Usage:
Fluid Spillage Containment
Care must be taken to ensure that the fluids are contained during performance of the inspection, the maintenance, the testing, the adjusting and the repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to the "Tools And Shop Products Guide, NENG2500" the tools and the supplies suitable to collect and contain any of the fluids in Caterpillar machines. Dispose of the fluids according to local regulations and mandates.
1. Prior to removing the swing motor, clean the swing motor and the area around it.
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At operating temperature, the hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible personal injury, release the pressure in the hydraulic system before any of the hydraulic lines or any of the components are disconnected or removed. |
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1. Release the pressure in all of the implement hydraulic circuits (the boom, the stick and the bucket) before any of the hydraulic lines or any of the components are disconnected or removed, as follows:
a. Fully retract the stick cylinder rod.
b. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.
c. Lower the boom until the bucket is flat on the ground.
d. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.
e. Move the control levers for the boom, the stick and the swing to all full stroke positions. This will release any pressure that might be present in the pilot system.
f. Return the key to "OFF" position.
g. Slowly loosen the fill plug on the hydraulic tank and release the pressure.
h. Tighten the fill plug on the hydraulic tank. Tighten the fill plug to a torque of 68 ± 7 N*m (50 ± 5 lb ft).
i. The pressure in the hydraulic system has been released and the hydraulic lines and the components can be removed.
2. Prior to removing the swing motor, clean the swing motor and the area around it.
3. Remove the cover assembly located over the swing motor.
4. Drain the oil from the swing drive in a suitable container for storage or disposal. The capacity of the swing drive is 8 liters (2.1 U.S. gal).
5. Put identification marks on all hose assemblies connected to the swing motor for installation purposes.
6. Disconnect hose assembly (1) and electrical connector (2) from the swing motor.
7. Disconnect four hoses (3) from the swing motor.
8. Remove 16 bolts (4) and the washers that hold the swing motor to the swing drive.
NOTE: For ease in the removal of the swing motor two bolts (4) and the washers, remove six bolts (5) and the washers, and remove valve body (6).
9. Fasten a lifting sling and a hoist to swing motor (7) using Tooling (A) as shown. The weight of the swing motor is 65 kg (141 lb).
NOTE: It may be necessary to use a screwdriver to separate the swing motor from the ring gear of the swing drive.
NOTE: The following steps are for the installation of the swing motor.
10. Make sure the mating surfaces of the swing motor and swing drive are thoroughly clean and dry.
11. Apply 1U-8846 Gasket Maker to the mating surfaces of the swing motor and swing drive.
12. Check the condition of the O-ring seal used between the swing motor and swing drive. Also, check the condition of the O-ring seals used in the ends of the hose assemblies. If any of the O-ring seals are damaged, use new parts for replacement.
13. Fasten a hoist to swing motor (7), and put it in its original position in the swing drive.
14. Position valve body (6), and install six bolts (5) and the washers.
15. Apply 9S-3263 Threadlock to 16 bolts (4) and install bolts (4) and the washers that secure swing motor.
16. Reconnect four hoses (3), hose assembly (1) and electrical connection (2) their original locations on the swing motor.
| NOTICE |
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To prevent damage to the swing motor, the case must be filled with hydraulic oil at least to the fill port prior to operation. |
NOTE: Refer to the topic "Lubricant Viscosities and Refill Capacities" in the "Operation & Maintenance Manual" for the proper filling procedure and the proper levels for the hydraulic system and the swing drive.
17. Fill the hydraulic oil tank and swing drive with oil to the correct level.
18. Start the machine, and check the operation of the swing drive. Also, check for leaks.
Disassemble & Assemble Swing Motor
Start By:
a. remove swing motor
NOTE: The disassembly and the assembly procedure which follows is for a swing motor which has a swing parking brake attachment.
