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Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

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Track gearbox, description


Track gearbox consists of a two stage planetary mechanism that converts the high speed rotation of the hydraulic motor,
into low speed, high torque rotating force at the sprocket hub.

Figure 1
2 stage planetary gearbox

1. Track motor
2. No.1 planetary gear assembly
3. No.2 planetary gear assembly
4. Ring gear
Figure 2
Port connections

1. Oil filling port (PT 1/2)


2. Oil level check port (PT 1/2)
3. Oil drain port (PT 1/2)
4. High speed
5. Low speed

Rotational direction

View from E axis Inlet Outlet


Clockwise A B
Counterclockwise B A

Port connections

Port symbol Port size Port


(A) (B) PF 1 Oil supply (Return)
(P1) (P2) PT1/4 Pressure check
(P) PF1/4 Displacement changeover valve oil supply
(D1) (D2) PF1/2 Drain
Figure 3
Track gearbox, sectional view

1 Housing 12 No.2 planetary gear 23 No.1 needle bearing


2 Angular bearing 13 No.2 needle bearing 24 Thrust washer
3 Seal 14 Thrust washer 25 No.1 pin
4 Shim 15 No.2 pin 26 Spring pin
5 Retainer 16 Spring pin 27 No.1 sun gear
6 Screw 17 Thrust ring 28 Cover
7 Parallel pin 18 No.1 planetary gear assembly 29 Pad (thrust)
8 Ring gear 19 No.1 carrier 30 Screw
9 Coupling 20 No.2 sun gear 31 Screw
10 No.2 planetary gear assembly 21 Retaining ring gear 32 Plug
11 No.2 carrier 22 No.1 planetary gear 33 Name plate
Figure 4
Track gearbox, exploded view

Figure 5
Track gearbox, torque flow

The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear (27) → spline of 1st
carrier (19) → 2nd sun gear (20) → 2nd planetary gear (12) → ring gear (8).
At this time, the reduction ratio of reduction gear is as follows:

(1) 1st reduction ratio

i=((Zs1 + Zr) · (Zs2 + Zr) / (Zs1 · Zs2)-1

 Zs1 = No.of tooth of 1st sun gear


 Zs2 = No.of tooth of 2nd sun gear
 Zr No.of tooth of ring gear
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, description


Track gearbox consists of a two stage planetary mechanism that converts the high speed rotation of the hydraulic motor,
into low speed, high torque rotating force at the sprocket hub.

Figure 1
2 stage planetary gearbox

1. Track motor
2. No.1 planetary gear assembly
3. No.2 planetary gear assembly
4. Ring gear
Figure 2
Port connections

1. Oil level check port (PF 3/4)


2. Oil filling and drain port (PF 3/4)
3. High speed
4. Low speed

Rotational direction

View from E axis Inlet Outlet


Clockwise A B
Counterclockwise B A

Port connections

Port symbol Port size Port


(A) (B) PF 1 Oil supply (Return)
(P1) (P2) PT1/4 Pressure check
(P) PF1/4 Displacement changeover valve oil supply
(D1) (D2) PF1/2 Drain
Figure 3
Track gearbox, sectional view

1 Housing 12 No.2 planetary gear 23 No.1 needle bearing


2 Angular bearing 13 No.2 needle bearing 24 Thrust washer
3 Seal 14 Thrust washer 25 No.1 pin
4 Shim 15 No.2 pin 26 Spring pin
5 Retainer 16 Spring pin 27 No.1 sun gear
6 Screw 17 Thrust ring 28 Cover
7 Parallel pin 18 No.1 planetary gear assembly 29 Pad (thrust)
8 Ring gear 19 No.1 carrier 30 Screw
9 Coupling 20 No.2 sun gear 31 Screw
10 No.2 planetary gear 21 Retaining ring gear 32 Plug
assembly
11 No.2 carrier 22 No.1 planetary gear 33 Name plate
Figure 4
Track gearbox, exploded view

Figure 5
Track gearbox, torque flow

The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear → spline of 1st carrier
→ 2nd sun gear → 2nd planetary gear → ring gear.
At this time, the reduction ratio of reduction gear is as follows:

1st reduction ratio

i=((Zs1 + Zr) · (Zs2 + Zr) / (Zs1 · Zs2)-1

 Zs1 = No.of tooth of 1st sun gear


 Zs2 = No.of tooth of 2nd sun gear
 Zr No.of tooth of ring gear
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, precautions Service Information 2014/6/12
for operation
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, precautions for operation


Installation

Figure 1
Mounting location

A. Main body mounted area


B. Sprocket mounted area

 Check that the mating mount surfaces are clean.


 Check that the motor is positioned correctly in the frame.
 If the gearbox to frame fit is tight, draw the assembly into the frame evenly with the mounting screws.
 Tighten the screws in a crisscross pattern in several stages to the specified torque.
 Apply these same precautions when mounting the sprocket.

Tightening torque
Tightening torque

Item Quantity Thread Torque, Nm (kgf m) (lbf ft)


Reduction screw (A) 30 M16 (P2.0) 265 (27 ±3) (195 ±22)
Sprocket screw (B) 22 M16 (P2.0) 265 (27 ±3) (195 ±22)

NOTE!
The screws must be 10.9 KS strength classification or above.

Lubricating oil

NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.

NOTE!
Gear oil specification
Use a gear oil equivalent to SAE 90 or 140, API classification GL4 or GL5.
Gear oil replacement period

 First (initial) oil replacement: 500 operating hours


 Subsequent oil replacement: 2000 operating hours
 After maintenance (initial): 250 operating hours

NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.

NOTE!
Do not mix different types, classifications or brands of oil.

NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.

Gear oil replacement procedure

 Rotate the gearbox until the drain plug and the fill plug are on the vertical axis.
 Remove the 3 plugs on the cover and drain the oil into a suitable container.
 Refill the gearbox through the fill port until oil exits from the level check port.
 Ensure that the O-ring on each plug is not damaged, then install the plugs and torque to specification.

Figure 2
Oil replacement location

1. Fill port
2. Level check port
3. Drain port

NOTE!
Oil capacity: 5.8 Liter (1.5 US gal)

Operating checks

 Check the oil level prior to operating the travel function.


 Check for oil leakage on the gearbox assembly.
 Check for loose mounting screws.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.

WARNING
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.

NOTE!
The temperature of the case must be lower than 90 °C, during continuous operation.
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, precautions Service Information 2014/6/12
for operation
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, precautions for operation


Installation

Figure 1
Mounting location

A. Main body mounted area


B. Sprocket mounted area

 Check that the mating mount surfaces are clean.


 Check that the motor is positioned correctly in the frame.
 If the gearbox to frame fit is tight, draw the assembly into the frame evenly with the mounting screws.
 Tighten the screws in a crisscross pattern in several stages to the specified torque.
 Apply these same precautions when mounting the sprocket.

Tightening torque
Tightening torque

Item Quantity Thread Torque, Nm (kgf m) (lbf ft)


Reduction screw (A) 30 M16 (P2.0) 265 (27 ±3) (195 ±22)
Sprocket screw (B) 22 M16 (P2.0) 265 (27 ±3) (195 ±22)

NOTE!
The screws must be 10.9 KS strength classification or above.

Lubricating oil

NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.

NOTE!
Gear oil specification
Use a gear oil equivalent to SAE 90 or 140, API classification GL4 or GL5.
Gear oil replacement period

 First (initial) oil replacement: 500 operating hours


 Subsequent oil replacement: 2000 operating hours
 After maintenance (initial): 250 operating hours

NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.

NOTE!
Do not mix different types, classifications or brands of oil.

NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.

Gear oil replacement procedure

 Rotate the gearbox until the drain plug and the level check plug are on the vertical axis.
 Remove the 2 plugs on the cover and drain the oil into a suitable container.
 Refill the gearbox through the level check port until oil exits from the level check port.
 Ensure that the O-ring on each plug is not damaged, then install the plugs and torque to specification.

Figure 2
Oil replacement location

1. Level check port


2. Drain port

NOTE!
Oil capacity: 5.8 Liter (1.5 US gal)

Operating checks

 Check the oil level prior to operating the travel function.


 Check for oil leakage on the gearbox assembly.
 Check for loose mounting screws.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.

WARNING
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.

NOTE!
The temperature of the case must be lower than 90 °C, during continuous operation.
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, Service Information 2014/6/12
troubleshooting
Profile:
EXC, EC210B LC [GB]

Track gearbox, troubleshooting


Track gearbox troubleshooting

Gearbox does not rotate. Motor overloaded. Reduce the load.

Gearbox is damaged. Replace the gearbox.

Oil leakage from mating joint Liquid gasket improperly applied. Disassembly and re-apply.
surfaces.

Mating surface damaged. Repair or replace.

Loosen screws. Tighten to specified torque.

Loosen plug. Tighten to specified torque.

Casing leakage. Cracks or pin holes. Replace the housing.

Cover damaged. Replace the cover.

Floating seal leakage. Sliding surface worn. Replace the floating seal
assembly.

O-ring distorted.

Abnormal operating temperature. Insufficient gear oil. Refill to specified level.

Gear or bearing damaged. Replace the gearbox.


Hydraulic and gear oil mixed. Replace the motor oil seal.

Abnormal operating sound. Gearbox is damaged. Replace the gearbox.


Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, removal Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Track gearbox, removal


Op nbr 00000

Figure 1
Removal, cover

1. Remove cover screw (2), and remove cover (1).

2. Remove the track.

3. Place a wooden block on the track, and place the lower roller on the block to raise the sprocket off the track.

4. Disconnect the hydraulic hoses at the track motor.Plug the pipe ends and ports to prevent the outflow of oil and
the entry of contamination.

5. Remove the track motor mounting screws from the undercarriage.

Figure 2
Removal, hydraulic hoses and screws

6. Pass a wire rope around the gearbox, and lift it.Remove the track motor as an assembly.Then, using screws in the
threaded holes of the undercarriage, force out the gearbox.
Figure 3
Removal, track gearbox
NOTE!
Lift the gearbox as close to the sprocket as possible to maintain balance.

NOTE!
The gearbox mounting screws may be used in the threaded frame holes.

NOTE!
Putting match-marks on the track frame and track gearbox will facilitate reassembly.
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, installation Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Track gearbox, installation


Op nbr 00000

NOTE!
Carefully check the mating surface of the undercarriage and the gearbox for burrs, dirt and rust scale.

1. Pass a wire rope around the gearbox, lift and install the gearbox to the undercarriage.

Figure 1
Install, track gearbox

2. Apply Loctite 277 to the gearbox mounting screws, and tighten them to the specified torque.
NOTE!
Tightening torque: 27 ± 3 kgf·m (195 ± 22 lbf·ft)

3. Connect the hydraulic hoses at the track motor.

4. Install the track motor cover.

5. Check the gear oil level of gearbox if necessary.


Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, Service Information 2014/6/12
maintenance standard
Profile:
EXC, EC210B LC [GB]

Track gearbox, maintenance standard


The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier (s) together, do not mix the bearings, gears, pins and thrust washers.
Seals
Replace the seals, oil seal and O-ring, although they appear not damaged.
Part replacement criteria
Replace all parts that appear damaged or are not within the allowable value.
Replace some parts in sets, i.e.gears, bearings, pins and thrust washers.

Remove air in the track motor before operating.

1. Check that the gearbox axis is horizontal. Rotate the gearbox housing until the drain plug is on the bottom of the
vertical axis of the end cover.
The gearbox is supplied with oil plugs (draining, filling and level) equipped with an hole that allows the air to bleed.
NOTE!
Remove the oil plugs with care. When the gearbox is warm, the air inside can be pressurized and this can cause
their strongly expulsion towards the worker.

2. Loose with caution the plugs (2~3 rounds) counterclockwise.


3. Clean the plug to be sure that the air bleed hole is not obstructed.
4. Wait a few seconds to allow the pressurized air to bleed from the gearbox.
5. Remove the plugs and let the oil flow in a large enough container; in order to facilitate the draining must be oil still
warm.
6. Wait a few minutes until all the oil is drained and then proceed to screw on the plugs.
7. Proceed with the oil fill-up following the procedures given.

NOTE!
Never mix mineral oils with synthetic oils and vice versa.

Do not dispose of the oil in the natural environment but be careful to eliminate it in compliance with the relative rules and
regulations that govern locally.

Tightening torque plug. See track gearbox, description.

Part replacement criteria

Item Part Condition Allowable value


No.
8 Ring gear The tooth surface is pitted or non uniformly Area rate: within 5%
12 No.2 planetary gear worn.
20 No.2 sun gear The gear is cracked.
22 No.1 planetary gear
27 No.1 sun gear
23 Needle bearing Fitting/flaking of the balls, rollers or races.
13 Needle bearing Does not rotate smoothly by hand.
2 Angular bearing
3 Seal Rust or damage on sliding face.
O-ring distorted or damaged.
15 No.2 pin The pin is cracked, galled or pitted.
25 No.1 pin
24 Thrust washer Excessively worn on the face area.
14

General tools
General tools

No. Description Size Quantity


1 Socket wrench 19 mm 1
2 L wrench 5 mm 1
10 mm
3 Torque wrench 400 ~ 1800 kgf cm 1
4 Eye bolt PT 1/2 2
M10
M12
5 Plastic hammer Approximately L = 300 ~ 500 mm 1
6 Screwdriver Approximately L = 200 mm 1
7 Depth gauge Range approximately 300 mm 1
(Vernier calliper) Min.scale 0.01 mm

Special tools
Special tools

No. Description Size Quantity


1 Bearing shim adjust fixture 8932-00290 Measuring plate 1
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, replacing Service Information 2014/6/12
cover
Profile:
EXC, EC210B LC [GB]

Track gearbox, replacing cover


Op nbr 431-117

1. Park the machine in the service position B, see 091 Service positions.
Rotate the gearbox until the drain plug and level plug are on the vertical axis.

2. Remove the 2 plugs (1,2) on the cover and drain the oil into a suitable container.

Figure 1
Removal, plugs

3. Remove gearbox cover screws (2).


Tighten two set-screws (1) to separate cover (3) from track gearbox.

Figure 2
Removal, gearbox cover

4. Remove gearbox cover (3) from track gearbox.

5. Install the two set-screws to a new gearbox cover.

6. Install the new gearbox cover to the track gearbox.


NOTE!
Before replacing cover (2), thoroughly clean the mounting surface and then apply sealing compound (1) to the
mounting surface.

Figure 3
Applying, sealing compound

7. Install drain plug (1) and tighten it to the specified torque.

Figure 4
Installation, drain plug

8. Fill the oil through the level port until oil exits from the level check port.

9. Install the level check plug and tighten it to the specified torque.
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, disassembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, disassembly


Op nbr 00000

Precautions

 Thoroughly clean the gearbox assembly prior to disassembly.


 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures – Determine the root cause!

1. Place the oil filling port and the oil drain port on the vertical axis. Remove plug (32) and drain the gear oil.

 Tools: L wrench 10 mm (0.394 inch) (PT 1/2) 8 litries pan

NOTE!
Drain oil into a clean container and check thoroughly for contamination.

NOTE!
Loosen the plug (1) for air extrusion before oil drain.

Figure 1
Removal, plug

1. Fill port
2. Level check port
3. Drain port

2. Remove screws (30) and remove cover (28).


NOTE!
Install a screw (31) and carefully lift the cover off.
Figure 2
Removal, screw and cover

3. Remove No.1 planetary gear assembly (18) from No.2 planetary gear assembly (10).
Disassemble No.1 planetary gear assembly.

Figure 3
Removal, No. 1 planetary gear assembly

 Tap spring pin (26) into No.1 pin (25).


 Remove thrust washer (24), No.1 planetary gear (22) and needle bearing (23) from No.1 carrier (19).
 Remove thrust ring (17).
 Remove retaining ring (21), then No.2 sun gear (20).
 Remove thrust ring (17).

 Tools: Eye bolt (M10), Plastic hammer

WARNING
The parts are heavy. Take appropriate safety precautions.

NOTE!
Match mark gears (22), pins (25) and carrier (19).

NOTE!
Do not mix the gears, bearings, thrust washers, and pin assemblies.
Figure 5
Removal, spring pins
NOTE!
Do not reuse spring pins (26).

NOTE!
If there are any flakes at the surface of No.1 pin, replace No.1 pin, No.1 carrier (28), No.1 planetary gear
(33) and needle bearing (34) simultaneously.

4. Remove No.1 sun gear (27) and coupling (9).


NOTE!
Remove No.1 carrier (19) and then remove No.2, No.1 sun gear (20, 27).

WARNING
The parts are heavy. Take appropriate safety precautions.

Figure 6
Removal, No.1 sun gear and coupling

Figure 7
Removal, No.2 planetary gear assembly
5. Remove No.2 planetary gear assembly (10) from spindle (302).
Disassembling No.2 planetary gear assembly

 Tap spring pin (16) into No.2 pin (15).


 Remove thrust washer (14), No.2 planetary gear (12) and needle bearing (13) from No.2 carrier (11).

 Tools: Eye bolt (M10), Plastic hammer

NOTE!
Match mark gears (12), pins (15) and carrier (11).

NOTE!
Do not mix the gears, bearing, thrust washers, and pin assemblies.

Figure 9
Removal, spring pins
NOTE!
Do not reuse spring pins (16).

6. Screw the eye bolts into ring gear (8), and remove ring gear.

 Tools: Eye bolt (M12), Plastic hammer

Figure 10
Removal, ring gear

7. Remove screw (6), retainer (5) and shim (4).

 Tools: 19 mm (0.748 inch) socket (M 12)

NOTE!
Do not reuse the screws.
Figure 11
Removal, screw, retainer and shim

8. Screw the eye bolts into housing (1), and remove housing (1), parallel pin (7), angular bearing (2) and seal (3) as an
assembly.

 Tools: Eye bolt (M12), Plastic hammer

Figure 12
Removal, housing, pin, angular bearing and seal

WARNING
The parts are heavy. Take appropriate safety precautions.

NOTE!
When difficult to remove, lift the body vertically and tap lightly with a plastic hammer.

9. Remove seal (3) from housing (1). Remove seal (3) from motor casing (spindle 302).
NOTE!
Be careful not to damage the O-ring and seal surface.

10. Remove angular bearing (2) from housing (1).

 Tools: Bearing fixture, Plastic hammer

Figure 13
Removal, angular bearing
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, disassembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, disassembly


Op nbr 00000

Precautions

 Thoroughly clean the gearbox assembly prior to disassembly.


 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures – Determine the root cause!

1. Place the oil level port and the oil drain port on the vertical axis. Remove plug (32) and drain the gear oil.

 Tools: L wrench 14 mm (0.551 inch) (PF 3/4) 8 liter pan

NOTE!
Drain oil into a clean container and check thoroughly for contamination.

NOTE!
Loosen the plug (1) for air extrusion before oil drain.

Figure 1
Removal, plug

1. Level check port


2. Filling and drain port

2. Remove screws (30) and remove cover (28).

 Tools: L wrench 10 mm (0.394 inch), 5 mm (0.197 inch)

NOTE!
Install a screw (31) and carefully lift the cover off.
Figure 2
Removal, screw and cover

3. Remove No.1 planetary gear assembly (18) from No.2 planetary gear assembly (10).
Disassemble No.1 planetary gear assembly.

Figure 3
Removal, No. 1 planetary gear assembly

 Tap spring pin (26) into No.1 pin (25).


 Remove thrust washer (24), No.1 planetary gear (22) and needle bearing (23) from No.1 carrier (19).
 Remove thrust ring (17).
 Remove retaining ring (21), then No.2 sun gear (20).
 Remove thrust ring (17).

 Tools: Eye bolt (M10), Plastic hammer

WARNING
The parts are heavy. Take appropriate safety precautions.

NOTE!
Match mark gears (22), pins (25) and carrier (19).

NOTE!
Do not mix the gears, bearings, thrust washers, and pin assemblies.
Figure 5
Removal, spring pins
NOTE!
Do not reuse spring pins (26).

NOTE!
If there are any flakes at the surface of No.1 pin, replace No.1 pin, No.1 carrier (28), No.1 planetary gear
(33) and needle bearing (34) simultaneously.

4. Remove No.1 sun gear (27) and coupling (9).


NOTE!
Remove No.1 carrier (19) and then remove No.2, No.1 sun gear (20, 27).

WARNING
The parts are heavy. Take appropriate safety precautions.

Figure 6
Removal, No.1 sun gear and coupling

Figure 7
Removal, No.2 planetary gear assembly
5. Remove No.2 planetary gear assembly (10) from spindle (302).
Disassembling No.2 planetary gear assembly

 Tap spring pin (16) into No.2 pin (15).


 Remove thrust washer (14), No.2 planetary gear (12) and needle bearing (13) from No.2 carrier (11).

 Tools: Eye bolt (M10), Plastic hammer

NOTE!
Match mark gears (12), pins (15) and carrier (11).

NOTE!
Do not mix the gears, bearing, thrust washers, and pin assemblies.

Figure 9
Removal, spring pins
NOTE!
Do not reuse spring pins (16).

6. Screw the eye bolts into ring gear (8), and remove ring gear.

 Tools: Eye bolt (M12), Plastic hammer

Figure 10
Removal, ring gear

7. Remove screw (6), retainer (5) and shim (4).

 Tools: 19 mm socket (M 12)

NOTE!
Do not reuse the screws.
Figure 11
Removal, screw, retainer and shim

8. Screw the eye bolts into housing (1), and remove housing (1), parallel pin (7), angular bearing (2) and seal (3) as an
assembly.

 Tools: Eye bolt (M12), Plastic hammer

Figure 12
Removal, housing, pin, angular bearing and seal

WARNING
The parts are heavy. Take appropriate safety precautions.

NOTE!
When difficult to remove, lift the body vertically and tap lightly with a plastic hammer.

9. Remove seal (3) from housing (1). Remove seal (3) from motor casing (spindle 302).
NOTE!
Be careful not to damage the O-ring and seal surface.

10. Remove angular bearing (2) from housing (1).

 Tools: Bearing fixture, Plastic hammer

Figure 13
Removal, angular bearing
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, assembly


Op nbr 00000

Preparation

 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Replace the O-rings and seals.
 Replace screws (6). DO NOT REUSE THESE SCREWS!

