34.

TRAVEL SYSTEM
TABLE OF CONTENTS

34.1 REMOVING AND INSTALLING.......................................................................................34-3

34.1.1 TRAVEL SYSTEM .................................................................................................34-3
34.1.2 CRAWLER..............................................................................................................34-3
34.1.3 UPPER ROLLER ....................................................................................................34-7
34.1.4 LOWER ROLLER ...................................................................................................34-13
34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY) ...........................................................34-21
34.1.6 SPROCKET ............................................................................................................34-30
34.1.7 TRAVEL MOTOR ..................................................................................................34-33
34.1.8 SWING BEARING ..................................................................................................34-35
34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT .......................................34-38
34.2.1 TRAVEL MOTOR ...................................................................................................34-38

34

Book Code No. S5YN3418E01

34-1
34. TRAVEL SYSTEM

Issue Date of Issue Applicable Machines Remarks

SK200–8 : YN11-45001~ S5YN3418E01
First edition August, 2006 K
SK210LC–8 : YQ11-06001~ (ASIA, OCE)

PREFACE
(1) This Manual describes all the procedures from removing to attaching, arranging them by item.
(2) This Manual consists of first part. Removing and attaching, and sequel. Disassembling and assembling.
(3) The removing and attaching can be performed in the procedure specified in Table of Contents, but in view of
actual repairing or time saving some process can be omitted.
(4) The removing and attaching procedure does not completely cover all possible situations because of differences
of field condition and defective section.
(5) Please be aware that the procedure to be followed must be determined according to the above conditions.
When disassembly and assembly are required, select the necessary section, itemize the work contents with
good understanding, then starts working.

34-2
 34. TRAVEL SYSTEM

34.1 REMOVING AND INSTALLING

34.1.1 TRAVEL SYSTEM

8. SWING BEARING

2. CRAWLER
7. TRAVEL MOTOR
5. FRONT IDLER 6. SPROCKET
GUARD LOWER FRAME
GREASE NIPPLE OF THE 3. UPPER ROLLER
TRACK SPRING ADJUSTER 4. LOWER ROLLER
Fig. 34-1 Designation and location of undercarriage

34.1.2 CRAWLER

34.1.2.1 REMOVING CRAWLER

(1) Position the machine to remove crawler.
(2) Pushing out master pin.
1) Find the master pin and place it in its removing/
fixing position in Fig. 34-3.
2) Loosen the grease nipple and slacken crawler.

: 19 mm

• When loosening the grease nipple of the adjuster,

Fig. 34-2 Crawler removing position
do not loosen it more than one turn.
• Where grease does not come out well, move the
machine back and forth. The over loosening of
grease nipple may cause it to jump out incurring
danger of injury. So be careful not to over loosen
the grease nipple.

3) Pushing out master pin

Apply jig on master pin and strike it out with a
mallet.
(Refer to Fig. 34-7 Press fitting of master pin)

!"#$%&' ( )%*%&'
+#,%-%#& #) ".,-!/ +%&
When using a big hammer, wear protective goggles
Fig. 34-3 Removing/fixing position of master pin
and a long-sleeved uniform so you do not injure
yourself by flying objects.

34-3
34. TRAVEL SYSTEM

(3) Removing crawler

!"#$%&'
Put attachment on ground so that weight is not "()*!+ ,%&
loaded to the lower frame, and remove track link
assy rotating sprocket.

Crawler end section may fall on the ground just before

extending it on the ground incurring danger of injury.
Please keep well away from the equipment.
Fig. 34-4 Removing crawler

34.1.2.2 INSTALLING
Installing is done in the reverse order of removing.
(1) Checking crawler installation direction.
Place the track links on the ground so they !"#$
converge, facing the front idler, as shown in the
%&'(! )%&(
figure on the right.

(2) Installing crawler

1) Preparation for installation
Treat paint flaking protection with care not to
damage lower flame.
Fig. 34-5 Installing direction of crawler
2) Winding crawler
Insert a crowbar into the master pin hole, lift the
lower frame 1 to 2cm above the ground level by
holding it by hand so the machine body weight is
not exerted on the shoe. Retract the sprocket to
help push the back winding of the crawler.

(3) Preparation for press fitting master pin

1) Preparing for installation
Put square wood under the shoe plate.
2) Aligning master pin holes
Aligning master pin holes through fine Fig. 34-6 Winding crawler
adjustment turning sprocket.

• When using a big hammer, exercise care so you

are not injured by flying objects the same way as
when pushing out the master pin.
• Coat the master pin with molybdenum disulfide
grease, before pressing it in.

(4) Press fitting of master pin !"## $%&&%'( )%(

Apply press fitting jig on master pin, and strike it *' +,#&"! -%'
with a mallet to press fit. Fig. 34-7 Press fitting of master pin

34-4
 34. TRAVEL SYSTEM

(5) Adjusting crawler tension (See Fig. 34-8)

After installing, adjust tension of crawler.

: 19 mm

!"#$"%$ $&'(#)&*# +
7&'(#)&*# *8 &%*# 9%":;(% &# ,-./,0.''
" '"<3 );"9=(#($ 9*#$&!&*# 12-34/2,35&#6

Fig. 34-8 Adjusting crawler tension

34.1.2.3 CONSTRUCTION

FLAT SHOE
2
1-6
1-1
1-8
1-4
1-3 TRIANGLE SHOE
1-8 2 RUBBER PAD SHOE 3
1-7 2

1-1
4 3
1-7 1-5 3
1-2 1-2
Fig. 34-9 Track link assy and shoe plate

SK200-8 SK200LC-8
Shoe assy

Shoe assy

YN60D00054F2 YN60D00055F2
YN60D00054F5 YN60D00055F4
YN60D00054F6 YN60D00055F5
No. NAME Q'TY No. NAME Q'TY
1 .LINK ASSY YN62D00017F1 1 1 1 1 .LINK ASSY YN62D00017F3 1 1 1
1-1 ..TRACK LINK R 46 46 46 1-1 ..TRACK LINK R 49 49 49
1-2 ..TRACK LINK L 46 46 46 1-2 ..TRACK LINK L 49 49 49
1-3 ..BUSHING 45 45 45 1-3 ..BUSHING 48 48 48
1-4 ..PIN 45 45 45 1-4 ..PIN 48 48 48
1-5 ..MASTER BUSHING 1 1 1 1-5 ..MASTER BUSHING 1 1 1
1-6 ..MASTER PIN 1 1 1 1-6 ..MASTER PIN 1 1 1
1-7 ..COLLAR 2 2 2 1-7 ..COLLAR 2 2 2
1-8 ..SEAL 90 90 90 1-8 ..SEAL 96 96 96
2 .SHOE 600mm 46 - - 2 .SHOE 600mm 49 - -
.SHOE 700mm - 46 - .SHOE 700mm - 49 -
.SHOE 800mm - - 46 .SHOE 800mm - - 49
3 .BOLT 2420Z1292 184 184 184 3 .BOLT 2420Z1292 196 196 196
4 .NUT 2420Z1293 184 184 184 4 .NUT 2420Z1293 196 196 196

34-5
34. TRAVEL SYSTEM

34.1.2.4 MAINTENANCE STANDARD

F E
D D G
B

Fig. 34-10

Unit : mm (in)
REPAIRAB SERVICE
No. ITEM STANDARD VALUE REMEDY
LE LEVEL LIMIT
A Link pitch 190 ± 0.1 (7.4803 ± 0.0039) 194 (7.64) 198 (7.80) Replace the link
B O.D. of bushing ø 58.78 (2.3142 ) ø 55 (2.17) ø 54 (2.13) assy if the service
C Height of link 106 ± 0.3 (4.1732 ± 0.0118) 100 (3.94) 98 (3.86) limit is exceeded
Basic
Tolerance Fit Fit
dimension
Interference between bushing + 0.11
D Interference
and link ø 58.78 (+0.0043) Interference
Shaft 0.05
(2.3142) - 0.05 0
(0.0020) Replace
(-0.0020)
+ 0.1
Interference
Interference between track pin ø 36.63 (+0.0039) Interference
E Shaft 0.05
and link (1.4421) - 0.05 0
(0.0020)
(-0.0020)
- 0.03
Interference
Interference between master ø 36.50 (-0.00118) Interference
F Shaft 0.05 Replace Link
pin and link (1.43701) - 0.088 0
(0.0020)
(-0.00315)
8 (0.32) 10 (0.39)
G Clearance between links 1.5 (0.06) (both side) Replace
(both side) (both side)
H Tightening torque of shoe bolt 853 N•m (629 lbf•ft) Reassembly

34.1.2.5 TOOLS AND JIGS

(1) Tightening tools

Unit : mm (in)
NAME OPPOSING FLATS

30 (1.2)
Socket

(2) Jig

NAME SHAPE

Master pin fixing jig for iron

crawler

34-6
 34. TRAVEL SYSTEM

34.1.3 UPPER ROLLER

34.1.3.1 UPPER ROLLER ASSY

UPPER ROLLER ASSY No. YN64D00032F1

ITEM NAME Q’TY REMARKS
1 ROLLER ASSY 4 YN64D01068F1
2 CAPSCREW (SEMS SCREW) 4 M20uP2.5u100
3 NUT 4
4 WASHER 4

34.1.3.2 REMOVING
(1) Preparation for removal
Remove crawler (Above mentioned).
3
4
(2) Removing upper roller (1)
1) Remove nuts on support tightening section, and
2
also remove capscrew (2) M20u100.
1
: 30 mm

Fig. 34-11 Removing upper roller

34.1.3.3 INSTALLING
Installing is done in the reverse order of removing.
(1) Inspection
Before reassembling, check it that it rotates smooth COUNTER-
manually and for leak. SINKING

(2) Installing upper roller (1)

1) To install the upper roller, turn up socket bolts (2)
toward the center of machine.

2) Insert it until collar comes in contact with support.

3) Fit it directing the countersinking mark of shaft

CENTER OF MACHINE

end upward.

4) Apply Loctite #262 on capscrew M20u100, and

tighten it to the specified torque.