1. Make sure the outside of the swing motor is clean and free of dirt and debris prior to disassembly.
2. Remove four bolts (1) that secure swing parking brake actuator (2) to swing motor (3).
3. Remove two O-ring seals (6) from the swing parking brake actuator (2).
4. Remove two bolts (5) that secure brake solenoid (4) to actuator (2).
5. Remove brake solenoid (4) from actuator (2).
6. Remove four O-rings (7) from the solenoid (4).
7. Remove fitting (9) from the brake actuator (2). Remove O-ring seal (8) from fitting (9).
8. Remove two relief valves (10) from the swing motor (3).
9. Remove plug (11) from relief valve (10).
10. Remove O-ring seal (12) from plug (11).
11. Remove plug (13) from relief valve (10).
12. Remove back-up ring (14) and O-ring (15) from plug (13).
13. Remove spring (16) and plunger (17) from relief valve (10).
14. Remove lock ring (18) from relief valve (10).
15. Remove inner valve body (19) from relief valve (10).
16. Remove spring retainer (20) from inner valve body (19).
17. Remove and inspect back up ring (23) and O-ring seal (24) from inner valve body (19).
18. Remove two inserts (21) and (22) from the inner valve body (19).
20. Remove back-up ring (25) and O-ring seal (26) from the relief valve (10).
21. Remove valve seat (28) from relief valve (10).
22. Remove spring (27) from relief valve (10).
23. Remove valve stem (29) from relief valve (10).
24. Assemble relief valve in reverse order.
a. Inspect the O-ring and the back-up rings for wear and damage.
b. Tighten plug (11) to a torque of 120 ± 10 N*m (90 ± 7 lb ft).
c. Tighten locking ring (16) to a torque of 160 ± 30 N*m (120 ± 23 lb ft) after the relief valve has been set. Refer to the appropriate "Testing & Adjusting Manual" for the adjusting procedure.
25. Repeat Steps 9 through 24 for the other valve.
26. Remove six bolts (30) that secure valve housing (31) to the swing motor.
NOTE: Valve housing (31) and bolts (30) may have been removed during the removal to the swing motor.
27. Remove three O-ring seals (33) from the valve body (31).
28. Remove two valve assemblies (32) from valve body (31).
29. Remove spring (39), plunger (36) and ball valve (38) from valve body (32).
30. Remove back-up ring (35), O-ring (37) and back-up rings (34) from valve body (32).
31. Remove plug (40) from valve body (32).
32. Remove O-ring (45) from plug (40).
33. Remove plungers (43) and (44), two retainers (42) and spring (41) from the valve body (32).
34. Assemble cross over relief valve in reverse order.
a. Inspect O-ring and back-up rings for wear and damage.
b. Tighten valve body (32) into valve housing (31) to a torque of 69 ± 7 N*m (50 ± 7 lb ft).
35. Repeat Step 29 through 34 for the other cross over relief valve.
36. Remove plug (46) from swing motor (3).
37. Remove O-ring (47) from plug (46).
38. Remove spring (48) and spool (49) from the swing motor (3).
39. Remove four bolts (50) that secure the head (51) to the swing motor. Remove head (51) from the swing motor.
40. Remove O-ring (52). Remove plate (53) from the head.
41. Remove bearing (55) from head. Remove two pins (54) from head.
42. Remove 24 springs (56) from the piston.
| NOTICE |
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During the removal of the barrel assembly (57) from the swing motor. Do Not let the components come apart. All the components in the barrel assembly must be reinstalled in their original locations. |
43. Put the swing motor on its side as shown. Remove barrel assembly (57) from the shaft in the body.
44. Disassemble barrel assembly (57) as follows:
a. Put identification marks on nine piston assemblies (58), as to their location in plate (59) and barrel (57).
b. Remove nine pistons (58) and plate (59), as a unit, from barrel (57).
c. Separate the piston assemblies from the plate.
d. Remove bushing (6) from the barrel.
e. Remove spacer (61).
NOTE: There are twelve pins (62) in barrel (57). Two pins are used in each hole location.
f. Remove 12 pins (62) from the barrel.
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There is spring force against spacer (63). When retaining ring (64) is removed, the spring force will be released. To prevent possible personal injury, the removal of the internal components in barrel (57) should be performed in a press in order to retain spring (65) and spacer (63). |
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| NOTICE |
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Spacer (63) and spacer (66) are different in size. Put identification marks on the two spacers as they are removed so they can be reinstalled in their original locations. |
g. Put barrel (57) in a press. Install a suitable size drive plate that is slightly smaller in diameter then spacer (63), on spacer (63). Put a slight amount of compression on spacer (63) with the press.
h. Remove retaining ring (64) with Tool (A), and slowly release the spring compression.
i. Remove spacer (63), spring (65) and spacer (66) from barrel (57).
| NOTICE |
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Plate (67) has beveled edges only on one side as shown. To prevent damage to the swing motor, the plate must be reinstalled in its original position. |
45. Note the position of plate (67) in the swing motor body. Remove plate (67) from the swing motor body.
46. Place a shop towel over piston (68). While retaining piston (68) by hand, apply shop air pressure (free of water) of approximately 525 kPa (75 psi) to the brake release port as shown. Piston (68) will move up and out of the swing motor body.
