4 Power Transmission

Service Information
Document Title: Function Group: Information Type: Date:

Power transmission, 400 Service Information 2014/6/13
description
Profile:
EXC, EC220D L [GB]
Power transmission, description

The excavator's power transmission is a generic name of all components that transmit motive force to perform the various
functions of the excavator.
The mechanical power from the engine transmitted via the pump coupling is converted to hydraulic power by the main
pumps. Hydraulic power from the main pump goes to the travel motors, swing motor and hydraulic cylinders via the main
control valve, where it is converted back to mechanical power, that actuates the travel action, swing action and attachments.
The reduction gears of the planetary mechanisms convert the high speed rotation of the hydraulic motor into low speed,
high torque rotating force, at the track unit / sprocket for travel, and at the swing unit / ring gear for swing.
The center passage 360° rotating unit allows high pressure hydraulic flow from the main control valve to the track motors.
The unit rotates with the superstructure without twisting hoses therefore oil flow is not obstructed by swing.
Service Information

Function description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Function description
Track gearbox consists of a two stage planetary mechanism that converts the high speed rotation of the hydraulic motor,
into low speed, high torque rotating force at the sprocket hub.
See 990 Hydraulic diagram, travel.
Gearbox, torque flow
The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear → spline of 1st carrier
→ 2nd sun gear → 2nd planetary gear → ring gear.
At this time, the reduction ratio of reduction gear is as follows :
Reduction ratio
1st reduction ratio
i1 = ((Zs1 + Zr) · (Zs2 + Zr) / (Zs1 · Zs2)) - 1
Figure 1
Track gearbox, torque flow
 Zs1 = No. of tooth of 1st sun gear

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

Track gearbox, description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track gearbox, description

Track gearbox consists of a two stage planetary mechanism that converts the high speed rotation of the hydraulic motor,
into low speed, high torque rotating force at the sprocket hub.
Figure 1
2 stage planetary gearbox
1. Track motor
2. No.1 planetary gear assembly
4. Ring gear
Figure 2
Port connections
1. Oil level check and oil filling port (PF 3/4): 186 Nm (19 kgf m)
2. Oil drain port (PF 3/4): 186 Nm (19 kgf m)
3. High speed
4. Low speed
Port connections
Port symbol Port size Port

(A), (B) 1-5/16-12 UN Oil supply (return)
(P2), (P3) PT 1/4 Pressure check
(P5) PT 1/8 Parking brake release pressure
Parking brake can be released manually when supply pressure minimum 1.47
MPa (14.99 kgf cm2) (213.2 psi) (14.7 bar) to port P5.
(P) 7/16-20 UNF Displacement changeover valve oil supply
(D1), (D2) 3/4-16 UNF Motor drain
Rotational direction
View from E axis Inlet Outlet

Clockwise A B
Counterclockwise B A
Figure 3
Track gearbox, sectional view
1 Housing 13 No.2 needle bearing 25 No.1 pin

2 Angular bearing 14 Thrust washer 26 Spring pin
3 Seal 15 No.2 pin 27 No.1 sun gear
4 Shim 16 Spring pin 28 Cover
5 Retainer 17 Thrust ring 29 Pad (thrust)
6 Screw 18 No.1 planetary gear assembly 30 Screw
113 Nm (11.5 kgf m) 132 Nm (13.5 kgf m)
7 Parallel pin 19 No.1 carrier 31 –
8 Ring gear 20 No.2 sun gear 32 Plug
186 Nm (19 kgf m)
9 Coupling 21 Retaining ring gear 33 Name plate
10 No.2 planetary gear assembly 22 No.1 planetary gear 34 O-ring
11 No.2 carrier 23 No.1 needle bearing
12 No.2 planetary gear 24 Thrust washer
Figure 4
Track gearbox, exploded view
The power transmitted from the hydraulic motor output shaft is transmitted to the 1st stage sun gear (27) → spline of 1st
carrier (19) → 2nd sun gear (20) → 2nd planetary gear (12) → ring gear (8).
Figure 5
Track gearbox, torque flow
At this time, the reduction ratio of reduction gear is as follows:

(1) 1st reduction ratio
i1 = ((Zs1 + Zr) · (Zs2 + Zr) / (Zs1 · Zs2)) - 1
 Zs1 = No. of tooth of 1st sun gear

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

Track gearbox, Service Information 2014/6/13
maintenance standard
Profile:
EXC, EC220D L [GB]
Track gearbox, maintenance standard

Track gearbox, maintenance standard
The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier (s) together, do not mix the bearings, gears, pins and thrust washers.
Seals
Replace the seals and O-rings, although they appear not damaged.
Part replacement criteria
Replace all parts that appear damaged or are not within the allowable value.
Replace some parts in sets, i.e. gears, bearings, pins and thrust washers.
No. Part Condition Allowable value

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

1 Socket wrench 19 mm (0.75 inch) 1
2 L wrench 5 mm (0.2 inch) 1
10 mm (0.39 inch)
12 mm (0.47 inch)
3 Torque wrench 39 ~ 177 Nm (29 ~ 130 lbf ft) 1
4 Eye bolt PF 3/4 2
M10
M12
5 Plastic hammer Approximately L = 300 ~ 500 mm (11.8 ~ 19.7 inch) 1
6 Screwdriver Approximately L = 200 mm (7.9 inch) 1
7 Depth gauge Range approximately 300 mm (11.8 inch) 1
(Vernier calliper) Minimum scale 0.01 mm (0.00039 inch)
Track gearbox, precautions for operation
Installation
Figure 1
Mounting location
A. Main body mounted area

B. Sprocket mounted area
 Check that the mating mount surfaces are clean.

 Check that the motor is positioned correctly in the frame.
 If the gearbox to frame fit is tight, draw the assembly into the frame evenly with the mounting screws.
 Tighten the screws in a crisscross pattern in several stages to the specified torque.
 Apply these same precautions when mounting the sprocket.
Tightening torque
Tightening torque
Reduction screw (A). See 700 Undercarriage, tightening torque

Sprocket screw (B). See 700 Undercarriage, tightening torque
NOTE!
The screws must be 10.9 KS strength classification or above.
Lubricating oil
NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
NOTE!
Gear oil specification
Use a gear oil equivalent to API classification GL-4 or GL-5, SAE 90.
Gear oil replacement period
 First (initial) oil replacement: 500 operating hours

 Subsequent oil replacement: 2000 operating hours
 After maintenance (initial): 250 operating hours
NOTE!
Regardless of the operating hours the gear oil must be replaced at least once per year.
NOTE!
Do not mix different types, classifications or brands of oil.
NOTE!
Drain the gear oil while it is still warm to flush out any contaminants.
Gear oil replacement procedure
Figure 2
Oil replacement location
1. Level check port and fill port

2. Drain port
 Rotate the gearbox until the drain plug is the lowest position on the ground.
 Remove the 2 plugs and drain the oil into a suitable container.
 Ensure that the drain plug O-ring is not damaged, then install the plug with specified tightening torque.
 Refill the gearbox through the fill port until oil exits from the level check port.
 Ensure that the O-ring on each plug is not damaged, then install the plugs with specified tightening torque.
NOTE!
Oil capacity. See 4311 Track gearbox, specifications.
Operating checks
 Check the oil level prior to operating the travel function.

 Check for oil leakage on the gearbox assembly.
 Check for loose mounting screws.
 Check for abnormal sound or vibration while rotating.
 Check for any abnormal temperature increase after operating for a short time.
WARNING
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.
NOTE!
The temperature of the case must be lower than 90 °C, during continuous operation.
Remove air in the track motor before operating.
1. Check that the gearbox axis is horizontal. Rotate the gearbox housing until the drain plug is on the bottom of the
vertical axis of the end cover.
The gearbox is supplied with oil plugs (draining, filling and level) equipped with an hole that allows the air to bleed.
NOTE!
Remove the oil plugs with care. When the gearbox is warm, the air inside can be pressurized and this can cause
their strongly expulsion towards the worker.
2. Loose with caution the plugs (2~3 rounds) counterclockwise.
3. Clean the plug to be sure that the air bleed hole is not obstructed.
4. Wait a few seconds to allow the pressurized air to bleed from the gearbox.
5. Remove the plugs and let the oil flow in a large enough container; in order to facilitate the draining must be oil still
warm.
6. Wait a few minutes until all the oil is drained and then proceed to screw on the plugs.
7. Proceed with the oil fill-up following the procedures given.
NOTE!
Never mix mineral oils with synthetic oils and vice versa.
Do not dispose of the oil in the natural environment but be careful to eliminate it in compliance with the relative rules and
regulations that govern locally.
Tightening torque plug. See track gearbox, description.
Track gearbox, troubleshooting
Gearbox does not rotate. Motor overloaded. Reduce the load.
Gearbox is damaged. Replace the gearbox.
Oil leakage from mating joint Liquid gasket improperly applied. Disassembly and re-apply.
surfaces.
Mating surface damaged. Repair or replace.
Loosen screws. Tighten to specified torque.
Loosen plug. Tighten to specified torque.
Casing leakage. Cracks or pin holes. Replace the housing.
Cover damaged. Replace the cover.
Track gearbox, troubleshooting
Floating seal leakage. Sliding surface worn. Replace the floating seal
assembly.
O-ring distorted.
Abnormal operating temperature. Insufficient gear oil. Refill to specified level.
Gear or bearing damaged. Replace the gearbox.
Hydraulic and gear oil mixed. Replace the motor oil seal.
Abnormal operating sound. Gearbox is damaged. Replace the gearbox.

Service Information

Track unit, replacing Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track unit, replacing

Op nbr 431-127
14566479 Pin kit

14560748 Track pin press
14548448 Pump
1. Park the machine in the service position F. See 091 Service positions.
2.  When the engine is running, the hydraulic line is under high pressure. Stop the engine, and remove the
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with the
ignition switch at "ON" position. Turn the ignition switch to "OFF" position.
 Remove the residual pressure inside the hydraulic tank by pressing the air breather on the hydraulic tank.
 After disconnecting the hose, install a plug to prevent oil leakage and contamination.
3.
Figure 1
Removal, sprocket
1. Track link
2. Track frame
3. Wood block
4. Sprocket
5. Screws
Remove the track shoes over the master pin and remove the pin to split the track chain. Insert a bar into the track
link to guide the track assembly. Rotate the track backward to remove the track chain from the drive sprocket.
See 7753 Track chain assembly, removing to remove the master pin and the track chain.
4. Raise the sprocket and insert block between track frame and link to support the undercarriage.
5. Remove the screws rotating sprocket and remove sprocket carefully.
6. Remove the screws and motor cover.

Figure 2
Removal, motor cover
1. Screws
2. Motor cover
7. Remove the track motor high pressure hoses.
Figure 3
Removal, hoses
1. High pressure hoses

2. Drain hose
3. 2nd speed hose
8. Remove the track motor drain hose.
9. Remove the track motor 2nd speed hose.
10. Remove the fittings.

Figure 4
Removal, fittings
1. Fittings
11. Hold the track unit with hoist and remove mounting screws of the track unit from track frame.
Figure 5
Removal, mounting screws
1. Hoist
2. Screws
3. Track frame
12. Lift the track unit with hoist, and lower to the workbench safely.
Figure 6
Removal, track unit
1. Hoist
2. Track unit
13. Install a new track unit in reverse order of the removal procedure.
14. Lift the track chain onto the drive sprocket, insert a bar into the track link to guide the track assembly. Rotate the
track forward until the master pin link is at the idler. Install the master pin and the track shoes.
See 7753 Track chain assembly, installing to install the master pin and the track chain.
15. Check the operation of the track and motor.

Service Information

Track gearbox, replacing Service Information 2014/6/13
cover
Profile:
EXC, EC220D L [GB]
Track gearbox, replacing cover

Op nbr 431-117
1. Park the machine in the service position B See 091 Service positions.
Rotate the gearbox until the drain plug and fill plug are on the vertical axis.
2. Remove the plugs on the cover and drain the oil into a suitable container.
NOTE!
Prepare container for collecting hydraulic oil.
Figure 1
Removal, plugs
1. Track gearbox cover

2. Level check port
3. Fill and drain port
3. Remove the gearbox cover screws.
Figure 2
Removal, screws (1)
4. Remove the gearbox cover from track gearbox.
WARNING
The parts are heavy. Take appropriate safety cautions when handling them.
5. NOTE!
Thoroughly clean the mounting surface.
Install the new gearbox cover to the track gearbox.

NOTE!
Before replacing cover, apply sealing compound to the mounting surface.
Figure 3
Applying, sealing compound
1. Track gearbox cover

2. Sealing compound
6. Install the level check port and tighten it to the specified torque.
Figure 4
Installation, level check port plug (1)
7. Fill the oil through the fill port until oil exits from the fill port. See 4311 Track gearbox, specifications.
8. Install the fill plug and tighten them to the specified torque. See 4311 Track gearbox, description.
Service Information

Track gearbox (removed), Service Information 2014/6/13
replacing floating seal
Profile:
EXC, EC220D L [GB]
Track gearbox (removed), replacing floating seal

Op nbr 431-115
8932-00290 Measuring plate
Tool: 14630696 Drift plate
1. Remove the 2 plugs on the cover and drain the oil into a suitable container.
Figure 1
Removal, cover

2. Drain port
3. Screw
4. Cover
NOTE!
Prepare container for collecting hydraulic oil.
2. Remove the screws and cover.
3. Remove the No.1 planetary gear assembly.

Figure 2
Removal, No. 1 planetary gear assembly (1)
4. Remove the No.1 sun gear and coupling.
Figure 3
Removal, No.1 sun gear (1) and coupling (2)
5. Screw the eye bolts into ring gear, and remove ring gear using a plastic hammer.
Figure 4
Removal, ring gear (1)
6. Remove the No.2 planetary gear assembly.

Figure 5
Removal, No.2 planetary gear assembly (1)
7. Remove the screws, retainer and the shim.
Figure 6
Removal, screws (1) and retainer (2)
8. Screw the eye bolts into housing and then remove housing.
NOTE!
When difficult to remove, lift the body vertically and tap lightly with a plastic hammer.
WARNING
The parts are heavy. Take appropriate safety precautions.
Figure 7
Removal, housing (1)
9. Replace the seal from housing.

Replace the seal from motor casing.
NOTE!
After replacing the seal, check if the O-ring is properly seated on the motor housing.
NOTE!
Apply a thin coat of grease (NLGI #2) to the O-ring.
NOTE!
Take care not to damage the mating surface of the seal.
Figure 8
Replacing, seals
1. Housing
2. Seals
3. Casing
4. Seals
10. Install the housing onto the motor aligning the angular bearing inner race to the motor housing.
WARNING
Figure 9
Installation, housing (1)
11. Install the shim and retainer and then install screws.
Figure 10
Installation, retainer
1. Screws
2. Retainer
12. Install the No.2 planetary gear assembly.
Figure 11
Installation, No.2 planetary gear assembly (1)
13. Install the ring gear.

NOTE!
Coat the mating surface of ring gear with liquid gasket, Loctite #5699.
Figure 12
Installation, ring gear (1)
14. Install the coupling and No.1 sun gear onto the motor shaft.
Figure 13
Installation, coupling (2) and No.1 sun gear (1)
15. Install the No.1 planetary gear assembly.
WARNING
Figure 14
Installation, No. 1 planetary gear assembly (1)
16. Install the cover and screws.

NOTE!
Coat the mating surface of the ring gear with liquid gasket, Loctite #5699.
NOTE!
Apply Loctite #277 to the threads of screws (4).
Figure 15
Installation, cover

2. Drain port
3. Screw
4. Cover
17. Install the drain plug and tighten it to the specified torque.
18. Fill with oil through the fill port until oil exits from the level check port. See 4311 Track gearbox, specifications.
19. Install the fill and level check plugs and tighten to the specified torque. See 4311 Track gearbox, description.
Service Information

Track gearbox, disassembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track gearbox, disassembly

Precautions
 Thoroughly clean the gearbox assembly prior to disassembly.

 Select a clean work area.
 Match mark attached components to indicate proper positioning during reassembly.
 Take care not to mix parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Thoroughly clean all parts and the inside of the casings.
 Inspect and analyze all failures.
– Determine the root cause!
Disassembly
1. Place the oil fill port and the oil drain port on the vertical axis.
Remove the plugs and drain the gear oil.
Figure 1
Removal, plugs

2. Drain port
 Tools: L wrench 12 mm (PF 3/4), 8 liter pan
NOTE!
Drain oil into a clean container and check thoroughly for contamination.
2. Remove the screws and remove cover.