: 30 mm
Tightening torque : 539 N•m (400 lbf•ft)
2 1 3,4

Fig. 34-12 Installing upper roller

34-7
34. TRAVEL SYSTEM

34.1.3.4 CONSTRUCTION

!""# $%%& '$ ( )!* &)+,-./.+01/ 11 8 4 6 7 3 2

)2* )$8# 9:(& )2* )$8# 9:(&

/ !""# / 6 1"!$(@)A %#$" /
3 %;$1( / 0 ! @)A B /$ '+5 /
4 <!""$ / 7 %!<C#( >!"( 3
, '"$(# / /. '"?A /
5 <!=# / // %)$' @)A /
+ >?%;@)A /

1 10 5 9
Fig. 34-13 Construction of upper roller

34.1.3.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly $
1) Draining out oil % !
Remove plug (10) and drain out oil.
&
: 6mm "

2) Removing snap ring (11)

Mount the end face inside upper roller (1) on
stand jig (f) and separate snap ring (11), using
snap ring pliers.
#

3) Removing cover (5)

Take off cover (5) upwards, utilizing the screwed
hole for the plug.

4) Removing O-ring (8)

Separate O-ring (8) from cover (5). Fig. 34-14 Construction of upper roller

5) Removing plate (4)

Loosen 2 socket bolts (9) and draw out plate (4)
from roller (1).

: 10mm
!

6) Removing shaft (2) "

Put the extrusion jig (h) against the end face of
#
shaft (2) and push shaft (2) with collar (3) for
floating seal (7), using a press or hammer.
$

Fig. 34-15 Extruding shaft

34-8
 34. TRAVEL SYSTEM

7) Removing floating seal (7).

Take out floating seal (7) from roller (1).

Fig. 34-16 Taking out floating seal

8) Removing floating seal (7).
#
Remove from collar (3), floating seal (7) that is
!
located on the side from which shaft (2) was $
disassembled. %
"

&
Collar (3) is press fitted into shaft (2). Therefore do not
disassemble it.

Fig. 34-17 Removing floating seal and extruding

bushing
9) Removing bushing (6)
Push with press (e)
Since the bushing is thin, machine it on a lathe or
scrape it off, take care so as not to damage the i
bore of roller (1).
If the bushing is not worn much, mount upper 6
roller (1) on jig (f), insert jig (g) into the end face
1
of bushing (6) and push it out with a press.

(2) Assembly
Assembly of the upper roller is done in the reverse f
order of disassembly.
1) Place upper roller (1) on the top end face of jig
(f), with its floating seal setting side facing down.

2) Confirm that the outer surface of bushing (6) is Fig. 34-18 Pushing in bushing
not scuffed and coat the outer surface of the
inserting side of the bushing, with molybdenum
disulfide grease. 2

7
3) Put jig (i) into bushing (6) and press it in, using
the bore of the bushing and the bore of the roller 7 1
as guides.
3

If you fail in this operation by pressing the bushing

unevenly, the bushing is distorted and gets
unserviceable. In that case, do not re-use the bushing Fig. 34-19 Fixing floating seal
as it may develop malfunctioning after assembly.

34-9
34. TRAVEL SYSTEM

4) Installing floating seals (7)

Two floating seals (7) make a pair. Attach one
floating seal to retainer fixed in shaft (2), and
another to the inside of upper roller (1). 2

• Prior to placing floating seal (7) in, apply 7

engine oil lightly to seal surface.
1
5) Inserting shaft (2)
Coat shaft (2) with a thin film of oil and insert it
into upper roller (1).

6) Installing plate (4) Fig. 34-20 Inserting shaft

Mount upper roller (1) on the stand jig (f) and
attach plate (4) to the end face of the shaft with
!
#
bolt (9). $
: 10mm,  "
Tightening torque : 115N•m (85 lbf•ft)

7) Installing O-ring (8)

Fit O-ring (8) to the groove of cover (5).
• Apply grease to O-ring.

8) Installing cover (5) %

Attach cover (5) to upper roller (1). Use a press
in this operation as a press fit is used.

9) Installing snap ring (11)

Fix snap ring (11) into upper roller (1), using snap
ring pliers.
Fig. 34-21 Installing cover

10) Filling oil

Fill in 30cc (1.83cu•in) of engine oil API grade
CD #30 through the plug hole in cover (4).

11) Installing plug (10)

!
Wind seal tape around plug (10) and screw it into
the plug hole of cover (4).

: 6mm, 
Tightening torque : 23N•m (17 lbf•ft)

"
• After assembling the upper roller, confirm that
oil is not leaking from it and that it rotates
smoothly by hand.

Fig. 34-22 Filling oil

34-10
 34. TRAVEL SYSTEM

34.1.3.6 MAINTENANCE STANDARD

C
A

E
F
D D
B

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. ø 140 (6.30) — —
B Width 150 (5.91) — —
Replace
C Tread dia. ø 120 (4.72) ø 107 (4.21) ø 105 (4.13)
D Tread width 33 (1.30) — —
Basic
Tolerance Fit Fit
dimension
Clearance between - 0.025
E
shaft and bushing (-0.00098) Clearance Clearance
ø 45 (1.772) Shaft
- 0.040 0.7 (0.028) 1.0 (0.039) Replace bushing
(-0.00157)
+ 0.030
Interference between Interference Clearance
F ø 50 (1.969) Hole (+0.00118)
roller and bushing 0 0.01 (0.0004)
0
Tightening torque of
G 115 N•m (85 lbf•ft)
socket bolt
Oil Engine oil API grade CD #30, 30cc (1.83cu•in) Refill
Roller rotation Roller rotates smoothly by hand. Reassembly

34-11
34. TRAVEL SYSTEM

34.1.3.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

30
Socket

Allen wrench 6,8

(2) Jigs

Unit : mm (in)
No. NAME SHAPE
120 (4.72)
90 (3.54)

160 (6.30)
f Stand jig

52.5(2.07)
For extruding
g
(0.709)

bushing
18

49(1.93)
For extruding
h
(1.18)

shaft
+0.1

+0.1
60(2.36)

49.5 0
44.6

Bushing fixing
i
1.756 +0.004

1.949 +0.004

jig (1.26)32
0

(1.46)37 50(1.97)
87(3.43)

34-12
 34. TRAVEL SYSTEM

34.1.4 LOWER ROLLER

34.1.4.1 LOWER ROLLER ASSY

)>33") +!. ($,-.///0/12 B5 Apply Loctite #262

T=397N.m (290 lbf.ft)
%++( 34 (1,-.////012

!"# $%#" &'!( )"#%)*+

2 3>? )>33") @ 2- ($,-.///2512

3>? )>33") 2, @ (1,-.////212

0 4%9+4)"? ,- <, #2676/89:2;<=

2 1 B2
Apply Loctite #262
T=397N.m (290 lbf.ft)
Fig. 34-23 Lower roller assy and track guide

34.1.4.2 REMOVAL
(1) Preparation for removal
1) Loosen the tension of the crawler, lift up the
lower frame by the front attachment and stop the
engine in that condition.
2) Place a safety block (wood) at the front and back
of the lower frame. !"#$% &'()*
+,((- &'()*.

(2) Removing track guide

Remove capscrews (B5) and remove track guide Fig. 34-24 Preparation for removal
(B2).

: 27mm, 
Weight of track guide : Approx. 25kg (55 lbs)
ROLLER

SK200-8 STD YN01F00035F1

LOW

B2,B5
SK210LC-8 LC YN01F00036F1 STD
ITEM NAME Q'TY
B2 TRACK GUIDE : YN63D00003P1 2 2
B5 CAPSCREW : M18X40(P=1.5) 8 8

(3) Remove lower roller

Remove capscrews (2) and remove lower roller (1). B2,B5
LC
: 27 mm,  Fig. 34-25 Installing track guide
Weight of lower roller : Approx. 33kg (73 lbs)

Fig. 34-26 Installing lower roller

34-13
34. TRAVEL SYSTEM

34.1.4.3 INSTALLATION
(1) Installation of lower roller
Coat mounting capscrews (2) with Loctite #262 and
fasten all 4 capscrews temporarily. Then tighten
them to a specified torque.

: 27 mm, 
Tightening torque : 397N•m (290 lbf•ft)
(2) Installation of track guide
Capscrews (4) with Loctite #262 and fasten all 4
capscrews temporarily. Then tighten them to a
specified torque.

: 27 mm, 
Tightening torque : 397N•m (290 lbf•ft)
(3) Adjusting tension of crawler
Tighten grease nipple and fill it with grease.

: 19 mm, 
Tightening torque : 59N•m (43 lbf•ft)

34-14
 34. TRAVEL SYSTEM

34.1.4.4 CONSTRUCTION

./) %&'()***+,-+ ! " # $ %

!"#$ $! #$ &
0 %-'()****+-+
&12 &:A# 89/% $#A:$B.
+ $! #$ +
3 0! :$ 3
4 .;:-/ +
( <=.;>&? 3 '
5 @>& 3
' - !:/>&? .#: 3 Fig. 34-27 Construction of lower roller
6 ! $>&? 3 +: ?'*
7 @ =? 3 @/+C(

34.1.4.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Drain oil
Remove plug (8) and drain out oil.

: 6mm !

2) Removing pin (5) "

Put both ends of lower roller assy on the V-
shaped blocks (K), apply push-out bar (L) on
upper end face of pin (5), and push pin (5) out
striking with mallet.
#

3) Removing collar (2), O-ring (7)

Put lower roller on jig (M) for repair stand so that
the shaft (3) is perpendicularly located, apply
Fig. 34-28 Pushing out collar fixing pin (5)
push-out jig (P) on shaft end on upper side, and
push shaft (3) until the O-ring (7) separate from
collar (2) with press or mallet, and take out collar
(2) and O-ring (7). JIG P
7
2
4) Removing shaft (3)
In addition, push out and remove shaft (3) 1
together with the lower collar (2) and O-ring (7).
3

JIG M
The shaft (3) extrusion operation may cause the
remaining lube oil to flow out. Prepare an oil container
beforehand.

