GROUP 6 TRAVEL DEVICE

1. REMOVAL AND INSTALL

1) REMOVAL
(1) Swing the work equipment 90Áand lower it
completely to the ground.
(2) Operate the control levers and pedals
several times to release the remaining
pressure in the hydraulic piping.
(3) Loosen the breather slowly to release the 13031GE18

pressure inside the hydraulic tank.

E scaping fluid under pressure can
penetrate the skin causing serious
injury. 1
ö When pipes and hoses are disconnected,
the oil inside the piping will flow out, so
catch it in oil pan.
Dr P
(4) Remove the track shoe assembly. 2
B
For details, see removal of track shoe A

assembly.
(5) Remove the cover.
(6) Remove the hose. 21078DA47

ö Fit blind plugs to the disconnected hoses.

(7) Remove the bolts and the sprocket.
(8) Sling travel device assembly (1).
(9) Remove the mounting bolts (2), then
remove the travel device assembly.
ÂWeight : 240kg (530lb)
2) INSTALL
(1) Carry out installation in the reverse order
to removal.
(2) Bleed the air from the travel motor.
Η Remove the air vent plug.
Θ Pour in hydraulic oil until it overflows from
the port.
Ι Tighten plug lightly.
Κ Start the engine, run at low idling, and
check oil come out from plug.
Λ Tighten plug fully.
(3) Confirm the hydraulic oil level and check
the hydraulic oil leak or not.

8-66
2) STRUCTURE

14072SF61

1 Hub 25 Needle bearing 106 Shoe 151 Roller 219 O-ring 355 O-ring
2 Spindle 27 Parallel pin 107 Retainer plate 161 Piston 2 220 Piston seal 357 RO plug
3 Carrier 28 O-ring 108 Thrust ball 162 Shoe 2 301 Rear flange 358 O-ring
4 Ring gear A 29 O-ring 109 Timing plate 167 Pivot 323 Spool 359 O-ring
5 Ring gear B 30 PT plug 110 Washer 171 Parallel pin 324 Plug 363 Spool 2
6 Cluster gear 31 Floating seal 111 Collar 193 Spring 325 Stopper 366 Spring
7 Sun gear 32 Socket bolt 112 Piston 201 Valve 326 Plug 368 Steel ball
8 Coupling gear 33 Spring washer 113 Spring 202 Sleeve 327 Valve 379 Filter
9 Cluster shaft 34 Parallel pin 114 Spring 203 Spring retainer 328 Spring 380 Plug
12 Distance piece 35 Socket bolt 115 Friction plate 204 Plug 330 Spring 381 Piston
13 Cover 36 Steel ball 116 Mating plate 205 Shim 336 O-ring 382 Plug
14 Thrust collar 40 O-ring 132 Oil seal 206 Spring 337 O-ring 383 O-ring
15 Ring 42 Parallel pin 135 O-ring 208 O-ring 341 Parallel pin 384 O-ring
17 Pin 102 Main shaft 139 O-ring 209 O-ring 343 Socket bolt 385 Steel ball
19 Coupling 103 Swash plate 145 Snap ring 210 O-ring 346 PT plug 397 Orifice
20 Thrust plate 104 Cylinder block 149 Ball bearing 211 Back-up ring 352 RO plug 398 PT plug
23 Seal ring 105 Piston 150 Ball bearing 217 Back-up ring 354 PT plug 399 Name plate
24 Ball bearing

8-67
2) TOOLS AND TIGHTENING TORQUE
(1) Tools

Tool name Remark

Allen wrench 5, 6, 8, 10, 14 B

Socket 22, 30, 32, 41

Socket for socket wrench, spanner
Rod 5, 6, 8, 10, 14, 19
Torque wrench Capable of tightening with the specified torques
Pliers -
(-) Driver 150mm
Plastic and iron hammer Wooden hammer allowed. Normal 1 or so
Steel rod approx 7Ý7Ý200mm
Monkey wrench -
Oil seal inserting jig -
Bearing pliers -
Seal tape -
Eye bolt M12, M16
Press(0.5 ton) -
Oil stone -
Bearing assembling jig -
Liquid packing Loctite #577
Screw lock Loctite #243

(2) Tightening torque

Torque
Part name Item Size
kgfÂm lbfÂft
Hexagon socket plug 30 PT 1/2 6.0Ü2.0 43.4Ü14.5
Hexagon socket bolt 32 M12Ý1.75Ý50 10.4Ü1.6 75.2Ü11.6
Hexagon socket bolt 35 M16Ý2.0Ý30 25.7Ü4.0 186Ü28.9
Sleeve 202 PF 1 25.0Ü5.0 181Ü36.2
Plug 204 PF 1/2 10.0Ü2.0 72.3Ü14.5
Plug 324 M36Ý1.5 45.0Ü9.0 326Ü65.1
Plug 326 M36Ý1.5 26.0Ü4.0 188Ü28.9
Hexagon socket bolt 343 M16Ý2.0Ý40 25.7Ü4.0 186Ü28.9
Plug 346 PT 1/4 3.0Ü0.5 21.7Ü3.6
Plug 352 PF 1/4 3.0Ü0.5 21.7Ü3.6
Hexagon socket plug 354 NTPF 1/16 0.6Ü0.25 4.3Ü1.8
Plug 357 PF 1/2 10.0Ü2.0 72.3Ü14.5
Plug 380 PF 3/8 6.0Ü1.0 43.4Ü7.2
Plug 382 PF 1/8 1.5Ü0.25 10.8Ü1.8
Hexagon socket plug 398 PT 1/8 1.25Ü0.25 9.0Ü1.8

8-68
3. DISASSEMBLY
1) GENERAL PRECAUTIONS
(1) Before disassembling the motor, check the items to be inspected and, for remedy against trouble,
closely examine the nature of the trouble, so that the motor can be disassembled effectively.
(2) To disassemble the motor, use the disassembling procedures described in section 2) and select a
clean place.
(3) Place a rubber or vinyl sheet or other such protective materials on your working bench to protect
the surface of the motor to be serviced.
(4) During disassembly, give a match mark to the mating surfaces of each part.
(5) Arrange removed parts in order so that they will not become damaged or missing during
disassembly.
(6) Once seals have been disassembled, they should be replaced even if damage is not observed.
Have replacement seals ready on hand before starting your disassembling job.

