SM Pc228us-2 Sebm015903
SM Pc228us-2 Sebm015903
PC228US-2
PC228USLC-1, 2
MACHINE MODEL
SERIAL NUMBER
PC228USLC-1
PC228US-2
PC228USLC-2
11001 and up
15001 and up
15001 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
2003 1
All Rights Reserved
Printed in Japan 05-03(01)
00-1
(3)
CONTENTS
No. of page
01
GENERAL ........................................................................
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OTHERS...........................................................................
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PC228USLC-1
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
00-3
SAFETY
00-4
SAFETY NOTICE
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. 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 service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
(
....) is recorded on the bottom of the pages.
REVISIONS
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
Symbol
Item
Remarks
Safety
Caution
Weight
Tightening
torque
Coat
Oil, water
Drain
6
5
2
3
4
FILING METHOD
1. 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):
SYMBOLS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
321
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
kN
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
100%
88%
79%
71%
41%
SAD00479
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of
the rope used.
00-7
FOREWORD
Disconnection
1) Release the residual pressure from the hydraulic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (See Fig. 1)
5 The adapter can be pushed in about 3.5
mm.
5 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 it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
5 Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
5 Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
5 When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
Type 1
FOREWORD
Type 3
Disassembly
Type 2
Connection
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
5
5
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and 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
LT-1A
790-129-9030
150 g
Tube
20 g
(2 pcs.)
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Can
LT-4
Polyethylene
container
LT-2
790-129-9050
LT-1B
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
1 kg
Can
790-129-9070
LG-5
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybdenum
disulphide
lubricant
09940-00040
200 g
LM-P
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
Various
SYG2-400M
400 g
(10 per
case)
Various
Molybdenum
disulphide
lubricant
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Belows type
Grease
Various
Various
00-11
FOREWORD
Width across
flats
mm
mm
6
8
10
12
14
10
13
17
19
22
13.2
31
66
113
177
1.4
3
7
10
19
1.35
3.2
6.7
11.5
18
0.15
0.3
0.7
1
2
16
18
20
22
24
24
27
30
32
36
279 30
382 39
549 59
745 83
927 103
28.5
39
56
76
94.5
3
4
6
8.5
10.5
27
30
33
36
39
41
46
50
55
60
1320
1720
2210
2750
3290
135
175
225
280
335
15
20
25
30
35
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
Nm
kgm
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
140
190
240
290
340
kgm
0
0
0
0
0.8
1.9
4.1
8.4
0.2
0.5
0.6
0.8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sealing surface
SAD00483
Thread diameter
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
5 2
8 2
14 3
18 3
20 5
25 5
30 5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
00-12
Tightening torque
FOREWORD
Thread diameter
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
6.7 0.7
11.5 1
28.5 3
0
0
0
0
0
Thread diameter
Tightening torque
mm
mm
Nm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
Norminal No.
3.5
9.5
14.5
43
89.5
0.5
1
2
6
13.5
0
0
0
0
0
0
0
0
0
0
02
03, 04
05, 06
10, 12
14
kgm
Thread diameter
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
n
36
n
n
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
7 1
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
08
10
12
14
16
18
20
24
30
33
36
42
52
00-13
FOREWORD
Tightening torque
mm
Nm
6
8
10
12
kgm
10 2
24 4
43 6
77 12
1.02
2.45
4.38
7.85
0
0
0
0
Thread diameter
0.20
0.41
0.61
1.22
0
0
0
0
Tightening torque
mm
Nm
6
8
10
12
14
kgm
8 2
10 2
12 2
24 4
36 5
0.81
1.02
1.22
2.45
3.67
0
0
0
0
0
Thread diameter
0.20
0.20
0.20
0.41
0.51
0
0
0
0
0
Tightening torque
mm
1 / 16
1/8
1/4
3/8
1/2
3/4
1
3 1
8 2
12 2
15 2
24 4
36 5
60 9
0
0
0
0
0
0
0
00-14
Nm
kgm
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0
0
0
0
0
0
0
Thread diameter
0.10
0.20
0.20
0.41
0.41
0.51
0.92
FOREWORD
CLASSIFICATION BY THICKNESS
Copper wire
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
0.32
2.09
3.1
20
65
0.32
5.23
4.6
37
15
84
0.45
13.36
7.0
59
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
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
WR
n
n
n
n
n
BW
RW
YR
GW
LW
WB
Auxiliary
WL
WG
5
Color White & Green
Color
n
n
Code
6
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
YG
GY
LY
Yellow &
Green
Green &
Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
n
n
Code
3
n
n
n
n
n
n
n
n
Primary
Ground
Code
Charging
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters 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.