Fig. 34-29 Removing shaft (3), collar (2), O-ring (7)

34-15
34. TRAVEL SYSTEM

5) Removing collar (2), O-ring (7)

Remove O-ring (7) from shaft (3) that was drawn
out in the previous paragraph.

6) Removing floating seal (6)

Remove floating seal (6) from collar (2). !

7) Removing floating seal (6)

Remove floating seal (6) from roller (1).
Fig. 34-30 Removing floating seal (6)

Fig. 34-31 Removing floating seal (6)

8) Removing bushing (4)
Since thickness of bushing (4) is thin [thickness
is 2.0mm (0.079in)], remove it through lathe or
N
strip it with care not damage inner hole of roller.
When the wear of bushing is not large, place
1
upper roller (1) on jig (M) for repair stand and
apply the end of push-out jig on the end face of
bushing (4) end, and push it out striking it with 4
mallet.

JIG M

Hammer the inside surface of roller lightly so as not to

damage the surface. Put the extrusion jig (N) uniformly Fig. 34-32 Extruding bushing (4)
over the circumference of bushing (4) and extrude it
perpendicularly little by little.

34-16
 34. TRAVEL SYSTEM

(2) Installing
!
1) Attach O-ring (7) to one side
Install O-ring (7) to groove on shaft.

• Grease O-ring.
• Replace O-ring with new one without fail at Fig. 34-33 Attach O-ring (7) to one side
reassembling.

2) Press fitting bushing (4)

Align inner hole of roller (1) and bushing (4) and JIG Q
press fit it vertically in capacity of press fit load,
5ton (11000 lbs), in the condition that bushing 4
push-in jig (Q) is inserted into bushing (4).

• Apply molybdenum disulfide grease on press-

fit section of bushing, and press fit it in
ordinary temperature.
• Bushing which fails to press-fit because of the
one-side pressing should not be fitted. Fig. 34-34 Press fitting bushing (4)

3) Press fitting collar (2) PRESS

Fit O-ring (7) to the one side of shaft (3) mating
pin hole of collar (2) on which floating seal (6) is PIN HOLE
fit with pin hole of shaft (3) in advance. Use the 6
2
press of capacity 17 ton (37500 lbs) or more.
PIN HOLE
3 7
• Care should be taken not to damage O-ring
(7) while press-fitting collar (2) to shaft (3).

4) Inserting pin (5) Fig. 34-35 Press fitting collar (2)

Press-fit pin (5) to pin hole on aligning pin holes
of shaft (3) and collar (2).

6 5

7 2

Fig. 34-36 Inserting pin (5)

34-17
34. TRAVEL SYSTEM

5) Attach floating seal (6) to roller side

Fit floating seal (6) to inner holes on both ends of
roller (1).
1
6
• Check that the seal surface is free from flaws,
rusts, etc. before reusing the floating seal.
3
6) Inserting roller (1)
Insert roller (1) from the side where collar (2), 
2
7
O-ring (7) is not press-fitted to the shaft (3).
Fig. 34-37 Inserting roller (1)
7) Installing O-ring (7)
PRESS
Install O-ring (7) to groove on shaft.

PIN HOLE
• Grease O-ring.
2
• Replace O-ring with new one without fail at
reassembling. PIN HOLE
7
8) Press fitting collar (2)
Press-fit collar (2) to shaft (3).

3
• Press-fit collar (2) on aligning pin (5) hole.

9) Inserting pin (5)

Press-fit pin (5) in to the pin hole mating pin hole
of collar (2) with pin hole on the end side of shaft
(3).

Fig. 34-38 Installing O-ring (7), collar (2)

10) Filling oil
Remove plug (8) and fill in 160cc (9.8cu•in) of
engine oil API grade CD #30.
11) Check it for leakage 8
Before tightening plug (8), check it for leakage in TIGHTENING
TORQUE
the condition of air pressure 0.2 MPa (29 psi). 23N.m (17 lbf.ft)
12) Installing plug (8)
Apply oil resistant sealant on plug (8), and
tighten it in the plug hole on the collar (2) end 2
face.

: 6 mm, 
Fig. 34-39 Installing filling oil plug (8)
Tightening torque : 23 N•m (17 lbf•ft)

After assembling the lower roller, confirm that oil is not

leaking and that the roller rotates smoothly by hand.

34-18
 34. TRAVEL SYSTEM

34.1.4.6 MAINTENANCE STANDARD

%
$
!

"
Fig. 34-40 Lower roller (Track roller)

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A O.D. of flange ø 185 (7.28) — — Reinforcement weld,
B Tread dia. ø 150 (5.91) ø 134 (5.28) ø 128 (5.04) repair or replace
C Flange width 23.5 (0.925) 18 (0.709) 16.5 (0.65)
Basic
Tolerance Fit Fit
dimension
Clearance between
- 0.060
D shaft and bushing
ø 65 (-0.00236) Clearance Clearance
(Wrapped bushing) Shaft
(2.55905) - 0.090 0.7 (0.276) 1.0 (0.394) Replace bushing
(-0.00354)
+ 0.030
Interference between ø 69 (+0.00118) Interference Clearance
E Hole
roller and bushing (2.71653) - 0.020 0 0.01 (0.0004)
(-0.00079)
F Oil Engine oil API grade CD #30, 160cc (9.8 cu•in) Refill
Execute air leak test at 0.2MPa (28psi)
H Plug (8)
before tightening the plug.
Roller rotation Rotates smoothly by hand. Reassembly

34-19
34. TRAVEL SYSTEM

34.1.4.7 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

19, 27
Socket

Allen wrench 6

(2) Jig

Unit : mm (in)
No. NAME SHAPE

K V-block

100(3.94)
Pin (5)
(0.551)

L
14

extrusion rod
16 (0.630)

200(7.87)
Bushing
N
extrusion rod

290(11.4)
160(6.30)

M Stand jig
(4.92)
125

270(10.6)
Shaft
P
(2.52)

extrusion jig
64
(1.18)
30

86(3.39)
94.5(3.72)
64.5(2.54)

Bushing
Q
fixing jig

+0.1
64.6 0
(2.543 +0.004
0 )

34-20
 34. TRAVEL SYSTEM

34.1.5 FRONT IDLER (IDLER ADJUSTER ASSY)

34.1.5.1 FRONT IDLER ASSY

!"#$ %&'(! )**+ +#,-&.../0 1 APPLY LOCTITE #262 OR

EQUIVALENT
#23 #)4( 67$+ !(4)!5* T=279N.m(210 lbf.ft)
1
1 %&'(! )**+ - +#,-&....> 1 3 2
- %&'(! )&89*$(! )**+ - +#,0&...1/ 1
/ :);*:!(< 0 41?@0,
0 =!()*( #%;;'( -

Fig. 34-41 Front idler assy

34.1.5.2 REMOVING
(1) Preparation for removal
Remove crawler. (Above mentioned)

(2) Removing idler assy

Sling idler assy, and push it forward with bar.
Weight ofÅ@crawlerÅEidler assy : 210kg (463 lbs) BAR

Keep away from the front side of front idler.

(3) Installing
Installing is done in the reverse order of removing.

(4) Where idling assy (1) has to be separated

Loosen capscrew (3), and separate idler assy (1)
from idler adjuster assy (2).
Fig. 34-42 Removing and installation the front idler
: 24 mm 
"
Weight of idler assy : 107kg (236 lbs)
Weight of idler adjuster assy : 103kg (227 lbs)

• The separated idler assy (1) should be placed on

square timbers.

! #

Fig. 34-43 Separating idler assy (1) from idler

adjuster

34-21
34. TRAVEL SYSTEM

34.1.5.3 IDLER ASSY

34.1.5.3.1 CONSTRUCTION

!"#$ %&&' '()*!++++,-.

(/0 (%6# 89:' $#6%$7&

"
. !"#$ . '()*!+.++3A.

* ;<&= (> * '

.
%
1 ?@""%$ '()*!+.+..A.

2 -"@%: (> &#%" *

!
) A ( * &
3 &=%-: * #
$
4 @B$ (> * .% >4+

5 A"<> * A:.C5

Fig. 34-44 Idler assy

34.1.5.3.2 REMOVING AND INSTALLING

(1) Removing 5
R
1) Drain oil
Remove plug (8) on the side of collar (3) to drain.

: 5 mm

2) Removing pin (5)

Apply pin push bar (jig R) to the top of pin, and
push out striking bar (jig R) lightly by hammer. Fig. 34-45 Removing pin (5)

PUSH WITH PRESS

3) Removing collar (3)
Put idler (1) on stand (U), apply push-out jig (S) S
6
on shaft (6), push out shaft (6) with collar (3), 3
then remove collar (3). 1

U
3

Fig. 34-46 Removing collar (3)

4) Removing collar (3) from shaft (6) PUSH WITH PRESS
If removal of collar (3) on the opposite side is
S
required, turn over front idler and proceed with
the procedure described in Par. 3). 6
3

Fig. 34-47 Removing collar (3)

34-22
 34. TRAVEL SYSTEM

5) Removing bushing (2) "

!
With idler (1) mounted on the stand, tap bushing
(2) lightly by hammer, while placing the bushing
drawing rod (T) against the end face of bushing
(2) evenly all round, till it comes out.

6) Removing floating seals (4)

Take out floating seals (4) from idler (1), collar
(3). If you intend to re-use floating seals (4), #
confirm that there is no scoring and rusting on
the contact surface and store the floating seals
Fig. 34-48 Removing bushing (2)
in pairs by placing card board between the
sealing faces.

7) Removing O-ring (7)

Separate O-ring (7) from shaft (6).
(2) Assembly PUSH WITH
2 PRESS V
1) Pressing in bushing (2)
1
Align inner hole of idler (1) and bushing (2) and
press fit it vertically with press so that jig (V) for
bushing press-fitting is inserted into bushing (2). 

