SM Pc228us-2 Sebm015903

SEBM015903
PC228US-2
PC228USLC-1, 2
MACHINE MODEL
SERIAL NUMBER
PC228USLC-1
PC228US-2
PC228USLC-2
11001 and up
15001 and up
15001 and up
This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
PC228US, PC228USLC mount the S6D102E-1 engine.

For details of the engine, see the 102 Series Engine Shop Manual.
2003 1
All Rights Reserved
Printed in Japan 05-03(01)
00-1
(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
1
PC228USLC-1
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PC228USLC-1
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
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 dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
Always wear safety glasses when hitting

parts with a hammer.
Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.
When carrying out welding work, always wear
welding gloves, apron, hand shield, cap and
other clothes suited for welding work.
4. When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting. Always inform your
fellow workers before starting any step of the
operation. Before starting work, hang UNDER
REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the
correct way to use them.
6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from falling. In addition, be sure to lock all the control
levers and hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10.Remove all mud and oil from the steps or other
places used to get on and off the machine.
Always use the handrails, ladders or steps when
getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
handrails, ladders or steps, use a stand to provide safe footing.
00-3
SAFETY
PRECAUTIONS DURING WORK

11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get
burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the negative () terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
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
SAFETY NOTICE
19.Be sure to assemble all parts again in their original places.

Replace any damaged parts with new parts.
When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance 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 component, 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
VOLUMES
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
(
....) is recorded on the bottom of the pages.
Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series
Each issued as one
Electrical volume:
Attachments volume: volume to cover all
models
REVISIONS
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)
Item number (2. Testing and Adjusting)
Consecutive page number for each
item.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
12-203
10-4
12-203-1
10-4-1
Added pages
12-203-2
10-4-2
12-204
10-5
00-6
Symbol
Item
Remarks
Safety
Special safety precautions

are necessary when performing the work.
Caution
Special technical precautions or other precautions

for preserving standards
are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary

when selecting hoisting
wire, or when working posture is important, etc.
Tightening
torque
Places that require special

attention for the tightening
torque during assembly.
Coat
Places to be coated with

adhesives and lubricants,
etc.
Oil, water
Places where oil, water or

fuel must be added, and
the capacity.
Drain
Places where oil or water

m u s t b e d r a i n e d , a nd
quantity to be drained.
6
5
2
3
4
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
So that the shop manual can be of ample practical

use, important safety and quality portions are
marked with the following symbols.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-todate information before you start any work.
SYMBOLS
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be
available.
321
Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
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
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Rope diameter
Allowable load
mm
tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
kN
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392.2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40.0
100%
88%
79%
71%
41%
SAD00479
3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically
wound onto the load.
Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol
Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have maximum strength at the middle portion.
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,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120 hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
lifting angle of 150.
The allowable load value is estimated to be onesixth 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

Before carrying out the following work, release
the residual pressure from the hydraulic tank.
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 hydraulic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into
mating adapter (3). (See Fig. 1)
5 The adapter can be pushed in about 3.5
mm.
5 Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
5 Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
5 Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
5 When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
Type 1
FOREWORD
Type 3
1) Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

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

until cover (3) contacts contact surface a of
3) Hold in the condition in Steps 1) and 2), and

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

pull out whole body (2) to disconnect it.
Disassembly
Type 2
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
Connection
Hold the mouthpiece of the tightening portion

the hexagonal portion at the male end to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
5
5
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Main applications, featuresr
Tube
20 g
(2 pcs.)
09940-00030
50 g
Polyethylene
container
LT-3
790-129-9060
(Set of
adhesive and
hardening
agent)
Adhesive:
1 kg
Hardenin
g
agent:
500 g
790-129-9040
250 g
Polyethylene
container
Holtz
MH 705
790-126-9120
75 g
Tube
Three bond
1735
790-129-9140
50 g
Polyethylene
container
2g
Polyethylene
container
Used as adhesive or sealant for

metal, glass and plastic.
Used as sealant for machined

holes.
Used as heat-resisting sealant for

repairing engine.
Quick hardening type adhesive

Cure time: within 5 sec. to 3 min.
Used mainly for adhesion of metals, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength after 30 minutes)
Used mainly for adhesion of rubbers, plastics and metals.
Can
LT-4
Polyethylene
container
LT-2
Features: Resistance to heat and

chemicals
Used for anti-loosening and sealant purpose for bolts and plugs.
790-129-9050
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polyprophylene, tetrafluoroet hl ene and vi nyl chl or ide) ,
rubber, metal and non-metal.
LT-1B
Used to prevent rubber gaskets,

rubber cushions, and cock plug
from coming out.
Adhesives
Aron-alpha
201
790-129-9130
Loctite
648-50
79A-129-9110
50 cc
Polyethylene
container
LG-1
790-129-9010
200 g
Tube
1 kg
Can
Used as adhesive or sealant for

gaskets and packing of power
train case, etc.
790-129-9070
Resistance to heat, chemicals

Used at joint portions subject to
high temperatures.
LG-5
Used as sealant for various

threads, pipe joints, flanges.
Used as sealant for tapered
plugs, elbows, nipples of hydraulic piping.
Gasket
sealant
LG-6
790-129-9020
200 g
Tube
00-10
Features: Silicon based, resistance to heat, cold

Used as sealant for flange surface, tread.
mab Used as sealant for oil pan,
final drive case, etc.
FOREWORD
Category
COATING MATERIALS
Komatsu code
Part No.
Q'ty
Container
Main applications, featuresr
LG-7
790-129-9070
1g
Tube
Three bond
1211
790-129-9090
100 g
Tube
LM-G
09940-00051
60 g
Can
Adhesives
Molybdenum
disulphide
lubricant
Ftures: Silicon based, quick hardening type