Tightening torque, Nm (kgf m) (lbf ft)

Item Part name Thread size Tightening torque


6 Screw M12 112.8 (11.5) (83)
30 Screw M12 132.4 (13.5) (98)
31 Screw M10
32 Plug PT 1/2 64.7 (6.6) (48)
32 Plug PF 3/4 186.3 (19) (137)

1. Press–fit angular bearing (2) into housing (1).

 Tools: Plastic hammer, Bench press

NOTE!
The outer races of the angular bearing must be properly aligned and fully seated.

NOTE!
Press–fit using a press or hammer.

Figure 1
Assembly, angular bearing

2. Press-fit seal (3) lightly into housing (1).


Press-fit lightly seal (3) onto the motor casing (spindle 302).
Assemble housing (1) onto the motor aligning the angular bearing inner race to the motor housing.
NOTE!
After assembling the seal, check if the O-ring is properly seated on the motor housing.
NOTE!
Apply a thin coat of grease (NLGI #2) to the o-ring.

NOTE!
Take care not to damage the mating surface of the seal.

Figure 2
Assembly, seal

3. Shim adjusting method:

 Measure the step on retainer (5) as shown. Dimension "B".


 Install shim thickness measuring tool (C) on inner race of bearing, and tighten four screws (6) to the
specified torque.

 Tools: See the shim thickness measuring fixture of the special tools (part number: 8932-00290
Measuring plate).

NOTE!
Tightening torque: 0.8 kgf m (6 lbf ft)

 Measure the dimension "A" from the top of the inner race of bearing to the motor as shown.
 Measure the dimension "B" of retainer (5).
 Shim thickness S = B – A + (0 ~ 0.05 mm)
 Select a shim (4) of the appropriate thickness, align the retainer (5) correctly, and tighten screws (6) to the
specified torque.

 Tools: 19 mm socket (M12), Torque wrench, Depth gauge

NOTE!
Shim: 0.1, 0.9, 1.0, and 1.2 mm

NOTE!
Torque: 0.8 kgf·m (6 lbf·ft)

NOTE!
Apply loctite # 277 onto the thread of screws (6).

Figure 3
Adjustment, shim
4. Mount parallel pin (7) into housing (1), align ring gear (8) correctly, and screws.

 Tools: Plastic hammer

NOTE!
Coat the mating surface of ring gear (8) with liquid gasket, loctite #5699.

NOTE!
Install 4 screws (30) temporarily.

Figure 4
Mount, pin

A. Applying, loctite

5. No.2 planetary gear assembly

 Place No.2 carrier (11) with its spline downward.


 Install thrust washers (14), No.2 planetary gear (12) and needle bearing (13) into No.2 carrier.
 Insert No.2 pin (15).
 Tap spring pin (16) into the pin holes of the No.2 carrier (11), and pin (15), then stake two points on No.2
carrier (11).

 Tools: Plastic hammer

NOTE!
Check if No.2 planetary gears rotate smoothly.

NOTE!
Align the spring pin holes of the carrier and No.2 pins.

NOTE!
Staking method:

WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 5
No.2 planetary gear assembly

A. Stake

6. Fit No.2 planetary gear assembly (10) into the spline of the motor correctly.

 Tools: Eye bolt (M10)

Figure 6
Fitting, No.2 planetary gear assembly

7. Insert coupling (9), and then No.1 sun gear (27) onto the motor shaft.
Figure 7
Insertion, coupling

8. No.1 planetary gear assembly.

 Install thrust ring (17) into No.1 carrier (19).


 Install assembled No.1 carrier onto No.2 sun gear (20), and mount retaining ring (21).
 Install thrust washers (24), No.1 planetary gear (22) and needle bearing (23) into No.1 carrier (19).
 Insert No.1 pin (25).Tap spring pin (26) into the pin holes of the No.1 carrier (17) and pin (25), then stake
two points on No.1 carrier (19).
 Insert thrust ring (17) into No.1 carrier (19).

 Tools: Plastic hammer

NOTE!
Align the spring pin holes of the carrier and No.1 pins.

NOTE!
Staking method:

NOTE!
Check if No.1 planetary gears rotate smoothly.

WARNING
The parts are heavy. Take appropriate safety precautions.

Figure 8
No.1 planetary gear assembly

A. Stake

9. Insert No.1 planetary gear assembly (18) into No.2 planetary gear assembly (10).

 Tools: Eye bolt (M10)


Figure 9
Insertion, No.1 planetary gear assembly

10. Install plugs (32) into cover (28) and tighten to specified torque.

 Tools: Torque wrench, L wrench 10 mm (PT 1/2)

Figure 10
Installation, plug
Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Track gearbox, assembly


Op nbr 00000

Preparation

 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Replace the O-rings and seals.
 Replace screws (6). DO NOT REUSE THESE SCREWS!
 Use a torque wrench to tighten the screws and plugs to the specified torque.

Tightening torque
Tightening torque, unit: Nm (kgf m) (lbf ft)

Item Part name Thread size Tightening torque


6 Screw M12 112.8 (11.5) (83)
30 Screw M12 132.4 (13.5) (98)
31 Screw M10
32 Plug PT 1/2 64.7 (6.6) (48)
32 Plug PF 3/4 186.3 (19) (137)

1. Press-fit angular bearing (2) into housing (1).

 Tools: Plastic hammer, Bench press

NOTE!
The outer races of the angular bearing must be properly aligned and fully seated.

NOTE!
Press–fit using a press or hammer.

Figure 1
Assembly, angular bearing

2. Press-fit seal (3) lightly into housing (1).


Press-fit lightly seal (3) onto the motor casing (spindle 302).
Assemble housing (1) onto the motor aligning the angular bearing inner race to the motor housing.
NOTE!
After assembling the seal, check if the O-ring is properly seated on the motor housing.

NOTE!
Apply a thin coat of grease (NLGI #2) to the O-ring.

NOTE!
Take care not to damage the mating surface of the seal.

Figure 2
Assembly, seal

3. Shim adjusting method:

 Measure the step on retainer (5) as shown. Dimension "B".


 Install shim thickness measuring tool (C) on inner race of bearing, and tighten four screws (6) to the
specified torque.

 Tools: See the shim thickness measuring fixture of the special tools (part number: 8932-00290
Measuring plate).

NOTE!
Tightening torque: 7.85 Nm (0.8 kgf m) (6 lbf ft)

 Measure the dimension "A" from the top of the inner race of bearing to the motor as shown.
 Measure the dimension "B" of retainer (5).
 Shim thickness S = B – A + (0 ~ 0.05 mm)
 Select a shim (4) of the appropriate thickness, align the retainer (5) correctly, and tighten screws (6) to the
specified torque.

 Tools: 19 mm socket (M12), Torque wrench, Depth gauge

NOTE!
Shim: 0.1, 0.9, 1.0, and 1.2 mm

NOTE!
Torque: 7.85 Nm (0.8 kgf m) (6 lbf ft)

NOTE!
Apply loctite # 277 onto the thread of screws (6).

Figure 3
Adjustment, shim

4. Mount parallel pin (7) into housing (1), align ring gear (8) correctly, and screws.

 Tools: Plastic hammer

NOTE!
Coat the mating surface of ring gear (8) with liquid gasket, loctite #5699.

NOTE!
Install 4 screws (30) temporarily.

Figure 4
Mount, pin

A. Applying, loctite

5. No.2 planetary gear assembly

 Place No.2 carrier (11) with its spline downward.


 Install thrust washers (14), No.2 planetary gear (12) and needle bearing (13) into No.2 carrier.
 Insert No.2 pin (15).
 Tap spring pin (16) into the pin holes of the No.2 carrier (11), and pin (15), then stake two points on No.2
carrier (11).

 Tools: Plastic hammer

NOTE!
Check if No.2 planetary gears rotate smoothly.

NOTE!
Align the spring pin holes of the carrier and No.2 pins.

NOTE!
Staking method:

WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 5
No.2 planetary gear assembly

A. Stake

6. Fit No.2 planetary gear assembly (10) into the spline of the motor correctly.

 Tools: Eye bolt (M10)

Figure 6
Fitting, No.2 planetary gear assembly

7. Insert coupling (9), and then No.1 sun gear (27) onto the motor shaft.
Figure 7
Insertion, coupling

8. No.1 planetary gear assembly.

 Install thrust ring (17) into No.1 carrier (19).


 Install assembled No.1 carrier onto No.2 sun gear (20), and mount retaining ring (21).
 Install thrust washers (24), No.1 planetary gear (22) and needle bearing (23) into No.1 carrier (19).
 Insert No.1 pin (25). Tap spring pin (26) into the pin holes of the No.1 carrier (17) and pin (25), then stake
two points on No.1 carrier (19).
 Insert thrust ring (17) into No.1 carrier (19).

 Tools: Plastic hammer

NOTE!
Align the spring pin holes of the carrier and No.1 pins.

NOTE!
Staking method:

NOTE!
Check if No.1 planetary gears rotate smoothly.

WARNING
The parts are heavy. Take appropriate safety precautions.

Figure 8
No.1 planetary gear assembly

A. Stake

9. Insert No.1 planetary gear assembly (18) into No.2 planetary gear assembly (10).

 Tools: Eye bolt (M10)


Figure 9
Insertion, No.1 planetary gear assembly

10. Screw an eye bolt into the oil level port and install cover (28) on ring gear (8).Install screw (31), screws (30), and
tighten to specified torque.

 Tools: Eye bolt (PT 1/2), L wrench 10 mm (M12), Torque wrench, Plastic hammer

NOTE!
Coat the mating surface of ring gear (8) with liquid gasket, loctite #5699.

NOTE!
Apply loctite #277 onto the threads of screws (30).

Figure 10
Installation, cover

11. Install plugs (32) into cover (28) and tighten to specified torque.

 Tools: Torque wrench, L wrench 14 mm (PF 3/4)


Figure 11
Installation, plug
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, description


Slew gearbox consists of the driving shaft as a group including the 1st planetary gear assembly, the 2nd planetary gear
assembly and the 1st and 2nd sun gear pinions, the housing supporting the driving shaft, and the ring gear including the
planetary gear.
Model code

Figure 1
Model code

1. Serial No
2. Reduction ratio code
3. Size No. (Theoretical output torque
ex. 100 = 1000 kgf·m
4. Type No.
(ex. S = Slew gearbox)

Slew gearbox, sectional view


Figure 2
Slew gearbox, sectional view

1 No.2 planetary gear assembly 17 Bearing 32 Bearing


2 No.2 carrier 18 Retaining ring 33 washer
3 No.2 planetary gear 19 Case 34 washer
4 No.2 pin assembly 20 Ring gear 35 Retaining ring
5 No.2 pin 21 Dowel pin 36 Spring pin
6 Bushing 22 Screw 37 No.1 sun gear
8 washer 23 Plate 38 Retaining ring
9 Spring pin 24 Screw 39 Level gauge
10 Drive shaft 25 Thrust ring 40 Pipe
11 Collar 26 No.2 sun gear 41 Name plate
12 Cover 27 Thrust washer 42 Screw
13 O-ring 28 No.1 planetary gear assembly 43 Drain valve
14 Seal 29 No.1 carrier 44 Pipe
15 Screw 30 No.1 planetary gear
16 Bearing 31 No.1 pin
Function
The 2–stage planetary gear reduction assembly converts the high speed / low torque output of the hydraulic motor to low
speed / high torque output, which is transmitted via the reduction drive shaft pinion gear to the slew ring inner
circumference gear to rotate the superstructure.
Operation
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (26) through the splines of the
1st sun gear (37), the 1st planetary gear (30), the 1st pin (31) and the 1st carrier (29). In the same way, power is transmitted
to output shaft (10) through the splines of the 2nd planetary gear (3), the 2nd pin (5) and the 2nd carrier (2).

Figure 3
Slew gearbox

A. Torque flow

At this time, the reduction ratio of reduction gear is as follows :

 1st reduction ratio


i1 = (Zr / ZS1) + 1
i1 = 1st reduction ratio
ZS1 = No. of gear teeth of the 1st sun gear
Zr = No. of tooth of ring gear
 2nd reduction ratio
i2 = (Zr / ZS2) + 1
i2 = 2nd reduction ratio
ZS2 = No. of gear teeth of the 2nd sun gear
Accordingly the total reduction ratio of reduction gear is as follows :
i = i1 × i2
= (Zr / ZS1 + 1) × (Zr / ZS2 + 1)
i = Total reduction ratio
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, description


Slew gearbox consists of the driving shaft as a group including the 1st planetary gear assembly, the 2nd planetary gear
assembly and the 1st and 2nd sun gear pinions, the housing supporting the driving shaft, and the ring gear including the
planetary gear.
Model code

Figure 1
Model code

1. Serial No
2. Reduction ratio code
3. Size No. (Theoretical output torque
ex. 100 = 1000 kgf·m
4. Type No.
(ex. S = Slew gearbox)

Slew gearbox, sectional view


Figure 2
Slew gearbox, sectional view

1 No.2 planetary gear assembly 17 Bearing 32 Bearing


2 No.2 carrier 18 Retaining ring 33 washer
3 No.2 planetary gear 19 Case 34 washer
4 No.2 pin assembly 20 Ring gear 35 Retaining ring
5 No.2 pin 21 Dowel pin 36 Spring pin
6 Bushing 22 Screw 37 No.1 sun gear
8 washer 23 Plate 38 Retaining ring
9 Spring pin 24 Screw 39 Level gauge
10 Drive shaft 25 Thrust ring 40 Pipe
11 Collar 26 No.2 sun gear 41 Name plate
12 Cover 27 Thrust washer 42 Screw
13 O-ring 28 No.1 planetary gear assembly 43 Drain valve
14 Seal 29 No.1 carrier 44 Pipe
15 Screw 30 No.1 planetary gear
16 Bearing 31 No.1 pin
Function
The 2–stage planetary gear reduction assembly converts the high speed / low torque output of the hydraulic motor to low
speed / high torque output, which is transmitted via the reduction drive shaft pinion gear to the slew ring inner
circumference gear to rotate the superstructure.
Operation
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (26) through the splines of the
1st sun gear (37), the 1st planetary gear (30), the 1st pin (31) and the 1st carrier (29). In the same way, power is transmitted
to output shaft (10) through the splines of the 2nd planetary gear (3), the 2nd pin (5) and the 2nd carrier (2).

Figure 3
Slew gearbox

A. Torque flow

At this time, the reduction ratio of reduction gear is as follows :

 1st reduction ratio


i1 = (Zr / ZS1) + 1
i1 = 1st reduction ratio
ZS1 = No. of gear teeth of the 1st sun gear
Zr = No. of tooth of ring gear
 2nd reduction ratio
i2 = (Zr / ZS2) + 1
i2 = 2nd reduction ratio
ZS2 = No. of gear teeth of the 2nd sun gear
Accordingly the total reduction ratio of reduction gear is as follows :
i = i1 × i2
= (Zr / ZS1 + 1) × (Zr / ZS2 + 1)
i = Total reduction ratio
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, lubrication Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, lubrication


Precautions for lubrication

 Check the oil level prior to operating the slew function.


 Check for oil leakage on the motor and gearbox assembly.
 Check for loose mounting screws.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
 Check the slew performance against the operating specifications.

WARNING
The temperature of the case is high just after running. Do not touch directly by hand to prevent a burn injury. Check
the temperature with a surface thermometer.

The temperature of the case must be lower than the ambient temperature + 60 °C, during continuous operation.
Gear oil specification

 Use a gear oil equivalent to SAE 90 or 140, API classification GL4 / GL5.

Gear oil replacement

 First (initial) oil replacement : 500 operating hours


 Subsequent oil replacement : 1000 operating hours
 After maintenance (initial) : 500 operating hours

NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.

NOTE!
Do not mix different types, classifications or brands of oil.

Gear oil level

Figure 1
Check, oil level

A. Level

* The level gauge also serves as an air breather for the gearbox.

 Take out the level gauge, wipe it on a clean cloth, re-insert, take out, and then check if the oil is within the slanting
lines as shown.
Gear oil replacement

Figure 2
Replacing, gear oil

 Open drain valve cap (D) from the drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into
a suitable container.
 After completely draining, remove drain hose (E), then close drain valve cap (D).
 After removing oil level gauge (A), refill the gearbox through the oil filling pipe using a funnel that allows the pipe
to breathe.
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, lubrication Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, lubrication


Precautions for lubrication

 Check the oil level prior to operating the slew function.


 Check for oil leakage on the motor and gearbox assembly.
 Check for loose mounting screws.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
 Check the slew performance against the operating specifications.

WARNING
The temperature of the case is high just after running. Do not touch directly by hand to prevent a burn injury. Check
the temperature with a surface thermometer.

The temperature of the case must be lower than the ambient temperature +60 °C, during continuous operation.
Gear oil specification

 Use a gear oil equivalent to SAE 90 or 140, API classification GL4 / GL5.

Gear oil replacement

 First (initial) oil replacement : 500 operating hours


 Subsequent oil replacement : 1000 operating hours
 After maintenance (initial) : 500 operating hours

NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.

NOTE!
Do not mix different types, classifications or brands of oil.

Gear oil level

Figure 1
Check, oil level

A. Level

* The level gauge also serves as an air breather for the gearbox.

 Take out the level gauge, wipe it on a clean cloth, re-insert, take out, and then check if the oil is within the slanting
lines as shown.
Gear oil replacement

Figure 2
Replacing, gear oil

NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.

 Open drain valve cap (D) from the drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into
a suitable container.
 After completely draining, remove drain hose (E), then close drain valve cap (D).
 After removing oil level gauge (A), refill the gearbox through the oil filling pipe using a funnel that allows the pipe
to breathe.
Service Information

Document Title: Function Group: Information Type: Date:


Swing gearbox, Service Information 2014/6/12
maintenance standard
Profile:
EXC, EC210B LC [GB]

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Swing gearbox, maintenance standard


The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier(s) together, do not mix the bushing, gears, pins and thrust washers.
Seals
Replace the seals and O-rings, although they appear not damaged.
Part replacement criteria

 Replace all parts that appear damaged or are not within the allowable value.
 Replace some parts in sets, i.e. gears, bushings and thrust washers.

Part replacement criteria

Item Part name Condition Standard value Allowable value


No.
37 No.1 sun gear Pitting on gear teeth surface. – Diameter clearance:
26 No.2 sun gear within φ 1 mm (0.039
30 No.1 planetary gear in)
3 No.2 planetary gear – Area ratio: within 5
20 Ring gear %
30 No.1 planetary gear Flaking on the needle bearing
31 No.1 pin sliding surface.
32 Needle bearing Partial wear
3 No.2 planetary gear Wear on outer diameter of
4 No.2 pin assembly bushing.
25 Thrust ring Wear on the shaft contact surface. Diameter clearance: Diameter clearance:
0.13 ~ 0.254 mm within 0.45 mm (0.018
(0.005 ~ 0.01 in) in)
38 Retaining ring Abnormal wear on the face area. Oil groove depth:
35 Retaining ring within 0.5 mm (0.02
18 Retaining ring in)
8 Thrust washer Abnormal wear on the face area.
33 Thrust washer
34 Thrust washer
27 Thrust washer
17 Spherical bearing Pitting/flaking of the race or rollers.
16 Spherical bearing Does not rotate smoothly by hand.
14 Oil seal Always replace.

General tools
General tools

No. Description Size Quantity


1 Spanner 17 × 19 mm (0.67 × 0.75 in) 1
24 × 27 mm (0.95 × 1.1 in) 1
2 Socket wrench – 1
3 Allen wrench 10 mm (0.39 in) 1
14 mm (0.55 in) 1
4 Torque wrench 3923 ~ 17652 Nm (2888 ~ 12996 lbf ft) 1
11768 ~ 47072 Nm (8664 ~ 34656 lbf ft) 1
5 Retaining ring pliers φ 35 1
φ 42
φ 90
6 Bearing puller – –
7 Plastic hammer – 1
8 Eye bolt M8 2
M12 2
M16 2
M18 2
9 (–) Screwdriver 150 mm (5.9 in) 1

Special tools
8932-00600 Drift
Special tools

No. Description Part number Quantity


1 Bearing assembly jig 8920-00280 1

2
3 Oil seal assembly jig 8920-00550 1

4 Oil seal assembly guide jig 8920-00570 1

5 Oil seal assembly guide jig 8920-00560 1


Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, maintenance Service Information 2014/6/12
standard
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, maintenance standard


The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier(s) together, do not mix the bushing, gears, pins and thrust washers.
Seals
Replace the oil seal and o-ring, although they appear not damaged.
Part replacement criteria

 Replace all parts that appear damaged or are not within the allowable value.
 Replace some parts in sets, i.e. gears, bushings and thrust washers.

Wear limit

Item Part name Condition Standard value Allowable value


No.
37 No.1 sun gear Pitting on gear teeth surface. Diameter
26 No.2 sun gear clearance :
30 No.1 planetary gear Within φ 1 mm
3 No.2 planetary gear Area ratio :
20 Ring gear Within 5 %

30 No.1 planetary gear Flaking on the needle bearing


31 No.1 pin sliding surface.
32 Needle bearing Partial wear
3 No.2 planetary gear Wear on outer diameter of bushing.
4 No.2 pin assembly
25 Thrust ring Wear on the shaft contact surface. Diameter clearance : Diameter
0.13 ~ 0.254 mm clearance :
Within 0.45 mm
38 Retaining ring Abnormal wear on the face area. Oil groove depth
35 Retaining ring : Within 0.5 mm
18 Retaining ring
8 Thrust washer Abnormal wear on the face area.
33 Thrust washer
34 Thrust washer
27 Thrust washer
17 Spherical bearing Pitting / Flaking of the race or
rollers.
16 Spherical bearing Does not rotate smoothly by hand.
14 Oil seal Always replace.
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, install Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Slew gearbox, install


Op nbr 00000

1. Install slew gearbox after coating the frame surface ("A") with liquid gasket, loctite # 5699.

2. Install slew gearbox (2) onto upper frame (4), then install screws (3 ).
NOTE!
Apply loctite #277 onto the threads of screws (3).

3. After tightening screw, seal it including head part of pin (1) at "B" with liquid gasket, loctite # 5699.
NOTE!
Be careful not to break oil drain pipe (5).

NOTE!
Prior to start up, purge the air from the circuit of the plumbing and the slew motor.

Figure 1
Slew gearbox, install
Service Information

Document Title: Function Group: Information Type: Date:


Swing gearbox, replacing Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Swing gearbox, replacing


Op nbr 431-021

1. Park the machine in the service position C. See 091 Service positions.

2.  When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
 Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
 Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
 After disconnecting the hose, install a plug to prevent oil leakage and contamination.

