembly

3. Wrap the edge of the track shoe (1) onto the take-up roller (2).

Place a wood plank (3) on the ground and lift the bottom-side link to align the position where the master pin is inserted.

1. Raise the lower side frame about 20 cm ( 7.874 in ).

Lift the track shoe (1) and align it with the sprocket (2).

Pay attention to the backwards and forward direction of the track shoe.

2 1

3 1

1

qberoe-003

2

4. Insert the master pin (1).

Insert the S-pin (2) and bend it so that it cannot slip out.

2

11

1 22 qberoe-012 qberoe-010

2. Slowly set the travel lever to forward and feed the track shoe to the take-up roller side as shown in the diagram.

In the middle of this procedure when the track shoe passes the upper roller, use a crowbar, etc. to lift the track shoe while it is being fed.

Lower the lower side frame after the shoe has reached position A shown in the diagram.

5. Tighten the check valve (1).

While monitoring the track shoe tension, inject grease into the grease cylinder.

1

qberoe-013

A qberoe-011

2-32

1

A. LOWER

A. LOWER

6. To adjust the track shoe tension, raise the lower side frame with a wood plank (1) as shown in the diagram.

1 4EE0A2A8

7. Adjust the tension so that the distance indicated with A between the frame bottom (1) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (2) is 290 - 310 mm ( 11.418 - 12.204 in ).

1

A

2 qberoe-007

2-33

A. LOWER Removal and Installation of Shoe Plate

2. Use a box wrench [ 30 mm ( 1.181 in ) ] to install the 4 shoe bolts (1).

Bolt (1) tightening torque: 751 - 849 N・m ( 554.00 - 626.30 lbf・ft )

Caution

･ Be sure to stop the engine before beginning work.

1

Items to prepare ･ Box wrench [ 30 mm ( 1.181 in ) ] ･ Grease ･ Rag ･ Cleaning fluid

Removal of Shoe Plate 1. Use a box wrench [ 30 mm ( 1.181 in ) ] to remove the 4 shoe bolts (1).

1

5qlrz1-003

1

5qlrz1-003

2. Remove the shoe plate (1).

1

5qlrz1-002

Installation of Shoe Plate 1. Install the shoe plate (1).

1

5qlrz1-002

2-34

1

A. LOWER

A. LOWER

Removal and Installation of Roller

2-35

A. LOWER Removal and Installation of Upper Roller Job code

Do not loosen the check valve all at once.

Loosen it slowly while monitoring the grease output and shoe loosening.

Use a rag to catch grease that trickles out of the check valve.

AJJR01

Warning

･ When loosening the check valve, loosen it a little at a time and stop when any grease appears.

The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.

The check valve adjustment procedure should not be done in front of the check valve.

Caution

･ Be sure to stop the engine before beginning work.

Items to prepare ･ Box wrenches [ 19 mm ( 0.748 in ), 30 mm ( 1.181 in ) ] ･ Jack (That meets the lifting weight.) ･ Rag ･ Cleaning fluid ･ Wood planks, etc.

1

zf29na-002

Removal of Upper Roller

2. Use a jack (3) to lift the top of the shoe, and then insert wood planks (4) to separate the shoe (2) and upper roller (1) by about 10 mm ( 0.394 in ).

1. Use a box wrench [ 19 mm ( 0.748 in ) ] to loosen the check valve (1) to release grease, and then loosen the track shoe tension.

2

Warning

･ If the check valve (1) is too loose, it may fly off. ･ Do not place your body in front.

4 j2kwlj-005

2-36

4

1 3

A. LOWER

1

1

2

1 j2kwlj-006

2vv687-010

4. To adjust the track shoe tension, raise the lower side frame as shown in the diagram.

Place a wood plank (1) under the lower frame to prevent falling.

Installation of Upper Roller 1. Use a jack (2) to lift the top of the shoe (1), and then insert wood planks (3).

1

3

2

3

1

2vv687-001

4EE0A2A8

2. Use a box wrench [30 mm (1.181 in)] to attach the 2 bolts (2), and then install the upper roller (1). ･ Apply Loctite. ･ Bolt (2) tightening torque: 521 - 608 N・m (384.34 - 448.51 lbf·ft)

5. Adjust the tension so that the distance indicated with A between the frame bottom (1) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (2) is 290 - 310 mm (11.417 - 12.205 in).

1

2 A

1

2

j2kwlj-006

2vv687-005

2-37

A. LOWER

3. Tighten the check valve (1).

While monitoring the track shoe tension, inject grease into the grease cylinder.

3. Use a box wrench [ 30 mm ( 1.181 in ) ] to remove the 2 bolts (2), and then remove the upper roller (1).

A. LOWER Assembly and Disassembly of Upper Roller Job code

AJJR02

Caution

･ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ･ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ･ Follow the precautions below when suspending the load. ･ The liftcrane must be operated by a qualified operator. ･ Do not stand or pass under the suspended load. ･ Check the weight of the roller to determine whether it can be carried by hand or whether a liftcrane must be used. ･ Fix the roller to a level surface so it does not roll. ･ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ･ If any parts are significantly rusted or dirty, clean them before disassembling. ･ Any foreign matter entering the equipment during assembly can create a malfunction.

Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ･ When assembling touching parts, be sure to coat them with new hydraulic oil. ･ As a rule, replace all O-rings and other seal parts with new parts. <General cautions> ･ Be careful not to drop precision parts or let bump them with other parts during work. ･ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. ･ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

2-38

Items to prepare ･ Hexagon wrench 6 mm ( 0.236 in ) ･ Hammer ･ Wrenches [ 13 mm ( 0.512 in ), 17 mm ( 0.669 in ) ] ･ Box wrench [ 17 mm ( 0.669 in ) ] ･ Screwdriver ･ Engine oil (Shell Rimula Oil #30) ･ Specialty jigs ･ Pressing machine ･ Loctite 262 ･ Special fiber cloth (Kimwipe) ･ Marking pen ･ Micrometer caliper ･ Caliper

Configuration Diagram

13 12 10

11 9 8 7 3 4

1 5 6

qezkke-005

A. LOWER High-strength bolt M10 x 16

102R010Y016N

2

2

Loctite #262

KRC5007

Reqd. amou nt

3

Cover (bolt stopper)

KRA1719

1

4

Plug with seal nylon

KHJ0300

1 1

5

O-ring

UHA0049

6

High-strength bolt M8 x 25

102R008Y025R

3

7

Thrust plate

KRA1123

1

8

Shaft

KRA1252

1

9

Bushing

KRA1248

1

10 Bushing

KRA1249

1

11 Roller

KRA1718

1

12 Floating seal

KBA0783

1

13 Bracket

KRA13740

1

mm ( in )

40 ( 1.575 )

Dimension Diagram 40 ( 1.575 )

11.5 ( 0.4528 ) *1

2

12

4

10 ( 0.394 )

3

5

D19 ( 0.748 )

D19 ( 0.748 ) (B1) 6

7

8

9

10

11

50 ( 1.969 )

2

D45 ( 1.772 )

13

10 ( 0.394 )

1

65 ( 2.559 )

D72 ( 2.835 )

1qtdrt-039

*1

Press fit length

D70.5 ( 2.7756 ) D80 ( 3.150 )

(B2)

C0.5 ( 0.0197 ) D72.5 ( 2.8543 )

C0.5 ( 0.0197 )

X X

C3 ( 0.118 )

D60 ( 2.362 ) (C) DED7E350

2-39

0.5 ( 0.0197 )

114.5 ( 4.5079 )

D65 ( 2.559 ) D45 ( 1.772 )

(A)

15 ( 0.591 )

mm ( in )

D49.8 - 50.0 ( 1.9606 - 1.9685 ) D45.8 - 46 ( 1.8031 - 1.811 )

20 ( 0.787 )

1

A. LOWER

Jig Dimension Diagram

Q'ty

40 ( 1.575 )

Part number

5 ( 0.197 )

Part name

A. LOWER A

Bushing removal jig

B1

Bushing press-fit jig (10)

B2

Bushing press-fit jig (9)

C

Floating seal installation jig

3. Use a wrench [ 13 mm ( 0.512 in ) ] to remove the 3 bolts (2) from the cover (1), and then remove the cover.

Disassembly Procedures

2

1. Stand the roller vertically and use a hexagon wrench [ 6 mm ( 0.236 in ) ] (1) to remove the plug (2). ･ The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, using seal tape is necessary.

1

jdlkdp-028

1

4. Remove the cover (1).

If the cover is difficult to remove, it is acceptable to use an air hose (2) with an adapter or to pry it open by inserting a flathead screwdriver into either end of the cover. ･ When using compressed air, be careful of flying parts.

2

jdlkdp-026

2. Face down the part of the roller from which the plug was removed and empty the oil from within the roller. ･ It may take a few hours to completely empty the oil. ･ Place an oil pan (1) under the roller to catch the oil.

1

2 jdlkdp-046

5. Use a box wrench [ 17 mm ( 0.669 in ) ] to remove the 2 bolts (2) inside the roller, and then remove the thrust plate (1).

2 1

1

jdlkdp-045

jdlkdp-047

2-40

A. LOWER 6. Lift the roller (1) and remove the shaft (2).

3 2

4

jdlkdp-181

7. Remove the floating seal (2) on the roller (1).

Check whether the sliding surface has rusted or is damaged. Also make sure the O-ring (3) on the seal ring (4) is not twisted.

1

2

5

jdlkdp-206

9. Remove the O-ring (2) on the cover (1) side. ･ Check whether the O-ring is twisted. If it is twisted, replace it with a new one.

1 4 3

2 1

1

2

jdlkdp-034

jdlkdp-205

8. Remove the floating seal (2) on the shaft (1). ･ The shaft and bracket (5) cannot be removed.

Check whether the sliding surface has rusted or is damaged. Also make sure the O-ring (4) on the seal ring (3) is not twisted.

2-41

A. LOWER

1

1

A. LOWER 10. Use a micrometer caliper (4), caliper (5), cylinder gauge (6), to measure the roller (with bushing) (1), bracket (2), and shaft (3) for wear and deformation. Replace with new parts as necessary.

･ In order to clean off adhered matter that forms sharp points and causes scratches, immerse parts in cleaning fluid (1) until dirt and grease float to the top.

1

1

865pau-220

2. After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

5 3

1 6

4 2

jdlkdp-050

11. When replacing bushings (1) (2), use jig A (4) to restrain it from the side where the shaft (3) was removed and press it out with a pressing machine (5).

5

865pau-221

3. If the bushing (2) was removed during disassembly, put it into the roller (1).

Face up the thrust plate installation side, restrain from above using jig B2 (3), and push in with the pressing machine (4).

4 4 1 3 2 1 3 jdlkdp-184

2

Assembly Procedures 1. Clean all parts. ･ Find a clean location. ･ Place a rubber plate or cloth on the work platform so as not to damage the parts.

2-42

865pau-222

A. LOWER 7. Apply hydraulic oil to the floating seal (1).

1

A. LOWER

4. Invert the roller (1) and insert the bushing (2).

Restraining from above using jig B1 (3), push in with the pressing machine (4).

Push in all the way to the position where jig B1 stops.

4 3

865pau-246

2

8. Attach the shaft (2) to the roller (1).

1 865pau-223

1

5. Insert the floating seal (3) into the roller (1) and bracket (2).

Use jig C (4) to press it into position.

4

2 3

4 865pau-225

9. Use a special fiber cloth to thoroughly wipe the surface of the thrust plate (1) to prevent any dust or scratches.

2 1

11

865pau-224

6. Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.

865pau-035

10. Install the thrust plate (1) with 2 bolts (2).

Degrease the bolts well, apply Loctite (3) to the bolt openings, and tighten the bolts.

865pau-052

2-43

A. LOWER After tightening the bolts, mark them (4).

Bolt (2) tightening torque: 62.8 - 72.6 N・m ( 46.327 - 53.556 lbf・ft )

13. Inject compressed air [ 0.2 MPa ( 29.011 psi ) ] from the oil fill port and immerse in water to check that there are no leaks.

1

1

2

3 4

865pau-226

865pau-229

11. Install the cover (1) with 3 bolts (2).

Degrease the bolts, apply Loctite (3) to the bolt openings, and tighten the bolts.

After tightening the bolts, mark them (4).

Bolt (2) tightening torque: 31.4 - 37.2 N・m ( 23.164 - 27.442 lbf・ft )

14. Inject engine oil (50 - 55 cc) into the roller.

After filling the engine oil, use a hexagon wrench (1) to tighten the plug (2) (coated with seal nylon).

After tightening the bolts, mark them (3). ･ To reuse a plug, wrap it with seal tape.

Plug (2) tightening torque: 24.5 N・m ( 18.073 lbf・ft )

2

4

1

1 3 2

865pau-227

12. Rotate the roller in the direction of the arrow and check that it rotates smoothly.

865pau-260

This completes the assembly.

865pau-228

2-44

3

A. LOWER Removal and Installation of Lower Roller Warning A. LOWER

･ Do not get under the main unit when it is jacked up.

Make sure to place the main unit on wood planks to prevent falling. ･ When loosening the grease cylinder check valve, loosen it a little at a time and stop when any grease appears.

The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.

1

Caution

･ Be sure to stop the engine before beginning work.

1

Items to prepare ･ Box wrenches [ 19 mm ( 0.748 in ), 27 mm ( 1.063 in ) ] ･ Rag ･ Cleaning fluid ･ Wood planks, etc.

zf29na-010

2. Jack up the side frame on the side where the roller is being replaced, as shown in the diagram.

Jack up so that the shoe is floating about 5 cm ( 1.969 in ), and insert wood plank (1) under the lower frame to prevent falling.

Removal of Lower Roller 1. Use a box wrench [ 19 mm ( 0.748 in ) ] to loosen the check valve (1), and then loosen the shoe tension.

Do not loosen the check valve all at once.

Loosen it slowly while monitoring the grease output and shoe loosening. ･ Grease drains out, so provide rag (2) close to the drain port.

1 4EE0A2A8

2-45

A. LOWER 3. If it is impossible to insert wood planks (3) under the lower frame, insert wood planks (3) between the side frame and the link shoe (2) to separate the link shoe and lower roller (1) by about 15 mm ( 0.591 in ).

2. Tighten the check valve (1).

While monitoring the track shoe tension, inject grease into the grease cylinder.

1

1 1 3

z63zkt-008

3

2

3. When adjusting the track shoe tension, raise the lower side frame as shown in the diagram.

Place a wood plank (1) under the lower frame to prevent falling.

6blj48-005

4. Use a box wrench [ 27 mm ( 1.063 in ) ] to remove the 4 bolts (2), then remove the lower roller (1).

1 2 1 6blj48-006

4EE0A2A8

Installation of Lower Roller 1. Insert wood planks (4) between the side frame and the link show (3), use a box wrench [27 mm (1.063 in)] to install 4 bolts (2) and then install the lower roller (1). ･ Bolt (2) tightening torque: 371 - 432 N・m (273.69 - 318.68 lbf・ft)

4. Adjust the tension so that the distance indicated with A between the lower frame (1) of the center area of the lower side frame and the lowest hanging part of the shoe plate (2) is 290 - 310 mm (11.418 12.204 in).

1

A 4

1 2

2 3

z63zkt-005

4

z63zkt-003

2-46

A. LOWER

Caution

･ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ･ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ･ Follow the precautions below when suspending the load. ･ The liftcrane must be operated by a qualified operator. ･ Do not stand or pass under the suspended load. ･ Check the weight of the roller to determine whether it can be carried by hand or whether a liftcrane must be used. ･ Fix the roller to a level surface so it does not roll. ･ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ･ If any parts are significantly rusted or dirty, clean them before disassembling. ･ Any foreign matter entering the equipment during assembly can create a malfunction.

Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ･ When assembling sliding parts, be sure to coat them with new hydraulic oil. ･ As a rule, replace all O-rings and other seal parts with new parts. <General cautions> ･ Be careful not to drop precision parts or let bump them with other parts during work. ･ Do not forcefully open or hit parts in an effort to speed up operations.

Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. ･ Disassembled parts can easily rust or collect dust.

Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare ･ Hexagon wrench [6 mm (0.236 in)] 2-47

･ ･ ･ ･ ･ ･ ･ ･ ･ ･ ･ ･ ･

Hammer Wire clip Pliers Gear puller Screwdriver Gear oil (Mobile Gear Oil SHC320) Specialty jigs Pressing machine Loctite Special fiber cloth (Kimwipe) Micrometer caliper Caliper Cylinder gauge

A. LOWER

Assembly and Disassembly of Lower Roller

Configuration Diagram 8 4 3

6 5

2 3 1 5

7

4 8 9 qezkke-002

Part name

Part number KBA13800

Q'ty

1

Roller

1

2

Shaft

KRA1195

1

3

Bushing

KRA1197

2

4

Floating seal

BHA1099

2

5

O-ring 1A-G60

BHA0863

2

6

Collar

KRA14400

1

7

Plug with seal nylon

KHJ0300

1

8

Wire clip

KNA0180

2

9

Collar (without plug)

KRA14410

1

A. LOWER Dimension Diagram

Jig Dimension Diagram

mm (in)

mm (in) D68.8 - 69.0 (2.7087 - 2.7165) D64.8 - 65.0 (2.5512 - 2.5590)

8

318 (12.520) 246 (9.685)

(A)

20 (0.787)

5 (0.197)

50 (1.968)

40 (1.575)

4 7

5

1 3

10 (0.394) D19 (0.748)

6

D111.4 - 111.6 (4.3859 - 4.3937) D109.4 - 109.6 (4.3071 - 4.3149) C0.5 (0.020)

2

35 (1.378)

B618C25C

D119 (4.625)

X

(B)

0.5 (0.0197) 12 (0.472)

9

D90 (3.543) D65 (2.559)

C3 (0.118)

X

D80 (3.149) 4C7CFC00

(C) A

Bushing removal jig

B

Bushing press-fit jig

C

Floating seal installation jig

Disassembly Procedures 1. Stand the roller vertically and use a hexagon wrench [6 mm (0.236 in)](1) to remove the plug (2). ･ The plug is coated with seal nylon, which comes off when the plug is removed.

To reuse the plug, using seal tape is necessary.

2-48

A. LOWER 4. Use pliers (2) to remove the pushed out wire clip (1).

1 2

A. LOWER

1

jdlkdp-014

2. Face down the part of the roller from which the plug was removed and empty the oil from within the roller. ･ It may take a few hours to completely empty the oil. ･ Place an oil pan (1) underneath to catch the oil. ･ Securely fasten so that the roller does not fall over.

1

2 jdlkdp-173

5. Use a gear puller (2) to remove the collar (1).

If the collar is difficult to remove, hook the collar on the bolt and catch the puller on that part. ･ If the collar has rusted or is difficult to remove due to an accumulation of debris, subject it to a shock, for example by hitting it with a hammer, to make it easier to move. ･ When hitting it with a hammer, be careful not to dent it.

2

1

jdlkdp-171

3. Remove the wire clip (1).

Tap another wire (2) with the hammer (3) from the outside to push out the wire clip that is already in the roller. ･ Place the roller horizontally and secure it so it does not roll before doing this work. ･ The wire in the roller is very securely fixed, so prepare several wire clips.

Also be sure to coat with lubricant.