2) Installing O-ring (7)

Fit O-ring (7) to O-ring groove on shaft (6).
Fig. 34-49 Pressing in bushing (2)
• Apply grease to O-ring

3) Installing collar (3) (See Fig. 34-50) PRESSING

Press fit the O-ring (7) installed side of shaft (6)
into collar (3), and drive pin (5). 6

4) Installing floating seal (4)

3
Fit the half of floating seal (4) on each side of
5
collar (3) and idler (1).

5) Inserting idler (1)

Fig. 34-50 Installing collar (3), shaft (6)
Insert floating seal (4) fitted side of idler (1) into
shaft (6). !

6) Installing floating seal (4)

Fit floating seal (4) on the other side of idler (1). "

Fig. 34-51 Inserting idler (1) and installing floating

seal (4)

34-23
34. TRAVEL SYSTEM

7) Installing collar (3)

Fit the half of floating seal (4) on the other collar "
(3), press fit it in shaft (6), and drive pin (5) in with #
hummer.
8) Filling oil•Inspection !
Fill in 200cc (12.2cu•in) of engine oil API grade
CD #30 through the plug hole of collar (3), wind
seal tape and tighten plug (8).

: 5 mm
Fig. 34-52 Installing collar (3) and filling oil
• After installing the idler assy to the idler
adjuster assy, make certain that no oil leaks
from floating seal and plug (8) and that idler
(1) rotates smoothly.

34.1.5.3.3 MAINTENANCE STANDARD

160(6.30)
C

F
D
E
B
A

Fig. 34-53 Front idler

Unit : mm (in)
REPAIRABLE SERVICE
No. ITEM STANDARD VALUE REMEDY
LEVEL LIMIT
A Dia. of idler projection ø 535 (21.1) — —
B Tread dia. ø 497 (19.6) ø 490 (19.3) ø 487 (19.2) Replace
C Flange width 84 ± 0.5 (3.307±0.020) 78 (3.07) 76 (2.99)
Basic
Tolerance Fit Fit
dimension
Clearance between shaft and - 0.03
D
bushing ø 75 (-0.00118) Clearance Clearance
Shaft Replace
(2.95275) - 0.06 1.5 (0.059) 2.0 (0.079)
bushing
(-0.00236)
+ 0.035 Clearance
Interference between idler and ø 83 Interference
E Hole (+0.00138) 0.01
bushing (3.26771) 0
0 (0.0004)
F Oil Engine oil API grade CD #30, 200cc (12.2cu•in) Refill
Idler rotation Rotates smoothly by hand Reassemble

34-24
 34. TRAVEL SYSTEM

34.1.5.3.4 TOOLS AND JIGS

(1) Tightening tools

Unit : mm
NAME OPPOSING FLATS

24
Socket

Allen wrench 5

(2) Jigs

Unit : mm (in)
No. NAME SHAPE
(0.591)

(1.18)
15

30
R Pin striking jig
(0.591)
105(4.13) 15

340 (13.4)

S Shaft push out jig

(2.91)
74
(0.630)
16

300(11.8)

T Bushing drawing rod

!!"#$%&'(
)'%*&+
!!"#$%.((
)/0%.+
U Stand
!!"#$%
,((
)&'%-+
/
(0.787)

105(4.13)
20
90(3.54)

Bushing press fitting

V
70(2.76)

jig

+0.1
74.6 0

(2.937 +0.004
0 )

103(4.06)
W Collar press fitting jig
(1.18)
30

34-25
34. TRAVEL SYSTEM

34.1.5.4 IDLER ADJUSTER ASSY

34.1.5.4.1 CONSTRUCTION

3*4! #*56%7! #%%& &'()*+++,-., % ! ( $ " ' ) #

'89 '#"! :;7& !"# $%

,< 2 !#%! A&43'*! ,
=< 1 #A$!7 ,
-< '67 ,
)< %B 3'2 B3' , /0/+
(< %B 3'2 ,
>< B3%7C' ,
$$ $&
?< AC44# ,
/ CD 3'2 , ,1 2/+ Fig. 34-54 Idler adjuster assy

@ C34 %!#4 ,
,+ B3' =
,, ACE! ,

34.1.5.4.2 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Spring set special jig 
M30
HOLDING-DOWN NUT

Before disassembling and assembling the idler RETAINER PLATE

adjuster assy, prepare spring setting jig (V).
Capacity of hydraulic jack : more than 20 tons
(44000 lbs)
V
: 46 mm
HYDRAULIC JACK

Large power is needed to set the spring. Prepare a

BASE
special jig before disassembly and assembly.
Fig. 34-55 Spring set special jig (V)
2) Preparation for working
Place a hydraulic jack between the jig base and
the stand. 2

Loosen the holding-down nuts of the jig and draw

out the retainer plate upward.

: 46 mm
3) Draw out grease cylinder (See Fig. 34-54) 
Draw out piston (6) from grease cylinder (1) of 5
the idler adjuster assy.
4) Removing oil seal (9), O-ring (8) (See Fig. 34-54) 
Remove oil seal (9) and O-ring (8) from grease
cylinder (1).
V
5) Slinging work idler adjuster
Set the idler adjuster assy on the stand of the jig, Fig. 34-56 Slinging work idler adjuster
with its bracket side facing up.

34-26
 34. TRAVEL SYSTEM

6) Fixing idler adjuster assy 

Fit retainer plate to bracket (2), tighten holding- 3
down nuts alternately, and secure idler adjuster
assy.

: 46 mm HOLDING-DOWN NUT

RETAINER PLATE
4
Fig. 34-57 Fixing idler adjuster assy
7) Compression of spring (5)
Remove spring pin (4), press spring (5) lifting it
with jack so that nut (3) can be turned freely, and
remove nut (3).
: Bar ø7.5u120

: 80 mm

Fig. 34-58 Compression of spring (5)

8) Removing bracket (2)
Allow the hydraulic jack to retract slowly till the
spring is extended to its free length. Remove the
retainer plate and take off bracket (2), cover (11). RETAINER PLATE
The free length of the spring : 540.1 mm (21.3 in)

2
11

Fig. 34-59 Removing retainer plate, bracket (2)

9) Removing spring (5), grease cylinder (1)
Hook lifting eye nut (W) to screw M52uP3 on
grease cylinder (1) top end and hoist it. Then, !
remove the set of grease cylinder (1) and spring
(5) using crane from the jig.
Remove spring (5), collar (7), grease cylinder
"
(1), in that order.

Fig. 34-60 Removing spring (5), grease cylinder (1)

34-27
34. TRAVEL SYSTEM

(2) Assembly 
Assembly is done in the reverse order of W
disassembly. 1
1) Installing spring (5), grease cylinder (1)
Insert grease cylinder (1), collar (7) into spring
5
(5) and attach lifting eye nut (W) to screw
M52uP3 at the tip of the grease cylinder. Lift the
grease cylinder by crane and erect it in the
center of the jig stand upright. 

2) Fixing idler adjuster assy 

Fig. 34-61 Attach spring (5) and grease cylinder (1)
to the jig
Install bracket (2), cover (11) on top of spring (5).
Center the rod of grease cylinder (1) and the
holes in bracket (2). Attach the retainer plate and
four holding-down nuts. Fasten the nuts evenly
all round and fix the idler adjuster assy to the jig
body.
(See Fig. 34-65)

: 46 mm
3) Compressing spring (5) and tightening nut (3)
HOLDING-
Extend the hydraulic jack, compress spring (5) to DOWN NUT
a set length and screw in nut (3) to the screwed
part at the tip of grease cylinder (1). RETAINER
PLATE
Set length of the spring : 429mm (16.9in)

2
4) Installing spring pin (4)
4
Tighten nut (3) till the holes for locking spring 3
pins (4) are aligned. Then fit spring pin (4).
11 7
: 80 mm 1

Fig. 34-62 Compression of spring (5), and attaching

nut (3) and spring pin (4)
5) Removing idler adjuster assy 
Remove idler adjuster assy from jig.

Fig. 34-63 Removing idler adjuster assy

34-28
 34. TRAVEL SYSTEM

6) Installing oil seal (9), O-ring (8)

1 9 8 6
Fit oil seal (9) and O-ring (8) to grease cylinder
(1).
• Grease oil seal (9) and O-ring (8).

7) Filling grease cylinder(1) with grease.

Fill up grease in cylinder (1), remove the grease
nipple from piston (6) to discharge the inside air,
and press in the piston by hand. GREASE NIPPLE
• Direct grease nipple hole downward to make Fig. 34-64 Grease cylinder (1)
air discharge easier.

8) Installing grease nipple

Tighten grease nipple to piston (6).

: 19 mm,
Tightening torque : 59 N•m (43 lbf•ft)

34.1.5.4.3 MAINTENANCE STANDARD

No. ITEM STANDARD VALUE

A Installed length of spring 429mm (16.9 in)
B Free length of spring Approx. 540.1mm (21.3 in)
C Stroke 51.8mm (2.04in)
D Set length 716mm (28.2in)
E Outside view of piston Nor scoring and rusting
Tightening torque of
F 59N•m (43 lbf•ft)
grease nipple

X
E

C
A, B F
X D Y

INSTALL A SPRING WHOSE STARTING POINT AT BRACKET SIDE TO BE 35 DEGREE.

BRACKET

DETAIL Y
SECTION XX

Fig. 34-65

34-29
34. TRAVEL SYSTEM

34.1.6 SPROCKET

34.1.6.1 REMOVING
(1) Preparation for removal
Remove crawler referring to "34.1.2 CRAWLER",
lift up crawler frame with attachment, and put it on
square timbers to float and stabilize.

Fig. 34-66 Preparation for removal

(2) Removing sprocket
Loosen 26 capscrews (2) M16u45, for the
attaching of the sprocket by means of a socket and
remove the sprocket (1).

Weight of sprocket : 48kg (106 lbs)

: 24 mm

Fig. 34-67 Removing sprocket

34.1.6.2 INSTALLING
(1) Check before installing 
Check the mating portion of the travel reduction unit
and the sprocket, eliminate burrs and
contamination thoroughly and install the sprocket.

(2) Installing sprocket temporarily

Coat the sprocket attaching capscrews with Loctite
#262 and fasten the sprocket temporarily.

