Komatsu Backhoe Pc228uslc-1 (Manual) PDF

SEBM015903
1
PC228US-2
PC228USLC-1, 2
MACHINE MODEL SERIAL NUMBER
PC228USLC-1 11001 and up

PC228US-2 15001 and up
PC228USLC-2 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.
• PC228US, PC228USLC mount the S6D102E-1 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
© 2003 1
All Rights Reserved 00-1
Printed in Japan 05-03(01) (3)
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 PC228USLC-1
1
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary actions Mark Indication Action required
be taken to these pages according to the table below.
fi Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
LIST OF REVISED PAGE
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
‡ 00- 1 (3) 01- 1 10-10 10-39 10-66

00- 2 (1) 01- 2 (1) 10-11 10-40 10-68
‡ 00- 2-1 (3) 01- 2-1 (1) 10-12 10-41 10-69
‡ 00- 2-2 (3) 01- 3 10-13 10-42 10-70
‡ 00- 2-3 (3) 01- 4 (2) 10-14 10-43 10-71
‡ 00- 2-4 (3) 01- 4-1 (1) 10-15 10-44 10-72
00- 3 01- 4-2 (2) 10-16 10-46 10-73
00- 4 01- 4-3 (1) 10-17 10-47 10-74
00- 5 01- 4-4 (1) 10-18 10-48 10-75
00- 6 01- 5 10-19 10-49 10-76
00- 7 01- 6 10-20 10-50 10-77
00- 8 01- 6-1 (1) 10-21 10-51 10-78
00- 9 01- 6-2 (1) 10-22 10-52 10-79
00-10 01- 6-3 (1) 10-23 10-53 10-80
00-11 01- 6-4 (1) 10-24 10-54 10-81
00-12 01- 7 10-25 10-55 10-82
00-13 01- 8 10-26 10-56 10-83
00-14 10-27 10-57 10-84
00-15 10-28 10-58 10-85
00-16 10- 1 10-29 10-59 10-86
00-17 10- 2 10-30 10-60 10-87
00-18 10- 3 10-31 10-61 10-88
00-19 10- 4 10-32 10-62 10-89
00-20 10- 5 10-34 10-63 10-90
00-21 10- 6 10-35 10-64 10-91
00-22 10- 7 10-36 10-65 10-92
10- 8 10-37 10-65-1 (2) 10-93
10- 9 10-38 10-65-2 (2) 10-94
PC228USLC-1 00-2-1
(3)

10-95 20-17 20-136 20-228 20-351

10-96 20-18 20-137 20-229 20-352
10-97 20-19 20-138 20-230 20-354
10-98 20-20 20-139 20-231 20-355
10-99 20-140 20-232 20-356
10-100 20-101 20-141 20-233 20-357
10-101 20-102 20-142 20-234 20-358
10-102 20-103 20-143 20-235 20-359
10-103 20-104 20-144 20-236 20-360
10-104 20-105 20-145 20-237 20-361
10-105 20-106 20-146 20-238 20-362
10-106 20-107 20-147 20-239 20-363
10-107 20-108 20-148 20-240 20-364
10-108 20-109 20-241 20-365
10-109 20-110 20-201 20-242 20-366
10-110 20-111 20-202 20-367
10-111 20-112 20-203 20-301 20-368
10-112 20-113 20-204 20-302 20-369
10-113 20-114 20-205 20-303 20-370
10-114 20-115 20-206 20-304 20-371
10-115 20-116 20-207 20-305 20-372
10-116 20-117 20-208 20-306 20-373
20-118 20-209 20-307 20-374
20-119 20-210 20-308 20-375
20- 1 20-120 20-211 20-309 20-376
20- 2 20-121 20-212 20-310 20-377
20- 3 20-122 20-213 20-311 20-378
‡ 20- 4 (3) 20-123 20-214 20-312 20-379
20- 5 20-124 20-215 20-313 20-380
20- 6 20-125 20-216 20-314 20-381
20- 7 20-126 20-217 20-315 20-382
20- 8 20-127 20-218 20-316 20-383
‡ 20- 9 (3) 20-128 20-220 20-317 20-384
20-10 20-129 20-221 20-318 20-385
20-11 20-130 20-222 20-319 20-386
20-12 20-131 20-223 20-320 20-387
20-13 20-132 20-224 20-321 20-388
20-14 20-133 20-225 20-322 20-389
20-15 20-134 20-226 20-323 20-390
20-16 20-135 20-227 20-391
00-2-2 PC228USLC-1
(3)

20-401 20-483 30-22 (1) 30-56-6 (2) 30-56-46 (2)

20-402 20-484 30-23 (1) 30-56-7 (2) 30-56-47 (2)
20-403 30-24 (1) 30-56-8 (2) 30-56-48 (2)
20-404 20-501 30-25 (1) 30-56-9 (2) 30-56-49 (2)
20-405 20-502 30-26 (1) 30-56-10 (2) 30-56-50 (2)
20-406 20-503 30-27 (1) 30-56-11 (2) 30-56-51 (2)
20-407 20-504 30-28 (1) 30-56-12 (2) 30-57 (1)
20-408 20-505 30-29 (1) 30-56-13 (2) 30-58 (1)
20-409 20-506 30-30 (1) 30-56-14 (2) 30-59 (1)
20-507 30-31 (1) 30-56-15 (2) 30-60 (1)
20-451 20-508 30-32 (1) 30-56-16 (2) 30-61 (1)
20-452 20-509 30-33 (1) 30-56-17 (2) 30-62 (1)
20-453 20-510 30-34 (1) 30-56-18 (2) 30-63 (1)
20-454 20-511 30-35 (1) 30-56-19 (2) 30-64 (1)
20-455 20-512 30-36 (1) 30-56-20 (2) 30-65 (1)
20-456 20-513 30-37 (1) 30-56-21 (2) 30-66 (1)
20-458 20-514 30-38 (1) 30-56-22 (2) 30-67 (1)
20-459 30-39 (1) 30-56-23 (2) 30-68 (1)
20-460 30-40 (1) 30-56-24 (2) 30-69 (1)
20-461 30- 1 (2) 30-41 (1) 30-56-25 (2) 30-70 (1)
20-462 30- 2 (1) 30-42 (1) 30-56-26 (2) 30-71 (1)
20-464 30- 3 (1) 30-43 (1) 30-56-27 (2) 30-72 (1)
20-465 30- 4 (1) 30-44 (1) 30-56-28 (2) 30-73 (1)
20-466 30- 5 (1) 30-45 (1) 30-56-29 (2) 30-74 (1)
20-467 30- 6 (1) 30-46 (1) 30-56-30 (2) 30-75 (1)
20-468 30- 7 (1) 30-47 (1) 30-56-31 (2) 30-76 (1)
20-469 30- 8 (1) 30-48 (1) 30-56-32 (2) 30-77 (1)
20-470 30- 9 (1) 30-49 (1) 30-56-33 (2) 30-78 (1)
20-471 30-10 (1) 30-50 (1) 30-56-34 (2) 30-79 (1)
20-472 30-11 (1) 30-51 (1) 30-56-35 (2) 30-80 (1)
20-473 30-12 (1) 30-52 (1) 30-56-36 (2) 30-81 (1)
20-474 30-13 (1) 30-53 (1) 30-56-37 (2) 30-82 (1)
20-475 30-14 (1) 30-54 (1) 30-56-38 (2) 30-83 (1)
20-476 30-15 (1) 30-55 (1) 30-56-39 (2) 30-84 (1)
20-477 30-16 (1) 30-56 (1) 30-56-40 (2) 30-85 (1)
20-478 30-17 (1) 30-56-1 (2) 30-56-41 (2) 30-86 (1)
20-479 30-18 (1) 30-56-2 (2) 30-56-42 (2) 30-87 (1)
20-480 30-19 (1) 30-56-3 (2) 30-56-43 (2) 30-88 (1)
20-481 30-20 (1) 30-56-4 (2) 30-56-44 (2) 30-89 (1)
20-482 30-21 (1) 30-56-5 (2) 30-56-45 (2) 30-90 (1)
PC228USLC-1 00-2-3
(3)

