GROUP 6 TRAVEL MOTOR

1. REMOVAL AND INSTALL

1) REMOVAL
If engine is running or full up pressure
into hydraulic system, absolutely does
not repair or tighten hose, fitting.
As hydraulic line explode, dangerous
accident may occur.
(1) Lowered the bucket on the ground.
(2) Shut off engine and raise the seat bar and
move pedals until both pedal lock.
(3) Tilt canopy and remove the front cover. Side cover
3
※ For tilting and lowering of the canopy,
refer to page 4-14 of the operator's manual.
(4) Loosen self lock nut(3) and remove the
2
side cover.
(5) Separate input, output, drain line from
1
travel motor and block the hole to avoid
alien.
(6) Loosen the bolt(2).
(7) Loosen bolt(1) from travel motor and
remove input gear from gear box.
(8) Remove travel motor from gear box, and
put it on the work bench to make
disassembly possible.

Input gear

Sealant

2-41
2) INSTALL
(1) Paint silicon sealant to travel motor flange
to prevent the final drive housing from oil
2
leakage.
(2) Assemble travel motor to the gear box.
(3) Tighten input gear, shaft joining bolt(2),
Input gear
washer and flat washer. At this time, the
normal torque for tightening bolt is
4.2kgf・m(30.4lbf・ft). Sealant

(4) Tighten mounting bolt(1) by 8.6kgf・m

(62.2lbf・ft) torque.
(5) Release the plug out of the motor port and
remove the cap from the hydraulic hose.
(6) Assemble hose assembly linked to the
lower port connector of the travel motor
from the valve block(Pump).
(7) Assemble hose assembly linked to the
upper port connector of the travel motor
3 Side cover
from the valve block.
(8) Assemble hose assembly(Drain) linked to
travel motor connector from the oil tank
2
elbow.
(9) Assemble the cover and tighten the self
lock nut(3). 1

2-42
2. STRUCTURE

34
23

71
76
70
13
81
75
21
29
28 64
27 75
26 63
3 2

39
38
39
74 24
72
31 118
45 119
116
65
117 121
116 134
119 20
118 8

2 Guide pin 29 Valve drive 72 O-ring

3 Guide pin 31 Spacer 74 O-ring
8 Plug 34 Screw 75 O-ring
13 Spline shaft 38 Back up ring 76 O-ring
20 Washer 39 Back up ring 81 Seal ring
21 Bearing housing 45 Spring washer 116 Spring
23 Front cover 63 Gear wheel set 117 Spool
24 Valve housing 64 Cardan shaft 118 Plug
26 Balance plate 65 Hexagon screw 119 O-ring
27 Disc valve 70 Dust seal 121 Plug
28 Channel plate 71 Shaft seal 134 Screw

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3. TOOLS
1) MAIN HOLDING TOOL

2) HOLDING TOOL

3) MANDREL FOR OUTPUT SHAFT

REMOVAL
~7(175)

φ1.2(30)
Unit:Inch(mm)

2-44
4) MANDREL AND BACKSTOP FOR FITTING φ2.039(51.8)

0.59(15)
0.12(3)
SHAFT SEAL φ2.031(51.6)
φ1.772(45.0)
φ1.764(44.8) 30

2.95(75)
4.13(105)
0.59(15)
0.12(3)
φ1.764(44.8) 30
φ1.756(44.6)
φ2.551(64.8)
φ2.543(64.6)

φ2.551(64.8)

1.38(35)
0.59(15)
φ2.543(64.6)
φ1.799(45.7)
φ1.783(45.3)

0.59(15)
φ2.390(60.7)
φ2.374(60.3)
φ3.142(79.8)
φ3.134(79.6)

Unit:Inch(mm)

5) TWO GUIDE BOLTS 0.12(3)

0.4(10)
0.08(2)
5.5(140)

10

M14 Unit:Inch(mm)

6) MANDREL TO REMOVE BALANCE PLATE

12(3)X45
3.9(100)

φ0.7244(18.40)
φ0.7224(18.35)
Unit:Inch(mm)

2-45
4. DISASSEMBLY
34
23

71
76
70
13
81
75
21
29
28 64
27 75
26 63
3 2

39
38
39
74 24
72
31 118
45 119
116
65
117 121
116 134
119 20
118 8

1) Cleanliness is extremely important when repairing a hydraulic motor.

Work in a clean area. Before disconnecting the lines, clean port area of motor thoroughly. Use a
wire brush to remove foreign material and debris from exterior joins of motor. Check shaft and
keyway, use 600grit paper/cloth to remove all nicks. Burrs and sharp edges that might damage the
shaft seals when installing retainer on shaft and bearing assembly. Before starting disassembly
procedures, drain oil from inside of motor.
2) Place motor in a vise with output shaft down. Clamp across edge of bearing housing not on
housing. Excessive clamping pressure on housing will cause distortion. When clamping, use
some protective device on vise, such as special soft jaws, pieces of hard rubber or board.
Although not all drawings show the motor in a vise, we recommend that you keep the motor in the
vise during disassembly.
Follow the clamping procedures explained throughout the manual.
3) Place the motor in holding tool and remove plug(8) and washer(20).
※ Use 5mm allen head spanner.
4) Tilt motor, screw come out.
5) Remove 4 bolts(65) from motor.
※ Use 22mm socket spanner.
6) Lift off carefully as a unit, holding your fingers under the channel plate(Item No.28).
7) Remove O-ring(75) from channel plate(28).
8) Remove channel plate(28).
9) Remove disc valve(27).