Figure 2
Removal, screw and cover
28 Cover 30 Screws
 Tools: L wrench 10 mm, 5 mm
NOTE!
Install a screw and carefully lift the cover off.
3. Remove the No.1 planetary gear assembly from No.2 planetary gear assembly.
Figure 3
Removal, No. 1 planetary gear assembly
10 No.2 planetary gear assembly

4. Disassembling No.1 planetary gear assembly.

Tap spring pin into No.1 pin.
Remove the thrust washer, No.1 planetary gear and needle bearing from No.1 carrier.
Remove the thrust ring.
Remove the retaining ring, then No.2 sun gear.
Remove the thrust ring.
Tools: Eye bolt (M10), Plastic hammer
Figure 4
Disassembly, No.1 planetary gear assembly
17 Thrust ring 19 No.1 carrier

20 No.2 sun gear 21 Retaining ring
23 Nneedle bearing 24 Thrust washer
25 No.1 pin 26 Spring pin
WARNING
Figure 5
No.1 planetary gear assembly
17 Thrust ring 19 No.1 carrier

20 No.2 sun gear 21 Retaining ring
23 Nneedle bearing 24 Thrust washer
NOTE!
Match mark gears, pins and carrier.
NOTE!
Do not mix the gears, bearings, thrust washers, and pin assemblies.
NOTE!
Do not reuse spring pins.
NOTE!
If there are any flakes at the surface of No.1 pin, replace No.1 pin, No.1 carrier, No.1 planetary gear and needle
bearing simultaneously.
5. Remove the No.1 sun gear and coupling.

Figure 6
Removal, No.1 sun gear (27) and coupling (9)
NOTE!
Remove the No.1 carrier and then remove No.2, No.1 sun gear.
WARNING
6. Remove the No.2 planetary gear assembly from spindle.
Figure 7
Removal, No.2 planetary gear assembly
10 Thrust ring
7. Disassembling No.2 planetary gear assembly
Figure 8
Disassembly, No.2 planetary gear assembly
11 No.2 carrier
13 Needle bearing 14 Thrust washer
17 Thrust ring
 Tap spring pin into No.2 pin.

 Remove the thrust washer, No.2 planetary gear and needle bearing from No.2 carrier.
 Tools: Eye bolt (M10), Plastic hammer
WARNING
Figure 9
Exploded view, No.2 planetary gear assembly
11 No.2 carrier
13 Needle bearing 14 Thrust washer
NOTE!
Match mark No.2 planetary gears, No.2 pins and No.2 carrier.
NOTE!
Do not mix the gears, bearing, thrust washers, and pin assemblies.
NOTE!
Do not reuse spring pins.
8. Screw the eye bolts into ring gear, and remove ring gear.
Figure 10
9. Remove the screw, retainer and shim.

Figure 11
Removal, screw, retainer and shim
4 Screw 5 Retainer
6 Shim
 Tools: 19 mm socket (M12)
NOTE!
Do not reuse the screws.
10. Screw the eye bolts into housing, and remove housing, parallel pin, angular bearing and seal as an assembly.
Figure 12
Removal, housing, pin, angular bearing and seal
1 Housing 5 Retainer
2 Angular bearing 6 Screws
3 Seal 7 Parallel pin
4 Bearing
WARNING
NOTE!
When difficult to remove, lift the body vertically and tap lightly with a plastic hammer.
11. Remove the seal from housing.

Remove the seal from motor casing (spindle).
NOTE!
Be careful not to damage the O-ring and seal surface.
12. Remove the angular bearing from housing.
 Tools: Bearing fixture, Plastic hammer
Figure 13
Removal, angular bearing
1 Housing
2 Angular bearing
Service Information

Track gearbox, assembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track gearbox, assembly

Tool: 8932-00290 Measuring plate
14630696 Drift plate
Precautions
 Clean all parts with cleaning solvent and dry with compressed air.
 Rework damaged parts and before assembling, prepare all replacement parts.
 Coat the sliding parts, bearings and gears with clean gear oil.
 Replace the O-rings, and seals.
 Replace screws (6). DO NOT REUSE THESE SCREWS!
 Use a torque wrench to tighten the screws and plugs to the specified torque. See 4311 Track gearbox, description.
Tightening torque
Tightening torque
No. Part name Thread size Tightening torque

6 Screw M12 113 Nm (11.5 kgf m) (83 lbf ft)
30 Screw M12 132 Nm (13.5 kgf m) (98 lbf ft)
32 Plug PF 3/4 186 ±9.8 Nm (18.9 ±0.99 kgf m) (137 ±7.2 lbf ft)
Assembly
1. Press-fit angular bearing into housing.
Figure 1
Installation, angular bearing
1 Housing 2 Bearing
 Tools: Plastic hammer, Bench press
NOTE!
The outer races of the angular bearing must be properly aligned and fully seated.
NOTE!
Press-fit using a press or hammer.
2. Press-fit seal lightly into housing.

Press-fit seal lightly onto the motor casing (spindle 302).
Assemble housing onto the motor aligning the angular bearing inner race to the motor housing.
Figure 2
Installation, seal
1 Housing 3 Seal
7 Pin
NOTE!
After assembling the seal, check if the O-ring is properly seated on the motor housing.
NOTE!
Apply a thin coat of grease (NLGI #2) to the O-ring.
NOTE!
Take care not to damage the mating surface of the seal.
3. Shim adjusting method:
 Measure the dimension "B" of retainer as shown.

 Install shim thickness measuring tool on inner race of bearing, and tighten four screws to the specified
torque.
NOTE!
Tightening torque: 7.9 Nm (0.806 kgf m) (5.8 lbf ft)
 Measure the dimension "A" from the top of the inner race of bearing to the motor as shown.
 Shim thickness S = B – A + (0 ~ 0.05 mm), (0 ~ 0.00197 inch)
 Remove shim thickness measuring tool.
 Select a shim of the appropriate thickness, align the retainer correctly, and tighten screws to the specified
torque.
 Tools: 19 mm socket (M12), Torque wrench, Depth gauge
NOTE!
Shim: 0.1, 0.9, 1.0, and 1.2 mm (0.04724 inch)
NOTE!
Tightening torque: 7.9 Nm (0.806 kgf m) (5.8 lbf ft)
NOTE!
Apply Loctite # 277 onto the thread of screws.
Figure 3
Adjustment, shim
4 Shim A –
5 Retainer B –
6 Screws C Tool
4. Install the parallel pin into housing, align ring gear correctly, and screws.
Figure 4
Installation, pin
1 Housing A Applying, Loctite

7 Parallel pin 8 Ring gear
 Tools: Plastic hammer
NOTE!
NOTE!
Install the 4 screws temporarily.
Figure 5
11 No.2 carrier A Stake

12 No.2 planetary gear 15 No.2 pin
13 Needle bearing 16 Spring pin
14 Thrust washers
 Place No.2 carrier with its spline downward.
 Install the thrust washers, No.2 planetary gear and needle bearing into No.2 carrier.
 Insert the No.2 pin.
 Tap spring pin into the pin holes of the No.2 carrier, and then stake two points on No.2 carrier.
NOTE!
Align No.2 planetary gear and holes of No.2 carrier correctly.
NOTE!
Check if No.2 planetary gears rotate smoothly.
WARNING
6. Fit the No.2 planetary gear assembly into the spline of the motor correctly.
Figure 6
Fitting, No.2 planetary gear assembly
8 No.1 carrier
 Tools: Eye bolt (M10)
7. Insert the coupling, and then No.1 sun gear onto the motor shaft.
Figure 7
Insertion, coupling
9 Coupling
27 No.1 sun gear
8. No.1 planetary gear assembly.
Figure 8
17 Thrust ring A Stake

19 No.1 carrier 23 Needle bearing
20 No.2 sun gear 24 Tthrust washers
21 Retaining ring 25 No.1 pin
22 No.1 planetary gear 26 Spring pin
 Install the thrust ring into No.1 carrier.

 Install the assembled No.1 carrier onto No.2 sun gear, and mount retaining ring.
 Install the thrust washers, No.1 planetary gear and needle bearing into No.1 carrier.
 Insert the No.1 pin.
 Tap spring pin into the pin holes of the No.1 carrier and then stake two points on No.1 carrier.
 Insert the thrust ring into No.1 carrier.
NOTE!
Align No.1 planetary gear and the holes of No.1 carrier correctly.
NOTE!
Check if No.1 planetary gears rotate smoothly.
WARNING
9. Insert the No.1 planetary gear assembly into No.2 planetary gear assembly.
Figure 9
Insertion, No.1 planetary gear assembly
10 Coupling
 Tools: Eye bolt (M10)
10. Screw an eye bolt into the oil level port and install the cover on ring gear.
Install the screws and tighten to the specified torque. See 4311 Track gearbox, description.
Figure 10
Installation, cover
28 Cover
30 Screws
 Tools: Eye bolt (PF 3/4), L wrench 10 mm (0.394 inch) (M12), Torque wrench, Plastic hammer
NOTE!
NOTE!
Apply Loctite #277 onto the threads of screws.
11. Install the plugs into cover and tighten to the specified torque. See 4311 Track gearbox, description.
Figure 11
Installation, plug

2. Drain port
 Tools: Torque wrench, L wrench 12 mm (0.472 inch) (PF 3/4)

Service Information

Function description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Function description
Swing gearbox consists of the driving shaft as a group including the 1st planetary gear assembly, the 2nd planetary gear
assembly and the 1st and 2nd sun gear pinions, the housing supporting the driving shaft, and the ring gear including the
planetary gear.
See 990 Hydraulic diagram, slew (left).
Gearbox, torque flow
The 2-stage planetary gear reduction assembly converts the high speed/low torque output of the hydraulic motor to low
speed/high torque output, which is transmitted via the reduction drive shaft pinion gear to the swing ring inner
circumference gear to rotate the superstructure.
Operation
Swing gearbox illustration. See 4312 Swing gearbox, description.
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (26) through the splines of the
1st sun gear (37), the 1st planetary gear (30), the 1st pin (31) and the 1st carrier (29). In the same way, power is transmitted
to output shaft (10) through the splines of the 2nd planetary gear (3), the 2nd pin (5) and the 2nd carrier (2).
Figure 1
Swing gearbox
A. Torque flow
 1st reduction ratio

i1 = (Zr1 / ZS1) + 1
i1 : 1st reduction ratio
ZS1 : No. of gear teeth of the 1st sun gear
Zr1 : No. of tooth of the 1st ring gear
 2nd reduction ratio
i2 = (Zr2 / ZS2) + 1
i2 : 2nd reduction ratio
ZS2 : No. of gear teeth of the 2nd sun gear
Zr2 : No. of gear teeth of the 2nd ring gear
Accordingly the total reduction ratio of reduction gear is as follows :
i = i1 × i2
= (Zr1 / ZS1 + 1) × (Zr2 / ZS2 + 1)
i : Total reduction ratio
Service Information

Swing gearbox, description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing gearbox, description

Swing gearbox consists of the driving shaft as a group including the 1st planetary gear assembly, the 2nd planetary gear
assembly and the 1st and 2nd sun gear pinions, the housing supporting the driving shaft, and the ring gear including the
planetary gear.
Model code
Figure 1
Model code
1. Serial number
2. Reduction ratio code
3. Size number
(Theoretical output torque, ex. 100 = 1000 kgf m)
4. Type number
(ex. S = Swing gearbox)
Swing gearbox, sectional view

Figure 2
Swing gearbox, sectional view
1 No.2 planetary gear assembly 17 Bearing 32 Bearing

2 No.2 carrier 18 Retaining ring 33 Washer
3 No.2 planetary gear 19 Case 34 Washer
4 No.2 pin assembly 20 Ring gear 35 Retaining ring
5 No.2 pin 21 Dowel pin 36 Spring pin
6 Bushing 22 Screw 37 No.1 sun gear
8 Washer 23 Plate 38 Retaining ring
9 Spring pin 24 Screw 39 Level gauge
10 Drive shaft 25 Thrust ring 40 Pipe
11 Collar 26 No.2 sun gear 41 Name plate
12 Cover 27 Thrust washer 42 Screw
13 O-ring 28 No.1 planetary gear assembly 43 Drain valve
14 Seal 29 No.1 carrier 44 Pipe
15 Screw 30 No.1 planetary gear
16 Bearing 31 No.1 pin
Tightening tqroue:
Screws (15): 63.7 Nm (6.5 kgf m) (46.9 lbf ft) Loctite #243
Screws (22): 264.8 Nm (27 kgf m) (194.9 lbf ft) Loctite #277
Screws (24): 118 ±12 Nm (12 ±1.2 kgf m) (87 ±9 lbf ft) Loctite #277
Pipe (40, 44): 49 ±4.9 Nm (5 ±0.5 kgf m) (36 ±3.6 lbf ft) Loctite #572
Drain valve (43):44 ±4.4 Nm (4.5 ±0.45 kgf m) (33 ±3.2 lbf ft)
Function
The 2-stage planetary gear reduction assembly converts the high speed/low torque output of the hydraulic motor to low
speed/high torque output, which is transmitted via the reduction drive shaft pinion gear to the swing ring inner
circumference gear to rotate the superstructure.
Operation
Power supplied to the output shaft of the hydraulic motor is transmitted to the 2nd sun gear (26) through the splines of the
1st sun gear (37), the 1st planetary gear (30), the 1st pin (31) and the 1st carrier (29). In the same way, power is transmitted
to output shaft (10) through the splines of the 2nd planetary gear (3), the 2nd pin (5) and the 2nd carrier (2).
Figure 3
Swing gearbox, operation
A. Torque flow
 1st reduction ratio

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

Swing gearbox, Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing gearbox, maintenance standard

The parts are precision finished and must be handled carefully.
Keep the parts of the planetary carrier(s) together, do not mix the bushing, gears, pins and thrust washers.
Seals
 Replace all parts that appear damaged or are not within the allowable value.
 Replace some parts in sets, i.e. gears, bushings and thrust washers.
Item Part name Condition Standard value Allowable value

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

1 Spanner 17 × 19 mm (0.67 × 0.75 in) 1
24 × 27 mm (0.95 × 1.1 in) 1
2 Socket wrench – 1
3 Allen wrench 10 mm (0.39 in) 1
14 mm (0.55 in) 1
4 Torque wrench 3923 ~ 17652 Nm (2888 ~ 12996 lbf ft) 1
11768 ~ 47072 Nm (8664 ~ 34656 lbf ft) 1
5 Retaining ring pliers φ 35 1
φ 42
φ 90
6 Bearing puller – –
7 Plastic hammer – 1
8 Eye bolt M8 2
M12 2
M16 2
M18 2
9 (–) Screwdriver 150 mm (5.9 in) 1
Special tools
8932-00600 Drift
Special tools
No. Description Part number Quantity

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

Service Information

Swing gearbox, replacing Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing gearbox, replacing

Op nbr 431-021
1. Park the machine in the service position C. See 091 Service positions.
 Mount the vacuum pump on hydraulic tank, and maintain a vacuum.
3. Remove the under cover.
4. Open the oil drain valve cap and install the oil drain hose. Drain the gearbox oil into a suitable container.
Figure 1
Draining, gearbox oil
1. Oil drain valve cap

2. Oil drain hose
5. Remove the anti-cavitation hose.
Figure 2
Removal, hoses
1. Anti-cavitation hose
2. Drain hose
3. Feed line hoses
4. Delay valve sub hoses
6. Remove the swing motor drain hose.
7. Remove the swing motor feed line hoses.
8. Remove the delay valve sub hoses.
9. Remove the swing gearbox mounting screws and remove the silicone from both back step holes.
Figure 3
Removal, mounting screws
1. Screws
2. Silicone
10. Install the back step screws to separate the swing gearbox from the superstructure.
NOTE!
The gearbox housing is not removed easily because of the dowel pin.
Figure 4
Installation, back step screw
1. Back step screw
11. Lift the swing unit with the sling, and lower to the workbench safely.
Figure 5
Removal, swing unit
1. Sling
2. Screws
12. Remove the screws, lift the swing motor with sling, and install it to a new swing gearbox.
NOTE!
Before installing the swing motor, thoroughly remove the sealing compound on the mounting surface.
NOTE!
Apply sealing compound to the mounting surface of the new swing gearbox and then install the swing motor.
13. Transfer drain pipe and dowel pin, to the new swing gearbox.
Figure 6
Transferring, drain pipe and dowel pin
1. Drain pipe
2. Dowel pin
14. Lift the swing unit with the hoist, and install it to the machine.
Figure 7
Installation, swing unit
1. Screws
2. Silicone
NOTE!
Before installing the swing unit, thoroughly remove the sealing compound on the seat surface of the
superstructure.
NOTE!
Apply sealing compound to the seat surface of the superstructure, and then install the swing unit.
NOTE!
Apply the loctite #277 to the mounting screws, and tighten them to the specified torque.
15. Fill the both back step holes, and cover the dowel pin with silicone.
16. Install the swing motor feed line hoses.
Figure 8
Installation, hoses
2. Drain hose
3. Feed line hoses
17. Install the delay valve sub hoses.
18. Install the swing motor drain hose.
19. Install the anti-cavitation hose.