30-91 (1) 30-131 (1) 30-176 (1) 40-37

30-92 (1) 30-132 (1) 30-177 (1) 40-38
30-93 (1) 30-133 (1) 30-178 (1) 40-40
30-94 (1) 30-134 (1) 30-179 (1) 40-41
30-95 (1) 30-135 (1) 30-180 (1) 40-42
30-96 (1) 30-136 (1) 40-43
30-97 (1) 30-137 (1) 40-44
30-98 (1) 30-138 (1) 40- 1 40-45
30-99 (1) 30-139 (1) 40- 2 40-46
30-100 (1) 30-140 (1) 40- 3 40-47
30-101 (1) 30-141 (1) 40- 4
30-102 (1) 30-142 (1) 40- 6 90- 1 (1)
30-103 (1) 30-144 (1) 40- 7 90- 3
30-104 (1) 30-146 (1) 40- 8 90- 3-2 (1)
30-105 (1) 30-147 (1) 40-10 90- 5
30-106 (1) 30-148 (1) 40-11 90- 7 (1)
30-107 (1) 30-149 (1) 40-12
30-108 (1) 30-150 (1) 40-13
30-109 (1) 30-151 (1) 40-14
30-110 (1) 30-152 (1) 40-15
30-111 (1) 30-153 (1) 40-16
30-112 (1) 30-155 (1) 40-17
30-113 (1) 30-156 (1) 40-18
30-114 (1) 30-157 (1) 40-20
30-115 (1) 30-158 (1) 40-21
30-116 (1) 30-159 (1) 40-22
30-117 (1) 30-160 (1) 40-23
30-118 (1) 30-161 (1) 40-24
30-119 (1) 30-162 (1) 40-25
30-120 (1) 30-163 (1) 40-26
30-121 (1) 30-164 (1) 40-27
30-122 (1) 30-165 (1) 40-28
30-123 (1) 30-166 (1) 40-29
30-124 (1) 30-168 (1) 40-30
30-125 (1) 30-170 (1) 40-31
30-126 (1) 30-171 (1) 40-32
30-127 (1) 30-172 (1) 40-33
30-128 (1) 30-173 (1) 40-34
30-129 (1) 30-174 (1) 40-35
30-130 (1) 30-175 (1) 40-36
00-2-4 PC228USLC-1
(3)
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.
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 actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
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 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 service
workshop. 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 FUNCTION

This 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 ADJUSTING

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This 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 any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic 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)
★ 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 it
clicks. (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.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ 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)
★ 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
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ 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 Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl or ide) ,
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
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.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
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 in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
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.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
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.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 0
8 2 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.
mm Nm kgm
1 / 16 0
3 1 0.31 0 0.10
1/8 0
8 2 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In 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
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
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
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C 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.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 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 1 2 3 4 5 6 7 8 9
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
Liter to U.S. Gallon

l
1 = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 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
Liter to U.K. Gallon

l
1 = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 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
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 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
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 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
Temperature
Fahrenheit-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 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.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
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
Bucket capacity m3 0.8

Operating weight kg 22,900
Max. digging depth mm 6,810

Working ranges
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

Performance
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

Dimensions
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
PC228USLC-1 01-3

Model S6D102E-1-A
Type 4-cycle, water-cooled, in-line, vertical,
direct injection, with turbocharger
No. of cylinders – bore × stroke mm 6 – 102 × 120
Piston displacement ¬ {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 96/2,000 {128/2,000}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 545.3/1,350 {55.6/1,350}

Max. speed at no load rpm 2,170 +70
–40
Min. speed at no load rpm 970 ± 60

Min. fuel consumption g/kWh {g/HPh} 218 {160}
Starting motor 24V, 4.5 kW
Alternator 24V, 50A
Battery 12V, 110 Ah × 2
Radiator core type Corrugated CWX-4
Carrier roller 2 on each side
carriage
Under-
Track roller 9 on each side

Track shoe Triple grouser, 49 on each side
Type × no. HPV95+95, variable displacement
Hydraulic
piston type × 2
pump
Delivery ¬/min Piston type: 206 × 2

2
Set pressure MPa {kg/cm } Piston type: 34.8 {355}
Type × No. 6-spool type × 1
Control
valve
Control method Hydraulic

Travel motor GM38VL, Piston type
Hydraulic
(with brake valve, parking brake: × 2

motor
Hydraulic system
Swing motor KMF90AEL-3, Piston type

(with safety valve, parking brake): × 1
Boom Arm Bucket
Hydraulic cylinder
Type Double acting Double acting Double acting

piston piston piston
Inside diameter of cylinder mm 120 135 130
Diameter of piston rod mm 85 95 90
Stroke mm 1,285 1,490 1,020
Max. distance between pins mm 3,155 3,565 2,625
Min. distance between pins mm 1,870 2,075 1,605
Hydraulic tank Box-shaped, sealed
Hydraulic filter Tank return side
Hydraulic cooler CFT-1 (Air cooled)
01-4 PC228USLC-1
2
Machine model PC228US-2
Bucket capacity m3 0.8

Operating weight kg 21,800
Max. digging depth mm 6,810

Working ranges
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

Performance
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

Dimensions
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
PC228USLC-1 01-4-1
1
Machine model PC228US-2

Model S6D102E-1-F
Type 4-cycle, water-cooled, in-line, vertical,
direct injection, with turbocharger
No. of cylinders – bore × stroke mm 6 – 102 × 120
Piston displacement ¬ {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 96/2,000 {128/2,000}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 545.3/1,350 {55.6/1,350}

Max. speed at no load rpm 2,170 +70
–40
Min. speed at no load rpm 970 ± 60

Min. fuel consumption g/kWh {g/HPh} 218 {160}
Starting motor 24V, 4.5 kW
Alternator 24V, 35A
Battery 12V, 110 Ah × 2
Radiator core type Corrugated CWX-4
Carrier roller 2 on each side
carriage
Under-
Track roller 7 on each side

Track shoe Triple grouser, 45 on each side
Type × no. HPV95+95, variable displacement
Hydraulic
piston type × 2
pump
Delivery ¬/min Piston type: 206 × 2

2
Set pressure MPa {kg/cm } Piston type: 37.2 {380}
Type × No. 6-spool type × 1
Control
valve
Control method Hydraulic

Travel motor GM38VL, Piston type
Hydraulic
(with brake valve, parking brake): × 2

motor
Hydraulic system
Swing motor KMF90ABE-3, Piston type

(with safety valve, parking brake): × 1
Boom Arm Bucket
Hydraulic cylinder
Type Double acting Double acting Double acting

piston piston piston
Inside diameter of cylinder mm 120 135 130
Diameter of piston rod mm 85 95 90
Stroke mm 1,285 1,490 1,020
Max. distance between pins mm 3,155 3,565 2,625
Min. distance between pins mm 1,870 2,075 1,605
Hydraulic tank Box-shaped, sealed
Hydraulic filter Tank return side
Hydraulic cooler CFT-1 (Air cooled)
01-4-2 PC228USLC-1
2
STRUCTURE AND FUNCTION TRAVEL MOTOR
3) When starting travel (or during normal

travel)
• When the travel lever is operated, the pres-
sure oil from the pump moves counterbal-
ance valve spool (19) to the right. When this
happens, the passage to the suction-safety
valve becomes the circuit flowing through
the small notch in the counterbalance valve
spool. As a result, a big difference in pres-
sure is created, and the pump pressure rises
to provide a powerful drawbar pull. (Fig. 7)
PC228USLC-1 10-65
PC228USLC-1, 2
GM38VL
A. From control valve Specifications

