8.section F - Transmission

Section F
Transmission
Service Manual - JS200 Asia Pacific
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section B - Body & Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section J - Track and Running Gear
Section K - Engine
Publication No.
9813/0400-1
World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Notes:
F-0 9813/0400-1 F-0

Contents Page No.

Technical Data
Travel Equipment ...................................................................................... F-1
Track Motor
Removal and Replacement ....................................................................... F-3
Start Up and Running In ............................................................................ F-6
Track Motor
Dismantling and Assembly ........................................................................ F-9
Performance Confirmation Test ............................................................... F-59
Fault Finding
Transmission ........................................................................................... F-61
E-i E-i
Page left intentionally blank
E-ii E-ii
Technical Data
Travel Equipment
JS200
Table 1.
Type Axial piston type
Final Drive Planetary reduction, bolt on sprockets
Working Pressure 343 bar, 4975 lb/in2
Working Flow 220 litre/min
Gearbox Ratio 1:49.5
Parking Brake Disc type, spring applied, automatic hydraulic released.
Tractive effort 164.7 KN
Displacement 129cc/rev
F-1 9813-0400-1 F-1

Technical Data
Travel Equipment
F-2 9813-0400-1 F-2

Track Motor
Removal and Replacement
Removal
1 Remove the track Section J, Track and Running
Gear.
2 Lift the side of the undercarriage high enough to

permit drive sprocket removal. Support with wooden
blocks.
3 Stop the engine and operate the control lever to

relieve pressure in the hydraulic system, refer to
Section 3, Routine Maintenance.
4 Remove the motor cover, attach identification tags to

the motor hoses, disconnect the hoses from the Fig 2.
motor and install plugs and caps to prevent the loss of
oil and ingress of dirt.
Fig 1.
5 Support the motor so that the cables are in tension,

then remove the motor installation bolts.
F-3 9813-0400-1 F-3

Track Motor
Precautions During Installation

Before installation, check the overall condition of the axial
piston motor, check for loose parts, check P1, P2 drain
ports and pilot ports are completely sealed so that
contaminants cannot enter the axial piston.
A
Replacement B
1 Before fitting, clean the assembly.
Make sure that all ports are plugged to prevent the

ingress of dirt.
2 Lift the assembly and position it on the undercarriage.
B
A
A408272-C1
Fig 4.
3 Remove the plugs and connect the motor hoses.

Fig 3.
Install the bolts and washers, using JCB Threadseal

on the bolt threads. Tighten the bolts in a diagonal
sequence. For torque settings, refer to Section 3,
Routine Maintenance.
Fig 5.
4 Do not fit the track at this stage. Follow the Start Up

and Running In procedure. K Start Up and Running
In ( T F-6).
5 Install the covers over the motor.
F-4 9813-0400-1 F-4

Track Motor
6 Check the amount of oil in the gearbox, refer to
Section 3 Routine Maintenance.
7 Refit the track Section J, Track and Running Gear.
F-5 9813-0400-1 F-5

Track Motor
Start Up and Running In
B B
709910-C1
Fig 6.
Start Up Note: The presence of residual air in the hydraulic circuit

will manifest itself with the presence of foam in the tank
!MWARNING and will lead to a jerking of the motor as well as excessive

noise coming from the motor and the valves.
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. 4 Start the track motor at a low speed and gradually
Before connecting or removing any hydraulic hose, increase it after having verified that it is functioning
residual hydraulic pressure trapped in the service correctly without any noises or vibrations.
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing Running In
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
Fluid Under Pressure
In this first stage it is advised to follow the measures given Fine jets of fluid at high pressure can penetrate the
below: skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
1 Remove hose from drain port B. Fully fill the piston Hold a piece of cardboard close to suspected leaks
motor case with clean hydraulic oil at the drain port - and then inspect the cardboard for signs of fluid. If
B. Also bleed air from each part of the piping. Make fluid penetrates your skin, get medical help
sure all hoses are correctly fitted. immediately.
INT-3-1-10_3
2 Check hydraulic fluid level, top up if necessary. refer
to Section 3, Routine Maintenance. During the running-in stage follow the steps given below.
3 Check gearbox oil level, refer to Section 3, Routine 1 Check the correct revolution and direction of rotation.
Maintenance.
F-6 9813-0400-1 F-6

Track Motor
2 Make sure that the motor is functioning correctly, with
out any excessive noises and vibrations.
3 Make sure that the oil temperature does not exceed

90°.
After having terminated this first running-in follow the

steps given below:
4 Check that there are no oil leakages.
5 Check the level of lubricating oil in the gear box.
6 The opening action of the brake could be slowed

down due to the presence of air during the first start-
up. It is advised to repeat the opening and closing
function of the brake by starting and stopping the
motor several times.
7 Check that there are no other problems.
F-7 9813-0400-1 F-7

Track Motor
F-8 9813-0400-1 F-8

Track Motor
Dismantling and Assembly
Track Motor
Tools
Equipment and facilities
Table 1.
Name Usage Description Qty
General work bench Product disassembly / assembly
Washing tank Parts washing For rough and finish washing 1
Press machine. Fitting of bearings, etc. Min. press capacity. 9800N (1000kgf) 1
Heating tank Warming parts before fitting Heating capacity: over 100 deg C. 1
Volume: 500×500×500 or more
Compressed air Drying washed parts Pressure: 0.29.49 MPa (3-5 kgf/cm2)
F-9 9813-0400-1 F-9

Track Motor
Special Tools Spindle removal tool
Note: Items numbered in brackets, i.e. [100], can be For removing spindle [101] from hub [1].
identified by referring to K Fig 143. ( T F-58)
Eye bolts
For lifting the motor, spindle [2] and hub [1].
Fig 2.
Spindle fixing tool
For connecting the spindle [101] to hub [1]

K Fig 3. ( T F-10) and K Fig 4. ( T F-11).
Fig 1.
Fig 3.
F-10 9813-0400-1 F-10

Track Motor
Fig 4.
Press tool
For pressing angular ball bearing [24] into hub [1]

K Fig 5. ( T F-11), K Fig 6. ( T F-12) and
K Fig 7. ( T F-12).
Fig 5.
F-11 9813-0400-1 F-11

Track Motor
Fig 6.
Fig 7.
F-12 9813-0400-1 F-12

Track Motor
Oil seal installation tool
For installing oil seal [132] to spindle [101]

K Fig 8. ( T F-13).
Fig 8.
F-13 9813-0400-1 F-13

Track Motor
Floating seal installation tool (I)
For installing floating seal [29] to hub [1] and spindle [101]
K Fig 9. ( T F-14).
Fig 9.
Floating seal installation tool (II)
For installing floating seal [29] to hub [1] and spindle [101]
K Fig 10. ( T F-14), K Fig 11. ( T F-15),
K Fig 12. ( T F-15) and K Fig 13. ( T F-16).
Fig 10.
F-14 9813-0400-1 F-14

Track Motor
Fig 11.
Fig 12.
F-15 9813-0400-1 F-15

Track Motor
Fig 13.
Rear flange locating guides
For guiding the rear flange during removal and

replacement.
Fig 14.
F-16 9813-0400-1 F-16

Track Motor
Valve seat removal tool
For removing valve seat [201] from rear flange [301].
Fig 15.
Fig 16.
F-17 9813-0400-1 F-17