3. Remove the under cover.

4. Open the oil drain valve cap and install the oil drain hose. Drain the gearbox oil into a suitable container.

Figure 1
Draining, gearbox oil

1. Oil drain valve cap


2. Oil drain hose

5. Remove the anti-cavitation hose.

Figure 2
Removal, hoses

1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses

6. Remove the swing motor drain hose.

7. Remove the swing motor feed line hoses.

8. Remove the delay valve sub hoses.

9. Remove the swing gearbox mounting screws and remove the silicone from both back step holes.

Figure 3
Removal, mounting screws

1. Screws
2. Silicone

10. Install the back step screws to separate the swing gearbox from the superstructure.
NOTE!
The gearbox housing is not removed easily because of the dowel pin.

Figure 4
Installation, back step screw

1. Back step screw

11. Lift the swing unit with the sling, and lower to the workbench safely.
Figure 5
Removal, swing unit

1. Sling
2. Screws

12. Remove the screws, lift the swing motor with sling, and install it to a new swing gearbox.
NOTE!
Before installing the swing motor, thoroughly remove the sealing compound on the mounting surface.

NOTE!
Apply sealing compound to the mounting surface of the new swing gearbox and then install the swing motor.

13. Transfer drain pipe and dowel pin, to the new swing gearbox.

Figure 6
Transferring, drain pipe and dowel pin

1. Drain pipe
2. Dowel pin

14. Lift the swing unit with the hoist, and install it to the machine.
Figure 7
Installation, swing unit

1. Screws
2. Silicone

NOTE!
Before installing the swing unit, thoroughly remove the sealing compound on the seat surface of the
superstructure.

NOTE!
Apply sealing compound to the seat surface of the superstructure, and then install the swing unit.

NOTE!
Apply the loctite #277 to the mounting screws, and tighten them to the specified torque.

15. Fill the both back step holes, and cover the dowel pin with silicone.

16. Install the swing motor feed line hoses.

Figure 8
Installation, hoses

1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses

17. Install the delay valve sub hoses.

18. Install the swing motor drain hose.

19. Install the anti-cavitation hose.


20. Remove the vacuum pump mounted on the hydraulic tank.

21. Fill the gearbox oil through the oil filling pipe.

22. Bleed air from the hydraulic circuit at the swing motor before operating.

23. After completion of the work, start the engine and check for leaks.
Service Information

Document Title: Function Group: Information Type: Date:


Swing unit, replacing Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Swing unit, replacing


Op nbr 431-053

14360000 Vacuum pump / 24V

1. Replacing the swing unit. See 4312 Swing gearbox, replacing.


Service Information

Document Title: Function Group: Information Type: Date:


Track gearbox, tools Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Track gearbox, tools


General tools
General tools

No. Description Size Quantity


1 Spanner 17 × 19mm 1
24 × 27mm 1
2 Socket wrench 1
3 Allen wrench 10mm 1
14mm 1
4 Torque wrench 400 ~ 1800 1
1200 ~ 4800 1
5 Snap ring pliers φ 35 1
φ 42
φ 90
6 Bearing puller –
7 Plastic hammer – 1
10 Eye bolt M8 2
M 12 2
M 16 2
M 18 2
11 (–) Screwdriver 150 mm 1

Special tools
Special tools

No. Description Quantity


1 Bearing assembly jig 8920-00280 Drift 1
2 Bearing assembly jig 8932-00600 Drift 1
3 Oil seal assembly jig 8920-00550 Drift 1
4 Oil seal assembly guide jig 8920-00570 Drift 1
5 Oil seal protector 8920-00560 1

Bearing assembly jig, unit : mm


Figure 1
Jig for bearing assembly

Bearing assembly jig, unit : mm

Figure 2
Jig for bearing assembly

Oil seal assembly jig (unit : mm)


Figure 3
Jig for oil seal assembly

Oil seal assembly guide jig, unit : mm

Figure 4
Jig for oil seal assembly guide

Oil seal assembly guide jig, unit : mm

Figure 5
Jig for oil seal assembly guide
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, Service Information 2014/6/12
troubleshooting
Profile:
EXC, EC210B LC [GB]

Slew gearbox, troubleshooting


Track gearbox troubleshooting

Gearbox does not rotate. The machine is overloaded. Reduce the load.

Gearbox is damaged. Replace the gearbox.

Oil leakage from mating joint Liquid gasket improperly applied. Disassemble and re-apply.
surfaces.

Mating surface damaged. Repair or replace.

Loose screws. Tighten to specified torque.

Loose plug. Tighten to specified torque.

Leakage from the shaft. Oil seal damaged. Replace the oil seal.

Shaft seal contact area damaged. Repair or replace the output


shaft.

O-ring distorted. Replace the gearbox.

Abnormal operating temperature. Insufficient gear oil. Refill to specified level.

Gear or bearing damaged. Replace the gearbox.

Abnormal operating sound. Gearbox is damaged. Replace the gearbox.


Service Information

Document Title: Function Group: Information Type: Date:


Swing gearbox, Service Information 2014/6/12
disassembly
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing gearbox, disassembly


Precautions

 Thoroughly clean the gearbox assembly prior to disassembly.


 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix the parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures.

 Determine the root cause!

Disassembly

1. Open drain valve cap (D) from drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into a
suitable container.

Figure 1
Removal, hydraulic motor
2. After completely draining, remove drain hose (E), then close drain valve cap (D).
3. Remove screws (24).
4. Lift the motor off the gearbox.
NOTE!
Make match marks (A) on hydraulic motor casing (301), plate (23), ring gear (20), and case (19).

Make sure match marks (A) are permanent and clearly visible.

5. Remove screws (22).


Figure 2
Removal, screw and plate
6. Remove plate (23).
7. Remove 1st sun gear (37).

Figure 3
Removal, 1st sun gear
8. Remove 1st planetary gear assembly (28) from ring gear (20).
Disassemble the 1st planetary gear assembly in the following order:

Figure 4
Removal, retaining ring

 Remove retaining ring (35), and then thrust washer (34), planetary gear (30), needle bearing (32) and
thrust washer (33).
 Remove thrust washer (27).
 Remove spring pin (36) from carrier (29) to take out pin (31).

NOTE!
Match mark gears (30), pins (31) and carrier (29).

NOTE!
Do not remove pins (31) if not worn or damaged.

NOTE!
Do not reuse spring pins (36).

Figure 5
Removal, spring pin
9. Remove ring gear (20) and dowel pin (21).

Figure 6
Removal, 2nd sun gear
10. Remove 2nd sun gear (26) and thrust ring (25).
11. Remove 2nd planetary gear assembly (1) from shaft (10).
Disassemble the 2nd planetary gear assembly in the following order:

Figure 7
Removal, 2nd planetary gear

 Tap spring pin (9) into pin (5).


 Remove pin (5) and bushing (6) from carrier (2).
 Remove planetary gear (3) thrust washers (8).

NOTE!
Match mark gears (3), pins (5), and carrier (2).

NOTE!
Do not mix the gears, thrust washers, bushings, and pin assemblies.

NOTE!
Do not reuse spring pins (9).

To remove spring pin (9), tap it into pin (5).

After removing pin (5), remove the spring pin.

12. Remove retaining ring (18).


Figure 8
Removal, retaining ring
13. Remove screws (15).

Figure 9
Removal, cover and oil seal
14. Remove cover (12).
15. Remove oil seal (14).
NOTE!
Do not reuse the oil seal

16. Block the reduction gear as shown.


Press shaft (10) from case (19).

Figure 10
Removal, shaft
17. Press spherical bearing (16) and collar (11) from shaft (10).
Figure 11
Removal, spherical bearing
NOTE!
If it is difficult to remove spherical bearing (16) as illustrated, use a bearing puller.

NOTE!
Be careful not to damage collar (11) by excessive force.

18. Remove O-ring (13) from collar (11).

Figure 12
Removal, O-ring
NOTE!
Do not reuse the O-ring.

19. Press spherical bearing (17) from case (19).

Figure 13
Removal, spherical bearing
NOTE!
Spherical bearing (17) can also be removed using a bench press.
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, disassembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, disassembly


Precautions

 Thoroughly clean the gearbox assembly prior to disassembly.


 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix the parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures.

 Determine the root cause !

Disassembly

Op nbr 00000

1. Removal of hydraulic motor.

Figure 1
Removal, hydraulic motor

 Open drain valve cap (D) from the drain valve (C) and connect drain hose (E) to drain valve (C) and drain
the oil into a suitable container.
 After completely draining, remove drain hose (E), then close drain valve cap (D).
 Remove screws (24).
 Lift the motor off the gearbox.

NOTE!
Match marks "A"

Make match marks on hydraulic motor casing (301), plate (23), ring gear (20), and case (19).
Make sure the match marks are permanent and clearly visible.

2. Removal of motor mount plate.

Figure 2
Removal, plate

 Remove screws (22).


 Remove plate (23).

3. 1st sun gear.

Figure 3
Removal, 1st sun gear

 Remove 1st sun gear (37).

4. 1st planetary gear assembly.


Remove 1st planetary gear assembly (28) from ring gear (20).
Disassemble the 1st planetary gear assembly in the following order :

Figure 4
Removal, retaining ring

 Remove retaining ring (35), and then thrust washer (34), planetary gear (30), needle bearing (32) and
thrust washer (33).
 Remove thrust washer (27).
 Remove spring pin (36) from carrier (29) to take out pin (31).

NOTE!
Match mark gears (30), pins (31) and carrier (29).
Do not remove pins (31) if not worn or damaged.

Do not reuse spring pins (36).

Figure 5
Removal, spring pin

5. Ring gear

 Remove ring gear (20) and dowel pin (21).

6. 2nd sun gear.

Figure 6
Removal, 2nd sun gear

 Remove 2nd sun gear (26) and thrust ring (25).

7. 2nd planetary gear assembly

Figure 7
Removal, 2nd planetary gear

 Remove 2nd planetary gear assembly (1) from shaft (10).


 Disassemble the 2nd planetary gear assembly in the following order :
 Tap spring pin (9) into pin (5).
 Remove pin (5) and bushing (6) from carrier (2).
 Remove planetary gear (3) thrust washers (8).

NOTE!
Match mark gears (3), pins (5), and carrier (2).

Do not mix the gears, thrust washers, bushings, and pin assemblies.

Do not reuse spring pins (9).


To remove spring pin (9), tap it into pin (5).

After removing pin (5), remove the spring pin.

8. Retaining ring

Figure 8
Removal, retaining

 Remove retaining ring (18).

9. Cover and oil seal

Figure 9
Removal, cover and oil seal

 Remove screws (15).


 Remove cover (12).
 Remove oil seal (14).

NOTE!
Do not reuse the oil seal

10. Shaft
Figure 10
Removal, shaft

 Block the reduction gear as shown.


 Press shaft (10) from case (19).

11. Press spherical bearing (16) and collar (11) from shaft (10).

Figure 11
Removal, spherical bearing
NOTE!
If it is difficult to remove spherical bearing (16) as illustrated, use a bearing puller.

NOTE!
Be careful not to damage collar (11) by excessive force.

12. Remove O-ring (13) from collar (11).


Figure 12
Removal, o-ring
NOTE!
Do not reuse the O-ring.

13. Bearing

Figure 13
Removal, spherical bearing

 Press spherical bearing (17) from case (19).

NOTE!
Spherical bearing (17) can also be removed using a bench press.
Service Information

Document Title: Function Group: Information Type: Date:


Swing gearbox, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing gearbox, assembly


8920-00550 Drift8920-00570 Drift8920-00280 Drift8932-00600 Drift
Tool part number: 8920–00550
Precautions

 When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain/fill ports are properly positioned.
 Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
 Use a torque wrench to tighten the mounting screws to the specified torque.
 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Replace the O-ring and oil seal.
 Use a torque wrench to tighten the screws and plugs to the specified torque.

Tightening torque
NOTE!
Swing gearbox, sectional view and tightening torque. See 4312 Swing gearbox, description.

Assembly

1. Install O-ring (13) in collar (11), and then install it on shaft (10).

Figure 1
Installation, collar
NOTE!
Apply grease (NLGI 2) onto O-ring (13).

2. Press spherical bearing (16) onto shaft (10).


Figure 2
Installation, spherical bearing
NOTE!
Heat the spherical bearing in oil to 110 °C (230 °F) prior to installation.

3. Press oil seal (14) into cover (12) using the seal pressing jigs.

Figure 3
Installation, oil seal
NOTE!
Apply loctite (#680) onto the outer diameter of the oil seal. Take care to get any loctite on the oil seal lip.

Figure 4
Apply, loctite
4. Install shaft (10) assembly into case (19) using an eye bolt (M8 × 1.25).
Figure 5
Installation, shaft

WARNING
The parts are heavy. Take appropriate safety cautions when handling them.

5. Install oil seal protector (A) onto the gear of shaft (10).

Figure 6
Installation, cover
6. Install cover assembly (12) on case (19) and install screws (15).
NOTE!
Coat the mating surface of cover (12) with liquid gasket, loctite # 5699.

Apply grease (NLGI2) onto the oil seal lip.

Apply loctite #277 onto the threads of screws (15).

7. Block case (19) as shown.


Figure 7
Installation, spherical bearing
8. Press–fit spherical bearing (17) into case (19).
NOTE!
Press–fit both inner and outer race simultaneously.

9. Fully seat spherical bearing (17), and install retaining ring (18) onto shaft (10).

Figure 8
Installation, retaining ring
NOTE!
Check if casing (19) rotates smoothly after assembling the bearing and retaining ring.

10. 2nd planetary gear assembly

Figure 9
Installation, 2nd planetary gear

 Insert thrust washers (8) and 2nd planetary gear (3) into carrier (2).
 Insert pin (5) and bushing (6).
 Tap spring pin (9) into the pin hole of carrier (2). After inserting, stake the pin into both sides of spring
pins (9).

NOTE!
Align the spring pin holes in pin assembly (4) and carrier (2).

Apply a dab of grease to hold thrust washers (8) to gear (3).

Install spring pin (9) with the slit facing the end of pin (5).

Ensure that gears (3) rotate smoothly.

Figure 10
Installation, pin

A. Stake

11. 1st planetary gear assembly

Figure 11
Installation, 1st planetary gear

 Press–fit pins (31) into carrier (29) and install spring pins (36). After inserting, stake both sides of spring
pins (36).
 Put thrust washer (27) on the surface of carrier (29).
 Onto pin (31) install thrust washer (33), gear (30) including bearing (32), thrust washer (34) and retaining
ring (35).

NOTE!
Check if planetary gears (30) rotate smoothly.
Figure 12
Checking, planetary gear

A. Stake

12. Ring gear and 2nd planetary assembly

Figure 13
Installation, 2nd planetary gear

 Insert dowel pins (21) at four places on case (19).


 Install ring gear (20) onto case (19).
 Insert 2nd planetary gear assembly (1) into ring gear (20).
 Insert thrust ring (25) into 2nd planetary gear (1), then install sun gear (26).

WARNING
The parts are heavy. Take appropriate safety cautions when handling them.

NOTE!

 Coat the mating surface of case (19) with liquid gasket loctite #5699.
 Support case (19).
Figure 14
Installation, 2nd planetary gear
13. 1st planetary gear assembly and 1st sun gear

Figure 15
Installation, 1st planetary gear

 Install 1st planetary gear assembly (28) into ring gear (20).
 Install retaining ring (38) into sun gear (37), and insert it into planetary (28).

NOTE!
Confirm that shaft (10) rotates smoothly by turning the 1st sun gear.

Figure 16
Installation, 1st planetary gear
14. Install plate (23) onto ring gear (20) then install screws (22).
Figure 17
Installation, plate

A. Tap hole

NOTE!
Align the match marks on casing (19) ring gear (20) and plate (23).

Coat the mating surface of ring gear (20) with liquid gasket loctite #5699.

Apply loctite #277 onto the threads of screw (22).

Align the tap hole with the drain pipe mounting port.

Figure 18
Installation, plate
15. Install the motor onto plate (23) then install screws (24).
Figure 19
Installation, motor
NOTE!
Align match marks (A) of the motor and plate (23).

Coat the mating surface of plate (23) with liquid gasket loctite #5699.

Apply loctite #277 onto the threads of screws (24).

16. Tighten drain valve (43) to pipe (44) and pipe (44) to case (19).

Figure 20
Installation, pipe
17. Install pipe (40) onto the motor, and insert level gauge (39).
NOTE!
Face the oil drain port of pipe sideward.

Coat with teflon tape or loctite #577 on the pipe and plug thread.
Service Information

Document Title: Function Group: Information Type: Date:


Slew gearbox, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew gearbox, assembly


Precaution

 When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain / fill ports are properly positioned.
 Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
 Use a torque wrench to tighten the mounting screws to the specified torque.
 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Replace the O-ring and oil seal.
 Use a torque wrench to tighten the screws and plugs to the specified torque.

Tightening torque
Tightening torque, unit : kgf·m (lbf·ft)

Item No. Description Thread size Tightening torque


24 Screw M12 12 ~ 13 (87 ~ 94)
22 Screw M16 27 ~ 28 (195 ~ 202
15 Screw M10 6.5 ~ 7 (47 ~ 50)
44 Pipe PT 1/2 4.4 (31.8)
43 Plug PT 1/2 4.5 (32.5)
40 Pipe PT 3/4 7.2 (52)

Assembly, slew gear box

Op nbr 00000

1. Shaft
Figure 1
Assembly, spherical bearing

 Install o-ring (13) in collar (11), and then install it on shaft (10).
 Press spherical bearing (16) onto shaft (10).

Figure 2
Assembly, spherical bearing
NOTE!

 Apply grease (NLGI 2) onto o-ring (13).


 Heat the spherical bearing in oil to 110°C (230°F) prior to installation.

2. Cover
Figure 3
Assembly, oil seal

 Press oil seal (14) into cover (12) using the seal pressing jigs.

Figure 4
Apply loctite
NOTE!
Apply loctite (#680) onto the outer diameter of the oil seal. Take care to get any loctite on the oil seal lip.

3. Case

Figure 5
Assembly, shaft

 Install shaft (10) assembly into case (19) using an eye bolt (M8 × 1.25).

WARNING
The parts are heavy. Take appropriate safety cautions when handling them.

4. Cover assembly.
Figure 6
Assembly, cover

 Install oil seal protector (A) onto the gear of shaft (10).
 Install cover assembly (12) on case (19) and install screws (15).

NOTE!
Coat the mating surface of cover (12) with liquid gasket, loctite # 5699.

Apply grease (NLGI2) onto the oil seal lip.

Apply loctite #277 onto the threads of screws (15).

5. Bearing

Figure 7
Spherical bearing, assembly

 Block case (19) as shown.


 Press–fit spherical bearing (17) into case (19).

NOTE!
Press–fit both inner and outer race simultaneously.

6. Retaining ring

Figure 8
Assembly, retaining ring

 Fully seat spherical bearing (17), and install retaining ring (18) onto shaft (10).

NOTE!

Check if casing (19) rotates smoothly after assembling the bearing and retaining ring.

7. 2nd planetary gear assembly.

Figure 9
Assembly, 2nd planetary gear

 Insert thrust washers (8) and planetary gear (3) into carrier (2).
 Insert pin (5) and bushing (6).
 Tap spring pin (9) into the pin hole of carrier (2). After inserting, stake the pin both sides of spring pin (9).

Figure 10
Assembly, pin
NOTE!
Align the spring pin holes in pin assembly (4) and carrier (2).

Apply a dab of grease to hold thrust washers (8) to gear (3).

Install spring pin (9) with the slit facing the end of pin (5).

Ensure that gears (3) rotate smoothly.

8. 1st planetary gear assembly.

Figure 11
Assembly, 1st planetary gear

 Press–fit pins (31) into carrier (29) and install spring pins (36). After inserting, stake both sides of spring
pins (36).
 Put thrust washer (27) on the surface of carrier (29).
 Onto pin (31) install thrust washer (33), gear (30) including bearing (32), thrust washer (34) and retaining
ring (35).

Figure 12
Checking, planetary gear
NOTE!

Check if planetary gears (30) rotate smoothly.

9. Ring gear and 2nd planetary assembly.


Figure 13
Assembly, 2nd planetary gear

 Insert dowel pins (21) at four places on case (19).


 Install ring gear (20) onto case (19).
 Insert 2nd planetary gear assembly (1) into ring gear (20).
 Insert thrust ring (25) into 2nd planetary gear (1), then install sun gear (26).

WARNING
The parts are heavy. Take appropriate safety cautions when handling them.

NOTE!

 Coat the mating surface of case (19) with liquid gasket loctite #5699.
 Support case (19).

Figure 14
Assembly, 2nd planetary gear

10. 1st planetary gear assembly and 1st sun gear.


Figure 15
Assembly, 1st planetary gear

 Install 1st planetary gear assembly (28) into ring gear (20).
 Install retaining ring (38) into sun gear (37), and insert it into planetary (28).

Figure 16
Assembly, 1st planetary gear
NOTE!

Confirm that shaft (10) rotates smoothly by turning the 1st sun gear.

11. Plate

Figure 17
Assembly, plate

 Install plate (23) onto ring gear (20) then install screws (22).
A : Tap hole
Figure 18
Assembly, plate
NOTE!
Align the match marks on casing (19) ring gear (20) and plate (23).

 Coat the mating surface of ring gear (20) with liquid gasket loctite #5699.
 Apply loctite #277 onto the threads of screw (22).
 Align the tap hole with the drain pipe mounting port.

12. Motor

Figure 19
Installing motor

 Install the motor onto plate (23) then install screws (24).

NOTE!
Align the match marks of the motor and plate (23).

 Coat the mating surface of plate (23) with liquid gasket loctite #5699.
 Apply loctite #277 onto the threads of screws (24).

13. Drain pipe and level gauge.


Figure 20
Installing level gauge

 Tighten drain valve (43) to pipe (44) and pipe (44) to case (19).
 Install pipe (40) onto the motor, and insert level gauge (39).

NOTE!
Face the oil drain port of pipe sideward.

Coat with teflon tape or loctite #577 on the pipe and plug thread.
Service Information

Document Title: Function Group: Information Type: Date:


Track motor, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Track motor, description

Figure 1
Track motor, structure

1. Hydraulic motor
2. Brake valve
3. Parking brake
4. Displacement changeover valve
5. Control valve
6. Main pump

 Hydraulic motor the hydraulic motor is a variable swash, axial piston design that includes the brake valve assembly
and parking brake. The rear flange contains the counterbalance valve, check valves, crossover relief valves and
displacement changeover valve.