B
A
Millimeters to inches
1 mm = 0.03937 in
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
A
00-16
2.165
2.559
2.953
3.346
3.740
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
0.264
0.528
0.793
1.057
1.321
1.585
10
2.642
2.906
3.170
3.434
3.698
3.963
20
5.283
5.548
5.812
6.076
6.340
30
7.925
8.189
8.454
8.718
40
10.567
10.831
11.095
50
13.209
13.473
60
15.850
70
1.849
2.113
2.378
4.227
4.491
4.755
5.019
6.604
6.869
7.133
7.397
7.661
8.982
9.246
9.510
9.774
10.039
10.303
11.359
11.624
11.888
12.152
12.416
12.680
12.944
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0.220
0.440
0.660
0.880
1.100
1.320
10
2.200
2.420
2.640
2.860
3.080
3.300
20
4.399
4.619
4.839
5.059
5.279
30
6.599
6.819
7.039
7.259
40
8.799
9.019
9.239
50
10.998
11.281
60
13.198
70
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.499
5.719
5.939
6.159
6.379
7.479
7.969
7.919
8.139
8.359
8.579
9.459
9.679
9.899
10.119
10.339
10.559
10.778
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column 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 of
Fahrenheit 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 of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-21
FOREWORD
UNITS
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}
00-22
}.
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model
PC228USLC-1
Serial Number
11001 and up
m3
0.8
Operating weight
kg
22,900
mm
6,810
mm
5,910
mm
9,850
mm
9,670
mm
10,700
mm
7,765
kN {kg}
Swing speed
rpm
11.0
deg.
16
Travel speed
km/h
Gradeability
deg.
35
kPa {kg/cm2}
41 {0.42}
mm
8,890
Overall width
mm
2,980
mm
3,080
mm
2,990
mm
2,990
mm
1,050
mm
440
mm
1,625
mm
2,310
mm
8,290
mm
3,640
Track gauge
mm
2,380
mm
2,280
Performance
Working ranges
Bucket capacity
Dimensions
Ground pressure
(triple grouser shoe width: 700 mm)
PC228USLC-1
01-3
GENERAL
SPECIFICATIONS
Machine model
PC228USLC-1
Serial Number
11001 and up
Model
S6D102E-1-A
Type
No. of cylinders bore stroke
mm
6 102 120
{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}
rpm
2,170 +70
40
rpm
970 60
g/kWh {g/HPh}
218 {160}
Performance
Piston displacement
Engine
Starting motor
24V, 4.5 kW
Alternator
24V, 50A
12V, 110 Ah 2
Battery
Radiator core type
Carrier roller
9 on each side
Track shoe
Hydraulic
motor
Control
valve
Hydraulic
pump
2 on each side
Track roller
Undercarriage
Type no.
Delivery
Set pressure
/min
2
MPa {kg/cm }
Type No.
6-spool type 1
Control method
Hydraulic
Travel motor
Swing motor
Hydraulic cylinder
Hydraulic system
Corrugated CWX-4
Arm
Type
Bucket
Double acting
piston
mm
120
135
130
mm
85
95
90
Stroke
mm
1,285
1,490
1,020
mm
3,155
3,565
2,625
mm
1,870
2,075
1,605
Hydraulic tank
Box-shaped, sealed
Hydraulic filter
Hydraulic cooler
01-4
2
PC228USLC-1
GENERAL
SPECIFICATIONS
Machine model
PC228US-2
Serial Number
15001 and up
m3
0.8
Operating weight
kg
21,800
mm
6,810
mm
5,910
mm
9,850
mm
9,670
mm
10,640
mm
7,720
kN {kg}
Swing speed
rpm
11.0
deg.