8-69
2) DISASSEMBLING PROCEDURE
(1) Disassembling the brake valve section
and the hydraulic motor section
ö When inspecting or repairing the motor,
use the disassembling procedures
described below.
ö Numbers in parentheses ( ) following the
part name denote the item numbers
shown in the attached assembly
drawings.
25038TM02(1)
ö Prior to disassembly, install the motor on
an inversion working bench.

Η Remove valve kit from the rear flange

(301).
Θ Remove the O-rings(208, 209, 210) and
back up rings(211, 217) from the valve
kit.
ö Do not reuse the O-ring after removal.

25038TM02(2)

Ι Remove the twelve hexagon socket head

bolts(343).

25038TM02(3)

Κ Remove the rear flange kit(301) from the

spindle(2).
ö Pay attention, shaft(102) may pulled up
with the rear flange kit.
ö Proceed to pages 8-72 through 8-76 to
see the brake valve disassembling
procedure.

25038TM02(4)

8-70
Λ Remove the timing plate(109), the two
pins(341) and the ball bearing(150) from
the rear flange kit(301).
Μ Remove the two O-ring(27) and O-ring
(29) from spindle(2).
ö Do not reuse the O-rings(27, 29) after
removal.
ö Proceed to pages 8-77 through 8-79 to
see the description of the hydraulic motor
25038TM03(1)
disassembling procedure.

(2) D isassembling the reduction gear/

Hydraulic motor shafts and oil seals
Η Turn the motor and cover(8) over.
Θ Remove three plugs(33).
Ι Remove twelve hexagon socket head
bolts(35).

25038TM03(2)

Κ Install two eye bolt(PF 1/2) to the threads

for plugs(33).
Λ Fasten hook to the eye bolts then lift up
cover(8).
ö When cover(8) do not come up easily
due to friction of O-ring(30), bang cover
(8) evenly using a plastic hammer.
Μ Remove O-ring(30) from cover(8).
ö Do not reuse the removed O-ring.
25038TM03(3)
Ν Drain lubricating oil from the reduction
gear.
ö Proceed to page 8-80 through 8-84 to
see the reduction gear disassembling
procedure.

8-71
3) DISASSEMBLY OF BRAKE VALVE
(1) Disassembly of the spool(323)
Η Remove the two plugs(324) from the rear
flange(301).
Remove the two O-ring(336) from the
plug(324).
ö Removal of the two plugs(324) from the
rear flange(301) is facilitated by
loosening plugs(324) with rear flange
(301) attached to the spindle(2).
ö Do not reuse the O-ring(336) after 25038TM03(4)

removal.

Θ Remove the two springs(328), the two

stoppers(325), and the spool(323) from
the rear flange(301).
ö Be careful not to damage the outer
surface of the spool(323) and the sliding
surface of the rear flange(301).
ö Spool is selectively fitted to the rear
flange(301). When replacing either or
them, therefore, the rear flange kit should
25038TM04(1)
be replaced.

(2) Disassembly of the check valves

Η Remove the two plugs(326) from the rear
flange(301).
ö Removal of the two plug(326) from the
rear flange(301) is facilitated by
loosening plug(326) with the rear flange
(301) attached to the spindle(2).

25038TM04(2)

8-72
 Θ Remove the two springs(330) and the
two valves(327) from the rear flange(301).
ö Be careful not to damage the seat
sections of the valves(327) or rear flange
(301).

25038TM04(3)

Ι Remove the O-ring(337) from the plug

(326).
ö Do not reuse the O-ring(337) after
removal.

(3) Disassembly of the spool(363) from the

rear flange(301)
Η Remove plug(357) from rear flange(301).
ö Removal of plug(357) from rear
flange(301) is facilitated by loosening
plugs(324) with rear flange(301) attached
to spindle(2).

25038TM04(4)

Θ Take out spool(363) from rear flange

(301).
Ι Remove O-ring(355) from plug(357).
ö Do not reuse removed O-ring(355).

25038TM05(1)

8-73
(4) Removal inner parts of the rear flange
assembly
Η Remove the two plugs(380) from rear
flange(301).

25038TM05(2)

Θ Remove the two O-rings(359) from each

plug(380).
Ι Take out piston(381) from rear flange
(301).
ö Do not reuse removed the O-rings(359).
ö Be careful not to scratch the outer
surface of the piston(381) and the sliding
surface of the rear flange(301).
ö Piston(381) is selectively fitted to rear
25038TM05(3)
flange(301). When replacing either of
them, therefore, the rear flange kit should
be replaced.

Κ Removed the two plugs(382) from rear

flange(301).

25038TM05(4)

Λ Take out each two O-rings(383, 384)

from each plug(382).
ö Do not reuse removed O-rings(383, 384).

8-74
 Μ 3Take out two steel balls(385) from the
rear flange.

