sm pc228us-2 sebm015903

SEBM015903

© 2003 1All Rights ReservedPrinted in Japan 05-03(01)

1

00-1(3)

MACHINE MODEL SERIAL NUMBER

PC228USLC-1 11001 and upPC228US-2 15001 and upPC228USLC-2 15001 and up

• This shop manual may contain attachments and optional equipment that are not availablein your area. Please consult your local Komatsu distributor for those items you mayrequire.Materials and specifications are subject to change without notice.

• PC228US, PC228USLC mount the S6D102E-1 engine.For details of the engine, see the 102 Series Engine Shop Manual.

PC228US-2

PC228USLC-1, 2

00-2 PC228USLC-11

CONTENTS

No. of page

01 GENERAL ........................................................................ 01-1

10 STRUCTURE AND FUNCTION ...................................... 10-1

20 TESTING AND ADJUSTING .......................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ................................. 30-1

40 MAINTENANCE STANDARD......................................... 40-1

90 OTHERS........................................................................... 90-1

00-2-1(3)

PC228USLC-1

‡ 00- 1 (3)00- 2 (1)

‡ 00- 2-1 (3)‡ 00- 2-2 (3)‡ 00- 2-3 (3)‡ 00- 2-4 (3)

00- 300- 400- 500- 600- 700- 800- 900-1000-1100-1200-1300-1400-1500-1600-1700-1800-1900-2000-2100-22

10-6610-6810-6910-7010-7110-7210-7310-7410-7510-7610-7710-7810-7910-8010-8110-8210-8310-8410-8510-8610-8710-8810-8910-9010-9110-9210-9310-94

10-3910-4010-4110-4210-4310-4410-4610-4710-4810-4910-5010-5110-5210-5310-5410-5510-5610-5710-5810-5910-6010-6110-6210-6310-6410-6510-65-1 (2)10-65-2 (2)

Mark Indication Action required

fi Page to be newly added Add

‡ Page to be replaced Replace

( ) Page to be deleted Discard

The affected pages are indicated by the use of thefollowing marks. It is requested that necessary actionsbe taken to these pages according to the table below.

Pages having no marks are those previously revisedor made additions.

LIST OF REVISED PAGE

Time ofMark Page revisionTime ofMark Page revision


Time ofMark Page revision

LIST OF REVISED PAGES

01- 101- 2 (1)01- 2-1 (1)01- 301- 4 (2)01- 4-1 (1)01- 4-2 (2)01- 4-3 (1)01- 4-4 (1)01- 501- 601- 6-1 (1)01- 6-2 (1)01- 6-3 (1)01- 6-4 (1)01- 701- 8

10- 110- 210- 310- 410- 510- 610- 710- 810- 9

10-1010-1110-1210-1310-1410-1510-1610-1710-1810-1910-2010-2110-2210-2310-2410-2510-2610-2710-2810-2910-3010-3110-3210-3410-3510-3610-3710-38

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PC228USLC-1

20-35120-35220-35420-35520-35620-35720-35820-35920-36020-36120-36220-36320-36420-36520-36620-36720-36820-36920-37020-37120-37220-37320-37420-37520-37620-37720-37820-37920-38020-38120-38220-38320-38420-38520-38620-38720-38820-38920-39020-391

20-22820-22920-23020-23120-23220-23320-23420-23520-23620-23720-23820-23920-24020-24120-242

20-30120-30220-30320-30420-30520-30620-30720-30820-30920-31020-31120-31220-31320-31420-31520-31620-31720-31820-31920-32020-32120-32220-323

20-13620-13720-13820-13920-14020-14120-14220-14320-14420-14520-14620-14720-148

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10-9510-9610-9710-9810-9910-10010-10110-10210-10310-10410-10510-10610-10710-10810-10910-11010-11110-11210-11310-11410-11510-116

20- 120- 220- 3

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‡ 20- 9 (3)20-1020-1120-1220-1320-1420-1520-16





20-1720-1820-1920-20

20-10120-10220-10320-10420-10520-10620-10720-10820-10920-11020-11120-11220-11320-11420-11520-11620-11720-11820-11920-12020-12120-12220-12320-12420-12520-12620-12720-12820-12920-13020-13120-13220-13320-13420-135

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PC228USLC-1





30-56-6 (2)30-56-7 (2)30-56-8 (2)30-56-9 (2)30-56-10 (2)30-56-11 (2)30-56-12 (2)30-56-13 (2)30-56-14 (2)30-56-15 (2)30-56-16 (2)30-56-17 (2)30-56-18 (2)30-56-19 (2)30-56-20 (2)30-56-21 (2)30-56-22 (2)30-56-23 (2)30-56-24 (2)30-56-25 (2)30-56-26 (2)30-56-27 (2)30-56-28 (2)30-56-29 (2)30-56-30 (2)30-56-31 (2)30-56-32 (2)30-56-33 (2)30-56-34 (2)30-56-35 (2)30-56-36 (2)30-56-37 (2)30-56-38 (2)30-56-39 (2)30-56-40 (2)30-56-41 (2)30-56-42 (2)30-56-43 (2)30-56-44 (2)30-56-45 (2)

30-22 (1)30-23 (1)30-24 (1)30-25 (1)30-26 (1)30-27 (1)30-28 (1)30-29 (1)30-30 (1)30-31 (1)30-32 (1)30-33 (1)30-34 (1)30-35 (1)30-36 (1)30-37 (1)30-38 (1)30-39 (1)30-40 (1)30-41 (1)30-42 (1)30-43 (1)30-44 (1)30-45 (1)30-46 (1)30-47 (1)30-48 (1)30-49 (1)30-50 (1)30-51 (1)30-52 (1)30-53 (1)30-54 (1)30-55 (1)30-56 (1)30-56-1 (2)30-56-2 (2)30-56-3 (2)30-56-4 (2)30-56-5 (2)

20-48320-484

20-50120-50220-50320-50420-50520-50620-50720-50820-50920-51020-51120-51220-51320-514

30- 1 (2)30- 2 (1)30- 3 (1)30- 4 (1)30- 5 (1)30- 6 (1)30- 7 (1)30- 8 (1)30- 9 (1)30-10 (1)30-11 (1)30-12 (1)30-13 (1)30-14 (1)30-15 (1)30-16 (1)30-17 (1)30-18 (1)30-19 (1)30-20 (1)30-21 (1)

20-40120-40220-40320-40420-40520-40620-40720-40820-409

20-45120-45220-45320-45420-45520-45620-45820-45920-46020-46120-46220-46420-46520-46620-46720-46820-46920-47020-47120-47220-47320-47420-47520-47620-47720-47820-47920-48020-48120-482

30-56-46 (2)30-56-47 (2)30-56-48 (2)30-56-49 (2)30-56-50 (2)30-56-51 (2)30-57 (1)30-58 (1)30-59 (1)30-60 (1)30-61 (1)30-62 (1)30-63 (1)30-64 (1)30-65 (1)30-66 (1)30-67 (1)30-68 (1)30-69 (1)30-70 (1)30-71 (1)30-72 (1)30-73 (1)30-74 (1)30-75 (1)30-76 (1)30-77 (1)30-78 (1)30-79 (1)30-80 (1)30-81 (1)30-82 (1)30-83 (1)30-84 (1)30-85 (1)30-86 (1)30-87 (1)30-88 (1)30-89 (1)30-90 (1)

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PC228USLC-1





30-91 (1)30-92 (1)30-93 (1)30-94 (1)30-95 (1)30-96 (1)30-97 (1)30-98 (1)30-99 (1)30-100 (1)30-101 (1)30-102 (1)30-103 (1)30-104 (1)30-105 (1)30-106 (1)30-107 (1)30-108 (1)30-109 (1)30-110 (1)30-111 (1)30-112 (1)30-113 (1)30-114 (1)30-115 (1)30-116 (1)30-117 (1)30-118 (1)30-119 (1)30-120 (1)30-121 (1)30-122 (1)30-123 (1)30-124 (1)30-125 (1)30-126 (1)30-127 (1)30-128 (1)30-129 (1)30-130 (1)

30-131 (1)30-132 (1)30-133 (1)30-134 (1)30-135 (1)30-136 (1)30-137 (1)30-138 (1)30-139 (1)30-140 (1)30-141 (1)30-142 (1)30-144 (1)30-146 (1)30-147 (1)30-148 (1)30-149 (1)30-150 (1)30-151 (1)30-152 (1)30-153 (1)30-155 (1)30-156 (1)30-157 (1)30-158 (1)30-159 (1)30-160 (1)30-161 (1)30-162 (1)30-163 (1)30-164 (1)30-165 (1)30-166 (1)30-168 (1)30-170 (1)30-171 (1)30-172 (1)30-173 (1)30-174 (1)30-175 (1)

30-176 (1)30-177 (1)30-178 (1)30-179 (1)30-180 (1)

40- 140- 240- 340- 440- 640- 740- 840-1040-1140-1240-1340-1440-1540-1640-1740-1840-2040-2140-2240-2340-2440-2540-2640-2740-2840-2940-3040-3140-3240-3340-3440-3540-36

40-3740-3840-4040-4140-4240-4340-4440-4540-4640-47

90- 1 (1)90- 390- 3-2 (1)90- 590- 7 (1)

SAFETY SAFETY NOTICE

00-3

SAFETYSAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe specific purpose.

To prevent injury to workers, the symbol¤ is used to mark safety precautions in this manual.The cautions accompanying these symbols should always be followed carefully. If any danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.

2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing.

• Always wear safety glasses when hittingparts with a hammer.

• Always wear safety glasses when grindingparts with a grinder, etc.

3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.

4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.

5. Keep all tools in good condition and learn thecorrect way to use them.

6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.

8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.

9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.

10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.

SAFETY SAFETY NOTICE

00-4

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.

12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive (–) terminal first.

14.When raising heavy components, use a hoist orcrane.Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.

15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.

16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.

17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.

18.As a general rule, do not use gasoline to washparts. In particular, use only the minimum ofgasoline when washing electrical parts.

19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts.• When installing hoses and wires, be sure

that they will not be damaged by contactwith other parts when the machine is beingoperated.

20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.

21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.

23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.

24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.

FOREWORD GENERAL

00-5

FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman anaccurate understanding of the product and by showing him the correct way to perform repairs and make judge-ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.

TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.

MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERSThis section mainly gives hydraulic circuit diagrams and electric circuit diagrams.In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without anyadvance notice. Use the specifications given in the book with the latest date.

FOREWORD HOW TO READ THE SHOP MANUAL

00-6

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:

Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series

Electrical volume:Attachments volume:

These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.

DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.

FILING METHOD1. See the page number on the bottom of the page.

File the pages in correct order.2. Following examples show how to read the page

number.Example 1 (Chassis volume):

10 - 3

Item number (10. Structure andFunction)Consecutive page number for eachitem.

Example 2 (Engine volume):

12 - 5

Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.

3. Additional pages: Additional pages are indicatedby a hyphen (-) and number after the pagenumber. File as in the example.Example:10-410-4-110-4-210-5

REVISED EDITION MARK

When a manual is revised, an edit ion mark(123....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISEDPAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.

Symbol Item Remarks

¤ SafetySpecial safety precautionsare necessary when per-forming the work.

s Caution

Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.

4 Weight

Weight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.

3 Tighteningtorque

Places that require specialattention for the tighteningtorque during assembly.

2 CoatPlaces to be coated withadhesives and lubricants,etc.

5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.

6 DrainPlaces where oil or watermust be dra ined, andquantity to be drained.

}·

Each issued as onevolume to cover allmodels

12-20312-203-112-203-212-204

Added pages

FOREWORD HOISTING INSTRUCTIONS

00-7

HOISTING INSTRUCTIONS

HOISTING

¤ Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol4

• If a part cannot be smoothly removed from themachine by hoisting, the following checksshould be made:1) Check for removal of all bolts fastening the

part to the relative parts.2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the

weight of parts to be hoisted, referring tothe table below:

Wire ropes(Standard "Z" or "S" twist ropes

without galvanizing)

★ The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength ofthe rope used.

2) Sling wire ropes from the middle portion of thehook.

Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load.¤ Slinging with one rope may cause turning

of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.

4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120° hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150°.

Rope diameter Allowable load

mm kN tons

1011.512.514161820

22.430405060

9.813.715.721.627.535.343.154.998.1176.5274.6392.2

1.01.41.62.22.83.64.45.6

10.018.028.040.0

SAD00479

41%71%79%88%100%

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-8

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.

¤ Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.

Disconnection1) Release the residual pressure from the hydrau-

l ic tank. For detai ls , see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)★ The adapter can be pushed in about 3.5

mm.★ Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),press rubber cap portion (4) against (3) until itclicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.(See Fig. 3)★ Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with eachother. (See Fig. 4)★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5)★ When the hose is pulled back, the rubber

cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.