20. Remove the vacuum pump mounted on the hydraulic tank.
21. Fill the gearbox oil through the oil filling pipe.
22. Bleed air from the hydraulic circuit at the swing motor before operating.
23. After completion of the work, start the engine and check for leaks.
Service Information

Swing unit, replacing Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing unit, replacing

Op nbr 431-053
14360000 Vacuum pump / 24V
1. Replacing the swing unit. See 4312 Swing gearbox, replacing.

Service Information

Swing gearbox removed, Service Information 2014/6/13
replacing seal
Profile:
EXC, EC220D L [GB]
Swing gearbox removed, replacing seal

Op nbr 431-026
1. Remove the screws.
Figure 1
Removal, screws (1)
2. Remove the cover and oil seal.
Figure 2
Removal, cover (1) and oil seal (2)
3. Remove the oil seal from cover and press a new oil seal into the cover using the seal pressing jig.
 Tool part number: 8920–00550

NOTE!
Apply loctite (#680) to the outer diameter of the oil seal. Take care not to get any loctite on the oil seal lip.
Figure 3
Replacing, oil seal
1. Cover
2. Oil seal
3. Seal pressing jig
4. Install the oil seal protector (A) onto the gear of shaft.
Install the cover, and oil seal on the case and then install the screws.
NOTE!
Coat the mating surface of cover with liquid gasket, loctite # 5699.
Apply grease (NLGI2) to the oil seal lip.
Apply loctite #277 to the threads of screws.
Figure 4
Installation, cover and oil seal
1. Shaft
2. Cover
3. Seal
4. Screws
Service Information

Swing gearbox removed, Service Information 2014/6/13
replacing shaft
Profile:
EXC, EC220D L [GB]
Swing gearbox removed, replacing shaft

Op nbr 431-027
8920-00550 Drift
8920-00570 Drift
8920-00280 Drift
8932-00600 Drift
Tool part number: 8920–00560
1. Open the drain valve cap, connect drain hose to drain valve and drain the oil into a suitable container.
After completely draining, remove the drain hose, then close drain valve cap.
NOTE!
Oil capacity. See 4312 Swing gearbox, specifications.
Figure 1
Removal, hydraulic motor
1 Screws A Marks line

2 Motor casing B Drain valve
3 Plate C Drain valve cap
4 Ring gear D Drain hose
5 Case
2. Remove the screws and lift the motor off the gearbox.
NOTE!
Make match marks on hydraulic motor casing, plate, ring gear, and case.
Make sure match marks are permanent and clearly visible.
3. Remove the screws and plate.
Figure 2
Removal, screw (1) and plate (2)
4. Remove the 1st sun gear.
Figure 3
Removal, 1st sun gear (1)
5. Remove the 1st planetary gear assembly.
Figure 4
Removal, 1st planetary gear assembly (1)
6. Remove the 2nd sun gear and the thrust ring.

Figure 5
Removal, 2nd sun gear (1) and thrust ring
7. Remove the ring gear.
Figure 6
Removal, ring gear
8. Remove the 2nd planetary gear assembly.
Figure 7
Removal, 2nd planetary gear assembly (1)
9. Remove the retaining ring.

Figure 8
Removal, retaining ring (1)
10. Turn the swing gearbox upside down.

Remove the screws, cover, and oil seal.
NOTE!
Do not reuse the oil seal
Figure 9
Removal, cover and oil seal
12 Cover 14 Screws
15 Oil seal
11. Block the reduction gear as shown.

Press shaft from case using a press jig.
Figure 10
Removal, shaft
10 Shaft 19 Case
12. Remove the spherical bearing from case using a press jig.
NOTE!
Spherical bearing can also be removed using a bench press.
Figure 11
Removal, spherical bearing
17 Bearing 19 Case
13. Press spherical bearing and collar from shaft.

NOTE!
If it is difficult to remove spherical bearing as illustrated, use a bearing puller.
NOTE!
Be careful not to damage collar by excessive force.
Figure 12
10 Shaft 16 Bearing
11 Collar
14. Remove the O-ring from collar.

NOTE!
Do not reuse the O-ring.
Figure 13
Removal, O-ring
11 Collar 13 O-ring
15. Install the a new O-ring in collar, and then install it on new shaft.
NOTE!
Apply grease (NLGI 2) to the new O-ring.
Figure 14
Installation, collar
1 Collar 2 Shaft
16. Install the spherical bearing on new shaft.

Press spherical bearing and collar onto new shaft using a press jig.
NOTE!
Heat the spherical bearing in oil to 110 °C (230 °F) prior to installation.
Figure 15
Installation, collar and bearing
1 Bearing 3 Shaft
2 Collar
17. Install the case using a sling.
WARNING
Figure 16
Installation, case (1)
18. Install the spherical bearing into case using a press jig.
Figure 17
Installation, spherical bearing
1 Bearing
2 Case

Install the oil seal protector onto the gear of shaft.
Install the cover, and oil seal on the case and then install the screws.
NOTE!
Coat the mating surface of cover with liquid gasket, loctite # 5699.
Apply grease (NLGI2) to the oil seal lip.

Figure 18
Installation, cover and oil seal
1 Seal 4 Shaft
2 Screws A Oil seal protector
3 Cover

Install the retaining ring onto the shaft.
Figure 19
Installation, retaining ring (1)
21. Install the 2nd planetary gear assembly.

Figure 20
Installation, 2nd planetary gear assembly (1)
22. Install the ring gear.

NOTE!
Coat the mating surface of the case with liquid gasket, loctite # 5699.
Figure 21
Installation, ring gear (1)
23. Install the thrust ring and 2nd sun gear.

NOTE!
Apply grease (NLGI2) to the thrust ring.
Figure 22
Installation, thrust ring and 2nd sun gear (1)
24. Install the 1st planetary gear assembly.

Figure 23
Installation, 1st planetary gear assembly (1)
25. Install the 1st sun gear.
Figure 24
Installation, 1st sun gear (1)
26. Install the plate and screws.

NOTE!
Align the match marks on the casing, the ring gear, and the plate.
Coat the mating surface of the ring gear with liquid gasket loctite #5699.
Apply loctite #277 to the threads of screw.
Align the tap hole with the drain pipe mounting port.
Figure 25
Installation, plate (2) and screws (1)
27. Install the motor onto plate and then install the screws.
NOTE!
Align match marks of motor and plate.
Coat the mating surface of plate with liquid gasket loctite #5699.
Figure 26
Installation, hydraulic motor
1 Motor A Marks line

2 Plate
3 Screws
28. Pull out the oil level gauge, and fill with oil to the correct level through the oil fill port.
29. Check the oil level using the oil level gauge and refill if necessary.
NOTE!
Wait about 5 minutes before checking for the correct level after filling oil.
Service Information

Swing gearbox, Service Information 2014/6/13
disassembly
Profile:
EXC, EC220D L [GB]
Swing gearbox, disassembly

Precautions

 Take care not to mix the parts of sub assemblies i.e. planetary bearings, gears and thrust washers.
 Determine the root cause!
Disassembly
1. Open drain valve cap (D) from drain valve (C) and connect drain hose (E) to drain valve (C) and drain the oil into a
suitable container.
Figure 1
Removal, hydraulic motor
2. After completely draining, remove drain hose (E), then close drain valve cap (D).
3. Remove screws (24).
4. Lift the motor off the gearbox.
NOTE!
Make match marks (A) on hydraulic motor casing (301), plate (23), ring gear (20), and case (19).
Make sure match marks (A) are permanent and clearly visible.

Figure 2
Removal, screw and plate
6. Remove plate (23).
7. Remove 1st sun gear (37).
Figure 3
Removal, 1st sun gear
8. Remove 1st planetary gear assembly (28) from ring gear (20).
Disassemble the 1st planetary gear assembly in the following order:
Figure 4
Removal, retaining ring
 Remove retaining ring (35), and then thrust washer (34), planetary gear (30), needle bearing (32) and
thrust washer (33).
 Remove thrust washer (27).
 Remove spring pin (36) from carrier (29) to take out pin (31).
NOTE!
Match mark gears (30), pins (31) and carrier (29).
NOTE!
Do not remove pins (31) if not worn or damaged.
NOTE!
Do not reuse spring pins (36).
Figure 5
Removal, spring pin
9. Remove ring gear (20) and dowel pin (21).
Figure 6
Removal, 2nd sun gear
10. Remove 2nd sun gear (26) and thrust ring (25).
11. Remove 2nd planetary gear assembly (1) from shaft (10).
Disassemble the 2nd planetary gear assembly in the following order:
Figure 7
Removal, 2nd planetary gear
 Tap spring pin (9) into pin (5).

 Remove pin (5) and bushing (6) from carrier (2).
 Remove planetary gear (3) thrust washers (8).
NOTE!
Match mark gears (3), pins (5), and carrier (2).
NOTE!
Do not mix the gears, thrust washers, bushings, and pin assemblies.
NOTE!
Do not reuse spring pins (9).
To remove spring pin (9), tap it into pin (5).
After removing pin (5), remove the spring pin.
12. Remove retaining ring (18).

Figure 8
Figure 9
Removal, cover and oil seal
14. Remove cover (12).
15. Remove oil seal (14).
NOTE!
Do not reuse the oil seal
16. Block the reduction gear as shown.

Press shaft (10) from case (19).
Figure 10
Removal, shaft
17. Press spherical bearing (16) and collar (11) from shaft (10).
Figure 11
NOTE!
If it is difficult to remove spherical bearing (16) as illustrated, use a bearing puller.
NOTE!
Be careful not to damage collar (11) by excessive force.
18. Remove O-ring (13) from collar (11).
Figure 12
Removal, O-ring
NOTE!
Do not reuse the O-ring.
19. Press spherical bearing (17) from case (19).
Figure 13
NOTE!
Spherical bearing (17) can also be removed using a bench press.
Service Information

Swing gearbox, assembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing gearbox, assembly

8920-00550 Drift8920-00570 Drift8920-00280 Drift8932-00600 Drift
Tool part number: 8920–00550
Precautions
 When mounting the gearbox assembly to the superstructure, position it on the dowel pin located in the mounting
plate to ensure that the drain/fill ports are properly positioned.
 Mount the hydraulic motor on the gearbox assembly so that the oil level gauge and plumbing connections are
positioned as shown in the construction drawings.
 Use a torque wrench to tighten the mounting screws to the specified torque.
 Replace the O-ring and oil seal.
 Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
NOTE!
Swing gearbox, sectional view and tightening torque. See 4312 Swing gearbox, description.
Assembly
1. Install O-ring (13) in collar (11), and then install it on shaft (10).
Figure 1
Installation, collar
NOTE!
Apply grease (NLGI 2) onto O-ring (13).
2. Press spherical bearing (16) onto shaft (10).

Figure 2
NOTE!
Heat the spherical bearing in oil to 110 °C (230 °F) prior to installation.
3. Press oil seal (14) into cover (12) using the seal pressing jigs.
Figure 3
Installation, oil seal
NOTE!
Apply loctite (#680) onto the outer diameter of the oil seal. Take care to get any loctite on the oil seal lip.
Figure 4
Apply, loctite
4. Install shaft (10) assembly into case (19) using an eye bolt (M8 × 1.25).
Figure 5
Installation, shaft
WARNING
5. Install oil seal protector (A) onto the gear of shaft (10).
Figure 6
Installation, cover
6. Install cover assembly (12) on case (19) and install screws (15).
NOTE!
Coat the mating surface of cover (12) with liquid gasket, loctite # 5699.
Apply grease (NLGI2) onto the oil seal lip.
Apply loctite #277 onto the threads of screws (15).
7. Block case (19) as shown.

Figure 7
8. Press–fit spherical bearing (17) into case (19).
NOTE!
Press–fit both inner and outer race simultaneously.
9. Fully seat spherical bearing (17), and install retaining ring (18) onto shaft (10).
Figure 8
Installation, retaining ring
NOTE!
Check if casing (19) rotates smoothly after assembling the bearing and retaining ring.
10. 2nd planetary gear assembly
Figure 9
Installation, 2nd planetary gear
 Insert thrust washers (8) and 2nd planetary gear (3) into carrier (2).
 Insert pin (5) and bushing (6).
 Tap spring pin (9) into the pin hole of carrier (2). After inserting, stake the pin into both sides of spring
pins (9).
NOTE!
Align the spring pin holes in pin assembly (4) and carrier (2).
Apply a dab of grease to hold thrust washers (8) to gear (3).
Install spring pin (9) with the slit facing the end of pin (5).
Ensure that gears (3) rotate smoothly.
Figure 10
Installation, pin
A. Stake
11. 1st planetary gear assembly
Figure 11
Installation, 1st planetary gear
 Press–fit pins (31) into carrier (29) and install spring pins (36). After inserting, stake both sides of spring
pins (36).
 Put thrust washer (27) on the surface of carrier (29).
 Onto pin (31) install thrust washer (33), gear (30) including bearing (32), thrust washer (34) and retaining
ring (35).
NOTE!
Check if planetary gears (30) rotate smoothly.
Figure 12
Checking, planetary gear
A. Stake
12. Ring gear and 2nd planetary assembly
Figure 13
 Insert dowel pins (21) at four places on case (19).