22
Travel speed
km/h
Gradeability
deg.
35
kPa {kg/cm2}
51 {0.52}
mm
8,700
Overall width
mm
2,995
mm
2,800
mm
2,965
mm
2,990
mm
1,050
mm
440
mm
1,680
mm
2,380
mm
8,210
mm
3,270
Track gauge
mm
2,200
mm
2,280
Performance
Working ranges
Bucket capacity
Dimensions
Ground pressure
(triple grouser shoe width: 700 mm)
PC228USLC-1
01-4-1
1
GENERAL
SPECIFICATIONS
Machine model
PC228US-2
Serial Number
15001 and up
Model
S6D102E-1-F
Type
No. of cylinders bore stroke
mm
6 102 120
{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}
rpm
2,170 +70
40
rpm
970 60
g/kWh {g/HPh}
218 {160}
Performance
Piston displacement
Engine
Starting motor
24V, 4.5 kW
Alternator
24V, 35A
12V, 110 Ah 2
Battery
2 on each side
Track roller
7 on each side
Track shoe
Control
valve
Hydraulic
motor
Type no.
Delivery
Set pressure
/min
2
MPa {kg/cm }
Type No.
6-spool type 1
Control method
Hydraulic
Travel motor
Swing motor
Hydraulic cylinder
Hydraulic system
Corrugated CWX-4
Carrier roller
Hydraulic
pump
Undercarriage
Arm
Type
Bucket
Double acting
piston
mm
120
135
130
mm
85
95
90
Stroke
mm
1,285
1,490
1,020
mm
3,155
3,565
2,625
mm
1,870
2,075
1,605
Hydraulic tank
Box-shaped, sealed
Hydraulic filter
Hydraulic cooler
01-4-2
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
10-65
TRAVEL MOTOR
PC228USLC-1, 2
GM38VL
A.
B.
D1.
D2.
From
From
Drain
Drain
control valve
control valve
port (to tank) (L.H. travel motor)
port (to tank) (R.H. travel motor)
10-65-1
2
Specifications
Type
: GM38VL
Theoretical delivery
: 140.5 cc/rev
Brake 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
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Plug
Spring
Valve
Spool
Spring
Valve
Spring
Sleeve
End cover
Cylinder block
Piston
PC228USLC-1
TRAVEL MOTOR
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Spring
Plate
Disc
Swash plate
Pivot
Spindle
Floating seal
Hub
RV gear A
RV gear B
Crankshaft
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Cover
spur gear
Input gear
Hold flange
Piston
Shoe
Shaft
Shoe
Piston
Spring
Timing plate
10-65-2
2
VALVE CONTROL
VALVE CONTROL
1.
2.
3.
4.
5.
6.
7.
10-66
8. Control valve
9. Hydraulic pump
10. L.H. work equipment
lever
11. L.H. PPC valve
12. Safety lock lever
Lever positions
1 HOLD
2 Boom RAISE
3 Boom LOWER
4 Bucket DUMP
5 Bucket CURL
6 HOLD
7 Arm IN
8 Arm OUT
9
0
A
B
C
D
E
Swing RIGHT
Swing LEFT
NEUTRAL
Travel REVERSE
Travel FORWARD
LOCK
FREE
PC228USLC-1
PC228USLC-1
Engine
S6D102-1
Item
Engine speed
Measurement condition
Standard value
Permissible value
1,800
2,000
Max. 1.0
2.0
Max. 0.5
1.5
0.25
0.51
Oil temperature:
40 60C
MPa
(engine speed: 250rpm) {kg/cm2}
(SAE15W-40 oil)
Min. 2.4
{Min. 24.6}
Difference between
cylinders
Min. 1.0
{Min. 10.3}
(Coolant temperature:
operating range)
At rated output
(SAE30 oil)
kPa
(mmH2O)
Max. 1.2
{Max. 123}
5.1
{520}
MPa
{kg/cm2}
0.39 0.52
{4.0 5.3}
0.25
{2.6}
Min. 0.12
{Min. 1.2}
0.09
{0.9}
80 110
120
18 1
18 1
Min. 10
Max. 6
58
58
Rated
speed
Working
rpm
Traveling
At sudden acceleration
Exhaust gas color
At high idling
Valve clearance
Unit
(normal temperature)
Intake valve
Bosch
index
mm
Exhaust valve
Compression pressure
Blow-by pressure
(Coolant temperature:
operating range)
(Measure at top of oil filter)
Oil pressure
At high idling
(SAE15W-40)
At low idling
(SAE15W-40)
Oil temperature
(B.T.D.C.)
