Assembly and Disassembly of Swing Reduction Gear

1.Disassembly [1] Remove the oil gauge (30) and plug (31), and then drain the gear oil.

[2] Remove all hexagon socket head bolts M20 × 200 (27).

[3] Use a liftcrane to carefully lift and remove the swing motor subassembly.

[4] Remove the sun gear No.1 (28), thrust plate (2) (first), and carrier No.1 subassembly (1).

[5] Remove the sun gear No.2 (26) and thrust plate (2) (second).

[6] Use lifting taps (M10, 2 locations) (*1) of the planetary carrier No.2 (4) to remove the carrier

No.2 subassembly while lifting gently with a liftcrane.

[7] In addition to reamed holes, tightening bolt holes, and oil gauge holes, 2 screw holes for push bolts are cut into the ring gear. Screw the push bolts into these holes (M20 × 200 full thread), push up the ring gear from the case, and remove from the knock pin.

(1) Disassembly of carrier No.1 subassembly [1] Push the spring pin 8 × 36 (39) all the way in with a jig (φ7 mm round rod). •At this time, be careful not to forcefully insert the parts, as this can scratch the inner diameter of the pin holes of the planetary carrier No.1 (34). [2] Place the carrier No.1 subassembly upside down on a jig (supporting the planetary carrier No.1 (34)) and push out the planetary pin No.1 (36) with a press. [3] Remove the side plate No.1 (38), planetary gear No.1 (35), and needle bearing (37) from the planetary pin No.1 (36). [4] Pull out the spring pin (39) from the spring pin hole of the planetary pin No.1 (36). •When securing the planetary pin No.1 in a vise, use a rag so as not to scratch the pin.

Perform steps [1] to [4] for 4 locations. (2) Disassembly of carrier No.2 subassembly [1] Push the spring pin 8 × 36 (44) all the way in with a jig. •At this time, be careful not to forcefully insert the parts, as this can scratch the inner diameter of the pin holes of the planetary carrier No.2 (40). [2] Tap from the casting hole on the bottom of the planetary carrier No.2 (40) and pull out the planetary pin No.2 (42). •At this time, be careful not to drop the planetary gear No.2 (41) and side plate No.2 (43). [3] Pull out the spring pin (44) from the SP pin hole of the planetary pin No.2 (42). •When securing the planetary pin No.2 in a vise, use a rag so as not to scratch the pin.

Perform steps [1] to [3] for 4 locations.

(3) Disassembly of the case subassembly [1] Reverse the case subassembly. [2] Remove all hexagon socket head bolts M10 × 30 (11).

[3] There are 2 M10 screw holes on the oil seal retainer. Screw the 2 M10 bolts (threaded section of 20 mm or more) evenly into these holes and remove the seal retainer subassembly. [4] Use tap holes (M16, 2 locations) on the shaft (15) end section to pull out the shaft subassembly.

(4) Disassembly of motor swing subassembly [1] Use pliers (for shaft) to remove the shaft retaining ring (1) attached to the swing motor output shaft.

(5) Disassembly of shaft subassembly

This cannot be disassembled to individual parts. (6) Disassembly of seal retainer subassembly [1] Insert a flathead screwdriver into the gap between the oil seal retainer and oil seal and remove the oil seal. The removed oil seal cannot be reused.

2.Assembly (1) Assembly of carrier No.1 subassembly [1] Mark the flange top surface of the pin in the direction of the oil hole (φ3) in the cylinder section of planetary pin No.1 (36).

[2] Insert the 1 side plate No.1 (38) into the planetary pin No.1 (36).

[3] Face the mark added in step [1] toward the outside of the circumference of the planetary carrier No.1 (34), match the planetary pin No.1 (36) and planetary carrier spring pin hole using the mark as a guide, and press fit. •Do not insert by striking with a hammer or other tool, as this can cause the inner diameter of the planetary carrier hole to stick, reducing the pin holding force and resulting in damage.

[4] Check that the spring pin insertion holes of the planetary pin No.1 (36) and planetary carrier No.1 (34) match, and then use a jig to hammer the part while paying attention to the direction and depth of the spring pin 8 × 36 (39).

•Perform caulking after hammering in the part.

•When caulking, use a punch to punch at a position about 1 mm from the spring pin, and then perform caulking by deforming the spring pin hole.