Used as sealant for flywheel
housing, intake manifold, oil an,
thermostat housing, etc.
09940-00040
200 g
Used as heat-resisting sealant for

repairing engine.
Used as lubricant for sliding portion (to prevent from squeaking).
LM-P
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
Tube
Various
SYG2-400M
400 g
(10 per
case)
Used for places with heavy load
Various
Molybdenum
disulphide
lubricant
Used for normal temperature,

light load bearing at places in contact with water or steam.
G2-CA
SYG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-160CNCA
General purpose type
G2-LI
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
SYG2-160LI
SYGA-160CNLI
Belows type
Grease
Various
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
5 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
of bolt
Width across
flats
mm
mm
6
8
10
12
14
10
13
17
19
22
13.2
31
66
113
177
1.4
3
7
10
19
1.35
3.2
6.7
11.5
18
0.15
0.3
0.7
1
2
16
18
20
22
24
24
27
30
32
36
279 30
382 39
549 59
745 83
927 103
28.5
39
56
76
94.5
3
4
6
8.5
10.5
27
30
33
36
39
41
46
50
55
60
1320
1720
2210
2750
3290
135
175
225
280
335
15
20
25
30
35
Thread diameter
of bolt
Width across
flats
mm
mm
Nm
6
8
10
12
10
13
14
27
7.85 1.95
18.6 4.9
40.2 5.9
82.35 7.85
Nm
kgm
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
140
190
240
290
340
kgm
0
0
0
0
0.8
1.9
4.1
8.4
0.2
0.5
0.6
0.8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

5 In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter
Width across flat
mm
mm
Nm
kgm
14
18
22
24
30
33
36
42
19
24
27
32
36
41
46
55
24.5 4.9
49 19.6
78.5 19.6
137.3 29.4
176.5 29.4
196.1 49
245.2 49
294.2 49
2.5 0.5
5 2
8 2
14 3
18 3
20 5
25 5
30 5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
00-12
Tightening torque
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

5 In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
10
12
16
14
17
22
65.7 6.8
112 9.8
279 29
6.7 0.7
11.5 1
28.5 3
0
0
0
0
0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

5 Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
14
20
24
33
42
Varies depending
on type of
connector.
34.3 4.9
93.1 9.8
142.1 19.6
421.4 58.8
877.1 132.3
Norminal No.
3.5
9.5
14.5
43
89.5
0.5
1
2
6
13.5
0
0
0
0
0
0
0
0
0
0
02
03, 04
05, 06
10, 12
14
kgm
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

5 Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter
Width across flat
Tightening torque
mm
mm
Nm
kgm
08
10
12
14
16
18
20
24
30
33
36
42
52
14
17
19
22
24
27
30
32
32
n
36
n
n
7.35 1.47
11.27 1.47
17.64 1.96
22.54 1.96
29.4 4.9
39.2 4.9
49 4.9
68.6 9.8
107.8 14.7
127.4 19.6
151.9 24.5
210.7 29.4
323.4 44.1
0.75 0.15
1.15 0.15
1.8 0.2
2.3 0.2
3 0.5
4 0.5
5 0.5
7 1
11 1.5
13 2
15.5 2.5
21.5 3
33 4.5
Norminal No.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
08
10
12
14
16
18
20
24
30
33
36
42
52
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

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

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

Use these torques for tapered screws (unit: inch) of Cummins Engine.
Tightening torque
mm
1 / 16
1/8
1/4
3/8
1/2
3/4
1
3 1
8 2
12 2
15 2
24 4
36 5
60 9
0
0
0
0
0
0
0
00-14
Nm
kgm
0.31
0.81
1.22
1.53
2.45
3.67
6.12
0
0
0
0
0
0
0
Thread diameter
0.10
0.20
0.20
0.41
0.41
0.51
0.92
FOREWORD
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
Cable O.D.
(mm)
Current
rating
(A)
Applicable circuit
0.88
2.4
12
Starting, lighting, signal

etc.
0.32
2.09
3.1
20
Lighting, signal etc.
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
Norminal
number
Number of
strands
Dia. of
strands
(mm2)
Cross
section
(mm 2)
0.85
11
0.32
26
CLASSIFICATION BY COLOR AND CODE

Circuits
Priority
Classification
Starting
Lighting
Instrument
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
WR
n
n
n
n
n
BW
RW
YR
GW
LW
WB
Color White & Black

Code
4
Auxiliary
WL
Color White & Blue

Code
WG
5
Color White & Green
Color
n
n
Code
6
White & Black Red & White Rellow & Red Green & White Blue & White
BY
RB
YB
GR
LR
Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
BR
RY
Black & Red Red & Yellow

RG
YG
GY
LY
Yellow &
Green
Green &
Yellow
Blue & Yellow
YL
GB
LB
Red & Green Yellow & Blue Green & Black Blue & Black
RL
YW
GL
Red & Blue Yellow & White Green & Blue
n
n
Code
3
n
n
n
n
Color White & Red
n
n
n
n
Primary
Ground
Code
Charging
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
from .
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
from .
(3) Take the point where the two lines cross as . This point
gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
A
Millimeters to inches
1 mm = 0.03937 in
0
10
20
30
40
0
0.394
0.787
1.181
1.575
0.039
0.433
0.827
1.220
1.614
0.079
0.472
0.866
1.260
1.654
0.118
0.512
0.906
1.299
1.693
0.157
0.551
0.945
1.339
1.732
0.197
0.591
0.984
1.378
1.772
0.236
0.630
1.024
1.417
1.811
0.276
0.669
1.063
1.457
1.850
0.315
0.709
1.102
1.496
1.890
0.354
0.748
1.142
1.536
1.929
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
A
00-16
2.165
2.559
2.953
3.346
3.740
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon

1 = 0.2642 U.S. Gal
0.264
0.528
0.793
1.057
1.321
1.585
10
2.642
2.906
3.170
3.434
3.698
3.963
20
5.283
5.548
5.812
6.076
6.340
30
7.925
8.189
8.454
8.718
40
10.567
10.831
11.095
50
13.209
13.473
60
15.850
70
1.849
2.113
2.378
4.227
4.491
4.755
5.019
6.604
6.869
7.133
7.397
7.661
8.982
9.246
9.510
9.774
10.039
10.303
11.359
11.624
11.888
12.152
12.416
12.680
12.944
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon

1 = 0.21997 U.K. Gal
0.220
0.440
0.660
0.880
1.100
1.320
10
2.200
2.420
2.640
2.860
3.080
3.300
20
4.399
4.619
4.839
5.059
5.279
30
6.599
6.819
7.039
7.259
40
8.799
9.019
9.239
50
10.998
11.281
60
13.198
70
1.540
1.760
1.980
3.520
3.740
3.950
4.179
5.499
5.719
5.939
6.159
6.379
7.479
7.969
7.919
8.139
8.359
8.579
9.459
9.679
9.899
10.119
10.339
10.559
10.778
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
FOREWORD
CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
0
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses {
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
}.
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model
PC228USLC-1
Serial Number
11001 and up
m3
0.8
Operating weight
kg
22,900
Max. digging depth
mm
6,810
Max. vertical wall depth
mm
5,910
Max. digging reach
mm
9,850
Max. reach at ground level
mm
9,670
Max. digging height
mm
10,700
Max. dumping height
mm
7,765
Max. digging force

(using power max. function)
kN {kg}
125 {12,800} (137 {14,000})
Swing speed
rpm
11.0
Swing max. slope angle
deg.
16
Travel speed
km/h
Lo: 3.4 Mi: 4.1 Hi: 5.1
Gradeability
deg.
35
kPa {kg/cm2}
41 {0.42}
Overall length (for transport)
mm
8,890
Overall width
mm
2,980
Overall width of track
mm
3,080
Overall height (for transport)
mm
2,990
Overall height to chassis
mm
2,990
Ground clearance to bottom of upper structure
mm
1,050
Min. ground clearance
mm
440
Tail swing radius
mm
1,625
Min. swing radius of work equipment
mm
2,310
Height of work equipment at min. swing radius
mm
8,290
Length of track on ground
mm
3,640
Track gauge
mm
2,380
Height of machine cab
mm
2,280
Performance
Working ranges
Bucket capacity
Dimensions
Ground pressure
(triple grouser shoe width: 700 mm)
PC228USLC-1
01-3
GENERAL
SPECIFICATIONS
Machine model
PC228USLC-1
Serial Number
11001 and up
Model
S6D102E-1-A
Type
No. of cylinders bore stroke
mm
6 102 120
{cc}
5.883 {5,883}
Flywheel horsepower
kW/rpm {HP/rpm}
96/2,000 {128/2,000}
Max. torque
Nm/rpm {kgm/rpm}
545.3/1,350 {55.6/1,350}
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}
Performance
Piston displacement
Engine
4-cycle, water-cooled, in-line, vertical,

direct injection, with turbocharger
Starting motor
24V, 4.5 kW
Alternator
24V, 50A
12V, 110 Ah 2
Battery
Radiator core type
Carrier roller
9 on each side
Track shoe
Triple grouser, 49 on each side
Hydraulic
motor
Control
valve
Hydraulic
pump
2 on each side
Track roller
Undercarriage
Type no.
Delivery
Set pressure
HPV95+95, variable displacement

piston type 2
Piston type: 206 2
/min
2
MPa {kg/cm }
Piston type: 34.8 {355}
Type No.
6-spool type 1
Control method
Hydraulic
Travel motor
GM38VL, Piston type

(with brake valve, parking brake: 2
Swing motor
KMF90AEL-3, Piston type

(with safety valve, parking brake): 1
Boom
Hydraulic cylinder
Hydraulic system
Corrugated CWX-4
Arm
Double acting Double acting

piston
piston
Type
Bucket
Double acting
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
01-4
2
CFT-1 (Air cooled)
PC228USLC-1
GENERAL
SPECIFICATIONS
Machine model
PC228US-2
Serial Number
15001 and up
m3
0.8
Operating weight
kg
21,800
Max. digging depth
mm
6,810
Max. vertical wall depth
mm
5,910
Max. digging reach
mm
9,850
Max. reach at ground level
mm
9,670
Max. digging height
mm
10,640
Max. dumping height
mm
7,720
Max. digging force

(using power max. function)
kN {kg}
125 {12,800} (137 {14,000})
Swing speed
rpm
11.0
Swing max. slope angle
deg.
22
Travel speed
km/h
Lo: 3.0 Hi: 5.3
Gradeability
deg.
35
kPa {kg/cm2}
51 {0.52}
Overall length (for transport)
mm
8,700
Overall width
mm
2,995
Overall width of track
mm
2,800
Overall height (for transport)
mm
2,965
Overall height to chassis
mm
2,990
Ground clearance to bottom of upper structure
mm
1,050
Min. ground clearance
mm
440
Tail swing radius
mm
1,680
Min. swing radius of work equipment
mm
2,380
Height of work equipment at min. swing radius
mm
8,210
Length of track on ground
mm
3,270
Track gauge
mm
2,200
Height of machine cab
mm
2,280
Performance
Working ranges
Bucket capacity
Dimensions
Ground pressure
(triple grouser shoe width: 700 mm)
PC228USLC-1
01-4-1
1
GENERAL
SPECIFICATIONS
Machine model
PC228US-2
Serial Number
15001 and up
Model
S6D102E-1-F
Type
No. of cylinders bore stroke
mm
6 102 120
{cc}
5.883 {5,883}
Flywheel horsepower
kW/rpm {HP/rpm}
96/2,000 {128/2,000}
Max. torque
Nm/rpm {kgm/rpm}
545.3/1,350 {55.6/1,350}
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}
Performance
Piston displacement
Engine
4-cycle, water-cooled, in-line, vertical,

direct injection, with turbocharger
Starting motor
24V, 4.5 kW
Alternator
24V, 35A
12V, 110 Ah 2
Battery
2 on each side
Track roller
7 on each side
Track shoe
Triple grouser, 45 on each side
Control
valve
Hydraulic
motor
Type no.
Delivery
Set pressure
HPV95+95, variable displacement

piston type 2
Piston type: 206 2
/min
2
MPa {kg/cm }
Piston type: 37.2 {380}
Type No.
6-spool type 1
Control method
Hydraulic
Travel motor
GM38VL, Piston type