25038TM06(1)

(5) Removal of the valve kit

Η Remove the plug(204) from sleeve(202).
ö The valve kit is pressure adjusted by
shim(205), when replacing of inner parts,
therefore, the valve kit should be
replaced.

25038TM06(2)

Θ Remove the O-ring(210) from plug(204).

Ι Take out shim(205) from plug(204).
ö Do not reuse removed the O-ring(210).

25038TM06(3)

8-75
Κ Take out spring retainer(203), spring
(206) and valve(201) in that order.

25038TM06(4)

25038TM07(1)

25038TM07(2)

Λ Remove piston seal(220) from valve

Piston seal
(201).
Valve

25038TM14

8-76
4) DISASSEMBLY OF HYDRAULIC
MOTOR
(1) Disassembly of the parking brake parts
Η Remove the piston(112) by injecting
compressed air from the parking brake
access hole in the spindle(2).
ö Take care that abrupt injection of
compressed air(3~5kgf/cm2) may cause
the piston(112) to pop out.
To ensure your safety, apply a protective
25038TM07(3)
cover to the piston.

Θ Remove the two O-rings(135, 139) from

the piston(112).
ö Do not reuse O-rings(135, 139) after
removal.

25038TM07(4)

(2) Disassembly of the internal parts of the

motor
Η Lay the motor body on the side.
Θ Drain out the oil from the motor.
Ι Hold the cylinder block(104) with both
hands, and remove it from the spindle(2).
ö When laying the motor on its side, place
a receptacle under it to receive spilling
hydraulic oil.
25038TM08(1)
ö Before pull out cylinder block(104), turn it
alternately clockwise & counterclockwise
two or three times to separate the piston
kit from swash plate(103). This means
that the parts attached to the cylinder
block(104) come out of it and fall in the
spindle.

8-77
Κ 3Detach the two friction plates(115) and
two mating plates(116) from cylinder
block(104) which has been taken out in
step Ι.
Λ Separate the piston assembly(105, 106),
retainer plate(107), thrust ball(108),
washer(111) and five needle rollers(151)
from cylinder block(104) which has been
taken out in step Ι.
25038TM08(2)
ö Cylinder block(104), piston assembly,
retainer plate, etc. which are included in
cylinder & piston kit and are not supplied
one by one, therefore, cylinder & piston
kit should be replaced.(Refer to class
shown in parts list.)

Μ Take out swash plate(103) from spindle

(2).

25038TM08(3)

Ν Take out shaft(102) from spindle(2). At

this time, ball bearing(149) is also taken
out together with shaft(102).
ö Oil seal(132) cannot be taken out.
ö Lightly shaft(102) end on the reduction
gear side with a plastic hammer to make
the removal easier.
Take notice when removing the shaft
(102) rap strongly and swiftly, the shaft
25038TM08(4)
will come quickly free from the spindle.
Ξ Take out two pivots(167) and two pins
(171) from spindle(2).

8-78
 Ο Remove the piston assembly and spring
(193) by compressed air(3~5kgf/cm2)
trough the passage for the piston
assembly in spindle(2).
ö Piston(161) and shoe(162) are included
in the piston assembly and are not
supplied one by one, therefore, the piston
assembly should be replaced.
ö Abrupt compressed air causes the piston
25038TM09(1)
assembly to spring out which dangerous.
The piston assembly can be taken out
safely by putting a protective cover or the
lie on it.

(3) Disassembly of the cylinder block

Η Place the cylinder block on the work
bench and take out snap ring(145) with
the snap ring pliers while pressing the
retainer against washer(110).
ö Before compressing spring(114), make
sure that cylinder block(104), retainer
and press arbor are in good alignment:
This is for galling or denting cylinder
25038TM09(2)
ö block(104).
Put a vinyl cover on the sliding surface of
Θ cylinder block(104) for protection.
Slacking the press force slowly, until free
ö of the spring force.
Do not remove spring(114) if it not to be
ö replaced.
When disassembling there is a possibility
that the spring may be injured.
Slacking very slowly in order to prevent
injury to the spring.

Ι Remove the snap ring(145), washer(110),

spring(114) and washer(110).

25038TM09(3)

8-79
5) DISASSEMBLY OF REDUCTION GEAR
(1) Disassembly of Input gear A(4)
Η Before removing ring gear A, give an
alignment match mark to both the ring
gear and hub(1).
Θ Remove the ring gear A(4) using a
crowbar or any other suitable tool.
ö After ring gear A(4) has been removed,
remove any adhesive residue from the
mating surfaces of the ring gear and the
TM27 (140-7)
hub.
Ι Remove the ten dowel pins(27) from the
hub(1).

Ring gear A(4)

Crowbar

R210TDD1(7)

(2) Disassembly of the hub(1), ring gear

B(5), and the coupling gear(8)
Η Remove the ten hexagon socket head
bolts(35).
ö Since the hexagon socket head bolts(35)
have their threaded sections coated with
an adhesive, a loosening torque larger
than the tightening one is needed to
remove the bolts.
TM-SPARE07
ö Tightening torque : 35.5Ü5.5 kgfÂm
(256.8Ü39.8 lbfÂft)
ö Be extra careful during removal not to let
the threaded sections of the hexagonal
socket head bolts(35) seize.
Θ Before removing the coupling gear(8)
from the spindle(2), mark the mating
surfaces of the coupling gear(8) and the
spindle(2) using a paint marker.