[5] Rotate the planetary gear No.1 (35) by hand and check that there is no rotation unevenness or catching. If there is any rotation unevenness or catching, disassemble according to 1. (1) disassembly of carrier No.1 subassembly and reassemble using this procedure. When reassembling, assemble using a new pin for the spring pin 8 × 36 (39). Using the spring pin from before disassembly can reduce the holding force and result in damage.

Perform steps [1] - [5] at 3 locations to complete operations.

(2) Assembly of carrier No.2 subassembly [1] Slide the planetary gear No.2 (41) and 2 side plates No.2 from the side of the planetary carrier No.2 (40), and place at the specified position.

[2] Insert the planetary pin No.2 (42) from the pin hole on the upper side of planetary carrier No.2 (40). At this time, the oil hole (*2) of the planetary pin No.2 faces toward the outside.

[3] Check that the spring pin insertion holes of the planetary carrier No.2 (40) and planetary pin No.2 (42) match, and then use a jig to hammer the part while paying attention to the direction and depth of the spring pin 8 × 36 (44). •Perform caulking after hammering in the part. When caulking, use a punch to punch at a position about 1 mm from the spring pin hole, and then perform caulking by deforming the spring pin hole. [4] Rotate the planetary gear No.2 (41) by hand and check that there is no rotation unevenness or catching. If there is any rotation unevenness or catching, disassemble according to 1. (2) disassembly of carrier No.2 subassembly and reassemble using this procedure. When reassembling, assemble using a new pin for the spring pin 8 × 36 (44). Using the spring pin from before disassembly can reduce the holding force and result in damage.

Perform steps [1] - [4] at 4 locations to complete operations.

(3) Assembly of shaft subassembly

This describes two methods for assembling the subassembly of this part by shrink fitting and press fitting the bearing. Select one method for assembly depending on the holding facility. 1)Assembly of shaft subassembly by shrink fitting [1] Use a bearing heater to warm up the roller bearing (7) to a temperature about 30 ℃ warmer than the outside air. •The bearing retainer is made of plastic, so be careful not to deform the part with excessive temperature.

[2] Remove the roller bearing (7) from the bearing heater and place it on a jig. [3] Align the inner diameter sides of the roller bearing (7) and place the spacer A on the roller bearing while being careful of the correct up-down direction of the spacer A (8).

[4] Lift the shaft (15) with a liftcrane and install it in the spacer A (8) and roller bearing (7) and leave the roller bearing until it reaches to about the temperature of the outside air. [5] Be careful to insert the spacer B (9) in the correct up-down direction.

[6] Heat and install the roller bearing (10) with a bearing heater using the same procedure described above.

[7] Heat and install the seal ring (14) with a bearing heater using the same procedure as roller bearing (10). •After installing, leave until it reaches to about the temperature of the outside air.

2)Assembly of shaft subassembly by press fitting bearing [1] Stand the shaft (15) with the short spline side up and place on a surface plate.

[2] Be careful to install the spacer A (8) in the correct up-down direction.

[3] Use a jig to press fit the roller bearing (7).

After setting the roller bearing to the specified position, continue to apply press-fit force for 3 - 5 sec.

[4] Invert the shaft subassembly being operated. [5] Be careful to install the spacer B in the correct up-down direction. [6] Press fit the roller bearing using the same procedure described above. [7] Press fit the seal ring using the same procedure described above.

(4) Assembly of seal retainer subassembly [1] Set the oil seal retainer (16) on a jig. [2] Apply liquid packing (33) (TH1208B) to the contact surface of the seal housing of the oil seal (13).

[3] Place the oil seal (13) on the oil seal retainer (16) and press fit the oil seal with a jig.

(5) Assembly of the case subassembly [1] Turn the gear case (17) upside-down (with the large flange up) and place on a surface plate. [2] Use lifting taps (M16, 2 locations) of the shaft (15) to lift the shaft subassembly (2.(3)) with a liftcrane and insert into the gear case (17).

[3] After degreasing the gear case (17) end surface, apply the liquid packing (TH1215) evenly. [4] Apply a thin coat of grease to the seal lip section and insert the seal retainer subassembly (2.(4)) while being careful not to scratch the lip.