(3) Installing sprocket completely

Remove the wooden blocks under the truck frame,
bring the machine down on the ground and tighten
the sprocket.

: 27 mm
Tightening torque : 279 N•m (206 lbf•ft)

Fig. 34-68 Installing sprocket completely

34-30
 34. TRAVEL SYSTEM

34.1.6.3 MAINTENANCE STANDARD (YN51D01003P1)

96.07mm NUMBER OF
PITCH 21
(3.78in) TEETH
SPECIFICATION
ø58.72mm 644.602
ROLLER DIA. PITCH DIA.
(2.31in) (25.333in)

C
Fig. 34-69 Sprocket

Unit:mm (in)
REPAIRABLE SERVICE
No. NAME STANDARD VALUE REMEDY
LEVEL LIMIT
Reinforcement weld,
A O.D. of sprocket ø 659 (25.9) ø 651 (25.6) ø 649 (25.6)
repair or replace.
B Width of sprocket teeth 66±2 (2.520±0.079) 60 (2.36) 58 (2.28) Replace.
Reinforcement weld,
C O.D. of sprocket bottom ø 586 (23.1) ø 578 (22.8) ø 576 (22.7)
repair or replace.

34.1.6.4 TOOLS AND JIGS

(1) Tools

Unit : mm
NAME OPPOSING FLATS

24
Socket

34-31
34. TRAVEL SYSTEM

(2) Sprocket tooth profile gauge : W

Unit : mm (in)

) "
. 2 36
(0 6
R
.7823)
96.07(3

Fig. 34-70 Tooth profile gauge (Full scale)

34-32
 34. TRAVEL SYSTEM

34.1.7 TRAVEL MOTOR

34.1.7.1 TRAVEL MOTOR

!"#$%% $""& &!'()***+,-+

!./ !$32 56#& 123$14"

( 7$8"7129 ', 3+<=''

0 #1$:2% 3;#;1 $""& , &!'()***+'-+

3
APPLY LOCTITE #262
OR EQUIVALENT
TIGHTENING TORQUE:
279 N.m(206 lbf.ft)

Fig. 34-71 Installing travel motor

34.1.7.2 REMOVING
(1) Preparation for removal
Remove crawler, lift up crawler frame using
attachment, and put it on square timbers to float
and stabilize.
(2) Removing cover (1)
Remove sems bolt (6) M12u25 and also remove
covers (1).
!
: 19 mm
(3) Preparation of oil pan
(4) Removing hydraulic pipe 
Release pressure from travel circuit, and bleed air Fig. 34-72 Removing and installing cover (1)
in hydraulic oil tank, then remove all pipes
connecting to travel motor. Then plug up all pipes
and joint section to protect them from entry of dust.

: 19mm, 27mm, 41mm

Refer to "Hydraulic pipe plug" 5.1
(See Chapter 11. TOOLS)
"Plug for flare hose" 5.2 (3) (See Chapter 11.
TOOLS)

Fig. 34-73 Removing and installing hydraulic pipe

34-33
34. TRAVEL SYSTEM

(5) Removing sprocket

Removing twenty two (one side) capscrews (2)
M18u55.

: 24 mm

Fig. 34-74 Removing and installing sprocket

(6) Loosening travel motor attaching bolts (3) REMOVE PIPES (DISCONNECT)
Apply match marks on travel motor and crawler
frame, and remove seventeen (one side)
capscrews (3) M20u60.

: 24 mm

Fig. 34-75 Removing and installing travel motor

attaching bolts
(7) Slinging travel motor assy
Sling travel motor with nylon sling applied on the
side close to sprocket installing section and remove
the motor.

Weight of motor : About. 260kg (573 lbs)

Fig. 34-76 Slinging travel motor

34.1.7.3 INSTALLING
Installing of the travel motor piping is performed in the '(()$ (, '%-*'#% -
reverse order of removal.
!"# $%&# *#+ '(./0#
,12345,567 .#"!.8$
1) Cleaning $#"$ :()' "@A @H B EI,G 2B@7 !;;)L
Check that contact surface of travel motor and )(9'%'#
crawler frame is free from burr and stain. 9!;$9.#< "@B AG I AJH 2ACB7 MABA
2) Tightening torque =)!.#)#$$ @C+@,D @H K GH2IB7
0' =(. @E+A,D IA K @GJ2@@C7
Tighten capscrew and hydraulic pipes to the ;%;#$> K AJD2ACC7
torque specified in "Tightening Torque". $)##?# AE G@
3) Fill inside from motor drain port to casing with *($# ;=@FG @H K AH,G2A@,J7
hydraulic oil before piping for drain. When
9!; ;=@FA AJ K JE,D2DJ,H7
;=@FG @H K IB,I2AJ7
starting operation, operate motor in low idling
9( #9'(. ;=@FA AJ K @CE2EC7
and at low speed for several minutes, and check
;=@ G@ K ADD2@HC7
it for possible oil leakage and noise.

34-34
 34. TRAVEL SYSTEM

34.1.8 SWING BEARING

34.1.8.1 SWING BEARING ASSY

!"#$ %&'("#$ ' ) )#*+,+++-.,/

#01 #'2& 456) (&2'(3
/ !"#$ %&'("#$ / )#*+,+++-8,/
- 9': 9(&! 78 2-+;:/1<;8<
FRONT A A

INNER S ZONE POSITION OF

SWING BEARING

SECTION AA

Fig. 34-77 Swing bearing assy

34.1.8.2 REMOVING
(1) Matchmarks
!"#$ %&'("#$
Remove upper structure, apply matchmarks on
inner race of swing bearing and lower frame. )*+&( (',&

(2) Remove 36 capscrews (2) M20u65 for installation

"##&( (',&
inner race. -'+,.-'(/
: 30 mm

(3) Removing grease 

Remove grease in grease bath.
Fig. 34-78 Matchmarks

(4) Removing swing bearing $+,- %"#!,-

Attach eyebolt on swing bearing and sling it. "(" %)*&

Weight of swing bearing : 243kg (536 lbs)

!"#$" %#&'

Fig. 34-79 Removing and installing swing bearing

34-35
34. TRAVEL SYSTEM

34.1.8.3 INSTALLING
(1) Cleaning
Clean it completely so that installing surfaces of
swing bearing and lower frame are free from dust
and dirt.
(2) Installing 
Install swing bearing on lower frame meeting the )#&!( - -

matchmarks and positioning the S mark on inner

race as shown in Fig. 34-80.
(3) Temporary fastening of inner race
Coat the threads of the capscrews (2) with Loctite
#262 and tighten all the capscrews (2) temporarily.

: 30 mm
!!"# $ %&!" '&$ ( &! &)
(4) Regular tightening of inner race $* !+ ,"-# !+

Tighten the capscrews (2) at 180 degrees intervals Fig. 34-80 Location of S mark on swing bearing
alternately to a specified torque.

: 30 mm, 
Tightening torque : 563 N•m (415 lbf•ft)
(5) Filling grease  )
Fill grease bath with 8.6kg (19 lbs) of grease NLGI-
2 (containing molybdenum disulfide) or equivalent. *&#$%$" + , &-
"./%0(*"'$
$& 1" (22*%"3
!"#$%&' (( $45,6'78 9:)5;<=7=>?

Fig. 34-81 Removing and installing capscrew (2)

34.1.8.4 CONSTRUCTION

'
!!" # $% &'( "&)*+***,-+.
! %
&/( & 01 23%" &/( & 01 23%"
#
. '6%1$ $ 71 . - !1 : .
&
, 8&&1$ $ 71 . ; % #1$ #8& . "
4 9 :: .,* < #:6> .
) $1% 8&1$ .,* = >$1 !1 &8##:1?#%.@<A . $
5 !1 : .
Fig. 34-82 Sectional view of swing bearing

34.1.8.5 DISASSEMBLY AND ASSEMBLY

(1) Disassembly
1) Remove seal (5) fitted in the groove in the outer EYE BOLT
6 2
circumference under inner race (2) and seal (6) 7
fitted in the groove in the inner circumference on
1
top of outer race (1) and place them level on a
SQUARE WOODEN
square wooden block or something. BLOCK
2) Remove taper pin (7), using a hammer and an
extrusion rod. 8
3) Remove plug (8), utilizing an pull bolt inserted in 5
the screwed hole (M10) in the center of the plug
and using a puller. Fig. 34-83 Disassembling swing bearing

34-36
 34. TRAVEL SYSTEM

4) While rotating outer race (1) little by little, take out

ball (3) and retainer (4) through plug hole, in that
order.

#
"
!
Fig. 34-84 Removing balls (3) and retainers (4)
(2) Installing
1) Thoroughly degrease the groove for seal (6)
located on the inner surface of outer race (1) and
the groove for seal (5) located on the outer
surface of inner race (2). Coat the grooves with 2
adhesive Cyano Bond PX-3000 equivalent, fit 3" 4 $'( 1
seal (5) and place it on a surface plate.
2) Lower outer race (1) to the position where upper 0
surface of inner race (2) and lower portion of seal !"#$% /
&''(%) *+',- .
groove is mated, put adjusting washer under
outer race (1) so that outer raceway surface of Fig. 34-85 Fitting balls (3)
ball (3) aligns with inner raceway, and support it.
! "#$%
3) Insert ball (3) and retainer (4), on which grease
is applied, through plug (8) hole on outer race
(1), alternately.
1##0 - +#-

To insert ball (3) and retainer (4), use a push rod, etc.,
to protect persons from injury from inserting fingers into &
plug hole. '()*+
,##- . "$#/0
4) Fit plug (8) to outer race (1) while checking it for Fig. 34-86 Fitting retainer (4)
direction and position of taper pin hole.
5) Coat seal (6) with adhesive Cyano Bond PX-
3000 equivalent and fit it in the groove of outer
race (1).
6) After completion of assembly, caulk the edge of
taper pin (7) by punching.
7) Check that grease nipple (9) is properly fitted,
and fill it with grease. Then, check bearing for
smooth rotation and flaws on seal lip portion.
• Shell Albania EP#2 ; 160cc (9.76cu•in)

34.1.8.6 MAINTENANCE STANDARD

Maintenance standard concerning wear of swing bearing is described in the section 13.6 MEASURING SWING
PERFORMANCES of "Maintenance Standard and Test Procedure" in this manual.

