Removal and Installation of Engine Assembly

Please follow these precautions.

Do not tamper with the relief valve adjuster. The set pressure of the relief valve may change and cause the motor to run out of control, which could cause personal injury or damage the machine.

Warning

Please follow these precautions.

Caution Do not operate the motor at settings beyond its specified range. This could cause damage to the machine. Do not touch the motor for 1 hr. after operation. The surface of the motor is very hot due to operation. Touching the surface could cause burns.

Do not suddenly remove the plugs for the oil fill, oil drain and oil check ports on the reduction gear. A plug may fly off and cause injury. Align the port positions with the specified positions and slowly loosen the plug for each port, starting with oil fill port on top, to release air inside the reduction gear.

When handling lines, make sure to confirm the input and output flow of the hydraulic oil and the motor rotation direction. It is extremely dangerous if the motor rotates in the opposite direction.

Do not use hydraulic oil other than the type specified. Doing so could cause damage to the machine.

Please follow these precautions.

Caution Do not use reduction gear lubricating oil other than the type specified. Doing so could cause damage to the machine. Do not let foreign matter into the motor. This will damage the machine. Perform motor maintenance and inspection after the motor has cooled down.

2.Tools for Assembly and Disassembly

Use the tools indicated below for assembly and disassembly of the motor. (1)Standard tools The necessary standard tools for assembly and disassembly of this motor are indicated in Table 1. Table 1. Standard tools for assembly and disassembly

No. Tool name Standardized number Manufacturer name Type and dimensions Part used with

1 2 3 4 5 6 Preset-type torque wrench JIS B4650

7 8 9 10 Rachet handle for socket wrench JIS B4641 11 12 13 14 15 16 17

Hexagon bit for socket wrench

18 19 20 21 Torx T-shaped bit JASO F116-89

Socket for socket wrench JIS B4636 Nominal size 60 1-2-6-6, 1-2-17, 1-2-18, 1-2-19 Nominal size 120 1-2-8 Nominal size 230 1-2-6-5 Nominal size 450 1-2-20 Nominal size 900 24, 28 Nominal size 1800 1-2-2-4, 1-2-6-3, 1-2-11, 1-2-14, 29 Nominal size 2800 11 Nominal size 4200 1-2-7 Nominal size 5600 8, 14

Bolt width 2.5 mm 1-2-6-6, 1-2-17, 1-2-18, 1-2-19 Bolt width 4 mm 1-2-8 Bolt width 6 mm 1-2-20 Bolt width 8 mm 28 Bolt width 10mm 1-2-6-3, 1-2-11 Bolt width 12 mm 11, 29 Bolt width 14 mm 1-2-2-4, 1-2-6-5 Size T50 24

Size T90

8, 14 Bolt width 10 mm 1-2-14 Bolt width 27 mm 1-2-7

22 23 Bolt width 2.5 mm 1-2-6-6, 1-2-17, 1-2-18, 1-2-19 Bolt width 4 mm 1-2-8

24 25 26 27 28 29 30 Hexagon bar wrench JIS B4648

Wrench JIS B4630 Bolt width 6 mm 1-2-20 Bolt width 8 mm 28 Bolt width 10 mm 1-2-6-3, 1-2-11 Bolt width 12 mm 11, 29 Bolt width 14 mm 1-2-2-4, 1-2-6-5 Bolt width 10 mm 1-2-14 Bolt width 27 mm 1-2-7

31 Longnose pliers 32 Snap ring pliers JIS B4631

S-2 type 33 Flathead screwdriver JIS B4609 6×100 34 Plastic hammer OF-05 Nominal size #3 1-2-7 1-4-5 2, 1-27, 1-2, 1-21

35 Punch 36 Press 37 Crane 38 39

Eyebolt

40 Chain string (wire) Length of about 10 mm 200 kgf or higher For 400 kg For M20 For M12 1-2

(2)Secondary materials

The necessary secondary materials for disassembly and assembly of this motor are indicated in

Table 2. Table 2. Secondary materials

(3)Special tools

The necessary special tools for assembly and disassembly of this motor are indicated in Table 3. Table 3. Special tools

No. Secondary materials name Standardized number Manufacturer name Type and dimensions Part used with 1 Seal tape 1-2-8 2 Adhesive Loctite 271 8, 14

3 Gear oil GL-4#90 equivalent

4 Hydraulic oil ISO VG46 equivalent

5 Grease Lithium-series 1-1, 1-7, 1-6 1-2-1, 1-2-2, 1-2-9, 1-4-1, 1-4-2, 1-21, 1-4-4, 1-4-3, 1-5, 1-4-2, 1-6

1-2-2-5, 1-2-6-2, 1-2-6-4, 1-2-12, 1-2-21, 1-2-24, 1-16, 1-17, 1-23, 1-12, 1-15, 1-21

6 White kerosene No.2 equivalent oil 7 Liquid packing ThreeBond 1211 4, 27 8 Lapping plate For sliding surface repair 1-4-1, 1-4-2, 1-5, 1-21 9 Lapping agent #1000 For sliding surface repair

10 Copper plate 11 Tube brush For cleaning 1-2-1, 1-4-1 12 Bamboo brush For cleaning 13 Oil pan For receiving oil 14 Plastic container For grease 15 Rag

No. Tool name Standardized number Manufacturer name Type and dimensions Part used with 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

(4)Measurement device

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

No. Tool name Standardized number Manufacturer name Type and dimensions Part used with 1 Dial gauge 2 Micrometer caliper JIS B7503 JIS B7502 5, 26 5, 26

3.Disassembly of Motor (1)Precautions before motor disassembly Begin motor disassembly only after thoroughly reading the precautions below. [1] When performing disassembly, always wear protective devices 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 mother 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 mother 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 mother 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 crane, 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. [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 scratching 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.