 Brake valve assembly the brake valve assembly consists of the following valves, each having a specific function as
described.

 Check valves the check valves open/close according to supply oil pressure, and route oil flow to the counterbalance
spool. The check valves also prevent cavitation in the travel motor.

 Counterbalance valve the counterbalance valve is used for smooth starting and stopping of the travel motor.It
blocks or throttles the circuit of the travel motor to control the travel speed according to the amount of oil
discharged by the pump to prevent machine run away on slopes.

 Crossover relief valves the relief valves protect the motor and circuit from pressure spikes, maintaining the starting
pressure/bypass pressure of the hydraulic motor at a constant value.

 High/low 2–speed travel the swash plate angle can be set in 2 positions: high speed/low torque or low speed/high
torque, according to the travel speed switch and the displacement changeover valve.

 Parking brake assembly the travel parking brake is spring applied and hydraulically released. The brake is
automatically applied whenever the travel control valve spools are in neutral.
Figure 2
Construction, track motor

1. High speed
2. Low speed

Port connection

Port symbol Port size Port


(A), (B) PF1 Oil supply (return)
(P1) ~ (P4) PT 1/4 Pressure check
(P5) PT 1/8 Displacement changeover valve oil supply
(P) PF 1/4 Brake release pressure
(D1) ~ (D2) PF 1/2 Drain

Rotational direction

Inlet Outlet View from X axis


A B Clockwise
B A Counterclockwise

Figure 3
Track motor, cylinder and piston kit

2 Shaft 93 Spring 246 Plug


3 Swash plate 101 Relief valve piston 252 Plug
4 Cylinder block 102 Sleeve 254 Plug
5 Piston 103 Retainer 257 Plug
6 Shoe 104 Plug 263 Spool
7 Retaining plate 105 Shim 266 Spring
8 Thrust ball 106 Spring 268 Ball
9 Valve plate 108 O-ring 279 Filter
10 Washer 109 O-ring 280 Plug
11 Roller 110 O-ring 281 Piston
12 Brake piston 111 Back-up ring 282 Plug
13 Brake spring 117 Back-up ring 283 O-ring
14 Spring 119 O-ring 284 O-ring
15 Friction plate 120 Seal 285 Steel ball
16 Mating plate 201 Rear flange 294 O-ring
32 Seal 223 Counter balance spool 295 O-ring
35 O-ring 224 Plug 296 O-ring
39 O-ring 225 Stopper 297 Orifice
45 Snap ring 226 Plug 298 Plug
49 Bearing 227 Check valve 299 Name plate
50 Bearing 228 Spring 302 Spindle
51 Needle roller 230 Spring 327 O-ring
61 Piston 236 O-ring 329 O-ring
62 Shoe 237 O-ring 342 Parallel pin
67 Steel ball 241 Parallel pin
71 Parallel pin 243 Screw

Operation, hydraulic motor


Figure 4
Hydraulic motor operation

TDC Top dead center


BDC Bottom dead center

The pressurized oil delivered via the control valve from the hydraulic pump enters port on rear flange (201) and flows to half
the pistons in cylinder block (4) through valve plate (9).
The pressurized oil in cylinder block (4) pushes half the pistons (5) out of the bores and force [F(kgf) = P(kgf/cm2 ) × A(cm2)]
is generated. This force is applied on swash plate (3) fixed to drive shaft (2) with angle (a°) so that it is divided into
components of force (F2 and F3).
Among the components of force, radial force (F3) generates the torque (T = F3 × ri) for (Y1) - (Y2), respectively.

The total of torque {T = Σ(F3 × ri)} is transmitted sequentially via pistons (5) to cylinder block (4) generating a rotational
force causing the cylinder block splined to output drive shaft (2) to rotate.
The top dead center port is the starting point of the high pressure rotational cycle ; for 180° the pistons move out of the
bores as they slide along the swash plate toward the bottom dead center port, then they begin moving into the bores
discharging low pressure oil to the return circuit.
Operation, brake valve
Figure 5
Brake valve released

Operating (Brake released)

When pressurized oil is supplied to port (A), it opens check valve (227) and the oil flows to inlet port (C) of the hydraulic
motor.
At the same time pressurized oil flows into chamber (b) through passage (a) via a small orifice in counterbalance spool (223).
As the pressure in chamber (b) increases spool (223) is moved to the left, connecting port (D) with outlet (B) allowing the
return oil from the motor to flow to tank, so that the hydraulic motor starts to rotate. And according to the movement of
spool (223), pressurized oil flows into port (P) and port (S). The oil flow through port (P) operates brake piston (12)
overcoming the brake spring force releasing the parking brake. If the supply port and the return port are interchanged the
travel motor rotates in the opposite direction.
Stopping or stalling (brake actuating)

Figure 6
Brake valve actuation

When the pressurized oil flow from the main control valve is blocked, the pressure in port (A) decreases rapidly. As this
happens the pressurized oil in chamber (b) escapes via passage (a) through the orifice in spool (223) to port (A) ; at the same
time spring (228) force acting on stopper (225) moves counterbalance spool (223) to the right (neutral position).
The return speed of spool (223) is controlled by the back pressure created by the throttling effect of the orifice at passage
(a). When the spool is completely returned to the neutral position, the passages to ports (A, B) are blocked, trapping the oil
in the motor to prevent rotation.
However inertia will tend to continue the motor rotation, creating a sharp rise in oil pressure at return port (D). (This referred
to as dynamic braking).
The pressurized oil flows through the orifice in the left relief valve piston (101) to chamber (f), then to chamber (g) and starts
to move piston (281) to the right. When the piston reaches the end of its stroke, the pressure in chambers (g & f) rise and
react on valve piston (101). At this time the opening pressure of the relief valve is higher than the normal relief setting
pressure. This sequence acts to cushion the pressure spike as the valve opens.
As the oil pressure at port (D) overcomes the combined force of the relief valve spring and pressurized oil in chambers (g &
f) the left relief valve opens, connecting ports (D & C) to prevent an abnormal pressure rise and cavitation.
When the oil pressure at port (D) drops the relief valve closes ; however if the pressure rises above the relief valve setting,
the relieving cycle is repeated. The 2 stage control of the relief valve stops the hydraulic motor smoothly.
Overspeed

Figure 7
Brake valve, overspeed

When travelling downhill the weight of the machine (inertia) tends to make the hydraulic motor rotate faster than the rate of
oil flow supplied by the hydraulic pump. This phenomenon is referred to as overspeed.
During this condition the hydraulic force of the motor decreases, and the counterbalance spool moves toward the neutral
position, blocking the return oil flow from port (D) to port (B). As the passage closes it creates a throttling action, causing a
back pressure at port (D), thereby decelerating the hydraulic motor until the pump flow begins applying force to the motor.
Operation, parking brake
When travelling
Figure 8
Parking brake, travelling

When the travel lever is operated pressurized oil from the pump actuates counterbalance spool (223), opening the circuit to
brake chamber (a) of brake piston (12).
When the oil pressure reaches approximately 6 kgf/cm2 (85psi) it starts to push brake piston (12) toward the rear flange (←)
overcoming the force of brake springs (13). As this happens the piston moves away from friction plates (15) and mating
plates (16) allowing the plates to separate, releasing the braking force holding cylinder block (4).
When stopping

Figure 9
Parking brake, stopping

When the travel lever is placed in neutral, the counterbalance spool returns to its neutral position closing the circuit to brake
chamber (a).
The pressurized oil in chamber (a) drains to tank through an orifice in the brake valve.
The throttling effect of the orifice slows the drain oil flow, preventing the brake springs from applying the brake abruptly.
As the pressure drops below 6 kgf/cm2 the force of brake springs (13) pushes brake piston (12) against (→) mating plates
(16) and friction plates (15), which are splined to gearbox spindle (302) and cylinder block (4).
When the plates are squeezed together the frictional force generated applies a brake torque of 40.6 kgf·m (293 lbf·ft) to the
motor output shaft (2).
Operation, displacement changeover valve
Low speed

When the travel solenoid valve is deactivated (ph) servo hydraulic flow to port (D) is cut off. The hydraulic pressure at (A, B)
port moves spool (263) upward overcoming the force of spring (266), and blocks port (C).
At the same time the pressurized oil in chamber (P) drains to the motor case. This allows the forces acting on the rotary
group to move swash plate (3) to maximum swash angle θ1, contacting y plane. Piston stroke is increased, cylinder
revolutions decrease, resulting in low speed with high torque.
Figure 10
Displacement changeover valve, low speed

High-speed

When the travel solenoid is energized (ph) servo hydraulic oil will flow to port (D).
The hydraulic pressure (40kgf/cm2) at port (D) combined with the force of spring (266) moves spool (263) downward
overcoming the force of the hydraulic oil pressure at port (A, B) and opens port (C).
The pressurized oil from port (C) flows into chamber (P) and pushes piston (61) moving swash plate (3) to minimum swash
angle θ2, contacting x plane. Piston stroke is decreased, cylinder revolutions increase, resulting in high speed with low
torque.

Figure 11
Displacement changeover valve, high speed

Automatic speed shifting to low speed during high speed travelling

When the load (tractive effort) is increased during high speed travel the oil pressure at port (A, B) increases.
If the pressure is approximately 260kgf/cm2 it overcomes the combined force of spring (266) and (ph) servo hydraulic flow
40kgf/cm2 at port (D), and moves spool (263) upward, blocking port (C). At the same time the pressurized oil in chamber (P)
drains to the motor case, and swash plate (3) moves to maximum swash angle θ1, contacting Y plane, and the motor rotates
at low speed.
Figure 12
Displacement changeover valve, automatic speed shifting
Service Information

Document Title: Function Group: Information Type: Date:


Track motor, precautions Service Information 2014/6/12
for operation
Profile:
EXC, EC210B LC [GB]

Track motor, precautions for operation

Figure 1
Mounting location

A. Screw, gearbox to frame


B. Screw, sprocket to gearbox

Installation

 Check that the mating mount surfaces are clean.


 Check that the motor is positioned correctly in the frame.
 If the gearbox to frame fit is tight, draw the assembly into the frame evenly with the mounting screws.
 Tighten the screws in a crisscross pattern in several stages to the specified torque.
 Apply these same precautions when mounting the sprocket.

Tightening torque

Screws Quantity Thread size Torque, kgf·m (lbf·ft)


A 30 M16 (P2.0) 27 ± 3 (195 ± 22)
B 22 M16 (P2.0) 27 ± 3 (195 ± 22)

NOTE!
The screws must be strength grade 10.9 (tensile strength: 100 kgf/mm2) or above.

Piping

 Check that there is no contamination in the ports or plumbing before connecting to the motor.
 Prior to start-up purge the air from the circuit plumbing and motor.
 Prior to start-up fill the motor casing with the specified hydraulic oil.
NOTE!
Oil capacity : 1.7 liters.

 Check that the case drain pressure is within specification.


NOTE!
Casing pressure : 2 ~ 7 kgf/cm2 (28 ~ 100 psi)

 Check if the direction of rotation according to the control lever is correct.

Lubrication

NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
Service Information

Document Title: Function Group: Information Type: Date:


Track motor, maintenance Service Information 2014/6/12
standard
Profile:
EXC, EC210B LC [GB]

Track motor, maintenance standard


Standard for parts service and replacement
The following standards of the serviceability of parts can be determined from measurements made at disassembly. However,
they are general standards and when parts show excessive external damage or discoloration, top priority should be given to
the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the
remaining life expectancy of the parts.
Seals
Replace oil seals and o-rings, although they appear not damaged.
Part replacement criteria
Replace all parts that appear damaged or are not within the allowable value.
Part replacement criteria

Item Part name Condition Standard value Allowable value


No.
2 Shaft The surface contacting seal (32) is worn.
The spline section is worn.
3 Swash plate Sliding surface for piston shoes (6) is damaged.
Sliding surface for piston shoe (62) is damaged.
4 Cylinder block The spline section is worn. Linear clearance Linear clearance
The piston bores are worn or scored. 28 ~ 45 µm 50 µm
The sliding surface that contacts valve plate (9) is
damaged or nonuniformly worn.
5 Piston An axial clearance is present between piston (5) Clearance Clearance
and shoe (6). 0.05 mm 0.05 mm
6 Shoe Shoe wear is excessive or nonuniform.

7 Retaining plate The peripheral edge is nonuniformly worn.


8 Thrust ball The spherical sliding section that contacts the
retaining plate (7) is nonuniformly worn.
9 Valve plate The sliding surface has traces of scoring or
nonuniform wear.
15 Friction plate Micro groove pattern is worn off. Brake torque Brake torque
The sliding surface is scored. more than 40.6 less than 40.6
16 Mating plate The edges are damaged. kgf·m (293 lbf·ft) kgf·m (293 lbf·ft)
The plates are warped.
49, 50 Bearing Pitting / flaking of the races or balls or
rollers.
Does not rotate smoothly by hand.
101 Relief valve piston The sliding surface is damaged.
102 Sleeve The seat surface is damaged.
The clearance against piston (101) is
excessive.
201 Rear flange Counterbalance spool (223) or bore is damaged. Linear clearance Linear clearance
Bore to spool, clearance is excessive. 10 ~ 20 µm 25 µm
Piston (281) or bore is damaged.
Bore to spool, clearance is excessive.
Check valve (227) face or seat is damaged or
worn.
Valve sealing surface/angle is abnormal.
223, Spool The sliding surface or bore is damaged.
263
281 Piston The sliding surface is damaged.

General tools

No. Description Size Quantity


1 Allen wrench 5 mm, 10 mm, 8 mm, 14 mm 1
2 Ratchet 1/2″ drive, 3/4″ drive 1
3 Torque wrench Approximately 280 n·m 1
Approximately 850 n·m
4 Socket 32, 41 mm 1
5 L wrench socket 5, 6, 8, 10, 14, 19 mm 2
6 Hammer Nominal 12 1
7 Plastic hammer Approximately L = 300 mm 1
8 Screwdriver Approximately L = 150 mm 1
9 Snap ring pliers Expansion 1
Retraction
10 Hoist Capacity 300kg or over
11 Eye bolt M16
PF 1 / 2
12 Bench press Capacity 200kg or over
13 Compressed air Capacity 3 ~ 5 kgf / cm2
Hose & nozzle
14 Drain pan W450 × D300 × H120
15 Heating vessel Temperature rise ability : 100°C or over
Volume 500 × 500 × 500 (mm) or over
16 Leather gloves
17 Seal tape
18 Depth micrometer Measuring range : approximately 30 mm
Min. scale : 0.01 mm
19 Feeler gauge Measuring range : 0.04 ~ 0.3 mm
20 Grinder Cast cutting
21 Air chisel BRH – 8 (compressed air 6 kgf/cm2 )

Special tools

No. Description & Part No. Quanti No. Description & Part No. Quanti
ty ty
1 Retainer (I) 1 4 Lifter 1

Part No. : 8932 – 00160


2 Retainer (II) 2

Part No. : 8932 – 00210


Part No. : 8932 – 00150
3 Retainer (III) 1

Part No. : 8933 – 00320


Service Information

Document Title: Function Group: Information Type: Date:


Track motor, Service Information 2014/6/12
troubleshooting
Profile:
EXC, EC210B LC [GB]

Track motor, troubleshooting


Travel motor does not rotate

Hydraulic pressure is low. Main relief pressure is low. Adjust to specification.

Pump failure Except for travelling, check if the


devices are operating. Repair as
necessary.

Safety solenoid valve failure. Check the safety solenoid valve


system.

Pressure is normal. Brake valve failure. Repair or replace the rear flange
(Counterbalance spool) assembly.

Hydraulic motor failure Check the case drain oil. If


contaminated, replace the
motor.

Input gear to the gearbox is Repair the gearbox assembly.


damaged.

Motor is overloaded. Reduce the load.

Oil leakage

Mating joint surfaces Mating surface is damaged. Remove burrs or nicks with fine
emery cloth.

Screw loosened. Tighten to the specified torque.

Leakage from casing Plugs loosened. Tighten to the specified torque.

Cracks or pin holes. Replace the gearbox assembly.


Leakage from floating seal Damage on the sliding surface. Replace the seal assembly.

Cracks or pin holes. Replace the seal assembly.

Leakage from rear flange Loosened screws. Tighten to the specified torque.

O-ring is damaged. Replace the o-ring.

Damage on flange/spindle surface. Remove burrs or nicks with fine


emery cloth.

Travel motor does not hold on slopes

Motor rotates. The volumetric efficiency of the motor Replace the hydraulic motor
is poor. assembly.

Internal leakage in brake valve. Replace the rear flange


assembly.

Parking brake does not operate. Springs are damaged. Replace all the springs.

Friction plates are worn. Replace the friction plates and


mating plates.

Machine zigzags

Occurs at low pressure. Pump flow to left and right motor Check P1/P2 pump flow.
differs. Check flow through the center
passage.

Left and right motor drain quantity Replace the hydraulic motor
are different. assembly.

Occurs at high pressure. Pump flow to left and right motor Check P1/P2 pump flow.
differs. Check flow through the center
passage.

Left and right motor drain quantity Replace the hydraulic motor
are different. assembly.
Brake valve operation is different Replace the rear flange
between left/right motors. assembly.

Pressure limit valve settings are not Adjust pressure correctly.


balanced. Replace the pressure limit
valves.

Speed does not increase (slower than normal)

Pump output is low. Pump regulator is faulty. Repair/replace the regulator


assembly.

Internal pump leakage is excessive. Repair/replace the pump


assembly.

Abnormal sound

Abnormal sound Motor or gearbox is damaged. Replace the motor/gearbox


assembly.

Hoses/pipes vibrate. Bleed the travel circuit.


Tighten/replace missing clamps.

Speed does not change from low to high

Speed does not change from low to High pressure select shuttle valve Check, and repair or replace if
high. malfunction. necessary.

Solenoid valve malfunction. Check if the spool is normal, and


repair or replace if necessary.

Servo hydraulic relief valve Adjust to the specified pressure.


malfunction.

Two speed piston malfunction. Check, and repair or replace if


necessary.

Speed does not change from high to low

Speed does not change from high to Solenoid valve malfunction. Check if the spool is normal, and
low. repair or replace if necessary.

Two speed piston malfunction. Check, and repair or replace if


necessary.
Service Information

Document Title: Function Group: Information Type: Date:


Track motor relief valve, Service Information 2014/6/12
replacing
Profile:
EXC, EC210B LC [GB]

Track motor relief valve, replacing


Op nbr 441-112

1. Park the machine in the service position F, see 091 Service positions.

2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by the travel control lever smoothly for 3 ~ 4 times with ignition switch at "ON"
position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.

3. Remove screws (1) and motor cover (2).

Figure 1
Removal, motor cover

4. Remove track motor relief valve (1).

Figure 2
Removal, relief valve

5. Install a new relief valve.

6. Check relief valve pressure of the track motor, and adjust if necessary
7. Install the motor cover.
Service Information

Document Title: Function Group: Information Type: Date:


Track motor, disassembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Track motor, disassembly


Op nbr

Precautions

 Thoroughly clean the gearbox assembly prior to disassembly.


 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix parts of sub assemblies.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures.

Brake valve and motor section

1. Prior to disassembly, install the motor on a rotary work stand. Drain the hydraulic oil & gear oil.
NOTE!
Oil pan size : 4 liter, 8 liter

Figure 1
Track motor

2. Remove the relief valve from rear flange (201).


Remove O-ring (108), (109), (110) and back-up rings (111), (117) from relief valve.
NOTE!
Do not reuse O-rings after removal.
Figure 2
Relief valve, removal

3. Remove screws (243).

Figure 3
Screws, removal

4. Remove rear flange (201) from spindle (302).


NOTE!
Take care not to remove shaft (2).
Figure 4
Rear flange, removal

5. Gearbox/hydraulic motor shaft and oil seal.

 Remove valve plate (9), parallel pin (241), brake springs (13) and bearing (50) from rear flange (201) and
hydraulic motor.
 Remove O-rings (329) from spindle (302).

NOTE!
Do not reuse O-rings (329) after removal.

Figure 5
Bearing, removal

Brake valve

6. Counterbalance spool removal.

 Remove plugs (224) from rear flange (201).


 Remove O-ring (236) from plug (224).
NOTE!
Do not reuse O-ring (236) after removal.
Figure 6
Counterbalance spool, removal
 Remove springs (228), the stoppers (225), and counterbalance spool (223) from rear flange (201).
NOTE!
Be careful not to damage the outer surface of counterbalance spool (223) and the sliding surface of rear
flange (201). Since rear flange (201) and counterbalance spool (223) are of the selective-fitting type,
replace them together as a kit even if only one of the two parts is damaged.

Figure 7
Plug, removal

7. Check valve removal.

 Remove plugs (226) from rear flange (201).

Figure 8
Plug, removal
 Remove springs (230) and check valves (227) from rear flange (201).
Figure 9
Check valve, removal
NOTE!
Be careful not to damage the seat sections of check valve (227) or rear flange (201).

 Remove O-ring (237) from plug (226).


NOTE!
Do not reuse O-ring (237) after removal.

8. Two-speed valve removal.

 Remove plugs (257) from rear flange (201).

Figure 11
Spool, removal
 Remove spool (263) and spring (266) from rear flange (201).
 Remove O-rings (295) from plugs (257).
NOTE!
Do not reuse O-ring (295) after removal.

9. Removal of internal parts.

Figure 12
Plug, removal

 Remove plug (280) from flange (201).

Figure 13
Piston, removal
 Remove O-ring (296) from plug (280).
 Remove piston (281) from rear flange (201).
NOTE!
Take care not to damage the piston hole.

NOTE!
Since rear flange (201) and piston (281) are of the selective fitting type, replace them together as a kit.

 Remove plug (282), O-ring (283), (284).

Figure 14
Plug, removal
NOTE!
Do not reuse O-ring after removal.

 Remove steel balls (285) from rear flange (201).

Figure 15
Steel ball, removal

10. Relief valve removal.


Figure 16
Plug, removal

 Remove plug (104) and remove sleeve (102).


NOTE!
Do not interchange the parts of the two relief valves.

 Remove O-ring (110) from plug (104).


NOTE!
Do not reuse O-ring after removal.

 Remove shim (105) from plug (104).


 Take out spring retainer (103), spring (106), and piston (101) in that order from sleeve (102).
 Remove seal (120) from piston (101).
 Disassemble the other side sleeve in the same method.
NOTE!
If the parts, except O-ring (110) and seal (120) need to be replaced the relief valve must be reset on a test
bench. Therefore replace the relief valve assembly.