B. From control valve Type : GM38VL
D1. Drain port (to tank) (L.H. travel motor) Theoretical delivery : 140.5 cc/rev
D2. Drain port (to tank) (R.H. travel motor) 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
10-65-1 PC228USLC-1
2
1. Plug 12. Spring 23. Cover

2. Spring 13. Plate 24. spur gear
3. Valve 14. Disc 25. Input gear
4. Spool 15. Swash plate 26. Hold flange
5. Spring 16. Pivot 27. Piston
6. Valve 17. Spindle 28. Shoe
7. Spring 18. Floating seal 29. Shaft
8. Sleeve 19. Hub 30. Shoe
9. End cover 20. RV gear A 31. Piston
10. Cylinder block 21. RV gear B 32. Spring
11. Piston 22. Crankshaft 33. Timing plate
PC228USLC-1 10-65-2
2
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
Lever positions
1. Travel PPC valve 8. Control valve 1 HOLD 9 Swing RIGHT
2. L.H. travel lever 9. Hydraulic pump 2 Boom RAISE 0 Swing LEFT
3. R.H. travel lever 10. L.H. work equipment 3 Boom LOWER A NEUTRAL
4. Solenoid block lever 4 Bucket DUMP B Travel REVERSE
5. Accumulator 11. L.H. PPC valve 5 Bucket CURL C Travel FORWARD
6. R.H. PPC valve 12. Safety lock lever 6 HOLD D LOCK
7. R.H. work equipment 7 Arm IN E FREE
lever 8 Arm OUT
10-66 PC228USLC-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 1,800 —
Rated
Engine speed rpm
speed Traveling 2,000 —
At sudden acceleration Max. 1.0 2.0

Bosch
Exhaust gas color
index
At high idling Max. 0.5 1.5
(normal temperature)
Intake valve mm 0.25 —
Valve clearance
Exhaust valve 0.51 —
Oil temperature: Difference between

40 – 60°C MPa Min. 2.4 cylinders
Compression pressure
(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)
Oil pressure At high idling MPa 0.39 – 0.52 0.25

(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}
Whole speed range

Oil temperature (inside oil pan) °C 80 – 110 120
Before top dead center ° 18 ± 1 18 ± 1

Fuel injection timing (B.T.D.C.) (degree)
Deflection Min. 10
when Fan-tension 8
pressed Max. 6
Belt tension with finger mm
force of Fan–
approx. air conditioner 5–8 5–8
58.8N{6kg} compressor
PC228USLC-1 20-3
‡ FOR CHASSIS
Applicable model PC228USLC-1
Cate- Item Measurement conditions Unit Standard value Permissible value

gory
At WORK · Hydraulic oil temperature: 2,200 ± 70 —
High idling 45 – 55°C
At TRAVEL
· Coolant temperature: 2,200 ± 70 —
Engine speed
Low idling Within operating range 970 ± 50

· 2-pump relief: Arm relief
rpm
2 pumps at relief 1,850 ± 100 —
Speed when auto- · Fuel control dial at MAX. 1,400 ± 120 1,400 ± 120
deceleration is operated · Control lever at neutral
a b a b
Boom control valve
Spool stroke
Arm control valve
Bucket control valve 9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5
Swing control valve
Travel control valve
· Center of lever knob Max. 110

Boom control lever mm 100 ± 10 Min. 90
· Read max. value to end of
Travel of control levers
travel Max. 110

Arm control lever 100± 10
· Engine stopped Min. 90
· Excluding neutral play Max. 110
Bucket control lever 100± 10 Min. 90
Max. 110
Swing control lever 100 ± 10 Min. 90
Max. 127
Travel control lever 115 ± 12 Min. 103
Play of control lever Max. 10 Max. 15

15.7 ± 3.9 Max. 24.5
Operating force of control levers
Boom control lever · Engine at high idling

· Oil temperature: 45 – 55°C {1.6 ± 0.4} {Max. 2.5}
· Fit push-pull scale to center 15.7 ± 3.9 Max. 24.5
Arm control lever {1.6 ± 0.4} {Max. 2.5}
of control lever knob to
measure 13.7 ± 2.9 Max. 22.6
Bucket control lever · Measure max. value to end {1.4 ± 0.3} {Max. 2.3}
N
of travel {kg} 13.7 ± 2.9 Max. 22.6
Swing control lever {1.4 ± 0.3} {Max. 2.3}
24.5 ± 5.9 Max. 39.2
Lever {2.5 ± 0.6} {Max. 4.0}
Travel control lever
74.5 ± 18.6 Max. 107.6
Pedal {7.6 ± 1.9} {Max. 11}
20-4 PC228USLC-1
(3)

gory
RAISE
Boom
4.4 ± 0.5 Max. 5.2
Bucket teeth in
contact with ground
↔
LOWER
Cylinder fully · Engine at high idling
extended · Hydraulic oil temperature: 4.0 ± 0.4 Max. 4.4
45 – 55°C
Work equipment speed
Arm 3.6 ± 0.4 Max. 4.5

IN
(To Just before cushion) (To Just before cushion)
Cylinder fully
retracted
↔
2.9 ± 0.3
OUT
· Engine at high idling Max. 3.5

Fully extended (To Just before cushion) (To Just before cushion)
· Hydraulic oil temperature:
45 – 55°C
CURL
Bucket 2.6 ± 0.4 Max. 3.3

Work equipment
Cylinder fully
retracted
↔
DUMP
Fully extended · Engine at high idling sec 2.1 ± 0.3 Max. 2.7
45 – 55°C
Boom BKP00114 Max. 1.0 Max. 1.2

· Lower boom and measure time
taken from point where bucket
contacts ground to point where
chassis rises from ground
· Engine at low idling
Time lag

45 – 55°C
Arm Max. 1.0 Max. 2.8

BKP00115
· Stop arm suddenly and measure

time taken for arm to stop
45 – 55°C
PC228USLC-1 20-9
(3)

gory
Time lag
Work equipment
BKP00116
Bucket sec. Max. 1.0 Max. 3.6
· Stop bucket suddenly and

measure time taken for bucket
to stop at bottom and then
start again.
45 – 55°C
Internal leakage
Cylinders · Hydraulic oil temperature: 4.5 20

45 – 55°C
cc/min
· Engine at high idling
Center swivel joint · Relieve circuit to be measured 10 50
· Engine at high idling

Performance in compound operation

45 – 55°C
fl Use a hard horizontal surface.
Travel deviation when 20m

work equipment + mm Max. 200 Max. 220
travel are operated
10m BKP00107
fl Measure dimension χ.
Performance of hydraulic pump
Hydraulic pump delivery
Piston pump See next page See next page
20-10 PC228USLC-1
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................... 30- 3 SPROCKET