Type 1

FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

00-9

Type 2 Type 3D

isas

sem

bly

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turnlever (4) to the right (clockwise).

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.

2) Hold in the condition in Step 1), and pushuntil cover (3) contacts contact surface a ofthe hexagonal portion at the male end.

3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.

Con

nect

ion

• Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

• Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.

FOREWORD COATING MATERIALS

00-10

COATING MATERIALS

★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.

★ For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

Adhesives

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets,

rubber cushions, and cock plugfrom coming out.

LT-1B 790-129-9050 20 g(2 pcs.)

Polyethylenecontainer

• Used in places requiring an imme-diately effective, strong adhesive.Used for plastics (except polyeth-ylene, polyprophylene, tetrafluor-oethlene and vinyl chlor ide),rubber, metal and non-metal.

LT-2 09940-00030 50 g Polyethylenecontainer

• Features: Resistance to heat andchemicals

• Used for anti-loosening and seal-ant purpose for bolts and plugs.

LT-3

790-129-9060(Set of

adhesive andhardening

agent)

Adhesive:1 kg

Hardening

agent:500 g

Can

• Used as adhesive or sealant formetal, glass and plastic.

LT-4 790-129-9040 250 g Polyethylenecontainer

• Used as sealant for machinedholes.

HoltzMH 705 790-126-9120 75 g Tube

• Used as heat-resisting sealant forrepairing engine.

Three bond1735 790-129-9140 50 g Polyethylene

container

• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of met-

als, rubbers, plastics and woods.

Aron-alpha201 790-129-9130 2 g Polyethylene

container

• Quick hardening type adhesive• Quick cure type (max. strength af-

ter 30 minutes)• Used mainly for adhesion of rub-

bers, plastics and metals.

Loctite648-50 79A-129-9110 50 cc Polyethylene

container

• Resistance to heat, chemicals• Used at joint portions subject to

high temperatures.

Gasketsealant

LG-1 790-129-9010 200 g Tube• Used as adhesive or sealant for

gaskets and packing of powertrain case, etc.

LG-5 790-129-9070 1 kg Can

• Used as sealant for variousthreads, pipe joints, flanges.

• Used as sealant for taperedplugs, elbows, nipples of hydrau-lic piping.

LG-6 790-129-9020 200 g Tube

• Features: Silicon based, resist-ance to heat, cold

• Used as sealant for flange sur-face, tread.

• mab Used as sealant for oil pan,final drive case, etc.

FOREWORD COATING MATERIALS

00-11

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

Adhesives

LG-7 790-129-9070 1 g Tube

• Ftures: Silicon based, quick hard-ening type

• Used as sealant for flywheelhousing, intake manifold, oil an,thermostat housing, etc.

Three bond1211 790-129-9090 100 g Tube

• Used as heat-resisting sealant forrepairing engine.

Molybdenumdisulphidelubricant

LM-G 09940-00051 60 g Can • Used as lubricant for sliding por-tion (to prevent from squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scuf-fling of the thread when press fit-ting or shrink fitting.

• Used as lubricant for linkage,bearings, etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI

Various Various

• General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

• Used for normal temperature,light load bearing at places in con-tact with water or steam.

Molybdenumdisulphidelubricant

SYG2-400M400 g

(10 percase)

Belows type• Used for places with heavy load

FOREWORD STANDARD TIGHTENING TORQUE

00-12

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in

the table below.

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS★ In the case of flared nuts for which there is no

special instruction, tighten to the torque given inthe table below.

Thread diameterof bolt

Width acrossflats

mm mm Nm kgm

68101214

1013171922

13.2 0 1.431 0 366 0 7

113 0 10177 0 19

1.35 0 0.153.2 0 0.36.7 0 0.711.5 0 118 0 2

1618202224

2427303236

279 0 30382 0 39549 0 59745 0 83927 0 103

28.5 0 339 0 456 0 6

76 0 8.594.5 0 10.5

2730333639

4146505560

1320 0 1401720 0 1902210 0 2402750 0 2903290 0 340

135 0 15175 0 20225 0 25280 0 30335 0 35

Thread diameterof bolt

Width acrossflats

mm mm Nm kgm

681012

10131427

7.85 0 1.9518.6 0 4.940.2 0 5.9

82.35 0 7.85

0.8 0 0.21.9 0 0.54.1 0 0.68.4 0 0.8

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

1418222430333642

1924273236414655

24.5 0 4.949 0 19.6

78.5 0 19.6137.3 0 29.4176.5 0 29.4196.1 0 49245.2 0 49294.2 0 49

2.5 0 0.55 0 28 0 2

14 0 318 0 320 0 525 0 530 0 5

SAD00483

Sealing surface


00-13

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the

table below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

101216

141722

65.7 0 6.8112 0 9.8279 0 29

6.7 0 0.711.5 0 128.5 0 3

Norminal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

0203, 0405, 0610, 12

14

1420243342

Varies dependingon type ofconnector.

34.3 0 4.993.1 0 9.8

142.1 0 19.6421.4 0 58.8877.1 0 132.3

3.5 0 0.59.5 0 114.5 0 243 0 6

89.5 0 13.5

Norminal No.Thread diameter Width across flat Tightening torque

mm mm Nm kgm

08101214161820243033364252

08101214161820243033364252

141719222427303232n36nn

7.35 0 1.4711.27 0 1.4717.64 0 1.9622.54 0 1.96

29.4 0 4.939.2 0 4.949 0 4.9

68.6 0 9.8107.8 0 14.7127.4 0 19.6151.9 0 24.5210.7 0 29.4323.4 0 44.1

0.75 0 0.151.15 0 0.15

1.8 0 0.22.3 0 0.23 0 0.54 0 0.55 0 0.57 0 1

11 0 1.513 0 2

15.5 0 2.521.5 0 333 0 4.5


00-14

TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)Use these torques for eye joints (unit: mm) of Cummins Engine.

TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)Use these torques for tapered screws (unit: inch) of Cummins Engine.

Thread diameter Tightening torque

mm Nm kgm

681012

10 0 224 0 443 0 6

77 0 12

1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22


mm Nm kgm

68101214

8 0 210 0 212 0 224 0 436 0 5

0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51


mm Nm kgm

1 / 161 / 81 / 43 / 81 / 23 / 4

1

3 0 18 0 212 0 215 0 224 0 436 0 560 0 9

0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.412.45 0 0.413.67 0 0.516.12 0 0.92

FOREWORD ELECTRIC WIRE CODE

00-15

ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wire

Cable O.D.(mm)

Currentrating

(A)Applicable circuit

Number ofstrands

Dia. ofstrands(mm2)

Crosssection(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1 Pri-mary

Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Auxi-liary

Code WR n BW RW YR GW LW

Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White

3Code WB n BY RB YB GR LR

Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

4

Code WL n BR RY YG GY LY

Color White & Blue n Black & Red Red & Yellow Yellow &Green

Green &Yellow Blue & Yellow

5Code WG n n RG YL GB LB

Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black

6Code n n n RL YW GL n

Color n n n Red & Blue Yellow & White Green & Blue n

FOREWORD CONVERSION TABLE

00-16

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod of using the Conversion Table, see the example given below.

EXAMPLE• Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.

(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal linefromA.

(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line downfromB.

(3) Take the point where the two lines cross asC. This pointC gives the value when converting from mil-limeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the

left) to convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

010203040

5060708090

00.3940.7871.1811.575

1.9692.3622.7563.1503.543

0.0390.4330.8271.2201.614

2.0082.4022.7953.1893.583

0.0790.4720.8661.2601.654

2.0472.4412.8353.2283.622

0.1180.5120.9061.2991.693

2.0872.4802.8743.2683.661

0.1570.5510.9451.3391.732

2.1262.5202.9133.3073.701

0.1970.5910.9841.3781.772

2.1652.5592.9533.3463.740

0.2360.6301.0241.4171.811

2.2052.5982.9923.3863.780

0.2760.6691.0631.4571.850

2.2442.6383.0323.4253.819

0.3150.7091.1021.4961.890

2.2832.6773.0713.4653.858

0.3540.7481.1421.5361.929

2.3232.7173.1103.5043.898

B

A

C


00-17

Millimeters to Inches1 mm = 0.03937 in

Kilogram to Pound1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

22.05

44.09

66.14

88.18

110.23

132.28

154.32

176.37

198.42

2.20

24.25

46.30

68.34

90.39

112.44

134.48

156.53

178.57

200.62

4.41

26.46

48.50

70.55

92.59

114.64

136.69

158.73

180.78

202.83

6.61

28.66

50.71

72.75

94.80

116.85

138.89

160.94

182.98

205.03

8.82

30.86

51.91

74.96

97.00

119.05

141.10

163.14

185.19

207.24

11.02

33.07

55.12

77.16

99.21

121.25

143.30

165.35

187.39

209.44

13.23

35.27

57.32

79.37

101.41

123.46

145.51

167.55

189.60

211.64

15.43

37.48

59.53

81.57

103.62

125.66

147.71

169.76

191.80

213.85

17.64

39.68

61.73

83.78

105.82

127.87

149.91

171.96

194.01

216.05

19.84

41.89

63.93

85.98

108.03

130.07

152.12

174.17

196.21

218.26


00-18

Liter to U.S. Gallon1l = 0.2642 U.S. Gal

Liter to U.K. Gallon1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.200

4.399

6.599

8.799

10.998

13.198

15.398

17.598

19.797

0.220

2.420

4.619

6.819

9.019

11.281

13.418

15.618

17.818

20.017

0.440

2.640

4.839

7.039

9.239

11.438

13.638

15.838

18.037

20.237

0.660

2.860

5.059

7.259

9.459

11.658

13.858

16.058

18.257

20.457

0.880

3.080

5.279

7.479

9.679

11.878

14.078

16.278

18.477

20.677

1.100

3.300

5.499

7.969

9.899

12.098

14.298

16.498

18.697

20.897

1.320

3.520

5.719

7.919

10.119

12.318

14.518

16.718

18.917

21.117

1.540

3.740

5.939

8.139

10.339

12.528

14.738

16.938

19.137

21.337

1.760

3.950

6.159

8.359

10.559

12.758

14.958

17.158

19.357

21.557

1.980

4.179

6.379

8.579

10.778

12.978

15.178

17.378

19.577

21.777


00-19

kgm to ft. lb1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

0

72.3

144.7

217.0

289.3

361.7

434.0

506.3

578.6

651.0

723.3

795.6

868.0

940.3

1012.6

1084.9

1157.3

1129.6

1301.9

1374.3

7.2

79.6

151.9

224.2

296.6

368.9

441.2

513.5

585.9

658.2

730.5

802.9

875.2

947.5

1019.9

1092.2

1164.5

1236.8

1309.2

1381.5

14.5

86.8

159.1

231.5

303.8

376.1

448.5

520.8

593.1

665.4

737.8

810.1

882.4

954.8

1027.1

1099.4

1171.7

1244.1

1316.4

1388.7

21.7

94.0

166.4

238.7

311.0

383.4

455.7

528.0

600.3

672.7

745.0

817.3

889.7

962.0

1034.3

1106.6

1179.0

1251.3

1323.6

1396.0

28.9

101.3

173.6

245.9

318.3

390.6

462.9

535.2

607.6

679.9

752.2

824.6

896.9

969.2

1041.5

1113.9

1186.2

1258.5

1330.9

1403.2

36.2

108.5

180.8

253.2

325.5

397.8

470.2

542.5

614.8

687.1

759.5

831.8

904.1

976.5

1048.8

1121.1

1193.4

1265.8

1338.1

1410.4

43.4

115.7

188.1

260.4

332.7

405.1

477.4

549.7

622.0

694.4

766.7

839.0

911.4

983.7

1056.0

1128.3

1200.7

1273.0

1345.3

1417.7

50.6

123.0

195.3

267.6

340.0

412.3

484.6

556.9

629.3

701.6

773.9

846.3

918.6

990.9

1063.2

1135.6

1207.9

1280.1

1352.6

1424.9

57.9

130.2

202.5

274.9

347.2

419.5

491.8

564.2

636.5

708.8

781.2

853.5

925.8

998.2

1070.5

1142.8

1215.1

1287.5

1359.8

1432.1

65.1

137.4

209.8

282.1

354.4

426.8

499.1

571.4

643.7

716.1

788.4

860.7

933.1

1005.4

1077.7

1150.0

1222.4

1294.7

1367.0

1439.4


00-20

kg/cm2 to lb/in2

1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

2560

2702

2845

2987

3129

3271

3414

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

2574

2717

2859

3001

3143

3286

3428

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

2589

2731

2873

3015

3158

3300

3442

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

2603

2745

2887

3030

3172

3314

3456

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

2617

2759

2901

3044

3186

3328

3470

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

2631

2773

2916

3058

3200

3343

3485

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

2646

2788

2930

3072

3214

3357

3499

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

2660

2802

2944

3086

3229

3371

3513

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

2674

2816

2958

3101

3243

3385

3527

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

2688

2830

2973

3115

3257

3399

3542


00-21

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.