Track Motor
Dismantling 8 The photographs and drawings contained in the

manual are of representative models. However,
Preparations disassembly procedure is not affected even if the
disassembled product is different from this manual.
Perform the following preparations before disassembling.
1 Workbench preparation
Prepare a travel motor workbench.
Prepare a sturdy workbench with which the internal

parts of the travel motor can be disassembled or
assembled, wide enough to place parts so they do not
move or fall off the bench while working.
Spread a rubber or vinyl sheet on the workbench.
2 Prepare all tools and facilities.
General Suggestions
Note: Internal parts are covered with hydraulic fluid and

gear oil during disassembly and are slippery.
1 Before disassembling, inspect and confirm clearly

any indication of abnormality which may be occurring
and work according to the disassembly procedure.
2 All parts are manufactured precisely. Be careful when

handling. Avoid rough contact and do not drop parts.
3 Do not bang or remove parts forcefully. Such acts

could cause burrs or damage to the parts which could
lead to failure of the assembly or inferior
performance.
4 If you leave parts disassembled or partially

disassembling, rust could develop on the parts due to
moisture or dirt. If you have to interrupt the work
before completion, take measures to protect against
rust or dust.
5 Place a mark against the mating faces of parts when

disassembling.
6 Tidy removed parts when disassembling so as not to

damage or lose the parts while working.
7 Once any type of seals are disassembled, they

should be replaced with new ones even if they show
no signs of damage. You should have new parts
ready prior to disassembling.
F-18 9813-0400-1 F-18

Track Motor
Disassembly Procedure 5 Turn the motor horizontally so that the drain port is at
the lowest position.
Note: Items numbered in brackets, i.e. [100], can be
identified by referring to K Fig 143. ( T F-58) 6 Loosen bleed plug [30] to release any pressure and
tighten plug again loosely.
1 Fasten two eye bolts to spindle. Hook the lifting wire
in the eyebolts, hoist the motor with a crane and carry Note: If the inside of the reduction gear is pressurised, the
to the washing tank. lubrication oil may spray out when the plug [30] is
loosened.
Note: Fasten the two eye bolts symmetrically in two screw
holes used for mounting the spindle. 7 Place a container under the workbench. Loosen the
drain plug [30] slowly. Drain the lubricating oil from
2 Wash each part of the motor with a brush. drain port.
Note: Soil and sand will be captured in the clearance Note: Prepare a container which can collect 5.3 litres of
between hub [1] and spindle [101] (floating seal mounting lubricating oil in the reduction gear.
section).
8 If the lubricating oil is not draining smoothly, loosen
3 Place the motor on the workbench. the filler plug slowly and remove the plug.
Note: While matching three holes of hub [1] and screw 9 Remove O-ring [31] from the plug.
holes of the workbench, carefully place the travel motor in
the mounting holes of the workbench. Note: Do not re-use the O-rings.
4 Fix the motor onto the workbench with three bolts.

Tighten the bolts securely.
Fig 18.
10 Turn the motor so that the reduction gear is

uppermost.
11 Loosen 18 M10 bolts and remove the bolts.
12 Place a steel bar on the offset of the cover and hit

upwards using a hammer to remove cover [14] from
hub [1].
Note: The cover could move suddenly when released.

Fig 17.
Take care to prevent it falling.
F-19 9813-0400-1 F-19

Track Motor
13 Fasten two eye bolts on the cover and use hoisting 16 Fasten three eye bolts to the tapped holes of carrier
equipment to lift it off K Fig 19. ( T F-20). [3]. Attach a wire sling and hook in the eyebolts, lift
carrier assembly by crane.
Note: When carrier assembly is lifted, the edge of the

planetary gears could damage the internal teeth of the hub.
Lift up slowly, and carefully.
17 Fasten three eye bolts to the tapped holes of the 2nd

stage reduction gear carrier [7]. Place a wire sling and
hook in the eyebolts, lift the carrier assembly by
crane.
Fig 19.
14 Fasten three eyebolts to the tapped holes of the 1st

stage reduction gear carrier [3].
Attach a wire sling and hook in the eyebolts and lift the
carrier assembly by crane.
Note: When the carrier assembly is lifted, the edge of the

Fig 21.
Note: When the carrier assembly is lifted, the edge of the

18 Remove sun gear [4].
Note: Be careful not to drop the sun gear. It could be

slippery with lubricant.
19 Remove coupling [15] from shaft [102].
Fig 20.
15 Remove sun gear [4].
Note: Be careful not to drop the sun gear. It could be

slippery with lubricant.
F-20 9813-0400-1 F-20

Track Motor
Fig 22.
20 Turn the motor over.

Fig 24.
21 Fix Hub [1] and spindle [101] with two fixing tools
23 Remove the fixing tools securing the hub and the
positioned symmetrically K Spindle fixing
spindle.
tool ( T F-10).
24 Fasten two eyebolts on the tapped holes of spindle
[101].
Place a wire sling and hooks in the eyebolts. Lift the

spindle by crane.
Fig 23.
22 Put a flat head screwdriver into the clearance

between the two locking washers [22] and widen the
clearance. Place the tip of the screwdriver to one end
of the lock washers, tap it with a hammer and remove
the lock washers. Fig 25.
Note: Lift up spindle slowly and carefully. If the spindle is

inclined against hub it could jam. If the spindle does not
come out smoothly, do not pull forcefully. Instead, use
other tools such as a press.
25 If the spindle cannot be pulled out or there is no

workbench, place the hub's collar on a cylinder with
the spindle facing downward, position the removal
tool on the spindle, and hit the tool with a hammer
F-21 9813-0400-1 F-21

Track Motor
until the spindle comes out K Fig 26. ( T F-22). See
K Spindle removal tool ( T F-10)
Note: When the hub is hoisted to place on the cylinder, the

spindle could fall off from the hub. Since it is dangerous to
hoist the hub quickly, do it slowly. To prevent the rear
flange from being damaged when the spindle falls off,
place a cushion inside the cylinder. When reusing the
spindle, be careful not to hit its spline otherwise the spline
will be deformed, preventing it meshing with the carrier.
Fig 27.
27 Put a steel rod on the inner race of angular ball

bearing [34], tap 3 or 4 points evenly and take care
not to damage the bearing.
Fig 28.
Fig 26.
Note: Do not remove the angular ball bearing except for
26 Grasp the inner side of the floating seal and lift it up replacing the bearing. The removal work could damage the
by hand. bearing race.
Note: Use work gloves to prevent cutting hands from the 28 To pull out parallel pin A [16], scrape the caulked part
edge of the floating seal. If lifting up by hand is difficult for of the hole B on carrier [3] by using a pencil grinder
any reason, use a flat head screwdriver as a lever. K Fig 29. ( T F-23) and K Fig 30. ( T F-23).
Note: Scraping the hole entrance excessively may cause

caulking to be ineffective, preventing re-use of the carrier.
F-22 9813-0400-1 F-22

Track Motor
Fig 29. Fig 30.
29 Lift parallel pin by using a slotted screwdriver and pull 30 After pulling out carrier pin [6] from carrier [3], remove
out the pin. planetary gear [5], needle roller bearings [27] and
thrust washers.
Note: Since standing the carrier during work can cause

the planetary gear to fall off when the carrier pin has just
been pulled out, be careful not to get your finger caught
between the planetary gear and the carrier.
31 Lower the hub from the work table. Install the

hydraulic motor on the work table and secure with
bolts. Tighten the bolts K Fig 31. ( T F-24).
F-23 9813-0400-1 F-23