(with brake valve, parking brake): 2
Swing motor
KMF90ABE-3, Piston type

(with safety valve, parking brake): 1
Boom
Hydraulic cylinder
Hydraulic system
Corrugated CWX-4
Carrier roller
Hydraulic
pump
Undercarriage
Radiator core type
Arm
Double acting Double acting

piston
piston
Type
Bucket
Double acting
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
01-4-2
2
CFT-1 (Air cooled)
PC228USLC-1
TRAVEL MOTOR
3) When starting travel (or during normal

travel)
When the travel lever is operated, the pressure oil from the pump moves counterbalance 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 pressure is created, and the pump pressure rises
to provide a powerful drawbar pull. (Fig. 7)
PC228USLC-1
10-65
TRAVEL MOTOR
PC228USLC-1, 2
GM38VL
A.
B.
D1.
D2.
From
From
Drain
Drain
control valve
control valve
port (to tank) (L.H. travel motor)
port (to tank) (R.H. travel motor)
10-65-1
2
Specifications
Type
: GM38VL
Theoretical delivery
: 140.5 cc/rev
Brake releasing pressure : 0.59 MPa {6.0 kg/cm2}
Travel speed switching pressure: 1.96 6.86 MPa
{20 70 kg/cm2}
Reduction ratio
: 66
PC228USLC-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Plug
Spring
Valve
Spool
Spring
Valve
Spring
Sleeve
End cover
Cylinder block
Piston
PC228USLC-1
TRAVEL MOTOR
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Spring
Plate
Disc
Swash plate
Pivot
Spindle
Floating seal
Hub
RV gear A
RV gear B
Crankshaft
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Cover
spur gear
Input gear
Hold flange
Piston
Shoe
Shaft
Shoe
Piston
Spring
Timing plate
10-65-2
2
VALVE CONTROL
VALVE CONTROL
1.
2.
3.
4.
5.
6.
7.
Travel PPC valve

L.H. travel lever
R.H. travel lever
Solenoid block
Accumulator
R.H. PPC valve
R.H. work equipment
lever
10-66
8. Control valve
9. Hydraulic pump
10. L.H. work equipment
lever
11. L.H. PPC valve
12. Safety lock lever
Lever positions
1 HOLD
2 Boom RAISE
3 Boom LOWER
4 Bucket DUMP
5 Bucket CURL
6 HOLD
7 Arm IN
8 Arm OUT
9
0
A
B
C
D
E
Swing RIGHT
Swing LEFT
NEUTRAL
Travel REVERSE
Travel FORWARD
LOCK
FREE
PC228USLC-1
TABLE OF JUDGEMENT STANDARD VALUE

FOR ENGINE
Machine model
PC228USLC-1
Engine
S6D102-1
Item
Engine speed
Measurement condition
Standard value
Permissible value
1,800
2,000
Max. 1.0
2.0
Max. 0.5
1.5
0.25
0.51
Oil temperature:
40 60C
MPa
(engine speed: 250rpm) {kg/cm2}
(SAE15W-40 oil)
Min. 2.4
{Min. 24.6}
Difference between
cylinders
Min. 1.0
{Min. 10.3}
(Coolant temperature:
operating range)
At rated output
(SAE30 oil)
kPa
(mmH2O)
Max. 1.2
{Max. 123}
5.1
{520}
MPa
{kg/cm2}
0.39 0.52
{4.0 5.3}
0.25
{2.6}
Min. 0.12
{Min. 1.2}
0.09
{0.9}
80 110
120
18 1
18 1
Min. 10
Max. 6
58
58
Rated
speed
Working
rpm
Traveling
At sudden acceleration
Exhaust gas color
At high idling
Valve clearance
Unit
(normal temperature)
Intake valve
Bosch
index
mm
Exhaust valve
Compression pressure
Blow-by pressure
(Coolant temperature:
operating range)
(Measure at top of oil filter)
Oil pressure
At high idling
(SAE15W-40)
At low idling
(SAE15W-40)
Oil temperature
Whole speed range

(inside oil pan)
Fuel injection timing
Before top dead center
(B.T.D.C.)
(degree)
Belt tension
Deflection
when
pressed
with finger
force of
approx.
58.8N{6kg}
PC228USLC-1
Fan-tension
mm
Fan
air conditioner
compressor
20-3
FOR CHASSIS
Applicable model
Category
Item
PC228USLC-1
Measurement conditions
Unit
Engine speed
Low idling
Permissible value
2,200 70
2,200 70
Hydraulic oil temperature:

45 55C
At TRAVEL
Coolant temperature:
Within operating range
2-pump relief: Arm relief
At WORK
High idling
Standard value
970 50
rpm
2 pumps at relief
1,850 100
Speed when auto Fuel control dial at MAX.

deceleration is operated Control lever at neutral
1,400 120
1,400 120
Spool stroke
Boom control valve
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
100 10
Max. 110
Min. 90
100 10
Max. 110
Min. 90
100 10
Max. 110
Min. 90
Swing control lever
100 10
Max. 110
Min. 90
Travel control lever
115 12
Max. 127
Min. 103
Play of control lever
Max. 10
Max. 15
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
15.7 3.9
{1.6 0.4}
Max. 24.5
{Max. 2.5}
13.7 2.9
{1.4 0.3}
Max. 22.6
{Max. 2.3}
13.7 2.9
{1.4 0.3}
Max. 22.6
{Max. 2.3}
Lever
24.5 5.9
{2.5 0.6}
Max. 39.2
{Max. 4.0}
Pedal
74.5 18.6
{7.6 1.9}
Max. 107.6
{Max. 11}
Operating force of control levers
Travel of control levers
Boom control lever