[5] After degreasing the threaded section of the hexagon socket head bolt M10 × 30 (11), apply the liquid packing (TH1360K) (12) to the threaded section and tighten to a tightening torque of 68.6 - 78.4 N•m at 16 locations.

[6] Invert the case subassembly being operated and place it on the jig. •At this time, be careful not to place an impact load on the shaft or allow the bottom end surface to receive the weight of the case subassembly. [7] Degrease the gear case (17) end surface and apply the liquid packing (TH1215) evenly.

[8] Install while paying attention to the installation direction and orientation of the ring gear (21), and tighten the jig bolts (M20 × 200 full threaded bolts) and spacers (outer diameter: φ27.2, inner diameter: φ21, height: 20 pipe) at each of the 2 locations.

[9] Use a jig to hammer the knock pins (5) from the 4 knock pin holes on the ring gear (21). •Be careful to hammer the knock pins into the correct knock pin holes so as not to damage the screws.

[10]Screw the plug (31) into the drain port on the gear case (17) side.

(6) Assembly of swing motor subassembly [1] Install the shaft retaining ring (1) on the swing motor shaft with pliers (for shaft).

(7) Assembly of the swing reduction gear [1] Set the case subassembly (5) on the jig. [2] Insert the thrust plate (2) (first) into the groove (φ60) on the shaft (15) end surface while paying attention to the installation direction.

[3] Use lifting taps (M10, 2 locations) (*1) of the planetary carrier No.2 (4) to lift the carrier No.2 subassembly (2) with a liftcrane and install it on the case subassembly (2.(5)). If installation is difficult, rotate the carrier a little to make installation easier.

[4] Insert the sun gear (26).

[5] Insert the thrust plate (2) (second) into the groove (φ60) on the sun gear No.2 (26) end surface while paying attention to the installation direction.

[6] Insert the carrier No.1 subassembly (1).

[7] Insert the sun gear No.1 (28).

[8] Check that the distance between the end surfaces of the sun gear No.1 (28) and ring gear (21) is 7.5 mm or less. If the distance is too great, the parts may have been assembled incorrectly or foreign matter may be caught inside. Disassemble and reassemble the parts.

[9] After removing all jig bolts (M20 × 200 full threaded bolts) and spacers used to assemble the case subassembly and degreasing the ring gear (21) end surface, apply the liquid packing (TH1215) (*1) evenly.

[10]After installing the swing motor subassembly (6) and degreasing the threaded sections of the hexagon socket head bolts M20 × 200 (27), apply the liquid packing (TH1360K) (12) to the threaded sections, and tighten to a tightening torque of 568.4 649.7 N•m at 12 locations. [11]Install the oil level pipe (29) to the motor swing.

[12]Insert the oil gauge (30) into the oil level pipe (29). [13]Fill with 13.5 L of gear oil (*2) (viscosity classification: GL-4 or greater) and coat with the specified paint.

Swing reduction gear structure diagram

Code Part name

Q'ty 2 Thrust plate 2 3 Planetary carrier No.1 assembly 1 4 Planetary carrier No.2 assembly 1 5 Knock pin 4 6 Liquid packing Reqd. amount 7 Roller bearing 8 Spacer A 9 Spacer B 1 1 1 10 Roller bearing 1 11 Hexagon socket head B M10 × 30 16 12 Liquid packing TB1360K Reqd. amount 13 Oil seal 1 14 Seal ring 1 15 Shaft 1 16 Oil seal retainer 1 17 Gear case 1 21 Ring gear 1 26 Sun gear No.2 1 27 Hexagon socket head B M20 × 200 12 28 Sun gear No.1 1 29 Oil level pipe 1 30 Oil gauge 1 31 Plug 1 33 Liquid packing TB1208B Reqd. amount Note 1)Apply ThreeBond #1215 liquid packing to 3 locations on the matching surface. 2)Apply ThreeBond #1208B to the coupling section of the oil seal and seal retainer. 3)Coat the lip section of the oil seal with grease (lithium-series grease) and press fit with a jig. 4)Degrease the threaded sections at codes and and apply ThreeBond #1360K, and then tighten to the specified torque. 5)After completing assembly of the reduction gear, check the dimensions of * (7.5 mm or less). Also, rotate the sun gear by hand and check that there is no rotation unevenness or abnormal sound.