3 2

1 jdlkdp-172

2-49

1 jdlkdp-179

6. Check whether the surface of the floating seal (2) sliding against the removed collar (1) has rusted or is damaged.

Also make sure the O-ring (3) on the seal ring (4) is not twisted. ･ The O-ring cannot be reused.

Replace it with new part.

A. LOWER

1

10. Check whether the surface of the floating seal (2) sliding against the removed collar (1) on the opposite side has rusted or is damaged.

Also make sure the O-ring (3) on the seal ring (4) is not twisted. ･ The O-ring cannot be reused.

Replace it with new part.

4

3

1

1

2

4

jdlkdp-174

7. Remove the floating seal (1) on the roller.

As described in step 6, check whether the sliding surface has rusted or is damaged.

Also make sure the O-ring is not twisted.

3

1

1

2

jdlkdp-174

1

11. As described in step 6,7, remove the floating seal (1) on the opposite side.

1

1 jdlkdp-175

8. Remove the O-ring (2) on the shaft (1). ･ The O-ring cannot be reused.

Replace it with new part.

2

jdlkdp-177

1

jdlkdp-021

9. Remove the shaft (1).

1 jdlkdp-176

2-50

A. LOWER

A. LOWER

12. Use a caliper (6), micrometer caliper (5), and cylinder gauge (7) to measure the roller (with bushing) (1), collars (2) (3), and shaft (4) for wear and deformation.

Replace with new parts as necessary.

7

6

1 865pau-210

2. After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

1

1

5

4 2

865pau-016

3. If the bushing (2) was removed during disassembly, put it into the roller (1).

Restraining from above using jig B (3), push in with the pressing machine (4).

Invert the roller and insert the bushing on the opposite side in the same manner.

3

jdlkdp-207

13. When replacing a bushing, insert jig A (3) into the bushing (1), and use a cylindrical object (such as a shaft) (2) to push from the top.

The bushing comes off.

3

4 3

1

2 2 1

865pau-211

jdlkdp-178

Assembly Procedures 1. Clean all parts by immersing them in cleaning fluid (1). ･ Select a clean location. ･ Place a rubber plate or cloth on the work platform so as not to damage the parts.

2-51

A. LOWER 4. Use jig C (5) to push the floating seal (4) into the collars (2) (3) and roller (1) by hand.

7. Attach O-rings (3) to the shaft (2) and mount into the roller (1).

5

1

4

1

4

2

3

3 1

3 2

5

865pau-215

8. Install the collars (1) (2) on both sides.

865pau-247

5. Use a special fiber cloth to wipe the surfaces of the floating seals so as to increase adhesion and prevent dust from entering.

2 1 865pau-022

9. Attach the wire clip (1). ･ When attaching the wire clip, secure the roller main unit so that it does not roll.

865pau-213

1

6. Apply gear oil to the floating seals (3) on the collars (1) (2).

3

1

865pau-216

1

10. Turn the main unit and check that the roller rotates properly.

2

865pau-214

865pau-217

2-52

A. LOWER

A. LOWER

11. Inject compressed air [0.2 MPa (29.011 psi)] from the oil fill port and immerse in water to check that there are no leaks.

865pau-218

12. Fill gear oil (125 cc) into the roller.

Use a hexagon wrench [6 mm (0.236 in)] (2) to tighten the plug (1) with the nylon seal applied. ･ Mobile Gear Oil SHC320 is recommended for use. ･ To reuse a plug, wrap it with seal tape.

Plug (1) tightening torque: 24.5 N·m (18.073 lbf·ft) 2 1

865pau-219

This completes the assembly.

2-53

A. LOWER Removal and Installation of the Sprocket

2. Slowly rotate the shoe so that the shoe joint section (1) is aligned as in the diagram on the right.

Place wood plank (2) under the shoe and return the bucket to its original position.

Perform air bleeding for the hydraulic line.

For details, see Air Bleed Procedures.

Warning

･ When loosening the check valve, loosen it a little at a time and stop when any grease appears.

The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.

1

Caution 1

･ Before removing the shoes, be sure to bleed off any air in the hydraulic circuits. ･ Be sure to inspect the wire rope and other lifting equipment before beginning work. ･ Do not stand or pass under the suspended load.

Items to prepare ･ Box wrenches [ 19 mm ( 0.748 in ) ] ･ Wrenches [ 19 mm ( 0.748 in ), 24 mm ( 0.945 in ) ] ･ Hammer (to remove the master pin) ･ Striking jig (to remove the master pin) ･ Liftcrane (with the required lifting capacity) ･ Wire rope (with the required breaking load) ･ Loctite #262 ･ Wood plank ･ Rag ･ Cleaning fluid

2

5s6qhg-050

Removal of Sprocket 1. Allow the bucket (1) to touch the ground so as to elevate the shoe (2) of the side to be removed as in the diagram on the right.

2 1

30BD9B2C

2-54

3. Use a box wrench [ 19 mm ( 0.748 in ) ] to rotate the grease cylinder check valve (1) and loosen the shoe tension. ･ Grease will flow out, so have rag ready.

If the check valve is loosened too much at this time, it may fly off.

Be careful not to work in front of the check valve.

A. LOWER

A. LOWER

6. Open the shoe (1) to the rear.

1 5s6qhg-054

7. Use a wrench [ 24 mm ( 0.945 in ) ] to remove the 22 bolts (1).

1

1 1

5s6qhg-051

4. Pull out the S-pin (1) from the rear of the joint section.

5s6qhg-033

8. Use a wire rope (1) to lift the drive sprocket (2) and remove it from the travel motor (3).

1

3

1 5s6qhg-052

2

5. Place a striking jig (2) against the master pin (1) and hit it with a hammer (3) to push the master pin out.

5s6qhg-034

Installation of Sprocket To install, perform the reverse of the removal procedure. ･ Tightening torque M16: 267 - 312 N・m ( 196.96 - 230.16 lbf・ft )

3

2

1

5s6qhg-053

2-55

A. LOWER Removal and Installation of Take-up Roller

3. Install the lifting equipment (4) on the takeup roller (1) and recoil spring assembly (3) and hang them from the side frame (2) with the liftcrane.

Warning

･ When loosening the grease cylinder check valve, loosen it a little at a time. ･ The pressure inside the cylinder is very high, so there is a danger of grease being expelled and the plug flying off.

The check valve adjustment procedure should not be done in front of the check valve. ･ Do not get under the machine when the main unit is jacked up. ･ Make sure to place the main unit on wood planks or the like to prevent falling. ･ Align the shoe assembly feed location and stop the engine except when working.

4 3

2 1 lbaqe2-002

4. Place the take-up roller (1) and recoil spring assembly (2) onto wood planks (4) as in the diagram.

Use a wrench [ 24 mm ( 0.945 in ) ] to remove the take-up roller bolt (3) and separate the roller and the recoil spring assembly.

Items to prepare ･ Wrench [ 24 mm ( 0.945 in ) ] ･ Hammer ･ Lifting equipment ･ Loctite #262 ･ Striking jig ･ Liftcrane ･ Crowbar ･ Wood planks, etc. ･ Rag

3 1

2

Removal of Take-up Roller

4

1. Remove the shoe assembly.

See the "Removal and Installation of Shoe Assembly".

2. Use a crowbar (3) to pull off the take-up roller (1) and recoil spring assembly from the side frame (2).

lbaqe2-006

3 1 2 lbaqe2-005

2-56

A. LOWER 1. Place the take-up roller (1) and recoil spring assembly (2) onto wood planks (4) as in the diagram. Use a wrench [ 24 mm ( 0.945 in ) ] to fasten the take-up roller (1) and recoil spring assembly (2) with the bolt (3).

At this time, be sure to coat the bolt with Loctite #262.

Installation bolt tightening torque: 267 - 312 N・m ( 196.96 - 230.16 lbf・ft ) 3 1

2 4 lbaqe2-006

2. Install the lifting equipment (4) on the takeup roller (1) and recoil spring assembly (3) as in the diagram, lift them up with the liftcrane, and insert them into the side frame (2).

Push in with the crowbar until the recoil spring assembly contacts the grease cylinder.

4 3

2 1 lbaqe2-002

3. Install the shoe assembly.

For details on installation, see the "Removal and Installation of Shoe Assembly" procedure.

2-57

A. LOWER

Installation of Take-up Roller

A. LOWER Assembly and Disassembly of Take-up Roller Caution

･ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ･ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ･ Follow the precautions below when suspending the load. ･ The liftcrane must be operated by a qualified operator. ･ Do not stand or pass under the suspended load. ･ Check the weight of the roller to determine whether it can be carried by hand or whether a liftcrane must be used. ･ Fix the roller to a level surface so it does not roll. ･ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ･ If any parts are significantly rusted or dirty, clean them before disassembling. ･ Any foreign matter entering the equipment during assembly can create a malfunction.

Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ･ When assembling sliding (5) parts, be sure to coat them with new hydraulic oil. ･ As a rule, replace all O-rings and other seal parts with new parts. ･ The take-up roller is a heavy object and requires at least 2 workers to handle. <General cautions> ･ Be careful not to drop precision parts or let bump them with other parts during work. ･ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. ･ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

2-58

Items to prepare ･ Hexagon wrench [ 6 mm ( 0.236 in ) ] ･ Hammer ･ Pliers ･ Gear puller ･ Screwdriver ･ Engine oil (Shell Rimula Oil #30) ･ Specialty jigs ･ Pressing machine ･ Loctite ･ Special fiber cloth (Kimwipe) ･ Micrometer caliper ･ Caliper ･ Cylinder gauge ･ Seal tape ･ Oil pan (drip pan) ･ Water container for inspection

Configuration Diagram 6 4 2

1

3 2 5

3

7

5 9

8 qezkke-004

6

A. LOWER Jig Dimension Diagram

Q'ty

2

4

Hub (without plug)

KRA14100

1

5

O-ring 1A-G50

BHA0863

2

6

Hub pin

KRA14110

2

7

Shaft

KRA14120

1

8

Plug with seal nylon

KHJ0300

1

9

Hub

KRA14090

1

D68.8 - 69.0 ( 2.709 - 2.716 ) D64.8 - 65.0 ( 2.552 - 2.559 ) 50 ( 1.968 )

mm ( in )

1

9

(A)

D124 ( 4.881 )

4 5

X

30 ( 1.181 )

6

7

D90 ( 3.543 )

D104 ( 4.094 )

D65 ( 2.559 )

40 ( 1.575 )

Dimension Diagram

284 ( 11.181 ) 202 ( 7.953 )

A. LOWER

BLA2371

D19 ( 0.778 ) (B)

(C)

D116.4-116.6 ( 4.583-4.590 ) D114.4-114.6 ( 4.504-4.511 ) C0.5 ( 0.020 )

)

Floating seal

20

3

mm ( in )

.0

2

(0

1

KRA1201

5

KRA1768

Bushing

0.

Roller

2

5 ( 0.197 ) 20 ( 0.787 )

1

C

Part number

10 ( 0.394 )

Part name

3 A5D27D5F

C3 ( 0.118 ) X

82B001D8

A

0.5 ( 0.020 ) 15 ( 0.590 )

2

Bushing removal jig

B

Bushing press-fit jig

C

Floating seal installation jig

Disassembly Procedures 1. After cleaning the roller with kerosene, use the hexagon wrench (1) to remove the plug (2) from the hub (3). ･ The plug is coated with seal nylon, which comes off when the plug is removed.

Seal tape is necessary for reusing.

2-59

A. LOWER 1 2

1

3

3

2

jdlkdp-039

4. Check whether the surface of the floating seal (1) sliding against the removed hub has rusted or is damaged. Also make sure the O-ring (2) on the seal ring (3) is not twisted. ･ The O-ring cannot be reused. Replace it with new part.

1 jdlkdp-037

2. Face down the part of the roller from which the plug was removed and empty the oil from within the roller. ･ It may take a few hours to completely empty the oil. ･ Place an oil pan (1) underneath to catch the oil.

3

2

1

1 jdlkdp-208

jdlkdp-038

3. Remove the hub pin (2) from the hub (1), and remove the hub (1) from the shaft (3). ･ Only remove on one side.

2-60

A. LOWER

1

1

jdlkdp-010

jdlkdp-041

6. Remove the O-ring (2) on the shaft (1) and then pull the shaft (1) out. ･ The O-ring cannot be reused. Replace it with new part.

2 1

jdlkdp-042

7. As described in step 3, remove the hub (1) on the opposite side and check that the sliding surface of the floating seal is not rusted and that the O-ring is not twisted.

1 jdlkdp-209

2-61

A. LOWER

8. As described in step 5, remove the floating seal (1) on the opposite side.

5. Remove the floating seal (1) on the roller.

As described in step 4, check whether the sliding surface has rusted or is damaged.

Also make sure the O-ring is not twisted.

A. LOWER 9. Use a micrometer caliper (4), cylinder gauge (5), and caliper (6) to measure the roller (with bushing) (1), hub (2), and shaft (3) for wear and deformation. Replace with new parts as necessary.

3 4

2 1 1 6 6

jdlkdp-012

11. Invert the roller (1), use jig A (4) to push up against the bushing (2), and press with a rod-shaped object (3) (such as a shaft).

The bushing comes off.

1

3

2

1

3 4

6

2

jdlkdp-210

5

Assembly Procedures

jdlkdp-044

10. When replacing the bushing (1), remove it by placing a striking rod (2) against the end surface and striking that with a hammer (3) uniformly left and right as in the diagram. ･ Do not disassemble the bushing (1) unless it has become unusable due to wear, etc. ･ Be careful not to scratch the inside of the roller when striking the end of the bushing.

2-62

1. Clean all parts. ･ Find a clean location. ･ Place a rubber plate or cloth on the work platform so as not to damage the parts. ･ In order to clean off adhered matter that forms sharp points and causes scratches, immerse parts in cleaning fluid (1) until dirt and grease float to the top.

4. Use the jigs (2) (3) attached to the pressing machine to attach the bushing (1). Use the pressing machine to press from the opposite side. Next, use a special fiber cloth to remove all dust and debris.

1

2

1 865pau-249

2. After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris. ･ If the parts are to be left as is for a long time after drying them, apply engine oil.

1 3

3

1

865pau-002

3. If the bushing (2) was removed during disassembly, put it into the roller (1). Use a pressing machine (3) to press in both the left and right sides.

865pau-251

5. Attach the floating seal (2) to the hub (1).

Use jig C (3) to press it into position.

3

2

3 2

1

1

865pau-252

865pau-250

2-63

A. LOWER

A. LOWER

A. LOWER 6. Use jig C (3) to attach the floating seal (2) to the roller (1) side.

1

9. After attaching the O-ring (4) to the shaft (1), attach the shaft to the hub (2) and fasten it with the hub pin (3).

2 3

1

1

4 865pau-253

2

7. Use a special fiber cloth to thoroughly wipe the sliding surface of the floating seal to prevent any dust or scratches.

865pau-045

10. Attach the shaft (2) to the roller (1).

2

1 865pau-258 865pau-254

11. Install the opposite side hub (1) on the roller (2) and fasten with the hub pin (3).

8. Apply engine oil to the floating seals (1) on the hubs (2) (3).

3

1

1 3 2

865pau-259

865pau-044

2-64

2

A. LOWER

A. LOWER

12. Inject compressed air [ 0.2 MPa ( 29.011 psi ) ] from the oil fill port and immerse in water to check that there are no leaks.

865pau-255

13. Fill engine oil (120 cc) into the roller main unit. ･ The roller main unit can be very unstable, so be careful in securing it.

865pau-256

14. After filling the oil, use a hexagon wrench [ 6 mm ( 0.236 in ) ] (2) to tighten the plug (1) with the nylon seal applied. ･ To reuse a plug, wrap it with seal tape.

1

2 865pau-257

2-65

A. LOWER Removal and Installation of Grease Cylinder

3. Jack up the side frame on the side where the grease cylinder is being removed as shown in the diagram.

Jack up so that the shoe is floating about 5 cm (1.969 in), and insert wood plank (1) under the lower frame to prevent falling.

Warning

･ When loosening the grease cylinder check valve, loosen it a little at a time. ･ The pressure inside the cylinder is very high, so there is a danger of grease being expelled and the plug flying off.

The check valve adjustment procedure should not be done in front of the check valve. ･ Do not get under the machine when the main unit is jacked up. ･ Make sure to place the main unit on wood planks or the like to prevent falling. ･ Align the shoe assembly feed location and stop the engine except when working.

1 4EE0A2A8

4. Use a wrench [27 mm (1.063 in)] to remove the bolts (1) and washers (2), and then remove the track guard (3).

Items to prepare ･ Wrench [ 24 mm ( 0.945 in ), 27 mm ( 1.063 in ) ] ･ Hammer ･ Lifting equipment ･ Loctite #262 ･ Striking jig ･ Striking jig ･ Crowbar ･ Wood planks, etc. ･ Rag

1

Removal of grease cylinder

2

3

tmvdbh-003

5. Install the wire (2) on the grease cylinder assembly (1), and then lift it with the liftcrane so that it is slightly tensed.

1. Remove the shoe assembly.

See the "Removal and Installation of Shoe Assembly" procedure.

2. Use a crowbar (3) to pull off the take-up roller (1) and recoil spring assembly about 100 mm (3.937 in) from the side frame (2).

When removing the grease cylinder, use a wood plank or the like (4) to prevent the take-up roller (1) and recoil spring assembly from coming out.

1

4 tmvdbh-004

3 1

2 tmvdbh-001

2-66

2

A. LOWER

1

A. LOWER

6. Use a wrench or box wrench [24 mm (0.945 in)] to remove the bolt (1) and washer (2), and then remove the grease cylinder (3).

Lower the liftcrane as is to lower to under the frame, and then take out from between the lower rollers.

2

3

3

tmvdbh-016

Installation of grease cylinder To install, perform the reverse of the removal procedure.

Grease cylinder installation bolt tightening torque: 267 - 312 N・m ( 196.96 - 230.16 lbf・ft ) When installing bolts, coat the threaded sections with Loctite #262.

2-67

A. LOWER ･ ･ ･ ･

･ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ･ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ･ Follow the precautions below when suspending the load. ･ The liftcrane must be operated by a qualified operator. ･ Do not stand or pass under the suspended load. ･ Check the weight of the grease cylinder to determine whether it can be carried by hand or whether a liftcrane must be used. ･ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ･ If any parts are significantly rusted or dirty, clean them before disassembling. ･ Any foreign matter entering the equipment during assembly can create a malfunction.

Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ･ When assembling touching parts, be sure to coat them with new hydraulic oil. ･ As a rule, replace all O-rings and other seal parts with new parts.

General cautions ･ Be careful not to drop precision parts or let bump them with other parts during work. ･ Do not forcefully open or hit parts in an effort to speed up operations.

Pay careful attention and proceed with caution so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment. ･ Disassembled parts can easily rust or collect dust.

Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare ･ Hammer ･ Wrenches [ 19 mm ( 0.748 in ) ] ･ Box wrench [ 19 mm ( 0.748 in ) ]

Configuration diagram

3 8

2 1

5

9

qezkke-011

Cod e

Part name

Q'ty

1

Dust seal

2

Piston rod

1

3

U-packing

1

4

Retaining ring

1

5

Grease cylinder

1

6

High-strength bolt

2

7

Spring washer

2

8

Bracket

1

9

Check valve assembly

1

1

Dimension diagram mm (in) 5

1

4

3

2

300 (11.811) A

80 (3.150)

6

7 8

608539D0

2-68

6

7

4

D70 (2.756)

Caution

Screwdriver Specialty jigs Special fiber cloth (Kimwipe) Marking pen

A

9

D120 (4.724)

Assembly and Disassembly of Tension Shock Absorber

A. LOWER Jig dimension diagram

2. Pull out the piston rod (2) from the grease cylinder (1).

mm (in)

A. LOWER

D86 (3.386)

[20 (0.787)]

D130 (5.118)

1 2

A

1

jdlkdp-119

1.5 (0.059) 97R) 5R (0.1

3. Use the removal jig (B) to remove the dust seal (2) from the grease cylinder (1).

1

2

D15 (0.591)

130 (5.118) B AE1B6D27

A

Dust seal press-fit jig

B

Removal jig

jdlkdp-120

4. Remove the retaining ring (2) from the piston rod (1), and then use the removal jig (B) to remove the U-packing (3).

Disassembly procedures 1. Clean the grease cylinder with kerosene, remove the bolt (1) and washer (2), and remove the bracket (3).

Remove the check valve (5) from the grease cylinder (4).

1

3

2

1 4 2 3 jdlkdp-121

5

Assembly procedures 1. Place parts in a rough cleaning container filled with kerosene to clean off any adhered matter that can form sharp points and cause scratches. ･ Immerse in kerosene until dust, grease, and other adhered matter comes off and floats to the surface.

jdlkdp-118

2-69

A. LOWER 2. Place parts in a finish cleaning container filled with kerosene and clean while gently moving the parts. After cleaning, wipe away the kerosene with a clean rag. ･ Place the parts in a location free of dust and moisture and use compressed air to dry the parts. After drying, coat parts with engine oil.

3. Install the U-packing (1) coated with grease onto the piston rod (2), and then install the retaining ring (3). ･ Use a new U-packing (1). ･ Be careful that the U-packing (1) faces correctly.

C A

2

2

1

1

3

865pau-150

865pau-234

4. Use the jig (A) and hammer (C) to install the dust seal (2) on the grease cylinder (1).

Apply grease to the lip section of the dust seal (2). ･ Use a new dust seal (2).

5. Coat the surface of the piston rod (1) with grease and insert into the grease cylinder (2).

1

865pau-151

2-70

2

6. Tighten the check valve (1) to the grease cylinder (2) to the specified tightening torque.

Install the bracket (3) and secure it with the spring washer (4) and the bolt (5).

Check valve tightening torque: 48.99 68.61 N•m (36.1394 - 50.6128 lbf・ft) 5 2 4 3 1

865pau-152

This completes the assembly.

2-71

A. LOWER

A. LOWER

A. LOWER Removal and Installation of Center Joint Job code

2. Attach the specialty adapter (1) to the area where the air breather is removed, and set the vacuum pump (2).

Create negative pressure in the hydraulic oil tank using the vacuum pump.

JRRJ01

Caution

･ Be sure to stop the engine before beginning work. ･ Be sure to inspect the wire rope and other lifting equipment before beginning work. ･ Do not stand or pass under the suspended load.

2

1

Items to prepare ･ Wrenches [ 17 mm ( 0.669 in ), 19 mm ( 0.748 in ), 27 mm ( 1.063 in ), 36 mm ( 1.417 in ) ] ･ Hexagon wrenches [ 5 mm ( 0.197 in ), 6 mm ( 0.236 in ) ] ･ Box wrench [ 19 mm ( 0.748 in ) ] ･ Specialty adapter for vacuum pump connection ･ Vacuum pump (vacuum pump power supply) ･ Extension cable ･ Marking pen ･ Cap ･ Plug ･ Wire rope (with the required breaking load) ･ Liftcrane (with the required lifting capacity) ･ Wood planks, etc. ･ Rag ･ Cleaning fluid ･ Waste oil can

mqap7t-002

3. Use a box wrench [ 19 mm ( 0.748 in ) ] to remove the 8 bolts (2), and then remove the lower under covers (1).

2 1 mqap7t-003

4. Prepare a waste oil can (1) to receive the oil that spills out under the center joint.

Removal of Center Joint 1. Use a hexagon wrench [ 5 mm ( 0.197 in ) ] to remove the 4 bolts (1), and then remove the air breather (2) on the hydraulic oil tank.

1 mqap7t-004

1

5. Use a wrench [ 36 mm ( 1.417 in ) ] to remove the travel hoses (1) and a wrench [ 27 mm ( 1.063 in ) ] to remove the drain hoses (2). ･ Mark the center joint and hoses so that the connectors match at the time of assembly.

2

mqap7t-001

2-72

A. LOWER 7. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the 2 bolts (2), and then remove the center joint lock bar (1).

･ Attach caps or plugs to the center joint and hoses to prevent any entry of water, dust or dirt. ･ Clean the center joint and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

A. LOWER

1

1

2 mqap7t-007

8. Use a wrench [ 36 mm ( 1.417 in ) ] to remove the 4 travel hoses (1). ･ Mark the hoses so that the connectors can be matched during assembly. ･ Attach caps or plugs to the hoses to prevent any entry of water, dust or dirt. ･ Clean the hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

2 mqap7t-016

6. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the pilot hoses (1) and a wrench [ 27 mm ( 1.063 in ) ] to remove the drain hose (2). ･ Attach caps or plugs to the center joint and hoses to prevent any entry of water, dust or dirt. ･ Clean the center joint and hoses by spraying them with a parts cleaner to prevent scratches and prevent dirt from accumulating on the connectors.

1

1 1

2

mqap7t-030

9. Wrap wire ropes (1) around the center joint and suspend it with a liftcrane so that the center joint does not fall during removal and installation operations.

1 mqap7t-006

1

mqap7t-009

2-73

A. LOWER 10. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the 4 bolts (1) from the center joint.

2. Use a wrench [ 19 mm ( 0.748 in ) ] to tighten the 4 bolts (1) for the center joint.

1

1

mqap7t-010

mqap7t-010

11. Use the wire ropes (2) and liftcrane to lift the center joint (1).

Thoroughly check that the location is safe before lowering the center joint on wood planks.

2

3. Use a wrench [ 36 mm ( 1.417 in ) ] to install the 4 travel hoses (1).

1

2

mqap7t-030

1

4. Use a wrench [ 19 mm ( 0.748 in ) ] to install the 2 bolts (2), then install the center joint lock bar (1).

Bolt (2) tightening torque: 88.3 - 107 N・m ( 65.14 - 78.93 lbf・ft ) ･ Apply Loctite #262 to the bolts.

mqap7t-022

Installation of Center Joint Tighten bolts being installed to the specified torque.

For bolts for which the torque is not specified, check the "Bolt Size and Torque Table".

1. Wrap the wire rope (2) around the center joint (1) and lift it with a liftcrane.

1

2

2 mqap7t-007

1 ze9tja-009

2-74

8. Use a hexagon wrench [ 5 mm ( 0.197 in ) ] to install the 4 bolts (1), then install the air breather (2) on the hydraulic oil tank to the location from which the specialty adapter for the vacuum pump was removed.

5. Use a wrench [ 19 mm ( 0.748 in ) ] to install the pilot hose (1) and a wrench [ 27 mm ( 1.063 in ) ] to install the drain hose (2).

1 1

1

2

1 ze9tja-005

6. Use a wrench [ 36 mm ( 1.417 in ) ] to install the travel hoses (1) and a wrench [ 27 mm ( 1.063 in ) ] to install the drain hoses (2).

ze9tja-008

1

2 mqap7t-016

7. Use a box wrench [ 19 mm ( 0.748 in ) ] to install the 8 bolts (2) and install the lower under cover (1). ･ Bolt (2) tightening torque: 63.9 - 73.5 N・ m ( 47.14 - 54.22 lbf・ft )

2 1 ze9tja-007

2-75

2

A. LOWER

A. LOWER

A. LOWER Assembly and Disassembly of Center Joint

Caution

Caution

･ The following cautions for hydraulic equipment should be observed with these parts. ･ To ensure safe operations, wear protective devices for the work and follow all precautions. ･ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ･ Make sure that the jig is used for disassembly of the axle and rotor. ･ Follow the precautions below when suspending the load. ･ The liftcrane must be operated by a qualified operator. ･ Do not stand or pass under the suspended load. ･ Check the weight of the load to determine whether it can be carried by hand or whether a liftcrane must be used. ･ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ･ If any parts are significantly rusted or dirty, clean them before disassembling. ･ Any foreign matter entering the equipment during assembly can create a malfunction.

Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ･ When assembling V-rings, O-rings, and other sliding parts, be sure to coat them with new grease. ･ As a rule, replace all O-rings and other seal parts with new parts.

2-76

General cautions ･ Be careful not to drop precision parts or let bump them with other parts during work. ･ Do not forcefully open or hit parts in an effort to speed up operations.

Pay careful attention and proceed slowly so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment, etc. ･ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust. ･ Make sure that foreign matter such as debris and moisture does not enter. ･ The work platform used should be solid, stable, and sufficiently spacious.

Also, items should be clean and free of debris and moisture.

Remove debris and moisture before performing work. ･ Inspect, remove debris and moisture, and clean tools and jigs before work. ･ Jigs and tools that are appropriate to the contents of work should be used.

Items to prepare ･ Hexagon wrenches [ 6 mm ( 0.236 in ), 14 mm ( 0.551 in ), or 17 mm ( 0.669 in ) ] ･ Torque wrench ･ Socket wrenches [ 6 mm ( 0.236 in ), 14 mm ( 0.551 in ), or 17 mm ( 0.669 in ) ] ･ Lights ･ Mirror ･ Specialty jigs

A. LOWER

A. LOWER

Configuration Diagram

1

2

4

3 9

6

7 8 5

5

10

10

qezkke-006

Cod e

Part name

Cod e

Part name

Cod e

Part name

1

Axle

5

Hexagon socket head bolt

9

Rotor

2

V-ring

6

O-ring

10

Loctite

3

O-ring

7

Cover

4

Packing ring

8

Thrust plate

2-77

A. LOWER Dimension Diagram mm ( in )

Nm lbf ft

31.4 - 37.3 23.164 - 27.515 1

2

3

4

5

10 6

7 *1

*2

272.5 ( 10.7283 ) A A *4

*6

31.4 - 37.3 23.164 - 27.515

9

*5

5

G1/2

A

*6

8

G1/2

2 x G1/4

A

10

11 12

*3

3B9B909D

1

Axle

7

Cover

*1

Maximum gap 10.0 ( 0.394 ) Minimum gap 8.5 ( 0.3346 )

2

V-ring

8

Thrust plate

*2

Maximum gap 0.7 ( 0.0276 ) Minimum gap 0.3 ( 0.0118 )

3

O-ring

9

Rotor

*3

2 x M12, screw depth 18 mm ( 0.709 in ), bottom hole depth 23 mm ( 0.906 in ) G1/2-A class

4

Packing ring

10

Loctite #262

*4

5

Hexagon socket head B

11

Company nameplate

*5

G1/4-A class

6

O-ring

12

Parker rivet

*6

4 x G3/4-A class

Do not coat any processed surfaces marked with a ★ symbol or port processed surfaces.

2-78

A. LOWER Disassembly Procedures

Axle removal jig

1. Use a hexagon wrench [ 6 mm ( 0.236 in ) ] to remove the 4 hexagon socket head bolts (3) from the rotor (1), then remove the cover (2).

mm ( in ) 30 - 40 ( 1.182 -1.574 ) 2

3 3

(20 ( 0.787 ))

4 2

*1

20 ( 0.787 )

5 ( 0.197 )

1 jdlkdp-194

2. Remove the O-ring (2) from the rotor (1).

(20 ( 0.787 ))

2

5 1

1

7C2D54A3

1

Axle removal jig

2

M16 - M20 full threaded bolt L = 370 - 420 mm ( 14.567 - 16.535 in )

3

M16 - M20 female thread

4

Hexagon socket head bolt (5) M8 x 25

5

Backing plate Axle (1) outer diameter - about 5 mm ( 0.197 in ) t = about 5 mm ( 0.197 in )

*1

Cover (7) installation dimensions

3. Use a hexagon wrench [ 6 mm ( 0.236 in ) ] to remove the 4 hexagon socket head bolts (2), then remove the thrust plate (1).

2 1

1.5 ( 0.059 )

mm ( in )

jdlkdp-195

D15 ( 0.591 ) 5 ( 0.197 ) R jdlkdp-196

4. Use axle removal jig 1 to push out the axle (2) from the rotor (1). ･ Do not strike it with the hammer at this time.

150 ( 5.905 ) 1 11503908

1

Removal jig (for O-ring and V-ring)

2-79

A. LOWER

Jig Dimension Diagram

A. LOWER

1

2 1 jdlkdp-197

865pau-237

5. Use removal jig 1 or the like to remove the V-ring (2) from the axle (1).

2

2. Place parts in a finish cleaning container filled with kerosene (1) and clean while gently moving the parts.

After cleaning, wipe away the kerosene with a clean rag. ･ Place the parts in a location free of dust and moisture and use compressed air to dry the parts.

After drying, coat parts with engine oil. ･ Polish away burrs, barbs, and scratches with a whetstone.

1

jdlkdp-198

6. Use removal jig 1 or the like to remove the O-ring (2) and packing ring (3) from the rotor (1).

2 1 3 1 865pau-238

3

3. Use cleaning fluid or compressed air to clean the rotor (1).

After cleaning, check inside the rotor and in the groove sections for burrs, barbs and scratches and for scratches caused by striking.

3 jdlkdp-199

Assembly Procedures 1. Place parts in a rough cleaning container filled with kerosene (1) to clean off any adhered matter that can form sharp points and cause scratches. ･ Immerse in kerosene until dust, grease, and other adhered matter comes off and floats to the surface.

1

865pau-073

2-80

4. Check the quantity of packing rings (1) and O-ring (2).

Coat with grease and install in the sequence below. ･ Set one packing ring (1) in each of the 7 grooves from the 2nd groove on the axle insertion side to the thrust plate side. ･ Set the O-ring (2) in the front-most groove on the axle insertion side. ･ Use new packing rings (1) and a new Oring (2).

5. After installing the O-ring and packing rings on the rotor (1), use the mirror to check for any parts that are sticking out or are twisted.

Also, check for installation mistakes.

After checking, coat with grease. After coating with grease, check again for any parts sticking out, etc.

1

2 865pau-075

1

6. Install the V-ring (2) on the axle (1) and coat sufficiently with grease.

Be careful that no water or dirt gets into the grease. ･ Use a new V-ring (2).

1 1

2 1

865pau-239 865pau-240

7. Install the axle (2) on the rotor (1).

Set in a way that the V-ring will not be cut or damaged.

1

2

865pau-241

2-81

A. LOWER

A. LOWER

A. LOWER 8. Using a hexagon wrench [ 6 mm ( 0.236 in ) ], coat the hexagon socket head bolts (3) with Loctite, install the thrust plate (2) on the axle (1), and tighten to the specified tightening torque. ･ Bolt (3) tightening torque: 31.4 - 37.3 N· m ( 23.164 - 27.515 lbf・ft ) 3 2 1

865pau-242

9. Install the O-ring (2) on the rotor (1). ･ Use new O-ring (2).

2

1

865pau-243

10. Using a hexagon wrench [ 6 mm ( 0.236 in ) ], coat the hexagon socket head bolts (3) with Loctite #262, install the cover (2) on the rotor (1), and tighten to the specified tightening torque. ･ Bolt (3) tightening torque: 31.4 - 37.3 N· m ( 23.164 - 27.515 lbf・ft ) 3

2 1

865pau-244

This completes the assembly.

2-82

Removal and Installation of Travel Motor

2. Slowly rotate the shoe so that the shoe joint section (3) is aligned as in the diagram on the right.

3. Place wood planks (4) under the shoe and return the bucket to its original position.

4. Perform air bleeding for the hydraulic line.

For details, see Air Bleed Procedures.

Warning

･ When loosening the check valve, loosen it a little at a time and stop when any grease appears.

The pressure inside the cylinder is very high, so there is the danger of grease being expelled and the plug flying off if the check valve is loosened too much.

Caution

･ Before removing the shoes, be sure to bleed off any air in the hydraulic circuits. ･ Be sure to inspect the wire rope and other lifting equipment before beginning work. ･ Do not stand or pass under the suspended load.

1

Items to prepare ･ Box wrenches [ 19 mm ( 0.748 in ), 24 mm ( 0.945 in ) ] ･ Wrenches [ 19 mm ( 0.748 in ), 27 mm ( 1.063 in ), 41 mm ( 1.614 in ) ] ･ Hammer (to remove the master pin) ･ Striking jig (to remove the master pin) ･ Liftcrane (with the required lifting capacity) ･ Wire rope (with the required breaking load) ･ Loctite #262 ･ Wood planks, etc. ･ Rag ･ Cleaning fluid

1

5s6qhg-029

Removal of Travel Motor 1. Allow the bucket (1) to touch the ground so as to elevate the shoe (2) of the side to be removed as in the diagram on the right.

5. Use a box wrench [19 mm (0.748 in)] to rotate the grease cylinder check valve (5) and loosen the shoe tension. ･ Grease will flow out, so have rag ready.

If the check valve is loosened too much at this time, it may fly off. Be careful not to work in front of the check valve.

2 1 1 5s6qhg-030

30BD9B2C

2-83

A. LOWER

A. LOWER

A. LOWER 6. Pull out the S-pin (6) from the rear of the joint section.

9. Use a wrench [19 mm (0.748 in)] to remove the 4 bolts (10), then remove the cover (11).

11

6 5s6qhg-004

10

7. Place a striking jig (9) against the master pin (7) and hit it with a hammer (8) to push the master pin out.

5s6qhg-007

10. Use wrenches [27 mm (1.063 in) for drain hose, 41 mm (1.614 in) for high-pressure hose ] to remove the drain hose (13) and 3 high-pressure hoses (12). ･ Be sure to use plugs on the removed drain and high-pressure hoses.

8

13 12

9

7

5s6qhg-005

8. Open the shoe (2) to the rear.

3 5s6qhg-047

2

1

5s6qhg-031

2-84

A. LOWER 11. Use a wrench [19 mm (0.748 in)] to remove the pilot hoses (15) (14) shown in the diagram.

13. Use a box wrench [24 mm (0.945 in)] to remove all 28 bolts (18).

A. LOWER

18

5s6qhg-049

14. Remove the travel motor (16).

1 15

14

1 5s6qhg-032

Installation of Travel Motor

5s6qhg-048

12. Attach the wire rope (17) to the travel motor (16) as in the diagram.

Adjust the wire rope so that it is located at the center of mass and lift it with the liftcrane so that it is slightly tensed.

1. Attach the travel motor to the lower frame as in the diagram. ･ Be careful of the installation angles.

1

17

16

q1n8d5-034

5s6qhg-014

2-85

A. LOWER 2. Apply Loctite #262 to the installation bolt (2) threaded sections and temporarily tighten all 28 bolts.

Use a wrench [24 mm (0.945 in) ] to tighten the top and bottom alternately to the specified torque so that an even tightening force acts on the opposing sides.