Track Motor
Fig 31. Fig 33.
A Motor 35 Remove rear flange [301] from spindle [101].
B Plate Note: Hold rear flange with both hands, and gently remove
C Work bench it. Timing plate [109] or spring [113] could fall off and get
damaged during this work.
Fig 32.
Fig 34.
32 Turn over rear flange [301].
36 Position a steel rod on the inner race of angular
bearing [24], tap 3 or 4 points evenly but take care not
33 Remove two hexagon socket bolts [343] diagonally
to damage the bearing.
then install the rear flange locating guides K Rear
flange locating guides ( T F-16).
Note: Do not remove the angular ball bearing except to
replacing the bearing. When the outer race of angular ball
Note: Loosen the plugs on rear the flange before
bearing separates from the fitness hub, angular ball
loosening the securing bolts. This makes it easier to
bearing falls from hub.
remove the plugs later.
Place a container under the workbench and put a
34 Loosen the rest of hexagon socket bolts [343]. Then
rubber mat on it so that the angular ball bearing does
remove the bolts from rear flange [301].
not get damage if it falls.
F-24 9813-0400-1 F-24

Track Motor
37 Turn over the motor so that the rear flange [301] is on 41 Removing the relief valve assemblies [203].
top.
a Unscrew and remove both plugs [204] and
38 Temporarily loosen the two plugs [324]. springs [207].
Note: Do not loosen the plugs if the rear flange is not to be b Pull out sleeve [203], piston [206], valve [202] and
disassembled. spring retainer [205] by putting a finger in the
sleeve hole.
39 Temporarily loosen the two plugs [352].
Note: Do not loosen the plugs if the rear flange is not to be

disassembled.
Fig 37.
Fig 35.
40 Loosen the two relief valve assemblies [203].
Fig 38.
c Pull out the valve seat [201] by hooking a steel bar

under the seat and withdrawing it as shown below
K Valve seat removal tool ( T F-17).
Fig 36.
Note: Do not reuse any O-rings and backup rings which

have been removed.
Fig 39.
F-25 9813-0400-1 F-25

Track Motor
42 Removing the two-speed spool
a Loosen and remove adapter [364].
b Loosen and remove plug [370] and spring [366].
c Lightly push spool [363] from the adapter end and

pull out the spool, spring retainer [367] and pin
[365].
Fig 41.
46 Pull out the 2 parallel pins [34] from the spindle [101].
Fig 40.
43 Removing the throttle and check valves
a After loosening and removing plug [374], remove

throttle valve spring [373] and throttle valve [372] Fig 42.
by using a magnet.
47 Remove both O-rings [32 and 33] from spindle [2]
b After loosening and removing plug, remove check K Fig 43. ( T F-27).
valve spring [378] and check valve [377] by using
a magnet. Note: Do not reuse any O-rings and backup rings which
have been removed.
Note: If there is no magnet available they can be removed
by cleaning the hole inside with washing solvent and then
shaking the rear flange with the hole entrance facing
downward.
44 Loosen and remove the 10 hexagon socket bolts

[343] from rear flange [301].
45 Remove rear flange [301] from the spindle [101].
Note: Hold rear flange with both hands, and gently remove
it. Timing plate [109] or spring [113] could fall off and get
damaged during this work.
F-26 9813-0400-1 F-26

Track Motor
Fig 43. Fig 45.
48 Lay removed rear flange [301] on the workbench with 51 Disassembling the brake valve parts inside the rear
the mating face upwards. flange
49 Remove timing plate [109] from rear flange [301]. a Remove 2 plugs [324] from rear flange [301].
Note: Timing plate may be stuck to the mating face of the b Remove 2 washers [325] and spring [328] from
rear flange. rear flange [301].
To separate the timing plate, insert a flat bar into the

groove of the rear flange and raise the timing plate
slowly.
Never try to pry the timing plate off with a sharp or

pointed tool or the precision finished mating faces will
suffer costly damage.
Fig 46.
c Remove spool assembly [323] from rear flange

[301] K Fig 47. ( T F-28).
Note: To remove the spool assembly, place your hand on

one part of the plug port of the rear flange and tilt it down.
The spool should then fall down. Hold the tip and remove it.
Fig 44.
50 Remove bearing [150] from the rear flange.
F-27 9813-0400-1 F-27

Track Motor
Fig 47.
Fig 49.
d Remove O-rings [336] from plugs [324].
54 Remove piston [381] from rear flange [301]
Note: Do not reuse O-rings which have been removed. K Fig 50. ( T F-28).
Fig 50.
Fig 48.
55 Disassembling ball check valve
52 Remove both plugs [380] from rear flange [301].
a Remove both plugs [352] from rear flange [301]
53 Remove O-rings [383] from both plugs [380]
K Fig 51. ( T F-29).
Note: Do not reuse O-rings which have been removed.
F-28 9813-0400-1 F-28

Track Motor
Fig 51. Fig 53.
b Remove O-rings [358] from plugs [352]. b Remove O-rings [135 and 139] from the piston.
Note: Do not reuse O-rings which have been removed. Note: Do not reuse any O-rings and backup rings which
have been removed.
c Remove steel balls [353] from rear flange [301].
Note: If it is hard to remove the steel balls, try using a

magnet etc.
Fig 54.
57 Disassembling rotary parts
Note: Place a container just below the motor to catch the

Fig 52. oil.
56 Disassembling the parking brake a Turn the motor 90 degrees.
Note: The sudden injection of compressed air could cause b Drain the hydraulic oil from the motor.
the piston to pop out. To ensure your safety hold a
protective cover over the piston. c Remove the 4 mating plates [116] and 3 friction
plates [115].
a Remove piston [112] from the spindle by injecting
compressed air into the across hole in the spindle. d Pull out cylinder block [104], pistons [105] and
retainer plate [107] at the same time
K Fig 55. ( T F-30).
F-29 9813-0400-1 F-29

Track Motor
Fig 55. Fig 57.
Note: When the cylinder block is removed, shoes [106] g Remove the 9 piston assemblies (pistons [105],
may remain adhered to the swash plate, and the pistons shoes [106]) from retainer plate [107].
[105], shoes [106] etc. will come out of the cylinder block
and fall into the spindle.
Fig 58.
Fig 56. h Remove thrust ball [108] from cylinder block [104]
K Fig 59. ( T F-31)
e Draw out cylinder block [104] from shaft [102].
f Remove piston assembly (pistons [105], shoes

[106]) and retainer plate [107] from cylinder block
[104].
Note: When removing the piston assembly, grip retainer

plate [107] with both hands and remove the piston
assembly together with the retainer plate. Components of
the piston assembly cannot be obtained separately. If
replacement is necessary, replace piston assembly as one
unit.
F-30 9813-0400-1 F-30

Track Motor
Fig 59. Fig 61.
i Remove 3 needle rollers [151] from cylinder block Note: Release the press slowly. Sudden releasing may
[104]. cause the spring to fly out, causing possible injury.
Fig 60.
58 Removing spring inside cylinder block Fig 62.
a Place cylinder block [104] on the press bench A Press

B Mandrel
Note: Spring [114] should be removed only when requiring
replacement. The spring is removed by lining up the shaft C Snap ring
centre of its holder and washer [110] in order to prevent D Spring
damage to cylinder block [104] through contact. Cover the
E Cylinder block
cylinder block with a vinyl sheet to prevent the sliding
surfaces of the cylinder block from being damaged.
c Remove snap ring [145], washer [110], spring
b Place holder on washer [110] and, while clamping [114] and washer [110] from cylinder block [104]
the holder with the press, remove snap ring [145] K Fig 63. ( T F-32).
using snap ring pliers.
F-31 9813-0400-1 F-31