47. Remove the three separator plates and two friction plates (69).
48. Use Tool (B) to remove retaining ring (70).
49. Using a soft faced hammer, remove shaft assembly (71) from the swing motor body.
50. Remove two O-ring seals (73) from the swing motor body.
51. Remove bearing (72) from the swing motor body.
52. Turn the swing motor body over. Use Tool (C) to remove retaining ring (74). Remove plate (75) from the swing motor body.
53. Remove seal (76) from the swing motor body.
NOTE: The following steps are for the assembly of the swing motor.
54. Make sure all of the components of the swing motor are clean and free of dirt and debris prior to assembly. Check the condition of all of the components in the swing motor. Guideline For Reusable Parts "Pistons Pumps And Motors", Form No. SEBF8032-01 can be used as a guide for reconditioning and determining the reusability of some parts.
55. Install seal (76) in the swing motor body. Install the seal with the sealing lip facing in toward the inside of the swing motor body. Lubricate the lip of the seal with clean hydraulic oil.
56. Install plate (75). Using Tool (C), install retaining ring (74) in the swing motor body.
57. Install bearing (72) in the swing motor body until it makes contact with the counterbore in the body.
58. Install two O-ring seals (73) in the swing motor body. Lubricate the O-ring seals with clean hydraulic oil.
59. Install shaft assembly (71) in the swing motor body. Using Tool (B), install retaining ring (70).
| NOTICE |
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The four tooth cut locations of each friction plate must be in alignment. Also, the four tooth cut locations of each separator plate must be in alignment in the swing motor body. |
60. Put clean hydraulic oil on three separator plates and two friction plates (69). Install the plates in alternating order in the body. Start with a separator plate, and end with a separator plate.
61. Install piston (68) in the swing motor body. The threaded holes in the piston can be used as a guide during the installation. If the piston is hard to install because of O-ring seal resistance, a soft faced hammer can be used as an aid in the installation.
62. Put a thin coat of 5P-0960 Multipurpose Grease on the back side of plate (67). Install plate (67) in the swing motor body. Install the plate with the beveled sides facing toward the inside of the swing motor body.
63. Assemble barrel assembly (57) as follows:
a. Install spacer (66) spring (65) and spacer (63) in barrel (57).
b. Put the barrel in a press. Install a suitable size drive plate on spacer (63), and compress spring (65) until retaining (64) can be installed.
c. Use Tool (A) to install retaining ring (64).
d. Install 12 pins (62) in the barrel.
e. Remove spacer (61) and bushing (60) on the barrel.
f. Put clean hydraulic oil on nine piston assemblies (58). Install the piston assemblies in their original bores in plate (59).
g. Install the plate with the piston assemblies in their original bores in barrel (57).
| NOTICE |
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Do Not let the barrel assembly fall apart when it is installed in the body. |
64. Put the swing motor body on its side. Install barrel assembly (57) in the body.
65. Install 24 springs (56) in the piston.
66. Install two pins (54) in the head. Install bearing (55).
67. Put 5P-0960 Multipurpose Grease on the face of plate (53) that makes contact with the head. Install plate (53) in its original position on the head. Install O-ring seal (52) in the head.
68. Put head (51) in its original position on the body. Install four socket head bolts (50) that hold it. Tighten four bolts (50) to a torque of 430 ± 43 N*m (320 ± 34 lb ft).
70. Install relief valve assemblies (10) in the head. Tighten the relief valve assemblies to a torque of 175 ± 10 N*m (130 ± 7 lb ft).
71. Install O-ring (8) on fitting (9). Install fitting (9) into brake actuator (2).
72. Install four O-rings on solenoid (4).
73. Install solenoid (4) in brake actuator (2). Install two bolts (5) that secure solenoid (4) into brake actuator (2).
74. Install two O-rings (6) in brake actuator (2).
75. Install four bolts (1) that secure brake actuator (2) to swing motor (3).
| NOTICE |
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To prevent damage to the swing motor, the unit must be filled with hydraulic oil at least to the fill port before operation. Refer to the "Operation & Maintenance Manual" for the correct filling procedure. |
End By:
a. install swing motor