Tightening torque M16: 267 - 312 N・m ( 196.97 - 230.15 lbf・ft )

3. Use a wrench [19 mm (0.748 in)] to remove the elbow joint (3) and pilot hose (4) shown in the diagram.

1

3

4

1

2

4

q1n8d5-002

3 2

q1n8d5-039

4. Use wrenches [ 27 mm ( 1.063 in ) for drain hose, 41 mm ( 1.614 in ) for highpressure hose ] to install the drain hose (6) and high-pressure hose (5).

q1n8d5-038

6

q1n8d5-040

2-86

5

A. LOWER 5. Use a wrench [ 19 mm ( 0.748 in ) ] to install the cover (8) with the 4 bolts (7).

8. Tighten the check valve (12).

While monitoring the track shoe tension, inject grease into the grease cylinder.

8

A. LOWER

1

12

7 q1n8d5-006

6. Wrap the shoe (9).

q1n8d5-027

9. When adjusting the track shoe tension, raise the lower side frame as shown in the diagram.

Place a wood plank (13) under the lower frame to prevent falling.

Adjust the tension so that the distance indicated with A between the frame bottom (14) of the center area of the lower side frame and the lowest hanging part of the top of the shoe plate (15) is 290 - 310 mm ( 11.417 - 12.205 in ).

9 q1n8d5-026

7. Insert the master pin (11).

Insert the S-pin (10) and bend it so that it cannot slip out.

2 1

30BD9B2C

10

14 11

q1n8d5-008

A

15 q1n8d5-011

2-87

A. LOWER Assembly and Disassembly of Travel Motor Tools for Assembly and Disassembly Use the tools indicated below for the assembly and disassembly of the motor.

Standard Tools The standard tools required for the assembly and disassembly of this motor are indicated in Table 1.

No.

Tool name

Standardized No. Manufacturer name

Type and dimensions

Part used with

1

Nominal size 60

1-2-19

2

Nominal size 120

1-2-8

3

Nominal size 230

4

Nominal size 450

1-2-20

Nominal size 900

24, 28

6

Nominal size 1800

1-2-2-4, 1-2-11, 1-2-14, 29

7

Nominal size 2800

11

8

Nominal size 4200

1-2-7

9

Nominal size 5600

8, 14

11

Bolt width 2.5 mm ( 0.0984 in )

1-2-19

12

Bolt width 4 mm ( 0.157 in )

1-2-8

13

Bolt width 6 mm ( 0.236 in )

1-2-20

Bolt width 8 mm ( 0.315 in )

28

15

Bolt width 10 mm ( 0.394 in )

1-2-11

16

Bolt width 12 mm ( 0.472 in )

11、29

17

Bolt width 14 mm ( 0.551 in )

1-2-2-4

Size T50

24

Size T90

8, 14

Bolt width 10 mm ( 0.394 in )

1-2-14

21

Bolt width 27 mm ( 1.063 in )

1-2-7

22

Bolt width 2.5 mm ( 0.0984 in )

1-2-19

23

Bolt width 4 mm ( 0.157 in )

1-2-8

24

Bolt width 6 mm ( 0.236 in )

1-2-20

25

Bolt width 8 mm ( 0.315 in )

28

5

10

14

18 19

Preset-type torque wrench

Rachet handle for socket wrench

JIS B4650

JIS B4641

Hexagon bit for socket wrench

Torx T-shaped bit

JASO F116-89

20 Socket for socket wrench

Hexagon wrench

JIS B4636

JIS B4648

2-88

A. LOWER

Tool name

Type and dimensions

Part used with

Bolt width 10 mm ( 0.394 in )

1-2-11

Bolt width 12 mm ( 0.472 in )

11, 29

28

Bolt width 14 mm ( 0.551 in )

1-2-2-4

29

Bolt width 10 mm ( 0.394 in )

1-2-14

Bolt width 27 mm ( 1.063 in )

1-2-7

26 Hexagon wrench

27

Wrench

JIS B4648

JIS B4630

30 31

Longnose pliers

32

Snap ring pliers

33

Flathead screwdriver

34

Plastic hammer

35

Punch

Length of about 10 mm ( 0.394 in )

36

Press

200 kgf or higher

37

Liftcrane

For 400 kg ( 881.854 lb )

38

JIS B4631

1-2-7 S-2 type

1-4-5

JIS B4609

6 x 100

2, 1-27, 1-2, 1-21

OF-05

Nominal size #3

For M20

Eyebolt

39 40

For M12

1-2

Chain string (wire)

Secondary Materials The secondary materials required for the assembly and disassembly of this motor are indicated in Table 2.

No.

Secondary materials name

Standardized No. Manufacturer name

1

Seal tape

2

Adhesive

Loctite

3

Gear oil

GL-4#90 equivalent

4

Hydraulic oil

ISO VG46 equivalent

5

Grease

Lithium-series

6

White kerosene

No.2 equivalent oil

7

Liquid packing

ThreeBond

8

Lapping plate

Type and dimensions

Part used with 1-2-8

271

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, 1-16, 1-17, 1-23, 1-12, 1-15, 1-21

1211

4, 27

For sliding surface 1-4-1, 1-4-2, 1-5、1-21 repair

2-89

A. LOWER

No.

Standardized No. Manufacturer name

A. LOWER

No.

Standardized No. Manufacturer name

Secondary materials name

Type and dimensions

Part used with

For sliding surface repair

9

Lapping agent

#1000

10

Copper plate

11

Tube brush

For cleaning

12

Bamboo brush

For cleaning

13

Oil pan

Oil pan

14

Plastic container

For filling grease

15

Rag

1-2-1, 1-4-1

Special Tool (jig) The special tools required for the assembly and disassembly of this motor are indicated in Table 3.

No.

Standardize Type and d No. Part used with Manufactur dimensions er name

Tool name

1

Pulley remover

1-8, 1-9

2

Bearing press-fit jig

1-8

3

Bearing press-fit jig

1-9

4

Floating seal mounting jig

2

5

Rod

3

6

Angular bearing press-fit jig

3

7

Shim thickness adjustment jig

5

8

Rod

1-2-2

10

Thrust plate selection jig

26

11

Oil seal press-fit jig

1-12

12

Brake piston positioning jig

1-15

13

Snap ring removal jig

1-4-5

14

Poppet seat removal jig

1-2-7-3

Measurement Device The measurement devices required for assembly of this motor are indicated in Table 4.

No.

Tool name

Standardize Type and d No. Part used with Manufactur dimensions er name

1

Dial gauge

JIS B7503

5, 26

2

Micrometer caliper

JIS B7502

5, 26

2-90

Motor Disassembly Procedures

7. To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform work on.

8. The motor comprises high-precision parts.

For this reason, foreign matter adhering to parts can be damaging.

Motor disassembly should be done in an inside space without dust, and mud and dirt should be prevented from adhering to parts.

9. The motor comprises high-precision parts.

For this reason, dents and scratches on part surfaces can be damaging.

Be very careful when handling parts during disassembly and do not create any dents or scratching.

10. To prevent personal injury and damage to parts during disassembly, do not force disassembly of parts which are especially tight to disassemble.

Precautions before Motor Disassembly Begin motor disassembly only after thoroughly reading the precautions below.

1. When performing disassembly, always wear protective gear such as a helmet, goggles and safety shoes.

2. Use the specified tools when performing disassembly.

3. Remove all lines connected to the motor and remove the motor from the machine only after making sure that the machine is on a level surface and there are no external forces acting on rotating parts, so that the machine does not operate uncontrollably when the motor is removed.

4. To prevent foreign matter from entering the lines and motor when removing the motor from the machine, sufficiently clean off mud and dirt adhered around the motor before removing lines connected to the motor.

5. When removing lines connected to the motor, hydraulic oil from inside the lines will spray out.

For this reason, remove these lines only after removing pressure from inside the lines and preparing an oil pan.

To prevent injuries due to the motor falling when transporting it by lifting the motor with a liftcrane, lift the machine with the eyebolts mounted in the positions indicated in the diagram below.

6. The motor is filled with hydraulic oil.

Before disassembling the motor, prepare an oil pan and drain the hydraulic oil from the motor.

*2 *1

*1

25zrvn-004

*1

Eyebolt

*2

Lifting

Tightening Torque Table 5 indicates tightening torque for each fastening section.

Referen ce number

Part name

Screw size

Bolt width

Tightening torque

1-2-2-4

Plug

M24 x 1.5

14 (0.551)

127 - 147 N・m (93.69 - 108.44 lbf・ft)

1-2-6-4

Hexagon socket head bolt

M12 x 1.75 x 40 (1.575) L

10 (0.394)

98 - 118 N・m (72.30 - 87.04 lbf・ft)

1-2-7

Relief valve assembly

1-5/16 12UNF

27 (1.063)

353 - 393 N・m (260.41 - 289.91 lbf・ft)

1-2-8

Plug

NPTF1/16

4 (0.157)

8.8 - 10.8 N・m (6.492 - 7.967 lbf・ft)

2-91

A. LOWER

A. LOWER

A. LOWER Referen ce number

Part name

Screw size

Bolt width

Tightening torque

1-2-11

Plug

G1/2

10 (0.394)

112 - 124 N・m (82.63 - 91.47 lbf・ft)

1-2-14

Plug

G1/2

10 (0.394)

112 - 124 N・m (82.63 - 91.47 lbf・ft)

1-2-17

Orifice

M5 x 0.8 x 5 (0.197) L

2.5 (0.0984)

1.96 - 2.94 N・m (1.4459 - 2.1688 lbf・ft)

1-2-18

Orifice

M5 x 0.8 x 5 (0.197) L

2.5 (0.0984)

1.96 - 2.94 N・m (1.4459 - 2.1688 lbf・ft)

1-2-19

Orifice

M5 x 0.8 x 5 (0.197) L

2.5 (0.0984)

1.96 - 2.94 N・m (1.45 - 2.16 lbf・ft)

1-2-20

Plug

G1/4

6 (0.236)

34.3 - 39.3 N・m (25.303 - 28.991 lbf・ft)

1-11

Hexagon socket head bolt

M14 x 2.0 x 35 (1.378) L

12 (0.472)

195 - 215 N・m (143.85 - 158.60 lbf・ft)

8

Bolt

M20 x 2.0 x 70 (2.756) L

Torx T90

512 - 566 N・m (377.70 - 417.53 lbf・ft)

14

Bolt

M20 x 2.0 x 130 (5.118) L

Torx T90

512 - 566 N・m (377.70 - 417.53 lbf・ft)

24

Screw

M10 x 1.5

Torx T50

53.9 - 63.7 N・m (39.762 - 46.990 lbf・ft)

28

Hexagon socket head bolt

M10 x 1.5 x 16 (0.630) L

8 (0.315)

69.77 - 77.03 N・m (51.4686 - 56.8241 lbf・ft)

29

Plug

G3/4

12 (0.472)

149 - 165 N・m (109.92 - 121.71 lbf・ft)

2-92

2. Removal of plunger assembly Lightly press the end of the plunger assembly (1-2-2) to partially eject the plunger assembly from the base plate (1-2-1).

Next, hold the end of the plunger assembly by hand and remove the plunger assembly from the base plate while rotating it.

Disassembly Procedure Perform disassembly by observing the precautions listed in Section 1 and following the procedure indicated below.

1. Removal of cap assembly Secure the motor on top of the stable work platform, loosen the 8 hexagon socket head bolts (1-2-6-4), and remove the 2 cap assemblies (1-2-6).

Next, remove the springs (1-2-4) and spring seats (1-2-3).

Caution

Caution

The cap assemblies are pushed out by the spring.

For this reason, observe the following precautions when working.

1.Loosen the hexagon socket head bolts evenly.

2.Loosen the hexagon socket head bolts while pressing down the cap assemblies.

39i7d4-043

The plunger assembly and base plate are fit together with a very small gap.

For this reason, observe the following precautions when working.

1.Do not try to force out the plunger assembly if it becomes stuck when being removed.

If it is forced out, this could scratch the inner diameter surface of the base plate hole or the outer diameter surface of the plunger assembly.

If the plunger assembly becomes stuck, lightly hit the end surface of it with a plastic hammer to insert it once into the base plate.

After this, check that the plunger assembly moves smoothly and remove it again while rotating it.

2.Do not perform disassembly of the plunger assembly if it is not necessary.

Disassembly can cause scratching on the outside diameter surface of the plunger assembly.

When disassembly is necessary, contact our company.

39i7d4-033

2-93

A. LOWER

A. LOWER

A. LOWER 3. Removal of relief valve assembly Loosen the plug (1-2-7-6) and remove the relief valve assembly (1-2-7).

At this time, each poppet seat (1-2-7-3) remains in the base plate (1-2-1).

Caution

The relief valve assemblies are at a set pressure.

The motor driving force and braking force are both determined by this set pressure.

For this reason, do not perform the following actions.

1.Loosen the nut (1-2-7-16) and do not tamper with the locking screw (1-2-7-15).

If this part is tampered with, the set pressure of the relief valve will change and the machine will no longer display prescribed capabilities.

2.Do not perform disassembly of the relief valve assemblies.

The set pressure will change and the machine will no longer display prescribed capabilities.

5. Removal of spool assembly Loosen the plugs (1-2-11) (1-2-14) and remove the plugs and spring (1-2-10).

Lightly press the end of the spool assembly (1-2-9) to partially eject the spool assembly from the base plate (1-2-1).

Next, hold the end of the spool assembly by hand and remove the spool assembly from the base plate while rotating it.

Caution

The spool assembly and base plate fit together with a very small gap.

For this reason, observe the following precautions when working.

1.Do not try to force out the spool assembly if it becomes stuck when being removed.

If it is forced out, it could scratch the inner diameter surface of the base plate hole or the outer diameter surface of the spool assembly.

If the spool assembly becomes stuck, lightly hit its end surface with a plastic hammer to insert it temporarily into the base plate.

After this, check that the spool assembly moves smoothly and remove it again while rotating it.

2.Do not disassemble the spool assembly unless it is necessary.

When disassembly is necessary, contact our company.

39i7d4-045

4. Poppet seat removal Use the poppet seat removal jig to remove each poppet seat (1-2-7-3) from the base plate (1-2-1).

Caution

Do not perform disassembly if it is not necessary.

39i7d4-047

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

Each orifice (1-2-22) (1-2-23) (1-2-19) is caulked to prevent loosening.

Do not perform disassembly.

39i7d4-046

2-94

A. LOWER 8. Removal of valve plate Use a flathead screwdriver to remove the valve plate (1-21) from the base plate (1-2-1).

Caution

When removing the base plate, observe the following precautions.

1.The base plate is pushed upwards by the springs (1-18).

For this reason, loosen the hexagon socket head bolts evenly when loosening.

2.Positioning pins (1-19) are mounted between the base plate and main unit.

For this reason, pull the base plate (1-2-1) straight off in alignment with the center axis of the motor when removing it so that it does not become stuck with the pins.

If it becomes stuck, lightly strike the base plate with a plastic hammer to put the pins in the correct position, and then remove the base plate.

3.When removing the base plate, the valve plate (1-21) is attached to the base plate.

The valve plate sliding surface is easily scratched, so be careful not to let the valve plate fall.

Caution

When removing the valve plate, observe the following precaution.

1.The valve plate sliding surface is easily scratched.

If the sliding surface is scratched, prescribed capabilities will disappear, so prevent scratching from occurring.

39i7d4-050

9. Removal of O-rings, pin and spring Remove the O-rings (1-22) (1-23), pin (1-19), and spring (1-18).

39i7d4-048 39i7d4-051

39i7d4-049

2-95

A. LOWER

7. Removal of base plate Loosen the hexagon socket head bolts (1-11) and remove the base plate (1-2-1).

A. LOWER 11. Removal of cylinder block assembly Remove the cylinder block assembly (1-4) from the flange (1-1).

10. Removal of brake piston Attach a pressured air nozzle to the flange (1-1) oil path for the parking brake, and inject compressed air to the parking brake cylinder chamber to raise the brake piston (1-15) and remove it.

After removing the brake piston, remove the disk plates (1-13) and friction plates (1-14), and remove the D-rings (1-16) (1-17) from the brake piston.

Caution

When removing the cylinder block assembly, observe the following precautions.

1.Hold the cylinder block assembly with both hands and lightly rotate it left and right to slowly remove it.

2.Be careful not to scratch the surface of the cylinder block (1-4-1) that slides against the valve plate (1-21).

If this surface is scratched, the machine will no longer display prescribed capabilities.

3.Be careful not to scratch the piston assembly (1-4-2) shoe sliding surfaces.

If this surface is scratched, the machine will no longer display prescribed capabilities.

39i7d4-052

Caution

When removing the brake piston, observe the following precautions.

1.When injecting compressed air from the flange oil path for the parking brake, do not let any compressed air leak out.

2.When injecting compressed air from the flange oil path for the parking brake, the brake piston may fly off if the pressure of the compressed air is high, and this may cause injury.

For this reason, set the air pressure at 0.29 MPa ( 42.07 psi ) or below, and hold down the brake piston while performing work so that it does not fly off.

39i7d4-054

12. Disassembly of cylinder block assembly [1] Mark the piston assemblies (1-4-2) and cylinder block (1-4-1) with permanent ink so that parts can be reassembled in the exact same configuration, and remove the piston assemblies and retainer plate (1-4-3) from the cylinder block.

39i7d4-053 39i7d4-055

2-96

[2] Mark the piston assemblies (1-4-2) and retainer plate (1-4-3) with permanent ink so that parts can be reassembled in the exact same configuration, and remove the piston assemblies from the retainer plate.

[4] Secure the cylinder block (1-4-1) on the manual press platform with the sliding surface facing up, remove the snap ring (1-4-5), press the collar (1-4-8) with the jig to make the spring (1-4-7) bend, and use snap ring pliers to remove the snap ring.

Caution

When removing the snap ring, observe the following precaution to prevent injuries.

1.The snap ring is stiff and may come off from the snap ring pliers when the snap ring is being removed, which could cause injury.

When removing the snap ring, make sure to use a disassembly jig and check that the nails of the snap ring pliers are in the snap ring hole before removal.

39i7d4-056

[3] Remove the retainer holder (1-4-4) from the cylinder block (1-4-1) and remove the pins (1-4-9) from the cylinder block.

39i7d4-058

[5] Remove the collar (1-4-8), spring (1-4-7), and spring seat (1-4-6) from the cylinder block (1-4-1).

39i7d4-057

39i7d4-059

2-97

A. LOWER

A. LOWER

A. LOWER 13. Removal of swash plate Remove the swash plate (1-5) from the flange (1-1).

15. Removal of shaft Remove the shaft (1-3) and ball bearing (1-8) from the flange (1-1).

Caution

Caution

When removing the swash plate, observe the following precautions.

1.Be careful not to scratch the swash plate sliding surface.

If this surface is scratched, the machine will no longer display prescribed capabilities.

2.Piston assemblies (1-7) and steel balls (1-6) may be attached to the swash plate.

When these are attached, be careful not to let them fall.

When removing the shaft, observe the following precautions.

1.Be careful not to scratch the splines on the shaft.

2.Be careful not to scratch the sliding section of the shaft oil seal (1-12).

Scratching this surface may cause oil leaking.

39i7d4-062

14. Removal of piston assembly and steel ball Remove the piston assemblies (1-7) from the flange (1-1) and remove the springs (1-20).

Remove the steel balls (1-6) from the flange.

16. Draining reduction gear lubricating oil Before disassembling the reduction gear section, use the tap for securing the flange (1-1) and mount two eyebolts in opposing positions to lift the reduction gear with a liftcrane.