Track Motor
Fig 63.
Fig 65.
59 Removing swash plate
60 Removing bearing
a Remove swash plate [103] from shaft [102].
Note: The bearing should only be removed if it needs
Note: When removing the swash plate, ensure that the replacing
pivots are not stuck to the swash plate.
a Place a holder on the press bench and put shaft
[102] into the holder.
b Remove bearing [149] from shaft [102] by

pressing on the shaft end with a press.
Note: Do not reuse the removed bearing.
Fig 64.
b Pull out shaft [102] from spindle [101].
Note: Carefully and lightly strike the tip of the shaft on the
reduction gear side using a plastic hammer to allow the
shaft to come off easily. Otherwise the shaft may pop out.
c Remove 2 pivots [167] and 2 parallel pins [171]

from spindle [101].
Fig 66.
A Press
B Holder
F-32 9813-0400-1 F-32

Track Motor
61 Remove snap ring [133] and oil seal [132] from
spindle [101].
Fig 69.
Fig 67.
A Spindle
B Oil seal
62 Removing spindle fittings
a Remove shim [23] from spindle [101].
Fig 68.
Note: Do not reuse floating seal [29] once it has been

removed.
F-33 9813-0400-1 F-33

Track Motor
Cleaning Parts
1 Washing
a Separate hub [1], spindle [101], cover [14] and

rear flange [301] from other parts (hereafter called
the build-in parts).
b Put the build-in parts in the washing vessel with

kerosene and wash them.
Note: Carefully wash to remove any dirt from the external

surface.
Note: To prevent the build-in parts from being damaged

Fig 71.
by dirt during washing, immerse the parts in kerosene long
enough for any dirt or oil to loosen before washing them.
2 Finish washing
a Rinse the washed parts in the rinsing sink filled

with clean kerosene by gently shaking each part
in the kerosene.
b Using clean, lint-free cloth, wipe each rinsed part

to remove dripping kerosene.
Fig 72.
Fig 70.
Note: Dry the inside of the hub and the spindle by spraying
with compressed air until they are dry and clean. Let other
parts dry naturally. After drying, coat every part with oil.
F-34 9813-0400-1 F-34

Track Motor
Inspection 2 Replace all seals
1 Service criteria Seal parts (O-ring, oil seal and floating seal) should
be replaced once disassembled even though no
Inspect the inside of the motor according to this damage is observed.
maintenance criterion. Handle every part carefully,
and use particular care that moving and sliding 3 Replace any severely damaged parts.
sections are not damaged.
4 Replace any parts if they have the following
abnormalities K Table 2. ( T F-35).

Table 2.
Item No Parts Trouble Reference value Allowance value
[1] Hub * Severe damage on appearance. *
Pitting on ring gear teeth.
*Abnormal wear such as scoring.
[101] Spindle *Severe damage on appearance.
*Abnormal wear such as scoring
[3][7] Carrier assembly * Abnormal wear such as scoring
others
[4] Sun gear [1]. Sun * Pitting on ring gear teeth. *
gear [2]. *Flaking on outer race of needle
[8] Planetary gear roller bearing.
[1].
[5]
Planetary gear
[9] [2]
[24] Angular ball * Dent, flaking or uneven wear on
bearing contact surface.
[301] Rear flange * Many scratches on sliding
surfaces between spool [323] and
piston [381].
[102] Shaft * Abnormal wear on contact
surface between oil seal [132].
* Abnormal wear on spline
[103] Swash plate * Marks of sticking.
[104] Cylinder block * Abnormal wear on spline.
* Abnormal wear on bore surface.

* Scratches or uneven wear on
sliding surface with timing plate
[109]
F-35 9813-0400-1 F-35

Track Motor
[105] Piston assembly * Abnormal clearance in the axial Clearance Clearance

direction between piston [105] and
[106] Piston Shoe shoe [106]. 0.05 mm 0.15 mm
* Abnormal wear on shoe [106].

[107] Retainer plate * Uneven wear on sliding surface
with shoe [106].
* Scratches or uneven wear on

sliding surface with thrust ball
[108].
[108] Thrust ball * Uneven wear on sliding surface
with retainer plate [107].
[109] Timing plate * Sticking or uneven wear on
sliding surface.
[115] Friction plate * Uneven wear on both contact Braking torque Braking torque 206
surface. 206 N-m N-m
[116] Mating plate
* Specified torque cannot be 21.0 kgf-m 21.0 kgf-m
obtained
or over or over
* Marks of sticking
[105] Piston * Scratches on sliding surface
[149] Ball bearing * Dent, flaking or uneven wear on
contact surface.
[150]
[323] Spool *Abnormal and uneven wear on
the outer circumference.
* Severe scratching on the outer

circumference.
[381] Piston * Severe scratching on the outer
circumference.
F-36 9813-0400-1 F-36

Track Motor
Assembly disassembling procedure is not affected even if the

products are different from this manual.
The assembly procedure is basically the reverse of
disassembly.

Preparation
Prepare the tools and facilities as required on

Disassembly.
General Precautions
1 Pay the same attention to general precautions at

paragraph 2, Disassembly.
2 When assembling, remove all foreign objects or metal

fragments from parts, and make sure there are no
burrs or dents etc. on parts. If necessary, remove
them by oilstone.
3 Replace O-rings, oil seals and floating seals with new

ones.
4 Completely remove any remaining adhesive in the

thread holes of hub [1] by using a tap (M10) and then
wash them with a solvent. After that, blow dry with
compressed air. Replace bolts [35].
5 Completely remove any remaining adhesive from the

mating surface of hub [1] and cover [14] using a
scraper.
6 Be careful not to damage O-rings, oil seals and

floating seals when mounting. Apply a small amount
of grease to them for smooth assembly.
7 Be sure to coat the moving and sliding parts of the

hydraulic motor and valves with clean hydraulic fluid.
8 Do not use cloth gloves during assembly. Fibre pieces

may cause faulty operation.
9 Bolts and plugs should be tightened to the torque

specified in Tightening Torque table below.
10 After assembling, plug all ports to protect motor from

contamination.
11 The photographs and drawings contained in this

manual are of representative models. However,
F-37 9813-0400-1 F-37

Track Motor
Tightening Torques
Part No. Bolt/ Nut Used Width across flats (mm) Qty Tightening Torque
30 Plug PF1/2 10 3 98.1±19.6 (10±2kgf/m)

35 Bolt PT1/16 8 18 57.9±9.81 (5.9±1kgf/m)
137 Hexagon socket plug M27 (P1.5) 4 1 13.7±1.37 (1.4±0.14kgf/m)
204 Plug M27 (P1.5) 32 2 157 - 177(16 - 18kgf/m)
324 Plug M38 (P1.5) 46 21 304±324 (31 - 33kgf/m)
364 Adapter PF3/8 21 6 49.0 - 58.8 (5 - 6kgf/m)
368 Plug PF1/4 6 8 29.4±2.94 (3±0.3kgf/m)
370 Plug PF3/8 8 5 49.0 - 58.8 (5 - 6kgf/m)
374 Plug PF1/8 5 14 14.7±1.47 (1.5±0.15kgf/m)
343 Hexagon socket bolt M16 14 230±23.0 (23.5±2.35kgf/m)
Weights
Part No Name Weight (kg)

Travel Motor About 277
Assembly
1 Hub About 79
101 Spindle About 60
3 Carrier [1] Assembly About 27
7 Carrier [2] Assembly About 47
F-38 9813-0400-1 F-38