Arm control lever
Bucket control lever
Boom control lever

Arm control lever
Bucket control lever
Center of lever knob

Read max. value to end of
travel
Engine stopped
Excluding neutral play
Engine at high idling

Oil temperature: 45 55C
Fit push-pull scale to center
of control lever knob to
measure
Measure max. value to end
of travel
Swing control lever
Travel control lever
20-4
(3)
mm
N
{kg}
PC228USLC-1
PC228USLC-1
Boom
Bucket teeth in
contact with ground
Arm
4.4 0.5
Max. 5.2
4.0 0.4
Max. 4.4
3.6 0.4
Max. 4.5
(To Just before cushion) (To Just before cushion)
2.9 0.3
Max. 3.5
(To Just before cushion) (To Just before cushion)
Cylinder fully
retracted
45 55C
CURL
Fully extended
2.6 0.4
Max. 3.3
2.1 0.3
Max. 2.7
Max. 1.0
Max. 1.2
Max. 1.0
Bucket
Work equipment
Permissible value
IN

45 55C
Unit
Work equipment speed
Cylinder fully
extended
Standard value
RAISE
Item
OUT
Category
LOWER
Applicable model
Max. 2.8
Fully extended
Boom

45 55C
DUMP
Cylinder fully
retracted
BKP00114
sec
Time lag
Lower boom and measure time

taken from point where bucket
contacts ground to point where
chassis rises from ground
Engine at low idling
45 55C
Arm
BKP00115
Stop arm suddenly and measure

time taken for arm to stop
45 55C
PC228USLC-1
20-9
(3)
PC228USLC-1
Applicable model
Time lag
Item
Unit
Standard value
Permissible value
BKP00116
sec.
Max. 1.0
Max. 3.6
4.5
20
10
50
Max. 200
Max. 220
Bucket
Cylinders
Center swivel joint

45 55C
cc/min
Relieve circuit to be measured
45 55C
Use a hard horizontal surface.
Travel deviation when

work equipment +
travel are operated
20m
mm
10m
BKP00107
Measure dimension .
Hydraulic pump delivery
Performance in compound operation

Performance of hydraulic pump
Stop bucket suddenly and

measure time taken for bucket
to stop at bottom and then
start again.
45 55C
Internal leakage
Work equipment
Category
20-10
Piston pump
See next page
See next page
PC228USLC-1
30
METHOD OF USING MANUAL ................... 30- 3

PRECAUTIONS WHEN CARRYING
OUT OPERATION ................................... 30- 5
SPECIAL TOOL LIST ..................................... 30- 7
SKETCHES OF SPECIAL TOOLS ................. 30- 9
STARTING MOTOR
Removal and Installation ...................... 30-12
ALTERNATOR
ENGINE OIL COOLER CORE
FUEL INJECTION PUMP
Removal .................................................. 30-15
Installation .............................................. 30-18
WATER PUMP
NOZZLE HOLDER
TURBOCHARGER
THERMOSTAT
CYLINDER HEAD
Removal .................................................. 30-24
Installation .............................................. 30-28
ENGINE, MAIN PUMP
Removal .................................................. 30-31
Installation .............................................. 30-34
DAMPER
ENGINE FRONT SEAL
ENGINE REAR SEAL
Removal .................................................. 30-38
Installation .............................................. 30-39
RADIATOR, HYDRAULIC COOLER
Removal .................................................. 30-40
Installation .............................................. 30-41
FUEL TANK
Removal .................................................. 30-42
Installation .............................................. 30-43
CENTER SWIVEL JOINT
Removal .................................................. 30-44
Installation .............................................. 30-45
CENTER SWIVEL JOINT
Disassembly and Assembly .................. 30-46
PC228USLC-1
SPROCKET
FINAL DRIVE, TRAVEL MOTOR
FINAL DRIVE
Disassembly ........................................... 30-49
Assembly ................................................ 30-52
TRAVEL MOTOR
Disassembly and Assembly .............. 30-56-1
SWING MOTOR, SWING MACHINERY
SWING MACHINERY
Disassembly ........................................... 30-58
Assembly ................................................ 30-62
SWING MOTOR
REVOLVING FRAME
Removal .................................................. 30-68
Installation .............................................. 30-69
SWING CIRCLE
Removal .................................................. 30-70
Installation .............................................. 30-71
IDLER, RECOIL SPRING
RECOIL SPRING
Disassembly ........................................... 30-73
Assembly ................................................ 30-74
IDLER
Disassembly ........................................... 30-75
Assembly ................................................ 30-76
TRACK ROLLER
Disassembly ........................................... 30-79
Assembly ................................................ 30-80
CARRIER ROLLER
Disassembly ........................................... 30-83
Assembly ................................................ 30-84
TRACK SHOE
HYDRAULIC TANK
MAIN PUMP
Removal ................................................ 30- 88
Installation ............................................ 30- 89
30-1
2
EPC VALVE
Removal and Installation .................... 30- 90
PC VALVE
LS VALVE
CONTROL VALVE
Removal ................................................ 30- 93
Installation ............................................ 30- 95
Disassembly ......................................... 30- 96
Assembly .............................................. 30-101
LS SELECT VALVE
Disassembly and Assembly ................ 30-107
PRESSURE COMPENSATION VALVE
Disassembly ......................................... 30-108
Assembly .............................................. 30-109
MAIN RELIEF VALVE
Removal and Installation .................... 30-110
SOLENOID VALVE
PUMP MERGE/DIVIDER
SOLENOID VALVE
2-STAGE RELIEF, TRAVEL HI/LO
SOLENOID VALVE
INTERFERENCE PREVENTION
SOLENOID VALVE
LEFT WORK EQUIPMENT PPC VALVE
(FOR SWING, ARM CONTROL)
RIGHT WORK EQUIPMENT PPC VALVE
(FOR BOOM, BUCKET CONTROL)
WORK EQUIPMENT PPC VALVE
(PPC VALVE FOR BOOM, BUCKET,
ARM, SWING CONTROL)
Disassembly ......................................... 30-118
Assembly .............................................. 30-119
TRAVEL PPC VALVE
PPC VALVE FOR OFFSET CONTROL
BOOM LOCK VALVE
BOOM CYLINDER
Removal ................................................ 30-124
Installation ............................................ 30-125
ARM CYLINDER
Removal ................................................ 30-126
Installation ............................................ 30-127
BUCKET CYLINDER
Removal ................................................ 30-128
Installation ............................................ 30-129
30-2
1
OFFSET CYLINDER
Removal ................................................ 30-130
Installation ............................................ 30-131
HYDRAULIC CYLINDER FOR OFFSET
Disassembly ......................................... 30-132
Assembly .............................................. 30-134
HYDRAULIC CYLINDER FOR BOOM,
ARM, BUCKET
Disassembly ......................................... 30-136
Assembly .............................................. 30-139
BUCKET
Removal ................................................ 30-144
Installation ............................................ 30-145
ARM
Removal ................................................ 30-146
Installation ............................................ 30-147
BUCKET, ARM
Removal ................................................ 30-150
Installation ............................................ 30-151
OFFSET BRACKET
SECOND BOOM
Removal ................................................ 30-156
Installation ............................................ 30-157
FIRST BOOM
Removal ................................................ 30-158
Installation ............................................ 30-160
SECOND, FIRST BOOM
Removal ................................................ 30-161
Installation ............................................ 30-163
OFFSET BRACKET, SECOND,
FIRST BOOM
Removal ................................................ 30-164
Installation ............................................ 30-166
BOOM
Removal ................................................ 30-168
Installation ............................................ 30-169
OPERATORS CAB
Removal ................................................ 30-170
Installation ............................................ 30-171
FLOOR FRAME
Removal ................................................ 30-172
Installation ............................................ 30-173
AIR CONDITIONER COMPRESSOR
AIR CONDITIONER CONDENSER
AIR CONDITIONER UNIT
Removal ................................................ 30-176
Installation ............................................ 30-177
COUNTERWEIGHT
CONTROLLER
MONITOR
PC228USLC-1
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 ............................................................................................................
1. General precautions ..............................................................................................................
2. Disassembly procedure ........................................................................................................
2-1. Disassembly of brake valve ..........................................................................................
2-2. Disassembly of hydraulic motor ..................................................................................
2-3. Disassembly of reduction gear assembly ...................................................................
30-56-13
30-56-13
30-56-14
30-56-16
30-56-20
30-56-23
MAINTENANCE STANDARD ............................................................................................................. 30-56-28