Remove the plugs (29) in the 2 locations and drain the reduction gear lubricating oil.

Caution

Caution

39i7d4-060

The steel balls are difficult to remove, so use the following procedure to do this.

1.With the steel balls mounted on the flange, use white kerosene or thinner to degrease.

2.Use a magnet to remove the steel balls from the flange.

1.Prepare an oil pan before performing work.

2.Do not lift to too high position when lifting with the liftcrane. Perform work with the reduction gear at the lowest possible position (at about knee height).

39i7d4-063 39i7d4-061

2-98

A. LOWER 19. Removal of drive gear Remove the driver gear (25).

A. LOWER

17. Removal of cover Loosen and remove the hexagon socket head bolts (28).

After this, remove the cover (27).

Caution

Use the following procedure when removing the cover.

1.Liquid packing has been applied between the cover and housing (4).

For this reason, it is difficult to remove the cover.

Loosen the socket head bolt and strike the top and side of the cover with a plastic hammer after removing the bolt.

2.Insert a flathead screwdriver in the gap between the cover and housing and remove the cover.

39i7d4-066

20. Removal of 1st stage holder assembly Remove the 1st stage holder assembly comprising the holder B (17), planetary gears B (21), needle bearings (20), inner races (19), thrust plates (18), thrust plates (22), thrust plate (23), and screws (24).

Caution

When removing the 1st stage holder assembly, observe the following precaution.

When removing the assembly, be careful of fingers getting caught.

39i7d4-064

18. Removal of thrust plate Remove the thrust plate (26) from the thrust plate (23) top surface.

39i7d4-067

39i7d4-065

2-99

A. LOWER 21. Disassembly of 1st stage holder assembly Secure the 1st stage holder assembly with a vise and warm the screws (24) with a dryer to loosen them.

Remove the screws, thrust plate (23), thrust plates (22), planetary gears B (21), needle bearings (20), inner races (19) and thrust plates (18) from holder B (17), in that order.

23. Removal of planetary gear C Secure the flange (1-1) and loosen the bolts (14) to remove them.

Next, remove the thrust plates (13), planetary gears C (12), needle bearings (11), inner races (10), and thrust plates (9), in that order.

Caution

When loosening bolts, observe the following precautions.

1.Loctite has been applied to the bolts to prevent loosening.

For this reason, securely fix the flanges.

2.When loosening bolts, use a tool such as a steel pipe to reach the bolts.

Straining excessively may cause back pain or injury.

Caution

When loosening the screws, observe the following precautions.

Loctite has been applied to the screws.

For this reason, they do not loosen easily.

If they are scratched due to being forcibly loosened, they cannot be used again.

Before loosening, warm the screws sufficiently with a dryer.

39i7d4-070 39i7d4-068

24. Disassembly of holder C Secure the flange (1-1) and loosen and remove the bolts (8).

22. Removal of sun gear C Remove sun gear C (15).

39i7d4-069

2-100

Holder C (6) is secured to the flange with the pins (31).

Mount the removal jig from the motor side and use the press to remove holder C. Caution

25. Separation of flange and housing Mount the jig on the outer circumference brim end surface of the housing (4), and then press the flange (1-1) with the press to separate the housing and flange.

When loosening bolts, observe the following precautions.

1.Loctite has been applied to the bolts to prevent loosening.

For this reason, securely fix the flanges.

2.When loosening bolts, use a tool such as a steel pipe to reach the bolts.

Straining excessively may cause back pain or injury.

39i7d4-072

26. Removal of floating seal Raise the outer circumference of the floating seals (2) with a flathead screwdriver and remove the floating seals.

39i7d4-071

39i7d4-073

27. Parts storage This completes the disassembly.

When storing disassembled parts, place parts in plastic bags in a cool, dark and dry location after cleaning the parts and applying anti-rust oil.

If parts are stored in a hot, moist location, rust will develop even if anti-rust oil is applied.

Also store them in a way so that dust does not collect on them.

39i7d4-029

Maintenance Standards Motor Parts Maintenance Standards

Table 6 indicates maintenance standards for motor parts.

2-101

A. LOWER

A. LOWER

A. LOWER Check each part according to the motor parts maintenance standards in Table 6. When a permissible limit has been exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures.

Applicable part

Inspection and measurement

Permissible limit value

location

0.8 a degree of roughness 1. Shoe sliding surface

Or the surface is rough or there is scratching at least 0.02 mm ( 0.00079 in ) deep.

2. Piston outer diameter

(#1000) If the scratching cannot be removed, replace the cylinder block assembly (1-4).

Or the surface is rough or there is scratching at least 0.02 mm ( 0.00079 in ) deep.

3. Piston outer diameters and

Replace the cylinder block assembly (1-4).

cylinder block (4-1) bore inner diameters

Gap 0.060 mm ( 0.002362 in )

4. Shoe ball backlash

0.4 mm ( 0.0157 in ) of backlash 0.8 a degree of roughness

Lap the sliding surface (#1000)

1. Sliding surface against the valve Or the surface is rough or there is

If the scratching cannot be

plate

scratching at least 0.02 mm ( 0.00079 in )

removed, replace the cylinder

deep.

block assembly (1-4).

1.6 a degree of roughness

Cylinder block (1-4-1)

Lap the shoe sliding surface

1.2a degree of roughness

Piston Assembly (1-4-2)

Repair, solution procedure

2. Bore inner diameter

3. Bore inner diameter and piston assembly (4-2) outer diameter

Or the surface is rough or there is scratching at least 0.02 mm ( 0.00079 in )

Replace the cylinder block

deep.

assembly (1-4).

Gap 0.060 mm ( 0.002362 in ) Diameter between parts 38.749 mm ( 1.525551 in )

Cylinder block (1-4-1)

1. Shaft bonding section spline

Diameter of measurement pin

Replace the cylinder block

D3.333 ( 0.131220 in ) [ V1 = 2.80

assembly (1-4).

( 0.11024 in ) ] mm Or breaking damage is occurring.

0.8 a degree of roughness Valve plate (1-21)

Retainer plate (1-4-3) Retainer holder

1. Sliding surface

1. Sliding surface

There is scratching at least 0.02 mm ( 0.00079 in ) deep on the sliding surface.

Lap the sliding surface (#1000) If the scratching cannot be

Or seizing is occurring.

removed, replace the valve plate

There is abnormal wear on the sliding surface.

(1-21).

0.8 a degree of roughness There is scratching at least 0.02 mm

Replace the retainer plate and

( 0.00079 in ) deep on the sliding surface.

retainer holder.

Or seizing is occurring.

(1-4-4)

0.8 a degree of roughness 1. Sliding surface

0.02 mm ( 0.00079 in ) deep on the sliding removed, replace the valve plate surface.

(1-21).

1.6 a degree of roughness

Swash plate (1-5)

Lap the sliding surface (#1000)

There is abnormal wear or scratching least If the scratching cannot be

2. Steel ball mounting section

There is scratching at least 0.02 mm

spherical hole

( 0.00079 in ) deep on the ball surface or the surface is rough.

3. Steel ball mounting section spherical hole

Ball depth 14.5 mm ( 0.5709 in )

2-102

Replace the swash plate.

A. LOWER Applicable part

Inspection and measurement

Permissible limit value

location

Repair, solution procedure

Aside from the oil seal lip sliding imprint,

diameter

there is scratching at least 0.02 mm

A. LOWER

1.6 a degree of roughness 1. Oil seal sliding section outer

( 0.00079 in ) deep or the surface is rough.

Over-pin diameter Shaft (1-3)

2. Cylinder block bonding section spline

47.380 mm ( 1.865354 in ) Diameter of measurement pin D3.00 mm ( 0.11811 in )

Replace the shaft.

Or breaking damage is occurring.

Diameter between parts 3. Drive gear bonding section spline

30.498 mm ( 1.200709 in ) Diameter of measurement pin D3.33 mm ( 0.13110 in ) Or breaking damage is occurring.

Brake piston

1. Exterior dimensions

Height 38.2 mm n( 1.5039 in )

2. Sliding surface

2.5 a degree of roughness There is scratching at least 0.02 mm

(1-15) 3. Exterior

Replace the brake piston.

( 0.00079 in ) deep. Or the surface is rough.

Disk plate

1. Exterior dimensions

(1-139)

2. Exterior

Ball bearing

1. Rotation surface

(1-8) Ball bearing

2. Operation

(1-9)

Thickness 3.2 mm ( 0.1260 in ) There is deep scratching or friction material is peeling off.

Flaking or pressure imprinting is occurring.

There are rotation abnormalities (abnormal Replace the ball bearing. noises, rotation unevenness).

1.6 a degree of roughness

1. Shoe sliding surface

Or the surface is rough or there is scratching at least 0.02 mm ( 0.00079 in ) deep.

Piston Assembly (1-7)

Replace the disk plate.

Lap the shoe sliding surface (#1000) If the scratching cannot be removed, replace using the flange holder kit.

1.2 a degree of roughness 2. Piston outer diameter

Or the surface is rough or there is scratching at least 0.02 mm ( 0.00079 in ) deep.

3. Piston outer diameters and flange holder (1-1) inner diameters 4. Shoe ball backlash

Replace using the flange holder kit.

Gap 0.040 mm ( 0.001575 in ) 1.0 mm ( 0.0394 in ) of backlash 0.8 a degree of roughness

Plunger assembly

1. Plunger outer diameter

2. Plunger outer diameter and base plate inner diameter 1. Plunger assembly (2-2) (1-2-1)

( 0.00079 in ) deep. Or the surface is rough.

(1-2-2)

Base plate

There is scratching at least 0.02 mm

mounting hole 2. Base plate inner diameter and plunger outer diameter

Replace using the base plate kit.

Gap 0.060 mm ( 0.002362 in ) 0.8 a degree of roughness There is scratching at least 0.02 mm deep.

Or the surface is rough.

Gap 0.060mm ( 0.002362 in )

2-103

Replace using the base plate kit.

A. LOWER Applicable part

Inspection and measurement

Permissible limit value

location

Repair, solution procedure

0.8 a degree of roughness 3. Spool assembly (2-11) mounting There is scratching at least 0.02 mm hole

( 0.00079 in ) deep. Or the surface is rough.

Base plate (1-2-1)

4. Base plate inner diameter and spool outer diameter 5. Relief valve assembly free piston sliding and seat sections

Spool assembly

1. Spool outer diameter

Gap 0.060 mm ( 0.002362 in ) There is scratching at least 0.02 mm ( 0.00079 in ) deep. Or the surface is rough.

0.8 a degree of roughness There is scratching at least 0.02 mm ( 0.00079 in ) deep. Or the surface is rough.

(1-2-9) 2. Spool outer diameter and base plate inner diameter Free piston

1. Sliding section against the base

(1-2-7-9)

plate and seat section

Relief housing

1. Sliding section against the free

(1-2-7-1)

piston (outer diameter) 1. Exterior dimensions

Spring (1-4-7)

2. Exterior

Spring (1-18)

Spring (1-20)

( 0.00079 in ) deep. Or the surface is rough.

There is scratching at least 0.02 mm ( 0.00079 in ) deep. Or the surface is rough.

Free length 61.0 mm ( 2.4016 in ) There is deformation and scratching on the coil surface.

There is deformation and scratching on the Replace using the relief valve assembly. coil surface.

1. Exterior dimensions

Free length 41.5 mm ( 1.6339 in )

1. Exterior dimensions

(1-2-10)

There is scratching at least 0.02 mm

2. Exterior

2. Exterior

Spring

Gap 0.060 mm ( 0.002362 in )

Free length 39.0 mm ( 1.5354 in )

1. Exterior dimensions

(1-2-4)

Replace using the base plate kit.

1. Exterior dimensions

2. Exterior

Spring

Replace using the base plate kit.

2. Exterior

Each O-ring and oil seal

There is deformation and scratching on the coil surface.

Free length 48.5 mm ( 1.9094 in ) There is deformation and scratching on the coil surface.

Free length 28.3 mm ( 1.1142 in ) There is deformation and scratching on the coil surface.

During disassembly

Replace each O-ring and oil seal.

Reduction Gear Parts Maintenance Standards Table 7 indicates maintenance standards for reduction gear parts.

Check each part according to the reduction gear parts maintenance standards in Table 7. When a permissible limit has been exceeded or is near being exceeded, perform part repair or replacement according to repair and solution procedures.

Applicable part Planetary gear B (21)

Inspection and measurement location Tooth thickness

Permissible limit value Across 6 teeth 66.649 mm ( 2.623976 in )

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Repair, solution procedure Replace planetary gear B.

A. LOWER Inspection and measurement location

Permissible limit value

Repair, solution procedure

Tooth surface

There is pitching on 10 % or Replace planetary gear B. more of the tooth surface or breaking damage is occurring.

Inner diameter

Flaking is occurring on the inner diameter surface.

Needle bearing (20)

Roller rotation surfaces

Flaking is occurring on the surface.

Inner race (19)

Outer diameter surface

Flaking is occurring on the surface.

Tooth thickness

Across 3 teeth 29.908 mm ( 1.177480 in )

Tooth surface

Replace the drive gear.

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Spline section

Over-pin diameter 38.989 mm ( 1.535000 in ) If replacing the drive gear, Diameter of measurement pin inspect the shaft at the D3.00 mm ( 0.11811 in ) same time.

Or breaking damage is occurring.

Tooth thickness of internal tooth

Diameter between parts 66.742 mm ( 2.627637 in ) Diameter of measurement pin Replace holder B. D7.00 mm ( 0.27559 in ) Or breaking damage is occurring.

Tooth thickness

Across 4 teeth 41.371 mm ( 1.628779 in )

Tooth surface

Replace sun gear C. There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Tooth thickness

Across 6 teeth 65.662 mm ( 2.585118 in )

Tooth surface

Replace planetary gear C. There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

Inner diameter

Flaking is occurring on the inner diameter surface.

Needle bearing (11)

Roller rotation surfaces

Flaking is occurring on the surface.

Inner race (10)

Outer diameter surface

Flaking is occurring on the surface.

Planetary gear B (21)

Drive gear (25)

Holder B (17)

Sun gear C (I5)

Planetary gear C (12)

Tooth thickness Housing (4) Tooth surface Shim (5)

Replace the planetary gear, needle bearing and inner race.

Replace the planetary gear, needle bearing and inner race.

Diameter between parts 330.449 mm ( 13.009803 in ) Diameter of measurement pin D7.000 mm ( 0.275590 in ) Replace the housing.

There is pitching on 10 % or more of the tooth surface or breaking damage is occurring.

During disassembly

2-105

Replace the shim.

A. LOWER

Applicable part

A. LOWER Applicable part

Flange (1-1)

Thrust plate (26)

Angular bearing (3)

Inspection and measurement location

Permissible limit value

Repair, solution procedure

2-speed piston hole inner diameter and piston assembly outer diameter

Gap 0.040 mm ( 0.001574 in )

2-speed piston hole inner diameter

1.2 a degree of roughness Or the surface is rough or there is scratching at least 0.02 mm ( 0.00078 in ) deep.

Thickness

Plate thickness 3.3 mm ( 0.1299 in ) Plate thickness 2.5 mm ( 0.0984 in ) Plate thickness 2.9 mm ( 0.1141 in ) Replace the thrust plate.

Plate thickness 2.0 mm ( 0.0787 in ) Plate thickness 2.7 mm ( 0.1062 in ) Or there is deep scratching on the sliding surface.

Ball rotation surfaces

Flaking is occurring.

Operation

Abnormal noise or unsmooth rotation occurs with rotation.

Sliding surface

There is deep scratching that may cause oil leaking.

O-ring

Cracking is occurring on the surface.

Floating seal (2)

Each O-ring

During disassembly

Motor Assembly Procedures Precautions before Motor Assembly Begin motor assembly only after thoroughly reading the precautions below.

1. When performing assembly, always wear protective gear such as a helmet, goggles and safety shoes.

2. Use the specified tools when performing assembly.

3. To prevent injuries during disassembly, prepare a waist-high, stable work platform to perform work on.

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Replace using the flange kit.

Replace the angular bearing.

Replace the floating seal.

When doing more disassembly beyond this, because oil leaking may occur due to the seal ring slide imprints not matching up of reused seals when reassembly is done, replace these seals before reassembly.

Replace each O-ring.

4. The motor comprises high-precision parts.

For this reason, foreign matter adhering to parts can be damaging.

Motor assembly should be done in an inside space without dust, and mud and dirt should be prevented from adhering to parts.

5. The motor comprises high-precision parts.

For this reason, dents and scratching on part surfaces can be damaging.

Be very careful when handling parts during assembly and do not create any dents or scratching.

6. Be sure to repair any damage discovered during disassembly and prepare replacement parts before beginning assembly.

7. Remove metal fragments and foreign matters from all parts and check that there are no burrs or dents on parts before beginning assembly.

If there are burrs or dents, use a whetstone to remove them.

8. When performing assembly, apply clean hydraulic oil to each sliding and rotating sections before assembly.

9. Thoroughly degrease areas where Loctite and liquid packing is used and remove oil and water before assembly.

10. Replace all seal parts such as O-rings and backup rings with new parts.

11. Be careful not to damage O-rings and backup rings during assembly.

When assembling O-rings and backup rings, apply a small amount of grease for assembly.

12. It is recommended that petroleum jelly or grease be used to prevent parts from falling during assembly.

13. Tighten the bolts and other fastening sections to the specified tightening torque indicated in "Tightening Torque".

Tightening torque should be controlled with a torque wrench.

14. After assembly is complete, plug all ports leading into the motor to prevent dirt from entering.

Assembly Procedure Perform assembly by observing the precautions listed in Section 1 and following the procedure indicated below.

1. Assembly of reduction gear section [1] Attachment of floating seal to flange After confirming the items below concerning the floating seals (2), use the floating seal installation jig to attach the floating seals to the flange (1-1).

Confirmation items: a) Check that there is no dirt adhered to the floating seal mounting surfaces on the flange. b) Thoroughly degrease the floating seal mounting surfaces on the flange. c) Check that there is no dirt adhered to the O-ring surfaces on the floating seals. d) Thoroughly degrease the O-ring surfaces on the floating seals.

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A. LOWER

A. LOWER

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[2] Attachment of angular bearing to housing Use the press-fit jig or press to press fit the angular bearings (3) to the housing (4).

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[3] Attachment of floating seal to housing After confirming the items below concerning the floating seals (2), use the floating seal installation jig to attach the floating seals to the housing (4).

Confirmation items: a) Check that there is no dirt adhered to the floating seal mounting surface on the housing. b) Thoroughly degrease the floating seal mounting surface on the housing c) Check that there is no dirt adhered to the O-ring surfaces on the floating seals. d) Thoroughly degrease the O-ring surfaces on the floating seals.

A. LOWER b. Measure the H level dimensions at this time for the angular bearings inner ring end surfaces and flange (1-1) end surface. c. Measure the h level dimensions of holder C (6). d. Select a shim and install it so that the shim thickness is appropriate to the dimensions (H-h).

Caution zwndch-119

[4] Attachment of the housing to the flange After confirming the items below, use a liftcrane to attach the housing to the flange so that the floating seal (2) section of the flange (1-1) is aligned with the floating seal section of the housing (4).