Track Motor
Assembly Procedure A Press
General B Hub
C Press tool
Note: If reassembling after replacing parts, preload
D Ball bearing
adjustment of angular ball bearing [24] is necessary.
Therefore, before assembling, make sure the following e Apply grease on the O-ring of floating seal [29],
parts have been replaced. and fit the O-ring into the floating seal groove on
hub [1] K Floating seal installation tool
Renew all parts required for preload adjustment of angular (I) ( T F-14) and K Floating seal installation
ball bearing: Hub [1], spindle [2], angular ball bearing [24]. tool (II) ( T F-14).
Note: If reassembling after replacing the parts listed Note: When applying grease to the O-ring, remove the O-
above, be sure to use parts that have been adjusted. If you ring from floating seal, and then apply grease thinly to the
reassembly with parts that have not been adjusted, it will entire surface. Use a floating seal installation tool. Keep
cause the motor to operate poorly or break down the seal parallel (tolerance 1mm) to end surface of the
prematurely. groove. If not, it could cause the seals to seize or leak.
1 Assembling hub
a Place hub [1] on a press bench.
b Place angular ball bearing [24] on hub [1] and

press in using the press tool K Press
tool ( T F-11).
c Turn the hub over.
d Insert angular ball bearing [24] into hub [1] in the

same way.
Note: Make sure that the installing direction of the angular

ball bearing is correct.
Fig 74.
A Floating seal installation tool (I)

B Floating seal installation tool (II)
C Floating seal
D Spindle
2 Assembling spindle
a Apply grease to the O-ring of floating seal [29],

and fit the O-ring into the floating seal groove on
spindle [101] K Floating seal installation tool
(I) ( T F-14) and K Floating seal installation
tool (II) ( T F-14).
Fig 73.
F-39 9813-0400-1 F-39

Track Motor
Fig 76.
Fig 75. Note: If hub [1], angular ball bearing [24] or spindle [2] are
replaced, clearance adjustment should be carried out. If
A Floating seal installation tool (I) this is not done, the angular ball bearings could break in a
short period.
B Floating seal installation tool (II)
C Floating seal 1 Insert lock washer [22] and measure the distance C
D Hub then remove the lock washer.
Note: When applying grease to the O-ring, remove the O-

ring from floating seal and apply grease thinly to the entire
surface. Use a floating seal installation tool. Make sure to
keep the seal parallel (tolerance 1mm) to the groove. If not,
it could cause the seals to seize or leak.
3 Install eye bolts to spindle [101] so they are

symmetrically positioned.
4 Fix spindle [101] on workbench with two hexagon

socket bolts, located symmetrically. Tighten the bolts
securely.
5 Clearance adjustment procedure for angular ball

bearing.
Fig 77.
2 Measure the distance D.
Note: Rotate hub assembly to stabilise the distance D.
F-40 9813-0400-1 F-40

Track Motor
Fig 78.
3 Select one of the listed shims [23] to achieve the

distance (C-D) from.0.17 to.0.13mm. Refer to the
following table for available shims. Fig 80.
b Fix hub [1] to the workbench with three long

Mark T (mm) Mark T (mm) hexagon socket bolts.
A 0.9 G 1.5
B 1.0 H 1.6
C 1.1 I 1.7
D 1.2 J 1.8
E 1.3 K 1.9
F 1.4 L 2.0
Fig 81.
c Locate angular ball bearing [24] on reduction gear

and, using a steel rod tapped softly with a
hammer, assemble the bearing onto spindle [2]
keeping both centre axes parallel.
d Place lock washers [22] into the groove of spindle

[101].
Fig 79.
4 Assemble shim [23] to spindle [101].
a Insert hub [1] into angular ball bearing [24]

assembled in spindle [101] while keeping both
centre axes parallel.
F-41 9813-0400-1 F-41

Track Motor
b Drive oil seal [132] into spindle [101] using a drift
to prevent it from being inclined. Ensure the seal
is assembled the correct way round K Oil seal
installation tool ( T F-13).
Fig 82.
e Fit lock washers [22] into the groove of spindle

[101] using an installation tool.
Fig 84.
c Install snap ring [133] using snap ring pliers.
Fig 83.
Note: Insert lock washers [22] fully into the groove so they
do not interfere with the carrier.
f Remove the long hexagon socket bolts, which

fixed hub [1] to the workbench.
Fig 85.
g Rotate hub [1] two or three times to seat the
bearing. d Install two parallel pins [171] into the pin holes of
spindle [101].
Note: Contact between the sliding surfaces of the floating
seal will be improved by rotating the spindle and prevent e Apply lithium grease to hemispherical surface of
initial oil leak. two pivots [167] and fit into parallel pins [171] of
spindle [101].
5 Turn over spindle [101].
f Assemble outer race of bearing [149] fully into its
a Apply grease to the spindle area in contact with oil bore using a suitable drift.
seal [132].
F-42 9813-0400-1 F-42

Track Motor
g Install piston [161] into its bore in the spindle
[101].
h Coat the steel ball with grease (to hold it in place)

and install it into the piston.
Fig 86.
Fig 88.
i Mount the pivot [167] with ‘L’ mark on the left side
of the spindle. Insert pivot until the seat face A Press
contacts the spindle.
B Shaft
C Ball bearing
D Support
b Turn the workbench 90 degrees.
c Insert shaft [102] into spindle [101].
Note: Take care not to scratch or cut the lip portion of the
oil seal with the splined end of the shaft.
Fig 87.
6 Assembling shaft
Note: Wear thick leather gloves while handling the heated

bearing.
a Put inner race of bearing [149] in a heating tank at

100±10 deg C for ten minutes and then insert it Fig 89.
onto shaft [102].
7 Insert swash plate [103] into spindle [101].
F-43 9813-0400-1 F-43

Track Motor
Note: Apply lithium grease to the swash plate where it
contacts the spindle. Make sure that the locating pivots of
the spindle enter the pivot holes of the swash plate.
Fig 92.
Note: When assembling the snap ring take care that the
tips of the pliers do not slip out of the snap ring holes or the
snap ring could jump out.
Fig 90.
Note: Press force of spring [114] is 1128N (115kgf) or
Note: Make sure that the swash plate is mounted correctly more. To prevent damage to the contact surface of the
on the two pivots. cylinder block protect by covering the cylinder block with a
vinyl sheet.
c Place a holder on washer [110] and, while

clamping with a press, fit snap ring [145] in the
groove of cylinder block [104] using snap ring
pliers.
Fig 91.
8 Assembling cylinder block components
a Insert washer [110], spring [114], washer [110]

and snap ring [145] in that order into cylinder Fig 93.
block [104].
9 Assembling rotary parts
b Place cylinder block [104] on the press bench.
a Place three needle rollers [151] into cylinder block
[104] and place thrust ball [108] on the top.
F-44 9813-0400-1 F-44

Track Motor
Fig 96.
Fig 94.
Note: Match the round surface portion of the thrust ball
b Install nine piston assemblies into retainer plate and the retainer plate.
[107].
Note: Make sure the retainer plate is fitted the correct way
round with the tapered face as shown.
Fig 97.
d After installing cylinder block [104], turn it by hand

and make sure that it fits properly. If not, inspect it.
Note: The cylinder block is not supported until piston [112]

is fitted. If the cylinder block moves outwards, thrust ball
[108] will separate and the motor will not rotate normally.
Fig 95.
c Fit retainer plate [107] and nine piston assemblies

into cylinder block [104].
F-45 9813-0400-1 F-45

Track Motor
lightly and equally with a plastic hammer. Take care not to
damage the O-rings.
Fig 98.
10 Inserting parking brake