8-80
Θ Mount ring bolts in the M12 tapped holes
of the hub(1),and then lift the hub(1) Lift up Hub(1)
Spindle(2)
using lifter and separate the hub(1) and
the spindle(2).
This also disconnects the two ball
bearings(24), the seal ring(23), the O-
ring(40), the coupling gear(8), ring gear
B(5), the ring(15), and the distance
piece(12).
R210TDD1(8)
ö Proceed as follows if disassembly is not
possible with the method mentioned
above :
 Rotate the motor through 180 degrees to
let the spindle side of the motor face
upward.
 As shown in the photo, lightly tap the
edge of the hub(1) equally with an
aluminum rod and a hammer until the
hub(1) has become disconnected from
the spindle(2).
This will also disconnect the following TM29 (140-7)

parts :
Two ball bearing(24), seal ring(23), O-
ring(40), coupling gear(8), ring gear B(5),
ring(15), distance piece(12).
ö Lay a rubber mat under the working
bench to the prevent damage to hub(1)
and other parts due to possible fall from
the working bench.

8-81
(3) Disassembly of the inside of the
spindle(2) Hammer
Η Remove the O-ring(29) from the spindle(2).
Screwdriver
Θ Rotate the spindle(2) through 180 degrees.
Ι Remove the oil seal(132) from the
spindle(2). Spindle(2)
(To remove the oil seal, set a (-) screwdriver Oil seal(132)
at the cylindrical edge of the oil seal and
lightly tap with a hammer.)
R210TDD2(1)

ö Do not reuse the O-ring(29) after

removal.
ö Remove the oil seal(132) only if it is to
be replaced.
Do not reuse the oil seal(132) once it
has been removed.
Κ Remove the floating seal(31) from the
spindle(2).

TM30 (140-7)

8-82
(4) Disassembly of the inside of the hub(1)
Η Place the hub(1) on the working bench
so that the cover side of the hub faces
upward.

Θ Remove one of the two ball bearings(24)

from the hub(1) as shown in the figure. Hub(1) Hammer
This also lets the seal ring(23) come
loose.
ö In principle, the ball bearings(24) should
not be removed from the hub(1) since
Steel bar
the former is shrinkage-fitted into the
latter. Ball bearing(24)
ö Do not reuse the ball bearings(24) after Seal ring(23)
R210TDD2(2)
removal.
Ι Place the hub(1) on the working bench
so that the hub end facing the spindle
points upward. Hammer
Κ Remove the other ball bearing(24) from Hub(1)
the hub(1) as shown in the figure.

Λ Remove the O-ring(40) from the hub(1).

ö Do not reuse the O-ring(40) after Steel bar
removal.
Ball bearing(24)
R210TDD2(3)

8-83
(5) Disassembly of the coupling gear(8)
Η Remove the ring(15) from ring gear B(5).
ö Do not reuse the ring(15) after removal.

TM31 (140-7)

Θ Remove the coupling gear(8) from ring

ö gear B(5).
Except for their replacement, do not
disassemble the coupling gear(8) or ring
gear B(5).
(6) Disassembly of the carrier assembly
Η Do not disassemble the carrier assembly
any further.
If a component of the carrier assembly is
irrecoverably damaged, replace the
entire carrier assembly with a new one.
ö Components of the carrier assembly
ÂCarrier(3)
ÂCluster gear(6)
ÂShaft(9)
ÂThrust collar(14)
ÂNeedle bearing(25)
ÂDowel pin(34)

TM32 (140-7)

8-84
4. ASSEMBLY
1) GENERAL PRECAUTIONS
(1) Reassemble in work area that is clean and free from dust and grit.
(2) Handle parts with bare hands to keep them free of linty contaminates.
(3) Repair or replace the damaged parts.
Each parts must be free of burrs its corners.
(4) Do not reuse O-rings, oil seal and floating seal that were removed in disassembly.
Provide the new parts.
(5) Wash all parts thoroughly in a suitable solvent.
Dry thoroughly with compressed air.
Do not use the cloths.
(6) When reassembling oil motor components of motor, be sure to coat the sliding parts of the motor
and valve with fresh hydraulic oil.(NAS class 9 or above)
(7) Use a torque wrench to tighten bolts and plugs, to the torque specified as follows.

8-85
2) ASSEMBLY OF BRAKE VALVE
(1) Assembly of the check valve
Η Fit the O-ring(337) on the plug(326).
Θ Insert the spring(330) and the valve(327)
into the plug(326), and then grease the
spring(330) and the valve(327) and
hand-lock the former.
Ι Insert the plug(326) in conjunction with
the spring(330) and the valve(327) into
the rear flange(301), and tighten the plug
25038TM04(2)
to the required torque.
ö Apply grease to the O-ring(337).
ö Tighten the plug(326) to a torque of
26Ü4kgfÂm(188Ü29lbfÂft).

(2) Assembly of the spool

Η Insert the spool(323) into the rear flange
(301).
ö Apply a working fluid to the spool(323)
and insert it into the rear flange(301).
ö Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
25038TM04(1)
the spool due to contact.
ö Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.
Θ Attach the O-ring(336) to the plug(324).
ö Apply grease to O-ring(336).

Ι Install stopper(325) and the spring(328)

into both plugs(324) and tighten the
plugs(324) into the rear flange(301) at the
required torque.
ö Apply grease to the O-ring(355).
ö Required torque : 45Ü9kgfÂm
(325Ü65lbfÂft)
ö Even if either the rear flange(301) or the
spool(323) is to be replaced, their entire
25038TM03(4)
assembly(kit) must be replaced.