Confirmation items: a) Check that there is no dirt adhered to the seal ring sliding surfaces of the floating seals. b) Apply reduction gear lubricating oil or hydraulic oil all around the seal ring sliding surfaces of the floating seals. c) When attaching the flange and housing, attach them after checking that the axis center is aligned.

1.Do not reuse shims.

2.Be sure to perform this procedure properly.

If precompression adjustment is not done properly, reduction gear damage could occur during operation.

3.Clean the measurement surfaces.

*1

*3 *2

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*1

Press load of 2.94 kN ( 661.0514 lbf )

*2

H dimensions

*3

h dimensions

[6] Holder attachment Secure the flange (1-1) and stand the pins (31) straight up on the flange in 4 locations.

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[5] Shim thickness selection Select the precompression adjustment shim (5) thickness according to the following procedure. a. Use the shim thickness adjustment jig to press the inner ring end sections of the angular bearings (3) with a load of 2.94 kN ( 661.0514 lbf ).

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A. LOWER Use grease to attach the shim selected in 5) to holder C (6), and press fit the shim while it is aligned with the pin holes on the holder.

Mount the washers (7) on the holder, apply Loctite to the threaded sections, and tighten the bolts (8) to the specified torque.

*2

A. LOWER

*1

Caution

1.Check that the pins (31) have not fallen.

2.The loosening stop spikes should be attached to the washers.

Put the spikes on the holder seating surface side to mount them.

3.Thoroughly clean the bolt threaded sections and apply Loctite after degreasing.

4.Also thoroughly clean the internal areas of the screw holes of the flange, and thoroughly degrease them.

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*

Be careful to attach the washers (7) in the correct direction.

Attach them in the direction shown in the diagram above.

*1

Holder side

*2

Bolt seating surface side

[7] Planetary gear attachment Attach the thrust plates (9) to planetary gear C (12).

Next, attach the needle bearings (11) to the planetary gears.

Finally, after attaching the inner races (10), join the flange trunnion sections (4 locations) with the internal diameter sections of the inner races to attach the planetary gears.

Caution

1.When attaching the thrust plates to the planetary gears, make sure the shear droop on the thrust plates created by the press is facing the 1-1 flange side.

2.When finally attaching the planetary gears to the flange, attach them so that the internal teeth of the housing (4) engage with the planetary gear teeth.

3.Be careful with the attachment directions of the planetary gears.

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A. LOWER

12

9

11

14

10

*1

*1

6

*2

13

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*1

Make the shear droop side face the holder C (6) side.

*2

Thrust plate (9) attachment direction

*1

[8] Thrust plate attachment Mount the thrust plates (13) on the planetary gears (12) in such a way that the chamfers of the bolt hole sections are the neck bottom section of the bolts (14).

After mounting, mount the bolts that have had Loctite applied to the threaded sections and tighten them to the specified torque.

Mount so that the C2 chamfer side is the seating surface side for the hexagon socket head bolts.

[9] Sun gear C attachment After checking that the snap ring (16) is mounted on sun gear C (15), mount sun gear C in the middle of the 4 planetary gears C (12).

Caution

Mount the sun gear C so that the teeth engage with the teeth of the planetary gears.

Caution

1.Be careful with the mounting direction of the thrust plates.

Mistakes could cause scratching on the bolt neck sections and this could result in damage.

2.Thoroughly clean the bolt threaded sections and apply Loctite after degreasing.

3.Also thoroughly clean the internal areas of the screw holes of the flange (1-1), and thoroughly degrease them.

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[10] Holder attachment Engage the internal teeth of holder B (17) with the teeth of sun gear C (15) and attach the holder to sun gear C.

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[11] Planetary gear attachment Attach the thrust plates (18) to planetary gear B (21).

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Next, attach the needle bearings (20) to the planetary gears.

Finally, after attaching the inner races (19), join the holder B (17) trunnion sections (3 locations) with the internal diameter sections of the inner races to attach the planetary gears to the holder.

Insert the screws (24) with Loctite applied in the threaded sections and tighten them to the specified torque.

Make the spline-side of the drive gear (25) face the motor section attachment side and attach the drive gear in the middle of the 3 planetary gears. Also engage the teeth of the planetary gears with the drive gear teeth.

Caution

1.When attaching the thrust plates to the planetary gears, make sure the shear droop on the thrust plates created by the press is facing the holder side.

2.When finally attaching the planetary gears to the holder, attach so that the internal teeth of the housing (4) engage with the planetary gear teeth.

3.Be careful with the attachment directions of the planetary gears.

Caution

1.Be careful with the attachment direction of the thrust plates.

2.Thoroughly clean and degrease the screw holes and threaded sections of holder B (17).

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12

13

*1 zwndch-132

11 21

18

20

10

19

6

*1

*2 zwndch-135

17 *1

*2

Make the shear droop side face the holder B (17) side.

*2

Thrust plate (18) attachment direction

Make the shear droop side face the planetary gear C (12) side.

*2

Thrust plate (13) attachment direction

[13] Thrust plate attachment Measure the level difference between the housing (4) end surface and the thrust plate (23) end surface with the thrust plate selection jig, and select and attach a thrust plate (26) according to the table below.

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*1

*1

[12] Drive gear attachment Attach the thrust plates (22) to planetary gear B (21), and attach the thrust plate (23).

Level difference dimensions [ mm ( in ) ] 1.20 - 0.67 ( 0.04724 - 0.02638 )

2-111

Appropriate thrust plate 20941-62306

A. LOWER

A. LOWER

A. LOWER Level difference dimensions [ mm ( in ) ]

Additionally, apply liquid packing to the centering location corners on the housing attachment surface-side of the cover, and align the housing screw holes and bolt openings on the cover to mount the cover on the housing.

Finally, mount the hexagon socket head bolts (28) and tighten them to the specified torque.

Appropriate thrust plate

0.66 - 0.04 ( 0.02598 - 0.00157 )

20941-62307

0.03 - (-0.16) ( 0.00118 - (-0.00629) )

20941-62308

(-0.17) - (-0.41) ( (-0.00668) - (-0.01613) )

20941-62309

(-0.42) - (-0.80) ( (-0.01653) - (-0.03149) )

B0841-23017

Caution

Align the center hole of the thrust plate with the protruding section of the drive gear (25) and attach.

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[15] Plug attachment Remove the O-rings (30) attached to the plugs (29), and replace them with new O-rings.

Next, attach plugs to the oil fill, oil drain and oil check ports (3 total) on the cover (27) and tighten them to the specified torque.

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*1

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*1

Measure the level difference

[14] Cover attachment Thoroughly clean off any foreign matter from the housing (4) end surface and cover (27) matching surface.

Next, thoroughly degrease the housing end surface and cover matching surface.

2-112

This completes assembly of the reduction gear parts.

Next is assembly of motor parts.

Perform assembly while referring to "[2] Assembly of motor section".

2. Assembly of motor section [1] Oil seal attachment Check whether the oil seal is mounted on the flange (1-1), and use an oil seal press-fit jig to press fit the oil seal (1-12) to the flange if it is not mounted already.

[2] Piston assembly attachment Attach the springs (1-20) to the flange (1-1) holes for attaching the piston assemblies (1-7).

Next, attach the piston assemblies to the flange.

Caution

Caution

1.Attach springs in the center of the hole when attaching.

2.When attaching the piston assemblies, have the cylinder sections facing down.

3.Before attaching the piston assemblies, apply hydraulic oil to the internal diameter surface of the flange mounting holes and the outer diameter of the piston assembly cylinder sections.

4.After attaching the piston assemblies, check that the piston assemblies move smoothly.

1.Press fit the oil seal after applying grease to the internal diameter surface of flange oil seal press-fit section and the oil seal outside diameter section.

2.Press fit the oil seal after applying grease to the lip section of the oil seal inner diameter.

3.When press fitting the oil seal, push it vertically with the press.

Slanting will cause damage to the oil seal outer diameter surface.

4.When press fitting the oil seal, be careful not to scratch the lip section of the oil seal internal diameter.

Scratching may cause oil leaking and reduction gear internal damage could occur during motor operation.

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[3] Steel ball attachment Attach steel balls (1-6) to the spherical hole sections of the flange (1-1).

Caution

Before attaching the steel balls, apply hydraulic oil to the inner diameter surface of the spherical holes of the flange.

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A. LOWER

A. LOWER

A. LOWER [4] Shaft attachment Use the bearing press-fit jig to press fit the ball bearing (1-8) to the shaft (1-3).

Next, attach the shaft to the center of the flange (1-1).

[5] Swash plate attachment Point the slanted surface of the swash plate (1-5) upwards and attach the swash plate to the flange (1-1).

Caution

Caution

1.Attach by matching the rear surface spherical holes of the swash plate with the steel balls (1-6).

2.Attach the swash plate after applying hydraulic oil to the surface of the steel balls.

3.After attaching the swash plate, check that it moves smoothly.

1.When attaching the ball bearing, attach it vertically.

2.After attaching the shaft, check that it rotates smoothly.

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[6] Assembly of cylinder block assembly a. Point the surface of the cylinder block (1-4-1) that slides against the valve plate (1-21) upwards and place the cylinder block on the work platform of the hand press.

Point the slanted surface of the spring seat (1-4-6) down and attach it to the cylinder block. Place both the spring (1-4-7) and collar (1-4-8) on top of spring seat with the collar on top.

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2-114

c. Point the surface of the cylinder block (1-4-1) that slides against the valve plate (1-21) down and place the cylinder block on the work platform.

Insert the 3 pins (1-4-9) into the diagonal holes of the cylinder block (1-4-1). *1

Caution

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*1

Cylinder block attachment direction

b. Use the jig to press the top surface of the collar (1-4-8) to attach the snap ring (1-4-5).

Caution

1.The snap ring is stiff and may come off from the snap ring pliers when the snap ring is being attached, which could cause injury.

Make sure to use a jig when attaching the snap ring, and check that the nails of the snap ring pliers are in the snap ring hole before attachment.

2.When retracting the snap ring is difficult, use the snap ring pliers that are one size bigger.

3.When pressing in the collar (1-4-8), make the centers of the cylinder block and press align with each other.

1.When placing the cylinder block on the work platform, check that there is no foreign matter on the work platform.

2.Be careful not to scratch the surface of the cylinder block that slides against the valve plate.

Scratching may cause a reduction in motor performance and early damage to the motor.

3.Apply grease to the pin holes before attaching the pins.

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d. Attach the retainer holder (1-4-4) to the cylinder block (1-4-1).

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A. LOWER

A. LOWER

A. LOWER [7] Cylinder block assembly attachment Place the valve plate (1-21) sliding surface side of the cylinder block assembly (1-4) upwards, engage the internal teeth splines of the retainer holder (1-4-4) and cylinder block (1-4-1) with the external teeth splines of the shaft (1-3), and attach the cylinder block assembly to the inside of the flange (1-1).

e. Place the side of the retainer plate (1-4-3) with a taper on the outer circumference down, and attach the 9 piston assemblies (1-4-2) to the retainer plate.

Caution

1.When performing attachment, check that the piston assemblies (1-4-2), retainer plate (1-4-3) and retainer holder do not come off from the cylinder block assembly.

2.Before performing attachment, apply hydraulic oil to the swash plate (1-5) surface and sliding surfaces of the piston assemblies.

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f. Attach the piston assemblies (1-4-2) to the cylinder block (1-4-1).

Caution

1.Apply hydraulic oil to the 9 cylinder block piston attachment holes before attaching the piston assemblies.

2.Apply hydraulic oil to the spherical surface of the retainer holder (1-4-4) before attaching it.

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[8] Disk plate attachment Engage the internal teeth of the disk plates (1-13) with the external teeth of the cylinder block (1-4-1) and attach the disk plates to the flange (1-1). zwndch-152

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Also, align the arc sections on the external circumference of the friction plates (1-14) with the notch sections of the flange and attach the friction plates to the flange.

Attach in this manner, attaching the disk plates before the friction plates.

Caution

[9] Brake piston attachment Attach the D-rings (1-16) (1-17) to the brake piston (1-15).

Next, place the large bore side of the brake piston upwards and attach it to the flange (1-1).

Caution

1.Thoroughly apply grease when attaching the D-rings.

2.Attach the brake piston after using a positioning jig to align the flange base plate (1-2-1) knock pin hole and brake piston knock pin hole so that they are arranged in a straight line.

3.When attaching the brake piston, apply grease to the outer circumference of the brake piston and inner diameter section of the flange.

4.Push and attach the brake piston evenly all around so that it does not become slanted.

If the brake piston is attached at a slant, this could cause operational problems or the Drings to break.

The disk plates are wet type disk.

Before attachment, immerse the friction material parts in hydraulic oil and have the friction materials thoroughly absorb the hydraulic oil.

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A. LOWER

A. LOWER

A. LOWER [10] Spring attachment Insert the springs (1-18) into the 8 spring mounting holes on the brake piston (1-15).

Attach the pins (1-19) to the base plate (1-2-1).

Place the valve plate (1-21) mounting surface of the base plate downwards and tighten it to the flange with the hexagon socket head bolts (1-11).

Caution

Caution: 1.Apply grease to the O-ring (1-23).

2.Do not apply grease to the O-rings (1-22).

3.Attach the pins with their tapered sections up.

4.Attach the base plate after applying hydraulic oil to the valve plate surface and cylinder block (1-4-1) surface.

5.Be careful that the valve plate does not fall because the valve plate mounting surface of the base plate is pointing down when the base plate is attached.

6.Check the mounting position of the O-rings on the flange and the position of the holes for the oil path on the base plate to attach the base plate.

7.Check the position of the knock pins mounted to the base plate, the spring (1-18) mounting holes on the base plate and the flange-side pin holes, and the spring positions, and then attach the base plate.

8.When tightening the socket head bolts, screw in all of the bolts around the circumference evenly.

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[11] Valve plate attachment Place the base plate (1-2-1) on top of the work platform and press fit the ball bearing (1-9) in the center of the base plate using the bearing press-fit jig.

Attach the valve plate (1-21) to the base plate after checking that the pins (1-19) are mounted to the base plate.

Caution

1.Place the copper alloy side of the valve plate up to attach it.

2.Thoroughly apply grease to the matching surface between the base plate and valve plate to prevent the valve plate from falling.

3.Be careful not to scratch the copper alloy surface of the valve plate.

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[13] Spool assembly attachment Attach the spring (1-2-10) to the spool assembly (1-2-9) and attach the assembly to the base plate (1-2-1).

[12] Base plate attachment Attach O-ring (1-23) and the 4 O-rings (1-22) to the top surface of the flange (1-1).

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After attaching the spool assembly, check that the O-rings (1-2-12) are mounted to the plug (1-2-11), attach the plug to the base plate, and tighten it to the specified torque.

Next, check that the O-rings (1-2-12) are mounted to the plug (1-2-14), attach the spring guide (1-2-13), and then attach the plug to the base plate and tighten it to the specified torque.

Caution

1.Attach the spool assembly to the base plate so that the base plate line port side is on the front and the spool assembly spring mounting side is on the right.

Attaching in the opposite direction may cause problems such as switching errors.

2.Attach the spool assembly after applying hydraulic oil to the outer circumference.

3.After attaching the spool assembly, check that it moves smoothly.

[14] Relief valve assembly attachment Attach the relief valve assemblies (1-2-7) to the base plate (1-2-1) and tighten to the specified torque after checking that poppet seat (1-2-7-3) is mounted on the end of each relief valve assemblies.

Caution

1.Replace the O-ring (1-2-7-7) with new one before attaching the relief valve assemblies.

2.Check that the O-ring (1-2-7-17) and backup rings (1-2-7-18) are mounted on the each poppet seat (1-2-7-3).

3.Apply grease to the O-rings and backup rings before attaching the relief valve assemblies.

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[15] Plunger assembly attachment Attach the base plate (1-2-1) to the plunger assembly (1-2-2).

Caution

1.Apply hydraulic oil to the plunger assembly outer circumference before attachment.

2.Attach the plunger assembly slowly and in a straight line while rotating it.

3.If the plunger assembly becomes stuck, do not force it too much and lightly strike it with a hammer.

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A. LOWER

A. LOWER

A. LOWER [16] Cap assembly attachment Attach the spring seats (1-2-3) and springs (1-2-4) to the plunger assembly (1-2-2) in that order.

Check that the O-ring (1-2-6-2) is mounted to the cap assembly (1-2-6), and then mount the spring seat (1-2-5) on the cap assembly and attach the cap assembly to the base plate (1-2-1).

Finally, tighten the hexagon socket head bolts (1-2-6-4) to the specified torque.

This completes assembly of the motor.

Motor Installation

Caution

1.Apply grease to the O-ring.

2.The cap assemblies are pushed by the springs.

Push the cap assemblies down by hand when tightening the socket head bolts.

3.When tightening the hexagon socket head bolts, evenly tighten the 4 bolts.

If the cap assemblies are tightened at a slant, this could cause damage O-rings and cause oil leaking.

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Inspection Before placing the motor in the hydraulic shovel, perform inspection for the following items. If there is a problem, perform the given procedure.

Solution for solving problem Inspection item before installation

When installing a new motor

When installing a motor stored after maintenance inspection

Contact our company's service plant concerning damage that occurred during Are there any damaged areas?

shipping.

Replace damaged parts.

Replace parts that have been damaged during storage.

Contact our company's service plant Are there any missing parts?

concerning parts lost during shipping.

Purchase parts that have been lost during storage.

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Purchase lost parts.

A. LOWER Solution for solving problem Inspection item before installation

When installing a new motor

When installing a motor stored after maintenance inspection

of the motor, contact our company's service Is there any looseness in the tightening sections of the bolts?

plant for instructions on tightening bolts to the

When there is looseness with bolts,

specified torque.

disassemble again and inspect the motor for

If there is bolt loosening on a stored motor,

rust on the inside.

contact our company's service plant as there is a chance that rust has formed internally.

When ports for lines are dirty, perform air Dirt around ports

When ports for lines are dirty, perform air

blowing with compressed air, or cleaning with blowing with compressed air, or cleaning with water vapor or high-pressure jet to remove dirt. water vapor or high-pressure jet to remove dirt.

When checking just after delivery When the plugs for each of the ports are loose, When the plugs for each of the ports are loose use after removing dirt adhered to the ports.

Are all of the port areas completely air-tight?

or there are no plugs on the ports, perform

When there are no plugs on the ports, contact disassembly for confirmation that dirt has not our company's service plant as dirt has entered the motor or there is no rust. probably entered the motor.

When checking after storage Contact our company's service plant as rust has probably formed inside the motor.

Is there any rust on the port sections or the

Contact our company's service plant after

installation sections on the machine?

confirming the presence of rust.

If there is light rusting, use the motor after removing the rust.

If rusting is severe, replace parts.

If oil leaking is discovered, there is probably a

Oil leaking from ports and connection surfaces

Contact our company's service plant if oil

problem with air-tightness and rust may have

leaking is discovered.

formed inside the motor, so perform disassembly again to check for rust.

Hydraulic Oil and Gear Oil Filling 1. Fill the inside of the piston motor case with hydraulic oil Before performing a driving check, fill the inside of the piston motor case with about 500 cc of hydraulic oil from the piston motor drain port to prevent problems at the start of driving in sliding sections of the piton motor.

When using a hand pump or a small-quantity electric pump for oil filling, make the internal case pressure of the piston motor 0.3 MPa ( 43.516 psi ) or less.