PRECAUTIONS WHEN CARRYING Removal and Installation ...................... 30-47
OUT OPERATION ................................... 30- 5 FINAL DRIVE, TRAVEL MOTOR
SPECIAL TOOL LIST ..................................... 30- 7 Removal and Installation ...................... 30-48
SKETCHES OF SPECIAL TOOLS ................. 30- 9 FINAL DRIVE
STARTING MOTOR Disassembly ........................................... 30-49
Removal and Installation ...................... 30-12 Assembly ................................................ 30-52
ALTERNATOR TRAVEL MOTOR
Removal and Installation ...................... 30-13 Disassembly and Assembly .............. 30-56-1
ENGINE OIL COOLER CORE SWING MOTOR, SWING MACHINERY
Removal and Installation ...................... 30-14 Removal and Installation ...................... 30-57
FUEL INJECTION PUMP SWING MACHINERY
Removal .................................................. 30-15 Disassembly ........................................... 30-58
Installation .............................................. 30-18 Assembly ................................................ 30-62
WATER PUMP SWING MOTOR
NOZZLE HOLDER REVOLVING FRAME
Removal and Installation ...................... 30-21 Removal .................................................. 30-68
TURBOCHARGER Installation .............................................. 30-69
Removal and Installation ...................... 30-22 SWING CIRCLE
THERMOSTAT Removal .................................................. 30-70
Removal and Installation ...................... 30-23 Installation .............................................. 30-71
CYLINDER HEAD IDLER, RECOIL SPRING
Removal .................................................. 30-24 Removal and Installation ...................... 30-72
Installation .............................................. 30-28 RECOIL SPRING
ENGINE, MAIN PUMP Disassembly ........................................... 30-73
Removal .................................................. 30-31 Assembly ................................................ 30-74
Installation .............................................. 30-34 IDLER
DAMPER Disassembly ........................................... 30-75
Removal and Installation ...................... 30-35 Assembly ................................................ 30-76
ENGINE FRONT SEAL TRACK ROLLER
ENGINE REAR SEAL Disassembly ........................................... 30-79
Removal .................................................. 30-38 Assembly ................................................ 30-80
Installation .............................................. 30-39 CARRIER ROLLER
RADIATOR, HYDRAULIC COOLER Removal and Installation ...................... 30-82
Removal .................................................. 30-40 Disassembly ........................................... 30-83
Installation .............................................. 30-41 Assembly ................................................ 30-84
FUEL TANK TRACK SHOE
Removal .................................................. 30-42 Removal and Installation ...................... 30-86
Installation .............................................. 30-43 HYDRAULIC TANK
CENTER SWIVEL JOINT Removal and Installation ...................... 30-87
Removal .................................................. 30-44 MAIN PUMP
Installation .............................................. 30-45 Removal ................................................ 30- 88
CENTER SWIVEL JOINT Installation ............................................ 30- 89
Disassembly and Assembly .................. 30-46
PC228USLC-1 30-1
2
EPC VALVE OFFSET CYLINDER
Removal and Installation .................... 30- 90 Removal ................................................ 30-130
PC VALVE Installation ............................................ 30-131
Removal and Installation .................... 30- 91 HYDRAULIC CYLINDER FOR OFFSET
LS VALVE Disassembly ......................................... 30-132
Removal and Installation .................... 30- 92 Assembly .............................................. 30-134
CONTROL VALVE HYDRAULIC CYLINDER FOR BOOM,
Removal ................................................ 30- 93 ARM, BUCKET
Installation ............................................ 30- 95 Disassembly ......................................... 30-136
Disassembly ......................................... 30- 96 Assembly .............................................. 30-139
Assembly .............................................. 30-101 BUCKET
LS SELECT VALVE Removal ................................................ 30-144
Disassembly and Assembly ................ 30-107 Installation ............................................ 30-145
PRESSURE COMPENSATION VALVE ARM
Disassembly ......................................... 30-108 Removal ................................................ 30-146
Assembly .............................................. 30-109 Installation ............................................ 30-147
MAIN RELIEF VALVE BUCKET, ARM
Removal and Installation .................... 30-110 Removal ................................................ 30-150
Disassembly and Assembly ................ 30-111 Installation ............................................ 30-151
SOLENOID VALVE OFFSET BRACKET
Removal and Installation .................... 30-112 Removal and Installation .................... 30-155
PUMP MERGE/DIVIDER SECOND BOOM
SOLENOID VALVE Removal ................................................ 30-156
Removal and Installation .................... 30-113 Installation ............................................ 30-157
2-STAGE RELIEF, TRAVEL HI/LO FIRST BOOM
INTERFERENCE PREVENTION SECOND, FIRST BOOM
LEFT WORK EQUIPMENT PPC VALVE OFFSET BRACKET, SECOND,
(FOR SWING, ARM CONTROL) FIRST BOOM
RIGHT WORK EQUIPMENT PPC VALVE Installation ............................................ 30-166
(FOR BOOM, BUCKET CONTROL) BOOM
WORK EQUIPMENT PPC VALVE Installation ............................................ 30-169
(PPC VALVE FOR BOOM, BUCKET, OPERATOR’S CAB
ARM, SWING CONTROL) Removal ................................................ 30-170
Disassembly ......................................... 30-118 Installation ............................................ 30-171
Assembly .............................................. 30-119 FLOOR FRAME
TRAVEL PPC VALVE Removal ................................................ 30-172
Disassembly and Assembly ................ 30-121 AIR CONDITIONER COMPRESSOR
PPC VALVE FOR OFFSET CONTROL Removal and Installation .................... 30-174
Removal and Installation .................... 30-122 AIR CONDITIONER CONDENSER
BOOM LOCK VALVE Removal and Installation .................... 30-175
Removal and Installation .................... 30-123 AIR CONDITIONER UNIT
BOOM CYLINDER Removal ................................................ 30-176
Removal ................................................ 30-124 Installation ............................................ 30-177
Installation ............................................ 30-125 COUNTERWEIGHT
ARM CYLINDER Removal and Installation .................... 30-178
Removal ................................................ 30-126 CONTROLLER
Installation ............................................ 30-127 Removal and Installation .................... 30-179
BUCKET CYLINDER MONITOR
Removal ................................................ 30-128 Removal and Installation .................... 30-180
Installation ............................................ 30-129
30-2 PC228USLC-1
1
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR

GM38VL
CONTENTS
ASSEMBLY DRAWINGS .................................................................................................................... 30-56- 2