8-86
(3) Assembly of the two-speed control
valve
Η Fit O-ring(355) on plug(357).
Θ Insert spring(366) in spool(363) and
insert spool(363) to rear flange(301).
ö Apply grease to O-ring(355).
ö Apply hydraulic oil to spool(363).
ö Align the center of the hole in the rear
flange with the axial center of the spool to
25038TM05(1)
prevent damage to the inner surface of
the rear flange and the outer surface of
the spool due to contact.
Above mentioned damage causes
internal leakage after reassembly, thus
degrading the motor performance.

Ι Tighten plug(357) to rear flange(301)

with specified torque.
ö Tightening torque : 10Ü2kgfÂm
(72.3Ü14.5lbfÂft)

25038TM04(4)

8-87
(4) Assembly the inner parts of the rear
flange assembly
Η Insert steel ball(385) to rear flange(301).

25038TM06(1)

Θ Fit O-rings(383, 385) on plug(382).

Ι Tighten plug(382) to rear flange(301)
with specified torque.
ö Tightening torque : 1.5Ü0.25kgfÂm
(10.8Ü1.8lbfÂft)
ö Apply grease to O-rings(383, 384).
ö Apply sealant to threaded section of
plug(382).

25038TM05(4)

Κ Insert piston(381) to rear flange(301).

ö Apply hydraulic oil to piston(381) and
then insert it into rear flange(301).
ö Align the center of the hole in the rear
flange with the axial center of the spool to
prevent damage to the inner surface of
the rear flange and the outer surface of
the piston due to contact. The above
mentioned damage causes internal
25038TM05(3)
leakage after reassembly, thus degrading
the motor performance.
ö Rear flange(301) and piston(381)
constitutes a rear flange kit. When
replacing either of them, therefore,
replace the rear flange kit.

8-88
Λ Fit O-ring(359) on plug(380).
Μ Install plug(380) to rear flange(301), and
tighten plug(380) to rear flange(301) with
the specified torque.
ö Apply grease to O-ring(359).
ö Tightening torque : 6Ü1kgfÂm
(43.4Ü7.2lbfÂft)

25038TM05(2)

Ν After fitted O-ring(358) on plug(352),

install steel ball(368) and plug(352) to
rear flange(301).
ö Apply grease to O-ring(358),
ö Do not disassemble and assemble any
further.

1408DA50

Ξ Install orifice(397) and filter(379) to rear

flange(301).
ö Do not disassemble and assemble any
further.

1408DA51

1408DA52

8-89
(5) Assembly of the relief valve
Η Fit O-rings(208, 209, 219) and back up
rings(211, 217) on sleeve(202).
Θ Fit O-ring(210) on plug(204).
ö Apply grease to the O-ring.
Ι Insert shim(205) into plug(204).
ö Use the disassembled shim, because the
pressure adjustment made by shim.
When replacing the inner parts of relief
25038TM06(3)
valve, therefore, the valve kit should be
replaced.

Κ Fit piston seal(220) to valve(201).

Piston seal
ö Piston seal(220) consist of O-ring and
Valve
polyester ring, apply grease to them and
then fit the O-ring and after fit the
polyester ring to valve(201).

25038TM14

8-90
Λ Insert valve(201), spring(206) and spring
retainer(203) to sleeve(202) and tighten
plug(204) fitted with shim(205) to the
specified torque.
ö Apply hydraulic oil to valve(201) and then
insert it to sleeve(202).
ö Align the center of hole in sleeve(202)
with the axial center of valve(201) to
prevent damage to the inner surface of
25038TM07(2)
the sleeve and outer surface of the valve
due to contact.
ÂTightening torque : 10Ü2kgfÂm
(72.3Ü14.5lbfÂft)
ö Use the disassembled parts, because
the relief valve is pressure adjusted.
When replacing the inner parts of the
relief valve, therefore, the valve kit should
be replaced.
ö Apply grease to mating surface of the
shim and then fit into the plug. The
above mentioned will keep the two faces 25038TM07(1)

practically glued together, the shim will

not drop down when install the plug to
the sleeve.

25038TM06(4)

25038TM06(2)

8-91
3) ASSEMBLY OF REDUCTION GEAR AND HYDRAULIC MOTOR
ö Before reassembling the reduction gear and the hydraulic motor following completion of parts
replacement, one of the following two operations must be carried out:
ÂSelecting a distance piece(12) of the appropriate thickness.
ÂSelecting a thrust bearing(20) of the appropriate thickness.
ö Reassembling must be down only after clearance adjustment of these parts.
ö Prior to the start of reassembling, check for parts that require replacement.

No A : Reassembling
(See page 8-93 through 8-105)

Parts
replacement
Parts to be replaced
B : Thickness selection of a distance
ÂHub kit
piece(12)
ÂSpindle kit
(See page 8-106)
ÂBall bearing(24)

Yes

Parts to be replaced C : Thickness selection of a thrust

ÂCarrier assembly bearing(20)
ÂCover(13) (See page 8-107 through 8-109)

ö If all of the above-name parts can be reused in reassembly, be sure to make these adjustments.
Disregard of these adjustments will result in malfunction or premature failure of the motor.

8-92
A : REASSEMBLING
Hammer
(1) Assembly of the hub section Force-fitting jig
Η Mount the hub(1) on a working bench so
that the mounting side of the cover(13) Ball bearing
faces upward.
Hub
Θ Insert the ball bearing(24) into the hub(1)
using a force-fitting jig.
ö Heat the hub(1) to a temperature of
90Ü5Á C R210TDD2(6)

ö Shrinkage-fit the ball bearing(24).