1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4–37.2–34.4–31.7–28.9

–28.3–27.8–27.2–26.7–26.1

–25.6–25.0–24.4–23.9–23.3

–22.8–22.2–21.7–21.1–20.6

–20.0–19.4–18.9–18.3–17.8

–17.2–16.7–16.1–15.6–15.0

–14.4–13.9–13.3–12.8–12.2

–40–35–30–25–20

–19–18–17–16–15

–14–13–12–11–10

–9–8–7–6–5

–4–3–2–1

0

12345

6789

10

–40.0–31.0–22.0–13.0

–4.0

–2.2–0.4

1.43.25.0

6.88.6

10.412.214.0

15.817.619.421.223.0

24.826.628.430.232.0

33.835.637.439.241.0

42.844.646.448.250.0

–11.7–11.1–10.6–10.0

–9.4

–8.9–8.3–7.8–7.2–6.7

–6.1–5.6–5.0–4.4–3.9

–3.3–2.8–2.2–1.7–1.1

–0.600.61.11.7

2.22.83.33.94.4

5.05.66.16.77.2

1112131415

1617181920

2122232425

2627282930

3132333435

3637383940

4142434445

51.853.655.457.259.0

60.862.664.466.268.0

69.871.673.475.277.0

78.880.682.484.286.0

87.889.691.493.295.0

96.898.6

100.4102.2104.0

105.8107.6109.4111.2113.0

7.88.38.99.4

10.0

10.611.111.712.212.8

13.313.914.415.015.6

16.116.717.217.818.3

18.919.420.020.621.1

21.722.222.823.323.9

24.425.025.626.126.7

4647484950

5152535455

56575859

0

6162636465

6667686970

7172737475

7677787980

114.8116.6118.4120.2122.0

123.8125.6127.4129.2131.0

132.8134.6136.4138.2140.0

141.8143.6145.4147.2149.0

150.8152.6154.4156.2158.0

159.8161.6163.4165.2167.0

168.8170.6172.4174.2176.0

27.227.828.328.929.4

30.030.631.131.732.2

32.833.333.934.435.0

35.636.136.737.237.8

40.643.346.148.951.7

54.457.260.062.765.6

68.371.173.976.779.4

8182838485

8687888990

9192939495

96979899

100

105110115120125

130135140145150

155160165170175

117.8179.6181.4183.2185.0

186.8188.6190.4192.2194.0

195.8197.6199.4201.2203.0

204.8206.6208.4210.2212.0

221.0230.0239.0248.0257.0

266.0275.0284.0293.0302.0

311.0320.0329.0338.0347.0

FOREWORD UNITS

00-22

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:N {kg}Nm {kgm}MPa {kg/cm2}kPa {mmH2O}kPa {mmHg}kW/rpm {HP/rpm}g/kWh {g/HPh}

01-3PC228USLC-1

SPECIFICATIONS

GENERAL SPECIFICATIONS

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Machine model PC228USLC-1

Serial Number 11001 and up

Bucket capacity m3 0.8

Operating weight kg 22,900

Max. digging depth mm 6,810

Max. vertical wall depth mm 5,910

Max. digging reach mm 9,850

Max. reach at ground level mm 9,670

Max. digging height mm 10,700

Max. dumping height mm 7,765

Max. digging force(using power max. function) kN {kg} 125 {12,800} (137 {14,000})

Swing speed rpm 11.0

Swing max. slope angle deg. 16

Travel speed km/h Lo: 3.4 Mi: 4.1 Hi: 5.1

Gradeability deg. 35

Ground pressure(triple grouser shoe width: 700 mm) kPa {kg/cm2} 41 {0.42}

Overall length (for transport) mm 8,890

Overall width mm 2,980

Overall width of track mm 3,080

Overall height (for transport) mm 2,990

Overall height to chassis mm 2,990

Ground clearance to bottom of upper structure mm 1,050

Min. ground clearance mm 440

Tail swing radius mm 1,625

Min. swing radius of work equipment mm 2,310

Height of work equipment at min. swing radius mm 8,290

Length of track on ground mm 3,640

Track gauge mm 2,380

Height of machine cab mm 2,280




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Cont

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Hydr

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+70–40

Model S6D102E-1-AType 4-cycle, water-cooled, in-line, vertical,

direct injection, with turbocharger

No. of cylinders – bore × stroke mm 6 – 102 × 120Piston displacement ¬ {cc} 5.883 {5,883}

Flywheel horsepower kW/rpm {HP/rpm} 96/2,000 {128/2,000}Max. torque Nm/rpm {kgm/rpm} 545.3/1,350 {55.6/1,350}Max. speed at no load rpm 2,170Min. speed at no load rpm 970 ± 60Min. fuel consumption g/kWh {g/HPh} 218 {160}

Starting motor 24V, 4.5 kWAlternator 24V, 50ABattery 12V, 110 Ah × 2Radiator core type Corrugated CWX-4Carrier roller 2 on each sideTrack roller 9 on each sideTrack shoe Triple grouser, 49 on each side

Type × no. HPV95+95, variable displacementpiston type × 2

Delivery ¬/min Piston type: 206 × 2Set pressure MPa {kg/cm2} Piston type: 34.8 {355}Type × No. 6-spool type × 1Control method HydraulicTravel motor GM38VL, Piston type

(with brake valve, parking brake: × 2

Swing motor KMF90AEL-3, Piston type(with safety valve, parking brake): × 1

Boom Arm BucketType Double acting Double acting Double acting

piston piston pistonInside diameter of cylinder mm 120 135 130Diameter of piston rod mm 85 95 90Stroke mm 1,285 1,490 1,020Max. distance between pins mm 3,155 3,565 2,625Min. distance between pins mm 1,870 2,075 1,605

Hydraulic tank Box-shaped, sealedHydraulic filter Tank return sideHydraulic cooler CFT-1 (Air cooled)

PC228USLC-101-42

PC228USLC-1 01-4-11


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Machine model PC228US-2


Bucket capacity m3 0.8

Operating weight kg 21,800

Max. digging depth mm 6,810

Max. vertical wall depth mm 5,910

Max. digging reach mm 9,850

Max. reach at ground level mm 9,670

Max. digging height mm 10,640

Max. dumping height mm 7,720

Max. digging force(using power max. function) kN {kg} 125 {12,800} (137 {14,000})

Swing speed rpm 11.0

Swing max. slope angle deg. 22

Travel speed km/h Lo: 3.0 Hi: 5.3

Gradeability deg. 35

Ground pressure(triple grouser shoe width: 700 mm) kPa {kg/cm2} 51 {0.52}

Overall length (for transport) mm 8,700

Overall width mm 2,995

Overall width of track mm 2,800

Overall height (for transport) mm 2,965

Overall height to chassis mm 2,990

Ground clearance to bottom of upper structure mm 1,050

Min. ground clearance mm 440

Tail swing radius mm 1,680

Min. swing radius of work equipment mm 2,380

Height of work equipment at min. swing radius mm 8,210

Length of track on ground mm 3,270

Track gauge mm 2,200

Height of machine cab mm 2,280


Machine model PC228US-2


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valve

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+70–40

Model S6D102E-1-FType 4-cycle, water-cooled, in-line, vertical,

direct injection, with turbocharger

No. of cylinders – bore × stroke mm 6 – 102 × 120Piston displacement ¬ {cc} 5.883 {5,883}

Flywheel horsepower kW/rpm {HP/rpm} 96/2,000 {128/2,000}Max. torque Nm/rpm {kgm/rpm} 545.3/1,350 {55.6/1,350}Max. speed at no load rpm 2,170Min. speed at no load rpm 970 ± 60Min. fuel consumption g/kWh {g/HPh} 218 {160}

Starting motor 24V, 4.5 kWAlternator 24V, 35ABattery 12V, 110 Ah × 2Radiator core type Corrugated CWX-4Carrier roller 2 on each sideTrack roller 7 on each sideTrack shoe Triple grouser, 45 on each side

Type × no. HPV95+95, variable displacementpiston type × 2

Delivery ¬/min Piston type: 206 × 2Set pressure MPa {kg/cm2} Piston type: 37.2 {380}Type × No. 6-spool type × 1Control method HydraulicTravel motor GM38VL, Piston type

(with brake valve, parking brake): × 2

Swing motor KMF90ABE-3, Piston type(with safety valve, parking brake): × 1

Boom Arm BucketType Double acting Double acting Double acting

piston piston pistonInside diameter of cylinder mm 120 135 130Diameter of piston rod mm 85 95 90Stroke mm 1,285 1,490 1,020Max. distance between pins mm 3,155 3,565 2,625Min. distance between pins mm 1,870 2,075 1,605

Hydraulic tank Box-shaped, sealedHydraulic filter Tank return sideHydraulic cooler CFT-1 (Air cooled)

PC228USLC-101-4-22

10-65PC228USLC-1

STRUCTURE AND FUNCTION TRAVEL MOTOR

3) When starting travel (or during normaltravel)

• When the travel lever is operated, the pres-sure oil from the pump moves counterbal-ance valve spool (19) to the right. When thishappens, the passage to the suction-safetyvalve becomes the circuit flowing throughthe small notch in the counterbalance valvespool. As a result, a big difference in pres-sure is created, and the pump pressure risesto provide a powerful drawbar pull. (Fig. 7)

10-65-12

PC228USLC-1


PC228USLC-1, 2GM38VL

A. From control valveB. From control valveD1. Drain port (to tank) (L.H. travel motor)D2. Drain port (to tank) (R.H. travel motor)

SpecificationsType : GM38VLTheoretical delivery : 140.5 cc/revBrake releasing pressure : 0.59 MPa {6.0 kg/cm2}Travel speed switching pressure: 1.96 – 6.86 MPa

{20 – 70 kg/cm2}Reduction ratio : 66

PC228USLC-1


10-65-22

12. Spring13. Plate14. Disc15. Swash plate16. Pivot17. Spindle18. Floating seal19. Hub20. RV gear A21. RV gear B22. Crankshaft

23. Cover24. spur gear25. Input gear26. Hold flange27. Piston28. Shoe29. Shaft30. Shoe31. Piston32. Spring33. Timing plate

1. Plug2. Spring3. Valve4. Spool5. Spring6. Valve7. Spring8. Sleeve9. End cover

10. Cylinder block11. Piston

PC228USLC-110-66

STRUCTURE AND FUNCTION VALVE CONTROL

VALVE CONTROL

1. Travel PPC valve2. L.H. travel lever3. R.H. travel lever4. Solenoid block5. Accumulator6. R.H. PPC valve7. R.H. work equipment

lever

8. Control valve9. Hydraulic pump

10. L.H. work equipmentlever

11. L.H. PPC valve12. Safety lock lever

Lever positions1 HOLD2 Boom RAISE3 Boom LOWER4 Bucket DUMP5 Bucket CURL6 HOLD7 Arm IN8 Arm OUT

9 Swing RIGHT0 Swing LEFTA NEUTRALB Travel REVERSEC Travel FORWARDD LOCKE FREE

20-3PC228USLC-1

TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE

TABLE OF JUDGEMENT STANDARD VALUE

‡ FOR ENGINE


Engine S6D102-1

Item Measurement condition Unit Standard value Permissible value

Working

TravelingRated 1,800 —

Engine speed rpmspeed 2,000 —

At sudden acceleration Bosch Max. 1.0 2.0Exhaust gas color

At high idling index Max. 0.5 1.5

(normal temperature)Valve clearance Intake valve mm 0.25 —

Exhaust valve 0.51 —

Oil temperature: Difference betweenCompression pressure 40 – 60°C MPa Min. 2.4 cylinders

(engine speed: 250rpm) {kg/cm2} {Min. 24.6} Min. 1.0(SAE15W-40 oil) {Min. 10.3}

(Coolant temperature:Blow-by pressure operating range) kPa Max. 1.2 5.1

At rated output (mmH2O) {Max. 123} {520}(SAE30 oil)

(Coolant temperature: operating range)(Measure at top of oil filter)

At high idling MPa 0.39 – 0.52 0.25Oil pressure (SAE15W-40) {kg/cm2} {4.0 – 5.3} {2.6}

At low idling Min. 0.12 0.09(SAE15W-40) {Min. 1.2} {0.9}

Oil temperature Whole speed range°C 80 – 110 120(inside oil pan)