PARTS LIST ......................................................................................................................................... 30-56- 8
TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY ........................................................................ 30-56-10
1. Standard tools ....................................................................................................................... 30-56-10
2. Manufactured tools ............................................................................................................... 30-56-11
DISASSEMBLY PROCEDURE ............................................................................................................ 30-56-13
1. General precautions .............................................................................................................. 30-56-13
2. Disassembly procedure ........................................................................................................ 30-56-14
2-1. Disassembly of brake valve .......................................................................................... 30-56-16
2-2. Disassembly of hydraulic motor .................................................................................. 30-56-20
2-3. Disassembly of reduction gear assembly ................................................................... 30-56-23
MAINTENANCE STANDARD ............................................................................................................. 30-56-28
1. Seals ....................................................................................................................................... 30-56-28
2. Maintenance standard for worn parts ................................................................................. 30-56-28
ASSEMBLY PROCEDURE .................................................................................................................. 30-56-30
1. General precautions .............................................................................................................. 30-56-30
2. Assembly procedure ............................................................................................................. 30-56-31
2-1. Assembly of brake valve .............................................................................................. 30-56-31
2-2. Assembly of reduction gear assembly and hydraulic motor .................................... 30-56-35
PERFORMANCE TEST ........................................................................................................................ 30-56-50
LIST OF CLEARANCE ADJUSTMENT PARTS .................................................................................. 30-56-51
PC228USLC-1 30-56-1
2
30-56-2 PC228USLC-1
2
PC228USLC-1 30-56-3
2
REDUCTION GEAR
30-56-4 PC228USLC-1
2
PC228USLC-1 30-56-5
2
HYDRAULIC MOTOR
RELIEF VALVE
CONTROL VALVE
30-56-6 PC228USLC-1
2
PC228USLC-1 30-56-7
2
PARTS LIST
No. Part name Q’ty No. Part name Q’ty
REDUCTION GEAR 1 HYDRAULIC MOTOR 1
1 Hub 1
Spindle kit 1 Cylinder & piston kit 1
• Spindle ass’y 1 • Piston kit 1
2 • • Spindle 1 • • Piston assembly 9
3 • • Hold flange 1 105 • • Piston 1
19 • Hexagon socket head bolt 3 106 • • • Shoe 1
34 • Parallel pin 6 104 • Cylinder block 1
(select one from 3 kinds) 107 • Retainer plate 1
37 • Plain washer 3 108 • Thrust ball 1
110 • Washer 2
RV gear assembly kit 1 111 • Washer 1
• RV gear kit 1 114 • Spring 1
4 • • RV gear A 1 145 • C-type snap ring for hole 1
5 • • RV gear B 1 151 • Needle roller 5
9 • Crankshaft 3
12 • Spacer 6 Piston assembly 1
22 • Tapered roller bearing 6 161 • Piston 1
23 • Needle roller bearing 6 162 • Shoe 1
6 Input gear 1 102 Shaft 1

103 Swash plate 1
Spur gear kit 1 109 Timing plate 1
7 • Spur gear 3 112 Piston 1
113 Spring 12
8 Cover 1 115 Friction plate 2
13 Distance piece 3 116 Mating plate 2
t: Above 3.30, up to 3.15 132 Oil seal 1
↓ <at interval of 0.05> 135 O-ring 1
t: Above 4.10 up to 4.15 139 O-ring 1
15 Coupling 1 149 Deep groove ball bearing 1
17 Pin 24 150 Deep groove ball bearing 1
20 C-type snap ring for hole 3 167 Pivot 2
21 Ball bearing 2 171 Parallel pin 2
25 C-type snap for shaft 3 173 Spring 1
27 O-ring 2
29 O-ring 1
30 O-ring 1
Floating seal kit 1

31 • Floating seal 2
33 Hexagon socket head plug 3

35 Hexagon socket head bolt 12
36 Ball 1
42 Parallel pin 2
43 O-ring 3
30-56-8 PC228USLC-1
2
No. Part name Q’ty No. Part name Q’ty

RELIEF VALVE 2 398 • Hexagon socket head plug 4
399 • Name plate 1
Valve kit 1 400 • Square head plug 2
201 • Valve 1
202 • Sleeve 1 341 • Parallel pin 1
203 • Spring retainer 1 343 • Hexagon socket head bolt 12
204 • Plug 1
205 • Shim 1
206 • Spring 1
208 • O-ring 1
209 • O-ring 1
210 • O-ring 1
211 • Back-up ring 2
217 • Back-up ring 2
219 • O-ring 1
220 • Piston seal 1
CONTROL VALVE 1
Rear flange assembly 1

• Rear flange kit 1
301 • • Rear flange 1
323 • • Spool 1
381 • • Piston 1
321 • Plug 1
324 • Plug 2
325 • Stopper 2
326 • Plug 2
327 • Valve 2
328 • Spring 2
330 • Spring 2
336 • O-ring 2
337 • O-ring 2
352 • Plug 2
354 • Hexagon socket head plug 7
355 • O-ring 1
357 • Plug 1
358 • O-ring 2
359 • O-ring 2
363 • Spool 1
366 • Spring 1
368 • Ball 2
373 • O-ring 1
379 • Filter 1
380 • Plug 2
382 • Plug 2
383 • O-ring 2
384 • O-ring 2
385 • Ball 2
397 • Orifice 1
PC228USLC-1 30-56-9
2
TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY

1. Standard tools
• Necessary tools for disassembly and assembly of GM38VL are shown below.
No. Name Model/Dimensions Q’ty
1 Hexagonal wrench 6 (For M8) (PF 1/4) 5 (PF 1/8) 1 each

10 (For M12) (PF 1/2) 8 (PF 3/8) 1 each
14 (For M16) 1 each
2 Socket wrench 1
(Ratchet handle)
3 Torque wrench Dial type for about 280 N 1

Dial 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 1

For hole 1
10 Sling parts Sling load: Min. 2,942 N {300 kg} 1 set

Eyebolt (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 set
Capacity: 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 1
Min. 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})
30-56-10 PC228USLC-1
2
2. Manufactured tools
No. Name and major dimensions Q’ty No. Name and major dimensions Q’ty
1 Preload adjustment jig for main bearing 1 6 Holder (III) 1
7 Holder (IV) 1
2 Clamp 2
8 Pointed punch 1
3 Press fitting jig 1 9 Steel rod 1
4 Holder (I) 1 10 Aluminum rod 1
11 Sling jig 1
5 Holder (II) 1
PC228USLC-1 30-56-11
2
No. Name and major dimensions Q’ty No. Name and major dimensions Q’ty
12 Floating seal fitting jig (I) 1 17 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
30-56-12 PC228USLC-1
2
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
2. DISASSEMBLY PROCEDURE
fl 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)
1) Remove the relief valve from rear 1) Remove hexagon socket head
flange (301). bolts (343) (12 pieces).
2) Remove O-rings (208), (209), and fl Necessary tools
(210) and backup rings (211) • Socket wrench
(2 pieces), and (217) (2 pieces) • Extension bar
from the relief valve. • Wrench adapter, rod of size 14
 Do not reuse removed O-ring (138).
fl Necessary tools
• Impact wrench or ratchet handle
• Wrench adapter, socket of size 32
(Disassembly of shaft and oil seals of reduction gear assembly and

hydraulic motor)
1) Turn the work table 180 degrees 1) Install eyebolts (2 pieces) to

so that cover (8) of the travel threaded plug holes (PF 1/2).
motor will be directed up. 2) Install hooks to the eyebolts and lift
2) Remove hexagon socket head off cover (8).
plugs (33) (3 pieces).  If the cover is not removed be-
3) Remove hexagon socket head cause of resistance of O-ring (30),
bolts (35) (12 pieces). hit the rim of the cover with a
fl Necessary tools plastic hammer.
• Ratchet handle 3) Remove O-ring (30) from cover (8).
• Wrench adapter, rod of size 10  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)
30-56-14 PC228USLC-1
2
See disassembly procedure

for brake valve
1) Remove rear flange (301) from

spindle (2).
Take care, since shaft (102) may See disassembly procedure
be removed, too. for hydraulic motor
1) Remove timing plate (109),

parallel pin (341) (1 piece),
springs (113) (12 pieces), and Removal of hydraulic
deep groove ball bearing (150) motor shaft
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).
See disassembly procedure for
reduction gear assembly
PC228USLC-1 30-56-15
2
2-1. DISASSEMBLY OF BRAKE VALVE

1. 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 of
work.
fl Do not reuse removed O-ring (336).
fl Necessary tools
• Socket wrench
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 rear
flange (301).
fl Slant rear flange (301) with either plug
port down, and spool (323) slides down.
Hold the end of the spool and take it
out.
2. Removal of check valve

1) Take plugs (326) (2 pieces) out of rear flange
(301).
fl Loosen the plugs when the motor is on
work.
fl Necessary tools
• Socket wrench
• Wrench adapter, rod of size 14
2) Take 2 springs (330) and 2 valves (327) out

of 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).