ö If a force-fitting jig is not available, insert
the ball bearing(24) into the hub(1) and
then hammer the former.
Ι Rotate the hub(1) through 180 degrees
to make the mounting side of the
spindle(2) face upward.
Κ Insert th ball bearing(24) into the hub(1)
using a force-fitting jig.
ö Shrinkage-fit the ball bearing(24).
Λ Assemble the O-ring(40) into the hub(1).
ö Apply a thin coat of grease to the O-
ring(40).
Μ Assemble the seal ring(23) into the
hub(1).
The seal ring can better be assembled
into the hub by tapping the edge of the
seal ring lightly with a plastic hammer.
ö When assembling the seal ring(23) into
the hub(1).
ö Be extra careful not to damage the O-
ring(40).

8-93
(2) Assembly of the spindle(2) section
Η Mount the two floating seals(26) in the
spindle(2).
ö Apply a thin coat of grease to the O-ring
in the floating seal(26).
ö Be extra careful to ensure that dust does
not stick to the seal surface.

TM-SPARE04

(3) Assembly of the hub(1) and the spindle(2)

Η Mount the spindle(2) on a working bench
so that the cover side of the spindle
faces upward.
Θ Fit eye-bolts to the hub(1), and then lift it
with a crane and gently insert it into the
spindle(2).
ö If the hub(1) or the spindle(2) does not
snugly fit because of the presence of the
TM-SPARE03
ball bearing(24) evenly tap the top of the
hub(1) with a plastic hammer during
fitting.

(4) Assembly of the coupling gear(8) in

ring gear B(5) and ring gear B(5)
Η Mount the coupling gear(8) in ring gear
B(5).
Θ Fit the ring(15) into the ring groove of
ring gear B(5).
ö Do not reuse the ring(15) after removal.
Use a new one during reassembling.

8-94
(5) Assembly of the coupling gear(8)
Η Attach a distance piece(12) to the
coupling gear(8) using grease.
ö During attachment, apply a thin coat of
grease to the mounting surface of the
coupling gear(8) to prevent possible fall
of the distance piece(12).

Parts to be replaced
ÂHub kit B : Proceed to thickness
ÂSpindle kit section of a distance piece(12)
ÂBall bearing(24) (see page 8-106)

No parts to Proceed directly to

be replaced the next step.

Θ Mount the coupling gear(8)

(fitted with ring gear B(5)) on a coupling
gear lifter, and then lift it with the crane
and mount it in the spindle.
Ι Match the match marks on the coupling
gear(8) and the spindle(2).
Κ Insert the ten pins(17), and caulk the pin
hole edges of the coupling gear(8).
ö Do not reuse the pins(17) after removal.
TM42 (140-7)
Use new ones during reassembling.
Λ Tighten the ten hexagonal socket
bolts(35) to the required torque using a
torque wrench.
ö Tightening torque : 25.7Ü4 kgfÂm
(185.9Ü28.9 lbfÂft)
ö Apply an adhesive to the threaded
section of the spindle(2) and the pin
holes after degreasing both.
ö After completely degreasing the
hexagonal socket bolts(35), apply
TM-SPARE05
molycoat to the bottom of each such bolt
neck.
Μ Rotate the motor through 180 degrees to
make the spindle side face upward.

8-95
(6) Assembly of the oil seal(132)
Η Fit the oil seal(132) into the oil seal
mounting hole of the spindle(2).
ö Apply white petrolatum or lithium grease
to the lip section of the oil seal(132).
ö Use a new oil seal during reassembling.

TM44 (140-7)

(7) Assembly of the roller bearing(149)

Η Shrinkage-fit the roller bearing(149) onto
the shaft(102).
ö If the roller bearing(149) has been
removed from the shaft(102) during
disassembling, replace the former with a
new one and then shrinkage-fit it onto
the shaft(102).
ö Shrinkage-fitting temperature :
TM45 (140-7)
100Ü10Á C.
ö Apply molybdenum disulfide grease to
the outer contact surface of the roller
bearing(149).
ö When inserting the poller bearing(149),
use leather gloves and take care not to
get burned.

8-96
(8) Assembly of the piston assembly (161,
162)
Η Mount spring(193) to piston assembly
(161,162).
ö Apply grease to spring(193).
Θ Mount the piston assembly(161, 162) in
the piston hole of the spindle(2).
ö Apply grease to piston assembly
(161,162). TM46 (140-7)

Piston kit

Spindle
R210TDD2(7)

(9) Assembly of the pivot(167)

Η Mount two pins(171) to the spindle(2)
and two pivots(171).
ö Apply grease on half round section of
pivot(167).

(10) Assembly of cylinder block section

Η Insert washer(110), spring(114),
washer(110) and snap ring(145) in that
order, into the shaft bore of cylinder
block(104).

TM47 (140-7)

8-97
 Θ Set cylinder block in the press in order to
compress the spring(114).
Place retainer on the washer(110) and
push down this tool with the press arbor
until the snap ring groove becomes
cleared.
Fit snap ring(145) into the groove.
ö When working on the cylinder block,
protect its sliding face by covering it with
TM48 (140-7)
a vinyl sheet.
ö A push of about 200kgf(440.9lbf) will be
needed to compress the spring.

(11) Assembly of piston motor sub

assembly
Η Fit 5-rollers(151) into the pin holes of
cylinder block(104), and then, put
collar(111) and thrust ball(108) on it.
ö Immerse piston assembly in hydraulic oil.

TM49 (140-7)

Θ Insert piston assembly into retainer

plate(107).
Ι Mount the piston assembly in the cylinder
block(104).
After mounting, immerse the entire them
in a working fluid.