Fuel injection timing Before top dead center °(B.T.D.C.) (degree) 18 ± 1 18 ± 1

Min. 108 Max. 6Belt tension mm

5 – 8 5 – 8

Fan-tension

Fan–air conditionercompressor

Deflectionwhenpressedwith fingerforce ofapprox.58.8N{6kg}

PC228USLC-120-4


‡ FOR CHASSIS

Applicable model

Cate- Item Measurement conditions Unit Standard value Permissible valuegory

PC228USLC-1

Low idling

1,850 ± 100 —

At TRAVEL

rpm

High idlingAt WORK

Trav

el o

f con

trol l

ever

s

1,400 ± 120 1,400 ± 120

2 pumps at relief

Speed when auto-deceleration is operated

Boom control valve

Arm control valve

Bucket control valve

Swing control valve

Travel control valve

Boom control lever

Arm control lever

Bucket control lever

Swing control lever

Travel control lever

Play of control lever

Boom control lever

Arm control lever

Bucket control lever

Swing control lever

Travel control lever

a b a b

100 ± 10

100± 10

100± 10

100 ± 10

115 ± 12

Max. 10

· Hydraulic oil temperature:45 – 55°C

· Coolant temperature:Within operating range

· 2-pump relief: Arm relief

· Fuel control dial at MAX.· Control lever at neutral

Engi

ne s

peed

9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5

Max. 110Min. 90

Max. 110Min. 90

Max. 110Min. 90

Max. 110Min. 90

Max. 127Min. 103

Max. 15

Spoo

l stro

ke

15.7 ± 3.9 Max. 24.5{1.6 ± 0.4} {Max. 2.5}15.7 ± 3.9 Max. 24.5{1.6 ± 0.4} {Max. 2.5}13.7 ± 2.9 Max. 22.6{1.4 ± 0.3} {Max. 2.3}13.7 ± 2.9 Max. 22.6{1.4 ± 0.3} {Max. 2.3}24.5 ± 5.9 Max. 39.2{2.5 ± 0.6} {Max. 4.0}74.5 ± 18.6 Max. 107.6{7.6 ± 1.9} {Max. 11}

· Engine at high idling· Oil temperature: 45 – 55°C· Fit push-pull scale to center

of control lever knob tomeasure

· Measure max. value to endof travel

Lever

PedalOpe

ratin

g fo

rce

of c

ontro

l lev

ers

N{kg}

mm· Center of lever knob· Read max. value to end of

travel· Engine stopped· Excluding neutral play

2,200 ± 70 —

2,200 ± 70 —

970 ± 50

(3)

20-9PC228USLC-1


Applicable model


RAIS

E

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uipm

ent s

peed

· Lower boom and measure timetaken from point where bucketcontacts ground to point wherechassis rises from ground

· Engine at low idling· Hydraulic oil temperature:

45 – 55°C

· Stop arm suddenly and measuretime taken for arm to stop


45 – 55°C

Arm Max. 1.0 Max. 2.8

Boom Max. 1.0 Max. 1.2

Arm

Cylinder fullyretracted

Fully extended

↔

LOW

ERIN

OU

TCU

RLDU

MP

Wor

k eq

uipm

ent

Tim

e la

g

sec

Boom

Bucket teeth incontact with ground

Cylinder fullyextended

↔

Bucket

Cylinder fullyretracted

Fully extended

↔

BKP00114

BKP00115

· Engine at high idling· Hydraulic oil temperature:

45 – 55°C


45 – 55°C


45 – 55°C

2.6 ± 0.4 Max. 3.3

2.1 ± 0.3 Max. 2.7

PC228USLC-1

4.4 ± 0.5 Max. 5.2

4.0 ± 0.4 Max. 4.4

(3)

3.6 ± 0.4 Max. 4.5(To Just before cushion) (To Just before cushion)

2.9 ± 0.3 Max. 3.5(To Just before cushion) (To Just before cushion)

PC228USLC-120-10


Applicable model


Cylinders 4.5 20cc/min

Inter

nal l

eaka

ge


45 – 55°C

fl Use a hard horizontal surface.

· Stop bucket suddenly andmeasure time taken for bucketto stop at bottom and thenstart again.


45 – 55°C

· Hydraulic oil temperature:45 – 55°C

· Engine at high idling· Relieve circuit to be measuredCenter swivel joint

Wor

k eq

uipm

ent

Tim

e la

g

Bucket sec. Max. 1.0 Max. 3.6

10 50

20m

10m BKP00107

fl Measure dimension χ.

Travel deviation whenwork equipment +travel are operated

mm Max. 200 Max. 220

Perfo

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pum

p de

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y

Piston pump See next page See next page

BKP00116

PC228USLC-1

30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL ................... 30- 3PRECAUTIONS WHEN CARRYING

OUT OPERATION ................................... 30- 5SPECIAL TOOL LIST ..................................... 30- 7SKETCHES OF SPECIAL TOOLS ................. 30- 9STARTING MOTOR

Removal and Installation ......................30-12ALTERNATOR

Removal and Installation ......................30-13ENGINE OIL COOLER CORE

Removal and Installation ......................30-14FUEL INJECTION PUMP

Removal .................................................. 30-15Installation .............................................. 30-18

WATER PUMPRemoval and Installation ......................30-20

NOZZLE HOLDERRemoval and Installation ......................30-21

TURBOCHARGERRemoval and Installation ......................30-22

THERMOSTATRemoval and Installation ......................30-23

CYLINDER HEADRemoval .................................................. 30-24Installation .............................................. 30-28

ENGINE, MAIN PUMPRemoval .................................................. 30-31Installation .............................................. 30-34

DAMPERRemoval and Installation ......................30-35

ENGINE FRONT SEALRemoval and Installation ......................30-36

ENGINE REAR SEALRemoval .................................................. 30-38Installation .............................................. 30-39

RADIATOR, HYDRAULIC COOLERRemoval .................................................. 30-40Installation .............................................. 30-41

FUEL TANKRemoval .................................................. 30-42Installation .............................................. 30-43

CENTER SWIVEL JOINTRemoval .................................................. 30-44Installation .............................................. 30-45

CENTER SWIVEL JOINTDisassembly and Assembly ..................30-46

SPROCKETRemoval and Installation ......................30-47

FINAL DRIVE, TRAVEL MOTORRemoval and Installation ......................30-48

FINAL DRIVEDisassembly ........................................... 30-49Assembly ................................................ 30-52

TRAVEL MOTORDisassembly and Assembly .............. 30-56-1

SWING MOTOR, SWING MACHINERYRemoval and Installation ......................30-57

SWING MACHINERYDisassembly ........................................... 30-58Assembly ................................................ 30-62

SWING MOTORRemoval and Installation ......................30-67

REVOLVING FRAMERemoval .................................................. 30-68Installation .............................................. 30-69

SWING CIRCLERemoval .................................................. 30-70Installation .............................................. 30-71

IDLER, RECOIL SPRINGRemoval and Installation ......................30-72

RECOIL SPRINGDisassembly ........................................... 30-73Assembly ................................................ 30-74

IDLERDisassembly ........................................... 30-75Assembly ................................................ 30-76

TRACK ROLLERRemoval and Installation ......................30-78Disassembly ........................................... 30-79Assembly ................................................ 30-80

CARRIER ROLLERRemoval and Installation ......................30-82Disassembly ........................................... 30-83Assembly ................................................ 30-84

TRACK SHOERemoval and Installation ......................30-86

HYDRAULIC TANKRemoval and Installation ......................30-87

MAIN PUMPRemoval ................................................ 30- 88Installation ............................................ 30- 89

PC228USLC-1 30-12

PC228USLC-130-21

OFFSET CYLINDERRemoval ................................................ 30-130Installation ............................................ 30-131

HYDRAULIC CYLINDER FOR OFFSETDisassembly ......................................... 30-132Assembly .............................................. 30-134

HYDRAULIC CYLINDER FOR BOOM,ARM, BUCKETDisassembly ......................................... 30-136Assembly .............................................. 30-139

BUCKETRemoval ................................................ 30-144Installation ............................................ 30-145

ARMRemoval ................................................ 30-146Installation ............................................ 30-147

BUCKET, ARMRemoval ................................................ 30-150Installation ............................................ 30-151

OFFSET BRACKETRemoval and Installation .................... 30-155

SECOND BOOMRemoval ................................................ 30-156Installation ............................................ 30-157

FIRST BOOMRemoval ................................................ 30-158Installation ............................................ 30-160

SECOND, FIRST BOOMRemoval ................................................ 30-161Installation ............................................ 30-163

OFFSET BRACKET, SECOND,FIRST BOOMRemoval ................................................ 30-164Installation ............................................ 30-166

BOOMRemoval ................................................ 30-168Installation ............................................ 30-169

OPERATOR’S CABRemoval ................................................ 30-170Installation ............................................ 30-171

FLOOR FRAMERemoval ................................................ 30-172Installation ............................................ 30-173

AIR CONDITIONER COMPRESSORRemoval and Installation .................... 30-174

AIR CONDITIONER CONDENSERRemoval and Installation .................... 30-175

AIR CONDITIONER UNITRemoval ................................................ 30-176Installation ............................................ 30-177

COUNTERWEIGHTRemoval and Installation .................... 30-178

CONTROLLERRemoval and Installation .................... 30-179

MONITORRemoval and Installation .................... 30-180

EPC VALVERemoval and Installation .................... 30- 90

PC VALVERemoval and Installation .................... 30- 91

LS VALVERemoval and Installation .................... 30- 92

CONTROL VALVERemoval ................................................ 30- 93Installation ............................................ 30- 95Disassembly ......................................... 30- 96Assembly .............................................. 30-101

LS SELECT VALVEDisassembly and Assembly ................30-107

PRESSURE COMPENSATION VALVEDisassembly ......................................... 30-108Assembly .............................................. 30-109

MAIN RELIEF VALVERemoval and Installation .................... 30-110Disassembly and Assembly ................30-111

SOLENOID VALVERemoval and Installation .................... 30-112

PUMP MERGE/DIVIDERSOLENOID VALVERemoval and Installation .................... 30-113

2-STAGE RELIEF, TRAVEL HI/LOSOLENOID VALVERemoval and Installation .................... 30-114

INTERFERENCE PREVENTIONSOLENOID VALVERemoval and Installation .................... 30-115

LEFT WORK EQUIPMENT PPC VALVE(FOR SWING, ARM CONTROL)Removal and Installation .................... 30-116

RIGHT WORK EQUIPMENT PPC VALVE(FOR BOOM, BUCKET CONTROL)Removal and Installation .................... 30-117

WORK EQUIPMENT PPC VALVE(PPC VALVE FOR BOOM, BUCKET,

ARM, SWING CONTROL)Disassembly ......................................... 30-118Assembly .............................................. 30-119

TRAVEL PPC VALVERemoval and Installation .................... 30-120Disassembly and Assembly ................30-121

PPC VALVE FOR OFFSET CONTROLRemoval and Installation .................... 30-122

BOOM LOCK VALVERemoval and Installation .................... 30-123

BOOM CYLINDERRemoval ................................................ 30-124Installation ............................................ 30-125

ARM CYLINDERRemoval ................................................ 30-126Installation ............................................ 30-127

BUCKET CYLINDERRemoval ................................................ 30-128Installation ............................................ 30-129

PC228USLC-1 30-56-12

DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTORGM38VLCONTENTS

ASSEMBLY DRAWINGS .................................................................................................................... 30-56- 2PARTS LIST ......................................................................................................................................... 30-56- 8TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY........................................................................ 30-56-10

1. Standard tools ....................................................................................................................... 30-56-102. Manufactured tools ............................................................................................................... 30-56-11

DISASSEMBLY PROCEDURE ............................................................................................................ 30-56-131. General precautions .............................................................................................................. 30-56-132. Disassembly procedure ........................................................................................................ 30-56-14

2-1. Disassembly of brake valve .......................................................................................... 30-56-162-2. Disassembly of hydraulic motor .................................................................................. 30-56-202-3. Disassembly of reduction gear assembly ................................................................... 30-56-23

MAINTENANCE STANDARD ............................................................................................................. 30-56-281. Seals ....................................................................................................................................... 30-56-282. Maintenance standard for worn parts ................................................................................. 30-56-28

ASSEMBLY PROCEDURE .................................................................................................................. 30-56-301. General precautions .............................................................................................................. 30-56-302. Assembly procedure ............................................................................................................. 30-56-31

2-1. Assembly of brake valve .............................................................................................. 30-56-312-2. Assembly of reduction gear assembly and hydraulic motor .................................... 30-56-35