34-37
34. TRAVEL SYSTEM

34.2 REMOVAL AND INSTALLATION OF TRAVEL MOTOR UNIT

34.2.1 TRAVEL MOTOR

34.2.1.1 CROSS-SECTIONAL VIEW

SECTION B-B

C C

SECTION C-C

SECTION A-A

34-38
 34. TRAVEL SYSTEM

No. Parts Q'ty No. Parts Q'ty No. Parts Q'ty

1 Hub 1 Piston assembly 1 Rear flange assembly
3 Carrier [1] 1 161 • Piston 1 301 • Rear flange 1
4 Sun gear [1] 1 163 • Seal 1
5 Planetary gear [1] 3 162 Steel ball 1 • Spool assembly 1
6 Carrier pin [1] 3 102 Shaft 1 323 •• Spool 1
7 Carrier [2] 1 326 •• Plug 2
8 Sun gear [2] 1 Swash plate kit 1 327 •• Valve 2
9 Planetary gear [2] 3 103 • Swash plate 1 328 •• Spring 2
10 Carrier pin [2] 3 167 • Pivot 2 331 •• O-ring 2
11 Thrust washer [1] 6 107 Retainer plate 1 324 • Plug 2
12 Thrust washer [2] 6 108 Thrust ball 1 325 • Spring retainer 2
13 Thrust plate 1 109 Timing plate 1 329 • O-ring 2
14 Cover 1 112 Piston 1 330 • Spring 2
15 Coupling 1 113 Spring 8 363 • Spool 1
16 Parallel pin [1] 3 114 Spring 9 364 • Connector 1
17 Parallel pin [2] 3 115 Friction plate 3 365 • Pin 1
22 Lock washer 2 116 Separator plate 4 366 • Spring 1
23 Shim 1 119 Shim 1~2 367 • Spring retainer 1
24 Angular ball bearing 2 132 Oil seal 1 368 • G (PF) 1/4 plug 2
27 Needle-roller bearing 3 133 Snap ring (for hole) 1 369 • O-ring 2
28 Needle-roller bearing 3 135 D ring 1 370 • G (PF) 3/8 plug 1
29 Floating seal 1 139 D ring 1 371 • O-ring 2
30 Plug 3 149 Taper roller bearing 1 372 • Orifice 2
31 O-ring 3 150 Taper roller bearing 1 373 • Orifice spring 2
35 Socket bolt 18 374 • G (PF) 1/8 plug 5
36 Snap ring (for hole) 1 Relief valve assembly 375 • O-ring 6
201 • Valve seat 2 376 • M6 orifice 3
101 Spindle 1 202 • Valve 1 377 • Check valve 3
137 Socket plug 1 203 • Sleeve 1 378 • Check valve spring 3
138 Expander 1 204 • Plug 1 379 • O-ring 1
205 • Spring retainer 1 380 • O-ring 1
Piston kit 1 206 • Piston 1 341 • Parallel pin 1
• Piston assembly 9 207 • Spring 1 343 • Socket bolt 8
105 •• Piston 1 208 • Piston seal 1 345 • Socket plug 15
106 •• Shoe 1 209 • Piston seal 1
104 Cylinder block 1 210 • O-ring 1 399 Name plate 1

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34. TRAVEL SYSTEM

34.2.1.2 GENERAL FOR MAINTENANCE

34.2.1.2.1 Tools
(1) Standard tools

No. Tools Size Q'ty

3 (For M6), 4 (For PT1/16)
5 (For PF1/8), 6 (For PF1/4)
1 Allen wrench 1 each
8 (For M10 and PF3/8)
10 (For PF1/2), 14 (For M16)
Socket wrench
2 (Ratchet handle) 1
(JIS B 4641)
Dial type Approx. 50N•m (37lbf•ft)
Dial type Approx. 100N•m (74lbf•ft)
3 Torque wrench 1 each
Dial type Approx. 300N•m (221lbf•ft)
Dial type Approx. 400N•m (295lbf•ft)
Nominal 32 (O.D. 44mm
4 Adapter for torque wrench (1.73inch) or less), 46 Socket,  1 each
Nominal 3,4,5,6,8,10,14 Hex key
5 Torque wrench (Wrench type) Opposing flats 21mm (0.83inch) 1
6 Extension bar 150mm (5.91inch) 1
7 Hammer Various size 1 each
8 Plastic mallet L= Approx. 400mm (15.7inch) 1
Flat-bladed screw driver Approx. 50mm (2 inch) 
9 1 each
Approx. 150mm (6 inch)
For shaft 1
10 Snap ring
For hole 1
Lifting capacity 9800 N (7230 lbf) 1 set
Eye bolt for M16 (2)
11 Lifting tool Eye bolt for M10 (3)
Eye bolt for PF1/2 (2)
Wire with hook (1)
12 Leather gloves 1 set

(2) Apparatuses

Application item
Apparatus Size Remarks Q'ty
(Use or number of relevant parts)
Work bench for
Disassembly and assembly 1 set
general-use
For rough cleaning and
Cleaning the parts Cleaning bath 1 set
finish cleaning
Pressing capacity 9800 N
24 (Angular ball bearing) Work bench for press 1 set
(7230 lbf) or over
Pressure 0.29 to 0.49 MPa
Drying after cleaning Compressed air —
(42 to71 psi)

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 34. TRAVEL SYSTEM

(3) JIGS

Name: Work bench for travel motor

• This is used to disassemble and to assemble of travel motor
safely and securely.

Name: Fixing metal

• This is used to assemble spindle (101) and hub (1).

Name: Jig for installing lock washer

• Jig for installing lock washer (22) into groove of spindle
(101).

Name: Jig for press-fitting angular ball bearing

• Jig for press-fit angular ball bearing (24) into hub (1).

Name: Steel bar (I)

• This is used to remove angular ball bearing (24) from hub
(1).

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34. TRAVEL SYSTEM

Name: Long eye bolts

• These are used to lift travel motor, spindle (101) and hub (1).

"#$ !

%&' 5 67

()*+,-$ 5 67

./01$- 2343/ 5 67

Name: Spatula
• This is used to remove timing plate (109) from rear flange
(301).

Name: Jig for installing floating seal (I)

• This is used to install floating seal (29) into hub (1).

Name: Jig for installing floating seal (II)

• This is used to install floating seal (29) into hub (1) and
spindle (101).

Name: Jig for installing floating seal (III)

• This is used to install floating seal (29) into spindle (101).

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 34. TRAVEL SYSTEM

34.2.1.2.2 Tightening torque

Number of Bolt / Nut

relevant parts Opposing flats Tightening torque
Q'ty
(In cross-sectional Name Size mm (inch) N•m (lbf•ft)
view)
98.1±19.6
30 Plug PF1/2 10 (0.394) 3
(72.4±14.5)
57.9±9.81
35 Socket bolt M10 (P1.5) 8 (0.315) 18
(42.7±7.24)
13.7±1.37
137 Socket plug PT1/16 4 (0.1575) 1
(10.1±1.01)
157~177
204 Plug M27 (P1.5) 32 (1.2598) 2
(116~131)
304~324
324 Plug M38 (P1.5) 46 (1.811) 2
(224~239)
49.0~58.8
364 Connector PF3/8 21 (0.8268) 1
(36.1~43.4)
29.4±2.94
368 Plug PF1/4 6 (0.2362) 2
(21.7±2.17)
49.0~58.8
370 Plug PF3/8 8 (0.315) 1
(36.1~43.4)
14.7±1.47
374 Plug PF1/8 5 (0.1969) 5
(10.8±1.08)
230±23.0
343 Bolt M16 14 (0.5512) 8
(170±17)

34.2.1.2.3 Weight of component

Number of relevant parts

Components Weight kg (lb)
(In cross-sectional view)
Travel motor assembly Approx. 277 (610)
1 Hub Approx.79 (175)
101 Spindle Approx. 60 (130)
3 and others Carrier (ÇP) Assy Approx. 27 (60)
7 and others Carrier (ÇQ) Assy Approx. 47 (105)

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34. TRAVEL SYSTEM

34.2.1.3 DISASSEMBLY

34.2.1.3.1 Preparation
The following preparations must be made before disassembly.
(1) Preparing working bench
• Prepare work bench for travel motor.
• Prepare work bench which is sturdy for disassembly and assembly of the travel motor's inner parts and has
enough space to put the parts, and from which the possibility of the dropping and movement of parts is
eliminated.
• Cover the work bench with rubber sheet, vinyl sheet, etc.

(2) Preparing tools and materials.

Prepare the tools and materials which are specified in paragraph 34.2.1.2.1.

34.2.1.3.2 General cautions required to perform the work

The inner parts which are under disassembly may be easily slipped because they are coated by gear oil and
hydraulic oil.
Special attention must be given to the handling of parts which might fall and injure, and might be damaged.

When flammable like diesel oil or kerosene, etc. is used to wash and clean the removed parts, pay attention to the
handling so as not to start a fire and get burn because the flammable is tending to catch fire.

(1) Identify the items to be checked and the property of abnormalities detected rightly before disassembly, and carry
out the disassembly according to the specified procedure.
(2) Handle parts taking care so as not to collide each other and not to drop because the each part is precisely made.
(3) Do not strike or pry parts even if made by hard material, otherwise the assembly might be difficult due to burrs
and damage and may cause the deterioration of performance.
(4) If the parts removed or under disassembly are left, it may cause rusting of parts due to moisture and dusts. If it
is unavoidably necessary to suspend the work, do not fail to protect the parts form rust and dust.
(5) Mark the mating face of each part at the time of disassembly.
(6) Go ahead with the work while putting the removed parts in order so as not to damage or miss the parts during
disassembly.
(7) The removed seals, etc. must be replaced with new ones even if no damage is found. Prepare the spare parts
before starting disassembling.
(8) The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and
figure differs from those of products in use, it has not an effect on the disassembling procedure.