TM50 (140-7)

8-98
Κ As shown in the figure, mount the swash
plate(103), the thrust plate(153), the
thrust ball(108), collar(111) the retainer
plate(107), the roller(151), the cylinder
block(104), and the piston assembly
(105,106) in the shaft(102).
Then, mount a lifter(ɇ) and make the
shaft(102) upright.
ö The outer lacing of the roller bearing
TM51 (140-7)
(149) must be mounted in the spindle(2)
beforehand.
ö Accurately align and assemble the
retainer plate(107) and the spherical
section of the thrust ball(108).
Λ Lift the motor assembly using a lifter, and
mount it in the spindle(2). Lifter
ö Mounting must be done so that the steel-
ball hole in the swash plate(103) and the
steel ball(167) come into a fit. Mounting
must also be done gently so that no
parts come into contact with the
spindle(2) or other sections.
Spindle(2)
Contact may damage parts.
ö After the motor assembly has been
mounted, turn the cylinder block by hand
to check for backlash. Perform
inspections if back-lash is present.

R210TDD2(8)

8-99
(12) Assembly of the parking brake section
Η Fit the mating plate(116) first and then
the friction plate(115), one by one, into
the grooves of the outer surface of the
cylinder block(104).
ö This order of fitting must be strictly
observed.
ö Immerse the friction plates(115) in a
working fluid before fitting them into the
TM52 (140-7)
grooves.

Θ Fit the O-rings(139,178) in the O-ring

grooves of the piston(112).
ö Apply a thin coat of grease to the O-
rings(139,178).

TM53 (140-7)

Ι Mount the piston(112) in the spindle(2).

ö If the piston(112) does not fit into the
spindle(2) because of the resistance of
the O-ring, tap the edge of the
piston(112) lightly and equally with a
plastic hammer.
Be careful not to damage the O-ring at
this time.

TM54 (140-7)

Κ Arrange the twelve springs(113) correctly

in the spring mounting hole of the
piston(112).

TM55 (140-7)

8-100
 Λ Fit the two O-rings(39) and the O-
ring(29) in the O-ring grooves of the
spindle(2).
ö Apply a thin coat of grease to the two O-
rings(39).
ö Remount the O-ring(29) without
greasing it.
If this O-ring is greased and remounted,
possible oozing of the grease from the
TM56 (140-7)
contact surfaces of the rear flange(101)
and the spindle(2) during motor
operation may be mistaken for oil
leakage.
Μ Fill the spindle(2) with a working fluid.
Quantity required : 1.7 liters.
(13) Assembly of the rear flange(101) back
in the spindle(2)
Η Mount the ball bearing(150) in the rear
flange(101).
ö Apply molybdenum disulfide grease to
the outer contact surface of the ball
bearing(150).

Θ Fit the two dowel pins(341) into the pin

holes of the rear flange(301).
Ι Using the dowel pins(341) as a guide,
mount the timing plate(109) in the rear
flange(301).
At this time, apply grease to the contact
surfaces of the timing plate(109) and the
rear flange(301).
Κ Fit the two dowel pins(42) into the
TM57 (140-7)
spindle(2).
ö Mount the timing plate(109) firmly in the
rear flange(301) to prevent the former
from falling out of the latter.

8-101
 Λ Mount the rear flange(301) on the
spindle(2).
At this time, the two dowel pins(42) that
have been fitted into the spindle(2) must
be aligned with the pin holes.

25038TM02(4)

Μ Tighten the nine hexagon socket head

bolts into the spindle(2) at the required
torque.
Tightening torque :
25.7Ü4 kgfÂm(185.9Ü28.9 lbfÂft)
ö If, in step (12)-Ι above, the piston(112)
does not fit into the spindle(2) because of
the resistances of the O-rings, proceed
as follows to mount the rear flange(101)
25038TM02(3)
on the spindle(2) : mount four hexagon
socket bolts(182) in diagonal form, and
tighten them equally so that the rear
flange(101) is kept horizontal.
Ν Assemble the relief valve to rear
flange(301), then tighten at required
torque.
Tightening torque :
25Ü5kgfÂm(185Ü36 lbfÂft)

25038TM02(2)

8-102
(15) Assembly of the carrier assembly
Η Attach one of the two thrust bearing(20)
to the coupling gear(8) using grease.
ö Apply a thin coat of molybdenum
disulfide grease to the thrust bearing(20).

Parts to be replaced if C : Thickness selection of a

required : thrust bearing(20)
Hub kit and spindle kit carrier (see pages 8-107
assembly cover(13) through 8-109)

No parts to Proceed directly to

be replaced the next step.

Θ Mount the coupling(19) on the shaft

(102).
ö Apply a thin coat of molybdenum
disulfide grease to the spline section of
the coupling(19).

Ι Place the steel ball(36) in the sun

gear(7), and place the sun gear in the
coupling(19).

UNTITLED

8-103
 Κ Insert the carrier assembly into the
hub(1), and correctly engage the teeth of
ring gear B(5) and teeth B of the cluster
gear(6).
ö This must be done only after determining
the timing point of carrier assembly
reassembling
(see next for further details).

TM62 (140-7)

ö Determining the timing point of carrier

Teeth A Sun gear installer
assembly reassembling
Match marking position (pre-installing jig)
To insert the carrier assembly into the procedure
hub(1) and correctly engage teeth B of
the cluster gear(6) and the teeth of ring Carrier(3)
gear B(5), carry out the operating
procedure described after this figure :
Cluster gear(6)
ö Procedure " "
Align the match marks of the three R210TDD3(1)

cluster gears(6) at the positions shown.