PERFORMANCE TEST ........................................................................................................................ 30-56-50LIST OF CLEARANCE ADJUSTMENT PARTS .................................................................................. 30-56-51

PC228USLC-130-56-22


PC228USLC-1 30-56-32


PC228USLC-130-56-42


REDUCTION GEAR

PC228USLC-1 30-56-52


PC228USLC-130-56-62


HYDRAULIC MOTORRELIEF VALVECONTROL VALVE

PC228USLC-1 30-56-72


PC228USLC-130-56-82


PARTS LISTNo. Part name Q’ty

REDUCTION GEAR 11 Hub 1

Spindle kit 1• Spindle ass’y 1

2 • • Spindle 13 • • Hold flange 1

19 • Hexagon socket head bolt 334 • Parallel pin 6

(select one from 3 kinds)37 • Plain washer 3

RV gear assembly kit 1• RV gear kit 1

4 • • RV gear A 15 • • RV gear B 19 • Crankshaft 3

12 • Spacer 622 • Tapered roller bearing 623 • Needle roller bearing 6

6 Input gear 1

Spur gear kit 17 • Spur gear 3

8 Cover 113 Distance piece 3

t: Above 3.30, up to 3.15↓ <at interval of 0.05>

t: Above 4.10 up to 4.1515 Coupling 117 Pin 2420 C-type snap ring for hole 321 Ball bearing 225 C-type snap for shaft 327 O-ring 229 O-ring 130 O-ring 1

Floating seal kit 131 • Floating seal 2

33 Hexagon socket head plug 335 Hexagon socket head bolt 1236 Ball 142 Parallel pin 243 O-ring 3

No. Part name Q’tyHYDRAULIC MOTOR 1

Cylinder & piston kit 1• Piston kit 1• • Piston assembly 9

105 • • Piston 1106 • • • Shoe 1104 • Cylinder block 1107 • Retainer plate 1108 • Thrust ball 1110 • Washer 2111 • Washer 1114 • Spring 1145 • C-type snap ring for hole 1151 • Needle roller 5

Piston assembly 1161 • Piston 1162 • Shoe 1

102 Shaft 1103 Swash plate 1109 Timing plate 1112 Piston 1113 Spring 12115 Friction plate 2116 Mating plate 2132 Oil seal 1135 O-ring 1139 O-ring 1149 Deep groove ball bearing 1150 Deep groove ball bearing 1167 Pivot 2171 Parallel pin 2173 Spring 1

PC228USLC-1 30-56-92


No. Part name Q’tyRELIEF VALVE 2

Valve kit 1201 • Valve 1202 • Sleeve 1203 • Spring retainer 1204 • Plug 1205 • Shim 1206 • Spring 1208 • O-ring 1209 • O-ring 1210 • O-ring 1211 • Back-up ring 2217 • Back-up ring 2219 • O-ring 1220 • Piston seal 1

CONTROL VALVE 1

Rear flange assembly 1• Rear flange kit 1

301 • • Rear flange 1323 • • Spool 1381 • • Piston 1321 • Plug 1324 • Plug 2325 • Stopper 2326 • Plug 2327 • Valve 2328 • Spring 2330 • Spring 2336 • O-ring 2337 • O-ring 2352 • Plug 2354 • Hexagon socket head plug 7355 • O-ring 1357 • Plug 1358 • O-ring 2359 • O-ring 2363 • Spool 1366 • Spring 1368 • Ball 2373 • O-ring 1379 • Filter 1380 • Plug 2382 • Plug 2383 • O-ring 2384 • O-ring 2385 • Ball 2397 • Orifice 1

No. Part name Q’ty398 • Hexagon socket head plug 4399 • Name plate 1400 • Square head plug 2

341 • Parallel pin 1343 • Hexagon socket head bolt 12

PC228USLC-130-56-102


No. Name Model/Dimensions Q’ty

1 Hexagonal wrench 6 (For M8) (PF 1/4) 5 (PF 1/8) 1 each10 (For M12) (PF 1/2) 8 (PF 3/8) 1 each14 (For M16) 1 each

2 Socket wrench 1(Ratchet handle)

3 Torque wrench Dial type for about 280 N 1Dial type for about 850 N 1

4 Torque wrench adapter Nominal size of socket: 22, 30, 32, 41 1 each(12.7 mm square drive) Nominal size of rod: 5, 6, 8, 10, 14 1 each(19.0 mm square drive) Nominal size of rod: 19 1 each

5 Extension bar 150 mm 1

6 Hammer Nominal size: 12 1

7 Plastic hammer L = About 300 1

8 Flat-head screwdriver About 150 mm 1

9 Snap ring pliers For shaft 1For hole 1

10 Sling parts Sling load: Min. 2,942 N {300 kg} 1 setEyebolt (For M16) (2)Eyebolt (For PF 1/2) (2)Wire with hook (1)

11 Press stand Press capacity: Min. 1,961 N {200 kg} 1 set

12 Compressed air For 0.3 – 0.5 MPa {3 – 5 kg/cm2} 1 set

13 Container Vat for general use, W450 x D300 x H120 2

14 Heating tank Heating ability: Min. 100°C 1 setCapacity: Min. 500 mm x 500 mm x 500 mm

15 Leather gloves 1 pair

16 Sealing tape 1

17 Depth micrometer Measurement range: About 30 mm 1Min. division: 0.01 mm

18 Thickness gauge Measurement range: 0.04 – 0.3 mm 1

19 Rotary bar For cutting cast iron 1

20 Air chisel BRH-8 1(Compressed air: 0.5 – 0.6 MPa {5 – 6 kg/cm2})

TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY1. Standard tools

• Necessary tools for disassembly and assembly of GM38VL are shown below.

PC228USLC-1 30-56-112


No. Name and major dimensions Q’ty1 Preload adjustment jig for main bearing 1

2. Manufactured tools

No. Name and major dimensions Q’ty6 Holder (III) 1

2 Clamp 2

3 Press fitting jig 1

4 Holder (I) 1

5 Holder (II) 111 Sling jig 1

10 Aluminum rod 1

9 Steel rod 1

8 Pointed punch 1

7 Holder (IV) 1

PC228USLC-130-56-122


No. Name and major dimensions Q’ty12 Floating seal fitting jig (I) 1

No. Name and major dimensions Q’ty17 Bending jig 1

13 Floating seal fitting jig (II) 1

14 Floating seal fitting jig (III) 1

15 Sling jig 1

16 Pulling jig 1

PC228USLC-1 30-56-132


DISASSEMBLY PROCEDURE

1. GENERAL PRECAUTIONS1) Before disassembling the travel motor, consider the inspection items, characteristics of the

detected trouble, etc. and then review the given disassembly procedure.

2) Disassemble the travel motor in a clean place according to the procedure in 2. Disassemblyprocedure.

3) Spread a rubber sheet, vinyl sheet, etc. on the worktable.

4) When disassembling, make match marks on the mating faces of the parts.

5) Arrange the removed parts well so that they will not be damaged or lost.

6) Replace each seal once the travel motor is disassembled, as a rule. Accordingly, prepare theall replacement seals before disassembling.

PC228USLC-130-56-142


2. DISASSEMBLY PROCEDUREfl When inspecting or repairing the travel motor, disassemble it according to the following procedure.fl The number in ( ) after each part name refers to the part No. in Parts list.fl Before disassembling the travel motor, install it to a turning work table.fl Prepare a container to collect lubricating oil (for 8 liters).fl Prepare a container to collect hydraulic oil (for 4 liters).

(Disassembly of hydraulic motor on brake valve side)

(Disassembly of shaft and oil seals of reduction gear assembly and hydraulic motor)

1) Remove the relief valve from rear flange (301).

2) Remove O-rings (208), (209), and (210) and backup rings (211) (2 pieces), and (217) (2 pieces) from the relief valve.

Do not reuse removed O-ring (138).fl Necessary tools

• Impact wrench or ratchet handle• Wrench adapter, socket of size 32

1) Remove hexagon socket head bolts (343) (12 pieces).

fl Necessary tools• Socket wrench• Extension bar• Wrench adapter, rod of size 14

1) Turn the work table 180 degrees so that cover (8) of the travel motor will be directed up.

2) Remove hexagon socket head plugs (33) (3 pieces).

3) Remove hexagon socket head bolts (35) (12 pieces).

fl Necessary tools• Ratchet handle• Wrench adapter, rod of size 10

1) Install eyebolts (2 pieces) to threaded plug holes (PF 1/2).

2) Install hooks to the eyebolts and lift off cover (8).

If the cover is not removed be-cause of resistance of O-ring (30), hit the rim of the cover with a plastic hammer.

3) Remove O-ring (30) from cover (8).Do not reuse removed O-ring (30).4) Drain oil from the reduction gear

assembly.fl Necessary tools

• Sling: 1 set• Eyebolt (for PF 1/2): 2 pieces• Plastic hammer• Container (for 8 liters)

PC228USLC-1 30-56-152


1) Remove rear flange (301) from spindle (2).Take care, since shaft (102) may be removed, too.

See disassembly procedure for brake valve

See disassembly procedure for hydraulic motor

See disassembly procedure for reduction gear assembly

1) Remove timing plate (109), parallel pin (341) (1 piece), springs (113) (12 pieces), and deep groove ball bearing (150) from rear flange (301) and hydraulic motor.

2) Remove O-rings (27) (2 pieces) and (29) from spindle (2).

Do not reuse removed O-rings (27) and (29).

Removal of hydraulic motor shaft

PC228USLC-130-56-162


2-1. DISASSEMBLY OF BRAKE VALVE1. Removal of spool

1) Remove plug (324) from rear flange (301).Remove O-ring (336) from plug (324).fl Loosen the plug when the motor is on

the turning work table for the ease ofwork.

fl Do not reuse removed O-ring (336).fl Necessary tools

• Socket wrench• Wrench adapter, socket of size 41

2) Remove 2 springs (328), 2 stoppers (325),and spool (323) from rear flange (301).fl Take care not to damage the periphery

of spool (323) and sliding surface of rearflange (301).

fl Slant rear flange (301) with either plugport down, and spool (323) slides down.Hold the end of the spool and take itout.

2. Removal of check valve1) Take plugs (326) (2 pieces) out of rear flange

(301).fl Loosen the plugs when the motor is on

the turning work table for the ease ofwork.

fl Necessary tools• Socket wrench• Wrench adapter, rod of size 14

2) Take 2 springs (330) and 2 valves (327) outof rear flange (301).fl Take care not to damage the seats of

valve (327) and rear flange (301).

3) Take O-ring (337) out of plug (326).fl Do not reuse removed O-ring (337).

PC228USLC-1 30-56-172


3. Disassembly of 2nd travel speed selection valve1) Remove plug (357) from rear flange (301).

fl Loosen the plug when the motor is onthe turning work table for the ease ofwork.

fl Necessary tools• Hexagonal wrench of size 10

2) Remove spool (363) and spring (366) fromrear flange (301).

3) Remove O-ring (355) from plug (357).fl Do not reuse removed O-ring (355).

4. Disassembly of internal parts (SRV)1) Remove plugs (380) (2 pieces).



3) Remove rear flange (301) from piston (381).fl Take care not to damage the piston hole.fl Since rear flange (301) and piston (381)

are matched to each other in the field,keep them coupled.

PC228USLC-130-56-182


4) Remove plugs (382) (2 pieces).fl Necessary tools

• Hexagonal wrench of size 5

5) Remove O-rings (383) and (384) from plug(382).fl Do not reuse removed O-rings (383) and

(384).

6) Remove steel balls (385) (2 pieces) from rearflange (301).

5. Disassembly of relief valve1) Remove plug (204) from sleeve (202).

fl Since shim (205) of the internal parts ofsleeve (202) is decided after relief pres-sure is set, keep those parts as a valvekit separately from other parts.



3) Take shim (205) out of plug (204).

PC228USLC-1 30-56-192


4) Take spring retainer (203), spring (206), andvalve (201) in order out of sleeve (202).

5) Remove piston seal (220) from valve (201).

6) Disassemble the other sleeve similarly. The parts other than O-ring (210) and

piston seal (221) in sleeve (202) cannotbe replaced singly, since relief pressuremust be set again. If those parts needto be replaced, replace the whole reliefvalve.

PC228USLC-130-56-202


2-2. DISASSEMBLY OF HYDRAULIC MOTOR1. Removal of parking brake parts

1) Supply compressed air through the parkingbrake passage of spindle (2) to take out pis-ton (112). If compressed air is supplied quickly, pis-

ton (112) may jump out to hurt you. Toprevent this, place a proper cover on pis-ton (112).

fl Necessary tools• Compressed air (0.3 – 0.5 MPa {3 – 5

kg/cm2})• Nozzle

2) Remove O-rings (135) and (139) from piston(112).fl Do not reuse removed O-rings (135) and

(139).