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 34. TRAVEL SYSTEM

34.2.1.3.3 Disassembling procedure

(1) Cleaning travel motor
1) Tighten eye bolt to the tapped hole for spindle (2), hang up the travel motor with hoist and carry it to washing
bath.

Tighten two eye bolts to the tapped holes for spindle in such locations that they are symmetrical each other.

2) Clean each section of travel motor with car washing brush.

Carefully clean the space between hub (1) and spindle (101) (floating seal fitting section) because earth and
sand might be entered.

(2) Installing travel motor

1) Put travel motor on work bench.

Align the thread hole of hub (1) to the threaded hole of work bench and softly insert the travel motor in
attaching hole of work bench.

2) Attach the travel motor on the work bench in such locations that two socket bolts are symmetrical each other.

Securely tighten the socket bolt. If not, there is a possibility of injury due to the drop of travel motor when it
has been turned over.

(3) Draining lube oil.

1) Lay the travel motor horizontally. (Direct the drain port downward.)
2) Loosen oil filler plug (30) and release the pressure in the reduction unit, and then lightly tighten the plug
again.

If the pressure is applied to the inside of reduction unit, lubricating oil may be gushed out when loosening
the plug of drain port.

3) Put the oil pan under the top end of drain port and slowly loosen the plug of drain port and then drain
lubricating oil.

Prepare the oil pan of which the capacity is sufficient for the lubricating oil quantity specified to the reduction
unit, 5.3L.

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34. TRAVEL SYSTEM

4) If it is hard to drain lubricating oil, slowly loosen and remove the plug of oil filler port.
5) Remove O-ring (31) from the removed plug.

Do not use the removed O-ring (31). It may cause oil leak.

(4) Removing cover

1) Turn over travel motor. (Direct reduction unit
upward.)
2) Loosen and remove bolt 18-M10.
3) Since the sealant is used on the mating faces of
cover (14) and hub (1), apply a protecting plate
to the cover obliquely and remove the cover
while striking it upward.

Be careful about the cover which might be sprung up

when striking the cover obliquely upward. Pay attention !"# $"%&'() *+ ,*&*( -"++)(# +(*, .%&'./ ,*&*(0
to the cover which might be drop on foot, etc.

4) Attach eye bolt to the PF1/2 port and hang up

and move the cover from the hub.

(5) Removing 1st gear

1) Attach eye bolts to 3 tapped holes M10 for carrier
[1] (3) and hang up and move carrier [1]
assembly by hoist.

When lifting carrier [1] assembly, slowly lift it directing

center shaft of hub and carrier [1] assembly upright to
protect the internal gear of hub from being damaged by
the edge of planetary gear [1] (5).

2) Lift and remove sun gear [1] (4) by hand.

Pay attention to sun gear [1] in order not to drop

because it is slippery because of lubricating oil applied.

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 34. TRAVEL SYSTEM

(6) Removing 2nd gear

1) Attach eye bolts to 3 tapped holes M10 for carrier
[2](7) and lift and move carrier [2] assembly by
hoist.

When lifting carrier [2] assembly, slowly lift directing

center shaft of hub and carrier [2] assembly upright to
protect the internal gear of hub from being damaged by
the edge of planetary gear [2] (9).

2) Lift and remove sun gear [2] (8) from carrier [2]
assembly by hand.

Pay attention to sun gear [2] in order not to drop

because it is slippery because of lubricating oil applied.

(7) Removing coupling

1) Remove coupling (15) from shaft (102).

(8) Removing lock washer

1) Direct the spindle side upward.
2) Secure it in shaft direction with special jig to
protect the spindle from dropping out by making
use of threaded hole M16 of hub (1) and spindle
(101).

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34. TRAVEL SYSTEM

3) Apply flat-blade driver or equivalent to the space

between two lock washers (22) and remove it
while striking the driver obliquely downward.

(9) Removing spindle

1) Direct the spindle side upward.
2) Remove the special jig used to secure hub and
spindle.
!"# $"%&'() *+ ,*&*( -"++)(# +(*, .%&'./ ,*&*(0
3) Attach eye bolt to spindle and lift the spindle by
hoist.

Slowly lift the spindle in parallel with the shaft of

hub. If the spindle is obliquely lift, a large force
which might cause the breakage of the hoisting
accessory, eye bolt, etc. is applied resulting in
injury by being hit by the hoisting accessory. When
it is hard to pull it out, do not be forced to lift, but
use press, etc. to pull it out safely.

(10) Removing floating seal

1) Touch the inner side of floating seal (29) by hand,
and remove it pushing upward.

There is a case where the edge of floating seal cuts

your finger. We recommend using glove when
removing it. And when it is stuck due to the intrusion of
mud, remove it using screw driver as a lever.

!"# $"%&'() *+ ,*&*( -"++)(# +(*, .%&'./ ,*&*(0

(11) Removing angular ball bearing
1) Apply iron bar to the inner ring of angular ball
bearing (24) and remove it little by little while
striking 3 or 4 points divided into equal divisions
on the circumference by hammer.

If the inner ring is struck, the raceway surface may be

damaged, and consequently the reuse of ball bearing
might be impossible. Therefore the angular ball bearing
should be removed only when required to be replaced.

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 34. TRAVEL SYSTEM

(12) Removing rear flange assembly

1) Directs rear flange (301) upward.
2) Loosen 8 socket bolts (348) and remove rear
flange.

3) Remove rear flange from spindle (101).

When the rear flange is removed by both hands, pay

attention to timing plate (109) and spring (113) so as not
to drop.

When disassembling the parts of rear flange section,

loosen each plug before loosening socket bolts used to
secure rear flange [operation of (12) 2] to facilitate
going ahead with the disassembly which is carried out
later.

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34. TRAVEL SYSTEM

(13) Removing taper roller bearing

1) Secure sliding surface of cylinder block (104)
with fixing plate.

Insert rubber-like cushioning material between cylinder

block sliding surface and fixing plate giving attention to
the sliding surface of cylinder block so as not to
damage.

2) Apply puller axis to the center hole of shaft (102)

and hook claw to the inner ring of taper roller
bearing (150).
3) Pull the taper roller bearing out of the shaft while
slowly turning the axis of puller with spanner, etc.
Put rear flange (301) on work bench while
directing the mating face with spindle (101)
upward.

When the retainer (cage) of the taper roller bearing is

accidentally damaged by puller, replace the retainer
(cage) with new one.

(14) Disassembling parking brake

1) Pull the piston out making use of the threaded
hole M6 of piston (112).

2) Turn work bench sideways.

3) Remove separator plate (116) and friction plate
(115).

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 34. TRAVEL SYSTEM

(15) Disassembling rotary section

1) Pull out cylinder block, piston (105) and retainer
plate (107) together.

2) Remove swash plate (103).

3) Remove shaft (102).

Slowly pull the shaft out being care not to damage the
lip of oil seal (132).

(16) Removing piston

1) Apply cloth on piston (161), blow air through the
drilled hole and remove the piston of spindle
(101).

34-51
34. TRAVEL SYSTEM

34.2.1.4 SERVICE STANDARDS

Disassemble GM motor according to this standard. At this time do not damage the moving and sliding part.

34.2.1.4.1 Seals
Replace all seals (O-ring, oil seal, floating seal with new one) once used even if no damage is seen.

34.2.1.4.2 Wear parts maintenance standard

(1) Replace any part that shows damage on appearance.
(2) Replace such parts that show the following abnormalities, as well.

Reference Allowable
Item No. Parts Trouble
value value
• Severe damage to appearance.
(1) Hub • Pitting occurs on tooth surface of ring gear. — —
• Abnormal wear such as scoring is present.
• Severe damage to appearance.
(101) Spindle — —
• Abnormal wear such as scoring is present.
(3)
Carrier assembly • Abnormal wear such as scoring is present. — —
and other
(4) Sun gear 1
(8) Sun gear 2 • Pitting occurs on tooth surface of gear.
— —
(5) Planetary gear 1 • Flaking is seen on race of bearing.
(9) Planetary gear 2
(11) Thrust washer 1 • Discoloration and abnormal wear appears
— —
(12) Thrust washer 2 on the sliding surface.
• Dent is present.
(24) Angular ball bearing • Flaking is seen. — —
• Uneven wear is present.
• Pitting occurs on roller.
(27) Needle-roller
• Abnormal wear is present on the end of — —
(28) bearing
cage.
• Sliding part is damaged due to valve (263)
(301) Rear flange — —
motion.
• Contact face between shaft and oil seal
(102) Shaft (132) was worn. — —
• Spline was worn.
(103) Swash plate • Seizure is present. — —
• Spline is worn.
• Bore surface is worn badly.
(104) Cylinder block — —
• The face between sliding surface and timing
plate (109) was scored or worn unevenly.
Clearance on Clearance on
• Clearance is present in the axial direction
Piston assembly diameter 0 to diameter 0 to
(105) between piston and shoe.
piston shoe 0.05mm 0.2mm
(106) • Shoe is worn abnormally and unevenly.
(0.002inch) (0.008inch)
• Deformation is present.
(107) Retainer plate • The sliding surface between thrust ball (108) — —
and plate is scored and worn unevenly.

34-52
 34. TRAVEL SYSTEM

Reference Allowable
Item No. Parts Trouble
value value
• The sliding surface between retainer plate
(108) Thrust ball (107) and spherical sliding part is worn — —
unevenly.
(109) Timing plate • Sliding surface is seized or worn unevenly. — —
• Both end face are worn unevenly. Braking torque Braking torque
(115) Friction plate
• Special torque can not be reached. 470N•m 470N•m
(116) Separator plate
• Seizure is seen. (347lbf•ft) (347lbf•ft)
(112) Piston
• Outer circumstance is scored.
(135) D ring — —
• Wear or nibbling are seen on D ring.
(139) D ring
• Dent is present.
(149)
Taper roller bearing • Flaking is seen. — —
(150)
• Uneven wear is present.
(161) Piston
• Wear or nibbling are seen on seal. — —
(163) Seal
(323) • Outer circumstance is scored.
Spool — —
(363) • Outer circumstance is worn unevenly.