Figure 17
Spring retainer, removal

Figure 18
Spring, removal

Figure 19
Shim, removal

Figure 20
Relief valve piston, removal

Hydraulic motor, disassembly

11. Parking brake removal.

WARNING
Abrupt injection of compressed air may cause piston to pop out. To ensure your safety, apply a protective
cover over the piston.

Figure 21
Apply the compressed air

 Remove brake piston (12) by injecting compressed air (pressure : 3~5 kgf/cm2) into the parking brake
access hole in spindle (302).
Figure 22
Brake piston, removal
 Remove O-rings (35 and 39) from piston (12).
NOTE!
Do not reuse O-rings (35) (39) after removal.

12. Removal of rotary group.

Figure 23
Cylinder block, removal

 Place an oil pan under spindle (302).


NOTE!
Pistons must be installed into the same bores because of wear pattern. Mark the pistons and respective
cylinder bores.

NOTE!
Before removal, hold cylinder block (4) with both hands and turn it two to three times in a clockwise and
counterclockwise direction alternately, to detach shoes (6) from swash plate (3).

NOTE!
Be careful when removing the cylinder block that the pistons and needle rollers (51) do not fall into the
spindle.

 Hold cylinder block (4) with both hands, and remove it from spindle (302).
 Remove swash plate (3), steel balls (67) from spindle (302).
 Remove the mating plates (16) and friction plates (15) that are mounted on the outer surface of cylinder
block (4).
 Remove the piston assembly (5), shoe (6)], retainer plate (7), thrust ball (8), and needle rollers (51) from
cylinder block (4).
Figure 24
Needle roller, removal

13. Remove the swash plate (3) from spindle (302).

Figure 25
Swash plate, removal

14. Remove the drive shaft (2) from spindle (302) by striking the front part lightly with a plastic hammer.

Figure 26
Drive shaft, removal

15. Remove the bearing (49) from drive shaft (2).


Figure 27
Bearing, removal

16. Remove the steel ball (67) and parallel pin (71) from spindle (302).

WARNING
Abrupt injection of compressed air may cause piston to pop out. To ensure your safety, apply a protective
cover over the piston.

Figure 28
Steel ball and parallel pin, removal

17. Remove the speed selector piston assembly [piston (61) and shoe (62)] from spindle (302) by feeding compressed
air (pressure : 3 ~ 5 kgf/cm2) into the access hole in spindle (302).

Figure 29
Piston, removal
NOTE!
The rotary group parts must be replaced as a set. Reference the parts catalog for details.
18. Remove the seal (32) from spindle (302).

Figure 30
Bearing and seal, removal

19. Cylinder block disassembly

 Place cylinder block (4) on a press bench, then while pressing holding retainer (I) against washer (10),
remove snap ring (45).
NOTE!
Press load : 200 kg or over.

NOTE!
When removing the spring, press the axial centers of retainer (I) and washer to prevent the cylinder block
from being damaged by contact.

NOTE!
Protect the sliding surface of the cylinder block with a rubber sheet.

NOTE!
Remove spring (14) only if it is to be replaced.

WARNING
Do not release the press abruptly. The spring could pop out and cause an injury.

Figure 31
Snap ring, removal
 Slowly release the press until the spring force is relaxed.
 Remove washer (10), spring (14), and washer (10), in that order, from cylinder block (4).
Figure 32
Spring, removal
Service Information

Document Title: Function Group: Information Type: Date:


Track motor, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Track motor, assembly


Op nbr

Precautions

 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Coat the motor assembly sliding parts and bearings with clean hydraulic oil.
 Replace the O-rings, and seals.
 Use a torque wrench to tighten the screws and plugs to the specified torque.

Tightening torque

Item No. Description Thread size Torque, kgf·m (lbf·ft)


102 Sleeve PF 1 25 ± 5 (180 ± 36)
104 Plug PF 1/2 10 ± 2 (72 ± 14)
224 Plug M36 (P 1.5) 45 ± 9 (325 ± 65)
226 Plug M36 (P 1.5) 26 ± 4 (188 ± 29)
243 Screw M16 (P 2.0) 25.7 ± 4 (186 ± 29)
246, 252 Plug PT 1/4 3 ± 0.5 (22 ± 4)
254 Plug NPTF 1/16 1.0 ± 0.25 (7.2 ± 1.8)
257 Plug PF 1/2 10 ± 2 (72 ± 14)
280 Plug PF 3/8 6 ± 1 (43 ± 7)
282 Plug PF 1/8 1.5 ± 0.25 (10.8 ± 1.8)
298 Plug PF 1/8 1.25 ± 0.25 (9 ± 1.8)

Brake valve, assembly

1. Check valves

 Fit O-ring (237) on plug (226).


 Install spring (230) and check valve (227) to plug (226), then grease the spring and valve assembly.
 Insert plug (226) in conjunction with spring and valve, into rear flange (201), and tighten the plug to the
required torque (26 ± 4 kgf·m (186 ±29 lbf·ft)).
NOTE!
Apply grease to O-ring (237).

NOTE!
Coat the thread section of plug (226) with loctite #577.
Figure 1
Plug, install

2. Counterbalance spool

 Insert spool (223) into rear flange (201).


NOTE!
Apply hydraulic oil to spool (223) and insert it into rear flange (201).

NOTE!
Damage to the bore section of the rear flange or the surface of the spool may cause internal leakage to
occur after reassembling, and motor performance to deteriorate.

Figure 2
Counterbalance spool, install
 Attach O-ring (236).
NOTE!
Apply grease to the O-ring.

 Install stopper (225) and spring (228) into both plugs (224), and tighten plugs (224) into rear flange (201)
to the required torque (45 ± 9 kgf·m (325 ± 65 lbf·ft)).
NOTE!
If either the rear flange (201) or spool (223) is to be replaced, the entire assembly (kit) must be replaced.

Figure 3
Plug, install
3. Speed selector valve.

 Fit O-rings (295) on plugs (257).


 Install spring (266) onto spool (263) and insert into rear flange (201).
NOTE!
Apply grease to the O-ring.

NOTE!
Apply hydraulic oil to spool (263) and insert it into rear flange (201).

NOTE!
Damage to the bore section of the rear flange or the surface of the spool may cause internal leakage to
occur after reassembling, and motor performance to deteriorate.

Figure 4
Spool, install
 Tighten plugs (257) into rear flange (201) to the required torque (10 ± 2 kgf·m (72 ± 14 lbf·ft)).

Figure 5
Plug, install

4. Shock relief valve parts.

 Insert steel balls (285) into rear flange (201).


 Mount O-rings (283), (284) on plugs (282).
NOTE!
Apply grease to the O-ring.
Figure 6
Steel ball, install
 Tighten plugs (282) into rear flange (201) to the required torque (1.5 ± 0.25 kgf·m (10.8 ± 1.8 lbf·ft)).
 Insert piston (281) into rear flange (201).
NOTE!
Apply hydraulic oil to piston (281) and insert it into rear flange (201). If there is damage to the bore section
of the rear flange or the surface of the spool, they must be replaced as an entire assembly.

 Mount O-ring (296) on plug (280).


NOTE!
Apply grease to the O-ring.

Figure 7
Piston, install
 Tighten plug (280) into rear flange (201) to the required torque (6 ± 1 kgf·m (43 ± 7 lbf·ft)).

Figure 8
Plug, install

5. Relief valves.

 Mount O-ring (108, 109, 119) and back-up ring (111, 117) on sleeve (202).
NOTE!
Apply grease to O-ring (108), (109) and (110).

 Mount O-ring (110) on plug (104).


 Install shims (105) onto plug (104).
NOTE!
The relief pressure is adjusted by shim, so install the original shims that were assembled.

NOTE!
Apply grease to the shims to hold them to plug (104).
 Mount piston seal (120) on piston (101).
NOTE!
Piston seal (120) consists of O-ring and teflon ring.

NOTE!
Apply grease to both sides of piston seal (120). Install O-ring and then teflon ring.

 Install piston (101), spring (106), spring retainer (103) and shims (105) with plug (104) then tighten to the
required torque (10 ± 2 kgf·m (72 ± 14 lbf·ft)).
NOTE!
Coat piston (101) with hydraulic oil and install into sleeve (102).

NOTE!
The internal parts of the sleeve is comprised of a sleeve kit. Take care to assemble correctly.

Figure 9
Relief valve, install
 Assemble the other relief valve in the same method.

6. Seal (32)

 Fit seal (32) into the seal mounting hole of shaft (2).
NOTE!
Apply white petroleum jelly or lithium grease to the lip section of seal (32).

WARNING
When inserting ball bearing use leather gloves and take care not to get burned.

Figure 10
Assembly, seal

7. Drive shaft (2)


 Shrink-fit ball bearing (49) onto shaft (2).

NOTE!
If ball bearing (49) has been removed from shaft (2) during disassembling replace the bearing with a new one and
then shrink-fit it onto shaft (2).

NOTE!
Shrinkage-fitting temperature : 100 ±10 °C

NOTE!
Take care not to heat (shaft (2) when shrink fitting ball bearing (49).

Figure 11
Assembly, bearing

8. To assemble piston assembly (61), (62).

 Apply grease on spring (93) and fit to the piston assembly.


 Apply hydraulic oil on the piston assembly and insert it into the piston bore of spindle (302).

Figure 12
Piston, assembly

9. Swash plate pivot.


 Insert pins (71) into spindle (302) and mount steel balls (67).
 Coat the pins and steel balls with grease.

Figure 13
Swash plate, mounting

10. Cylinder block.

 Put cylinder block (4) on a press bench.


 Insert spring (14) and washer (11) into the cylinder block (4).
NOTE!
Insert the sharp-edge part of washer (10) as shown in figure left.

Figure 14
Spring, assembly
 Put the retainer on washer (10), and using the press force-fit spring (14), then mount snap ring (45).

 retainer : part number 8932-00160

NOTE!
When working on the cylinder block, protect its sliding face by covering it with a vinyl sheet.

NOTE!
Force to compress spring (14) : 200 kg or above.

NOTE!
Ensure that snap ring (45) is fully seated.
Figure 15
Retainer, install

11. Motor assembly.

 Fit needle rollers (51) into cylinder block (4), and then, put collar (11) and thrust ball (8) on it.

Figure 16
Needles, install
 Insert piston assembly (5), (6) into retainer plate (7).
 Coat the piston assembly with hydraulic oil, and then fit to cylinder block (4).
NOTE!
Piston must be installed into the same bores because of wear pattern.

NOTE!
Align the match marks of the pistons and cylinder block made prior to disassembly.

 Apply hydraulic oil on the sliding face of shoe (6) and the spherical section of thrust ball (8).
Figure 17
Piston, assembly
 As shown in the diagram below, mount swash plate (3), thrust ball (8), collar, retaining plate (7), needle
roller (51), cylinder block (4), and piston assembly (5), (6), on shaft (2). Then install the lifter and turn the
shaft upright.

 Lifter (A) : part number 8932-00210

Figure 18
Cylinder block, assembly

12. Fitting motor assembly.

 Lift the motor assembly via lifter, and mount the guide inserting jig on the spline section of shaft (2).
NOTE!
Align steel ball (67) to the ball hole in swash plate (3).

 Insert the motor shaft slowly, into spindle (302).


 After assembling, remove lifter and the guide inserting jig (A).
NOTE!
After the motor assembly is installed, rotate cylinder block (4) by hand to check for backlash.

If there is any backlash, correct the fault.


Figure 19
Motor assemble, installing

13. Mount friction plate (15) and mating plate (16) alternately in that order on the cylindrical groove of cylinder block
(4).
NOTE!
Immerse friction plate (15) in hydraulic oil.

Figure 20
Brake, installing
NOTE!
Note the assembly order of friction plate and mating plate. If wrong, the parking brake force may be weakened.

14. Fit O-ring (35), (39) and assemble piston (12) into spindle (2).
Figure 21
Brake piston O-ring, installing

15. Fit brake piston (12) into spindle (302) by lightly tapping the sectional surface of piston (12) using a plastic hammer,
to prevent the piston from being distorted.
NOTE!
Apply grease on O-ring (35), (39).

Figure 22
Brake piston, installing

16. Mount ball bearing (50), valve plate (9), parallel pin (241), and springs (13) on rear flange (201).
NOTE!
Coat spring (13) and valve plate (9) with grease to hold it to rear flange (201).

NOTE!
Apply hydraulic oil on ball bearing (50).

Figure 23
Bearing, mounting

17. Fill with hydraulic oil.

 Oil capacity : 1.7 liter


Figure 24
Hydraulic oil. apply

18. Insert O-ring (329), (327) and (342) into spindle (302), and mount rear flange (201).
NOTE!
Do not apply grease on O-ring (329) or mating surface. (Because the grease may be mistaken for oil leakage)

Figure 25
Rear flange, assembly
NOTE!
The rear flange (201) must be mounted so that the two parallel pin (342) mounted on spindle (302) and the pin
hole align.

19. Tighten screw (243) to spindle (302) at the required torque.

 Tightening torque : 25.7 ±4 kgf·m (186 ±29 lbf·ft)


Figure 26
Screw, tightening torque

20. Mount O-ring (295) on plug (257) and the drain port not pipe-connected

 Tightening torque : 10 ±2 kgf·m (72 ±14 lbf·ft)

21. Mount the relief on rear flange (201).


Tighten to the required torque.

 Tightening torque : 25 ±5 kgf·m (180 ±36 lbf·ft)

Figure 27
Relief valve mounting
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing motor, description


Rotary group consists of cylinder block (III) and 9 piston assemblies (II) located in the cylinder. Both ends of cylinder block
(III) are supported by bearings (443) and (444). Piston assemblies (II) are guided by return plate (123) and shoe (122) so they
slide smoothly on the swash plate. Valve plate (131) is pressed against the cylinder block surface by the mechanical pressure
of spring (114) and hydraulic pressure working on the bushing.
Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted.
The cover section has a relief valve for cushioning and an anti-cavitation valve to prevent cavitation.
Components of swing system
Swing system, components

Swing unit Swash type axial piston hydraulic motor Mechanical brake

Relief valve

Anti-cavitation valve

Rebound damping valve

2 stage planetary gearbox

Swing motor, construction


Figure 1
Swing motor, construction

Rotational direction

lnlet Outlet View from shaft end


A B Clockwise
B A Counterclockwise

Port size and torque, Nm (lbf ft)

Port Symbol Screw size and depth Tightening torque


Main pump A, B 1 5/16-12 UN-2B-19 *1 300 (222)
Anti-cavitation M 1 5/16-12 UN-2B-19 *1 300 (222)
Pressure measurement PA, PB 9/16-18 UNF-2B-12.7 *1 48 (35.5)
Drain D 3/4-16 UNF-2B-14.3 *1 82 (61)
Brake release PG 9/16-18 UNF-2B-12.7 *1 48 (35.5)
Brake servo hydraulic SH 9/16-18 UNF-2B-12.7 *1 48 (35.5)
Gear oil filling (oil level checking) L, Gl R 3/4-19 98 (72.5)
Bleeding air when filling gear oil E R 3/8-14 44 (33)
Gear oil outlet Go M26 –
*1: Port with O-ring seal based on ISO 11926-1

Swing motor, sectional view


Figure 2
Swing motor, sectional view

031 Delay valve 355 Spring


031-1 Plug 390 Name plate
033 Screw 391 Pin
051 Relief valve 400 Rebound damping valve
051-1 O-ring 400-1 O-ring
052 Rebound damping valve assembly 400-2 Backup-ring
100 Rebound damping valve casing 401 Screw
101 Drive shaft 437 Retaining ring
111 Cylinder 443 Roller bearing
114 Plate spring 444 Roller bearing
121 Piston 451 Pin
122 Shoe 469 Plug
123 Thrust plate 472 O-ring
124 Shoe plate 488 O-ring
131 Valve plate 491 Oil seal
151 Plug 702 Brake piston
161 O-ring 706 O-ring
162 O-ring 707 O-ring
163 O-ring 712 Brake spring
171 Screw 742 Friction plate
301 Casing 743 Mating plate
303 Valve casing 984 Plug
305 Seal cover 985 Plug
351 Spool
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing motor, description


Hydraulic motor
Rotary group consists of cylinder block (III) and 9 piston assemblies (II) located in the cylinder. Both ends of cylinder block
(III) are supported by bearings (443) and (444). Piston assemblies (II) are guided by return plate (123) and spring (122) so
they slide smoothly on the swash plate. Valve plate (131) is pressed against the cylinder block surface by the mechanical
pressure of spring (114) and hydraulic pressure working on the bushing.
Between the outer diameter of the cylinder block and housing a mechanical brake for parking is mounted.
The cover section has a relief valve for cushioning and an anti-cavitation valve to prevent cavitation.
Slew Ring Gear
The slew ring gear is a single row sealed ball bearing that supports the superstructure on the undercarriage and allows the
superstructure to rotate smoothly.
The outer race is bolted to the superstructure and the inner race (with inner circumference gear) is bolted to the
undercarriage. The slew reduction gear pinion meshes with the internal gear of the inner race and drives it to rotate the
superstructure.
Components of slew system
Slew system, components

Slew unit Swash type axial piston hydraulic Mechanical brake


motor

Relief valve

Anti-cavitation valve

Rebound damping valve

2 stage planetary gearbox

Slew system diagram


The oil supplied from main pump (1) passes through control valve (2) to rotate slew motor (3). The turning force of the
motor is transmitted through gearbox (4), pinion (5) and slew ring gear (6), making the superstructure revolve.
Figure 1
Slew motor circuit

1 Main pump 3 Slew motor 5 Pinion gear


2 Control valve 4 Gearbox 6 Slew ring gear

Construction
Figure 2
Slew motor

1. Relief valve
2. Rebound damping valve
3. Lifting screw (2-M12)

Rotational direction

lnlet Outlet View from shaft end


A B Clockwise
B A Counterclockwise

Piping port size and torque

Port Symbol Thread size Tightening torque kgf·m


(*1 : JIS B2351 ″O″ Size) (lbf·ft)
Main pump A, B PF 3/4–20 *2 17 (123)
Anti–cavitation M PF 3/4–20 *2 17 (123)
Drain Dr PF 3/8–15 *1 7.5 (54)
Brake releasing PG PF 1/4–12 *1 3.7 (27)
Brake servo hydraulic SH PF 1/4–12 *1 3.7 (27)
Pressure checking PA, PB 2–PF 1/4–15 *1 3.7 (27)
Gear oil filling port (oil level Gl, L PF 3/4–19 10 (72)
checking)
Gear oil outlet GO PT 1/2–15 6.6 (48)
Sectional view

Figure 3
Slew motor
031 Delay valve 390 Name plate
031-1 Plug 391 Rivet
033 Screw 400 Rebound damping valve
051 Relief valve 400- O-ring
1
051-1 O-ring 400- Backup-ring
2
052 Rebound damping valve casing 401 Screw
100 Plug 437 Snap ring
101 Shaft 438 Snap ring
111 Cylinder 443 Roller bearing
113 Retainer 444 Roller bearing
114 Spring-Cylinder 451 Pin-dowel
116 Push rod 465 Plug
117 Spacer F 469 Plug
118 Spacer 471 O-ring
121 Piston 472 O-ring
122 Shoe 488 O-ring
123 Thrust plate 491 Oil seal
124 Shoe plate 702 Piston-brake
131 Valve plate 706 O-ring
151 Plug 707 O-ring
161 O-ring 712 Spring-brake
171 Screw 742 Friction plate
301 Casing 743 Mating plate
303 Valve casing 981 Plug
305 Seal cover 984 Plug
351 Spool 994 Level gauge and pipe
355 Spring
Service Information

Document Title: Function Group: Information Type: Date:


Slew motor, principle of Service Information 2014/6/12
operation
Profile:
EXC, EC210B LC [GB]

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Slew motor, principle of operation


Hydraulic motor
When high pressure oil from the hydraulic pump delivered via the main control valve, enters port (a) of valve plate (1), it
flows to half of the 9 pistons spaced equidistance in cylinder block (4) and pushes the pistons out of the bores against the
inclined swash plate, generating force F in an axial direction.
Force F vector divides into components of radial force F1, F2, and is transmitted sequentially via pistons (5) to cylinder block
(4), generating a rotational torque causing the cylinder block splined to output drive shaft (6) to rotate.
The top dead center port (A) is the starting point of the high pressure rotational cycle : for 180° the pistons move out of the
bores as they slide along the swash plate toward bottom dead center port (B), then they begin moving into the bores
discharging low pressure oil to the return circuit. If the supply port and return port are interchanged, the slew motor rotates
in the opposite direction.
The theoretical output torque T is calculated by the following formula.
T =( p × q) / (2 × π)
p : Effective differential pressure, kgf/cm2
q : Capacity per one rotation, cc/rev

Figure 1
Operation, slew motor

1 Valve plate L Low pressure oil


2 Shoe H High pressure oil
3 Swash plate O Outlet port
4 Cylinder block I Inlet port
5 Piston
6 Drive shaft
Anti–cavitation check valve

Figure 2
Circuit

1. Control valve
2. Return

The motor can be rotated faster than supplied oil flow because there is no counter-balancing valve to prevent overspeed. In
order to prevent cavitation of the motor due to insufficient flow, oil is drawn through the anti-cavitation check valve to
compensate insufficient flow.
Relief valve (type : KRD 20EK60)
Operation
When the port P begins to be under pressure by the tank, P & R port is shown in figure (1) as an initial tank pressure state.
When the force from the area (A1) and pressure (P) becomes the same as spring (321) plus the force generated by pressure
(Pg) in chamber (g), the relief valve starts working.
Piston (303) moves first, but the pressure in chamber (g) remains constant low pressure P2 until the piston stroke is end, as
shown figure(3). Then piston (302) starts moving but the spring (321) force is getting stronger and pressure (P) goes up
gradually.
In this procedure the relief pressure, P, is under control from P1 to Ps by pressure time, t1.
The following shows moving status of each components and relationships with relief pressure in figure (2)~(4).

 Figure (2)

When P port is under pressure, chamber (g) is pressurized by orifice (m) in plunger (301). When the pressure applies to the
hydraulic pressurized area (A2-A3) in the piston (303), it overcomes the force of spring (322) and the piston acting to the
right. At that time the piston (303) moves to the right and relief valve start acting so that the plunger (301) moves to the
right.
At this moment the relationship is shown as,
P1 x A1 = Fsp1 + Pg1 x A2 [Fsp1: Initial spring (231) load]
As piston (303) moves to the right, the oil in chamber (h) is drained to port (R) via the slot in the piston.