(degree)
Belt tension
Deflection
when
pressed
with finger
force of
approx.
58.8N{6kg}
PC228USLC-1
Fan-tension
mm
Fan
air conditioner
compressor
20-3
FOR CHASSIS
Applicable model
Category
Item
PC228USLC-1
Measurement conditions
Unit
Engine speed
Low idling
Permissible value
2,200 70
2,200 70
High idling
Standard value
970 50
rpm
2 pumps at relief
1,850 100
1,400 120
1,400 120
Spool stroke
9.5 0.5
Max. 110
Min. 90
100 10
Max. 110
Min. 90
100 10
Max. 110
Min. 90
100 10
Max. 110
Min. 90
115 12
Max. 127
Min. 103
Max. 10
Max. 15
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
13.7 2.9
{1.4 0.3}
Max. 22.6
{Max. 2.3}
13.7 2.9
{1.4 0.3}
Max. 22.6
{Max. 2.3}
Lever
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
Pedal
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
20-4
(3)
mm
N
{kg}
PC228USLC-1
PC228USLC-1
Measurement conditions
Boom
Bucket teeth in
contact with ground
Arm
4.4 0.5
Max. 5.2
4.0 0.4
Max. 4.4
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)
Cylinder fully
retracted
Engine at high idling
Hydraulic oil temperature:
45 55C
CURL
Fully extended
2.6 0.4
Max. 3.3
2.1 0.3
Max. 2.7
Max. 1.0
Max. 1.2
Max. 1.0
Bucket
Work equipment
Permissible value
IN
Unit
Cylinder fully
extended
Standard value
RAISE
Item
OUT
Category
LOWER
Applicable model
Max. 2.8
Fully extended
Boom
DUMP
Cylinder fully
retracted
BKP00114
sec
Time lag
Arm
BKP00115
PC228USLC-1
20-9
(3)
PC228USLC-1
Applicable model
Time lag
Item
Unit
Standard value
Permissible value
BKP00116
sec.
Max. 1.0
Max. 3.6
4.5
20
10
50
Max. 200
Max. 220
Bucket
Cylinders
Center swivel joint
20m
mm
10m
BKP00107
Measure dimension .