1. Seals ....................................................................................................................................... 30-56-28
2. Maintenance standard for worn parts ................................................................................. 30-56-28
ASSEMBLY PROCEDURE ..................................................................................................................
1. General precautions ..............................................................................................................
2. Assembly procedure .............................................................................................................
2-1. Assembly of brake valve ..............................................................................................
2-2. Assembly of reduction gear assembly and hydraulic motor ....................................
30-56-30
30-56-30
30-56-31
30-56-31
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
2
TRAVEL MOTOR
PC228USLC-1
PC228USLC-1
TRAVEL MOTOR
30-56-3
2
TRAVEL MOTOR
REDUCTION GEAR
30-56-4
2
PC228USLC-1
PC228USLC-1
TRAVEL MOTOR
30-56-5
2
TRAVEL MOTOR
HYDRAULIC MOTOR
RELIEF VALVE
CONTROL VALVE
30-56-6
2
PC228USLC-1
PC228USLC-1
TRAVEL MOTOR
30-56-7
2
TRAVEL MOTOR
PARTS LIST
No.
Part name
Qty
37
REDUCTION GEAR
Hub
Spindle kit
Spindle assy
Spindle
Hold flange
Hexagon socket head bolt
Parallel pin
(select one from 3 kinds)
Plain washer
4
5
9
12
22
23
RV gear assembly kit

RV gear kit
RV gear A
RV gear B
Crankshaft
Spacer
Tapered roller bearing
Needle roller bearing
1
1
1
1
3
6
6
6
Input gear
Spur gear kit

Spur gear
1
3
1
3
15
17
20
21
25
27
29
30
Cover
Distance piece
t: Above 3.30, up to 3.15
<at interval of 0.05>
t: Above 4.10 up to 4.15
Coupling
Pin
C-type snap ring for hole
Ball bearing
C-type snap for shaft
O-ring
O-ring
O-ring
1
24
3
2
3
2
1
1
31
Floating seal kit

Floating seal
33
35
36
42
43
Hexagon socket head plug

Ball
Parallel pin
O-ring
Part name
Qty
1
2
3
12
1
2
3
2
3
19
34
8
13
30-56-8
2
1
1
1
1
1
1
3
6
No.
HYDRAULIC MOTOR
105
106
104
107
108
110
111
114
145
151
Cylinder & piston kit

Piston kit
Piston assembly
Piston
Shoe
Cylinder block
Retainer plate
Thrust ball
Washer
Washer
Spring
C-type snap ring for hole
Needle roller
1
1
9
1
1
1
1
1
2
1
1
1
5
161
162
Piston assembly
Piston
Shoe
1
1
1
102
103
109
112
113
115
116
132
135
139
149
150
167
171
173
Shaft
Swash plate
Timing plate
Piston
Spring
Friction plate
Mating plate
Oil seal
O-ring
O-ring
Deep groove ball bearing
Pivot
Parallel pin
Spring
1
1
1
1
12
2
2
1
1
1
1
1
2
2
1
PC228USLC-1
No.
No.
Valve kit
Valve
Sleeve
Spring retainer
Plug
Shim
Spring
O-ring
O-ring
O-ring
Back-up ring
Back-up ring
O-ring
Piston seal
1
1
1
1
1
1
1
1
1
1
2
2
1
1
398
399
400