 Figure (3)

When piston (303) reaches its stroke end, the pressure of chamber (g) applies to pressurized area of piston (302), A4,
overcomes spring (321) force and piston (302) so that piston (302) starts moving.
When piston (302) starts moving, chamber (f) located in piston"s (302) sliding contact area of adjusting plug (401) and relief
slot acts like a damping seal so that the pressure of chamber (g) goes up gradually while the spring (321) load is increasing.
In this procedure, relief pressure P goes up gradually and smoothly from P2 to Ps.

 Figure (4)

When piston (302) reaches the end of adjustment plug (401), chamber (g) goes to Ps in order to prevent moving left side
and the pressure equals to relief pressure. The steady state relief is applied at this condition.
From the (1) to (4) procedure, the relief pressure changes as shown in figure (5).

 when the pressure at port (p) is decreased


Following is the procedure of relief pressure down.
When the pressure is gone in P port, chamber (g) pressure goes down to the tank pressure together with P port pressure.
The plunger (301) that was open goes to the left side and engaged in the seat (341), simultaneously piston (302) goes to
right by spring (321) and finally returns to the original state.
At that time the ball check valve on the top area opens to supply oil from R port so the piston (303) returns immediately
without delay.

Figure 3
Operation, relief valve

301 Plunger 303 Piston 322 Spring


302 Piston 321 Spring 401 Plug

Rebound damping valve


The rebound damping valves allow, fast/responsive, but
smooth/gentle acceleration and retardation of the superstructure without jerking or impact, thereby greatly reducing
mechanical stress on the slew mechanism and extending component service life.
Operation
Figure (1) shows the damping valve in neutral condition in relation to normal slew operation.
Figure (2) shows the valve operating condition with brake pressure at port Am.
Oil pressure applied at port Am flows through passage (l), the orifice in seat (313), and passage (m) of spool (311) to
chamber (n). When pressure (P) is more than set value of spring (321) force (Ps), it moves spool (311) left compressing spring
(321), pushing seat (313) to compress spring (322).
Figure (3) shows the valve condition when movement of the inertia load stops, [Y point in figure (4)], and the brake pressure
is lowered. When pressure (P) is less than spring (321) force (Ps), spool (311) moves right, then spring (322) starts to move
seat (311) right, but the seat return is delayed since the oil in chamber (P) exits via narrow passage (g) which causes a
damping function. The delay allows seat (t) to open and a passage is connected between port Am & Bm, by (l → t → r → k).
This rapidly equalizes the pressure at port Am & Bm, [Z point in figure (4)], which prevents the slew motor from over
running.
Figure 4
Operation, rebound damping valve

Slew brake
The slew brake is spring applied and hydraulically released. Friction plates (742) are splined to and rotate with cylinder block
(111). Mating plates (743) are splined to motor casing (301). When the remote control valve pilot pressure to SH port is
blocked, the primary pilot oil pressure flow to brake piston (702) is cut off and the force of brake springs (712) acting on
piston (702) squeeze the mating and friction plates together, preventing output shaft (101) from rotating thereby stopping
the superstructure from slewing.
When the primary pilot oil pressure reacts on the opposite side of brake piston (702) it overcomes the force of springs (712)
and moves the piston creating clearance between the friction and mating plates, thereby releasing the brake.
Figure 5
Slew brake

1. Oil pressure
2. Spring force
3. Oil pressure chamber

Slew motor, lubrication and air purging

Figure 6
Position, drain

Dr Drain port

 Following the repair or replacement of the slew motor assembly it is necessary to prelubricate the internal
components to prevent scoring/scuffing of the bearings and sliding parts.
Remove the upper case drain port plug and fill the casing with the specified hydraulic oil.
 Oil capacity : 900 cc
 Prior to start up purge the air from the circuit plumbing and motor.

Precautions for lubrication

 Check that there is no contamination in the ports or plumbing before connecting to the motor.
 Check for oil leakage on the motor assembly.
 Check if the direction of rotation according to the control lever is correct.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
 Check if the hydraulic pressures are set to the specified values.

Standard for parts service and replacement


The following standards of the serviceability of parts can be determined from measurements made at disassembly. However,
they are general standards and when parts show excessive external damage or discoloration, top priority should be given to
the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the
remaining life expectancy of the parts.
Wear limits

Item Standard Recommended Remedy


dimension value for
mm (in) replacement mm (in)
Clearance between piston and 0.032 0.062 Replace cylinder.
cylinder bore (D–d) (0.0012) (0.0024)

Gap between piston and 0 0.3 Replace piston shoe


caulked part of shoe (α) (0.0118) assembly.

Thickness of shoe (t) 6 5.8 Replace piston shoe


(0.2360) (0.2280) assembly.

Assembled height of retainer 7 6.5 Replace spherical bushing


plate and spherical bushing (H-h) (0.2760) (0.2560) and retainer plate as a set.

Thickness of friction plate (t) 4 3.6 Replace


(0.1570) (0.1420)

Standard for correcting sliding surfaces


If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the part.
Sliding surface

Part Standard surface roughness Standard roughness requiring correction


Shoe 0.8–Z (Ra=0.2) 3–Z (Ra=0.8)
(lapping)
Swash plate 0.4–Z (Ra=0.1) 3–Z (Ra=0.8)
(lapping)
Cylinder 1.6–Z (Ra=0.4) 12.5–Z (Ra=3.2)
(lapping)
Valve plate 0.8–Z (Ra=0.2) 6.3–Z (Ra=1.6)
(lapping)

 Lap each sliding surface to a standard roughness level or finer.


 If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace the
parts as sub assemblies.
Service Information

Document Title: Function Group: Information Type: Date:


Slew motor, principle of Service Information 2014/6/12
operation
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Slew motor, principle of operation


Hydraulic motor
When high pressure oil from the hydraulic pump delivered via the main control valve, enters port (a) of valve plate (1), it
flows to half of the 9 pistons spaced equidistance in cylinder block (4) and pushes the pistons out of the bores against the
inclined swash plate, generating force F in an axial direction.
Force F vector divides into components of radial force F1, F2, and is transmitted sequentially via pistons (5) to cylinder block
(4), generating a rotational torque causing the cylinder block splined to output drive shaft (6) to rotate.
The top dead center port (A) is the starting point of the high pressure rotational cycle : for 180° the pistons move out of the
bores as they slide along the swash plate toward bottom dead center port (B), then they begin moving into the bores
discharging low pressure oil to the return circuit. If the supply port and return port are interchanged, the slew motor rotates
in the opposite direction.
The theoretical output torque T is calculated by the following formula.
T =( p × q) / (2 × π) x 1 / 100, Nm
p : Effective differential pressure, MPa
q : Capacity per one rotation, cm3/rev

Figure 1
Operation, slew motor

1 Valve plate L Low pressure oil


2 Shoe H High pressure oil
3 Shoe plate O Outlet port
4 Cylinder block I Inlet port
5 Piston
6 Drive shaft
Anti–cavitation check valve

Figure 2
Circuit, check valve

1. Control valve
2. Return

The motor can be rotated faster by inertia than supplied oil flow because there is no counter-balancing valve to prevent
overspeed. In order to prevent cavitation of the motor, oil compensating insufficient flow is drawn through the anti-
cavitation check valve.
Relief valve (Type : KRD22EK10C)
Operation
When ports (P & R) are pressurized by hydraulic tank pressure, the initial condition of the relief valve is closed as shown in
figure (1).
When port P is pressurized by hydraulic tank pressure, the relief valve begins to open at the point that the hydraulic force
[area (A1) of plunger (301) x pressure P] is equal to spring (321) force plus pushing force [area (A2) of plunger x pressure of
chamber g (Pg)]. And then, the force of spring (321) increases according to movement of piston (302) by the increasing
pressure of chamber g.
The relief pressure P is controlled with pressure-up timing t1 from P1 to Ps. For each step in figure (2) ~ (4), relations of the
movement and relief pressure is explained as follows.

 Figure (2)

When port P of the relief valve is pressurized, chamber g is pressurized through orifice m, fitted into plunger (301). As
hydraulic force in plunger (301) increases and it reaches equal to spring (321) force, the relief valve operates with pressure
P1.
At this time, the relation is expressed in following formula.
P1 x A1 = Fsp1 + Pg1 x A2 [* Fsp1: the initial setting load of spring (321)]

 Figure (3)

The pressure of chamber g acts on piston (302) area (A3 - A4). If this hydraulic force is greater than spring (321) force, the
piston begins moving to the left.
At this time, chamber h functions as a damping chamber because the oil in chamber h, which is between piston (302) and
adjustment plug (401), discharges through orifice n, which is installed at piston (302), and then it moves to the left. The relief
pressure P increases gradually because tensional load increases according to the compression of the spring until piston (302)
approaches the end of the adjustment plug.

 Figure (4)

When the piston (302) contacts the end of adjustment plug (401), it does not move to the left any more, and it becomes
normal condition, then the relief pressure keeps as Ps.
By the above procedure, the relief pressure varies as figure (2).

 When the pressure at port (P) is decreased

As the oil pressure decreases, the pressure of port P and chamber g decreases to tank pressure. Therefore, the opening
plunger (301) is pushed to the left and contacts seat (341). Simultaneously, the piston (302) moves to the right by spring
(321) force as shown in figure (1).

Figure 3
Operation, relief valve
Rebound damping valve
The rebound damping valves allow, fast/responsive, but smooth/gentle acceleration and retardation of the superstructure
without jerking or impact, thereby greatly reducing mechanical stress on the slew mechanism and extending component
service life.
Operation
Figure (1) shows the damping valve in neutral condition in relation to normal slew operation.
Figure (2) shows the valve operating condition with brake pressure at port (A).
Oil pressure applied at port (A) flows through passage (l), the orifice in seat (313), and passage (m) of spool (311) to chamber
(n). When pressure (P) is more than set value of spring (321) force (Ps), it moves spool (311) left compressing spring (321),
pushing seat (313) to compress spring (322).
Figure (3) shows the valve condition when movement of the inertia load stops, [Y point in figure (4)], and the brake pressure
is lowered. When pressure (P) is less than spring (321) force (Ps), spool (311) moves right, then spring (322) starts to move
seat (311) right, but the seat return is delayed since the oil in chamber (p) exits via narrow passage (g) which causes a
damping function. The delay allows seat (t) to open and a passage is connected between port (A) & (B), by (l → t → r → k).
This rapidly equalizes the pressure at port (A) & (B), [Z point in figure (4)], which prevents the slew motor from over running.
Figure 4
Operation, rebound damping valve

R Rebound damping valve


T Time
P Pressure

Slew brake
The slew brake is spring applied and hydraulically released. Friction plates (742) are splined to and rotate with cylinder block
(111) which is splined to shaft (101). Mating plates (743) are held by arc grooves in motor casing (301). Brake springs (712)
force acting on brake piston (702) squeeze the mating and friction plates together, friction force is generated stopping
output shaft (101) from rotating, thereby halting the superstructure movement.
When primary oil pressure acts on the opposite side of brake piston (702) it overcomes brake springs (712) force and the
piston moves creating clearance between the plates, thereby releasing the brake.

Figure 5
Operation, slew brake

A. Oil pressure force


B. Spring force
C. Oil chamber
Service Information

Document Title: Function Group: Information Type: Date:


Slew motor, adjustment Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Slew motor, adjustment


Crossover relief valve

 Remove pressure port plug PA or PB.


 Install oil pressure gauge (600 kgf/cm2 : 8530 psi).
Tools : 6 mm Allen wrench
Fitting size of pressure checking port : PF 1/4″
 Secure the superstructure by putting the bucket against an immovable object or in a trench.
 Operate the slew lever in the appropriate direction and check the relief pressure.
 Loosen lock nut (1) and turn adjusting screw (2) as follows :

 To increase pressure, turn clockwise.


 To decrease pressure, turn counter clockwise.

 If the relief pressure can not be adjusted correctly, replace the relief valve assembly.

Figure 1
Position, pressure measuring

PA Gauge port 1 Lock nut


PB Gauge port 2 Adjusting screw
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, maintenance Service Information 2014/6/12
standard
Profile:
EXC, EC210B LC [GB]

Swing motor, maintenance standard


Swing motor, lubrication and air purging

Figure 1
Position, drain

D Drain port

 Following the repair or replacement of the swing motor assembly it is necessary to prelubricate the internal
components to prevent scoring/scuffing of the bearings and sliding parts.
 Remove the upper case drain port plug and fill the casing with the specified hydraulic oil.
 Oil capacity: 0.8 liters (0.21 US gal)
 Prior to start up purge the air from the circuit plumbing and motor.

Precautions for lubrication

 Check that there is no contamination in the ports or plumbing before connecting to the motor.
 Check for oil leakage on the motor assembly.
 Check if the direction of rotation according to the control lever is correct.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
 Check if the hydraulic pressures are set to the specified values.

Standard for parts service and replacement


The following standards of the serviceability of parts can be determined from measurements made at disassembly. However,
they are general standards and when parts show excessive external damage or discoloration, top priority should be given to
the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the
remaining life expectancy of the parts.
Seals
Replace the seals and O-rings, although they appear not damaged.
Part replacement criteria
Replace all parts that appear damaged or are not within the allowable value.
Part replacement criteria, unit: mm (in)

Item Standard Recommended Remedy


dimension value for replacement
Clearance between piston and cylinder 0.027 0.052 Replace piston or cylinder.
bore (D–d) (0.0011) (0.0021)

Gap between piston and caulked part of 0 0.3 Replace assembly of piston
shoe (α) (0.0118) and shoe.

Thickness of shoe (t) 5.5 5.3 Replace assembly of piston


(0.2165) (0.2087) and shoe.

Thickness of friction plate (t) 2 1.8 Replace friction plate.


(0.0787) (0.0709)

Standard for correcting sliding surfaces


If the surface roughness of the sliding surface of a part exceeds the following standard, correct it or replace the part.
Sliding surface

Part Standard surface roughness Standard roughness requiring correction


Shoe 0.8–Z (Ra=0.2) 3–Z (Ra=0.8)
(lapping)
Shoe plate 0.4–Z (Ra=0.1) 3–Z (Ra=0.8)
(lapping)
Cylinder 1.6–Z (Ra=0.4) 12.5–Z (Ra=3.2)
(lapping)
Valve plate 0.8–Z (Ra=0.2) 6.3–Z (Ra=1.6)
(lapping)

 Lap each sliding surface to a standard roughness level or finer.


 If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace the
parts as sub assemblies.

Crossover relief valve, pressure adjustment

 Remove pressure port plug PA or PB.


 Install oil pressure gauge (60 MPa, 8702 psi, 600 bar).
 Secure the superstructure by putting the bucket against an immovable object or in a trench.
 Operate the swing lever in the appropriate direction and check the relief pressure.
 Loosen lock nut (1) and turn adjusting screw (2) as follows :

 To increase pressure, turn clockwise.


 To decrease pressure, turn counter clockwise.

 If the relief pressure can not be adjusted correctly, replace the relief valve assembly.

Figure 2
Pressure adjustment

PA Gauge port 1 Lock nut


PB Gauge port 2 Adjusting screw

General tools
General tools

Tool Size Name of parts applied and remarks


Allen wrench 14 mm (0.6 in) RO plug (469)
17 mm (0.7 in) Screw (401)
Spanner, socket wrench 41 mm (1.6 in) Relief valve (051)
Hammer Plastic and steel hammers
Steel rod 10 × 8 × 200 mm Bearings (443, 444), pin (451)
(0.4 × 0.3 × 7.9 in)
Torque wrench 5 ~ 10 Nm (3.7 ~7.4 lbf ft)
10 ~ 45 Nm (7.4 ~ 33.3 lbf ft)
40 ~ 180 Nm (29.6 ~ 133.2 lbf ft)
120 ~ 480 Nm (88.8 ~ 355.2 lbf ft)
Screw driver 2 pieces
Bearing pliers Bearings (443, 444)

Special tool
Special tool

No. Description Part number Quantity


1 Brake piston tool 14559282 1
Service Information

Document Title: Function Group: Information Type: Date:


Tools Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Tools
General tools
General tools

Description Size (mm) Thread Tool


Screw 17 M 20 Allen wrench
VP Plug 19 PF 1/4 Socket allen wrench
Plug 13 M8 Socket allen wrench
RO Plug 14 M 30 Allen wrench
Screw 10 M6 Spanner, socket wrench
Relief valve 41 M 33 Spanner, socket wrench
Plug 10 PT 1/2 Allen wrench
Plug 14 PT 3/4 Allen wrench

Special tools
Special tools

Description Size
Snap ring plier φ 52, φ 60 (φ 2.05, φ 2.36)
Driver (–) Medium (2)
Pry bar 10 × 8 × 200 mm (0.4 × 0.3 × 7.9 in)
Hammer Plastic and steel hammers
Torque wrench Tightening torque
100 ~ 450 kgf cm (80 ~ 400 lbf in)
400 ~ 1800 kgf cm (80 ~ 1600 lbf in)
1200 ~ 4800 kgf cm (1000 ~ 4200 lbf in)
Slide hammer bearing puller 14559282 Puller
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, replacing Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Swing motor, replacing


Op nbr 441-021

1. Park the machine in the service position C. See 091 Service positions.

2.  When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
 Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
 Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
 After disconnecting the hose, install a plug to prevent oil leakage and contamination.

3. Remove the anti-cavitation hose.

Figure 1
Removal, hoses

1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses
5. Screws

4. Remove the swing motor drain hose.

5. Remove the swing motor feed line hoses.

6. Remove the delay valve sub hoses.

7. Remove the swing motor mounting screws.

8. Lift swing motor with sling, and lower to the workbench safely.
Figure 2
Removal, swing motor

1. Sling
2. Oil filling pipe
3. Swing motor

9. Transfer oil filling pipe and the connectors to the new swing motor.
NOTE!
Before installing the drain port connector, fill the new swing motor casing with hydraulic fluid.

10. Thoroughly remove the sealing compound on swing gearbox.


Apply sealing compound to the swing gearbox mounting surface.

Figure 3
Applying, sealing compound

1. Swing gearbox
2. Sealing compound

11. Install the swing motor.

12. Install the swing motor feed line hoses.

13. Install the delay valve sub hoses.

14. Install the swing motor drain hose.

15. Install the anti-cavitation hose.


NOTE!
Fill the motor casing with oil before operation. See 4412 Swing motor, specifications.
16. Remove the vacuum pump mounted on the hydraulic tank.

17. Bleed air from the hydraulic circuit at the swing motor before operating.

18. After completion of the work, start the engine and check for leaks.
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor relief valve, Service Information 2014/6/12
replacing
Profile:
EXC, EC210B LC [GB]

Swing motor relief valve, replacing


Op nbr 441-022

1. Park the machine in the service position C, see 091 Service positions.

2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at
"ON" position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.

3. Remove slew motor relief valve (1).

Figure 1
Replacing, relief valve

4. Install a new relief valve on the slew motor.

5. After completion of the work, start the engine and check for leaks.

6. Check relief valve pressure of the slew motor, and adjust if necessary.
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor removed, Service Information 2014/6/12
replacing seal
Profile:
EXC, EC210B LC [GB]

Swing motor removed, replacing seal


Op nbr 441-026

1. Remove the retaining rings.

Figure 1
Removal, retaining rings

1. Retaining ring
2. Retaining ring

2. Remove the seal cover from the swing motor housing.

Figure 2
Removal, seal cover

1. Seal cover

3. Remove the seal from the swing motor housing.


Figure 3
Replacing, seal

1. Seal

4. Install the a new seal to the swing motor housing.


NOTE!
Apply grease on lip of seal.

5. Install the seal cover to the swing motor housing.

Figure 4
Installation, seal cover

1. Seal cover

6. Install the retaining rings.


Figure 5
Installation, retaining rings

1. Retaining ring
2. Retaining ring
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, replacing Service Information 2014/6/12
brake piston seal
Profile:
EXC, EC210B LC [GB]

Swing motor, replacing brake piston seal


Op nbr 441-025

14559282 Puller

1. Park the machine in the service position B. See 091 Service positions.

2.  When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
 Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
 After disconnecting the hose, install a plug to prevent oil leakage and contamination.

3. Remove the anti-cavitation hose.

Figure 1
Removal, hoses

1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses

4. Remove the swing motor drain hose.

5. Remove the swing motor feed line hoses.

6. Remove the two valves from the block.


Figure 2
Removal, motor cover

1. Valves
2. Screw
3. Swing motor cover

7. Remove the mounting screws.

8. Lift the swing motor cover.

9. Remove the springs from the brake piston and remove the plate on the cylinder.

Figure 3
Removal, springs and plate

1. Springs
2. Plate

10. Fit the special tool to brake piston as shown and then tighten screws to the casing.
Pull the brake piston vertically by tightening the screws of special tool.

 Tool part number (1): 14559282


Figure 4
Removal, brake piston

1. Special tool
2. Brake piston
3. Screws

11. Replace O-rings in the casing.

Figure 5
Replacing, O-rings

1. O-ring
2. O-ring

12. Install the brake piston into the casing using the special tool.

 Tool part number (1): 14559282

13. Install the springs to the brake piston.

14. Apply grease on plate and install it to swing motor cover.


Figure 6
Installation, plate

1. Plate
2. Swing motor cover

15. Install the swing motor cover to the casing.

16. Install the hoses in reverse order of removal procedure.


NOTE!
Fill the motor casing with oil before operation. See 4412 Swing motor, specifications.

17. Bleed air from the hydraulic circuit at the swing motor before operating.
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, disassembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing motor, disassembly


Disassemble

Op nbr 00000

1. Lift the motor assembly with a wire rope and crane. Clean with cleaning solvent, and dry with compressed air.
NOTE!
Clean the motor thoroughly before separating from the reduction gear.

2. Before disassembling make a match mark (A) on motor casing (301) and valve casing (303).
NOTE!
Select a clean place. Put a rubber sheet on the work bench to prevent the parts from being damaged.

Figure 1
Removal, drain plug

3. Remove screws (032) and delay valve (031) from casing (301).
Figure 2
Marking, A

4. Remove level gauge and pipe (994) from casing (301).

Figure 3
Removal, delay valve

5. Remove screw (171) and rebound damping valve (052) from valve casing (303).

Figure 4
Removal, rebound damping valve

6. Remove relief valve (051) from valve casing (303).


Replace O-ring and back-up ring.