Measurement conditions
Internal leakage
Work equipment
Category
20-10
Piston pump
PC228USLC-1
30
SPROCKET
Removal and Installation ...................... 30-47
FINAL DRIVE, TRAVEL MOTOR
Removal and Installation ...................... 30-48
FINAL DRIVE
Disassembly ........................................... 30-49
Assembly ................................................ 30-52
TRAVEL MOTOR
Disassembly and Assembly .............. 30-56-1
SWING MOTOR, SWING MACHINERY
Removal and Installation ...................... 30-57
SWING MACHINERY
Disassembly ........................................... 30-58
Assembly ................................................ 30-62
SWING MOTOR
Removal and Installation ...................... 30-67
REVOLVING FRAME
Removal .................................................. 30-68
Installation .............................................. 30-69
SWING CIRCLE
Removal .................................................. 30-70
Installation .............................................. 30-71
IDLER, RECOIL SPRING
Removal and Installation ...................... 30-72
RECOIL SPRING
Disassembly ........................................... 30-73
Assembly ................................................ 30-74
IDLER
Disassembly ........................................... 30-75
Assembly ................................................ 30-76
TRACK ROLLER
Removal and Installation ...................... 30-78
Disassembly ........................................... 30-79
Assembly ................................................ 30-80
CARRIER ROLLER
Removal and Installation ...................... 30-82
Disassembly ........................................... 30-83
Assembly ................................................ 30-84
TRACK SHOE
Removal and Installation ...................... 30-86
HYDRAULIC TANK
Removal and Installation ...................... 30-87
MAIN PUMP
Removal ................................................ 30- 88
Installation ............................................ 30- 89
30-1
2
EPC VALVE
Removal and Installation .................... 30- 90
PC VALVE
Removal and Installation .................... 30- 91
LS VALVE
Removal and Installation .................... 30- 92
CONTROL VALVE
Removal ................................................ 30- 93
Installation ............................................ 30- 95
Disassembly ......................................... 30- 96
Assembly .............................................. 30-101
LS SELECT VALVE
Disassembly and Assembly ................ 30-107
PRESSURE COMPENSATION VALVE
Disassembly ......................................... 30-108
Assembly .............................................. 30-109
MAIN RELIEF VALVE
Removal and Installation .................... 30-110
Disassembly and Assembly ................ 30-111
SOLENOID VALVE
Removal and Installation .................... 30-112
PUMP MERGE/DIVIDER
SOLENOID VALVE
Removal and Installation .................... 30-113
2-STAGE RELIEF, TRAVEL HI/LO
SOLENOID VALVE
Removal and Installation .................... 30-114
INTERFERENCE PREVENTION
SOLENOID VALVE
Removal 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 ......................................... 30-118
Assembly .............................................. 30-119
TRAVEL PPC VALVE
Removal and Installation .................... 30-120
Disassembly and Assembly ................ 30-121
PPC VALVE FOR OFFSET CONTROL
Removal and Installation .................... 30-122
BOOM LOCK VALVE
Removal and Installation .................... 30-123
BOOM CYLINDER
Removal ................................................ 30-124
Installation ............................................ 30-125
ARM CYLINDER
Removal ................................................ 30-126
Installation ............................................ 30-127
BUCKET CYLINDER
Removal ................................................ 30-128
Installation ............................................ 30-129
30-2
1
OFFSET CYLINDER
Removal ................................................ 30-130
Installation ............................................ 30-131
HYDRAULIC CYLINDER FOR OFFSET
Disassembly ......................................... 30-132
Assembly .............................................. 30-134
HYDRAULIC CYLINDER FOR BOOM,
ARM, BUCKET
Disassembly ......................................... 30-136
Assembly .............................................. 30-139
BUCKET
Removal ................................................ 30-144
Installation ............................................ 30-145
ARM
Removal ................................................ 30-146
Installation ............................................ 30-147
BUCKET, ARM
Removal ................................................ 30-150
Installation ............................................ 30-151
OFFSET BRACKET
Removal and Installation .................... 30-155
SECOND BOOM
Removal ................................................ 30-156
Installation ............................................ 30-157
FIRST BOOM
Removal ................................................ 30-158
Installation ............................................ 30-160
SECOND, FIRST BOOM
Removal ................................................ 30-161
Installation ............................................ 30-163
OFFSET BRACKET, SECOND,
FIRST BOOM
Removal ................................................ 30-164
Installation ............................................ 30-166
BOOM
Removal ................................................ 30-168
Installation ............................................ 30-169
OPERATORS CAB
Removal ................................................ 30-170
Installation ............................................ 30-171
FLOOR FRAME
Removal ................................................ 30-172
Installation ............................................ 30-173
AIR CONDITIONER COMPRESSOR
Removal and Installation .................... 30-174
AIR CONDITIONER CONDENSER
Removal and Installation .................... 30-175
AIR CONDITIONER UNIT
Removal ................................................ 30-176
Installation ............................................ 30-177
COUNTERWEIGHT
Removal and Installation .................... 30-178
CONTROLLER
Removal and Installation .................... 30-179
MONITOR
Removal and Installation .................... 30-180
PC228USLC-1
TRAVEL MOTOR
30-56-13
30-56-13
30-56-14
30-56-16
30-56-20
30-56-23
30-56-30
30-56-30
30-56-31
30-56-31
30-56-35
PC228USLC-1
30-56-1
2
30-56-2
2
TRAVEL MOTOR
PC228USLC-1
PC228USLC-1
TRAVEL MOTOR
30-56-3
2
TRAVEL MOTOR
REDUCTION GEAR
30-56-4
2
PC228USLC-1
PC228USLC-1
TRAVEL MOTOR
30-56-5
2
TRAVEL MOTOR
HYDRAULIC MOTOR
RELIEF VALVE
CONTROL VALVE
30-56-6
2
PC228USLC-1
PC228USLC-1
TRAVEL MOTOR
30-56-7
2
TRAVEL MOTOR
PARTS LIST
No.