 Install ring gear (20) onto case (19).
 Insert 2nd planetary gear assembly (1) into ring gear (20).
 Insert thrust ring (25) into 2nd planetary gear (1), then install sun gear (26).
WARNING
NOTE!
 Coat the mating surface of case (19) with liquid gasket loctite #5699.
 Support case (19).
Figure 14
13. 1st planetary gear assembly and 1st sun gear
Figure 15
 Install 1st planetary gear assembly (28) into ring gear (20).
 Install retaining ring (38) into sun gear (37), and insert it into planetary (28).
NOTE!
Confirm that shaft (10) rotates smoothly by turning the 1st sun gear.
Figure 16
14. Install plate (23) onto ring gear (20) then install screws (22).
Figure 17
Installation, plate
A. Tap hole
NOTE!
Align the match marks on casing (19) ring gear (20) and plate (23).
Coat the mating surface of ring gear (20) with liquid gasket loctite #5699.
Apply loctite #277 onto the threads of screw (22).
Align the tap hole with the drain pipe mounting port.
Figure 18
Installation, plate
15. Install the motor onto plate (23) then install screws (24).
Figure 19
Installation, motor
NOTE!
Align match marks (A) of the motor and plate (23).
Coat the mating surface of plate (23) with liquid gasket loctite #5699.
Apply loctite #277 onto the threads of screws (24).
16. Tighten drain valve (43) to pipe (44) and pipe (44) to case (19).
Figure 20
Installation, pipe
17. Install pipe (40) onto the motor, and insert level gauge (39).
NOTE!
Face the oil drain port of pipe sideward.
Coat with teflon tape or loctite #577 on the pipe and plug thread.
Service Information

Track motor, description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track motor, description
Figure 1
Track motor, structure
1. Hydraulic motor
2. Brake valve
3. Parking brake
4. Displacement changeover valve
5. Main control valve
6. Main pump
 Hydraulic motor
The hydraulic motor is a variable swash, axial piston design that includes the brake valve assembly and parking
brake. The rear flange contains the counterbalance valve, check valves, crossover relief valves and displacement
changeover valve.
 Brake valve assembly

The brake valve assembly consists of the following valves, each having a specific function as described.
 Check valves
The check valves open/close according to supply oil pressure, and route oil flow to the counterbalance spool. The
check valves also prevent cavitation in the travel motor.
 Counterbalance valve
The counterbalance valve is used for smooth starting and stopping of the travel motor. It blocks or throttles the
circuit of the travel motor to control the travel speed according to the amount of oil discharged by the pump to
prevent machine run away on slopes.
 Crossover relief valves

The relief valves protect the motor and circuit from pressure spikes, maintaining the starting pressure/bypass
pressure of the hydraulic motor at a constant value.
 High/low 2–speed travel

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

The travel parking brake is spring applied and hydraulically released. The brake is automatically applied whenever
the travel control valve spools are in neutral.
Figure 2
Track motor, port connections
1. High speed
2. Low speed
Port connections
Port symbol Port size Port

(A), (B) 1-5/16-12 UN Oil supply (return)
(P2), (P3) PT 1/4 Pressure check
(P5) PT 1/8 Parking brake release pressure
Parking brake can be released manually when supply pressure minimum 1.47
MPa (14.99 kgf cm2) (213.2 psi) (14.7 bar) to port P5.
(P) 7/16-20 UNF Displacement changeover valve oil supply
(D1), (D2) 3/4-16 UNF Motor drain
View from X axis Inlet Outlet
Clockwise B A
Counterclockwise A B
Figure 3
Track motor, sectional view
Figure 4
Track motor, exploded view
2 Shaft 93 Spring 246 Plug
3 Swash plate 101 Piston 252 Plug
4 Cylinder block 102 Sleeve 254 Plug
5 Piston 103 Retainer 257 Plug
6 Shoe 104 Plug 263 Spool
7 Retaining plate 105 Shim 266 Spring
8 Thrust ball 106 Spring 268 Ball
9 Timing plate 108 O-ring 279 Filter
10 Washer 109 O-ring 280 Plug
11 Roller 110 O-ring 281 Piston
12 Brake piston 111 Back-up ring 282 Plug
13 Spring 117 Back-up ring 283 O-ring
14 Spring 119 O-ring 284 O-ring
15 Friction plate 120 Piston seal 285 Steel ball
16 Mating plate 201 Rear flange 294 O-ring
32 Oil seal 223 Spool 295 O-ring
35 O-ring 224 Plug 296 O-ring
39 O-ring 225 Stopper 297 Orifice
45 Snap ring 226 Plug 298 Plug
49 Bearing 227 Valve 299 Name plate
50 Bearing 228 Spring 302 Spindle
51 Needle roller 230 Spring 327 O-ring
61 Piston 236 O-ring 329 O-ring
62 Shoe 237 O-ring 342 Parallel pin
67 Steel ball 241 Parallel pin
71 Parallel pin 243 Screw
Tightening torque
No. Name Tightening torque: Nm (kgf m)

III Relief valve PF1 245 ±49.0 (25.0 ±2.0)
III-104 Plug PF1/2 98.1 ±19.6 (10.0 ±2.0)
IV-221 Plug 3/4-16 UNF 58.5 ±9.81 (6.0 ±1.0)
IV-224 Plug M36xP1.5 441 ±88.2 (45.0 ±9.0)
IV-226 Plug M36xP1.5 255 ±39.2 (26.0 ±4.0)
IV-246 PT Plug PT 1/4 29.4 ±4.9 (3.0 ±0.5)
IV-252 Plug PF 1/4 29.4 ±4.9 (3.0 ±0.5)
IV-254 PT Plug NPTF 1/16 98.1 ±19.6 (10.0 ±2.0)
IV-257 Plug PF1/2 98.1 ±19.6 (10.0 ±2.0)
IV-279 Filter M6 0.49 ±0.1 (0.05 ±0.01)
IV-297 Orifice M6 0.49 ±0.1 (0.05 ±0.01)
IV-280 Plug PF3/8 58.5 ±9.81 (6.0 ±1.0)
IV-282 Plug PF1/8 14.8 ±2.45 (1.5 ±0.25)
243 Socket screw M16xP2.0 252 ±39.2 (25.7 ±4.0)
Operation, hydraulic motor

Figure 5
Hydraulic motor operation
TDC Top dead center

BDC Bottom dead center
2 Shaft 9 Valve plate

3 Swash plate 201 Rear flange
4 Cylinder block 105 Cylinder block
5 Pistons
The pressurized oil delivered via the control valve from the hydraulic pump enters port on rear flange and flows to half the
pistons in cylinder block through valve plate.
The pressurized oil in cylinder block pushes half the pistons out of the bores and force [F (kgf) = P (kgf cm2 ) × A (cm2)] is
generated. This force is applied on swash plate fixed to drive shaft with angle (a°) so that it is divided into components of
force (F2 and F3).
Among the components of force, radial force (F3) generates the torque (T = F3 × ri) for (Y1) - (Y2), respectively.
The total of torque {T = Σ (F3 × ri)} is transmitted sequentially via pistons to cylinder block generating a rotational force
causing the cylinder block splined to output drive shaft to rotate.
The top dead center port is the starting point of the high pressure rotational cycle ; for 180° the pistons move out of the
bores as they slide along the swash plate toward the bottom dead center port, then they begin moving into the bores
discharging low pressure oil to the return circuit.
Operation, brake valve
Operating (Brake released)
Figure 6
Brake valve released
12 Brake piston
223 Spool
228 Cylinder block
227 Check valve
When pressurized oil is supplied to port (A), it opens check valve and the oil flows to inlet port (C) of the hydraulic motor.
At the same time pressurized oil flows into chamber (b) through passage (a) via a small orifice in counterbalance spool. As
the pressure in chamber (b) increases spool is moved to the left, connecting port (D) with outlet (B) allowing the return oil
from the motor to flow to tank, so that the hydraulic motor starts to rotate. And according to the movement of spool,
pressurized oil flows into port (P) and port (S). The oil flow through port (P) operates brake piston overcoming the brake
spring force releasing the parking brake. If the supply port and the return port are interchanged the travel motor rotates in
the opposite direction.
Stopping or stalling (brake actuating)
Figure 7
Brake valve actuation
101 Relief valve 227 –
223 Spool 228 Spring
225 Stopper 281 Piston
When the pressurized oil flow from the main control valve is blocked, the pressure in port (A) decreases rapidly. As this
happens the pressurized oil in chamber (b) escapes via passage (a) through the orifice in spool to port (A) ; at the same time
spring force acting on stopper moves counterbalance spool to the right (neutral position).
The return speed of spool is controlled by the back pressure created by the throttling effect of the orifice at passage (a).
When the spool is completely returned to the neutral position, the passages to ports (A, B) are blocked, trapping the oil in
the motor to prevent rotation.
However inertia will tend to continue the motor rotation, creating a sharp rise in oil pressure at return port (D). (This referred
to as dynamic braking).
The pressurized oil flows through the orifice in the left relief valve piston to chamber (f), then to chamber (g) and starts to
move piston to the right. When the piston reaches the end of its stroke, the pressure in chambers (g & f) rise and react on
valve piston. At this time the opening pressure of the relief valve is higher than the normal relief setting pressure. This
sequence acts to cushion the pressure spike as the valve opens.
As the oil pressure at port (D) overcomes the combined force of the relief valve spring and pressurized oil in chambers (g &
f) the left relief valve opens, connecting ports (D & C) to prevent an abnormal pressure rise and cavitation.
When the oil pressure at port (D) drops the relief valve closes ; however if the pressure rises above the relief valve setting,
the relieving cycle is repeated. The 2 stage control of the relief valve stops the hydraulic motor smoothly.
Over speed
Figure 8
Brake valve, over speed
12 Brake piston
223 Spool
228 Cylinder block
227 Check valve
When travelling downhill the weight of the machine (inertia) tends to make the hydraulic motor rotate faster than the rate of
oil flow supplied by the hydraulic pump. This phenomenon is referred to as over speed.
During this condition the hydraulic force of the motor decreases, and the counterbalance spool moves toward the neutral
position, blocking the return oil flow from port (D) to port (B). As the passage closes it creates a throttling action, causing a
back pressure at port (D), thereby decelerating the hydraulic motor until the pump flow begins applying force to the motor.
Operation, parking brake
When travelling
Figure 9
Parking brake, travelling
4 Cylinder block 15 Friction plates

12 Brake piston 16 Plates
13 Brake springs
When the travel lever is operated pressurized oil from the pump actuates counterbalance spool, opening the circuit to brake
chamber (a) of brake piston.
When the oil pressure reaches approximately 6 kgf/cm2 (0.59 MPa) (85 psi) (5.9 bar) it starts to push brake piston toward the
rear flange (←) overcoming the force of brake springs. As this happens the piston moves away from friction plates and
mating plates allowing the plates to separate, releasing the braking force holding cylinder block (4).
When stopping
Figure 10
Parking brake, stopping
4 Cylinder block 15 Friction plates

12 Brake piston 16 Plates
13 Brake springs
When the travel lever is placed in neutral, the counterbalance spool returns to its neutral position closing the circuit to brake
chamber (a).
The pressurized oil in chamber (a) drains to tank through an orifice in the brake valve.
The throttling effect of the orifice slows the drain oil flow, preventing the brake springs from applying the brake abruptly.
As the pressure drops below 6 kgf/cm2 (0.59 MPa) (85 psi) (5.9 bar) the force of brake springs pushes brake piston against
(→) mating plates and friction plates, which are splined to gearbox spindle and cylinder block.
When the plates are squeezed together the frictional force generated applies a brake torque of 40.6 kgf m (398 Nm) (293 lbf
ft) to the motor output shaft.
Operation, displacement changeover valve
Low speed
When the travel solenoid valve is deactivated (ph) servo hydraulic flow to port (D) is cut off. The hydraulic pressure at (A, B)
port moves spool upward overcoming the force of spring, and blocks port (C).
At the same time the pressurized oil in chamber (P) drains to the motor case. This allows the forces acting on the rotary
group to move swash plate to maximum swash angle θ1, contacting y plane. Piston stroke is increased, cylinder revolutions
decrease, resulting in low speed with high torque.
Figure 11
Displacement changeover valve, low speed
3 Plates
263 Spool
266 Spring
High-speed
When the travel solenoid is energized (ph) servo hydraulic oil will flow to port (D).
The hydraulic pressure 40 kgf cm2 (3.9 MPa) (569 psi) (39 bar) at port (D) combined with the force of spring moves spool
downward overcoming the force of the hydraulic oil pressure at port (A, B) and opens port (C).
The pressurized oil from port (C) flows into chamber (P) and pushes piston (61) moving swash plate to minimum swash
angle θ2, contacting x plane. Piston stroke is decreased, cylinder revolutions increase, resulting in high speed with low
torque.
Figure 12
Displacement changeover valve, high speed
3 Plates
263 Spool
266 Spring
Automatic speed shifting to low speed during high speed travelling
When the load (tractive effort) is increased during high speed travel the oil pressure at port (A, B) increases.
If the pressure is approximately 260 kgf cm2 (25.5 MPa) (3698 psi) (255 bar) it overcomes the combined force of spring and
(ph) servo hydraulic flow 40 kgf cm2 (3.9 MPa) (569 psi) (39 bar) at port (D), and moves spool upward, blocking port (C). At
the same time the pressurized oil in chamber (P) drains to the motor case, and swash plate moves to maximum swash angle
θ1, contacting Y plane, and the motor rotates at low speed.
Figure 13
Displacement changeover valve, automatic speed shifting
3 Plates
263 Spool
266 Spring
Service Information

Track motor, maintenance Service Information 2014/6/13
standard
Profile:
EXC, EC220D L [GB]
Track motor, maintenance standard

Standard for parts service and replacement
The following standards of the serviceability of parts can be determined from measurements made at disassembly. However,
they are general standards and when parts show excessive external damage or discoloration, top priority should be given to
the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the
remaining life expectancy of the parts.
Seals
No. Part name Condition Standard value Allowable value

2 Shaft The surface contacting seal is worn.
The spline section is worn.
3 Swash plate Sliding surface for piston shoes is damaged.
Sliding surface for piston shoe is damaged.
4 Cylinder block The spline section is worn. Linear clearance: Linear clearance:
The piston bores are worn or scored. 28 ~ 45 µm 50 µm
The sliding surface that contacts valve plate is
damaged or nonuniformly worn.
5 Piston An axial clearance is present between piston and Clearance: 0.05 Clearance: 0.05
6 Shoe shoe. mm (0.002 inch) mm (0.002 inch)
Shoe wear is excessive or nonuniform.
7 Retaining plate The peripheral edge is nonuniformly worn.
8 Thrust ball The spherical sliding section that contacts the
9 Valve plate retaining plate is nonuniformly worn.
The sliding surface has traces of scoring or
nonuniform wear.
15 Friction plate Micro groove pattern is worn off. Brake torque: Brake torque: less
16 Mating plate The sliding surface is scored. more than 398 Nm than 398 Nm (293
The edges are damaged. (293 lbf ft) lbf ft)
The plates are warped.
49, 50 Bearing Pitting/flaking of the races or balls or
rollers.
Does not rotate smoothly by hand.
101 Relief valve piston The sliding surface is damaged.
102 Sleeve The seat surface is damaged.
The clearance against piston is
excessive.
201 Rear flange Counterbalance spool or bore is damaged. Linear clearance: Linear clearance:
Bore to spool, clearance is excessive. 10 ~ 20 µm 25 µm
Piston or bore is damaged.
Bore to spool, clearance is excessive.
Check valve face or seat is damaged or worn.
Valve sealing surface/angle is abnormal.
223, Spool The sliding surface or bore is damaged.
263
281 Piston The sliding surface is damaged.
General tools
General tools
No. Description Size Quantity

1 Allen wrench 5, 8, 10, 14 mm (0.2, 0.32, 0.39, 0.55 in) 1
2 Ratchet 1/2″ drive, 3/4″ drive 1
3 Torque wrench Approximately 280 Nm (207 lbf ft) 1
Approximately 850 Nm (629 lbf ft)
4 Socket 32, 41 mm (1.3, 1.6 inch) 1
5 L wrench socket 5, 6, 8, 10, 14, 19 mm 2
(0.2, 0.24, 0.32, 0.39, 0.55, 0.75 inch)
6 Hammer Nominal 12 1
7 Plastic hammer Approximately L = 300 mm (11.8 inch) 1
8 Screwdriver Approximately L = 150 mm (5.9 inch) 1
9 Retaining ring pliers Expansion 1
Retraction
10 Hoist Capacity 300 kg (661 lbs) or over
11 Eye bolt M16
PF 1 / 2
12 Bench press Capacity 200 kg (441 lbs) or over
13 Compressed air Capacity 0.29 ~ 0.49 MPa (42.7 ~ 71.1 psi) (2.9 ~ 4.9 bar)
Hose & nozzle
14 Drain pan W 450 × D 300 × H 120
15 Heating vessel Temperature rise ability : 100 °C or over
Volume 500 × 500 × 500 mm (19.7 × 19.7 × 19.7 in) or over
16 Leather gloves -
17 Seal tape -
18 Depth micrometer Measuring range: approximately 30 mm (1.18 in)
Minimum scale: 0.01 mm (0.00039 inch)
19 Feeler gauge Measuring range: 0.04 ~ 0.3 mm (0.0016 ~ 0.012 inch)
20 Grinder Cast cutting
21 Air chisel BRH – 8 (compressed air: 0.59 MPa, 85.3 psi, 5.9 bar)
Installation
Figure 1
Mounting location
A. Main body mounted area

B. Sprocket mounted area
 Check that the mating mount surfaces are clean.

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

Reduction screw (A) See 700 Undercarriage, tightening torque.
Sprocket screw (B)
NOTE!
The screws must be 10.9 KS strength classification or above.
Piping
 Check that there is no contamination in the ports or plumbing before connecting to the motor.
 Prior to start-up purge the air from the circuit plumbing and motor.
 Prior to start-up fill the motor casing with the specified hydraulic oil.
NOTE!
Oil capacity. See 4411 Track motor, specifications.
 Check that the case drain pressure is within specification.