Motor lifting positions

(2)Tightening torque

Table 5 indicates tightening torque for each connection section. Table 5. Tightening torque for each section Reference number Part name Screw size Bolt width Tightening torque

1-2-2-4 Plug M24 x 1.5 14 137 ± 10 N•m 1-2-6-3 Hexagon socket head bolt M12 x 1.75 x 40L 10 108 ± 10 N•m 1-2-6-5 Plug G1/8 14 20.6 ± 1.0 N•m 1-2-6-6 Orifice M5 x 0.8 x 5L 2.5 2.45 ± 0.49 N•m

1-2-7 Relief valve assembly 1-5/16 12UNF 27 373 ± 20 N•m 1-2-8 Plug NPTF 1/16 4 9.8 ± 1.0 N•m 1-2-11 Plug G1/2 10 118 ± 6 N•m 1-2-14 Plug G1/2 10 118 ± 6 N•m 1-2-17 Orifice M5 x 0.8 x 5L 2.5 2.45 ± 0.49 N•m

1-2-18 Orifice M5 x 0.8 x 5L 2.5 2.45 ± 0.49 N•m

1-2-19 Orifice M5 x 0.8 x 5L 2.5 2.45 ± 0.49 N•m

1-2-20 Plug G1/4 6 36.8 ± 2.5 N•m 1-11 Hexagon socket head bolt M14 x 2.0 x 35L 12 205 ± 10 N•m 8 Bolt M20 x 2.0 x 70L Torx T90 539 ± 28 N•m

14 Bolt M20 x 2.0 x 130L Torx T90 539 ± 28 N•m

24 Screw M10 x 1.5 Torx T50 58.8 ± 4.9N•m

28 Hexagon socket head bolt M10 x 1.5 x 16L 8 73.4 ± 3.63 N•m 29 Plug G3/4 12 157 ± 8 N•m

(3)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 spring seats (1-2-5), springs (1-2-4), and spring seats (1-2-3). Cautions: The cap assemblies are pushed out by the spring. For this reason, observe the following precautions when working. a.Loosen the hexagon socket head bolts evenly. b.Loosen the hexagon socket head bolts while pressing down the cap assemblies. [2] Removal of plunger assembly Lightly press the end of the plunger assembly (1-2-2), and eject one part of the plunger assembly out from the base plate (1-2-1). Next, grasp the end of the plunger assembly by hand and remove the plunger assembly from the base plate while rotating it. Cautions: The plunger assembly and base plate are fit together with a very small gap. For this reason, observe the following precautions when working. a.Do not try to force out the plunger with extreme force if the plunger assembly becomes stuck when it is 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. b.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.

[3] Removal of relief valve assembly

Loosen the plug (1-2-7-6) to remove the relief valve assemblies (1-2-7).

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

Cautions: 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. a.Loosen the nut (1-2-7-16), and do not tamper with the set 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. b.Do not perform disassembly of the relief valve assemblies. The set pressure will change and the machine will no longer display prescribed capabilities. [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.

[5] Removal of valve assembly

Loosen the plugs (1-2-11) and (1-2-14) and remove the plugs and spring (1-2-10).

Lightly press the end of the valve assembly (1-2-9), and eject one part of the valve assembly out from the base plate (1-2-1).

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

Cautions: The valve assembly and base plate are fit together with a very small gap. For this reason, observe the following precautions when working. a.Do not try to force out the plunger with extreme force if the valve assembly becomes stuck when it is 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 valve assembly. If the valve assembly becomes stuck, lightly hit the end surface of it with a plastic hammer to insert it once again into the base plate. After this, check that the valve assembly moves smoothly and remove it again while rotating it. b.Do not perform disassembly of the valve assembly if it is not necessary. When disassembly is necessary, contact our company. [6] Do not remove the plugs (1-2-8) if it is not necessary.

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

Do not perform disassembly.

[7] Removal of base plate

Loosen the hexagon socket head bolts (111) and remove the base plate (1-2-1).

Cautions: When removing the base plate, observe the following precautions. a.The base plate is pushed upwards by the springs (1-18). For this reason, loosen the hexagon socket head bolts evenly when loosening. b.Positioning knock 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 knock pins. If it becomes stuck, lightly strike the base plate with a plastic hammer to put the knock pins in the correct position, and then remove the base plate. c.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.

[8] Removal of valve plate

Use a flathead screwdriver to remove the valve plate (1-21) from the base plate (12-1).

Caution: When removing the valve plate, observe the following precaution. a.The valve plate sliding surface is easily scratched. If the sliding surface is scratched, prescribed capabilities will disappear so prevent scratching from occurring.