Figure 5
Removal, relief valve
NOTE!
Replace O-ring .

7. Remove Ro plug (469) and take out spring (355) and spool (351) from the valve casing.
Figure 6
Removal Ro plug
NOTE!
Be careful not to damage the spool seat.

8. Remove screws (401) and valve casing (303) from casing (301). When loosening the screws casing (303) will be
raised by brake springs (712). Remove valve plate (131) from the valve casing.

Figure 7
Removal screws

Figure 8
Removal, valve plate
NOTE!
Be careful not to drop the valve plate from the valve casing. (Sometimes the valve plate is adhered to the cylinder.)

9. Remove brake springs (712) from the brake piston.

Figure 9
Removal, brake springs

10. Disassemble brake piston (702) from casing (301) by using the special tool.

Figure 10
Disassembly, brake piston
NOTE!
Lift it straight, using the screw holes in the brake piston.

Special tool Part No. : 14559282 Puller

11. After placing the motor horizontally, take out cylinder (111) from drive shaft (101). Remove pistons (121), retainer
(123), spherical bushing (113), spacer (117) and swash plate (124).
Figure 11
Removal, cylinder
NOTE!
When taking out the cylinder, be careful not to pull out push rod (116). Piston must be installed into the same
bores because of wear pattern. Mark the pistons and respective cylinder bores.

12. Pull out friction plates (742) and mating plates (743) from casing (301).

Figure 12
Removal, friction and mating plates

13. Remove drive shaft (101) and shoe plate (124).

Figure 13
Removal drive shaft
Figure 14
Removal, drive shaft
NOTE!
Tape drive shaft spline to prevent oil seal damage.

14. Do next step if required.


Remove the inner race of roller bearing (443) from drive shaft (101) with a press.
NOTE!
Do not reuse the bearing race.

Figure 15
Remove the inner race

A. Press
B. Drive shaft
C. Bearing
D. Support the inner race

15. Remove snap ring (437) and pull out seal cover (305) from casing (301). Remove oil seal (491) from seal cover (305)
using a seal driver.
Figure 16
Removal, seal cover

16. Use a slide hammer and a bearing puller or a press to remove the outer race of bearing (443) from casing (301).

Figure 17
Removal, bearing outer race
NOTE!
Do not reuse the bearing.

17. Pull out roller bearing (444) from valve casing (303) with a sliding hammer and a bearing puller.

Figure 18
Removal, roller bearing
NOTE!
Do not reuse the bearing.

NOTE!
Disassembling is finished. Check each component thoroughly.

Oil seal replacement (When replacing the oil seal only)

Op nbr 00000
1. Remove snap ring (437) and pull out seal cover (305) from casing (301).

Figure 19
Removal, snap ring

2. Remove oil seal (491) from casing (301) with a seal driver (M4 × 0.7 screws).

Figure 20
Removal, oil seal

3. Install new oil seal (491) to casing (301) and drive shaft (101) after assembling two screws (M4 × 0.7) on the oil seal.

Figure 21
Assembly, oil seal
NOTE!

Coat the lip of the oil seal with grease. Be careful not to damage the lip of the oil seal, tape the shaft splines. The
seal lip must face toward casing (301) – downward in the picture.

4. Insert seal cover (305) and install snap ring (437) to casing (301).
Figure 22
Assembly, seal cover
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, disassembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing motor, disassembly


1. Ensure that the motor is clean and free from dirt and debris prior to any disassembly.
NOTE!
All port are to be plugged to prevent ingress of dirt during external cleaning.

2. Remove the drain plug and drain the oil from casing (301).
3. Put identification marks on the parts to indicate proper positioning during reassembly.
NOTE!
Prevent damage to disassembled parts, by keeping them protected and in a clean area.

Figure 1
Identification marks
4. Remove relief valves (051) from the valve casing (303).
NOTE!
Be sure to replace O-rings of relief valves because they are frequently damaged during disassembly.

Figure 2
Removal, relief valves
5. Remove plugs (469), spring (355) and spools (351) from the valve casing (303).
NOTE!
Handle carefully to prevent damage to the seat on spool (351).
Figure 3
Removal, plugs
6. Remove screws (401) and remove valve casing (303) from casing (301) then remove valve plate (131).
NOTE!
When the screws are loosened the valve casing is slightly lifted by the brake springs (712).

Be careful not to drop the valve plate from the valve casing. It is often adhered to the cylinder.

Figure 4
Removal, screws
7. Remove springs (712) from the brake piston (702).

Figure 5
Removal, springs
8. Remove brake piston (702) from casing (301) by using special tool.
– Tool part number: 14559282
NOTE!
Pull brake piston (702) vertically by using the special tool.
Figure 6
Removal, brake piston
9. Put the motor on its side as shown in the figure. Remove the rotation group from drive shaft (101).
NOTE!
During the removal of the rotation group from the swing motor, do not let the pistons fall out of the cylinder. All
pistons in the rotation group must be re-installed in their original locations.

Figure 7
Removal, rotation group
10. Disassemble the rotation group as follows:
Put identification marks on nine pistons (121), showing their location in plate (123) and cylinder (111). Remove nine
pistons (121) and plate (123) as a unit from the cylinder. Separate the piston assemblies from the plate.
NOTE!
Handle carefully so as not to damage the sliding face on the retainer or shoes (122).

11. Remove friction plates (742) and mating plates (743) from casing (301).

Figure 8
Removal, friction and mating plates
12. Turn the motor body over, and remove the shaft assembly from casing (301).
Figure 9
Removal, shaft assembly
13. Remove roller bearing (443) using a press if necessary.
NOTE!
Be careful not do damage the sliding face on the shaft. If the bearing is removed, a new bearing must be used
during reassembly.

Figure 10
Removal, bearing
14. Remove bearing (443) from casing (301) using a rod and hammer.
NOTE!
When hammering, be sure to use a soft metal bar to prevent damage to parts. Never hit directly with a hammer or
iron bar.

NOTE!
If the bearing is removed a new bearing must be used during reassembly.

15. Remove bearing (444) from the motor body using bearing pliers, only if necessary.
NOTE!
If the bearing is removed a new bearing must be used during reassembly.
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing motor, assembly


Cleanliness is a primary means of ensuring satisfactory motor life, for new and repaired units. Clean parts by using a clean
solvent wash and air-drying. As with any precision equipment, the internal mechanism and related items must be kept free
of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and contamination.
It is highly recommended that all oil seals and O-rings be replaced. Lightly lubricate all oil seals and O-rings with clean oil
prior to assembly. Lubricate all sliding sections, bearings, and cylinders with clean oil prior to assembly.
Tightening torque
Tightening torque, unit : Nm (lbf ft)

Description Item No. Thread size Tightening torque


Plug 031–1 9/16–18UNF–2B 0.9 (0.7)
Screw 033 M6 12 (8.9)
Relief valve 051 M33 x 1.5 177 (131)
Plug 151 9/16–18UNF–2B 48 (36)
Screw 171 M8 29 (21.5)
Rebound damping valve 400 M22 x 1.5 69 (51)
Screw 401 M20 430 (318)
Plug 469 M30 x 1.5 334 (247)
Plug 984 3/4–16UNF–2B 1.7 (1.3)
Plug 985 1–5/16–12UN–2B 4.4 (3.3)

1. Place the motor in a vertical position with bell housing face down.
2. Heat bearing inner race (443) to 110 °C (230 °F) maximum and install onto drive shaft (101).
NOTE!
Do not exceed temperature 110 °C (230 °F).

Figure 1
Heating, bearing inner race

A. Output side
B. Bearing inner race

3. Heat bearing inner race (444) to 110 °C (230 °F) maximum and install onto drive shaft (101).
NOTE!
Do not exceed temperature 110 °C (230 °F).
4. Apply grease to seal (491) and install the seal to casing (301).
NOTE!
Be careful of direction of the oil seal. The seal lip must face toward casing (301).

NOTE!
Be careful not to damage the lip of the oil seal.

Figure 2
Installation, oil seal
5. Insert bearing (443) to casing (301).

Figure 3
Installation, bearing
6. Insert shaft (101) to casing (301).
NOTE!
Be careful not to damage the lip of the oil seal.

Figure 4
Installation, shaft
7. Install shoe plate (124) into casing (301).
NOTE!
The shoe plate lapped side must face outwards.
Figure 5
Installation, shoe plate
8. Put thrust plate (123) on plate spring (114) and install piston assembly (121, 122) into thrust plate (123).

Figure 6
Installation, piston assembly
9. Insert piston assemblies into cylinder (111).
Install the rotation group into casing (301).

Figure 7
Installation, rotation group
10. Place the motor in a vertical position with bell housing face down.
First, insert a mating plate (743), and then insert a friction plate (742) and mating plate (743) alternately.
NOTE!
Mating plate: 4 EA, Friction plate: 3 EA
Figure 8
Installation, friction and mating plates
11. Install O-ring (707) and O-ring (706) into casing (301).
NOTE!
Coat the O-rings with grease prior to installation.

Figure 9
Installation, O-ring
12. Install brake piston (702) into casing (301) by tapping the piston into position using a plastic hammer, and then
press firmly to ensure the brake piston is seated correctly.

Figure 10
Installation, brake piston
13. Install spring (712) into brake piston (702).
Figure 11
Installation, spring
14. Install bearing (444) into valve casing (303) using a hammer and steel rod.
NOTE!
Tap evenly at the periphery of bearing using a hammer and steel rod until it is fully seated.

Figure 12
Installation, bearing
15. Install valve plate (131) and O-ring (472) onto valve casing (303). Brass face must be upwards.
NOTE!
Coat the face of the valve casing lightly with grease to hold valve plate (131) in position.

Figure 13
Installation, valve plate and O-ring
16. Install valve casing (303) and four screws (401) into casing (301).
Figure 14
Installation, valve casing
17. Insert spool (351) and spring (355) into valve casing (303) and install plug (469) with O-ring (488) in valve casing
(303).
NOTE!
Check spool (351) to ensure it moves smoothly.

Figure 15
Installation, spool
18. Put the O-ring on relief valve (051) and install relief valve (051) into valve casing (303).

Figure 16
Installation, relief valve
Service Information

Document Title: Function Group: Information Type: Date:


Swing motor, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Swing motor, assembly


Tightening torque
Tightening torque, unit : kgf·m (lbf·ft)

Description Item No. Thread size Tightening torque


Screw 401 M20 44 (317)
VP Plug 464 PF 1/4 3.7 (26.7)
Screw 171 M8 3 (21.7)
RO plug 469 M30 22.5 (162.5)
Plug 992 PT 1/2 6.6 (47.7)
Plug 994 PT 3/4 10 (72.2)
Relief valve 051 M33 18 (130)
Rebound damping valve 400 M22 7 (50.5)

Preparation
Clean all part with cleaning solvent and dry with compressed air.
Rework damaged parts and before assembling, prepare all replacement parts.
Coat the sliding parts and bearings with clean hydraulic oil.
Replace the o-rings and oil seal.
Use a torque wrench to tighten the screws and plugs, to the specified torque.
Assembly, slew motor

Op nbr 00000

1. Place casing (301) on the work bench with the valve casing side upward.

Figure 1
Casing
2. Heat the inner race of bearing (443) and press–fit to drive shaft (101).

Figure 2
Assembly, inner race collar
NOTE!
Pay attention to the direction of the inner race collar.

A. Output shaft

3. Heat the inner race of bearing (444) and press–fit to drive shaft (101).

Figure 3
Assembly, inner race bearing

4. Install snap ring (437) in casing (301) and seal cover (305). Install oil seal (491) in casing (301) using the oil seal
driver.
NOTE!
Pay attention the direction of oil seal. The seal lip must face toward casing (301) – upward in the drawing. Coat the
lip of the oil seal with grease.
Figure 4
Assembly, snap ring

5. Using a brass tap the outer race of roller bearing (443) until the bearing is fully seated in casing (301).

Figure 5
Assembly, roller bearing

6. Install drive shaft (101) to casing (301).


Figure 6
Assembly, drive shaft
NOTE!
Be careful not to damage the lip of the oil seal, tape the shaft splines.

7. Set the casing horizontally and assemble shoe plate (124) casing side.

Figure 7
Assembly, shoe plate

A. Casing side

NOTE!
Insert it with the larger chamfered side of the shoe plate toward the casing. Coat lightly with grease.

8. Insert push rods (116) and spacer F (117) to cylinder (111) and install spherical bushing (113) with the larger O.D.
toward the cylinder.
NOTE!
Be careful not to damage the sliding surface of the cylinder. Insert 2 push rods into each hole.
Figure 8
Assembly, push rods

9. Fit piston sub assembly unit (121, 122) to retainer (123).

Figure 9
Assembly, piston

10. Assemble the retainer with the piston sub assembly unit to the cylinder block and install it on drive shaft (101)
aligning the splines.

Figure 10
Assembly, piston sub

11. Set casing (301) with seal cover (305) downward and assemble three mating plates (743) and four friction plates
(742) in sequence.
NOTE!
Align 4 tangs to the notches as shown.
Figure 11
Assembly, plates

12. Mount o-rings (706, 707) to casing (301).

Figure 12
Assembly, o-rings
NOTE!
Coat the o-rings with grease.

13. Assemble brake piston (702) to casing (301).

Figure 13
Assembly, brake piston
Figure 14
Assembly, brake piston
NOTE!
Place 4 notches of the brake piston as shown below. The piston is difficult to assemble because of the restriction of
the o-ring; screw two M8 screws into the brake piston and tap them gently.

A. 2–M8
B. Brake piston
C. Screw hole
D. Mounting side

14. Assemble brake springs (712) into brake piston (702).

Figure 15
Assembly, brake springs
NOTE!
Confirm the springs are fitted to the brake piston completely.

15. (This procedure is needed only when roller bearing is disassembled)


Install the outer race of roller bearing (444) in valve casing (303) while tapping it lightly.

Figure 16
Assembly, roller bearing
NOTE!
Tap evenly on the outer diameter of the outer race with a brass bar until it is fully seated.

16. Assemble valve plate (131) to valve casing (303) and fit o-ring (472).
NOTE!
Coat lightly with grease. Ensure dowel pins (451) are installed in the valve casing.

Figure 17
Assembly, valve plate

17. Mount valve casing (303) to casing (301) and tighten screws (401) to the specified torque.

Figure 18
Assembly, valve casing
NOTE!
Be careful to note the mounting direction of the valve casing. (See the drawing) Be careful not to drop the valve
plate or let the brake springs pop out. Tighten the screws evenly.

18. Insert spool (351) and spring (355) into the valve casing and install RO plug (469) with o-ring (488). Tighten the
plug to the specified torque.
Figure 19
Assembly, spool
NOTE!
Confirm the smooth movement of the spool before installing the plug.

19. Assemble relief valve (051) to valve casing (303).

Figure 20
Assembly, relief valve

20. Assemble delay valve(031) with screw (032) to casing (301).

Figure 21
Assembly, delay valve

21. Assemble o-ring (161) to rebound damping valve sub assembly (052) and install the valve with screw (171) to valve
casing (303).
Figure 22
Assembly, rebound damping valve
NOTE!
Be sure to install all the o-rings.

22. Assemble plug with o-ring to casing(301)

Figure 23
Assembly, plug
Service Information

Document Title: Function Group: Information Type: Date:


Slew motor, Service Information 2014/6/12
troubleshooting
Profile:
EXC, EC210B LC [GB]

Slew motor, troubleshooting


Given below are actions to be taken when you have found any abnormality with the hydraulic motor during operation.
Identify possible causes
Before proceeding to work, try to determine the nature of the fault, check all related systems and discuss the malfunction
with the operator. Finally recheck the most likely causes of the malfunction again before dismantling the motor.
Beware of dirt
Many faults result from dirt. Therefore take adequate measures prior to disassembly and during assembly to prevent entry of
any contamination.
Handling parts
Parts are precision finished and sufficient care should be taken in handling so as not to damage them.
NOTE!
It is recommended during assembly to replace O-rings and oil seals with new ones.

Fault finding of motor


It is extremely difficult to trace trouble in the hydraulic circuits. Inspect the following items and investigate whether or not
the fault is caused by the motor.
Inspecting the oil in casing
Remove the drain plug and inspect the hydraulic oil in the casing. If a large amount of metallic particles drain out with the
oil, you should suspect a failure of internal parts.
Presence of abnormal sound
Check whether the motor emits an abnormal sound.
Pressure measurement of various points
Measure pressures at various points and check for faults, instead of disassembling parts at random.
Measuring the motor case drain flow

 Put the bucket in a trench to prevent the superstructure from rotating.


Operate the slew lever to fully load the slew motor. The normal drain oil flow in stall condition is below
approximately 25 l/min (6.5 gpm) (pressure 270 kgf/cm2 : temperature 100 °C).
 The drain oil flow during the normal slew is below 2 l/min (0.5 US gal/min).

The hydraulic motor does not rotate.


Troubleshooting

Phenomenon Cause Remedy


Pressure does not increase.
1. Safety valve is not set correctly. 1. Set valve at correct value.
2. Relief valve does not function 2. a) Repair or replace stuck
well. section.
a) Sticking of spool b) Disassemble spool.
b) Clogging of spool throttle 3. Check seat section and replace
3. Seat of spool does not function it, if damaged.
well.

Pressure rises.
1. Overload 1. Remove load.
2. Seizure of moving parts 2. Check and repair piston/shoes,
3. Brake is not applied with release cylinder, valve plate, etc.
of oil pressure. 3. a) Check and repair circuit.
4. Brake piston sticks. b) Check time delay valve for
5. Spool sticks. brake.
6. Friction plate is seized. 4. Disassemble and check it.
5. Disassemble and check it.
6. Disassemble and check it.
Replace seized plates.

The motor rotation is reversed.


Troubleshooting

Phenomenon Cause Remedy


The motor rotation is reversed to
lever direction. 1. Motor is assembled incorrectly. 1. Reassemble motor.
2. Piping connected to inlet and 2. Correct piping.
outlet is reversed.

The slew speed does not reach the set value.


Troubleshooting

Phenomenon Cause Remedy


Slew speed does not reach set
value. 1. Oil flow rate is insufficient. 1. Check pump's delivery flow and
2. Oil temperature is high and oil circuit to motor.
leaks abnormally. 2. Reduce oil temperature.
3. Sliding parts are worn or 3. Replace damaged parts.
damaged.

The braking torque is insufficient.


Troubleshooting

Phenomenon Cause Remedy


Brake torque is insufficient.
1. Friction plate is worn. 1. Disassemble and check it.
2. Brake piston sticks. Replace, if worn more than
3. Brake release pressure cannot be criterion.
cut off. 2. Disassemble and check it.
4. Spline for friction plates is 3. a) Check and repair circuit.
damaged. b) Check time delay valve for
brake.
4. Disassemble and check it.
Replace, if damaged.

The hydraulic motor slips excessively.


NOTE!
Investigate the drain flow rate of the motor. If it is about 400 cm3/min (24.4 in3/min) or lower, the motor is considered to be
normal.

Troubleshooting

Phenomenon Cause Remedy


When external driving torque is
applied to motor, it slips 1. Relief valve does not function 1. Replace it.
excessively. well. 2. Replace it.
2. Seat of spool does not function
well.

Oil leaks from oil seal.


Troubleshooting

Phenomenon Cause Remedy


Oil leaks from oil seal.
1. Lip catches particles of dirt and is 1. Replace oil seal.
damaged. 2. Seal lip/shaft contact position,
2. Shaft is scratched or worn. repair or replace parts.
3. Because of excessively-high 3. If drain piping is clogged, clean
casing internal pressure, lip of oil it out.
seal is turned up. 4. Disassemble and repair it.
4. Shaft is rusted.

Oil leaks through mating faces.


Troubleshooting

Phenomenon Cause Remedy


Oil leaks through mating faces.
1. O-ring is twisted. 1. Fit it correctly and carry out
2. O-ring is damaged. reassembling.
3. Seal surface is damaged. 2. Replace it.
4. Screws are loose or damaged. 3. Disassemble and repair it.
4. Tighten to specified torque or
replace if damaged.
Service Information

Document Title: Function Group: Information Type: Date:


Hydraulic pump coupling, 442 Service Information 2014/6/12
description
Profile:
EXC, EC210B LC [GB]

Hydraulic pump coupling, description


The flexible coupling consists of the spline hub, the inserts and the elements, and evenly transmit the engine power to the
hydraulic pump absorbing the rotating shocks. The engine torque is transmitted to the interface ring connected to the
engine flywheel → the spline hub of the flexible coupling → the shaft of the hydraulic pump.

Figure 1
Structure, coupling

1. Element
2. Hub
3. Insert A
4. Insert R
5. Screw (M18 × 60) Tightening torque: 304 ~ 324 Nm (31 ~ 33 kgf m) (224 ~ 238 lbf ft)
6. Screw (M16 × 55) Tightening torque: 304 ~ 324 Nm (31 ~ 33 kgf m) (224 ~ 238 lbf ft)
7. Clamping screw (M16 × 22) Tightening torque: 98 ~ 118 Nm (10 ~ 12 kgf m) (72 ~ 87 lbf ft)
8. Spring pin (φ5 × 10)
9. Coupling assembly weight: 6.5 kg (14.3 lbs)

Flexible coupling, removal


NOTE!
Remove any residual pressure in the system by turning off the engine, returning key to ON position and moving RCVs. Also
remove the residual oil pressure from inside the hydraulic oil tank by using the air breather.
Op nbr 00000

1. Remove all hydraulic hoses, pipes and wire connectors from hydraulic pump, and then plug them.

2. Remove screws and hydraulic pump from the engine while keeping the pump shaft horizontal.
NOTE!
Before loosening screws take appropriate action to hold and support hydraulic pump.

3. Remove screws and the flexible coupling assembly from flywheel.

4. Inspect and analyze all defects.

Flexible coupling, installation

Op nbr 00000

NOTE!
Take care not to enter dust and foreign materials around coupling assembled.

1. After inserting the spring pin, install the flexible coupling assembly to flywheel by using screws.

 Apply Loctite onto the screws thread.

2. When assembling the hub spline onto the pump shaft, leave 3 mm (0.12 in) gap.
Adjust using two clamping screws on hub.

3. Install hydraulic pump to the engine while keeping the pump shaft horizontal by using screws.

 Apply Loctite onto the screws thread.