NOTE!
Casing pressure. See 4411 Track motor, specifications.
 Check if the direction of rotation according to the control lever is correct.
Lubrication
NOTICE
Prior to operating the travel function, fill the gearbox with the specified oil to the correct level.
Operating checks
WARNING
The temperature of the case is high just after running. Use a thermometer to measure. Do not touch directly by hand
to prevent a burn injury.
 Check the oil level prior to operating the travel function.

 Check for oil leakage on the gearbox assembly.
 Check for loose mounting screws.
NOTE!
The temperature of the case must be lower than 90 °C, during continuous operation.
Performance check
After the completion of motor service, perform the performance check test according to the following procedure.
Check procedure
Prior to conducting the performance check ensure that :
 The track assembly is removed from the gearbox.
 The hydraulic system pressures are set to specification.
Performance check procedure
1. Motor installation/ Check the gearbox assembly and circuit plumbing for any abnormalities.
piping
2. Motor break-in test Travel speed Motor speed Pressure Rotating Operating time
condition direction
Low 10 rpm No load Left, Right More than 1
High 20 rpm hour
3. Motor performance 1 Warm up check Warm up until reaching the setup temperature.
check Operating temperature: 45 ~ 55 ºC
Outside temperature of gearbox hub: 40 ~ 80 ºC
Confirmation check After measuring following items, decide the
acceptance.
2 Motor driving pressure 1.96 MPa (285 psi) (19.6 bar) or less at 1st speed, 10
rpm
2.94 MPa (427 psi) (29.4 bar) or less at 2nd speed, 20
rpm
Hydraulic motor drain 2 liters/min or less at 10 rpm for both 1st and 2nd
volume speed.
Accepted Rejected
Mount the track link. Disassemble and adjust

again.
Special tools
Special tools

1 Retainer 8932-00160 Guide pin 1
2 Retainer 8932-00150 2
3 Retainer 8933-00320 1
4 Lifter 8932-00210 Lifting eye 1
Track motor does not rotate
Hydraulic pressure is low. Main relief pressure is low. Adjust to specification.
Pump failure Check if the devices except for

traveling are operating. Repair
as necessary.
Safety solenoid valve failure. Check the safety solenoid valve

system.
Pressure is normal. Brake valve failure. Repair or replace the rear flange
(Counterbalance spool) assembly.
Hydraulic motor failure Check the case drain oil.

If contaminated, replace the
motor.
Input gear to the gearbox is Repair the gearbox assembly.

damaged.
Motor is overloaded. Reduce the load.

Service Information

Track motor, replacing Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track motor, replacing

Op nbr 441-111
1. Remove the track chain, sprocket and track unit. See 4311 Track unit, replacing.
Figure 1
Removal, track unit
1. Hoist
2. Track unit
2. NOTICE
Do the work in an environmentally safe manner.
NOTICE
Mark up all parts when dismantling so that they are assembled in the correct order when assembling.
Remove the screw at the track gear box cover.
Figure 2
Removal, cover mounting screws (1)
3. Remove the set screws and install the screws.

Figure 3
Disconnect, gear box cover
1. Set screws
2. Disconnecting screws
4. Lift the gear box cover hoist and lower to the workbench safely.
Figure 4
Removal, gear box cover
1. Hoist
2. Gear box cover
5. Hold the No1 planetary gear with hoist and remove the No1 planetary gear and No1 sun gear.
Figure 5
Removal, No1 planetary gear
1. No1 planetary gear

2. No1 sun gear
6. Hold the No2 sun gear with hoist and remove the No2 sun gear.
Figure 6
Removal, No2 sun gear (1)
7. Hold the ring gear with hoist and remove the ring gear.
Figure 7
8. Remove the screws and retaining ring.

Hold the gear box housing with hoist and remove the gear box housing.
Figure 8
Removal, gear box housing
1. Screws
2. Retaining ring
3. Gear box housing
9. Assemble at clean condition.
NOTE!
Take care not to damage the retainer ring, seal and O-ring when assembling.
Figure 9
New track motor
10. Install the screws and retaining ring.

Hold the gear box housing with hoist and install the gear box housing.
Figure 10
Installation, gear box housing
1. Screws
2. Retaining ring
3. Gear box housing
11. Thoroughly clean the mounting surface. Apply sealing compound to the mounting surface
Hold ring gear with hoist and install the ring gear.
Figure 11
Installation, ring gear
1. Ring gear
2. Sealing compound
12. Hold the No2 sun gear with hoist and install the No2 sun gear.
Figure 12
Installation, No2 sun gear (1)
13. Hold the No1 planetary gear with hoist and install the No1 planetary gear and No1 sun gear.
Figure 13
Installation, No1 planetary gear
1. No1 planetary gear

2. No1 sun gear
14. Thoroughly clean the mounting surface. Apply sealing compound to the mounting surface
Lift the gear box cover hoist and install the gear box cover. See tightening torque, 4311 Track gearbox, description.
Figure 14
Installation, gear box cover
1. Hoist
2. Gear box cover
15. Install the track unit, sprocket and track chain. See 4311 Track unit, replacing.
Figure 15
Installation, track unit
Service Information

Track motor relief valve, Service Information 2014/6/13
replacing
Profile:
EXC, EC220D L [GB]
Track motor relief valve, replacing

Op nbr 441-112
1. Park the machine in the service position F. See 091 Service positions.
3. Remove the screws and motor cover.
Figure 1
1. Screws
2. Motor cover
4. Remove the track motor relief valve.
Figure 2
Removal, relief valve
1. Relief valve
5. Install a new relief valve.
Figure 3
Installation, relief valve
6. Check relief valve pressure of the track motor, and adjust if necessary
7. Install the motor cover.

NOTE!
Tightening torque. See 4311 Track gearbox, description.
Service Information

Track motor, disassembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track motor, disassembly

Tool: 8932–00210, Tool: 8932–00150, Tool: 8932-00160 Guide pin
Precautions

 Take care not to mix parts of sub assemblies.
Disassembly
Track motor illustration. See 4411 Track motor, description.
1. Prior to disassembly, install the motor on a rotary work stand. Drain the hydraulic oil and gear oil.
NOTE!
Oil pan size. See 4411 Track motor, specifications.
Figure 1
Track motor
2. Remove the relief valve from rear flange (201).
Remove O-ring (108), (109), (110) and back-up rings (111), (117) from relief valve.
NOTE!
Do not reuse O-rings after removal.
Figure 2
Removal, relief valve
3. Remove the screws (243).
Figure 3
Removal, screws
4. Remove the rear flange (201) from spindle (302).
NOTE!
Take care not to remove the shaft (2).
Figure 4
Removal, rear flange
5. Gearbox/hydraulic motor shaft and oil seal
Figure 5
Removal, bearing
 Remove the valve plate (9), parallel pin (241), brake springs (13) and bearing (50) from rear flange (201)
and hydraulic motor.
 Remove the O-rings (329) from spindle (302).
NOTE!
Do not reuse O-rings (329) after removal.
6. Counterbalance spool removal
 Remove the plugs (224) from rear flange (201).

Figure 6
Removal, plug
 Remove the O-ring (236) from plug (224).
NOTE!
Do not reuse O-ring (236) after removal.
 Remove the springs (228), stoppers (225), and counterbalance spool (223) from rear flange (201).
NOTE!
Be careful not to damage the outer surface of counterbalance spool (223) and the sliding surface of rear
flange (201). Since rear flange (201) and counterbalance spool (223) are of the selective-fitting type,
replace them together as a kit even if only one of the two parts is damaged.
Figure 7
Removal, counterbalance spool
7. Check valve removal
Figure 8
Removal, plug
 Remove the springs (230) and check valves (227) from rear flange (201).
NOTE!
Be careful not to damage the seat sections of check valve (227) or rear flange (201).
Figure 9
Removal, check valve
NOTE!
8. Two-speed valve removal
Figure 10
Removal, plug
 Remove the spool (263) and spring (266) from rear flange (201).
Figure 11
Removal, spool
 Remove the O-rings (295) from plugs (257).
NOTE!
9. Removal of internal parts

Figure 12
Removal, plug
 Remove the plug (280) from flange (201).

 Remove the piston (281) from rear flange (201).

NOTE!
Take care not to damage the piston hole.
NOTE!
Since rear flange (201) and piston (281) are of the selective fitting type, replace them together as a kit.
Figure 13
Removal, piston
 Remove the plug (282), O-ring (283), and (284).
NOTE!
Do not reuse O-ring after removal.
Figure 14
Removal, plug
 Remove the steel balls (285) from rear flange (201).
Figure 15
Removal, steel ball
10. Relief valve removal
Figure 16
Removal, plug
 Remove the plug (104) and remove sleeve (102).

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

NOTE!
Do not reuse O-ring after removal.
 Remove the shim (105) from plug (104).
Figure 17
Removal, shim
 Take out spring retainer (103), spring (106), and piston (101) in that order from sleeve (102).
Figure 18
Removal, spring retainer
Figure 19
Removal, spring
 Remove the seal (120) from piston (101).
Figure 20
Removal, relief valve piston
 Disassemble the other side sleeve in the same method.
NOTE!
If the parts, except O-ring (110) and seal (120) need to be replaced the relief valve must be reset on a test
bench. Therefore replace the relief valve assembly.
11. Parking brake removal
WARNING
Abrupt injection of compressed air may cause piston to pop out. To ensure your safety, apply a protective
cover over the piston.
Figure 21
Injecting, compressed air
 Remove the brake piston (12) by injecting compressed air (pressure: 0.29 ~ 0.49 MPa (42.7 ~ 71.1 psi) (2.9
~ 4.9 bar)) into the parking brake access hole in spindle (302).
 Remove the O-rings (35 and 39) from piston (12).
NOTE!
Do not reuse O-rings (35), (39) after removal.
Figure 22
Removal, brake piston
12. Removal of rotary group

Figure 23
Removal, cylinder block
 Place an oil pan under spindle (302).

NOTE!
Pistons must be installed into the same bores because of wear pattern. Mark the pistons and respective
cylinder bores.
NOTE!
Before removal, hold cylinder block (4) with both hands and turn it two to three times in a clockwise and
counterclockwise direction alternately, to detach shoes (6) from swash plate (3).
NOTE!
Be careful when removing the cylinder block that the pistons and needle rollers (51) do not fall into the
spindle.
 Hold cylinder block (4) with both hands, and remove it from spindle (302).
 Remove the swash plate (3), steel balls (67) from spindle (302).
 Remove the mating plates (16) and friction plates (15) that are mounted on the outer surface of cylinder
block (4).
 Remove the piston assembly (5), shoe (6), retainer plate (7), thrust ball (8), and needle rollers (51) from
cylinder block (4).
Figure 24
Removal, needle roller
13. Remove the swash plate (3) from spindle (302).
Figure 25
Removal, swash plate
14. Remove the drive shaft (2) from spindle (302) by striking the front part lightly with a plastic hammer.
Figure 26
Removal, drive shaft
15. Remove the bearing (49) from drive shaft (2).
Figure 27
Removal, bearing
16. Remove the steel ball (67) and parallel pin (71) from spindle (302).
WARNING
Abrupt injection of compressed air may cause piston to pop out. To ensure your safety, apply a protective
cover over the piston.
Figure 28
Removal, steel ball and parallel pin
17. Remove the speed selector piston assembly [piston (61) and shoe (62)] from spindle (302) by feeding compressed
air (pressure: 0.29 ~ 0.49 MPa (42.7 ~ 71.1 psi) (2.9 ~ 4.9 bar)) into the access hole in spindle (302).
NOTE!
The rotary group parts must be replaced as a set. Reference the parts catalog for details.
Figure 29
Removal, piston
18. Remove the seal (32) from spindle (302).
Figure 30
Removal, seal
19. Cylinder block disassembly
Figure 31
 Place cylinder block (4) on a press bench, then while pressing holding retainer (I) against washer (10),
remove retaining ring (45).
NOTE!
Press load: 200 kg (441 lbs) or over.
NOTE!
When removing the spring, press the axial centers of retainer (I) and washer to prevent the cylinder block
from being damaged by contact.
NOTE!
Protect the sliding surface of the cylinder block with a rubber sheet.
NOTE!
Remove the spring (14) only if it is to be replaced.
 Slowly release the press until the spring force is relaxed.
Figure 32
Removal, spring
 Remove the washer (10), spring (14), and washer (10), in that order, from cylinder block (4).
Service Information

Track motor, assembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Track motor, assembly

Tools: 8932-00160 Guide pin, 8932-00210 Lifting eye, 8933–00320 Seal installation
Precautions
 Coat the motor assembly sliding parts and bearings with clean hydraulic oil.
 Replace the O-rings, and seals.
 Use a torque wrench to tighten the screws and plugs to the specified torque.
Tightening torque
Tightening torque
No. Part name Thread size Tightening torque

102 Sleeve PF 1 245 ±49 Nm (181 ±36.1 lbf ft)
104 Plug PF 1/2 98.1 ±19.6 Nm (72 ±14 lbf ft)
221 Plug 216-3/4-16 UNF 58.8 ±9.8 Nm (425 ±71 lbf ft)
224 Plug M36 (P 1.5) 441 ±88.2 Nm (325 ±65 lbf ft)
226 Plug M36 (P 1.5) 255 ±39.2 Nm (188 ±29 lbf ft)
243 Screw M16 (P 2.0) 252 ±39.2 Nm (186 ±29 lbf ft)
246, 252 Plug PF 1/4 29.4 ±4.9 Nm (22 ±4.0 lbf ft)
254 Plug NPTF 1/16 9.81 ±1.96 Nm (7.2 ±1.4 lbf ft)
257 Plug PF 1/2 98.1 ±19.6 Nm (72 ±14 lbf ft)
279 Filter M6 0.49 ±0.1 Nm (3.54 ±0.72 lbf ft)
280 Plug PF 3/8 58.8 ±9.81 Nm (43.3 ±7.2 lbf ft)
282 Plug PF 1/8 14.7 ± 2.45 Nm (10.8 ±1.8)
297 Orifice M6 0.49 ±0.1 Nm (3.54 ±0.72 lbf ft)
298 Plug PT 1/8 12.3 ±2.45 Nm (9.0 ±1.8 lbf ft)
Assembly
Track motor illustration. See 4411 Track motor, description.
1. Check valves
Figure 1
Installation, plug
 Fit O-ring (237) on plug (226).
 Install the spring (230) and check valve (227) to plug (226), then grease the spring and valve assembly.
 Insert the plug (226) in conjunction with spring and valve, into rear flange (201), and tighten the plug to
the required torque.
NOTE!
Apply grease to O-ring (237).
NOTE!
Coat the thread section of plug (226) with loctite #577.
2. Counterbalance spool
Figure 2
Installation, counterbalance spool
 Insert the spool (223) into rear flange (201).

NOTE!
Apply hydraulic oil to spool (223) and insert it into rear flange (201).
NOTE!
Damage to the bore section of the rear flange or the surface of the spool may cause internal leakage to
occur after reassembling, and motor performance to deteriorate.
 Attach O-ring (236).

NOTE!
Apply grease to the O-ring.
 Install the stopper (225) and spring (228) into both plugs (224), and tighten plugs (224) into rear flange
(201) to the required torque.
NOTE!
If either the rear flange (201) or spool (223) is to be replaced, the entire assembly (kit) must be replaced.
Figure 3
Installation, plug
3. Speed selector valve
Figure 4
Installation, spool
 Fit O-rings (295) on plugs (257).

 Install the spring (266) onto spool (263) and insert into rear flange (201).
NOTE!
NOTE!
Apply hydraulic oil to spool (263) and insert it into rear flange (201).
NOTE!
Damage to the bore section of the rear flange or the surface of the spool may cause internal leakage to
occur after reassembling, and motor performance to deteriorate.
 Tighten plugs (257) into rear flange (201) to the required torque.
Figure 5
Installation, plug
4. Shock relief valve parts
Figure 6
Installation, steel ball
 Insert the steel balls (285) into rear flange (201).
 Mount O-rings (283), (284) on plugs (282).
NOTE!
 Tighten plugs (282) into rear flange (201) to the required torque.
 Insert the piston (281) into rear flange (201).