Part name
Qty
37
REDUCTION GEAR
Hub
Spindle kit
Spindle assy
Spindle
Hold flange
Hexagon socket head bolt
Parallel pin
(select one from 3 kinds)
Plain washer
4
5
9
12
22
23
1
1
1
1
3
6
6
6
Input gear
1
3
1
3
15
17
20
21
25
27
29
30
Cover
Distance piece
t: Above 3.30, up to 3.15
<at interval of 0.05>
t: Above 4.10 up to 4.15
Coupling
Pin
C-type snap ring for hole
Ball bearing
C-type snap for shaft
O-ring
O-ring
O-ring
1
24
3
2
3
2
1
1
31
33
35
36
42
43
Part name
Qty
1
2
3
12
1
2
3
2
3
19
34
8
13
30-56-8
2
1
1
1
1
1
1
3
6
No.
HYDRAULIC MOTOR
105
106
104
107
108
110
111
114
145
151
1
1
9
1
1
1
1
1
2
1
1
1
5
161
162
Piston assembly
Piston
Shoe
1
1
1
102
103
109
112
113
115
116
132
135
139
149
150
167
171
173
Shaft
Swash plate
Timing plate
Piston
Spring
Friction plate
Mating plate
Oil seal
O-ring
O-ring
Deep groove ball bearing
Deep groove ball bearing
Pivot
Parallel pin
Spring
1
1
1
1
12
2
2
1
1
1
1
1
2
2
1
PC228USLC-1
No.
No.
Valve kit
Valve
Sleeve
Spring retainer
Plug
Shim
Spring
O-ring
O-ring
O-ring
Back-up ring
Back-up ring
O-ring
Piston seal
1
1
1
1
1
1
1
1
1
1
2
2
1
1
398
399
400
4
1
2
341
343
Parallel pin
Hexagon socket head bolt
1
12
CONTROL VALVE
301
323
381
321
324
325
326
327
328
330
336
337
352
354
355
357
358
359
363
366
368
373
379
380
382
383
384
385
397
Qty
RELIEF VALVE
201
202
203
204
205
206
208
209
210
211
217
219
220
Part name
TRAVEL MOTOR
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
7
1
1
2
2
1
1
2
1
1
2
2
2
2
2
1
PC228USLC-1
Part name
Qty
30-56-9
2
TRAVEL MOTOR
Name
Model/Dimensions
Qty
Hexagonal wrench
Socket wrench
(Ratchet handle)
Torque wrench
Extension bar
150 mm
Hammer
Nominal size: 12
Plastic hammer
L = About 300
Flat-head screwdriver
About 150 mm
For shaft
For hole
1
1
10
Sling parts
1 set
(2)
(2)
(1)
11
Press stand
1 set
12
Compressed air
1 set
13
Container
14
Heating tank
15
Leather gloves
16
Sealing tape
17
Depth micrometer
18
Thickness gauge
19
Rotary bar
20
Air chisel
BRH-8
(Compressed air: 0.5 0.6 MPa {5 6 kg/cm2})
30-56-10
2
1 each
1 each
1 each
1
1
1
1 each
1 each
1 each
2
1 set
1 pair
1
PC228USLC-1
TRAVEL MOTOR
2. Manufactured tools
No.