2. Reduction gear lubricating oil check Use the oil fill, oil drain and oil check ports for reduction gear lubricating oil shown in Diagram 8 to check that the reduction gear case contains the stipulated level of lubricating oil.

How to check the quantity of reduction gear lubricating oil in a new motor Remove the lubricating oil check port plug and check that lubricating oil flows out.

If lubricating oil seems to be flowing out, return the oil check port plug to its original position and tighten it to the specified torque.

If lubricating oil does not flow out even though the oil check port is open, open the oil fill port and fill with oil until reduction gear lubricating oil flows out from the oil check port.

After filling with oil, return the plugs for the oil fill port and oil check port and tighten them to the specified torque.

Caution

When motors are shipped from the plant they are filled with Nippon Oil Hypoid Gear Oil 90 lubricating oil to the stipulated volume [ 5.0 L ( 1.32 gal ) ].

2-121

A. LOWER

If there is looseness in bolts just after delivery

A. LOWER

*1

*2 *3

*1

mz8svb-003

Diagram 8. Oil fill, oil drain and oil check ports for reduction gear lubricating oil and stipulated oil volume

Initial Pre-conditioning Operation Slowly operate the machine and perform airbleeding for inside the motor circuit and inside the line according the Operator's Manual for the Machine Main Unit.

First, perform an operation check by repeating "C direction rotation and stopping and A direction rotation and stopping" a number of times at low-speed rotation.

At this time, remaining air inside the circuit may cause abnormal noises from the valves, etc.

The abnormal noises will stop as air is bled out while operation is done repeatedly at low speed.

If abnormal noises go away through repeated operation over a while, there is no problem with the motor and it can be used as is.

If operation is done repeatedly and abnormal noises do not stop, there is an abnormality within the motor and it should be replaced.

Check for the presence of oil leaking from the motor, line port sections, each line and each piece of equipment.

2-122

*1

Reduction gear lubricating oil fill port

*2

Reduction gear lubricating oil check port

*3

Lubricating oil level

When oil leaking has been confirmed, retighten the bolts and line joints at the location where the leak is occurring to the specified torque.

After checking is completed, raise the pressure and perform load operation, and check that no abnormal noises or vibrations, etc. are occurring in the motor.

Important

･ When tightening lines, etc. after confirming oil leaking, make sure to have operation of hydraulic devices stopped. ･ Make sure that the operating pressure on the motor is low when checking for oil leaking.

If the operating pressure is high and there is oil leaking, there is the danger of oil spraying out.

A. LOWER

See the troubleshooting section below to perform checking, countermeasures and to solve problems when any kind of problem occurs in the motor during operation.

1. Piston motor troubleshooting Trouble phenomenon

The motor does not rotate

Suggested cause

Countermeasure and solution

There is an operation problem in a piece of equipment other than the piston motor or reduction gear.

After investigating whether pressure is reaching the motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

If the cause is in the motor itself, there is dirt clogging an operation section or there is an operation problem.

Perform disassembly and clean and remove dirt from parts before reassembling the motor.

If parts are damaged due to dirt, replace the parts.

Motor inlet side pressure is low.

Operate the main relief valve of the circuit and raise the set pressure.

Perform disassembly and replace abnormally There is abnormal wear on the sliding sections worn parts. of the piston motor and pressure oil is After completely removing surface scratching, escaping. burrs, etc. and cleaning, perform reassembly.

Damage is occurring with the main parts of the Perform disassembly and replace damaged piston motor. parts.

In this instance, abnormal noise is coming from Perform reassembly after cleaning parts. the piston motor.

Motor rotation speed is insufficient

Motor rotation variation is high

Noise is high

The load on the piston motor is too large and the relief valve is operating.

Investigate the load conditions and adjust the load to an amount appropriate to the set pressure of the relief valve.

The cause resides in the hydraulic pump, pressure control valve, flow control valve, etc.

Required oil flow is not being supplied to the piston motor and rotation is insufficient.

After investigating whether the required flow is being supplied to the piston motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

Pressure oil is moving from the high-pressure side to the low-pressure side due to wear on the sliding sections of the piston motor (volume efficiency reduction) and speed is insufficient.

Perform disassembly, investigate the status of wear on the sliding sections of the piston motor, and perform repair or replacement according to the maintenance standards.

There is looseness in the piston motor base plate fastening bolts. Internal leaking is increased and speed is insufficient.

Retighten the base plate fastening bolts to the specified torque.

There is wear on the sliding sections of the piston motor and high-pressure oil is leaking and flowing out from the drain port, which is causing speed to greatly decrease and causing rotation variation.

Perform disassembly, check the status of wear on the sliding sections, and perform repair or replacement according to the maintenance standards.

When going down an incline, the double counter balance valve is causing hunting and rotation variation.

Perform disassembly, check the status of wear on the double counter balance valve, and perform repair or replacement according to the maintenance standards.

The shaft is touching driven parts due to problems with shaft core alignment, and this is Make the shaft core alignment accurate. producing noise.

2-123

A. LOWER

Troubleshooting

A. LOWER Trouble phenomenon Noise is high

Oil leak

Cavitation is causing abnormal noise, rotation variation and pressure variation.

Motor rotation stopped during operation

Suggested cause

Countermeasure and solution

There is wear or damage on the piston motor bearings or damage has occurred on springs, etc. and noise is being produced.

Perform disassembly and replace damaged parts such as bearings or springs.

Perform reassembly after cleaning parts.

There is looseness in bolts on matching surfaces, etc. and oil leaking is occurring.

Retighten the fastening bolts to the specified torque.

Oil leaking is occurring due to damage to oil seals, O-rings, packings, etc.

Perform disassembly and replace seals.

Check the hydraulic oil temperature.

When the temperature of the hydraulic oil is 80 °C ( 176.0 °F ) or higher during operation, recheck the cooler and reduce the temperature of the hydraulic oil to below 80 °C ( 176.0 °F ).

The amount of drain oil is high due to wear on the sliding sections of the piston motor and oil leaking is occurring due to damage to the oil seals.

Perform disassembly, check the status of wear on the sliding sections, and perform repair or replacement according to the maintenance standards.

Replace oil seals.

Perform reassembly after cleaning parts.

Drain pressure has increased due to clogging in the drain line or because the drain line is long and thin, and this has damaged the oil seals and oil leaking is occurring.

Perform disassembly and replace oil seals.

Perform drain line cleaning and remove foreign matter.

Recheck lines and minimize resistance in line paths.

The amount of hydraulic oil in the hydraulic tank has decreased and aeration is occurring due to tank taking in air.

Check the amount of hydraulic oil in the hydraulic tank and fill with hydraulic oil according to the instructions on the machine main unit.

Hydraulic oil within the motor lines and motor circuit is flowing out while hydraulic devices are turned off because the motor installation direction is inappropriate or the hydraulic tank position is inappropriate, and this is causing aeration to occur within the motor just after the motor is started.

Check the motor installation direction and correct it.

Check that the oil surface within the hydraulic tank is above the motor, and either modify it so that it is above the motor or set up a selfsupply circuit so that the insides of the motor circuit and lines are fully supplied with oil before driving.

When the motor is pumping, pressure on the motor inlet side becomes negative due to double counter balance valve operation problem, and cavitation occurs.

Perform disassembly and perform repair or replacement of the double counter balance valve according to the maintenance standards.

The load is too large and this caused the engine to stall.

Check the load conditions and change the load to an appropriate amount.

Seizing occurred in the sliding sections of the piston motor and the motor stopped rotating.

Investigate specifications values (especially flow amount and motor speed).

If the motor speed has exceeded the upper limit, lower the flow amount.

It is not possible to reuse the inside of the motor, so the motor should be replaced.

2. Parking brake troubleshooting Trouble phenomenon

Suggested cause

Countermeasure and solution

The motor rotates Parking brake torque has decreased due to if it is stopped with disk wear. external load 2-124

Perform disassembly and replace the parking brake disk.

Perform reassembly after cleaning parts.

A. LOWER

acting on the motor.

Motor drive force is not being produced.

Motor is heating up to an abnormal degree.

Suggested cause

Countermeasure and solution

Parking brake torque has decreased due to disk wear.

Perform disassembly and replace the parking brake disk.

Perform reassembly after cleaning parts.

The disk surface has been altered due to contact errors, etc., and the parking brake torque has decreased.

Perform disassembly and replace the disk.

Also, repair the surface of the disk companion parts and perform reassembly.

The springs are worn or damaged and the parking brake torque is reduced.

Perform disassembly and replace the spring.

Perform reassembly after cleaning parts.

The external load is too large and the parking brake capabilities are insufficient.

Check the external load and change the load to an appropriate amount.

O-rings are damaged and pressure oil is escaping, so the parking brake cannot be released.

Perform disassembly and replace the O-rings.

Perform reassembly after cleaning parts.

Foreign matter is clogging the orifice inside the parking brake release oil path and pressure oil is not reaching the parking brake cylinder chamber, which prevents the parking brake from being released.

Perform disassembly and remove foreign matter from the orifice.

Perform reassembly after cleaning parts.

Also, flush the inside of the line.

Drain pressure has increased due to clogging Clean the drain line. in the drain line or because the drain line is Also, recheck the line system and minimize long and thin, and the parking brake cannot be resistance in the line path. released.

3. Relief valve troubleshooting Trouble phenomenon

Suggested cause

Countermeasure and solution

There is foreign matter caught between the Perform disassembly and remove foreign poppet seat and poppet on the relief valve, matter. which is causing seating problems, and highPerform reassembly after cleaning parts. pressure oil is leaking to the low-pressure side.

The motor does not rotate or motor rotation is slow.

Replace the relief valve.

The relief valve spring is damaged and highDisassemble the motor and reassemble it after pressure oil is leaking to the low-pressure side. cleaning each part.

The relief valve spring is worn and the set pressure is decreased, which causes the relief Replace the relief valve. to operate at low pressure.

There is foreign matter caught in the seat section of the free piston and base plate of the Remove the relief valve and remove foreign matter. relief valve and the set pressure has decreased.

There is foreign matter clogging the orifice set Remove the relief valve and remove foreign in the poppet of the relief valve, and the set matter. pressure has decreased.

The motor does not stop or stopping is slow.

There is foreign matter caught between the poppet seat and poppet on the relief valve, which is causing seating problems, and the relief valve does not close.

Perform disassembly and remove foreign matter.

Perform reassembly after cleaning parts.

The relief valve spring is damaged and the relief does not close.

Replace the relief valve.

Disassemble the motor and reassemble it after cleaning each part.

2-125

A. LOWER

Trouble phenomenon

A. LOWER Trouble phenomenon

Suggested cause

Countermeasure and solution

The relief valve spring is worn and the set pressure has decreased, which has caused the Replace the relief valve. brake force to decrease.

The motor does not stop or stopping is slow.

There is foreign matter caught in the seat section of the free piston and base plate of the Remove the relief valve and remove foreign matter. relief valve, and the set pressure and brake force have decreased.

There is foreign matter clogging the orifice set Remove the relief valve and remove foreign in the poppet of the relief valve, and the set matter. pressure and brake force have decreased.

There is foreign matter caught in the sliding section of the poppet and the poppet is not Shock at stopping moving.

There is foreign matter caught in the free is high piston and the piston is not moving.

The relief set pressure is too high.

Replace the relief valve.

Remove the relief valve and reassemble after removing foreign matter.

Replace the relief valve.

4. Counter balance valve troubleshooting Trouble phenomenon

Suggested cause

Countermeasure and solution

After investigating whether pressure oil is reaching the motor inlet side, investigate the Pressure oil is not reaching the motor inlet and causes of problems and countermeasures for the plunger is not switching. each piece of equipment and perform inspection and repair.

The motor does not rotate or motor rotation is slow.

Measure the pressure of the return side inside the motor circuit, and check that the pressure Pressure is reaching the motor inlet, but has increased. foreign matter is clogging the orifice in the pilot After this, perform disassembly and remove oil path and the plunger is not switching. foreign matter.

Next, perform reassembly.

There is foreign matter caught in the plunger and it is not switching.

The motor does not stop or stopping is slow.

Perform disassembly and remove foreign matter.

Investigate the degree of damage according to the maintenance standards and reassemble the plunger if reusing is possible.

If scratching makes the plunger unusable, replace it using the base plate kit.

Perform disassembly and remove foreign matter.

There is foreign matter caught in the plunger, Investigate the degree of damage according to so the plunger does not return and brake force the maintenance standards and reassemble the plunger if reusing is possible. has decreased.

If it is unusable, replace it using the base plate kit.

There is damage to the plunger spring, so the plunger does not return and brake force has decreased.

Perform disassembly and replace the spring after removing foreign matter.

Foreign matter is clogging the orifice in the pilot oil path, and the plunger does not return or return is slow.

Perform disassembly and remove foreign matter.

Next, perform reassembly.

The plunger spring is not fit in place.

Fit the spring correctly in place.

2-126

A. LOWER

The motor does not stop or stopping is slow.

When an external load acts on the motor and pumping operation is done, rotation variation occurs.

When an external load acts on the motor and pumping operation is done, cavitation occurs and abnormal noise is created.

Suggested cause

Countermeasure and solution

The check valve is not fit in place.

Fit the check valve correctly in place.

The check valve spring is damaged.

Perform disassembly and replace the spring after removing foreign matter.

The check valve spring is not fit in place.

Fit the spring correctly in place.

There is foreign matter caught in the plunger and plunger movement is not smooth.

Perform disassembly and remove foreign matter. After this, clean the plunger and perform reassembly.

The diameter of the pilot oil path orifice is wrong.

Attach the correct orifice.

The pilot oil path orifice is not fit in place.

Attach the orifice in the correct position.

There is foreign matter caught in the plunger, plunger movement is poor, and counter balance functions are not fulfilled.

Perform disassembly and remove foreign matter.

Investigate the degree of damage according to the maintenance standards and reassemble the plunger if reusing is possible.

If reusing is impossible, perform replacement with the base plate kit.

There is damage to the plunger spring and counter balance functions are not fulfilled.

Perform disassembly and replace the spring and perform reassembly after removing foreign matter.

The plunger spring is not fit correctly in place Fit the spring correctly in place. and counter balance functions are not fulfilled.

There is damage to the check valve spring and Perform disassembly and replace the spring counter balance functions are not fulfilled. after removing foreign matter.

The check valve spring is not fit in place and counter balance functions are not fulfilled.

Fit the spring correctly in place.

Foreign matter is clogging the orifice in the pilot oil path, and counter balance functions are not fulfilled.

Perform disassembly and reassemble after removing foreign matter.

5. 2-speed control function section troubleshooting Trouble phenomenon

Will not switch to high-speed rotation

Suggested cause

Countermeasure and solution

Pilot pressure oil is not reaching the Ps port.

After investigating whether pilot pressure oil is reaching the Ps port, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

There is foreign matter caught between the spool and base plate, and the spool does not switch.

After performing disassembly and removing foreign matter, investigate the degree of damage according to the maintenance standards and perform reassembly if reusing is possible.

If reusing is impossible, perform replacement with the base plate kit.

There is abnormal wear in the 2-speed control Perform disassembly and replace using the piston section, and pressure oil is leaking into flange holder kit. the case.

The 2-speed control piston is not fit in place.

2-127

Attach the 2-speed piston in the correct position.

A. LOWER

Trouble phenomenon

A. LOWER Trouble phenomenon Will not switch to high-speed rotation

Suggested cause

Countermeasure and solution

Foreign matter is clogging the orifice in the 2Perform disassembly and reassemble after speed oil path, and pressure oil is not reaching removing foreign matter. the 2-speed control piston.

Switching to highspeed rotation occurs, but switching to low- There is abnormal wear in the 2-speed control Perform disassembly and replace using the piston section, and pressure oil is leaking into speed rotation flange holder kit. the case. occurs if the hydraulic oil temperature increases.

Even if the speed control switch is set to low speed, the Ps port pressure does not decrease.

Investigate whether the Ps port pressure is 0.5 MPa ( 72.5 psi ) or lower and recheck the line system.

The 2-speed control valve spring is damaged.

Perform disassembly and replace the spring after removing foreign matter.

The 2-speed control valve spring is not fit in place.

Attach the spring in the correct position.

Not switching to There is foreign matter caught between the low-speed rotation spool and base plate, and the spool does not return.

Switching to lowspeed rotation occurs, but switching to highspeed rotation occurs during operation.

After performing disassembly and removing foreign matter, investigate the degree of damage according to the maintenance standards.

Perform reassembly if reusing is possible.

If reusing is impossible, perform replacement with the base plate kit.

Foreign matter is clogging the orifice in the 2speed oil path, and pressure cannot escape from inside the 2-speed control piston chamber.

Perform disassembly and reassemble after removing foreign matter.

The 2-speed control valve spring is worn and the switching pressure is reduced.

Perform disassembly and replace the spring.

Foreign matter is clogging the pilot line, and the pilot pressure increases up to switchover pressure due to leaking from the 2-speed control valve.

Clean the inside of the line and remove foreign matter.

Also, recheck the line system.

6. Reduction gear troubleshooting Trouble phenomenon

Suggested cause

Countermeasure and solution

There is an operation problem in a piece of equipment other than the piston motor or reduction gear.

After investigating whether pressure is reaching the motor inlet side, investigate the causes of problems and countermeasures for each piece of equipment and perform inspection and repair.

There is an operation problem in the motor aside from the reduction gear.

See [1] - [5] in troubleshooting.

A load exceeding the motor output torque is operating.

After investigating the load, remove the load acting on the motor.

No rotation

2-128

A. LOWER Suggested cause

Countermeasure and solution

The reduction gear angular bearing is damaged and will not rotate.

No rotation

Replace the reduction gear.

Investigate whether an excessive external load is acting on the motor.

If the external load is excessive, remove this load.

The gear inside the reduction gear is damaged and it does not rotate.

The bearing inside the reduction gear is damaged and it does not rotate.

Replace the reduction gear.

The spline inside the reduction gear is damaged and it does not rotate.

The gear inside the reduction gear is damaged.

The bearing inside the reduction gear is damaged.

Abnormal noise is coming from the reduction gear There is wear on the sliding section of the during driving. reduction gear and interference between parts is occurring.

The reduction gear section is heating up to an abnormal degree.

Replace the reduction gear.

Perform disassembly and check the status of damage.

If damage is discovered, replace the reduction gear.

In there are no parts that are especially damaged, replace worn parts and reassemble after cleaning.

Reduction gear lubricating oil is insufficient.

Check that there are no locations from which oil is leaking.

Perform disassembly and check the status of damage within the reduction gear.

If damage is discovered, replace the reduction gear. Fill with lubricating oil to the specified volume.

There is too much reduction gear lubricating oil.

Adjust the lubricating oil amount to the specified volume.

The bearing inside the reduction gear is damaged.

Replace the reduction gear.

Perform disassembly and check the status of internal damage.

If damage is discovered, replace the reduction An abnormal thrust load is occurring in the reduction gear due to inappropriate thrust plate gear.

If no especially notable amount of damage is selection. discovered, replace the thrust plate with another one of the correct thickness.

There is looseness in fastening bolts on the reduction gear cover, and oil leaking is occurring.

Oil leaking is occurring

Remove the cover, reapply liquid packing, and tighten the cover to the specified torque.