Name plate
Square head plug
4
1
2
341
343
Parallel pin
1
12
CONTROL VALVE
301
323
381
321
324
325
326
327
328
330
336
337
352
354
355
357
358
359
363
366
368
373
379
380
382
383
384
385
397
Qty
RELIEF VALVE
201
202
203
204
205
206
208
209
210
211
217
219
220
Part name
TRAVEL MOTOR
Rear flange assembly

Rear flange kit
Rear flange
Spool
Piston
Plug
Plug
Stopper
Plug
Valve
Spring
Spring
O-ring
O-ring
Plug
O-ring
Plug
O-ring
O-ring
Spool
Spring
Ball
O-ring
Filter
Plug
Plug
O-ring
O-ring
Ball
Orifice
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
7
1
1
2
2
1
1
2
1
1
2
2
2
2
2
1
PC228USLC-1
Part name
Qty
30-56-9
2
TRAVEL MOTOR
TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY

1. Standard tools
Necessary tools for disassembly and assembly of GM38VL are shown below.
No.
Name
Model/Dimensions
Qty
Hexagonal wrench
Socket wrench
(Ratchet handle)
Torque wrench
Dial type for about 280 N

Dial type for about 850 N
Torque wrench adapter

(12.7 mm square drive)
(19.0 mm square drive)
Nominal size of socket: 22, 30, 32, 41

Nominal size of rod: 5, 6, 8, 10, 14
Nominal size of rod: 19
Extension bar
150 mm
Hammer
Nominal size: 12
Plastic hammer
L = About 300
Flat-head screwdriver
About 150 mm
Snap ring pliers
For shaft
For hole
1
1
10
Sling parts
Sling load: Min. 2,942 N {300 kg}

Eyebolt (For M16)
Eyebolt (For PF 1/2)
Wire with hook
1 set
(2)
(2)
(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
14
Heating tank
Heating ability: Min. 100C

Capacity: Min. 500 mm x 500 mm x 500 mm
15
Leather gloves
16
Sealing tape
17
Depth micrometer
Measurement range: About 30 mm

Min. division: 0.01 mm
18
Thickness gauge
Measurement range: 0.04 0.3 mm
19
Rotary bar
For cutting cast iron
20
Air chisel
BRH-8
(Compressed air: 0.5 0.6 MPa {5 6 kg/cm2})
30-56-10
2
6 (For M8) (PF 1/4) 5 (PF 1/8)

10 (For M12) (PF 1/2) 8 (PF 3/8)
14 (For M16)
1 each
1 each
1 each
1
1
1
1 each
1 each
1 each
2
1 set
1 pair
1
PC228USLC-1
TRAVEL MOTOR
2. Manufactured tools
No.
Name and major dimensions
Qty
No.
Preload adjustment jig for main bearing
Holder (III)
Holder (IV)
Pointed punch
Clamp
Qty
Press fitting jig
Steel rod
Holder (I)
10
Aluminum rod
11
Sling jig
Holder (II)
PC228USLC-1
30-56-11
2
No.
TRAVEL MOTOR
Qty
No.
17
12
Floating seal fitting jig (I)
13
Floating seal fitting jig (II)
Floating seal fitting jig (III)
15
Sling jig
16
Pulling jig
30-56-12
2
Bending jig
Qty
14
PC228USLC-1
TRAVEL MOTOR
DISASSEMBLY PROCEDURE
1. GENERAL PRECAUTIONS
1) Before disassembling the travel motor, consider the inspection items, characteristics of the
detected trouble, etc. and then review the given disassembly procedure.
2) Disassemble the travel motor in a clean place according to the procedure in 2. Disassembly
procedure.
3) Spread a rubber sheet, vinyl sheet, etc. on the worktable.
4) When disassembling, make match marks on the mating faces of the parts.
5) Arrange the removed parts well so that they will not be damaged or lost.
6) Replace each seal once the travel motor is disassembled, as a rule. Accordingly, prepare the
all replacement seals before disassembling.
PC228USLC-1
30-56-13
2
TRAVEL MOTOR
2. DISASSEMBLY PROCEDURE
When inspecting or repairing the travel motor, disassemble it according to the following procedure.
The number in (
) after each part name refers to the part No. in Parts list.
Before disassembling the travel motor, install it to a turning work table.
Prepare a container to collect lubricating oil (for 8 liters).
Prepare a container to collect hydraulic oil (for 4 liters).
(Disassembly of hydraulic motor on brake valve side)
1) Remove the relief valve from rear

flange (301).
2) Remove O-rings (208), (209), and
(210) and backup rings (211)
(2 pieces), and (217) (2 pieces)
from the relief valve.
Do not reuse removed O-ring (138).
Necessary tools
Impact wrench or ratchet handle
Wrench adapter, socket of size 32
1) Remove hexagon socket head

bolts (343) (12 pieces).
Necessary tools
Socket wrench
Extension bar
Wrench adapter, rod of size 14
(Disassembly of shaft and oil seals of reduction gear assembly and

hydraulic motor)
1) Turn the work table 180 degrees

so that cover (8) of the travel
motor will be directed up.
plugs (33) (3 pieces).
bolts (35) (12 pieces).
Necessary tools
Ratchet handle
30-56-14
2
1) Install eyebolts (2 pieces) to

threaded plug holes (PF 1/2).
2) Install hooks to the eyebolts and lift
off cover (8).
If the cover is not removed because of resistance of O-ring (30),
hit the rim of the cover with a
plastic hammer.
3) Remove O-ring (30) from cover (8).
4) Drain oil from the reduction gear
assembly.
Necessary tools
Sling: 1 set
Eyebolt (for PF 1/2): 2 pieces
Plastic hammer
Container (for 8 liters)
PC228USLC-1
TRAVEL MOTOR
See disassembly procedure