Qty
No.
Holder (III)
Holder (IV)
Pointed punch
Clamp
Qty
Steel rod
Holder (I)
10
Aluminum rod
11
Sling jig
Holder (II)
PC228USLC-1
30-56-11
2
No.
TRAVEL MOTOR
Qty
No.
17
12
13
15
Sling jig
16
Pulling jig
30-56-12
2
Bending jig
Qty
14
PC228USLC-1
TRAVEL MOTOR
DISASSEMBLY PROCEDURE
1. GENERAL PRECAUTIONS
1) 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. Disassembly
procedure.
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 the
all replacement seals before disassembling.
PC228USLC-1
30-56-13
2
TRAVEL MOTOR
2. DISASSEMBLY PROCEDURE
When inspecting or repairing the travel motor, disassemble it according to the following procedure.
The number in (
) after each part name refers to the part No. in Parts list.
Before disassembling the travel motor, install it to a turning work table.
Prepare a container to collect lubricating oil (for 8 liters).
Prepare a container to collect hydraulic oil (for 4 liters).
30-56-14
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
Removal of hydraulic
motor shaft
30-56-15
2
TRAVEL MOTOR
30-56-16
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-17
2
TRAVEL MOTOR
30-56-18
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-19
2
TRAVEL MOTOR
30-56-20
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-21
2
TRAVEL MOTOR
30-56-22
2
PC228USLC-1
TRAVEL MOTOR
3. Removal of coupling
1) Remove coupling (15) from shaft (102).
PC228USLC-1
30-56-23
2
TRAVEL MOTOR
30-56-24
2
PC228USLC-1
TRAVEL MOTOR
5. Removal of clamps
1) Turn over the travel motor.
2) Remove the clamps (2 pieces).
Necessary tools
Clamp
PC228USLC-1
30-56-25
2
TRAVEL MOTOR
30-56-26
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-27
2
TRAVEL MOTOR
MAINTENANCE STANDARD
Disassemble and inspect the travel motor according to the following standard. Handle its parts
carefully. 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 are
free from damage.
2. Maintenance standard for worn parts
1) Replace all the parts which have visible extreme damages.
2) Replace the parts which have the following trouble (phenomenon).
Part
No.
Part name
Spindle kit
Spindle
Hold flange
Hexagon socket head bolt
Parallel pin
Plain washer
(2)
(3)
(19)
(34)
(37)
RV gear assembly
RV gear (A)
RV gear (B)
Crankshaft
Spacer bearing
Tapered roller bearing
Needle roller bearing with
retainer
(4)
(5)
(9)
(12)
(22)
(23)
13
20
Snap ring
21
Ball bearing
(301)
(323)
Spool
(381)
Piston
30-56-28
2
Trouble
Standard value
(Standard dimension)
Allowable value
(Criterion)
PC228USLC-1
Part
No.
Part name
TRAVEL MOTOR
Trouble
102
Shaft
Swash plate
Cylinder block
Clearance:
0.05 mm
Clearance:
0.15 mm
Braking torque:
Min. 398 Nm
{40.6 kgm}
Braking torque:
Max. 398 Nm
{40.6 kgm}
104
Allowable value
(Criterion)
103
Standard value
(Standard dimension)
Spline is worn.
Inside of bore is worn remarkably.
Sliding surface against timing
plate (109) is scratched and
worn unevenly.
(105)
(106)
Piston assembly
Piston
Shoe
107
Retainer plate
108
Thrust ball
109
Timing plate
115
116
Friction plate
Mating plate
149
150
There is bruise.
Surface is flaked.
Surface is worn unevenly.
363
Spool
201
Valve
202
Sleeve
PC228USLC-1
30-56-29
2
TRAVEL MOTOR
ASSEMBLY PROCEDURE
1. 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 Orings.
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.