Fill with lubricating oil to the specified volume.

Plugs for the oil fill, oil drain and oil check ports Retighten the plugs to the specified torque. on the reduction gear cover are loose, and oil After tightening, fill with lubricating oil to the stipulated volume. leaking is occurring.

O-rings for oil fill, oil drain and oil check ports on the reduction gear cover are deteriorating, and oil leaking is occurring.

2-129

Replace the O-rings for the plugs.

After replacement, tighten the plugs to the specified torque and fill with lubricating oil to the stipulated volume.

A. LOWER

Trouble phenomenon

A. LOWER Trouble phenomenon

Suggested cause

Countermeasure and solution

There is cracking in the housing and oil leaking Replace the reduction gear. is occurring.

Oil leaking is occurring

There is foreign matter caught on the sliding surface of the floating seal and oil leaking is occurring.

Disassemble the reduction gear, remove foreign matter from the floating seal and perform reassembly.

Oil leaking is occurring due to corrosion on the sliding surface of the floating seal.

The O-ring of the floating seal is deteriorated or damaged and oil leaking is occurring.

The seal collar of the floating seal is split and oil leaking is occurring.

2-130

Disassemble the reduction gear and replace the floating seal.

-24

uwsfm5-009

2-131

A

1-18

-5

1-2

-6

-4

1-10

-3

-7

-2

-4

-3

-2

-12

-19

-5

-14

-13

1-27

1-26

1-19

-10 -8

1-2

1-28

-8

-1 -19

1-24

-8

1-2

-1

-2

-2

-18

1-25

-3

-17

-2

-3

-5

-4

-4

-2

-18 -3

1-11

-21 -20

-6

-1

-1

-9

-9

-5

-24

-7

-11

1-2

-16 -15

A. LOWER

-6

-5 -13 -14 -7

-11 -4

-11 -10

-12

1-2

A. LOWER

Structural Diagram

1-6

1-20

-5

1-7

-2

1-1

-3

1-12

-4

-9

1-8

-1

1-4

1-3

1-13

1-14

-6

1-13

-7

1-14

-8

1-13

-5

1-21

1-17

1-16

1-9

1-15

1-22

1-23

A

A. LOWER

uwsfm5-004

2-132

28

29

27

uwsfm5-005

2-133

14

30

26

13

24

23

12

22

11

21

10

20

9

19

8

6

18

7

17

5

25

3

16

4

3

15

2

31

1

A. LOWER

A. LOWER

A. LOWER Internal Structure Diagram -1

Z2

Z2

-2

Z3

Z3

1-2-9

1-2 -12

-9 -7

-11

-10

-12

-13

-14

-7

X1

X1

-4

-5 -24

-6 -5

1-26

-3 -4

-1

-3 -19

-2 -2 1-2 1-24

Z4

Z4

-8

1-2

Z4

gq1ebq-003

2-134

1-25

Z4

A. LOWER 1-2

1-2 -8

-8

Z2 Z2

Z3 Z3

1-4 -9 -5

-8

A. LOWER

-8

1-20

-3

-2

-1

5

-4

4

8

16

7

1-7

6

17

1-19

1-11

19

29

-7

22

-6

23

1-10

1-28

24

1-21

20 21 25

-20 1-2

26

-21 -20 -1

15

1-9 1-27

27

1-18

29

1-15 1-23

16 1-13

1-19

1-17 1-16

1-22

1-14

1-5 1-3

1-1

2 1-6

9

3

1-8 1-12

14

10

31

11

12

13

X1 X1 -1 -3

-5 -4

-2

-9

-16 -6 -15 -13

-18

-18 gq1ebq-004

2-135

-14

-11

-17

-11 -10

-7 1-2-7

30

A. LOWER Part Table Code

Part name

Q'ty

Code

1

Piston motor

1

1-2-13

1-1

Flange

1

1-2

Base plate assembly

1

Part name

Q'ty

Code

Part name

Q'ty

Spring guide

1

1-27

Plug

1

1-2-14

Plug

1

1-28

Plug

1

1-2-19

Orifice

2

2

Floating seal

2

1-2-1

Base plate

1

1-2-20

Plug

5

3

Angular bearing

2

1-2-2

Plunger assembly

1

1-2-21

O-ring

5

4

Housing

1

1-2-2-1

Spool

1

1-2-22

Orifice

3

5*

Shim t = 0.05

1

1-2-2-2

Check valve

2

1-2-23

Orifice

1

5*

Shim t = 0.1

1

1-2-2-3

Spring

2

1-3

Shaft

1

5*

Shim t = 0.3

1 1

1-2-2-4

Plug

2

1-4

Cylinder block assembly

1

5*

Shim t = 0.5

1-2-2-5

O-ring

2

1-4-1

Cylinder block

1

5*

Shim t = 1.0

1

1-2-3

Spring seat

2

1-4-2

Piston Assembly

9

6

Holder C

1

1-2-4

Spring

2

1-4-3

Retainer plate

1

7

Washer

8

1-2-6

Cap assembly

2

1-4-4

Retainer holder

1

8

Bolt

8

1-2-6-1

Cap

1

1-4-5

Snap ring

1

9

Thrust plate

4

1-2-6-2

O-ring

1

1-4-6

Spring seat

1

10

Inner race

4

1-2-6-4

Hexagon socket head bolt 4

1-4-7

Spring

1

11

Needle bearing

4

1-2-7

Relief valve assembly

2

1-4-8

Collar

1

12

Planetary gear C

4

1-2-7-1

Relief housing

1

1-4-9

Pin

3

13

Thrust plate

4

1-2-7-2

Poppet

1

1-5

Swash plate

1

14

Bolt

4

1-2-7-3

Poppet seat

1

1-6

Steel ball

2

15

Sun gear C

1

1-2-7-4

Spring seat

1

1-7

Piston Assembly

2

16

Snap ring

1

1-2-7-5

Spring

1

1-8

Ball bearing

1

17

Holder B

1

1-2-7-6

Plug

1

1-9

Ball bearing

1

18

Thrust plate

3

1-2-7-7

O-ring

1

1-10

Pin

1

19

Inner race

3

1-2-7-9

Free piston

1

1-11

Hexagon socket head bolt 10

20

Needle bearing

3

1-2-7-10

O-ring

1

1-12

Oil seal

1

21

Planetary gear B

3

1-2-7-11

Backup ring

2

1-13

Disk plate

3

22

Thrust plate

3

1-2-7-13

Spring guide

1

1-14

Friction plate

2

23

Thrust plate

1

1-2-7-14

O-ring

1

1-15

Brake piston

1

24

Screw

3

1-2-7-15

Locking screw

1

1-16

D-ring

1

25

Drive gear

1

1-2-7-16

Nut

1

1-17

D-ring

1

26 *

Thrust plate t = 3.6

1

1-2-7-17

O-ring

1

1-18

Spring

8

26 *

Thrust plate t = 2.3

1

1-2-7-18

Backup ring

2

1-19

Pin

4

26 *

Thrust plate t = 2.8

1

1-2-8

Plug

8

1-20

Spring

2

26 *

Thrust plate t = 3.0

1

1-2-9

Spool assembly

1

1-21

Valve plate

1

26 *

Thrust plate t = 3.2

1

1-2-9-1

Spool A

1

1-22

O-ring

4

27

Cover

1

1-2-9-2

Spool C

1

1-23

O-ring

1

28

Hexagon socket head bolt 16

1-2-10

Spring

1

1-24

Nameplate

1

29

Plug

1-2-11

Plug

1

1-25

Rivet

2

30

O-ring

3

1-2-12

O-ring

2

1-26

Plug

2

31

Pin

4

* 1 is selected and used.

2-136

3

A. LOWER Maintenance Standards

A. LOWER

Drive Sprocket

p

c

b

d

a

hpyedr-001

* See the gauge list for measurement gauges.

Part name

Code

Measurement dimensions [mm (in)]

a

Drive sprocket

Standard value [mm (in)]

Usage limits [mm (in)]

Judgment

66 (2.598)

56 (2.205)

Acceptable/ Unacceptable

Solution

b

D

D585.5 (23.0512)

D575.5 (22.6575)

Acceptable/ Unacceptable

c

D

D659 (25.945)

D649 (25.551)

Acceptable/ Cladding by welding Unacceptable or replacement

d

D

D644.6 (25.3780) -

Acceptable/ Unacceptable

190 (7.480)

Acceptable/ Unacceptable

p

-

2-137

A. LOWER

b

Take-up Roller

a

c

f

d

e

qbvjy4-001

* See the gauge list for measurement gauges.

Part name

Code

Standard value [mm (in)]

Usage limits [mm (in)]

Judgment

Solution

D494 (19.449)

D488 (19.213)

Acceptable/ Unacceptable

b

19 (0.748)

-

Acceptable/ Cladding by welding Unacceptable or replacement

c

84 (3.307)

80 (3.150)

Acceptable/ Unacceptable

a Take-up roller

Measurement dimensions [mm (in)] D

Shaft

d

D

D65 (2.559)

D64 (2.520)

Acceptable/ Replacement Unacceptable

Bushing

d

D

D65 (2.559)

D65.8 (2.5906)

Acceptable/ Replacement Unacceptable

2-138

A. LOWER Code

Measurement dimensions [mm (in)]

Standard value [mm (in)]

Usage limits [mm (in)]

Judgment

Solution

Bushing

e

69 (2.717)

68.6 (2.7008)

Acceptable/ Replacement Unacceptable

Hub

f

12.4 (0.4882)

11.9 (0.4685)

Acceptable/ Replacement Unacceptable

Upper Roller

f e

a

d

b

g

c

crhj98-001

* See the gauge list for measurement gauges.

Part name

Code

Standard value [mm (in)]

Usage limits [mm (in)]

Judgment

Solution

D120 (4.724)

D108 (4.252)

Acceptable/ Unacceptable

b

10 (0.394)

-

Acceptable/ Cladding by welding Unacceptable or replacement

c

85 (3.346)

79 (3.110)

Acceptable/ Unacceptable

a Carrier roller

Measurement dimensions [mm (in)] D

Shaft

d

D

D46 (1.811)

D45 (1.772)

Acceptable/ Replacement Unacceptable

Bushing

d

D

D46 (1.811)

D46.8 (1.8425)

Acceptable/ Replacement Unacceptable

Bushing

e

42 (1.654)

41.6 (1.6378)

Acceptable/ Replacement Unacceptable

Thrust plate

f

5.5 (0.2165)

4.5 (0.1772)

Acceptable/ Replacement Unacceptable

2-139

A. LOWER

Part name

A. LOWER Part name

Code

Cover

Measurement dimensions [mm (in)]

g

Standard value [mm (in)] 29.7 (1.1693)

Usage limits [mm (in)] 29.2 (1.1496)

Judgment

Solution

Acceptable/ Replacement Unacceptable

Lower Roller

c

f

b

d

a

e

bp1yub-001

* See the gauge list for measurement gauges.

Part name

Code

Shaft

Standard value [mm (in)]

Usage limit [mm (in)]

Solution

D142 (5.591)

Acceptable/ Unacceptable

b

15 (0.591)

-

Acceptable/ Cladding by welding Unacceptable or replacement

d

173 (6.811)

179 (7.047)

Acceptable/ Unacceptable

D

e

D

D65 (2.559)

D64 (2.520)

Acceptable/ Replacement Unacceptable

e

D

D65 (2.559)

D66 (2.598)

Acceptable/ Unacceptable

Bushing

Collar

Judgment

D150 (5.906)

a Track roller

Measurement dimension [mm (in)]

Replacement

f

D69 (2.717)

D68 (2.677)

Acceptable/ Unacceptable

g

23.3 (0.9173)

22.8 (0.8976)

Acceptable/ Replacement Unacceptable

2-140

A. LOWER

c'

c

d'

d

e'

e

A. LOWER

Track Shoe (grouser shoe)

f

f

a

b

f'

yfpzwr-001

Part name

Code

Measurement dimensions [mm (in)]

Standard value [mm (in)]

Usage limits [mm (in)]

Judgment

Solution

Shoe plate

a

36 (1.417)

30 (1.181)

Acceptable/ Replacement Unacceptable

Link

b

106 (4.173)

101 (3.976)

Acceptable/ Cladding by welding or Unacceptable replacement

c

D

D58.72 (2.31181)

D57.5 (2.2638)

Acceptable/ Unacceptable

d

D

D37.3 (1.4685)

D38.3 (1.5079)

Acceptable/ Unacceptable

e

D

D36.6 (1.4409)

D35.5 (1.3976)

Acceptable/ Replacement Unacceptable

190 (7.480)

193.7 (7.6260)

Acceptable/ Unacceptable

760 (29.921)

774.9 (30.5079)

Acceptable/ Unacceptable

D58.72 (2.31181)

D57.5 (2.2638)

Acceptable/ Unacceptable Acceptable/ Unacceptable

Acceptable/ Replacement Unacceptable

Master bushing

Master pin

Link pitch (4-link portion)

f f' c'

D

Track bushing

Track pin

d'

D

D37.3 (1.4685)

D38.3 (1.5079)

e'

D

D36.65 (1.44291)

D35.5 (1.3976)

2-141

Replacement

Replacement

Replacement

A. LOWER Inspection Gauge For Drive Sprocket

mm ( in ) 260 ( 10.236 )

100 ( 3.937 )

190 ( 7.480 ) 60 30 4.5 ( 0.1772 ) R6 6)

.23

(0 (1 R29.5

0 78 5.3 (2 4.6 724 ) 64 .D 2.9 (1 P.C .5 29

R3

.1614 )

)

603F12F1

For Take-up Roller

mm ( in ) 159 ( 6.260 ) 84 ( 3.307 )

( 1.

654

55 ( 2.165 )

10q

)

97 )

R5 ( 0.1

[ 10 (0.394) ]

0.6 ( 0.0236 )

R3

(0

.11

8)

R42

19 ( 0.748 )

26 ( 1.024 )

180 ( 7.087 )

A9D9497F

2-142

A. LOWER For Upper Roller

A. LOWER

mm ( in ) 180 ( 7.087 ) 85 ( 3.346 ) 78.6 ( 3.0945 )

8 .11 (0 R3

52 ( 2.047 )

35 ( 1.378 )

24 ( 0.945 ) 16 ( 0.630 )

)

29 ( 1.142 )

25 ( 0.984 )

68 ( 2.677 )

80

R3 ( 0.118 ) 2532C00F

For Lower Roller

mm ( in ) 260 ( 10.236 ) 232 ( 9.134 ) 210 ( 8.268 ) 185.7 ( 7.311 )

.3

(0 94

R1 0

(0

.39

)

4) R 5( 0.1 97 )

19 (0.

23

0

10

R5

26

84 ( 3.307 )

R

F387C40A

2-143

60 ( 2.362 )

)

7)

)

29 ( 1.142 )

97

0.1

( R5

7 .19

15 ( 0.591 ) 25 ( 0.984 ) 22 ( 0.866 )

( R5

178 ( 7.008 ) 173 ( 6.811 )

A. LOWER Pressure Measurement and Adjustment Procedures

2

1

Main Pressure Measurement 1. Pressure gauge installation Remove the pressure sensor (a1) (a2) installed on the hydraulic pump (1) and install the pressure gauge. a1: Can be measured

a2: Can be measured

Travel left

Travel right

Option

Bucket

B0E0DE9D

Swing

Travel pressure measurement

Arm 1 pump flow

Arm 2 pumps flow

Boom 2 pumps flow

Boom 1 pump flow

1. Install the stopper (1) on the crawler sprocket section (2) and lock the travel motor.

2. Measure with the following operations.

1 1

Engine speed

2000 min-1 (2000 rpm)

Work mode

SP mode (1st speed)

Lever operation

Travel relief

Oil temperature

45 (113.0) - 55 °C (131.0 °F)

Measuring port a2

a1

Set pressure

9E2AB24B

Left travel: P1 port Right travel: P2 port 34.3 MPa (4975.341 psi)

Install the adapter (2) on the gauge port (1).

2

1

2

A5737B8B

Install the pressure gauge (2) on the adapter (1) and fasten it.

Pressure gauge Port size

for 60 MPa (8703.22 psi) G1/4

1

a4q8ke-001 wzmg8v-003

2-144

1

Drain Volume Measurement Procedures

3. Always lay a rag (2) underneath before removing the drain hose (1).

Use a wrench [ 27 mm ( 1.063 in ) ] to remove the drain hose (1).(Always install a cap on the removed drain hose (1).)

Preparations Measuring conditions Engine speed

2000 min-1 (2000 rpm)

Mode

SP mode

Oil temperature

About 50°C (122.0 °F)

* Be careful.

The drain volume varies greatly with the oil temperature.

Travel Motor Drain Volume Measurement 1. Allow the bucket (2) to touch the ground so as to elevate one shoe crawler (1) as in the diagram on the right.

1 2 uzk9zv-003

4. Install the extension hose for measurement (1) on the side of the motor from which the drain hose was removed.

2 1

30BD9B2C

2. Use a wrench [ 19 mm ( 0.748 in ) ] to remove the bolts (1), then remove the cover (2).

Tightening torque for bolt installation：63.7 - 73.5 N・m ( 46.991 - 54.220 lbf・ft )

1 uzk9zv-004

5. Prepare a waste oil can (1) and measuring container (2) and set them as in the diagram on the right.

2 1

1

2

uzk9zv-002 uzk9zv-005

2-145

A. LOWER

A. LOWER

A. LOWER 6. Catch the stopper (1) between the sprocket section and the frame and lock the travel motor.

a

1

2 3

1

1 uzk9zv-007

a uzk9zv-013

7. In SP mode at medium speed, relieve the travel operation, and move the extension hose to the measuring container (1) at the same time the motor starts. (At starting, start measurement with a stop watch (2).)

After 30 sec., move the extension hose to the waste oil can (1).

Measure the volume of oil in the measuring container (1) as the drain volume for 30 sec.

Forward 1st speed

2nd speed

Backward 1st speed

2nd speed

Right Left

* Measure at least 3 times each for left, right, forward, and backward.

2-146

30 seconds

A. LOWER Air Bleed Procedure Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or replacing hydraulic equipment, or removing hydraulic pipes.

Air bleed procedure mode (when bleeding, follow the procedure below.)

Hydraulic pump air bleeding

Cylinder air bleeding

Swing motor air bleeding

Travel motor air bleeding

Check

Hydraulic oil or hydraulic pump replacement Cylinder replacement Swing motor replacement Travel motor replacement

* Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and lead to damage.

Travel Motor 1. Remove the bolts (2) , then remove the cover (1).

Tightening torque for bolt installation：63.7 - 73.5 N・m ( 46.991 - 54.220 lbf・ft )

3. Pour in about 500 cc of hydraulic oil (1) from the air bleed port.

When inside the motor is filled with hydraulic oil (1) , tighten the air bleed plug.

1

1

2

kjqptt-006 kjqptt-004

2. Use a hexagon wrench [ 6 mm ( 0.236 in ) ] (1) to remove the air bleed plug (2) as in the figure on the left.

4. Start the engine and execute a slow travel operation.

5. Repeatedly travelling forward and backward bleeds off the air.

Check After the air bleeding is complete, stop the engine for at least 5 minutes to allow any air bubbles in the hydraulic oil tank to dissipate.

1

2

kjqptt-005

2-147

A. LOWER

Caution

A. LOWER

2-148