30-56-16 PC228USLC-1
2
3. Disassembly of 2nd travel speed selection valve

1) Remove plug (357) from rear flange (301).
fl Loosen the plug when the motor is on
work.
fl Necessary tools
• Hexagonal wrench of size 10
2) Remove spool (363) and spring (366) from

rear flange (301).
3) Remove O-ring (355) from plug (357).

4. Disassembly of internal parts (SRV)

1) Remove plugs (380) (2 pieces).
fl Necessary tools

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-1 30-56-17
2
4) Remove plugs (382) (2 pieces).

fl Necessary tools
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 rear

flange (301).
5. Disassembly of relief valve

1) Remove plug (204) from sleeve (202).
fl Since shim (205) of the internal parts of
sleeve (202) is decided after relief pres-
sure is set, keep those parts as a valve
kit separately from other parts.
fl Necessary tools

3) Take shim (205) out of plug (204).
30-56-18 PC228USLC-1
2
4) Take spring retainer (203), spring (206), and

valve (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) cannot
be replaced singly, since relief pressure
must be set again. If those parts need
to be replaced, replace the whole relief
valve.
PC228USLC-1 30-56-19
2
2-2. DISASSEMBLY OF HYDRAULIC MOTOR

1. Removal of parking brake parts
1) Supply compressed air through the parking
brake 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. To
prevent 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 motor

1) 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 the
motor to receive the oil.
fl Necessary tools
• Container
2) Drain the oil from the travel motor.
3) Hold cylinder block (104) with both hands

and take it out of spindle (2).
fl Before pulling out cylinder block (104),
hold it with the hands and rotate it in
both directions by 2 - 3 turns to separate
shoe (106) from swash plate (103).
 If cylinder block (104) is pulled out with-
out performing the above action, the
shoe is left on the swash plate and the
parts sticking to the cylinder block (pis-
ton, shoe, etc.) come off the cylinder
block and fall in the spindle.
30-56-20 PC228USLC-1
2
4) Remove 2 mating plates (116) and 2 friction

plates (115) from the periphery of cylinder
block (104).
5) Remove the piston assembly (piston (105)

and shoe (106)), retainer plate (107), thrust
ball (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)), retainer
plate (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 parts
classification 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. If
it is hit strongly it may jump out.
8) Take pivots (167) (2 pieces) and parallel pins

(171) (2 pieces) out of spindle (2).
PC228USLC-1 30-56-21
2
9) Take out 2nd travel speed selection valve

assembly (piston (161) and shoe (162)) and
spring (193) by supplying compressed air
through the passage of spindle (2).
fl Since piston (161) and shoe (162) are set
in 1 unit, if either of them needs to be
replaced, replace both of them.
 If compressed air is supplied quickly, the
2nd travel speed selection valve assem-
bly may jump out to hurt you. To pre-
vent this, place a proper cover on valve
assembly.
Compressed air: 0.3 – 0.5 MPa
{3 – 5 kg/cm2}
fl Necessary tools
• Compressed air (0.3 – 0.5 MPa {3 – 5
kg/cm2})
• Nozzle
3. Disassembly of internal parts of cylinder block

1) Place cylinder block (104) on a press stand.
Apply holder (I) to washer (110) and take out
C-type hole snap ring (145) with snap ring
pliers.
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 needs
to be replaced.
fl Necessary tools
• Press stand
• Holder (I)
• Snap ring pliers
2) Loosen the press slowly until the spring force

is reduced to zero.
 If the press is loosened quickly, the
spring may jump out to hurt you. Loosen
it slowly.
3) Take C-type hole snap ring (145), washer

(110), spring (114), and washer (110) out of
cylinder block (104).
30-56-22 PC228USLC-1
2
2-3. DISASSEMBLY OF REDUCTION GEAR

ASSEMBLY
1. Removal of input gear
1) Remove steel ball (36) and input gear (6)
from coupling (15).
2. Removal of spur gears

1) 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. Take
care.
fl Necessary tools
2) Remove spur gear (7) (3 pieces) from crank-

shaft (9).
3. Removal of coupling
1) Remove coupling (15) from shaft (102).
PC228USLC-1 30-56-23
2
4. Removal of hold flange

1) 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
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.
fl Necessary tools
5) Cut the bent part of the top of the parallel
pin hole.
 When the bent part is cut with a rotary
bar, metal chips are scattered. Put on
protective goggles, mask, etc.
fl Necessary tools
• Rotary bar
6) Install the jig to pull out parallel pin (34) and

pull out the parallel pin to the end of hold
flange (3). (6 places)
fl Necessary tools
30-56-24 PC228USLC-1
2
7) Loosen hexagon socket head bolts (19).

fl Since the threaded parts of the hexagon
socket head bolts (19) are coated with
adhesive, those bolts may be difficult to
remove. Accordingly, loosen the bolts
as slowly as possible.
(Loosening torque:
Min. 686 Nm {70 kgm})
fl Necessary tools
• Torque wrench
8) Remove hold flange (3) from spindle (2).

fl Make match marks on the hold flange
and spindle so that they will be installed
to the original positions.
5. Removal of clamps
2) Remove the clamps (2 pieces).

fl Necessary tools
• Clamp
6. Separation of hub and spindle

1) Install eyebolts (for M16) to spindle (2). In-
stall hooks to the eyebolts and sling them
with 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-1 30-56-25
2
7. Removal of ball bearing, RV gear assembly, and

pin
1) 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 needle
roller 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 end
lightly so that the bearing will not be
slanted.
fl If the outer race of ball bearing (21) is
removed from hub (1), ball bearing (21),
RV gear assembly, and pin (17) fall from
hub (1). Accordingly, place a container
and a rubber mat on it under the work
table to protect the falling parts.
fl The RV gear assembly is the minimum
parts unit. If any part of this assembly
needs to be replaced, replace the whole
assembly. (See parts classification in the
parts list.)
fl Necessary tools
• Pin punch [1]
• Hammer [2]
8. Removal of ball bearing

1) Take floating seal (31) out of hub (1).
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 protect
it.
fl Necessary tools
• Pin punch [1]
• Hammer [2]
30-56-26 PC228USLC-1
2
9. Removal of spindle parts

1) 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 seal

1) Apply a flat-head screwdriver to the rim of
oil seal (132) in spindle (2) and hit it with a
hammer [1] to take out oil seal (132).
fl Remove oil seal (132) only when it needs
to be replaced. Do not reuse the removed
oil seal.
fl Remove the oil seal after the reduction
gear 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-1 30-56-27
2
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 Standard value Allowable value

Part name Trouble
No. (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 are

worn abnormally.
20 Snap ring • Periphery and end faces are
worn 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.
30-56-28 PC228USLC-1
2
Part Standard value Allowable value

Part name Trouble
No. (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 and
worn 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 are

worn unevenly.
108 Thrust ball • Spherical sliding parts against

retainer plate (107) is worn
unevenly.
109 Timing plate • Sliding surface is seized and
worn 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.

