Removal and Installation of Turbo Charger

15)Plunger assembly attachment

Attach the base plate (1-2-1) to the plunger assembly (1-2-2).

Cautions: a.Apply hydraulic oil to the plunger assembly outer circumference before attachment. b.Attach the plunger assembly slowly and in a straight line while rotating it. c.If the plunger assembly becomes stuck, do not force it too much and lightly strike it with a hammer.

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.

After checking that the O-ring (1-2-6-2) is mounted to the cap assemblies (1-26) and that the O-ring (1-2-24) is mounted to the base plate, mount the spring seats (1-2-5) on the cap assemblies and attach the cap assemblies to the base plate.

Finally, tighten the hexagon socket head bolts (1-2-6-4) to the specified torque.

Cautions: a.Apply grease to the O-rings. b.The cap assemblies are pushed by the springs. Push the cap assemblies down by hand when tightening the socket head bolts. c.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 Orings and cause oil leaking.

This completes assembly of the motor. When installing the motor in the machine body, see "7. Installation of Motor", "8. Operation Check", and the Operator's Manual for the machine.

6.Motor Section Names

Diagram 1. Motor section names

7.Installation of Motor (1)Motor inspection Before placing the motor in the mother machine, perform inspection for the following items. If there is a problem, perform the given procedure. Table 14. Motor inspection and solving problems before installation

Inspection item before installation Solution for solving problem When installing a new motor When installing a motor stored after maintenance inspection

Are there any damaged areas?

Are there any missing parts?

Is there any looseness in the tightening sections of the bolts? Contact our company's service plant concerning damage that occurred during shipping. Replace parts that have been damaged during storage. Contact our company's service plant concerning parts lost during shipping. Purchase parts that have been lost during storage. If there is looseness in bolts just after delivery of the motor, contact our company's service plant for instructions on tightening bolts to the specified torque. If there is bolt loosening on a stored motor, contact our company's service plant as there is a chance that rust has formed internally. Replace damaged parts.

Purchase lost parts.

When there is looseness with bolts, disassemble again and inspect the motor for rust on the inside.

Dirt around ports When ports for lines are dirty, perform air blowing with compressed air or a high-pressure jet or cleaning with water vapor to remove dirt. When ports for lines are dirty, perform air blowing with compressed air or a high-pressure jet or cleaning with water vapor to remove dirt.

Are all of the port areas completely air-tight? When checking just after delivery When the plugs for each of the ports are loose, use the plugs after removing dirt adhered to the ports. When there are no plugs on the ports, contact our company's service plant as dirt has probably entered the motor. When the plugs for each of the ports are loose or there are no plugs on the ports, perform disassembly for confirmation that dirt has not entered the motor or there is no rust.

Is there any rust on the port sections or the installation sections on the mother machine?

Oil leaking from ports and connection surfaces When checking after storage Contact our company's service plant as rust has probably formed inside the motor.

Contact our company's service plant after confirming the presence of rust. If there is light rusting, use the motor after removing the rust. If rusting is severe, replace parts.

Contact our company's service plant if oil leaking is discovered. If oil leaking is discovered, there is probably a problem with air-tightness and rust has formed inside the motor, so perform disassembly again to check for rust.

8.Operation Check

Before performing work driving after installing the new motor or post-inspection motor in the machine main unit and completing all line operations, perform a driving check according to the procedure listed below. (1)Check before driving check [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 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 the 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 lubrication 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 Mitsubishi Diamond Hypoid Gear Oil 90 to the stipulated volume (3.5 L).

Diagram 8. Oil fill, oil drain and oil check ports for reduction gear lubricating oil and stipulated oil volume (2)Motor operation check

Slowly operate the machine and perform air-bleeding 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. 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. 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.

•When tightening lines, etc. after confirming oil leaking, make sure to have operation of hydraulic devices stopped. •Make sure that the pressure operating 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.