At those positions, engage the sun gear
installer correctly with the cluster gears(6)
and fix the sun gear installer.
Insert the carrier assembly into the
hub(1). This dismounts the sun gear
installer automatically.
(16) Assembly of ring gear A(4)
Η Mount ring gear A(4) on the hub(1). Insert
Check at this time that the teeth of ring
Match mark Ring gear A(4)
gear A and teeth A of the cluster gear are
in correct engagement.
Θ Rotate the hub(1) to fit the match marks Hub(1)

on ring gear A and the hub.

Ι Fit the ten dowel pins(27) into the hub(1).
ö After completely degreasing that surface
R210TDD3(2)
of ring A(4) that contacts the hub(1),
apply a thin coat #SS60F hermetic
sealant to that contact surface.
Κ Fill the reducer section with a lubricating
oil.
Quantity required : Approx. 3.3 liters

8-104
(17) Assembly of the cover(13)
Η Attach the thrust bearing(20) to the
carrier(3) using grease.
ö Apply a thin coat of molybdenum
disulfide grease to the surface of the
thrust bearing(20).

Θ Install cover(8) to hub(1).

ö Apply slightly loctite No. 24 to that
matching face of cover which is to mate
with the surface of hub(1).

TM63 (140-7)

Ι Fasten cover(13) to hub(1) with 20

hexagonal bolts(32) and 20 supper lock
washers(33), applying to the specified
torque.
ö Tightening torque :
10.4Ü1.6 kgfÂm(75.2Ü11.6 lbfÂft)
Before tighting bolts, apply loctite 242 to
the hexagon bolts(32).
Κ Tighten 3-plugs(30) to cover(13) to the
TM64 (140-7)
specified torque.
ö Tightening torque :
6Ü2 kgfÂm(45Ü14 lbfÂft)
ö Before tighting plugs, wrap the threaded
portion of each plug with two lagers of
the seal tape.
ö Tighten each plug until the last thread
becomes nearly flush with the cover
surface within an extent equal to plus or
minus one thread relative to the surface.

8-105
B : THICKNESS SELECTION OF A
DISTANCE PIECE(12)
(1) If the parts listed below have been
replaced, select a distance piece(12) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (5) of
subsection 3] and carry out the next step
of that procedure.
Hub kit
Parts replacement Spindle kit
Ball bearing(24)

(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
Η Mount a measure plate on the spindle(2)
without inserting a distance piece(12).
Θ Lightly tighten a few hexagon socket
bolts(35).
Ι As shown in the figure at right, measure
dimension A using a depth micrometer. TM65( 140-7)

ö Tighten the hexagon socket head bolts

equally.
Κ Measure dimension C of the coupling
gear(8) to be mounted see the figure at
right.
Λ Using the clearance measurements, Measure plate for distance Depth micrometer
piece thickness
calculate the appropriate distance piece
Spindle(2)
thickness as follows.
 Measure the clearance between the
A
B

edge of the spindle(2) and that of the ball

X

bearing(24).
Take this clearance as X.
X=A-B Coupling gear(8)
Ball bearing(24)
 Next, determine the distance piece of
the appropriate thickness.
c
Take this thickness as T.
T = (C + X) Ü0.1
Μ Using the results of steps (1) through (5)
A : Dimension required
above, select the appropriate thickness.
B : Jig dimension
Then, proceed with the original
R210TDD3(3)
reassembling operation.

8-106
C : THICKNESS SELECTION OF A
THRUST BEARING(20)

(1) If the parts listed below have been

replaced, select a thrust bearing(20) of
the appropriate thickness.
After selection, return to the original
reassembling procedure [procedure (15)
at page 8-103] and carry out the next
step of that procedure.
Hub kit
Spindle kit
Parts replacement
Carrier assembly
Cover(13)

(2) Steps(1) through(4) of the original

reassembling procedure must be carried
out as directed.
Η Attach one of the two thrust bearings(20)
to the coupling gear(8).
At this time, use the thinnest distance
piece.
Θ Mount the coupling(19) on the shaft
(102). TM66 (140-7)

Ι Place the sun gear(7) in the coupling

(19).
Κ Insert the carrier assembly into the
hub(1), and correctly engage the teeth B
of the cluster gear(6).
ö This must be done only after determining
the timing point of carrier assembly
reassembling (see page 8-105 for further
details.)
ö Do not apply molybdenum disulfide
grease to the thrust bearing(20).

8-107
Λ Fit the match marks on ring gear A(4)
and the hub(1), and mount the ring gear Insert
on the hub. Check at this time that teeth
Match mark Ring gear A(4)
A of the cluster gear(6) and the teeth of
ring gear A(4) are in correct engagement.
Hub(1)

R210TDD3(2)

Μ Mount a thrust-bearing adjusting plate

on the hub(1), and lightly tighten the
former using two M12 hexagon socket
bolts.
Don not mount the thrust bearing(20) at
this time.

TM67 (140-7)

Ν As shown in the figure at right, measure

Depth micrometer
dimension A using a depth micrometer. Thrust bearing
adjusting plate

A
B
X

Carrier

Ring gear A(4)

R210TDD3(4)

Ξ Measure dimension C of the cover(13) to

be mounted.
See the figure at right.
Cover(13)

R210TDD3(5)

8-108
Ο Using the clearance measurements,
calculate the appropriate thrust bearing
thickness as follows.
 Measure the clearance between the
edge of the carrier(3) and that of ring
gear A(4).
Take this clearance as X
X=B-A
A : Dimension required
B : Jig dimension
 Next, determine the thrust bearing of the
appropriate thickness.
Take this thickness as T.
T = (C - X) - (0.3 to 0.6)
Π Using the results of steps(7) through(9)
above,select the appropriate thickness
from three types.
Then, proceed with the original
reassembling operation.

8-109