2. Taking internal parts out of motor1) Lay the travel motor on its side.

(Turn the travel motor by 90 degrees.)fl When the travel motor is laid on its side,

oil spills. Place a container under themotor to receive the oil.

fl Necessary tools• Container

2) Drain the oil from the travel motor.

3) Hold cylinder block (104) with both handsand take it out of spindle (2).fl Before pulling out cylinder block (104),

hold it with the hands and rotate it inboth directions by 2 - 3 turns to separateshoe (106) from swash plate (103).

If cylinder block (104) is pulled out with-out performing the above action, theshoe is left on the swash plate and theparts sticking to the cylinder block (pis-ton, shoe, etc.) come off the cylinderblock and fall in the spindle.

PC228USLC-1 30-56-212


4) Remove 2 mating plates (116) and 2 frictionplates (115) from the periphery of cylinderblock (104).

5) Remove the piston assembly (piston (105)and shoe (106)), retainer plate (107), thrustball (108), collar (111), and needle rollers(151) (5 pieces) from removed cylinder block(104).fl Cylinder block (104), piston assembly

(piston (105) and shoe (106)), retainerplate (107), etc. are the cylinder and pis-ton kit, which is the minimum parts unit.If any part of this kit needs to be re-placed, replace the whole kit. (See partsclassification in the parts list.)

6) Take swash plate (103) out of spindle (2).

7) Take out shaft (102).fl Oil seal (132) cannot be taken out. The shaft can be pulled out easily by

hitting its end on reduction gear assem-bly side lightly with a plastic hammer. Ifit is hit strongly it may jump out.

8) Take pivots (167) (2 pieces) and parallel pins(171) (2 pieces) out of spindle (2).

PC228USLC-130-56-222


9) Take out 2nd travel speed selection valveassembly (piston (161) and shoe (162)) andspring (193) by supplying compressed airthrough the passage of spindle (2).fl Since piston (161) and shoe (162) are set

in 1 unit, if either of them needs to bereplaced, replace both of them.

If compressed air is supplied quickly, the2nd travel speed selection valve assem-bly may jump out to hurt you. To pre-vent this, place a proper cover on valveassembly.Compressed air: 0.3 – 0.5 MPa

{3 – 5 kg/cm2}fl Necessary tools

• Compressed air (0.3 – 0.5 MPa {3 – 5kg/cm2})

• Nozzle

3. Disassembly of internal parts of cylinder block1) Place cylinder block (104) on a press stand.

Apply holder (I) to washer (110) and take outC-type hole snap ring (145) with snap ringpliers.fl Press load: Min. 1,961 N {200 kg}fl When removing the spring, align holder

(I) with the washer and protect the cylin-der block from washer and spring.

fl Cover the sliding surfaces of the cylin-der block with vinyl sheet for protection.

fl Remove spring (114) only when it needsto be replaced.

fl Necessary tools• Press stand• Holder (I)• Snap ring pliers

2) Loosen the press slowly until the spring forceis reduced to zero. If the press is loosened quickly, the

spring may jump out to hurt you. Loosenit slowly.

3) Take C-type hole snap ring (145), washer(110), spring (114), and washer (110) out ofcylinder block (104).

PC228USLC-1 30-56-232


2-3. DISASSEMBLY OF REDUCTION GEARASSEMBLY

1. Removal of input gear1) Remove steel ball (36) and input gear (6)

from coupling (15).

2. Removal of spur gears1) Remove C-type shaft snap rings (25)

(3 pieces) from crankshafts (9). When the snap ring is removed, it may

come off the pliers nose and fly out. Takecare.

fl Necessary tools• Snap ring pliers

3. Removal of coupling1) Remove coupling (15) from shaft (102).

2) Remove spur gear (7) (3 pieces) from crank-shaft (9).

PC228USLC-130-56-242


4. Removal of hold flange1) Turn over the travel motor.2) Install clamps (2 pieces) to hub (1) and spin-

dle (2) to secure. Set the clamps symmetri-cally.fl If hold flange (3) is removed without set-

ting the clamps, hub (1) and spindle (2)will separate from each other and spin-dle (2) will fall from the work table.

fl Necessary tools• Clamp• Hexagonal wrench of size 14

3) Turn over the travel motor.4) Remove 3 snap rings (20) and distance pieces

(13) from hold flange (3).fl Make match marks on the snap rings

and hold flange so that they will be in-stalled to the original positions.


5) Cut the bent part of the top of the parallelpin hole. When the bent part is cut with a rotary

bar, metal chips are scattered. Put onprotective goggles, mask, etc.

fl Necessary tools• Rotary bar

6) Install the jig to pull out parallel pin (34) andpull out the parallel pin to the end of holdflange (3). (6 places)fl Necessary tools

• Wrench adapter, socket of size 22

PC228USLC-1 30-56-252


7) Loosen hexagon socket head bolts (19).fl Since the threaded parts of the hexagon

socket head bolts (19) are coated withadhesive, those bolts may be difficult toremove. Accordingly, loosen the boltsas slowly as possible.(Loosening torque:

Min. 686 Nm {70 kgm})fl Necessary tools

• Torque wrench• Wrench adapter, rod of size 19

8) Remove hold flange (3) from spindle (2).fl Make match marks on the hold flange

and spindle so that they will be installedto the original positions.

5. Removal of clamps1) Turn over the travel motor.

2) Remove the clamps (2 pieces).fl Necessary tools

• Clamp

6. Separation of hub and spindle1) Install eyebolts (for M16) to spindle (2). In-

stall hooks to the eyebolts and sling themwith a crane to remove spindle (2) from hub(1).fl Lift up spindle (2) slowly so that it will

not damage the retainer of ball bearing(21).

fl Necessary tools• 1 set of sling• 2 eyebolts• Plastic hammer

PC228USLC-130-56-262


7. Removal of ball bearing, RV gear assembly, andpin1) Hit the end of pin (17) with a pin punch [1]

and hammer [2] to remove ball bearing (21)from hub (1). At this time, RV gear assem-bly (RV gear A (4), RV gear B (5), crankshafts(9), tapered roller bearing (22), and needleroller bearing with retainer (23)) and pin (17)are removed, too.fl When removing ball bearing (21), hit 3 -

4 points on the periphery of the pin endlightly so that the bearing will not beslanted.

fl If the outer race of ball bearing (21) isremoved from hub (1), ball bearing (21),RV gear assembly, and pin (17) fall fromhub (1). Accordingly, place a containerand a rubber mat on it under the worktable to protect the falling parts.

fl The RV gear assembly is the minimumparts unit. If any part of this assemblyneeds to be replaced, replace the wholeassembly. (See parts classification in theparts list.)

fl Necessary tools• Pin punch [1]• Hammer [2]

8. Removal of ball bearing1) Take floating seal (31) out of hub (1).2) Turn over the travel motor.3) Hit ball bearing (21) with a pin punch [1] and

hammer [2] from the cover (8) side of hub(1) to remove the ball bearing from hub (1).fl If ball bearing (21) is removed, it falls

from hub (1). Accordingly, place a rub-ber mat under the work table to protectit.

fl Necessary tools• Pin punch [1]• Hammer [2]

PC228USLC-1 30-56-272


9. Removal of spindle parts1) Take floating seal (31) out of spindle (2).

fl Necessary tools• Flat-head screwdriver

2) Take the outer race of tapered roller bearing(22) out of spindle (2).

10. Taking outer race out of tapered roller bearing(22)1) Take the outer race of tapered roller bearing

(22) out of hold flange (3).fl Necessary tools

• Aluminum rod• Hammer

11. Removal of oil seal1) Apply a flat-head screwdriver to the rim of

oil seal (132) in spindle (2) and hit it with ahammer [1] to take out oil seal (132).fl Remove oil seal (132) only when it needs

to be replaced. Do not reuse the removedoil seal.

fl Remove the oil seal after the reductiongear assembly is disassembled and spin-dle (2) is separated.

fl Necessary tools• Flat-head screwdriver• Hammer [1]

12. Removal of deep groove ball bearing (149) Remove deep groove ball bearing (149) only

when it needs to be replaced.1) Place holder [II] on the press stand and put

shaft (102) in it. Do not reuse the removed deep groove

ball bearing.fl Necessary tools

• Press stand• Holder [II]

2) Press the tip of shaft with press [1] and re-move deep groove ball bearing (149).

PC228USLC-130-56-282


MAINTENANCE STANDARDDisassemble and inspect the travel motor according to the following standard. Handle its partscarefully. In particular, take care not to damage the moving parts and sliding parts.1. Seals

Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, even if they arefree from damage.

2. Maintenance standard for worn parts1) Replace all the parts which have visible extreme damages.2) Replace the parts which have the following trouble (phenomenon).

Part Part name Trouble Standard value Allowable valueNo. (Standard dimension) (Criterion)

Spindle kit(2) Spindle • Part surface has visible serious(3) Hold flange damage.

(19) Hexagon socket head bolt • Part surface is scuffed or worn(34) Parallel pin easily.(37) Plain washer

RV gear assembly(4) RV gear (A) • RV gear tooth surface is worn(5) RV gear (B) unevenly.(9) Crankshaft • When crankshafts (9) are

(12) Spacer bearing revolved, each part does not(22) Tapered roller bearing move smoothly.(23) Needle roller bearing with

retainer

13 Distance piece (Rank) • Periphery and end faces areworn abnormally.

20 Snap ring • Periphery and end faces areworn abnormally.

21 Ball bearing • There is bruise.• Surface is flaked.• Surface is worn unevenly.

Rear flange kit(301) Rear flange • Moving part against spool (323)

has flaw.• Clearance between rear flange Diameter clearance Diameter clearance

and spool is large. 10 – 20 µ 25 µ• Sliding surface against piston

(381) has flaw.• Clearance between rear flange

and piston is large.• Contact face against valve (327)

has flaw.• Depth to contact face against

valve (327) is large.

(323) Spool • Outside surface has flaw.• Outside surface is worn unevenly.

(381) Piston • Outside surface has flaw.• Outside surface is worn unevenly.

PC228USLC-1 30-56-292


Part Part name Trouble Standard value Allowable valueNo. (Standard dimension) (Criterion)

102 Shaft • Contact face against oil seal(132) is worn.

• Spline is worn.

103 Swash plate • Swash plate is seized.

104 Cylinder block • Spline is worn.• Inside of bore is worn remarkably.• Sliding surface against timing

plate (109) is scratched andworn unevenly.

Piston assembly(105) Piston • There is axial clearance between Clearance: Clearance:(106) Shoe piston (105) and shoe (106). 0.05 mm 0.15 mm

• Shoe is worn abnormally.• Shoe is worn unevenly.

107 Retainer plate • Periphery and end faces areworn unevenly.

108 Thrust ball • Spherical sliding parts againstretainer plate (107) is wornunevenly.

109 Timing plate • Sliding surface is seized andworn unevenly.

115 Friction plate • Both end faces are worn Braking torque: Braking torque:116 Mating plate unevenly. Min. 398 Nm Max. 398 Nm

• Specified torque is not produced. {40.6 kgm} {40.6 kgm}• Plate is seized.

149 Deep groove ball bearing • There is bruise.150 Deep groove ball bearing • Surface is flaked.

• Surface is worn unevenly.

363 Spool • Outside surface has flaw.• Outside surface is worn unevenly.

201 Valve • Outside surface has flaw.• Outside surface is worn unevenly.

202 Sleeve • Seat has flaw.• Clearance between sleeve and

valve (201) is large.

PC228USLC-130-56-302


ASSEMBLY PROCEDURE1. GENERAL PRECAUTIONS

1) Work in a clean place.

2) When assembling, do not put on cloth gloves. (Prevention of entry of fibers)

3) Repair the parts damaged during disassembly and be sure to prepare new oil seals and O-rings.

4) Be sure to replace removed “hexagon socket head bolts (19)” with new ones.

5) Clean each part in kerosene and dry it with compressed air. Never use cloths to wipe the parts.(Prevention of entry of fibers)(1) Clean the hub, spindle, cover, and rear flange in a cleaning tank.

Remove all sand and dirt from each part. Kerosene is flammable. Take care of a fire extremely.

(2) Clean the other parts in a container with kerosene. If dirty parts are washed in kerosene from first, they may be scratched. Wait until dirt

and grease are dissolved sufficiently.

6) Be sure to apply clean hydraulic oil (NAS Grade 9 or equivalent) to the moving and slidingparts of the hydraulic motor valves before assembling.

7) Tighten each mounting bolt and plug to the specified torque with a torque wrench, etc.