2-46
 34
23

71
76
70
13
81
75
21
29
28 64
27 75
26 63
3 2

39
38
39
74 24
72
31 118
45 119
116
65
117 121
116 134
119 20
118 8

10) Remove spacer(31).

11) Fill in oil into the spacer hole and use the Ø18.4mm mandrel as a piston to press up the balance
plate and remove balance plate(26).
12) Remove guide pin(3) and O-rings(38, 39, 72, 74), 2 spring washers(45) from valve housing.
13) Remove valve drive(29).
14) Remove guide pin(2).
15) Hold fingers under the gearwheel set(63) to prevent the parts from dropping out.
16) Remove O-ring(75) from gearwheel set(63).
17) Remove cardan shaft(64).
18) Remove seal ring(81).
19) Unscrew with 13mm socket spanner.
20) Remove front cover(23) and O-ring(76).
21) Dust seal(70) and shaft seal(76) to be knocked out by means of the special mandrel(4 on page 2-45).
22) Press out the shaft/bearing assembly using a hydraulic press(Pressing force max 550lbf) using the
special mandrel(3 on page 2-44).
※ Shaft/bearing assembly should not be disassembly.
23) Remove plugs(118) and spring(116), spool(117) from valve housing(29).
24) Remove O-ring(119) from plugs(118).
※ After disassembling, clean all parts in low aromatic kerosene.
※ Examine the parts and exchange them if necessary.
※ Immediately before assembly, lubricate each part with hydraulic oil and grease rubber parts with vaseline.

2-47
5. REASSEMBLY

34
23

71
76
70
13
81
75
21
29
28 64
27 75
26 63
3 2

39
38
39
74 24
72
31 118
45 119
116
65
117 121
116 134
119 20
118 8

1) Check all mating surfaces. Replace any parts that have scratches of burrs that could cause
leakage. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe with cloth or paper
towel because lint or other matter could get into the hydraulic system and cause damage. Do not
use a coarse grit papers/cloth or try to file or grind motor parts. Check around the keyway and
chamfered area of the shaft for burrs, nicks or sharp edges that can damage the seals when
reassembling the retainer.
※ Lubricate all seals(Prior to installation) with petroleum jelly such as vaseline. Use new seals when
reassembling the motor.
2) Fit seal ring(81) into recess in bearing housing, placed in the holding tool.
3) Fit shaft / bearing assy(13) into housing(21). Use the hydraulic press(Max 250kgf(550lbf)).
4) Knock shaft seal(71) into position in the front cover, using the assembly mandrel. Grease lip with vaseline.
5) Assemble dust seal(70) to front cover(23).
Use assembly mandrel, plastic hammer and support(To prevent the shaft seal from being knocked
out). Grease lip with vaseline.

2-48
 34
23

71
76
70
13
81
75
21
29
28 64
27 75
26 63
3 2

39
38
39
74 24
72
31 118
45 119
116
65
117 121
116 134
119 20
118 8

6) Assemble O-ring(76) to front cover(23).

Grease with vaseline.
7) Tighten cover(23) and bearing(21) with
screw(34). Use 13mm socket spanner.
Turn the motor upside down. Fill up
splines area in the shaft with oil. Mount 2
off guide bolts.
・Tightening torque : 27~31.8kgf・m
(195~230lbf・in)
8) Assemble cardan shaft(64) to bearing A
housing(21). If visible difference in splines
length. Longest splines to be mounted in
the output shaft.
9) Fit O-ring(75) to gear wheel set(63).
Grease with vaseline.
10) Hold fingers under the gearwheel set(63) to
prevent parts from dropping out.
Hole(6mm)to be aligned with hole in the
bearing housing(21). Mark the gearwheel
set(63) rotor at the point where the tip of a
spline tooth is opposite the bottom of a
tooth in the external rotor teeth(Right fig).

2-49
 34
23

71
76
70
13
81
75
21
29
28 64
27 75
26 63
3 2

39
38
39
74 24
72
31 118
45 119
116
65
117 121
116 134
119 20
118 8

11) Mark the bottom of a spline tooth on the valve drive(29). Line up mark on rotor and valve drive(29).
12) Grease with vaseline to O-ring(75) and mount in channel plate(28) groove.
13) Assemble gearwheel set(63) and channel plate(28) with guide pin(2).
Align mark on valve drive(29) with a hole in the outer rim(A on drawing previous page). Turn disc
valve(27) counter clockwise until splines in the two parts engage.
14) Place 2 spring washer(45) into valve housing(24).
15) Fit the two O-rings(Greased with vaseline, 72, 74) and 2 back up ring(30) in the balance plate(26) grooves.
16) Mount guide pin(3) in valve housing(24).
17) Grease with vaseline to prevent the spacer(31) from dropping out in balance plate(26).
18) Mount valve housing(24) on the rest of the motor. Ports should face in the same direction as the
drain port.
19) Lubricate threads and cross tighten 4 hexagonal bolts(65).
・Tightening torque : 164.5~177kgf・m(1190~1280lbf・in)
20) Screw in the orifice(134) and tighten it.
21) Plug the hole with plug(8) and washer(20) and tighten it.
22) Lubricate the two O-ring(119) with hydraulic oil or grease and place them in the bottom of the holes.
23) Place the spool(117) with the two spring(116).
24) The two plug(118) must be greased on the tappered end and the surface for the O-ring before they
are preset in the holes.

2-50