Part name
Thread size
Qty
Tightening torque
709 108 Nm {72.3 11 kgm}
19
M24 (P3.0)
33
PF 1/2
35
M12 (P1.75)
12
202
Sleeve
PF 1
204
Plug
PF 1/2
324
Plug
M36 (P1.5)
326
Plug
M36 (P1.5)
343
M16 (P2.0)
12
346
Plug
PT 1/4
352
Plug
PF 1/4
354
NPTF 1/16
357
Plug
PF 1/2
380
Plug
PF 3/8
382
Plug
PF 1/8
398
PT 1/8
30-56-30
2
PC228USLC-1
TRAVEL MOTOR
2. ASSEMBLY PROCEDURE
2-1. ASSEMBLY OF BRAKE VALVE
1. Installation of check valve
1) Fit O-ring (337) to plug (326).
Apply grease to O-ring (337).
Necessary tools
Torque wrench
Wrench adapter, rod of size 14
2) Put spring (330) and valve (327) in plug (326).
Apply grease to valve (327) and spring (330)
and fix spring (330) temporarily.
Apply HERMSEAL to the threads of plug
(326).
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 spool
1) Insert spool (323) in rear flange (301).
Apply hydraulic oil to spool (323) and
insert it in rear flange (301).
When inserting the spool, align it with
rear flange hole.
A flaw on the rear flange hole or outside
of the spool can cause internal leakage
and lowering of performance of the travel
motor. Take care.
Necessary tools
Torque wrench
Wrench adapter, socket of size 41
2) Fit O-ring (336) to plug (324).
Apply grease to O-ring (336).
3) Install stopper (325) and spring (328) to plug
(324) and tighten plugs (324) (2 pieces) into
rear flange (301) to the specified torque.
3 Plug: 441 88.3 Nm {45 9 kgm}
Rear flange (301) and spool (323) are handles as a kit. If either of them needs to
be replaced, be sure to replace both of
them.
PC228USLC-1
30-56-31
2
TRAVEL MOTOR
30-56-32
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-33
2
TRAVEL MOTOR
30-56-34
2
PC228USLC-1
TRAVEL MOTOR
[A] ASSEMBLY
(page 30-56-36)
No
<Replaced part>
Hub (1)
Spindle kit
Ball bearing (21)
<Replaced part>
Spindle kit
RV gear assembly
Yes
When assembling after replacing the above parts, be sure to adjust each part. If the parts are put
together without adjustment, the travel motor will malfunction and will be broken soon.
PC228USLC-1
30-56-35
2
TRAVEL MOTOR
[A] ASSEMBLY
1. 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] and
hammer [1].
Necessary tools
Press fitting jig
Hammer
30-56-36
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-37
2
TRAVEL MOTOR
30-56-38
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-39
2
TRAVEL MOTOR
30-56-40
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-41
2
TRAVEL MOTOR
30-56-42
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-43
2
TRAVEL MOTOR
30-56-44
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
A: Measured value
B: Dimension of jig
C: Clearance
30-56-45
2
TRAVEL MOTOR
30-56-46
2
PC228USLC-1
TRAVEL MOTOR
1. Lightly hit the outer race of tapered roller bearing (22) installed to crankshaft (9) of the RV gear
assembly with holder [IV] and hammer.
Perform this procedure to insert the RV gear
assembly in spindle (2) securely.
Necessary tools
Holder [IV]
Hammer
Thickness gauge
PC228USLC-1
30-56-47
2
TRAVEL MOTOR
30-56-48
2
PC228USLC-1
TRAVEL MOTOR
PC228USLC-1
30-56-49
2
TRAVEL MOTOR
PERFORMANCE TEST
After maintaining the travel motor, execute the performance test according to the following
procedure.
1) Necessary measuring tools
1
Pressure gauge
(For 3.4 MPa {35 kg/cm2})
2 pieces
1 piece
Stopwatch
1 piece
2) Test procedure
1
High
Pressure
Revolving
direction
Operation
time
No load
Gear
speed
Low
Min. 1 minute
each
20 rpm
Accepted
Install tracks.
30-56-50
2
Rejected
PC228USLC-1
TRAVEL MOTOR
Dimension
Unit: mm
Classification
No.
E
PC228USLC-1
Dimension (T)
30-56-51
2