Tightening torque table

Part No. Part name Thread size Q’ty Tightening torque

19 Hexagon socket head bolt M24 (P3.0) 3 709 ± 108 Nm {72.3 ± 11 kgm}

33 Hexagon socket head plug PF 1/2 3 98.1 ± 19.6 Nm {10 ± 2 kgm}

35 Hexagon socket head bolt M12 (P1.75) 12 102 ± 15.7 Nm {10.4 ± 1.6 kgm}

202 Sleeve PF 1 2 245 ± 49 Nm {25 ± 5 kgm}

204 Plug PF 1/2 2 98.1 ± 19.6 Nm {10 ± 2 kgm}

324 Plug M36 (P1.5) 2 255 ± 39.2 Nm {26 ± 4 kgm}

326 Plug M36 (P1.5) 2 441 ± 88.3 Nm {45 ± 9 kgm}

343 Hexagon socket head bolt M16 (P2.0) 12 252 ± 39.2 Nm {25.7 ± 4 kgm}

346 Plug PT 1/4 2 29.4 ± 4.9 Nm {3 ± 0.5 kgm}

352 Plug PF 1/4 2 29.4 ± 4.9 Nm {3 ± 0.5 kgm}

354 Hexagon socket head plug NPTF 1/16 8 9.81 ± 2.45 Nm {1.0 ± 0.25 kgm}

357 Plug PF 1/2 2 98.1 ± 19.6 Nm {10 ± 2 kgm}

380 Plug PF 3/8 2 58.8 ± 9.81 Nm {6 ± 1 kgm}

382 Plug PF 1/8 2 14.7 ± 2.45 Nm {1.5 ± 0.25 kgm}

398 Hexagon socket head plug PT 1/8 4 12.3 ± 2.45 Nm {1.25 ± 0.25 kgm}

PC228USLC-1 30-56-312


2. ASSEMBLY PROCEDURE2-1. ASSEMBLY OF BRAKE VALVE1. Installation of check valve

1) Fit O-ring (337) to plug (326).fl Apply grease to O-ring (337).fl Necessary tools


2) Put spring (330) and valve (327) in plug (326).Apply grease to valve (327) and spring (330)and fix spring (330) temporarily.fl Apply HERMSEAL to the threads of plug

(326).fl Tighten plug (326) with torque wrench.3 Plug: 255 ± 39.2 Nm {26 ± 4 kgm}

3) Put assembled plug (326) in rear flange (301)and tighten to the specified torque.

2. Installation of spool1) Insert spool (323) in rear flange (301).

fl Apply hydraulic oil to spool (323) andinsert it in rear flange (301).

When inserting the spool, align it withrear flange hole.

A flaw on the rear flange hole or outsideof the spool can cause internal leakageand lowering of performance of the travelmotor. Take care.

fl Necessary tools• Torque wrench• Wrench adapter, socket of size 41

2) Fit O-ring (336) to plug (324).fl Apply grease to O-ring (336).

3) Install stopper (325) and spring (328) to plug(324) and tighten plugs (324) (2 pieces) intorear flange (301) to the specified torque.3 Plug: 441 ± 88.3 Nm {45 ± 9 kgm}fl Rear flange (301) and spool (323) are han-

dles as a kit. If either of them needs tobe replaced, be sure to replace both ofthem.

PC228USLC-130-56-322


3. Assembly of 2nd travel speed selection valve1) Fit O-ring (355) to plug (357).

fl Apply grease to O-ring (355).

2) Fit spring (366) to spool (363) and insert themin rear flange (301).fl When inserting spool (363) in rear flange

(301), apply hydraulic oil to it.fl A flaw on the hole of rear flange (301) or

outside of spool (363) can cause internalleakage and lowering of performance ofthe travel motor. Take care.

fl When inserting spool (163), align it withthe hole of rear flange (301) to preventcontact damage on the inside of rearflange and outside of the spool.

3) Install plug (357) to rear flange (301) andtighten it to the specified torque.3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}fl Necessary tools


4. Assembly of internal parts (SRV)1) Put steel balls (385) (2 pieces) in rear flange

(301).

2) Fit O-rings (383) and (384) to plug (382). (2pieces)fl Apply grease to O-rings (383) and (384).

3) Install plugs (382) (2 pieces) to rear flange(301) and tighten them to the specifiedtorque.3 Plug: 14.7 ± 2.45 {1.5 ± 0.25 kgm}fl Necessary tools


PC228USLC-1 30-56-332


4) Put piston (381) in rear flange (301).fl Apply hydraulic oil to piston (381) and

insert it in rear flange (301). Align pis-ton (381) with the hole of rear flange(301) (to prevent contact damage on thebody hole and outside of the piston).

Since the clearance between piston (381)and rear flange (301) is adjusted for eachcombination, take care not to mistake incombination.


6) Install plug (380) to rear flange (301) andtighten it to the specified torque.3 Plug: 58.8 ± 9.81 Nm {6 ± 1 kgm}fl Use a vise for the ease of work.fl Necessary tools


5. Assembly of relief valve1) Fit O-rings (208), (209), and (219), and backup

rings (211) and (217) (2 pieces) to sleeve(202).fl Apply grease to O-rings (208) and (209).


3) Put shim (205) in plug (204).fl Since the relief pressure is adjusted with

the shim, install the removed shim as itis.

4) Install piston seal (220) to valve (201).fl Piston seal (220) consists of an O-ring

and a Teflon ring. Apply grease to bothof them. Put in the O-ring first, then putin the Teflon ring.

PC228USLC-130-56-342


5) Insert valve (201), spring (206), and springretainer (203) in sleeve (202) and tighten plug(204) having shim (205).fl Apply hydraulic oil to valve (201) and

insert it in sleeve (202).fl When inserting valve (201), align it with

the hole of sleeve (202) (to prevent con-tact damage on the hole of the sleeveand outside of the valve).

fl Since the internal parts of the sleeve areadjusted for each combination, take carenot to mistake in combination.

3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}fl Necessary tools


fl Stick shim (205) to plug (204) with hy-draulic oil or grease to prevent it fromfalling.

6) Install the other sleeve similarly.

PC228USLC-1 30-56-352


2-2. ASSEMBLY OF REDUCTION GEAR ASSEMBLY AND HYDRAULIC MOTOR

If any part has been replaced, Procedure for adjusting thickness of hold flange (3) and/orProcedure for selecting thickness of distance piece (13) must be performed. Before startingassembly, see if the following parts have been replaced.

When assembling after replacing the above parts, be sure to adjust each part. If the parts are puttogether without adjustment, the travel motor will malfunction and will be broken soon.

Was any part replaced? <Replaced part>• Hub (1)• Spindle kit• Ball bearing (21)

<Replaced part>• Spindle kit• RV gear assembly

Yes

[A] ASSEMBLY(page 30-56-36)

[B] PROCEDURE FOR ADJUSTING THICKNESS OF HOLD FLANGE (3)(page 30-56-45)

[C] PROCEDURE FOR SELECTING THICKNESS OF DISTANCE PIECE (13)(page 30-56-47)

No

PC228USLC-130-56-362


[A] ASSEMBLY1. Assembly of hub (1)

1) Install hub (1) to the turning work table.2) Press fit the outer race of ball bearing (21)

to hub (1) with press fitting jig [2] andhammer [1].fl Necessary tools

• Press fitting jig• Hammer

3) Install floating seal (31) to hub (1). Do not apply grease to the O-ring of float-

ing seal (31).fl Place floating seal fitting jig [I], floating

seal, and floating seal fitting jig [II] inorder and press them until jig [II] comesin contact with jig [I]. Remove the jigsand check that the parallelism error ofthe end face of the hub and floating sealsurface is less than 1 mm.

fl Necessary tools• Floating seal fitting jig [I]• Floating seal fitting jig [II]

2. Assembly of spindle (2)1) Fit floating seal (31) to the floating seal

groove of spindle (2). Do not apply grease to the O-ring of float-

ing seal (31).fl Place floating seal fitting jig [III], floating

seal, and floating seal fitting jig [II] inorder and press them until jig [II] comesin contact with jig [III]. Remove the jigsand check that the parallelism error ofthe end face of the spindle groove andfloating seal surface is less than 1 mm.

fl Necessary tools• Floating seal fitting jig [II]• Floating seal fitting jig [III]

PC228USLC-1 30-56-372


3. Assembly of hub (1) and spindle (2)1) Install eyebolts (for M16) (2 pieces) symmetri-

cally to spindle (2).fl Necessary tools

• Eyebolt, 2 pieces2) Install hooks to the eyebolts and put spindle

(2) in hub (1) slowly. If spindle (2) is inserted in hub (1) quickly,

it may be slanted and scratched in mainbearing (21). Insert it slowly.

When spindle (2) is inserted, if it isslanted, separate it from hub (1) and in-sert it again slowly.

fl Necessary tools• Set of sling

3) Install clamps (2 pieces) to hub (1) and spin-dle (2) to secure. Set the clamps symmetri-cally.fl Necessary tools

• Clamp• Hexagonal wrench of size 14

4) Turn over the travel motor to bring the coverside to the top.fl Turn the travel motor 180 degrees.

5) Fit outer races (3 pieces) of tapered rollerbearing (22) to the outer race fitting holes inspindle (2).

4. Assembly of RV gear assembly1) Install a sling [1] to the RV gear assembly.

fl Necessary tools• Sling (RV gear assembly)

2) Install a hook to the sling and put it in spin-dle (2) slowly. Match the inner race of the tapered roller

bearing of the crankshaft to the outerrace hole of tapered roller bearing (22)fitted to spindle (2), and install the RVgear assembly to the spindle slowly.

If the RV gear assembly is loweredquickly, the tapered roller bearing willbe damaged and the travel motor willmalfunction.

3) Insert pins (17) (24 pieces) between the pingrooves of hub (1) and tooth grooves of thegear.fl Apply lubricating oil to pins (17) before

inserting them.

PC228USLC-130-56-382


5. Assembly of ball bearing1) Insert ball bearing (21) in hub (1).

fl Ball bearing (21) is to be press fitted tohub (1). Fit it evenly little by little byhitting it lightly with a hammer. Put ballbearing (21) in hub (1) securely.

fl Necessary tools• Hammer [1]• Press fitting jig [2]

2) Install the outer races of 3 tapered rollerbearings (22).

6. Installation of hold flange1) Install spindle (2) to hold flange (3).

Check the match marks of spindle (2)and hold flange (3).

PC228USLC-1 30-56-392


7. Installation of hexagon socket head bolts (19)and parallel pin (34)1) Apply LOCTITE #638 to the threads of spin-

dle (2).fl Necessary tools


2) Put plain washers (37) (3 pieces) on the boltseats of hold flange (3).

3) Tighten hexagon socket head bolts (19) (3pieces) to about 19.6 Nm {20 kgm}.fl Degrease hexagon socket head bolts (19)

thoroughly.4) Drive parallel pins (34) (6 pieces) with an air

chisel (BRH-8) until they reach the pin holebottoms of spindle (2).fl Degrease parallel pins (34) thoroughly.

Set air pressure to 49 – 58.8 Nm {5 – 6kg/cm2}.

Take care not to mistake the fitting di-rections and positions of parallel pins(34).

When driving parallel pins (34), take carenot to slant them. (Slanting them cancause burrs and sharp fins.)

fl Necessary tools• Air chisel (BRH-8)

5) After installing parallel pins (34), bend thepin hole edge of hold flange (3).fl Apply the bending jig around the pin

hole of hold flange (3) and hit it with ahammer.

fl Necessary tools• Bending jig• Hammer

6) Tighten hexagon socket head bolts (19) tothe specified torque.3 Bolt: 709 ± 108 Nm {72.3 ± 11 kgm}

fl If any parts (spindle kit and/or RV gear as-sembly) are replaced, refer to [C] PROCE-DURE FOR SELECTING THICKNESS OF DIS-TANCE PIECE (13) (page 30-56-47).

fl If no parts are replaced, go to item 8. below.

PC228USLC-130-56-402


8. Fitting of snap rings (20) and distance pieces(13)1) Fit distance pieces (13) in hold flange (3).2) Fit snap rings (20) to the snap ring groove in

hold flange (3).fl Fit 3 snap rings (20) and 3 distance pieces

(13) to their original positions, matchingthe match marks.


9. Assembly of spur gears (7)1) Fit spur gears (7) (3 pieces) to crankshafts

(9), matching their match marks as shownbelow.fl Necessary tools

• Snap ring pliers

Match marks on spur gears (7)

2) Fit C-type shaft snap rings (25) to the snapring grooves of crankshafts (9). Snap ring (25) may come off the pliers

and fly off. Hold it securely with thepliers.


fl When fitting spur gear (7), set their matchmarks a (punch marks) as shown here.