NOTE!
Apply hydraulic oil to piston (281) and insert it into rear flange (201). If there is damage to the bore section
of the rear flange or the surface of the spool, they must be replaced as an entire assembly.
Figure 7
Installation, piston
 Mount O-ring (296) on plug (280).
NOTE!
 Tighten plug (280) into rear flange (201) to the required torque.
Figure 8
Installation, plug
5. Relief valves
 Mount O-ring (108, 109, 119) and back-up ring (111, 117) on sleeve (202).
NOTE!
Apply grease to O-ring (108), (109) and (110).
 Mount O-ring (110) on plug (104).

 Install the shims (105) onto plug (104).
NOTE!
The relief pressure is adjusted by shim, so install the original shims that were assembled.
NOTE!
Apply grease to the shims to hold them to plug (104).
 Mount piston seal (120) on piston (101).

NOTE!
Piston seal (120) consists of O-ring and teflon ring.
NOTE!
Apply grease to both sides of piston seal (120).
Install O-ring and then teflon ring.
 Install the piston (101), spring (106), spring retainer (103) and shims (105) with plug (104) then tighten to
the required torque.
NOTE!
Coat piston (101) with hydraulic oil and install into sleeve (102).
NOTE!
The internal parts of the sleeve is comprised of a sleeve kit. Take care to assemble correctly.
Figure 9
 Assemble the other relief valve in the same method.
6. Seal (32)
Figure 10
Installation, seal
 Fit seal (32) into the seal mounting hole of shaft (2).
– Retainer (III)
NOTE!
Apply white petroleum jelly or lithium grease to the lip section of seal (32).
WARNING
When inserting ball bearing use leather gloves and take care not to get burned.
7. Drive shaft (2)

Figure 11
Installation, bearing
 Shrink-fit ball bearing (49) onto shaft (2).

NOTE!
If ball bearing (49) has been removed from shaft (2) during disassembling replace the bearing with a new
one and then shrink-fit it onto shaft (2).
NOTE!
Shrinkage-fitting temperature: 100 ± 10 °C
NOTE!
Take care not to heat shaft (2) when shrink fitting ball bearing (49).
8. Assembly of piston assembly (61), (62)
Figure 12
Installation, piston assembly
 Apply grease on spring (93) and fit to the piston assembly.

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

Figure 13
Installation, pin and steel ball
 Insert the pins (71) into spindle (302) and mount steel balls (67).
 Coat the pins and steel balls with grease.
10. Cylinder block
Figure 14
Installation, spring
 Put cylinder block (4) on a press bench.

 Insert the spring (14) and washer (11) into the cylinder block (4).
NOTE!
Insert the sharp-edge part of washer (10) as shown in figure left.
 Put the retainer on washer (10), and using the press force-fit spring (14), then mount retaining ring (45).
– Retainer (I)
NOTE!
When working on the cylinder block, protect its sliding face by covering it with a vinyl sheet.
NOTE!
Force to compress spring (14): 200 kg (441 lbs) or above.
NOTE!
Ensure that retaining ring (45) is fully seated.
Figure 15
Installation, retainer
11. Motor assembly
Figure 16
Installation, needle roller
 Fit needle rollers (51) into cylinder block (4), and then, put collar (11) and thrust ball (8) on it.
 Insert the piston assembly (5), (6) into retainer plate (7).
Figure 17
 Coat the piston assembly with hydraulic oil, and then fit to cylinder block (4).
NOTE!
Piston must be installed into the same bores because of wear pattern.
NOTE!
Align the match marks of the pistons and cylinder block made prior to disassembly.
 Apply hydraulic oil on the sliding face of shoe (6) and the spherical section of thrust ball (8).
 As shown in the diagram below, mount swash plate (3), thrust ball (8), collar, retaining plate (7), needle
roller (51), cylinder block (4), and piston assembly (5), (6), on shaft (2). Then install the lifter and turn the
shaft upright.
– Lifter eye (A)
Figure 18
Installation, cylinder block
12. Fitting motor assembly
Figure 19
Installation, motor assembly
 Lift the motor assembly via lifter, and mount the guide inserting jig on the spline section of shaft (2).
NOTE!
Align steel ball (67) to the ball hole in swash plate (3).
 Insert the motor shaft slowly, into spindle (302).

 After assembling, remove lifter and the guide inserting jig (A).
NOTE!
After the motor assembly is installed, rotate cylinder block (4) by hand to check for backlash.
If there is any backlash, correct the fault.
13. Mount friction plate (15) and mating plate (16) alternately in that order on the cylindrical groove of cylinder block
(4).
NOTE!
Immerse friction plate (15) in hydraulic oil.
NOTE!
Note the assembly order of friction plate and mating plate. If wrong, the parking brake force may be weakened.
Figure 20
Installation, brake
14. Fit O-ring (35), (39) and assemble piston (12) into spindle (2).
Figure 21
Installation, brake piston and O-ring
15. Fit brake piston (12) into spindle (302) by lightly tapping the sectional surface of piston (12) using a plastic hammer,
to prevent the piston from being distorted.
NOTE!
Apply grease on O-ring (35), (39).
Figure 22
Installation, brake piston
16. Mount ball bearing (50), valve plate (9), parallel pin (241), and springs (13) on rear flange (201).
NOTE!
Coat spring (13) and valve plate (9) with grease to hold it to rear flange (201).
NOTE!
Apply hydraulic oil on ball bearing (50).
Figure 23
17. Fill with hydraulic oil.
Figure 24
Filling, hydraulic oil
 Oil capacity: 1.7 liters (0.45 US gal)
18. Insert the O-ring (329), (327) and (342) into spindle (302), and mount rear flange (201).
NOTE!
Do not apply grease on O-ring (329) or mating surface. (Because the grease may be mistaken for oil leakage)
NOTE!
The rear flange (201) must be mounted so that the two parallel pin (342) mounted on spindle (302) and the pin
hole align.
Figure 25
Installation, rear flange
19. Tighten screw (243) to spindle (302) at the required torque.
Figure 26
Installation, screw
20. Mount O-ring (295) on plug (257) and the drain port not pipe-connected
21. Mount the relief on rear flange (201).
Tighten to the required torque.
Figure 27
Service Information

Swing motor, description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing motor, description

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

Figure 1
Swing motor, construction
lnlet Outlet View from shaft end

A B Clockwise
B A Counterclockwise
Port size and torque, Nm (lbf ft)
Port Symbol Screw size and depth Tightening torque

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

Figure 2
Swing motor, sectional view
031 Delay valve 355 Spring

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

Swing motor, maintenance Service Information 2014/6/13
standard
Profile:
EXC, EC220D L [GB]
Swing motor, maintenance standard

Swing motor, lubrication and air purging
Figure 1
Position, drain
D Drain port
 Following the repair or replacement of the swing motor assembly it is necessary to prelubricate the internal
components to prevent scoring/scuffing of the bearings and sliding parts.
 Remove the upper case drain port plug and fill the casing with the specified hydraulic oil.
 Oil capacity: 0.8 liters (0.21 US gal)
 Prior to start up purge the air from the circuit plumbing and motor.
Precautions for lubrication
 Check that there is no contamination in the ports or plumbing before connecting to the motor.
 Check for oil leakage on the motor assembly.
 Check if the direction of rotation according to the control lever is correct.
 Check if the hydraulic pressures are set to the specified values.
Standard for parts service and replacement

The following standards of the serviceability of parts can be determined from measurements made at disassembly. However,
they are general standards and when parts show excessive external damage or discoloration, top priority should be given to
the determination of the extent to which parts are to be replaced, according to the purpose of disassembly and the
remaining life expectancy of the parts.
Seals
Part replacement criteria, unit: mm (in)
Item Standard Recommended Remedy

dimension value for replacement
Clearance between piston and cylinder 0.027 0.052 Replace piston or cylinder.
bore (D–d) (0.0011) (0.0021)
Gap between piston and caulked part of 0 0.3 Replace assembly of piston
shoe (α) (0.0118) and shoe.
Thickness of shoe (t) 5.5 5.3 Replace assembly of piston

(0.2165) (0.2087) and shoe.
Thickness of friction plate (t) 2 1.8 Replace friction plate.

(0.0787) (0.0709)
Standard for correcting sliding surfaces

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

Shoe 0.8–Z (Ra=0.2) 3–Z (Ra=0.8)
(lapping)
Shoe plate 0.4–Z (Ra=0.1) 3–Z (Ra=0.8)
(lapping)
Cylinder 1.6–Z (Ra=0.4) 12.5–Z (Ra=3.2)
(lapping)
Valve plate 0.8–Z (Ra=0.2) 6.3–Z (Ra=1.6)
(lapping)
 Lap each sliding surface to a standard roughness level or finer.

 If the sliding surface of the cylinder block, valve plate, retaining plate or spherical bushing is roughened, replace the
parts as sub assemblies.
Crossover relief valve, pressure adjustment
 Remove pressure port plug PA or PB.

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

 To decrease pressure, turn counter clockwise.
 If the relief pressure can not be adjusted correctly, replace the relief valve assembly.
Figure 2
Pressure adjustment
PA Gauge port 1 Lock nut

PB Gauge port 2 Adjusting screw
General tools
General tools
Tool Size Name of parts applied and remarks

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

1 Brake piston tool 14559282 1
Service Information

Swing motor, replacing Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing motor, replacing

Op nbr 441-021
Figure 1
Removal, hoses
2. Drain hose
3. Feed line hoses
5. Screws
6. Remove the delay valve sub hoses.
7. Remove the swing motor mounting screws.
8. Lift swing motor with sling, and lower to the workbench safely.
Figure 2
Removal, swing motor
1. Sling
2. Oil filling pipe
3. Swing motor
9. Transfer oil filling pipe and the connectors to the new swing motor.
NOTE!
Before installing the drain port connector, fill the new swing motor casing with hydraulic fluid.
10. Thoroughly remove the sealing compound on swing gearbox.

Apply sealing compound to the swing gearbox mounting surface.
Figure 3
Applying, sealing compound
1. Swing gearbox
2. Sealing compound
11. Install the swing motor.
12. Install the swing motor feed line hoses.
13. Install the delay valve sub hoses.
14. Install the swing motor drain hose.
15. Install the anti-cavitation hose.

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

Swing motor relief valve, Service Information 2014/6/13
replacing
Profile:
EXC, EC220D L [GB]
Swing motor relief valve, replacing

Op nbr 441-022
3. Remove the swing motor relief valve.
Figure 1
Replacing, relief valve
1. Relief valve
4. Install a new relief valve on the swing motor.
Figure 2
7. Check relief valve pressure of the swing motor, and adjust if necessary. See relief valve pressure,
4412 Swing motor, specifications.
Service Information

Swing motor removed, Service Information 2014/6/13
replacing seal
Profile:
EXC, EC220D L [GB]
Swing motor removed, replacing seal

Op nbr 441-026
1. Remove the retaining rings.
Figure 1
Removal, retaining rings
1. Retaining ring
2. Retaining ring
2. Remove the seal cover from the swing motor housing.
Figure 2
Removal, seal cover
1. Seal cover
3. Remove the seal from the swing motor housing.

Figure 3
Replacing, seal
1. Seal
4. Install the a new seal to the swing motor housing.

NOTE!
Apply grease on lip of seal.
5. Install the seal cover to the swing motor housing.
Figure 4
Installation, seal cover
1. Seal cover
6. Install the retaining rings.

Figure 5
Installation, retaining rings
1. Retaining ring
2. Retaining ring
Service Information

brake piston seal
Profile:
EXC, EC220D L [GB]
Swing motor, replacing brake piston seal

Op nbr 441-025
14559282 Puller
1. Park the machine in the service position B. See 091 Service positions.
Figure 1
Removal, hoses
2. Drain hose
3. Feed line hoses
6. Remove the two valves from the block.

Figure 2
1. Valves
2. Screw
3. Swing motor cover
7. Remove the mounting screws.
8. Lift the swing motor cover.
9. Remove the springs from the brake piston and remove the plate on the cylinder.
Figure 3
Removal, springs and plate
1. Springs
2. Plate
10. Fit the special tool to brake piston as shown and then tighten screws to the casing.
Pull the brake piston vertically by tightening the screws of special tool.
 Tool part number (1): 14559282

Figure 4
1. Special tool
2. Brake piston
3. Screws
11. Replace O-rings in the casing.
Figure 5
Replacing, O-rings
1. O-ring
2. O-ring
12. Install the brake piston into the casing using the special tool.
13. Install the springs to the brake piston.
14. Apply grease on plate and install it to swing motor cover.

Figure 6
Installation, plate
1. Plate
15. Install the swing motor cover to the casing.
16. Install the hoses in reverse order of removal procedure.

NOTE!
Service Information

plate (brake)
Profile:
EXC, EC220D L [GB]
Swing motor, replacing plate (brake)

Op nbr 441-024
14559282 Puller
Figure 1
Removal, hoses
2. Drain hose
3. Feed line hoses
6. Remove the two valves from the block.

Figure 2
1. Valves
2. Screw
7. Remove the mounting screws.
8. Lift the swing motor cover.
9. Remove the springs from the brake piston and remove the plate on the cylinder.
Figure 3
Removal, springs and plate
1. Springs
2. Plate
10. Fit the special tool to brake piston as shown and then tighten screws to the casing.
Pull the brake piston vertically by tightening the screws of special tool.

Figure 4
1. Special tool
2. Brake piston
3. Screws
11. Replace friction plates and mating plates using a magnetic bar.
Figure 5
Replacing, plates
1. Mating plate
2. Friction plate
12. Install the brake piston into the casing using the special tool.
13. Install the springs to the brake piston.
14. Apply grease on plate and install it to swing motor cover.

Figure 6
Installation, plate
1. Plate
15. Install the swing motor cover to the casing.
16. Install the hoses in reverse order of removal procedure.

NOTE!
Service Information

Swing motor, disassembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing motor, disassembly

1. Ensure that the motor is clean and free from dirt and debris prior to any disassembly.
NOTE!
All port are to be plugged to prevent ingress of dirt during external cleaning.
2. Remove the drain plug and drain the oil from casing (301).
3. Put identification marks on the parts to indicate proper positioning during reassembly.
NOTE!
Prevent damage to disassembled parts, by keeping them protected and in a clean area.
Figure 1
Identification marks
4. Remove relief valves (051) from the valve casing (303).
NOTE!
Be sure to replace O-rings of relief valves because they are frequently damaged during disassembly.
Figure 2
Removal, relief valves
5. Remove plugs (469), spring (355) and spools (351) from the valve casing (303).
NOTE!
Handle carefully to prevent damage to the seat on spool (351).
Figure 3
Removal, plugs
6. Remove screws (401) and remove valve casing (303) from casing (301) then remove valve plate (131).
NOTE!
When the screws are loosened the valve casing is slightly lifted by the brake springs (712).
Be careful not to drop the valve plate from the valve casing. It is often adhered to the cylinder.
Figure 4
Removal, screws
7. Remove springs (712) from the brake piston (702).
Figure 5
Removal, springs
8. Remove brake piston (702) from casing (301) by using special tool.
– Tool part number: 14559282
NOTE!
Pull brake piston (702) vertically by using the special tool.
Figure 6
9. Put the motor on its side as shown in the figure. Remove the rotation group from drive shaft (101).
NOTE!
During the removal of the rotation group from the swing motor, do not let the pistons fall out of the cylinder. All
pistons in the rotation group must be re-installed in their original locations.
Figure 7
Removal, rotation group
10. Disassemble the rotation group as follows:
Put identification marks on nine pistons (121), showing their location in plate (123) and cylinder (111). Remove nine
pistons (121) and plate (123) as a unit from the cylinder. Separate the piston assemblies from the plate.
NOTE!
Handle carefully so as not to damage the sliding face on the retainer or shoes (122).
11. Remove friction plates (742) and mating plates (743) from casing (301).
Figure 8
Removal, friction and mating plates
12. Turn the motor body over, and remove the shaft assembly from casing (301).
Figure 9
Removal, shaft assembly
13. Remove roller bearing (443) using a press if necessary.
NOTE!
Be careful not do damage the sliding face on the shaft. If the bearing is removed, a new bearing must be used
during reassembly.
Figure 10
Removal, bearing
14. Remove bearing (443) from casing (301) using a rod and hammer.
NOTE!
When hammering, be sure to use a soft metal bar to prevent damage to parts. Never hit directly with a hammer or
iron bar.
NOTE!
If the bearing is removed a new bearing must be used during reassembly.
15. Remove bearing (444) from the motor body using bearing pliers, only if necessary.
NOTE!
If the bearing is removed a new bearing must be used during reassembly.
Service Information