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34. TRAVEL SYSTEM

34.2.1.5 ASSEMBLY
The assembly is carried out by the reverse procedure of disassembly.

34.2.1.5.1 Preparation
Prepare work bench, tools and materials similarly to the disassembly specified in paragraph 34.2.1.3.

34.2.1.5.2 General caution necessary to perform the work

(1) Pay attention to the same general caution as the disassembly explained in paragraph 34.2.1.3.
(2) On assembling, remove metal chips and foreign matters from all parts and make sure that parts are free from
burr, dent, etc. If burr and dent are found, remove them by means of oil stone.
(3) Replace O-ring, oil seal and floating seal with new one.
(4) Remove adhesive left on the threaded hole of hub (1) by passing tap M10uP1.5 through the hole. Then clean
and degrease the threaded hole, and blow air to remove cleaning fluid.
Replace socket bolt (7) with new one.
(5) Use care about O-ring, oil seal and floating seal when fitting them so as not to damage. (Apply grease in small
amounts to smooth.)
(6) Be sure to apply clean hydraulic oil (NAS grade 9 or more) to the moving parts and sliding parts provided on the
hydraulic motor and valve before assembling.
(7) Do not use cloth glove during assembling work. (To prevent malfunction due to lint of fiber)
(8) Torque bolts and plugs to values specified in paragraph 34.2.1.2.2 "Table of Torque".
(9) At the time the assembly was completed, plug all ports to prevent dust entering.
(10)The pictures and figures carried in this document are taken by typical models. Even if a part of the picture and
figure differs from those of products in use, it has not an effect on the assembling procedure.

34.2.1.5.3 Assembling procedure

• Remove adhesive adhered on female thread hole M10 of hub (1) by means of tapping.
• Remove sealant adhered on mating surface of hub (1) and cover (14) with scraper, grindstone, etc.
• Sufficiently clean all parts in cleaning bath before assembling.

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 34. TRAVEL SYSTEM

(1) Assembling spindle

1) Set spindle (101) on work bench.
2) Fit outer ring of taper roller bearing (149) into the
center hole of spindle.
3) Place piston (161) in the cylinder hole of spindle.
4) Place steel balls (162) in piston hole.

Apply grease to the steel ball to fix on the piston hole to

be sure the steel ball does not drop out of the piston
during assembly which will be carried out later.

5) Attach L side of pivot (167) to the left side in the

picture.
6) Insert shaft (102).

Apply grease to spline of shaft and slowly insert it taking

care not to damage the lip of oil seal.

(2) Assembling rotary section

1) Apply grease to the sliding surface of swash
plate (103) and pivot.
2) Tilt the swash plate and place it in spindle.

• Make sure that the speed is changed in High and

Low smoothly while blowing air through the drilled
hole after assembling the swash plate in.
• Apply clean hydraulic oil to the sliding surface of
swash plate.

3) Turn work bench sideways.

4) Set cylinder block (104), piston (105), spring
(114), thrust ball (108) and retainer plate (107)
and insert it in the shaft.

• Apply clean hydraulic oil to the sliding surface of

cylinder block, piston, thrust ball and shoe (106).
• On inserting cylinder block assembly in the shaft, fix
the reduction unit side of shaft first and the insertion
can be performed smoothly.

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34. TRAVEL SYSTEM

(3) Assembling parking brake

1) Direct rear flange attaching face of piston
upward while turning the work bench.
2) Install separator plate (116), friction plate and
separator plate in that order.

3) Apply soft metal bar to piston (112) and insert it

in spindle (101) while striking the bar with a
hammer.

Strike 3 or 4 points divided into equal divisions on the

circumference of piston in order and assemble it in the
condition where the piston is held in level because the
sliding surface might be damaged if the piston is largely
tilted.

(4) Assembling taper roller bearing

1) Push taper roller bearing (150) on which the
outer ring has been removed against shaft (102),
and then apply metal bar to the inner race and
insert it while striking the bar with a hammer.

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 34. TRAVEL SYSTEM

(5) Adjusting clearance of taper roller bearing

When spindle (101), shaft (102), rear flange (301) or

taper roller bearing (149) (150) is replaced, adjust the
clearance of taper roller bearing. When the clearance is
improper, the life of taper roller bearing might be
shortened.

1) Direct the mating surface with the rear flange of

spindle (101) upward.
2) Press taper roller bearing (150) into shaft (102)
while striking it with plastic hammer.
3) Measure dimension A.
4) Measure dimension B of rear flange (301).
5) Subtract dimension A from dimension B, and
select shim (119) which makes the clearance to
0~0.17mm (0~0.0067in).

(6) Assembling rear flange

1) Place shim and outer race of taper roller bearing
(150) in the center hole of rear flange (301) in
that order.
2) Install timing plate to rear flange so that parallel
pin (341) which is press-fitted in the rear flange
aligns with the hole on the perimeter of timing
plate (109).
3) Install spring (113) into the hole of rear flange.

Apply grease to timing plate and spring to prevent the

parts from missing when the rear flange assembly is
assembled to the spindle.

4) Make sure those O-rings (375), (379), (380) are

fitted into O-ring grooves of rear flange.

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34. TRAVEL SYSTEM

5) Turn work bench sideways.

6) Install rear flange.

7) Tighten socket bolt (343) to the specified torque.

When the parts of rear flange are disassembled, tighten

each plug to the specified torque.

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 34. TRAVEL SYSTEM

(7) Assembling hub

1) Place hub (1) on press work bench. PRESS
2) Install angular ball bearing (24) in the hub, place
ball bearing press fitting jig on the outer race of HUB
angular ball bearing, and press fit it in the hub by JIG FOR PRESS-FITTING
ANGULAR BALL BEARING
means of press.
3) Turn over the hub.
4) Press fit angular ball bearing in the hub by the
same procedure as that described in above 2).
BALL BEARING
STAND

Pay attention to the direction of ball bearing (24) to be

attached.
JIG FOR !
INSTALLING F/S (II)
5) Place the hub on work bench and fix it.

JIG FOR !
INSTALLING F/S (I)

FROATING !
SEAL (F/S) HUB

6) Apply grease to O-ring of floating seal (29), and

fit floating seal into floating seal groove of hub
(1).
7) Similarly, fit floating seal into floating seal groove
of spindle (101).

• When applying grease to O-ring of floating seal,

take O-ring out of floating seal and apply thin coat
of grease to perimeter of O-ring.
• Remove jig F/S (I) for installing floating seal and
make sure that spindle groove end face is in
parallel with floating seal surface within the range of
1mm. When it is not in parallel, it might cause
leaking oil and seizure. Perform the procedure from
the first again.

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34. TRAVEL SYSTEM

(8) Adjust clearance of angular contact ball bearing

When hub (1), angular ball bearing (24) or spindle (101)

is replaced, do not fail to adjust the clearance. When
the clearance is improper, the life of angular ball
bearing might be shortened.

1) Temporarily attach lock washer (22) to spindle,

and measure dimension C.

2) Measure bearing width D of angular ball bearing

as shown in figure.

Turn hub and angular ball bearing several times to

make the bearing level.

3) Subtract dimension D from dimension C and

select shim (23) which makes the clearance
within -0.08~+0.02mm (-0.0031~+0.0008in).
(9) Assembling spindle :
1) Fit shim (23) in spindle (101) with grease.
2) Align the lifted spindle with the center shaft of
hub (1) and insert the spindle in angular ball
bearing (24) while lowering the spindle slowly.

3) Tighten and secure it with special jig making use

of the threaded hole M16 of hub and spindle.
4) Direct the reduction unit upward while turning
work bench.
5) Apply metal bar to the inner race of angular ball
bearing on the reduction side and strike it lightly
by means of hammer to make the inner race
level.

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6) Fit lock washer (22) to the groove of spindle.

7) Press lock washer into the groove of spindle by

means of jig.

Be sure to press lock washer into the groove bottom to

prevent the interference with the lock washer when
placing carrier [2] (7) in.

8) Direct spindle upward while turning work bench.

9) Remove special jig which is used to fix hub and
spindle.
10) Turn spindle several times.

The sliding surface of floating seal fits surface of hub

and spindle by turning the spindle. This results in
prevention of imitated oil leaks at test run.

(10)Assembling 2nd stage gear

1) Assemble coupling (15) to shaft (102).

2) Hoist carrier [2] assembly. And install it in hub (1).

When placing carrier [2] assembly in, align the center

shaft of carrier [2] assembly with the hub and lower it in
slowly giving attention to the internal tooth of hub in
order not to be damaged by the edge of planetary gear
[2] (9).

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34. TRAVEL SYSTEM

Locate planetary gear [2] and the port of flange as

shown in the figure.

PLANETARY GEAR (2)

(11)Assembling 2nd stage gear

1) Hoist carrier [1] assembly. And install it in the hub
(1).

When placing carrier [2] assembly in, align the center

shaft of carrier [2] assembly with the hub and lower it in
slowly giving attention to the internal tooth of hub in
order not to be damaged by the edge of planetary gear
[1] (5).

2) Place sun gear [1](4) in while being matched to

the spline of coupling.

In cases where it is hard to place sun gear [1] in

because the spline of sun gear [1] interferes with the
gear tooth of planetary gear, lift carrier [1] assembly
once until the connection of coupling to sun gear [2](8)
comes off and place sun gear [1] in again.

3) Place thrust plate (13) in carrier [1](3).

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 34. TRAVEL SYSTEM

(12)Assembling cover
1) Apply sealant "Loctite #515" to the surface of
hub in contact with the cover.

Apply sealant throughout the end face of hub (1) as

shown in figure.

2) Place cover on hub to the position of bolt hole.

3) Tighten socket bolts (35) to the specified torque.

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34. TRAVEL SYSTEM

(13)Lubricating
1) Fill lubrication oil through filling port.

2) Tighten plug (30) to the specified torque at

respective ports.

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