Fig 100.
Note: Immerse friction plates in hydraulic fluid before
assembly.
11 Fit the taper roller bearing
a Turn the workbench 90 degrees.
a Remove the outer race from the taper roller
bearing [150].
b Insert four mating plates [116] and three friction
plates [115] alternately. Insert mating plate first.
b Drive the taper roller bearing (150) onto the shaft
[102] using a suitable drift and hammer.
Fig 101.
Fig 99.
c Place outer race onto the inner race.
c Apply a thin coat of grease to O-rings [135] and
[139] and fit into O-ring grooves of piston [112]. 12 Clearance adjustment procedure for taper roller
bearing
d Insert piston [112] into spindle [101]. Take care to
keep the piston parallel with the spindle.
Note: If the piston does not fit into the spindle because of
the resistance of the O-rings, tap the edge of the piston
F-46 9813-0400-1 F-46

Track Motor
Note: Clearance adjustment should be carried out if a Apply 2 or 3 drops of JCB Locking Fluid Medium
spindle, shaft, rear flange or tapered roller bearing are Strength to M6 orifice [376] and tighten orifice
replaced. If not the tapered roller bearing could break. into rear flange using a hexagon socket key. Do
not overtighten as the thread may be damaged.
a Turn the motor vertically.
Note: If sealant is applied excessively it could run down
b Tap the tapered roller bearing softly using a plastic and close off the orifice.
hammer to stabilise the shaft.
c Measure the distance A.
Fig 104.
A
14 Assembling ball check valve parts in rear flange
a Fit O-rings [358] to two plugs [352].
Note: Apply grease to O-rings.
b Insert steel ball [353] into rear flange [301].
Fig 102.
d Measure the distance B.
B Fig 105.
c Temporarily tighten plugs [352] into rear flange

[301] using hexagon wrench.
Fig 103.
e Select a shim [119] to achieve the distance A - B

from 0 to 0.17mm.
f Insert shim and outer race of taper roller bearing

[150] into bearing bore in rear flange [301].
13 Assembling M6 orifice
F-47 9813-0400-1 F-47

Track Motor
Fig 108.
Fig 106.
Note: After carrying out the seating process, check the
15 Assembling throttle and check valve valve movement by using the pin to lift the valve slightly.
a After inserting throttle valve [372] and throttle

spring [373] into rear flange, fit and tighten plug
[374] to specified torque.
Note: The orifice of the throttle valve is very small and

could be easily blocked by foreign matter. Wash
thoroughly and check by shining a light behind the orifice.
Fig 109.
Fig 107.
Note: Since the bores for the throttle and check valves
have the same diameter make sure they are fitted into the
b After inserting check valve [377] and check valve
correct bores as shown.
spring [378], fit and tighten plug to specified
torque.
Note: If a new rear flange is used it is necessary to seat

both the throttle and check valves before assembly to
prevent subsequent leakage. Using a steel pin inserted
into the spring cavity as shown, gently tap the spool 2 or 3
times to seat the valve.
Fig 110.
F-48 9813-0400-1 F-48

Track Motor
16 Assembling counterbalance spool the rear flange with the spool centre so as to prevent the
inner surface of the bore and the outer surface of the spool
a Insert the spool assembly [323] into almost the from being damaged due to interference. Otherwise
centre of the rear flange to prevent the bore from internal leaks will occur after reassemble, resulting in
being damaged. performance deterioration of the motor.
Note: Insert the spool in the direction shown in the b Fit two O-rings [336] to two plugs [324].
illustrations noting particularly the position of the two small
holes A and the balance grooves B. If the spool is inserted Note: Apply grease to the O-ring.
the opposite way round the parking brake will not operate.
c Attach washers [325] and springs [328] to both
plugs [324].
A
B
Fig 111.
Fig 113.
d Assemble both plugs [324] to rear flange [301].
Note: When fitting the plug to the rear flange, insert

carefully so as not to deform spring [328].
Fig 112.
b Attach spring retainers [325] and springs [330] to

both ends of the inserted spool.
c Fit plugs [324] to both ends and tighten them to

specified torque.
17 Assembling brake valve parts in rear flange
a Insert spool [323] into rear flange [301]. Fig 114.
Note: Apply hydraulic fluid to the spool and insert spool e Temporarily tighten plugs [324].
into the rear flange. To insert the spool, align the bore of
F-49 9813-0400-1 F-49

Track Motor
b Insert two parallel pins [341] in the pin holes of
rear flange [301].
c Apply grease to the mating faces of timing plate

[109] and rear flange [301].
d Fit timing plate [109] on rear flange [301] using

parallel pins [341] as the guide.
Note: Make sure that the timing plate adheres to the rear
flange. Adhesion prevents the plate from dropping when
the rear flange is mounted on the spindle.
Fig 115.
18 Assembling two-speed spool
a Assemble adapter [364] to the rear flange.
b Assemble spool [363], spring retainer [367] and

pin [365] together and place into bore in rear
cover.
c After inserting spring [366] fit plug [370].
d Tighten the adapter and plug to specified torque.
Fig 117.
e Mount springs [113] in the holes of rear flange

[301].
Note: Apply grease to the springs in order to prevent them

from dropping from the rear flange.
Fig 116.
19 Assembling rear flange mounted parts
a Apply hydraulic fluid to ball bearing [150] and fit

into rear flange [301].
Fig 118.
F-50 9813-0400-1 F-50

Track Motor
20 Assembling rear flange 21 Tightening bolts
a Fit O-rings [32] and [33]in the O-ring grooves of a Tighten hexagon socket bolts [343] to 102±15.7
spindle [101]. Nm (10.4±1.6 kgf/m).
Note: Fit O-ring [32] without applying grease. If

reassembled with grease applied, the grease may bleed
from the mating face of the rear flange and the spindle
when the motor is running.
b Put 1.0 litres of hydraulic fluid in spindle [101].
Fig 121.
b Tighten plugs [324] to 441±39.2 Nm (45.0±4.0 kgf/

m).
Fig 119.
c Install rear flange [301] on spindle [101] so that

two parallel pins [34] on the spindle enter the pin
holes in rear flange [301].
d Fit and temporarily tighten the ten hexagon socket

bolts [343] using a hexagon wrench.
Fig 122.
c Tighten plugs [380] to 58.8 ± 9.81 Nm (6.0±1.0

kgf/m).
Fig 120.
F-51 9813-0400-1 F-51

Track Motor
Fig 123.
Fig 125.
22 Tighten plugs [352] to 12.3 ± 2.45 Nm (1.25±0.25 kgf/
m). c Tighten relief valve assemblies [203] to 98.1 ±
19.6 Nm (10.0±2.0 kgf/m).
23 Fitting relief valve assembly
a The orifice diameter of the valves are small

enough to be easily blocked by foreign matter.
Wash thoroughly and check orifices are clear.
Fig 126.
24 Sub assembling 1st stage planetary gears
a Insert needle roller bearing [27] into planetary

gears [5] and place into carrier [3] with thrust
washers [11] either side of gear.
Fig 124.
b Fit the two relief valve assemblies [203] to rear

flange [301].
F-52 9813-0400-1 F-52

Track Motor
Fig 127.
Note: The planetary gears are designed with a taper

crowning so each gear should be assembled with its
identification groove uppermost as shown.
Fig 129.
25 Sub assembling 2nd stage planetary gears
a Insert needle roller bearing [28] into planetary

gears [9] and place into carrier [7] with thrust
washers [12] either side of gear.
Fig 128.
b Align the gears bores with the holes in the carrier.
c Insert each gear shaft [6] into the carrier and align
the securing pin holes.
d Insert each parallel pin B [16] and push below the

carrier’s face.
e Calk the hole entrance A using the calking tool.