4. Install all hydraulic hoses, pipes and wire connectors.

Inspection after installation

1. Increase the engine rpm gradually to high rpm and operate boom, arm and bucket cylinder slowly.
2. Check for any abnormalities or leakage. Correct abnormal phenomena, if any.
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Center passage, description


The center passage consists of hub (1), shaft (2), seal (5), cover (3), plug (13), spacer (8) and screws (9).
The hub contains oil grooves to route the flow of oil. The shaft has passages to supply oil into the hub. The seal prevents oil
leakage between shaft and hub. The cover prevents external oil leakage and with screws (9), fix spacer (8), hub (1) and shaft
(2) together.
High pressure oil from the main control valve is delivered to the center passage, and flows through ports C - D or E - F to the
left and right track motor, to drive the track motors.
Drain oil returns to the reservoir via port G, also track (high speed) control servo hydraulic oil flows into port B.
Hub assembly (1) is fixed to the under carriage and shaft (2) rotates freely in the hub with the superstructure. The oil flows
through circumferential grooves in the hub, therefore oil flow is not obstructed by slew.

Figure 1
Center passage, section view and exploded view

1 Hub 6 O-ring 11 Screw 16 Plug-PF 1 (C, D, E, F)


2 Shaft 7 O-ring 12 Washer 17 Plug-PF 3/4
3 Cover 8 Spacer 13 Plug-PT 3/8 18 O-ring
4 Bushing 9 Screw 14 Plug-PT 3/8
5 Seal 10 Washer 15 Plug-PF 3/8 (A, B)

Port connection

Main control valve port Center passage Port size Pressure Track motor Application
port kgf/cm2 (psi) port
– A PF 3/8″ 35 (498) Plug –
– B PF 3/8″ 35 (498) Ps Low/high speed
BL4 C PF 1″ 350 (4980) A Forward–left
BR3 D PF 1″ 350 (4980) B Forward–right
AL4 E PF 1″ 350 (4980) B Reverse–left
AR3 F PF 1″ 350 (4980) A Reverse–right
Track motor drain G PF 3/4″ 7 (100) D1, D2 Drain
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, description Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Go back to Index Page

Center passage, description

Figure 1
Center passage, mounting

Tightening torque, unit : kgf·m

Description Torque Description Torque Description Torque


A Gap 15mm E Hub – I Upper frame –
B Stopper – F Screw – J Screw 26.7 ±2.7
C Nut 24.7 ±2.5 G Screw 1.0 ±0.1 K Lower frame –
D Shaft – H Screw 2.3 ±0.2
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, replacing Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Center passage, replacing


Op nbr 443-037

1. Park the machine in the service position C, see 091 Service positions.

2.  When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with
ignition switch at "ON" position.
 Mount the vacuum pump on hydraulic tank, and maintain a vacuum.

NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.

NOTE!
After disconnecting the hose, install a plug to prevent oil leakage and contamination.

3. Remove screws (1) and protecting plates (2) in the middle of undercarriage.

Figure 1
Removal, protecting plates

4. Remove 2nd speed hoses (1).

Figure 2
Removal, hoses
5. Remove motor drain hoses (3).

6. Remove motor high pressure hoses (2).

7. Remove motor drain hose (1).

Figure 3
Removal, hoses and fitting

8. Remove motor high pressure hoses (3).

9. Remove 2nd speed hose (2) and fittings.

10. Remove screws (3) and plates (4).

Figure 4
Removal, plates and plugs

11. Remove stop screw (1).

12. Remove clamp and rubber seal (2).

13. Install eye bolts (2) on center passage and hold the center passage with hoist (1).
Figure 5
Holding, center passage

14. Remove the center passage mounting screws (1) installed at the bottom.

Figure 6
Removal, screws

WARNING
The parts are heavy. Take appropriate safety cautions when handling them.

15. Lower the center passage with the hoist and move it to the workbench safely.

16. Remove the connector and tee.


Install them on a new center passage.

17. Install the new center passage in reverse order of the removal procedure.

Figure 7
Installation, stop screw
NOTE!
Turn the bolt (1) until the gap between bracket (2) and bolt (3) is 15 mm and then tighten the nut.
18. Remove the vacuum pump mounted on the hydraulic tank.
Service Information

Document Title: Function Group: Information Type: Date:


Center passage hose (valve Service Information 2014/6/12
– center passage), replacing
Profile:
EXC, EC210B LC [GB]

Center passage hose (valve – center passage), replacing


Op nbr 443-039

1. Park the machine in the service position C, see 091 Service positions.

2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at
"ON" position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.

NOTE!
After disconnecting the hose, install a plug to prevent oil leakage and contamination.

3. Remove screws (1) and main control valve cover (2).

Figure 1
Removal, cover

4. Remove the high pressure hose of main control valve port (1) and the high pressure hose of center passage port
(2).

Figure 2
Removal, hose
5. Install a new center passage hose in reverse order of the removal procedure.
Service Information

Document Title: Function Group: Information Type: Date:


Center passage hose Service Information 2014/6/12
(center passage – motor),
replacing
Profile:
EXC, EC210B LC [GB]

Center passage hose (center passage – motor), replacing


Op nbr 443-040

1. Park the machine in the service position C, see 091 Service positions.

2. When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the residual
pressure inside the hydraulic line by operating the control lever smoothly for 3 ~ 4 times with ignition switch at
"ON" position.
NOTE!
Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.

NOTE!
After disconnecting the hose, install a plug to prevent oil leakage and contamination.

3. Remove screws (1) and motor cover (2).

Figure 1
Removal, motor cover

4. Remove the high pressure hose of motor port (1).

Figure 2
Removal, hose
5. Remove screws (1) and protecting plates (2) in the middle of undercarriage.

Figure 3
Removal, protecting plates

6. Remove the high pressure hose of center passage port (1).

Figure 4
Removal, hose

7. Install a new center passage hose in reverse order of the removal procedure.
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, tools Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Center passage, tools


General tools
General tools

No Tool Remark
1 Hammer
1. Steel hammer
2. Wooden or plastic hammer

2 Rubber mat Not less than 500 mm (20 in) square


3 Wrench
1. Allen wrench
2. Double ended and singe ended wrench
3. Extension pipe

4 Torque wrench 100 kgf·m (700 ft·lbs)


5 Pin

A. Grind the tip of a ″nail″ to shape as a screwdriver.

6 Spatula

A. Made from a hack-saw blade.


B. Approximately 120 mm(4.7 in)
C. Vinyl tape
D. Remove the edge completely

7 Vise Vise adjustable over 150 mm (5.9 in)


8 Locking fluid Three bond 1360K (Loctite 242)
9 Lubricating oil Hydraulic oil or vaseline
10 Cleaning oil

Apparatus
Hoist or crane
The lifting device should be capable of lifting the center passage assembly.
Work bench
The work bench should have an area of 1.2 m × 1.5 m (4 ft × 5 ft).
Others
Also prepare clean cloth, wooden block and oil pan.
Special tools
Dry bearing assembly jug
Special tools (unit : mm)

ØA ØB ØC ØD O N M L Part No.
129 104 100 30 Thru 25 33 45 103 8920-01520

Figure 1
Dimension, special tool

Plug size and tightening torque


Tightening torque, unit : kgf·m

PT Plug PO Plug Screws


Thread size Torque Thread size Torque Thread size Torque
PT 1/8 1.5 ± 0.15 PF 1/8 1.1 ± 0.1 M4 0.4 ± 0.04
PT 1/4 4 ± 0.4 PF 1/4 2.6 ± 0.2 M5 0.8 ± 0.08
PT 3/8 8 ± 0.8 PF 3/8 4.6 ± 0.3 M6 1.4 ± 0.14
PT 1/2 17 ± 1.7 PF 1/2 8.5 ± 0.4 M8 3.3 ± 0.3
PT 3/4 25 ± 2.5 PF 3/4 19 ± 1.0 M10 6.5 ± 0.7
PT 1 50 ± 5 PF 1 33 ± 2.0 M12 11.3 ± 1.1
M14 17.9 ± 1.8
M16 26.7 ± 2.7
M18 38.0 ± 3.8
M20 52.2 ± 5.2
M22 69.4 ± 6.9
M24 90.2 ± 9.0
M30 176.1 ±17.6
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, Service Information 2014/6/12
disassembly
Profile:
EXC, EC210B LC [GB]

Center passage, disassembly


Op nbr 00000

WARNING
The plate is heavy, take appropriate safety precautions.

NOTE!
Clean the outside of the center passage with hot water or steam.

NOTE!
Clean center passage with the ports plugged.

NOTE!
Mark each hose assembly to identify its location on the center passage.

NOTE!
Mark shaft (2) and hub (1) to aid in reassembly.

1. Detach the bottom plate in the middle of undercarriage.

2. Remove hydraulic lines connected to the center passage hub, and plug each hose and oil port.

3. Remove hydraulic lines connected to the upper side of center passage shaft, and plug each hose and oil port.

4. Remove the center passage shaft clamping screw.

5. Screw an eye bolt in the middle of the center passage shaft, attach a sling to the lifting equipment. (To prevent the
center passage from dropping when removing the mounting screws.)

6. Unscrew the four sling mounting screws from the bottom.

7. Lower the sling slowly and take the center passage out through the bottom.

8. Dip the center passage into a cleaning solution to thoroughly clean the assembly.

9. Put the center passage on a work bench.

Figure 1
Center passage, fixing
10. Remove screws (11), washer (12) and cover (3) from the center passage.

Figure 2
Cover, removal

11. Pull out o-ring (7), remove screws (9), washer (10) and spacer (8).

Figure 3
Spacer, removal

12. Remove shaft (2) and hub(1).

Figure 4
Shaft and hub, removal

13. Remove o-ring (6) from hub (1).


Figure 5
O-rings, removal

14. Remove bushing (4) mounted in the hub using a bushing driver.
Replace only if necessary.
Take care not to damage the bushing / housing mounting surface.

Figure 6
Bearings, removal

15. Remove seals (5) assembled in the hub using a sharp pin.
NOTE!
Take care not to damage the seal grooves of hub (1).

Figure 7
Seals, removal

16. Inspect each part, and repair or replace the defective or worn parts.

17. Do not reuse o-ring or seals. Be sure to replace with new ones.
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, assembly Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Center passage, assembly


Op nbr 00000

WARNING
The plate is heavy, take appropriate safety precautions.

1. Prepare the required parts and clean all parts thoroughly.


Wash all parts thoroughly with a cleaning solvent and clear the passages using compressed air.
Polish minor scratches with fine emery or crocus cloth.
NOTE!
Especially, take care that dust and foreign materials do not enter the seal grooves of the hub or oil ports of the
shaft.

Figure 1
Cleaning with solvent and compressed air

1. Shaft
2. Hub
3. Cover

2. Coat the dry bearing outer diameter and hub section with loctite (#609) and press–fit using a jig.

3. Press–fitting with press (1) and jig (2).


NOTE!
Take care not to damage the dry bearing.

NOTE!
Ensure the bearing is fully seated.

NOTE!
Wipe excess loctite off the hub and bearing surface.
Figure 2
Assembly, dry bearing

4. Before installing the seals (5) and o-ring (6), coat the seal grooves with hydraulic oil (2 ~ 3 times).
NOTE!
Take care not to twist or damage the seals.

NOTE!
Check the seal mounting condition.

NOTE!
Ensure the seals are not damaged or twisted, then by hand rubbing seat the seals inside of assembly section as
close as possible to a cylindrical condition.

Figure 3
Seal assembled in front

5. Sling the center passage with the shaft section upward.


NOTE!
Take care to align the match marks of shaft and hub.
Figure 4
Seal assembled in rear

6. Coat the shaft with hydraulic oil.

7. Fix hub to the stopper, and then operate the press slowly and insert the shaft.

8. Press–fit shaft. Before the horizontal support interferes, remove it.


NOTE!
Hub and shaft must be parallel (horizontal) and when press-fitting, take care not to damage the seals (6).

Figure 5
Assembly, hub and shaft

1 Horizontal support 4 Hub


2 Shaft 5 Stopper
3 Plate X Press

9. Assemble plug (13).


NOTE!
Coat the plug with a sealant.

 After tightening plug 1/3 and applying loctite (#572), tighten completely.
 Tightening torque : P/T 3/8 : 8 ± 0.8 kgf·m (58 ± 6 lbf·ft)

Assemble o-ring (18) and plug (17).

 Tightening torque : P/F 3/4 : 19 ± 1 kgf·m (137 ± 7 lbf·ft)

Figure 6
Assembly, plug

10. Fasten spacer (8) to the end of shaft (2) and tighten the screws (9) with lock washer (10) to specified torque.
NOTE!
The spacer must fully contact the shaft.

If it does not, check that the bushing is fully seated.


Tightening torque : 6 ~ 7 kgf·m (43 ~ 51 lbf·ft)

Figure 7
Assembly, spacer

11. Mount the o-ring (7) to the hub groove, then install cover (3) and tighten the screws (11) with lock washer (12) to
specified torque.
NOTE!
Apply a dab of grease on the surface of o-rings and install ensuring they are not twisted or damaged.

Tightening torque : 11 ~ 12 kgf·m (79 ~ 87 lbf·ft)

Figure 8
Assembly, cover

12. After the completion of assembly with shaft fixing jig (1) and hub fixing jig (2), check the hub, shaft and rotating
torque (X).
Starting torque : 25 kgf·m (181 lbf·ft)
Rotating torque : 20 kgf·m (144 lbf·ft)

Figure 9
Check of rotating torque and pressure

13. Connect adapter (3) to each port for internal/external leakage test.
Each port pressure
A, B : 35 kgf/cm2 (498 psi)
C, D, E, F : 350 kgf/cm2 (4980 psi)
G : 7 kgf/cm2 (100 psi)

14. Plug each port.

15. Assemble fitting by port if necessary.


After washing the fitting and plug with a solvent and drying, apply teflon tape and loctite (#542) on the entire
threaded section, and assemble.

Figure 10
Assembly, fittings

16. Install the four mounting screws, the clamping screw and tighten to specified torque.

17. Connect each hydraulic line to the premarked location.

18. Check for operating condition and leakage, and track motor functions
NOTE!
When assembling elbows (4) to center passage (5), take care that o-ring (1) and washer (2) are installed closely to
nut (3).

Figure 11
Elbows, install
Service Information

Document Title: Function Group: Information Type: Date:


Center passage, inspection Service Information 2014/6/12
and troubleshooting
Profile:
EXC, EC210B LC [GB]

Center passage, inspection and troubleshooting


Inspection method

Interval Check item Checking procedure Remedy


2,000 hours. Seal for oil leakage. Check oil leakage at cover, Replace o-ring, if any oil leakage is
top end and fittings. found.
4,000 hours. All sealing parts. Replace all sealing parts such as slipper
In principle, disassemble seal with square seal and o-rings.
and check regardless of All wearing parts. Check abnormal wear, Repair or replace referring to their limit
apparent condition. scoring or corrosion caused of serviceability.
by contamination or
burning.
When disassembled for All parts. Check shaft and hub Repair or replace referring to their limit
repair. grooves / lands for scoring. of serviceability.
O-rings and seals must be replaced.

Wear limits

Part Normal Allowable Replace


Hub Internal seal contact area and the If the wear of seal contact area is The wear of seal contact area is
stepped part have no visible wear. within 0.1 mm (0.004 in) as more than 0.1 mm in depth.
measuring by finger nail (when the
dimension can"t be measured in
this way, visually check), it is
allowable.
However, oil leakage will occur, if
A. More than 0.1 mm
it is used continuously in this
(0.004″)
condition.

Shaft There is no damage or wear of New shaft external surface is The depth of damage is more than
external surface. finished as 1.5s. If the pitting of 0.1mm.
the shaft is slight, it is allowable.

A. More than 0.1 mm


(0.004″)

Replace with a new assembly, as


soon as possible, or replate.
Thrust There is no surface scuffing and no Replace when scoring is
washer visible wear. considerable, even if the wear of
the spacer thickness is slight.
A. 0.3 mm (0.012 inch)
B. 0.5 mm (0.020 inch) or
less

O-ring Replace o-rings whenever Never fail to replace the o-rings


disassembling. and the seals.

Inspection after assembly


After assembling, check for leakage and pressure test as shown in figure.
High pressure port

Figure 1
Checking, high pressure port

A. Connect to hub side


B. Connect to shaft side

Install a changeover valve and pressure gauge to the shaft port and hub port respectively, and while watching the pressure
gauge (for high pressure) installed on the hub and also by regulating high pressure relief valve (7), gradually increase the
pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve (3) to trap the
hydraulic oil in the center passage. Keep stop valve (6) on the low pressure relief valve side closed at this time.
Low pressure port
(Drain port, return port, etc.)
Similar to the high pressure port, install a changeover valve and pressure gauge on each port of the shaft and hub.
Open stop valve (6) on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure)
connected to the hub and also by regulating low relief valve (5), gradually increase the pressure and check for leakage with a
pressure of 10 kgf/cm2 (142 psi).
Checking, low pressure port

Item Description Remark


1 Pressure gauge High and low pressures are required.
2 Center passage
3 Stop valve
5 Relief valve for low pressure Setting pressure : 10 kgf/cm2 (142 psi)
6 Stop valve
7 Relief valve for high pressure Setting pressure : working pressure × 1.5
8 Changeover valve
9 Piping, etc.

Troubleshooting
Troubleshooting

Trouble Cause Remedy


External / internal leakage, machine When the pressure between pump and Check the circuit between pump and
does not track straight on level ground valve drops. valve, and repair or replace.
or a slope, even if the track motor and The circuit for valve is defective. Check pump, valve, and center passage
pump are normal. by pressure gauge in that sequence.
When the pressure between pump and Check for leakage between center
center passage drops. passage and valve.
The circuit for center passage is If it is normal, separate center passage
defective. and test the pressure by gauge.
If the pressure drops, disassemble and
check the o-ring, etc. visually.
When noise comes from the center Check the center passage plumbing for If the center passage is defective,
passage. vibration or abnormal heating by hand. disassemble to check the shaft and
seals. Repair or replace a worn shaft.
Service Information

Document Title: Function Group: Information Type: Date:


Slew ring gear, description 492 Service Information 2014/6/12
Profile:
EXC, EC210B LC [GB]

Slew ring gear, description


The slew ring gear is a single row sealed ball bearing that supports the superstructure on the undercarriage and allows the
superstructure to rotate smoothly.
The outer race is screwed to the superstructure and inner race (with inner circumference gear) is screwed to the
undercarriage. The slew pinion gear meshes with the internal gear of the inner race and drives it to rotate the superstructure.

Figure 1
Slew ring gear, structure

A Filler plug (soft zone) "S" Soft zone 4 Filler plug 8 Name plate
B Grease port 1 Outer race 5 Ball 9 Rivet
C Pin holes 2 Inner race 6 Support 10
D Grease port 3 Taper pin 7 Seal 11
Service Information

Document Title: Function Group: Information Type: Date:


Slew ring gear seals, 492 Service Information 2014/6/12
installation
Profile:
EXC, EC210B LC [GB]

Slew ring gear seals, installation


Op nbr 00000

1. Remove seal (A).

Figure 1
Seal, removal

2. Scrape old adhesive from seal groove (B). Thoroughly clean seal groove and new seal using aerosol solvent.

3. Apply instant gel adhesive to seal groove.

4. Install seal with seal lip against outer race (A). Start about 76 mm (3 in) from end of seal using a blunt instrument to
force seal into groove. Push seal in direction of portion already installed to avoid stretching.

5. Before bringing ends of seal together, cut off excess length.

6. Apply adhesive to both ends of seal. Push ends into seal groove making sure they come together.
NOTE!
To avoid pulling seal out of groove, adhesive must cure for at least 24 hours before using slew function.

Figure 2
Adhesive, applying
Service Information

Document Title: Function Group: Information Type: Date:


Slew ring gear, removal 492 Service Information 2014/6/12
and installation
Profile:
EXC, EC210B LC [GB]

Slew ring gear, removal and installation


Op nbr

WARNING
Confirm the weight of slew ring gear, and take appropriate safety measures.

1. Remove superstructure.

2. Connect slew bearing to a hoist using lifting brackets (C).

Figure 1
Lifting, slew ring gear

C Lifting bracket (3 points)


D Slew ring bearing assembly

3. Remove screws and lock washers and slew ring bearing (D).

4. Replace upper and lower seals as necessary.

5. Clean mating surfaces of slew bearing, superstructure, and undercarriage.


NOTE!
The tooth (A) marked with the letter “S” is the starting and stopping point for the surface hardening process. The
tooth and the bearing loading plug must be installed on the right side of the machine so the wearing of slew
bearing is minimized.
Figure 2
Marks of starting and stopping

A. Tooth
B. Loading plug

6. Install slew bearing on undercarriage so the tooth marked “S” or equivalent and bearing loading plug is the right
side of machine as shown.

7. Install screws and lock washers. Tighten screws to specified torque.

8. Apply Alvania EP #2 grease to slew bearing teeth and pinion gear.


NOTE!
Grease amount : 17 liter (4.5 gal)

Figure 3
Grease, applying
1 Pin 6 Cover 11 Screw
2 Pin 7 Screw, tightening torque : 2.3 ± 0.2 kgf·m (16.6 ± 1.4 lbf·ft) 12 Elbow
3 Pin 8 Screw, tightening torque : 2.3 ± 0.2 kgf·m (16.6 ± 1.4 lbf·ft) 13 Grease nipple
4 Soft zone filler plug 9 Screw, tightening torque : 52.2 ± 5.2 kgf·m (377 ± 38 lbf·ft)
5 Soft zone "S" 10 Screw, tightening torque : 52.2 ± 5.2 kgf·m (377 ± 38 lbf·ft)

NOTE!
The "E" hole (outer race) is not assembled screw, and seal it with liquid gasket, loctite # 5699.
Service Information

Document Title: Function Group: Information Type: Date:


Ring gear grease pipe, 492 Service Information 2014/6/12
replacing
Profile:
EXC, EC210B LC [GB]

Ring gear grease pipe, replacing


Op nbr 492-091

1. Park the machine in the service position B, see 091 Service positions.
NOTE!
Ring gear grease points are 3 points and 2 point type. See 173 Swing ring gear bearing, lubricate.

Figure 1
Ring gear grease 3 points (A) and 2 point (B)

2. Remove screw (2) and loosen nut (1, 3).


Remove the ring gear grease pipe.

Figure 2
Replacing, ring gear grease pipe

3. Install a new ring gear grease pipe in reverse order of the removal procedure.
Thank you for your purchase.
Have a nice day.

file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/12 9:26:42]