Swing motor, assembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing motor, assembly

Cleanliness is a primary means of ensuring satisfactory motor life, for new and repaired units. Clean parts by using a clean
solvent wash and air-drying. As with any precision equipment, the internal mechanism and related items must be kept free
of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and contamination.
It is highly recommended that all oil seals and O-rings be replaced. Lightly lubricate all oil seals and O-rings with clean oil
prior to assembly. Lubricate all sliding sections, bearings, and cylinders with clean oil prior to assembly.
Tightening torque
Tightening torque, unit : Nm (lbf ft)
Description Item No. Thread size Tightening torque

Plug 031–1 9/16–18UNF–2B 0.9 (0.7)
Screw 033 M6 12 (8.9)
Relief valve 051 M33 x 1.5 177 (131)
Plug 151 9/16–18UNF–2B 48 (36)
Screw 171 M8 29 (21.5)
Rebound damping valve 400 M22 x 1.5 69 (51)
Screw 401 M20 430 (318)
Plug 469 M30 x 1.5 334 (247)
Plug 984 3/4–16UNF–2B 1.7 (1.3)
Plug 985 1–5/16–12UN–2B 4.4 (3.3)
1. Place the motor in a vertical position with bell housing face down.
2. Heat bearing inner race (443) to 110 °C (230 °F) maximum and install onto drive shaft (101).
NOTE!
Do not exceed temperature 110 °C (230 °F).
Figure 1
Heating, bearing inner race
A. Output side
B. Bearing inner race
3. Heat bearing inner race (444) to 110 °C (230 °F) maximum and install onto drive shaft (101).
NOTE!
Do not exceed temperature 110 °C (230 °F).
4. Apply grease to seal (491) and install the seal to casing (301).
NOTE!
Be careful of direction of the oil seal. The seal lip must face toward casing (301).
NOTE!
Be careful not to damage the lip of the oil seal.
Figure 2
Installation, oil seal
5. Insert bearing (443) to casing (301).
Figure 3
6. Insert shaft (101) to casing (301).
NOTE!
Be careful not to damage the lip of the oil seal.
Figure 4
Installation, shaft
7. Install shoe plate (124) into casing (301).
NOTE!
The shoe plate lapped side must face outwards.
Figure 5
Installation, shoe plate
8. Put thrust plate (123) on plate spring (114) and install piston assembly (121, 122) into thrust plate (123).
Figure 6
9. Insert piston assemblies into cylinder (111).
Install the rotation group into casing (301).
Figure 7
Installation, rotation group
10. Place the motor in a vertical position with bell housing face down.
First, insert a mating plate (743), and then insert a friction plate (742) and mating plate (743) alternately.
NOTE!
Mating plate: 4 EA, Friction plate: 3 EA
Figure 8
Installation, friction and mating plates
11. Install O-ring (707) and O-ring (706) into casing (301).
NOTE!
Coat the O-rings with grease prior to installation.
Figure 9
Installation, O-ring
12. Install brake piston (702) into casing (301) by tapping the piston into position using a plastic hammer, and then
press firmly to ensure the brake piston is seated correctly.
Figure 10
Installation, brake piston
13. Install spring (712) into brake piston (702).
Figure 11
Installation, spring
14. Install bearing (444) into valve casing (303) using a hammer and steel rod.
NOTE!
Tap evenly at the periphery of bearing using a hammer and steel rod until it is fully seated.
Figure 12
15. Install valve plate (131) and O-ring (472) onto valve casing (303). Brass face must be upwards.
NOTE!
Coat the face of the valve casing lightly with grease to hold valve plate (131) in position.
Figure 13
Installation, valve plate and O-ring
16. Install valve casing (303) and four screws (401) into casing (301).
Figure 14
Installation, valve casing
17. Insert spool (351) and spring (355) into valve casing (303) and install plug (469) with O-ring (488) in valve casing
(303).
NOTE!
Check spool (351) to ensure it moves smoothly.
Figure 15
Installation, spool
18. Put the O-ring on relief valve (051) and install relief valve (051) into valve casing (303).
Figure 16
Service Information

Hydraulic pump coupling, 442 Service Information 2014/6/13
description
Profile:
EXC, EC220D L [GB]
Hydraulic pump coupling, description

The hydraulic pump coupling consists of the spline hub, the inserts and the elements, and evenly transmit the engine power
to the hydraulic pump absorbing the rotating shocks. The engine torque is transmitted to the interface ring connected to the
engine flywheel → the spline hub of the hydraulic pump coupling → the shaft of the hydraulic pump.
Figure 1
Hydraulic pump coupling, sectional view
1 Insert A 5 Screw 9 Screw 13 Flywheel housing

2 Element 6 Screw 10 Hydraulic pump
3 Insert R 7 Clamping screw 11 Flywheel
4 Hub 8 Spring pin 12 Flange
NOTE!
Tightening torque:
Screws (No. 5) : 304~324 Nm (31~33 kgf m) (224~238 lbf ft)
Screws (No. 7) : 98~118 Nm (10~12 kgf m) (72~87 lbf ft)
Screws (No. 9) : 436 Nm (44.5 kgf m) (321 lbf ft)

Service Information

Pump gearbox coupling 442 Service Information 2014/6/13
assembly, replacing
Profile:
EXC, EC220D L [GB]
Pump gearbox coupling assembly, replacing

Op nbr 431-031
1. Remove the hydraulic pump from the engine.

See 913 Hydraulic pump, replacing to remove the hydraulic pump.
2. Remove the element, socket screws and inserts A.
Figure 1
Removal, element and inserts (A)
1. Screws
2. Element
3. Remove the sets screws and inserts R.

Install to the new inserts A and inserts R.
Figure 2
Removal and Installation, inserts
1. Screws
2. Inserts R
NOTE!
Tightening torque screws, see 442 Hydraulic pump coupling, description.
4. Install the hydraulic pump to the engine.

See 913 Hydraulic pump, replacing to install the hydraulic pump.
Service Information

Center passage, description Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Center passage, description

The center passage consists of hub, shaft, seal, cover, plug, spacer and screws.
The hub contains oil grooves to route the flow of oil. The shaft has passages to supply oil into the hub. The seal prevents oil
leakage between shaft and hub. The cover prevents external oil leakage and with screws, fix spacer, hub and shaft together.
High pressure oil from the main control valve is delivered to the center passage, and flows through ports C - D or E - F to the
left and right track motor, to drive the track motors.
Drain oil returns to the reservoir via port G, also track (high speed) control servo hydraulic oil flows into port B.
Hub assembly is fixed to the under carriage and shaft rotates freely in the hub with the superstructure. The oil flows through
circumferential grooves in the hub, therefore oil flow is not obstructed during swing operation.
Figure 1
Center passage, section view and exploded view
1 Hub 6 O-ring 11 Screw 16 Plug (C, D, E, and F port)

2 Shaft 7 O-ring 12 Washer 17 Plug (1-1/16-12 UN)
3 Cover 8 Spacer 13 Plug (PT 3/8) 18 O-ring
4 Bushing 9 Screw 14 Plug (1-1/16-12 UNF)
5 Seal 10 Washer 15 Plug (A and B port)
Center passage port connection

Port Size (UNF-2B) Rated pressure, MPa (kgf cm2) Flow rate, litres (US Application
(psi) (bar) gal)
A 9/16-18 3.4 (35) (498) (34) 10 (2.64) Servo hydraulic 2 speed
B 9/16-18 3.4 (35) (498) (34) 10 (2.64) Servo hydraulic 2 speed
C 1-5/16-12 34.3 (350) (4978) (343) 200 (52.8) Track motor
D 1-5/16-12 34.3 (350) (4978) (343) 200 (52.8) Track motor
E 1-5/16-12 34.3 (350) (4978) (343) 200 (52.8) Track motor
F 1-5/16-12 34.3 (350) (4978) (343) 200 (52.8) Track motor
G 1-1/16-12 0.69 (7) (100) (6.9) – Drain
Service Information

Center passage, Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Center passage, maintenance standard

Inspection method
Interval Check item Checking procedure Remedy

2,000 hours. Seal for oil leakage. Check oil leakage at cover, Replace O-ring, if any oil leakage is found.
top end and fittings.
4,000 hours. All sealing parts. Replace all sealing parts such as slipper
In principle, seal with square seal and O-rings.
disassemble and check All wearing parts. Check abnormal wear, Repair or replace referring to their limit of
regardless of apparent scoring or corrosion caused serviceability.
condition. by contamination or
burning.
When disassembled for All parts. Check shaft and hub Repair or replace referring to their limit of
repair. grooves/lands for scoring. serviceability.
O-rings and seals must be replaced.
Wear limits
Part Normal Allowable Replace

Hub Internal seal contact area and the If the wear of seal contact area is The wear of seal contact area is
stepped part have no visible wear. within 0.1 mm (0.004 in) as more than 0.1 mm (0.004 inch) in
measuring by finger nail (when depth.
the dimension can't be measured
in this way, visually check), it is
allowable.
However, oil leakage will occur, if
it is used continuously in this
A. More than 0.1 mm (0.004
condition.
inch)
Shaft There is no damage or wear of New shaft external surface is The depth of damage is more than
external surface. finished as 1.5s. If the pitting of 0.1 mm (0.004 inch).
the shaft is slight, it is allowable.
A. More than 0.1 mm (0.004

inch)
Replace with a new assembly, as

soon as possible, or re-plate.
Thrust There is no surface scuffing and Replace when scoring is
washer no visible wear. considerable, even if the wear of the
spacer thickness is slight.
A. 0.3 mm (0.012 inch)
B. 0.5 mm (0.020 inch) or
less
O-ring Replace O-rings whenever Never fail to replace the O-rings and
disassembling. the seals.
Inspection after assembly

After assembling, check for leakage and pressure test as shown in figure.
High pressure port
Figure 1
Checking, high pressure port
A. Connect to hub side

B. Connect to shaft side
Install a changeover valve and pressure gauge to the shaft port and hub port respectively, and while watching the pressure
gauge (for high pressure) installed on the hub and also by regulating high pressure relief valve, gradually increase the
pressure and when the pressure has reached 1.5 times the maximum working pressure, close stop valve to trap the hydraulic
oil in the center passage. Keep stop valve on the low pressure relief valve side closed at this time.
Low pressure port
(Drain port, return port, etc.)
Similar to the high pressure port, install a changeover valve and pressure gauge on each port of the shaft and hub.
Open stop valve on the side of low pressure relief valve (5) and while watching the pressure gauge (for low pressure)
connected to the hub and also by regulating low relief valve, gradually increase the pressure and check for leakage with a
pressure of 0.98 MPa (142 psi) (9.8 bar).
Checking, low pressure port
Item Description Remark

1 Pressure gauge High and low pressures are required.
2 Center passage –
3 Stop valve –
5 Relief valve for low pressure Setting pressure: 0.98 MPa (142 psi) (9.8 bar)
6 Stop valve –
7 Relief valve for high pressure Setting pressure: working pressure × 1.5
8 Changeover valve –
9 Piping, etc. –
Troubleshooting
Troubleshooting
Trouble Cause Remedy

External/internal leakage, machine When the pressure between pump Check the circuit between pump and valve, and
does not track straight on level and valve drops. repair or replace.
ground or a slope, even if the track The circuit for valve is defective. Check pump, valve, and center passage by
motor and pump are normal. pressure gauge in that sequence.
When the pressure between pump Check for leakage between center passage and
and center passage drops. valve.
The circuit for center passage is If it is normal, separate center passage and test
defective. the pressure by gauge.
If the pressure drops, disassemble and check
the O-ring, etc. visually.
When noise comes from the center Check the center passage plumbing If the center passage is defective, disassemble
passage. for vibration or abnormal heating by to check the shaft and seals. Repair or replace
hand. a worn shaft.
Service Information

Center passage, replacing Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Center passage, replacing

Op nbr 443-037
NOTICE
When a hose has been disconnected, plug both the hose and the connection immediately. The
hoses should be marked for correct connection.
3. Remove the motor drain hose, motor high pressure hoses and 2nd speed hose.
Figure 1
Removal, hoses and fitting
1. Motor drain hose

2. 2nd speed hose
3. Motor high pressure hoses
4. Remove the screws, plates and stop screw.

Figure 2
Removal, plates
1. Screws
2. Plates
3. Stop screw
4. Clamp
5. Rubber seal
5. Remove the clamp and rubber seal.
6. Install the eye bolts on center passage and hold the center passage with sling.
Figure 3
Hold sling
1. Sling
2. Center passage
7. Remove the screws and protecting plates in the middle of undercarriage.
WARNING
Figure 4
Removal, protecting plates
1. Screws
2. Protecting plates
8. Remove the 2nd speed hoses, motor drain hoses and high pressure hoses.
Figure 5
Removal, hoses
1. 2nd speed hoses

2. Motor drain hoses
4. Mounting screws
9.
Figure 6
Removal, mounting screws (1)
Remove the center passage mounting screws installed at the bottom.
WARNING
10. Lower the center passage with the hoist and move it to the workbench safely.
11. Remove the connector and tee and install them on a new center passage.
Figure 7
Replacing, connector and tee
12.
Figure 8
Installation, stop screw (5)
Install the new center passage in reverse order of the removal procedure. See Tightening torque
4431 Tightening torque, specifications.
Stop screw (5): 15 mm (0.59 inch), 242.2 ±24.5 Nm (24.7 ±2.5 kgf m) (178.3 ±18 lbf ft)
14. Check the operation of the swing system.

Service Information

Center passage, replacing Service Information 2014/6/13
seal kit
Profile:
EXC, EC220D L [GB]
Center passage, replacing seal kit

Op nbr 443-038
residual pressure inside the hydraulic line by operating the control lever smoothly 3-4 times with ignition
switch at "ON" position.
3. Remove the screws and protecting plates in the middle of undercarriage.
Figure 1
Removal, protecting plates
1. Screws
2. Protecting plates
4. Remove the 2nd speed hoses.
Figure 2
Removal, hoses
1. 2nd speed hoses

2. Motor drain hoses
4. Mounting screws
5. Remove the motor drain hoses.
6. Remove the motor high pressure hoses.
7. Remove the motor drain hose and fitting.
Figure 3
Removal, hoses and fitting
1. Motor drain hose

2. 2nd speed hose
8. Remove the motor high pressure hoses and fittings.
9. Remove the 2nd speed hose.
10. Remove the screws and plates.
Figure 4
Removal, plates and plugs
1. Screws
2. Plates
3. Plugs
11. Remove the plugs.

12. Remove the stop screw.
Figure 5
Holding, center passage
1. Hoist
2. Stop screw
3. Center passage
4. Rubber seal
5. Eye bolts
6. Clamp
13. Remove the clamp and rubber seal.
14. Install the eye bolts on center passage and hold the center passage with hoist.
15. Remove the center passage mounting screws installed at bottom.
WARNING
16. Lower the center passage with the hoist and move it to the workbench safely.
17. See 4431 Center passage, disassembly and 4431 Center passage, assembly to replace the center passage seal kit.
18. Install the center passage in reverse order of the removal procedure.

Service Information

Center passage, Service Information 2014/6/13
disassembly
Profile:
EXC, EC220D L [GB]
Center passage, disassembly

General tools
General tools
No Tool Remark
1 Hammer
1. Steel hammer
2. Wooden or plastic hammer
2 Rubber mat Not less than 500 mm (20 inch) square

3 Wrench
1. Allen wrench
2. Double ended and single ended wrench
3. Extension pipe
4 Torque wrench 981 Nm (100 kgf m) (722 lbf ft)

5 Pin
A. Grind the tip of a “nail” to shape as a screwdriver.
6 Spatula
A. Made from a hack-saw blade.

B. Approximately 120 mm (4.7 inch)
C. Vinyl tape
D. Remove the edge completely
7 Vise Vise adjustable over 150 mm (5.9 inch)

8 Locking fluid Three bond 1360K (Loctite 242)
9 Lubricating oil Hydraulic oil or vase line
10 Cleaning oil
Apparatus
Hoist or crane
The lifting device should be capable of lifting the center passage assembly.
Work bench
The work bench should have an area of 1.2 m × 1.5 m (4 lbf ft × 5 lbf ft).
Others
Also prepare clean cloth, wooden block and oil pan.
Center passage, disassembly
WARNING
The plate is heavy, take appropriate safety precautions.
NOTE!
Clean the outside of the center passage with hot water or steam.
NOTE!
Clean center passage with the ports plugged.
NOTE!
Mark each hose assembly to identify its location on the center passage.
NOTE!
Mark shaft and hub to aid in reassembly.
1. Detach the bottom plate in the middle of undercarriage.