Make sure the pin cannot get out by lifting the pin
with a screwdriver as shown.
Fig 130.
F-53 9813-0400-1 F-53

Track Motor
Note: The planetary gears are designed with a taper
crowning so each gear should be assembled with its
identification groove uppermost as shown.
Identification mark
Fig 131.
b Align the gears bores with the holes in the carrier.
c Insert each gear shaft [10] into the carrier and

align the securing pin holes.
Fig 133.
26 Assembling the hub
a Place hub [1] on the press bench.
b Fit hub [1] onto the work bench with two socket
bolts located symmetrically.
c Remove the O-ring of floating seal [31], apply

grease thinly to the entire surface and fit the O-
ring into the floating seal groove on the hub.
d Fit the floating seal using the seal installation tool

Fig 132. K Floating seal installation tool (I) ( T F-14).
d Insert each parallel pin B [17] and push below the Note: Keep the seal parallel (tolerance 1mm) to the
carrier’s face K Fig 133. ( T F-54). groove. If not, it could cause the seals to seize or leak.
e Calk the hole entrance A using a calking tool. 27 Assembling 2nd stage planetary gears
Make sure the pin cannot get out by lifting the pin
with a screwdriver as shown. a Rotate the workbench so that the reduction gear
side is upwards.
b Attach sun gear [8] to carrier [7].
F-54 9813-0400-1 F-54

Track Motor
c Fasten three eyebolts into the tapped holes of Note: When inserting the carrier assembly, take care not
carrier [7]. Place a wire sling and hook in the to damage internal teeth of hub with the edge of the
eyebolts, position carrier assembly slowly in hub planetary gears.
[1].
Fig 134. Fig 136.
Note: When inserting the carrier assembly, take care not b Insert sun gear [4] with spline towards coupling
to damage internal teeth of hub with the edge of the [15].
planetary gears.
Note: If the sun gear does not engage with the planetary
Note: Position carrier so that planetary gears are located gears, lift the carrier assembly until the sun gear spline is
as shown K Fig 135. ( T F-55). disengaged. Reposition the planetary gears then engage
the spline.
Fig 135. Fig 137.
28 Attaching coupling c Place thrust plate [13] on carrier [3].
a Attach coupling [15] to shaft [102].
29 Assembling 1st stage planetary gears
a Attach coupling [15] to shaft [102].
F-55 9813-0400-1 F-55

Track Motor
Fig 140.
Fig 138.
c Apply JCB Locking Fluid Medium Strength to
30 Assembling cover
the 12 hexagon socket bolts [35]. Tighten socket
bolts to 66.7 ± 3.92 Nm (6.8 ± 0.4 kgf/m).
a Apply JCB Sealant Medium Strength to the
mating surface of hub [1] and cover [14].
31 Filling lubrication oil
Note: Sealant should be applied around the mating
a Fill the motor with gear oil (lubrication oil) through
surface only. Keep sealant away from gear teeth.
the filling port.
Note: Supply 2.1 litres of gear oil.
Fig 139.
b Fasten two eye bolts to the tapped holes of cover

[14]. Place a wire sling and hook in the eyebolts,
place cover [14] on hub [1] aligning the position of
bolt holes.
Fig 141.
b Fit plugs [30] to ports of cover [14] and tighten to

98.1 ± 19.6 Nm (10.0±2.0 kgf/m).
F-56 9813-0400-1 F-56

Track Motor
Fig 142.
32 Removing reassembled motor from the workbench
a Turn the workbench upside down (motor side

upwards).
b Remove the bolts securing the motor to the

workbench.
c Fasten two eyebolts (M16) to spindle [2].
d Place a wire sling and hook in the eye bolts,

remove the motor from the workbench using a
crane.
F-57 9813-0400-1 F-57

Track Motor
Fig 143.
F-58 9813-0400-1 F-58

Track Motor
Performance Confirmation Test
After servicing the motor, the following test should be Test Procedure
completed.
1) Motor Mounting and Piping
Required Measuring Devices
Mount the motor and gearbox on the track frame but do not
1 Pressure gauge - 3.43 MPa (35 kgf/cm ) 2 2 pieces fit the tracks. The performance test is completed under no-
load conditions.
2 Graduated cylinder - 5 litres 1 piece
3 Stop watch 1 piece Connect the piping so that the pressure gauge is fitted into
the main feed connection. Connect a hose to the motor
drain connection and position the other end into the
graduated cylinder.
2) Warm-up Procedure
Run the motor as detailed in table below.
Speed range Motor revolving speed Pressure Rotation direction Running time
Low speed 10 rev/min.
No-load CW/CCW 1 minute each
High speed 20 rev/min.

1 Carry out pre-test preparatory operation.
Operate the motor until the following temperatures

are recorded:
a Hydraulic fluid temperature: 45 - 55 deg C.
b Hub external temperature: 40 - 80 deg C.
2 Measure the following items which should be as

follows:
a Motor drive pressure:
Max. 1.57 MPa (16 kgf/cm2) at 10 rev/min.
b Hydraulic motor drain volume:
Max. 1.2 l/min. at 10 rev/min.
3 If the readings do not match the above criteria the

motor should be disassembled and re-adjusted.
F-59 9813-0400-1 F-59

Track Motor
F-60 9813-0400-1 F-60

Fault Finding
Transmission
Fault Finding
Transmission
Traction Motor
Symptom Possible Cause Remedy

a Motor does not run. 1 Device external to the piston motor or Check that the specified pressurised oil is
reduction gear malfunctioning. delivered to the motor input side. Inspect all
associated devices and repair if necessary.
2 Sliding area of motor is excessively worn, Renew the excessively worn part. Remove
allowing pressurised oil to escape. scratches and burrs from the surface and
completely clean all parts. Reassemble.
3 Malfunction resulting from damaged motor Dismantle and renew the damaged part(s).
part(s), resulting in excessive noise. Completely clean all parts and then
reassemble.
4 Relief valve operating due to excessive motor Check the load and only operate the machine
loading. with a suitable load.
b Motor speed low. 1 Oil not supplied to motor at specified rate due Check that the specified pressurised oil is
to problems in hydraulic pump, pressure control delivered to the motor input side. Inspect all
valve etc. associated devices and repair if necessary.
2 Volume efficiency of motor low. After dismantling, check for abnormal wear of
the sliding area and repair or renew the worn
parts.
c Motor speed varies 1 Large amount of pressurised oil escapes and Dismantle and renew excessively worn parts.
greatly. flows out of the drain port due to wear on the Clean all parts and reassemble.
sliding area of the motor.
2 Wear in the bearings. Renew motor bearings.
3 Motor load is excessive and automatic 2- Check the load and only operate the machine
speed function is operating. with a suitable load.
d Oil leaks. 1 Oil leaks due to damaged oil seals or O-rings. Renew damaged oil seals or O-rings. When
fitting an oil seal, be careful not to damage the
lip. Check the system to ensure the running
temperature does not exceed 80 °C. Take the
necessary steps to ensure the temperature
remains within the acceptable range.
2 Refer to a2 and/or c1. Refer to a2 and/or c1.
3 Clogging due to foreign matter in drain pipe or Clean the clogged drain piping. Recheck the
long, narrow pipes causing the oil seal to break. piping system and reduce the passage
resistance. Renew the oil seal taking care not
to damage the lip.
e Abnormal noise, 1 When the motor works as a pump, when the Recheck the hydraulic circuit and by
excessive speed and closed circuit is used, when the boost pressure remedying or renewing the double
pressure variation due is low (standard: 0.4 -5 kgf/cm2) or when the counterbalance valve, prevent the generation
to cavitation. double counterbalance valve operates of negative pressure. Dismantle the motor
improperly, negative pressure is generated on and renew any abnormally worn or broken
the suction side of the motor, resulting in parts.
cavitation.
F-61 9813-0400-1 F-61