PC228USLC-1 30-56-412


fl Take care of the direction of each snapring. Fit it with its square side a up.

10. Fitting of oil seal1) Turn over the travel motor.2) Fit oil seal (132) to the oil seal hole of spin-

dle (2).fl Apply lithium grease to the lip of oil seal

(132).fl Necessary tools

• Hammer• Holder [III]

11. Installation of shaft (102)1) Install deep groove ball bearing (149) to shaft

(102) by shrink fit.fl When installing, put on leather gloves

and take care not to get burned.fl If deep groove ball bearing (149) was

removed during disassembly, replace itwith new one.

fl Shrink fit temperature: 100 ± 10°C When installing the bearing, take care

that it will not slant from shaft (2).fl Necessary tools

• Heating oven• Leather gloves• Holder [II]

PC228USLC-130-56-422


12. Installation of piston ring assemblies (161) and(162)1) Apply grease to spring (193) and install it to

the piston assembly.2) Apply hydraulic oil to the sliding surfaces of

the piston assembly and install it to the pis-ton hole in spindle (2).

13. Installation of pivot (167)1) Insert pins (171) (2 pieces) in spindle (2) and

install pivots (167) (2 pieces).2) Apply grease to the hemisphere parts of the

pivots.

14. Assembly of internal parts of cylinder block1) Place cylinder block (104) on the press stand.

2) Put washer (110), spring (114), and washer(110) in cylinder block (104).fl Put washers (110) as shown in the figure

at right.

PC228USLC-1 30-56-432


3) Place the above cylinder block on the pressstand. Apply holder [I] to washer (110) topress spring (114) and fit C-type hole snapring (145).fl Cover the sliding surfaces of cylinder

block with a vinyl sheet for protection.fl Pressing force of spring (114):

Min. 1,961 N {200 kg} Snap C-type hole snap ring (145) may

come off the pliers and fly off. Hold itsecurely with the pliers.

fl Necessary tools• Press stand• Holder [I]• Snap ring pliers

15. Installation of motor assembly1) Fit needle rollers (151) (5 pieces) to cylinder

block (104) and place collar (111) and thrustball (108) on them.

2) Put piston assemblies (105) and (106) in re-tainer plate (107).

3) Apply hydraulic oil to the piston assembliesand install them to cylinder block (104).

4) Apply hydraulic oil to the sliding surface ofshoe (106) and spherical part of thrust ball(108).

PC228USLC-130-56-442


5) Install swash plate (103), thrust ball (108),collar (111), retainer plate (107), needle roll-ers (151), cylinder block (104), and pistonassemblies (105) and (106) to shaft (102) asshown at right, and then install a sling [I]and set the whole assembly vertically.fl Necessary tools

• 1 set of sling• Sling [I]

16. Installation of motor assembly1) Using sling [I], lift up the motor assembly

and install an insertion jig to the spline atthe end of shaft (102).fl Match the pivot hole of swash plate (103)

to pivot (167) and install the motor as-sembly slowly, taking care not to dam-age spindle (2), etc. with the motor as-sembly.

fl Necessary tools• Shaft insertion jig

2) Lift up the motor shaft slowly and install itto spindle (2).

3) After installing the motor assembly, removesling [I] and insertion jig.fl After installing the motor assembly, re-

volve the cylinder block with the hand tocheck that it does not have play. If thecylinder block has play, check it. Whenchecking, do not pull out the cylinderblock, however. If it is pulled out, collar(111) and thrust ball (108) will come offand the cylinder block will not revolvenormally.

PC228USLC-1 30-56-452


[B] PROCEDURE FOR ADJUSTING THICKNESSOF HOLD FLANGE (3)

Assembly processes to be finished before adjust-mentfl Finish assembly procedures 1 – 5 (on pages 30-

56-36 to 30-56-38) before adjusting the thick-ness of the hold flange.

1. Install the preload adjustment jig [2] for mainbearing to spindle (2).fl Necessary tools

• Preload adjustment jig [2] for main bearing

3. Obtain depth A through the measurement holeof the preload adjustment jig for main bearingwith depth micrometer [4].fl Necessary tools

• Depth micrometer [4]

4. Since dimension B of the preload adjustment jigfor main bearing is known, obtain clearance Cby the following formula.

C = A – B A: Measured valueB: Dimension of jigC: Clearance

2. Tighten special nut [3] of preload adjustment jig[2] for main bearing to the specified torque.3 Nut [3]: 118 ± 19.6 Nm {12 ± 2 kgm}fl Necessary tools

• Torque wrench [1]• Wrench adapter, socket of size 30

PC228USLC-130-56-462


5. Obtain dimension D of hold flange (3).

6. From the result of procedures 1 – 5 above, ad-just hold flange (3) according to the followingprocedure. Dimension C is the standard dimen-sion of the hold flange.Adjust to D = C ± 0.02.1) If dimension D of actual hold flange (3) is

less than the standard value, cut face E ofhold flange (3) with a lathe, etc. until thestandard value is obtained.

2) If dimension D of actual hold flange (3) is inthe tolerance of the standard value, use thehold flange as it is.

3) If dimension D of actual hold flange (3) islarger than the standard value, replace thespindle assembly with new one. Hold flange(3) of the new spindle assembly has adjust-ment allowance.fl Carry out disassembly and assembly

again.

7. Remove the preload adjustment jig for mainbearing from spindle (2).

PC228USLC-1 30-56-472


[C] PROCEDURE FOR SELECTING THICKNESSOF DISTANCE PIECE (13)

Assembly processes to be finished before selectionfl Finish assembly procedures 1 – 7 (on pages 30-

56-36 to 30-56-39) before selecting the thicknessof the distance piece.

1. Lightly hit the outer race of tapered roller bear-ing (22) installed to crankshaft (9) of the RV gearassembly with holder [IV] and hammer.fl Perform this procedure to insert the RV gear

assembly in spindle (2) securely.fl Necessary tools

• Holder [IV]• Hammer• Thickness gauge

2. Install thinnest distance piece (13) into holdflange (3) and fit snap ring (20) to the snap ringgroove inside hold flange (3).

3. Lightly hit the periphery of snap ring (20) withholder [IV] and hammer.fl Perform this procedure to check that the RV

gear assembly is inserted in spindle (2) se-curely.

4. Insert thickness gauge between snap ring (20)and distance piece (13) to measure the clear-ance.Measurement of thickness of distance piece

5. After deciding the thickness of the distance piece,select proper ones from 17 types and installthem.fl See clearance adjustment parts list (on page

30-56-51).

1 Set thickness of distance piece (Max.)Max. = Thickness of thickness gauge + Thickness of distance piece currently inserted

2 Set thickness of distance piece (Min.)Min. = Thickness of thickness gauge + Thickness of distance piece currently inserted – 0.05

PC228USLC-130-56-482


See assembly procedure forhydraulic motor parts

(pages 30-56-41 to 30-56-44)

See assembly procedure for brake valve

(pages 30-56-31 to 30-56-33)

See assembly procedure for reduction gear assembly and hydraulic motor shaft

(pages 30-56-35 to 30-56-41)

1) Fit 2 couples of friction plate (115) and mating plate (116) to the peripheral groove of cylinder block (104) with friction plate (115) ahead.

fl When fitting friction plates (115), dip them in hydraulic oil.

Take care not to mistake the fitting order of the friction plates and mating plates. If it is mistaken, the braking force of the parking brake may lower.

1) Put piston (112) having O-rings (135) and (139) in spindle (2).

2) Insert piston (112) into spindle (2) by hitting its end with a plastic hammer. Take care not to slant it.

fl Apply grease to O-rings (135) and (139).fl Necessary tools

• Plastic hammer

1) Install deep groove ball bearing (150), timing plate (109), parallel pin (341) (1 piece), and springs (113) (12 pieces) to rear flange (301).

Apply sufficient amount of grease to spring (113) and timing plate (109) so that they will not fall from rear flange (301).

fl Apply hydraulic oil to deep groove ball bearing (150).fl Necessary tools

• Grease • Hydraulic oil

1) Add hydraulic oil.5 Hydraulic oil (1.7 liters)

2) Install O-rings (29) and (27) (2 pieces) and parallel pins (42) (2 pieces) to spindle (2) side and install rear flange (301) to the spindle.

Do not apply grease to O-ring (29) on the mating face (since oozing grease can be mistaken for oil leakage).

fl When installing rear flange (301), match the pinholes to parallel pins (42) fitted in spindle (2).

1) Set coupling gear (15).2) Set input gear (6). Apply grease to the hollow of input gear (6) and steel ball (36), and then place steel ball (36).3) Fit O-ring (29) to cover (8).4) Install 2 eyebolts to the plug holes of cover (8). Lift up cover (8) and install it to hub (1).fl Apply grease to O-ring (30). When installing cover (8) into hub (1), take care not to damage the O-ring, etc.fl Match the bolt holes of cover (8) to the tap holes of hub (1).fl Necessary tools

• Grease • Plastic hammer • Eyebolts (2 pieces), PF 1/2 • 1 set of sling

PC228USLC-1 30-56-492


1) Tighten hexagon socket head bolts (343) (12 pieces) into spindle (2) to the specified torque.

3 Bolt: 252 ± 39.2 Nm {25.7 ± 4 kgm}2) Fit O-ring (355) to plug (357) and install them to

a drain port which will not be used. 3 Plug: 98.1 ± 19.6Nm {10 ±2 kgm}fl Necessary tools

• Torque wrench• Wrench adapter, rods of sizes 10 and 14

1) Install the relief valve to rear flange (301).2) Tighten the relief valve to the specified torque. 3 Bolt: 245 ± 49Nm {25 ± 5kgm}fl Necessary tools

• Torque wrench• Wrench adapter, socket of size 32

1) Tighten hexagon socket head bolts (35) (12 pieces) to the specified torque with a torque wrench.

2) Add lubricating oil (5.4 liters). 3 Bolt: 102 ± 15.7 Nm {10.4 ± 1.6 kgm}fl Necessary tools

• Torque wrench• Wrench adapter, rod of size 10• Lubricating oil: 5.4 liters

1) Fit O-rings (43) to hexagon socket head plugs (33).

2) Tighten hexagon socket head plugs (33) (3 pieces) for cover (8).

3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}fl Necessary tools


PC228USLC-130-56-502


1 Pressure gauge 2 pieces(For 3.4 MPa {35 kg/cm2})2 Measuring cylinder (For 5 liters) 1 piece

3 Stopwatch 1 piece

1 Installation and piping oftravel motor

PERFORMANCE TESTfl After maintaining the travel motor, execute the performance test according to the following

procedure.

1) Necessary measuring tools

2) Test procedureInstall the travel motor to machine body and connect thepipes. Do not install the tracks, however.(For the performance test (no-load operation) of the travelmotor)Note)1. Connect the pipes so that a pressure gauge (main cir-

cuit) can be installed and the drainage from the hydrau-lic motor can be measured.

2. When installing the travel motor, do not hit it with ahammer but fix it slowly by using the bolt holes.

Gear Speed of Pressure Revolving Operationspeed travel motor direction time

Low 10 rpmNo load Right and left Min. 1 minute

High 20 rpm each

1) Preparatory operation for test ..... Operate until temperature rises to the following levels.• Hydraulic oil: 45 – 55°C• Temperature of outside part of

reduction gear assembly hub: 40 – 80°C

2) Performance test ........................... Measure and judge the following items.Criteria for acceptance — Travel motor drive pressure

Max. 2.0 MPa {20 kg/cm2} in 1st gear speed at 10 rpmMax. 2.9 MPa {30 kg/cm2} in 2nd gear speed at 20 rpm

Drainage from hydraulic motorMax. 2 liters/min in both 1st and 2nd gears at 10 rpm

2 Run-in operation of travelmotor

3 Performance test of travelmotor

Accepted Rejected

Install tracks. Disassemble and adjust again.

PC228USLC-1 30-56-512


LIST OF CLEARANCE ADJUSTMENT PARTS

Classification Dimension (T)No.E Above 3.30 to 3.35F Above 3.35 to 3.40G Above 3.40 to 3.45H Above 3.45 to 3.50I Above 3.50 to 3.55J Above 3.55 to 3.60K Above 3.60 to 3.65L Above 3.65 to 3.70M Above 3.70 to 3.75N Above 3.75 to 3.80O Above 3.80 to 3.85P Above 3.85 to 3.90Q Above 3.90 to 3.95R Above 3.95 to 4.00S Above 4.00 to 4.05T Above 4.05 to 4.10U Above 4.10 to 4.15

Distance piece (13) Unit: mm

Part name Dimension

sm pc228us-2 sebm015903

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