201 Valve • Outside surface has flaw.

202 Sleeve • Seat has flaw.

• Clearance between sleeve and
valve (201) is large.
PC228USLC-1 30-56-29
2
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 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 sliding
parts 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}
30-56-30 PC228USLC-1
2
2. ASSEMBLY PROCEDURE
2-1. ASSEMBLY OF BRAKE VALVE
1. Installation of check valve
1) Fit O-ring (337) to plug (326).
fl Apply grease to O-ring (337).
fl Necessary tools
• Torque wrench
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 spool
1) Insert spool (323) in rear flange (301).
fl 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.
fl Necessary tools
• Torque wrench

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}
fl Rear flange (301) and spool (323) are han-
dles as a kit. If either of them needs to
be replaced, be sure to replace both of
them.
PC228USLC-1 30-56-31
2
3. Assembly of 2nd travel speed selection valve

2) Fit spring (366) to spool (363) and insert them

in 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 internal
leakage and lowering of performance of
the travel motor. Take care.
fl When inserting spool (163), align it with
the hole of rear flange (301) to prevent
contact damage on the inside of rear
flange and outside of the spool.
3) Install plug (357) to rear flange (301) and

tighten it to the specified torque.
3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}
fl Necessary tools
• Torque wrench
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). (2

pieces)
fl Apply grease to O-rings (383) and (384).
3) Install plugs (382) (2 pieces) to rear flange

(301) and tighten them to the specified
torque.
3 Plug: 14.7 ± 2.45 {1.5 ± 0.25 kgm}
fl Necessary tools
• Torque wrench
30-56-32 PC228USLC-1
2
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 the
body hole and outside of the piston).
 Since the clearance between piston (381)
and rear flange (301) is adjusted for each
combination, take care not to mistake in
combination.

6) Install plug (380) to rear flange (301) and
tighten 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
• Torque wrench
5. Assembly of relief valve

1) 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 it
is.
4) Install piston seal (220) to valve (201).

fl Piston seal (220) consists of an O-ring
and a Teflon ring. Apply grease to both
of them. Put in the O-ring first, then put
in the Teflon ring.
PC228USLC-1 30-56-33
2
5) Insert valve (201), spring (206), and spring

retainer (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 sleeve
and outside of the valve).
fl Since the internal parts of the sleeve are
adjusted for each combination, take care
not to mistake in combination.
3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}
fl Necessary tools
• Torque wrench
fl Stick shim (205) to plug (204) with hy-
draulic oil or grease to prevent it from
falling.
6) Install the other sleeve similarly.
30-56-34 PC228USLC-1
2
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/or
Procedure for selecting thickness of distance piece (13) must be performed. Before starting
assembly, see if the following parts have been replaced.
[A] ASSEMBLY
No (page 30-56-36)
Was any part replaced? <Replaced part> [B] PROCEDURE FOR

• Hub (1) ADJUSTING THICKNESS OF
• Spindle kit HOLD FLANGE (3)
• Ball bearing (21) (page 30-56-45)
Yes
[C] PROCEDURE FOR

<Replaced part>
SELECTING THICKNESS OF
• Spindle kit
DISTANCE PIECE (13)
• RV gear assembly
(page 30-56-47)
 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
[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].
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] in
order and press them until jig [II] comes
in contact with jig [I]. Remove the jigs
and check that the parallelism error of
the end face of the hub and floating seal
surface 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] in
order and press them until jig [II] comes
in contact with jig [III]. Remove the jigs
and check that the parallelism error of
the end face of the spindle groove and
floating seal surface is less than 1 mm.
fl Necessary tools
• Floating seal fitting jig [II]
• Floating seal fitting jig [III]
30-56-36 PC228USLC-1
2
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 pieces
2) 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 main
bearing (21). Insert it slowly.
 When spindle (2) is inserted, if it is
slanted, 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
4) Turn over the travel motor to bring the cover
side to the top.
fl Turn the travel motor 180 degrees.
5) Fit outer races (3 pieces) of tapered roller
bearing (22) to the outer race fitting holes in
spindle (2).
4. Assembly of RV gear assembly

1) 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 outer
race hole of tapered roller bearing (22)
fitted to spindle (2), and install the RV
gear assembly to the spindle slowly.
 If the RV gear assembly is lowered
quickly, the tapered roller bearing will
be damaged and the travel motor will
malfunction.
3) Insert pins (17) (24 pieces) between the pin
grooves of hub (1) and tooth grooves of the
gear.
fl Apply lubricating oil to pins (17) before
inserting them.
PC228USLC-1 30-56-37
2
5. Assembly of ball bearing

1) Insert ball bearing (21) in hub (1).
fl Ball bearing (21) is to be press fitted to
hub (1). Fit it evenly little by little by
hitting it lightly with a hammer. Put ball
bearing (21) in hub (1) securely.
fl Necessary tools
• Hammer [1]
• Press fitting jig [2]
2) Install the outer races of 3 tapered roller

bearings (22).
6. Installation of hold flange

1) Install spindle (2) to hold flange (3).
 Check the match marks of spindle (2)
and hold flange (3).
30-56-38 PC228USLC-1
2
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
• Torque wrench
2) Put plain washers (37) (3 pieces) on the bolt
seats of hold flange (3).
3) Tighten hexagon socket head bolts (19) (3
pieces) 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 hole
bottoms of spindle (2).
fl Degrease parallel pins (34) thoroughly.
Set air pressure to 49 – 58.8 Nm {5 – 6
kg/cm2}.
 Take care not to mistake the fitting di-
rections and positions of parallel pins
(34).
 When driving parallel pins (34), take care
not to slant them. (Slanting them can
cause burrs and sharp fins.)
fl Necessary tools
• Air chisel (BRH-8)
5) After installing parallel pins (34), bend the

pin hole edge of hold flange (3).
fl Apply the bending jig around the pin
hole of hold flange (3) and hit it with a
hammer.
fl Necessary tools
• Bending jig
• Hammer
6) Tighten hexagon socket head bolts (19) to

the 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-1 30-56-39
2
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, matching
the match marks.
fl Necessary tools
9. Assembly of spur gears (7)

1) Fit spur gears (7) (3 pieces) to crankshafts
(9), matching their match marks as shown
below.
fl Necessary tools
Match marks on spur gears (7)

fl When fitting spur gear (7), set their match
marks a (punch marks) as shown here.
2) Fit C-type shaft snap rings (25) to the snap

ring grooves of crankshafts (9).
 Snap ring (25) may come off the pliers
and fly off. Hold it securely with the
pliers.
fl Necessary tools
30-56-40 PC228USLC-1
2
fl Take care of the direction of each snap

ring. Fit it with its square side a up.
10. Fitting of oil seal

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 it
with 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-1 30-56-41
2
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 block

1) 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.
30-56-42 PC228USLC-1
2
3) Place the above cylinder block on the press

stand. Apply holder [I] to washer (110) to
press spring (114) and fit C-type hole snap
ring (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 it
securely with the pliers.
fl Necessary tools
• Press stand
• Holder [I]
15. Installation of motor assembly

1) Fit needle rollers (151) (5 pieces) to cylinder
block (104) and place collar (111) and thrust
ball (108) on them.
2) Put piston assemblies (105) and (106) in re-

tainer plate (107).
3) Apply hydraulic oil to the piston assemblies
and install them to cylinder block (104).
4) Apply hydraulic oil to the sliding surface of

shoe (106) and spherical part of thrust ball
(108).
PC228USLC-1 30-56-43
2
5) Install swash plate (103), thrust ball (108),

collar (111), retainer plate (107), needle roll-
ers (151), cylinder block (104), and piston
assemblies (105) and (106) to shaft (102) as
shown 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 assembly

1) Using sling [I], lift up the motor assembly
and install an insertion jig to the spline at
the 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 it
to spindle (2).
3) After installing the motor assembly, remove
sling [I] and insertion jig.
fl After installing the motor assembly, re-
volve the cylinder block with the hand to
check that it does not have play. If the
cylinder block has play, check it. When
checking, do not pull out the cylinder
block, however. If it is pulled out, collar
(111) and thrust ball (108) will come off
and the cylinder block will not revolve
normally.
30-56-44 PC228USLC-1
2
[B] PROCEDURE FOR ADJUSTING THICKNESS