Fault Finding
Transmission
Parking Brake

a Braking force is low 1 Friction plates worn. Renew discs. Completely remove foreign
or insufficient. matter and repair damaged areas. After
cleaning, reassemble.
2 Counter places surface damaged or making Grind and recondition the affected area.
poor contact. Reassemble after cleaning. Renew plates if
excessively damaged.
3 Spring is deformed or damaged. Renew the spring. Completely remove
foreign matter and reassemble after
cleaning.
b Motor speed low. 1 Brake not releasing.
i Oil leaks due to broken O-ring. Renew broken O-ring.
ii Orifice is clogged. Clean and reassemble.
F-62 9813-0400-1 F-62

Fault Finding
Transmission
Relief Valve

a Motor does not run or 1 Relief valve not closing fully:
rotation speed is slow. i Foreign matter clogging components. Completely remove foreign matter, repair
damaged part and reassemble after
cleaning. Renew if damage or leakage is
excessive.
ii Spring broken. Renew the spring. Completely remove
foreign matter, repair any damage and
reassemble after cleaning. Renew if
damage or leakage is excessive.
2 The cracking pressure of relief valve is low.
i Spring is deformed. Renew relief valve sub-assembly.
ii Poppet orifice is clogged. After cleaning, reassemble.
b Motor does not stop 1 Relief valve not closing fully.
or stops slowly. i Foreign matter clogging components. Completely remove foreign matter, repair
damaged part(s) and reassemble after
excessive.
2 Refer to a2. Refer to a2.
c Motor does not run or 1 Shockless function does not work.
rotation speed is slow. i Foreign matter in piston section. Completely remove foreign matter, repair
damaged part and reassemble after
excessive.
iii Relief valve pressure set too high. Adjust the relief valve set pressure.
F-63 9813-0400-1 F-63

Fault Finding
Transmission
Counterbalance Valve

a Motor does not run or 1 Plunger not switching.
rotation speed is slow. i External pilot pressure not present. Inspect the piping for damage.
ii Foreign matter between plunger and body. Completely remove foreign matter, repair
any damage and reassemble after cleaning.
Renew if damage or leakage is excessive.
iii Orifice clogged. Completely remove foreign matter, repair
iv Foreign matter caught between dumper piston Renew spring. Completely remove foreign
and cap. matter, repair any damage and reassemble
after cleaning. Renew if damage or leakage
is excessive.
b Motor does not stop 1 Plunger does not return.
or stops slowly. i Foreign matter between plunger and body. Completely remove foreign matter, repair
the damaged part and reassemble after
excessive.
ii Spring broken. Renew spring. Completely remove foreign
matter, repair any damage and reassemble
is excessive.
iii Spring not fitted. Fit spring in specified position.
iv Orifice clogged. Reassemble after cleaning.
c Rotation varies. 1 Plunger does not move smoothly.
i Foreign matter between plunger and body. Completely remove foreign matter, repair
ii Orifice clogged. Reassemble after cleaning.
d Abnormal noise is 1 Plunger does not return.
heard. i Foreign matter between plunger and body. Completely remove foreign matter, repair
ii Spring broken. Renew spring. Completely remove foreign
matter, repair any damage and reassemble
is excessive.
iii Orifice clogged. Reassemble after cleaning.
e Travel not linear. 1 Dumper piston or cap is excessively worn. Renew dumper piston and cap. Completely
remove foreign matter, repair any damage
and reassemble after cleaning.
F-64 9813-0400-1 F-64

Fault Finding
Transmission
Speed Range Changing

a Travel is not linear. 1 Plunger not switching.
i Foreign matter between plunger and body. Completely remove foreign matter, repair the
damage and reassemble after cleaning.
Replace if the damage or leakage is large.
ii Spring not installed. Install spring.
iii Spring broken. Renew spring. Completely remove foreign
matter, repair any damage, reassemble after
cleaning. Renew if the damage or leakage is
excessive.
iv Foreign matter is caught between the two Completely remove foreign matter, repair any
spools. damage and reassemble after cleaning.
Renew if the damage or leakage is large.
2 Pressurised oil leaks due to excessive wear of Renew the 2-speed control piston.
2-speed control piston. Completely remove foreign matter and
reassemble after cleaning.
3 2-speed control piston is not installed. Install 2-speed control piston.
4 Steel balls badly worn. Renew steel balls. Completely remove
foreign matter and reassemble after cleaning.
5 Set pressure is rising due to excessive spool Renew the two spools. Completely remove
wear. foreign matter and reassemble after cleaning.
6The orifice of the 2-speed piston compartment Fit a new orifice of correct diameter.
oil passage is incorrect.
7 The orifice of the 2-speed piston compartment Reassemble after cleaning.
oil passage is clogged.
8 Number of washers is different, making set Confirm number of washers.
pressure different between the left and right.
F-65 9813-0400-1 F-65

Fault Finding
Transmission
F-66 9813-0400-1 F-66

8.section F - Transmission

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8.section F - Transmission

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Section F

F-0 9813/0400-1 F-0

Contents Page No.

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F-1 9813-0400-1 F-1

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F-2 9813-0400-1 F-2

2 Lift the side of the undercarriage high enough to

3 Stop the engine and operate the control lever to

4 Remove the motor cover, attach identification tags to

5 Support the motor so that the cables are in tension,

F-3 9813-0400-1 F-3

Precautions During Installation

1 Before fitting, clean the assembly.

Make sure that all ports are plugged to prevent the

2 Lift the assembly and position it on the undercarriage.

3 Remove the plugs and connect the motor hoses.

Install the bolts and washers, using JCB Threadseal

4 Do not fit the track at this stage. Follow the Start Up

5 Install the covers over the motor.

F-4 9813-0400-1 F-4

7 Refit the track Section J, Track and Running Gear.

F-5 9813-0400-1 F-5

Start Up and Running In

Start Up Note: The presence of residual air in the hydraulic circuit

!MWARNING and will lead to a jerking of the motor as well as excessive

F-6 9813-0400-1 F-6

3 Make sure that the oil temperature does not exceed

After having terminated this first running-in follow the

4 Check that there are no oil leakages.

5 Check the level of lubricating oil in the gear box.

6 The opening action of the brake could be slowed

7 Check that there are no other problems.

F-7 9813-0400-1 F-7

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F-8 9813-0400-1 F-8

F-9 9813-0400-1 F-9

For lifting the motor, spindle [2] and hub [1].

Spindle fixing tool

For connecting the spindle [101] to hub [1]

F-10 9813-0400-1 F-10

For pressing angular ball bearing [24] into hub [1]

F-11 9813-0400-1 F-11

F-12 9813-0400-1 F-12

For installing oil seal [132] to spindle [101]

F-13 9813-0400-1 F-13

Floating seal installation tool (II)

F-14 9813-0400-1 F-14

F-15 9813-0400-1 F-15

Rear flange locating guides

For guiding the rear flange during removal and

F-16 9813-0400-1 F-16

For removing valve seat [201] from rear flange [301].

F-17 9813-0400-1 F-17

Dismantling 8 The photographs and drawings contained in the

Prepare a travel motor workbench.

Prepare a sturdy workbench with which the internal

Spread a rubber or vinyl sheet on the workbench.