2. Remove the hydraulic lines connected to the center passage hub, and plug each hose and oil port.
3. Remove the hydraulic lines connected to the upper side of center passage shaft, and plug each hose and oil port.
4. Remove the center passage shaft clamping screw.
5. Screw an eye bolt in the middle of the center passage shaft, attach a sling to the lifting equipment. (To prevent the
center passage from dropping when removing the mounting screws.)
6. Unscrew the four sling mounting screws from the bottom.
7. Lower the sling slowly and take the center passage out through the bottom.
8. Dip the center passage into a cleaning solution to thoroughly clean the assembly.
9. Put the center passage on a work bench.
Figure 1
Fixing, center passage
10. Remove the screws, washer and cover from the center passage.
Figure 2
Removal, cover
1 Screws 11 Screws
3 Cover 12 Washer
11. Pull out O-ring, remove the screws, washer and spacer.
Figure 3
Removal, spacer
1 Hub 9 Screws
7 O-ring 10 Washer
8 Spacer
12. Remove the shaft and hub.
Figure 4
Removal, shaft (2) and hub (1)
13. Remove the O-ring from hub.
Figure 5
Removal, O-rings (6) and hub (1)
14. Remove the bushing mounted in the hub using a bushing driver.
Replace only if necessary.
Take care not to damage the bushing/housing mounting surface.
Figure 6
Removal, bearings (4) and hub (1)
15. Remove the seals assembled in the hub using a sharp pin.
NOTE!
Take care not to damage the seal grooves of hub.
Figure 7
Removal, seals (5) and hub (1)
16. Inspect each part, and repair or replace the defective or worn parts.
17. Do not reuse O-ring or seals. Be sure to replace with new ones.
Service Information

Center passage, assembly Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Center passage, assembly

WARNING
The plate is heavy, take appropriate safety precautions.
1. Prepare the required parts and clean all parts thoroughly.

Wash all parts thoroughly with a cleaning solvent and clear the passages using compressed air.
Polish minor scratches with fine emery or crocus cloth.
NOTE!
Especially, take care that dust and foreign materials do not enter the seal grooves of the hub or oil ports of the
shaft.
Figure 1
Cleaning with solvent and compressed air
1. Shaft
2. Hub
3. Cover
2. Coat the dry bearing outer diameter and hub section with loctite (#609) and press–fit using a jig.
3. After press–fitting with press and jig, apply loctite 2 ~ 3 times between hub and bearing.
NOTE!
Take care not to damage the dry bearing.
NOTE!
Ensure the bearing is fully seated.
NOTE!
Wipe excess loctite off the hub and bearing surface.
Figure 2
Assembly, dry bearing
1 press
2 Jig
4 Bearing
4. Before installing the seals and O-ring, coat the seal grooves with hydraulic oil (2 ~ 3 times).
NOTE!
Take care not to twist or damage the seals.
NOTE!
Check the seal mounting condition.
NOTE!
Ensure the seals are not damaged or twisted, then by hand rubbing seat the seals inside of assembly section as
close as possible to a cylindrical condition.
Figure 3
Seal assembled in front
5 Seals
6 O-ring
5. Sling the center passage with the shaft section upward.

NOTE!
Take care to align the match marks of shaft and hub.
Figure 4
Seal (5) assembled in rear
6. Coat the shaft with hydraulic oil.
7. Fix hub to the stopper, and then operate the press slowly and insert the shaft.
8. Press-fit shaft. Before the horizontal support interferes, remove it.
NOTE!
Hub and shaft must be parallel (horizontal) and when press-fitting, take care not to damage the seals.
Figure 5
Assembly, hub and shaft
1 Horizontal support 4 Hub

2 Shaft 5 Stopper
3 Plate X Press
9. Assemble the plug.

NOTE!
Coat the plug with a sealant.
Figure 6
Assembly, plug
13 Plug 17 Plug
18 O-ring
 After tightening plug and applying loctite (#572), tighten completely.

 Tightening torque: 79 ±7.9 Nm (8.1 ±0.8 kgf m) (58 ±5.8 lbf ft)
10. Assemble the O-ring and plug.
 Tightening torque: 186 ±9.8 Nm (19 ±1.0 kgf m) (137 ±7.2 lbf ft)
11. Fasten spacer to the end of shaft and tighten the screws with lock washer to specified torque.
NOTE!
The spacer must fully contact the shaft.
If it does not, check that the bushing is fully seated.
Figure 7
Assembly, spacer
2 Shaft 9 Screws
8 Spacer 10 Lock washer
 Tightening torque: 59 ~ 69 Nm (6.0 ~ 7.0 kgf m) (43 ~ 51 lbf ft)
12. Mount the O-ring to the hub groove, then install cover and tighten the screws with lock washer to specified torque.
NOTE!
Apply a dab of grease on the surface of O-rings and install ensuring they are not twisted or damaged.
Figure 8
Assembly, cover
3 Cover 11 Screws
7 O-ring 12 Lock washer
 Tightening torque: 108 ~ 118 Nm (11 ~ 12 kgf m) (79 ~ 87 lbf ft)
13. After the completion of assembly with shaft fixing jig and hub fixing jig, check the hub, shaft and rotating torque.
Figure 9
Check of rotating torque and pressure
1 Shaft jig 3 Screws

2 Hub jig X Rotating torque
 Starting torque: 245 Nm (25 kgf m) (181 lbf ft)

 Rotating torque: 196 Nm 20 kgf m) (144 lbf ft)
14. Connect adapter to each port for internal/external leakage test.

15. Plug each port.
16. Assemble fitting by port if necessary.
After washing the fitting and plug with a solvent and drying, apply teflon tape and loctite (#542) on the entire
threaded section, and assemble.
Figure 10
Assembly, fittings
17. Install the four mounting screws, the clamping screw and tighten to specified torque.
18. Connect each hydraulic line to the premarked location.
19. Check for operating condition and leakage, and track motor functions
NOTE!
When assembling elbows to center passage, take care that O-ring and washer are installed closely to nut.
Figure 11
Elbows, install
1 O-ring 3 Nut
2 Washer 4 Elbows
5 Center passage
Service Information

Swing ring gear, 492 Service Information 2014/6/13
description
Profile:
EXC, EC220D L [GB]
Swing ring gear, description

Swing ring gear consists of inner race, outer race, inner seal, outer seal, ball, support, taper pin and mounting screws.
Outer races are assembled to upper frame and inner seal is assembled to lower frame.
Pinion of swing driver and outer race of ring gear are touched internally and the power transferred from swing driver let
outer race swinging and let upper frame assembled to outer race swinging.
Figure 1
Swing ring gear, sectional view
1. Outer race (swing ring gear) + upper frame mounting screws: See 400 Tightening torque, specifications
2. Lower frame + swing ring gear mounting screws: See 400 Tightening torque, specifications
3. Dowel pins
4. Lower frame
5. Plug (outer race)
6. “S” mark soft zone (inner race)
– Grease-elbow: 74 Nm (7.5 kgf m) (54 lbf ft)
– Grease nipple: 23 ±2.3 Nm (2.3 ±0.23 kgf m) (17 ±1.7 lbf ft)
– Clamp mounting screw: 23 ±2.3 Nm (2.3 ±0.23 kgf m) (17 ±1.7 lbf ft)
A Outer race E Ball

B Inner race F Support
C Taper pin G Outer seal
D Filler plug H Inner seal
Service Information

Swing ring gear inner seal, 492 Service Information 2014/6/13
replacing
Profile:
EXC, EC220D L [GB]
Swing ring gear inner seal, replacing

Op nbr 492-032
1. Remove the superstructure. See 710 Superstructure, removal.

The numbers indicate wire (cable) (1), superstructure (2), and undercarriage (3).
Figure 1
Removal, superstructure
2. Remove the inner seal attached to the machine with a (-) screwdriver.
Figure 2
Removal, inner seal
1. Inner seal
2. Inner race
3. Outer race
3. Remove the impurities (grease, dirt, bond, etc.) around the seal groove and clean the seal groove.
NOTE!
If impurities remain, adhesion with bond agent will not be good.
Clean the seal groove and around the seal groove with cleaning solvent on a soft pad.
Finally clean the seal groove and around the seal groove with a dry pad.
4. Clean the new sealing surface with a clean pad.
5. Apply instant bond to the inner seal groove.

NOTE!
Bond: TB1735
6. Install the seal with seal lip against outer race. Start about 76 mm (3 inch) from the end of the seal using a blunt
instrument to force the seal into the groove. Push the seal in the direction of the portion already installed to avoid
stretching.
Before bringing ends of the seal together, cut off the excess length.
Figure 3
Cut, seal
7. Apply adhesive to both ends of the seal. Push the ends into the seal groove, make sure they come together.
Finally, apply the bond agent to the seal and all contact parts of the seal groove as well.
Figure 4
Applying, adhesive (A)
NOTE!
To avoid pulling the seal out of groove, the adhesive must cure for at least 24 hours before using the swing
function.
8. Install the superstructure. See 710 Superstructure, installation.

Service Information

Swing ring gear, replacing 492 Service Information 2014/6/13
Profile:
EXC, EC220D L [GB]
Swing ring gear, replacing

Op nbr 492-021
1. Remove the superstructure. See 710 Superstructure, removal.
2. Hold the swing ring gear with chains. See weight 492 Swing ring gear, specifications.
WARNING
Figure 1
Lifting, swing ring gear
1. Chain
2. Swing ring gear
3. Remove the swing ring gear's attaching bolts and the swing ring gear.
Figure 2
Removal, bolts
1. Swing ring gear

2. Swing ring gear, attaching bolts
4. Replace the swing ring gear's outer seal and the swing ring gear's inner seal as necessary. See
492 Swing ring gear outer seal, replacing and 492 Swing ring gear inner seal, replacing.
5. Remove the ring gear's grease pipes, nipples, and install to the new swing ring gear.
6. Install the swing ring gear on the undercarriage so the tooth marked “S” (soft zone) or equivalent and bearing
loading plug (outer race) is the right side of machine as shown. See 492 Swing ring gear, description.
7. Install the swing ring gear's attaching bolts. Apply Loctite #277 or equivalent locking fluid. See
492 Swing ring gear, description.
8. Apply Alvania EP #2 grease to the swing ring gear's teeth and pinion gear. See 492 Swing ring gear, specifications.
Figure 3
Grease (1)
9. Install the superstructure. See 710 Superstructure, installation.

Service Information

Swing ring gear outer seal, 492 Service Information 2014/6/13
replacing
Profile:
EXC, EC220D L [GB]
Swing ring gear outer seal, replacing

Op nbr 492-031
2. Remove the outer seal attached to the machine with a (-) screwdriver.
Figure 1
Removal, outer seal
1. Outer seal
2. Outer race
3. Inner seal
4. Inner race
3. Remove the impurities (grease, dirt, bond, etc.) around the seal groove and clean the seal groove.
NOTE!
If impurities remain, adhesion with bond agent will not be good.
4. Clean the seal groove and around seal groove with cleaning solvent on a soft pad. Finally clean the seal groove and
around seal groove with a dry pad.
5. Clean the new sealing surface with a clean pad.

6.
Figure 2
Replacing, swing ring gear's outer seal
1. Swing ring gear

2. Seal
3. Bond: TB1735
With clearance (approx. 100 mm (3.9 inch)) between (A) and (B), apply the bond agent to the seal groove and seal,
then insert the seal.
At this time, do not apply the bond agent all over the seal and seal groove. Apply the bond agent on about 300
mm (11.8 inch) of the seal and seal groove.
Work quickly when inserting the seal. If there is a time delay after applying the bond agent, it will solidify.
7. When inserting the seal, pull the seal slightly and insert the seal by pushing it with a (-) screwdriver.
8. Insert the seal from (B) to (C). Grip the seal (A) and (D) with both hands, and overlap the seal, and then fit the length
properly. Cut the seal correctly and clean both ends of seal.
NOTE!
At final assembly, if the seal is too long, grip the seal with both hands and overlap the seal, and then cut the seal
about 20 mm (0.79 inch) short.
9. Apply the bond agent lightly on both seal ends cut cleanly, and stretch the seal with both hands. Fit both ends of
the seal together in correct form and join them. Hold the seal for awhile, until the ends are joined.
10. Apply the bond agent to the seal and the seal groove between (B) and (C), and insert the seal quickly.
11. Finally, apply the bond agent to the seal and all contact parts of the seal groove as well.
12. Approx. 1 minute later, check the seal by rotating the machine's superstructure slowly.
Service Information

Ring gear grease pipe, 492 Service Information 2014/6/13
replacing
Profile:
EXC, EC220D L [GB]
Ring gear grease pipe, replacing

Op nbr 492-091
2. Loosen the nut of the pipe.
Figure 1
Ring gear grease pipe
1. Grease nipple
2. Grease pipe
3. Nut
3. Loosen the nut of the pipe.
Figure 2
Ring gear grease pipe
1. Nut
2. Grease pipe
4. Loosen the screw of the clamp completely, and remove the ring gear grease pipe.
Figure 3
Removal, grease pipe
1. Clamp
2. Grease pipe
5. Tighten the screw of the clamp on a new ring gear grease pipe by a half turn.
Figure 4
Installation, new ring gear grease pipe (1)
6. Tighten the nut of the pipe to the elbow. See 492 Swing ring gear, description.
Figure 5
Installation, nut
1. Grease nipple
2. Grease pipe
3. Nut
7. Tighten the nut of the pipe to the elbow.

Figure 6
Installation, nut
1. Nut
2. Grease pipe
8. Tighten the screw of the clamp completely. See 492 Swing ring gear, description.
Figure 7
Tighten, screw
1. Clamp
2. Grease pipe
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/13 8:29:42]

4 Power Transmission

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Service Information

Document Title: Function Group: Information Type: Date:

Power transmission, description

Document Title: Function Group: Information Type: Date:

 Zs1 = No. of tooth of 1st sun gear

Document Title: Function Group: Information Type: Date:

Track gearbox, description

Port symbol Port size Port

View from E axis Inlet Outlet

1 Housing 13 No.2 needle bearing 25 No.1 pin

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

 Zs1 = No. of tooth of 1st sun gear

Document Title: Function Group: Information Type: Date:

Track gearbox, maintenance standard

No. Part Condition Allowable value

No. Item Size Quantity

A. Main body mounted area

 Check that the mating mount surfaces are clean.

Reduction screw (A). See 700 Undercarriage, tightening torque

Gear oil replacement period

 First (initial) oil replacement: 500 operating hours

Gear oil replacement procedure

1. Level check port and fill port

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

Remove air in the track motor before operating.

Tightening torque plug. See track gearbox, description.

Track gearbox, troubleshooting

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

Gearbox is damaged. Replace the gearbox.

Mating surface damaged. Repair or replace.

Loosen screws. Tighten to specified torque.

Loosen plug. Tighten to specified torque.

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

Cover damaged. Replace the cover.

Track gearbox, troubleshooting

Gear or bearing damaged. Replace the gearbox.

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

Document Title: Function Group: Information Type: Date:

Track unit, replacing

14566479 Pin kit

5. Remove the screws rotating sprocket and remove sprocket carefully.

6. Remove the screws and motor cover.

7. Remove the track motor high pressure hoses.

1. High pressure hoses

8. Remove the track motor drain hose.

9. Remove the track motor 2nd speed hose.

10. Remove the fittings.

15. Check the operation of the track and motor.

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Track gearbox, replacing cover

Prepare container for collecting hydraulic oil.

1. Track gearbox cover

3. Remove the gearbox cover screws.

Install the new gearbox cover to the track gearbox.

1. Track gearbox cover

Document Title: Function Group: Information Type: Date:

Track gearbox (removed), replacing floating seal

8932-00290 Measuring plate

Tool: 14630696 Drift plate

1. Level check port and fill port

Oil capacity. See 4311 Track gearbox, specifications.

2. Remove the screws and cover.

3. Remove the No.1 planetary gear assembly.