OF HOLD FLANGE (3)
Assembly processes to be finished before adjust-
ment
fl 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 main

bearing to spindle (2).
fl Necessary tools
• Preload adjustment jig [2] for main bearing
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]
3. Obtain depth A through the measurement hole

of the preload adjustment jig for main bearing
with depth micrometer [4].
fl Necessary tools
• Depth micrometer [4]
4. Since dimension B of the preload adjustment jig

for main bearing is known, obtain clearance C
by the following formula.
C=A–B A: Measured value

B: Dimension of jig
C: Clearance
PC228USLC-1 30-56-45
2
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 following
procedure. 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 of
hold flange (3) with a lathe, etc. until the
standard value is obtained.
2) If dimension D of actual hold flange (3) is in
the tolerance of the standard value, use the
hold flange as it is.
3) If dimension D of actual hold flange (3) is
larger than the standard value, replace the
spindle 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 main

bearing from spindle (2).
30-56-46 PC228USLC-1
2
[C] PROCEDURE FOR SELECTING THICKNESS

OF DISTANCE PIECE (13)
Assembly processes to be finished before selection
fl Finish assembly procedures 1 – 7 (on pages 30-
56-36 to 30-56-39) before selecting the thickness
of the distance piece.
1. Lightly hit the outer race of tapered roller bear-

ing (22) installed to crankshaft (9) of the RV gear
assembly 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 hold

flange (3) and fit snap ring (20) to the snap ring
groove inside hold flange (3).
3. Lightly hit the periphery of snap ring (20) with

holder [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
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
5. After deciding the thickness of the distance piece,

select proper ones from 17 types and install
them.
fl See clearance adjustment parts list (on page
30-56-51).
PC228USLC-1 30-56-47
2
See assembly procedure for

hydraulic motor parts
(pages 30-56-41 to 30-56-44)
1) Fit 2 couples of friction plate (115) and mating 1) Put piston (112) having O-rings (135) and
plate (116) to the peripheral groove of cylinder (139) in spindle (2).
block (104) with friction plate (115) ahead. 2) Insert piston (112) into spindle (2) by hitting
fl When fitting friction plates (115), dip them in its end with a plastic hammer.
hydraulic oil. Take care not to slant it.
 Take care not to mistake the fitting order of the fl Apply grease to O-rings (135) and (139).
friction plates and mating plates. If it is mistaken, fl Necessary tools
the braking force of the parking brake may lower. • Plastic hammer

brake valve
(pages 30-56-31 to 30-56-33)
1) Install deep groove ball bearing (150), timing 1) Add hydraulic oil.
plate (109), parallel pin (341) (1 piece), and 5 Hydraulic oil (1.7 liters)
springs (113) (12 pieces) to rear flange (301). 2) Install O-rings (29) and (27) (2 pieces) and parallel
 Apply sufficient amount of grease to spring (113) pins (42) (2 pieces) to spindle (2) side and install
and timing plate (109) so that they will not fall rear flange (301) to the spindle.
from rear flange (301).  Do not apply grease to O-ring (29) on the mating face
fl Apply hydraulic oil to deep groove ball bearing (150). (since oozing grease can be mistaken for oil leakage).
fl Necessary tools fl When installing rear flange (301), match the pin
• Grease • Hydraulic oil holes to parallel pins (42) fitted in spindle (2).

reduction gear assembly
and hydraulic motor shaft
(pages 30-56-35 to 30-56-41)
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).
 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
30-56-48 PC228USLC-1
2
1) Tighten hexagon socket head bolts (343) 1) Install the relief valve to rear flange (301).
(12 pieces) into spindle (2) to the specified torque. 2) Tighten the relief valve to the specified torque.
3 Bolt: 252 ± 39.2 Nm {25.7 ± 4 kgm} 3 Bolt: 245 ± 49Nm {25 ± 5kgm}
2) Fit O-ring (355) to plug (357) and install them to fl Necessary tools
a drain port which will not be used. • Torque wrench
3 Plug: 98.1 ± 19.6Nm {10 ±2 kgm} • Wrench adapter, socket of size 32
fl Necessary tools
• Torque wrench
• Wrench adapter, rods of sizes 10 and 14
1) Tighten hexagon socket head bolts (35) 1) Fit O-rings (43) to hexagon socket head
(12 pieces) to the specified torque with a plugs (33).
torque wrench. 2) Tighten hexagon socket head plugs (33)
2) Add lubricating oil (5.4 liters). (3 pieces) for cover (8).
3 Bolt: 102 ± 15.7 Nm {10.4 ± 1.6 kgm} 3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}
fl Necessary tools fl Necessary tools
• Torque wrench • Torque wrench
• Wrench adapter, rod of size 10 • Wrench adapter, rod of size 10
• Lubricating oil: 5.4 liters
PC228USLC-1 30-56-49
2
PERFORMANCE TEST
fl After maintaining the travel motor, execute the performance test according to the following
procedure.
1) Necessary measuring tools

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

3 Stopwatch 1 piece
2) Test procedure
1 Installation and piping of Install the travel motor to machine body and connect the
travel motor pipes. Do not install the tracks, however.
(For the performance test (no-load operation) of the travel
motor)
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 a
hammer but fix it slowly by using the bolt holes.
2 Run-in operation of travel Gear Speed of Revolving Operation

speed travel motor Pressure direction time
motor
Low 10 rpm Min. 1 minute
No load Right and left
High 20 rpm each
3 Performance test of travel

motor
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 rpm
Max. 2.9 MPa {30 kg/cm2} in 2nd gear speed at 20 rpm
Drainage from hydraulic motor
Max. 2 liters/min in both 1st and 2nd gears at 10 rpm
Accepted Rejected
Install tracks. Disassemble and adjust again.
30-56-50 PC228USLC-1
2
LIST OF CLEARANCE ADJUSTMENT PARTS

Part name Dimension
Distance piece (13)

Unit: mm
Classification
Dimension (T)
No.
E Above 3.30 to 3.35
F Above 3.35 to 3.40
G Above 3.40 to 3.45
H Above 3.45 to 3.50
I Above 3.50 to 3.55
J Above 3.55 to 3.60
K Above 3.60 to 3.65
L Above 3.65 to 3.70
M Above 3.70 to 3.75
N Above 3.75 to 3.80
O Above 3.80 to 3.85
P Above 3.85 to 3.90
Q Above 3.90 to 3.95
R Above 3.95 to 4.00
S Above 4.00 to 4.05
T Above 4.05 to 4.10
U Above 4.10 to 4.15
PC228USLC-1 30-56-51
2

Komatsu Backhoe Pc228uslc-1 (Manual) PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Komatsu Backhoe Pc228uslc-1 (Manual) PDF

Uploaded by

Copyright:

Available Formats

SEBM015903

PC228USLC-1 11001 and up

• PC228US, PC228USLC mount the S6D102E-1 engine.

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

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

‡ 00- 1 (3) 01- 1 10-10 10-39 10-66

Time of Time of Time of Time of Time of

10-95 20-17 20-136 20-228 20-351

Time of Time of Time of Time of Time of

20-401 20-483 30-22 (1) 30-56-6 (2) 30-56-46 (2)

Time of Time of Time of Time of Time of

30-91 (1) 30-131 (1) 30-176 (1) 40-37

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15