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

spindle (2).
Take care, since shaft (102) may
be removed, too.
See disassembly procedure

for hydraulic motor
1) Remove timing plate (109),

parallel pin (341) (1 piece),
springs (113) (12 pieces), and
deep groove ball bearing (150)
from rear flange (301) and
hydraulic motor.
2) Remove O-rings (27) (2 pieces)
and (29) from spindle (2).
Do not reuse removed O-rings
(27) and (29).
PC228USLC-1
Removal of hydraulic
motor shaft
See disassembly procedure for

reduction gear assembly
30-56-15
2
TRAVEL MOTOR
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).
Loosen the plug when the motor is on
the turning work table for the ease of
work.
Necessary tools
Socket wrench
2) Remove 2 springs (328), 2 stoppers (325),

and spool (323) from rear flange (301).
Take care not to damage the periphery
of spool (323) and sliding surface of rear
flange (301).
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).
Loosen the plugs when the motor is on
work.
Necessary tools
Socket wrench
2) Take 2 springs (330) and 2 valves (327) out

of rear flange (301).
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
2
PC228USLC-1
TRAVEL MOTOR
3. Disassembly of 2nd travel speed selection valve

1) Remove plug (357) from rear flange (301).
Loosen the plug when the motor is on
work.
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).
Necessary tools

3) Remove rear flange (301) from piston (381).
Take care not to damage the piston hole.
Since rear flange (301) and piston (381)
are matched to each other in the field,
keep them coupled.
PC228USLC-1
30-56-17
2
TRAVEL MOTOR
4) Remove plugs (382) (2 pieces).

Necessary tools
5) Remove O-rings (383) and (384) from plug
(382).
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).
Since shim (205) of the internal parts of
sleeve (202) is decided after relief pressure is set, keep those parts as a valve
kit separately from other parts.
Necessary tools
3) Take shim (205) out of plug (204).
30-56-18
2
PC228USLC-1
TRAVEL MOTOR
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
TRAVEL MOTOR
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 piston (112).
If compressed air is supplied quickly, piston (112) may jump out to hurt you. To
prevent this, place a proper cover on piston (112).
Necessary tools
Compressed air (0.3 0.5 MPa {3 5
kg/cm2})
Nozzle
2) Remove O-rings (135) and (139) from piston

(112).
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.)
When the travel motor is laid on its side,
oil spills. Place a container under the
motor to receive the oil.
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).
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 without performing the above action, the
shoe is left on the swash plate and the
parts sticking to the cylinder block (piston, shoe, etc.) come off the cylinder
block and fall in the spindle.
30-56-20
2
PC228USLC-1
TRAVEL MOTOR
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).
Cylinder block (104), piston assembly
(piston (105) and shoe (106)), retainer
plate (107), etc. are the cylinder and piston kit, which is the minimum parts unit.
If any part of this kit needs to be replaced, 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).

Oil seal (132) cannot be taken out.
The shaft can be pulled out easily by
hitting its end on reduction gear assembly 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
TRAVEL MOTOR
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).
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 assembly may jump out to hurt you. To prevent this, place a proper cover on valve
assembly.
Compressed air: 0.3 0.5 MPa
{3 5 kg/cm2}
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.
Press load: Min. 1,961 N {200 kg}
When removing the spring, align holder
(I) with the washer and protect the cylinder block from washer and spring.
Cover the sliding surfaces of the cylinder block with vinyl sheet for protection.
Remove spring (114) only when it needs
to be replaced.
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
2
PC228USLC-1
TRAVEL MOTOR
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.
Necessary tools
Snap ring pliers
2) Remove spur gear (7) (3 pieces) from crankshaft (9).
3. Removal of coupling
1) Remove coupling (15) from shaft (102).
PC228USLC-1
30-56-23
2
TRAVEL MOTOR
4. Removal of hold flange

1) Turn over the travel motor.
2) Install clamps (2 pieces) to hub (1) and spindle (2) to secure. Set the clamps symmetrically.
If hold flange (3) is removed without setting the clamps, hub (1) and spindle (2)
will separate from each other and spindle (2) will fall from the work table.
Necessary tools
Clamp
4) Remove 3 snap rings (20) and distance pieces
(13) from hold flange (3).
Make match marks on the snap rings
and hold flange so that they will be installed to the original positions.
Necessary tools
Snap ring pliers
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.
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)
Necessary tools
30-56-24
2
PC228USLC-1
TRAVEL MOTOR
7) Loosen hexagon socket head bolts (19).

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})
Necessary tools
Torque wrench
8) Remove hold flange (3) from spindle (2).

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).
Necessary tools
Clamp
6. Separation of hub and spindle

1) Install eyebolts (for M16) to spindle (2). Install hooks to the eyebolts and sling them
with a crane to remove spindle (2) from hub
(1).
Lift up spindle (2) slowly so that it will
not damage the retainer of ball bearing
(21).
Necessary tools
1 set of sling
2 eyebolts
Plastic hammer
PC228USLC-1
30-56-25
2
TRAVEL MOTOR
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 assembly (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.
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.
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.
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.)
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).
If ball bearing (21) is removed, it falls
from hub (1). Accordingly, place a rubber mat under the work table to protect
it.
Necessary tools
Pin punch [1]
Hammer [2]
30-56-26
2
PC228USLC-1
TRAVEL MOTOR
9. Removal of spindle parts

1) Take floating seal (31) out of spindle (2).
Necessary tools
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).
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).
Remove oil seal (132) only when it needs
to be replaced. Do not reuse the removed
oil seal.
Remove the oil seal after the reduction
gear assembly is disassembled and spindle (2) is separated.
Necessary tools
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.
Necessary tools
Press stand
Holder [II]
2) Press the tip of shaft with press [1] and remove deep groove ball bearing (149).
PC228USLC-1
30-56-27
2
TRAVEL MOTOR
MAINTENANCE STANDARD
Disassemble and inspect the travel motor according to the following standard. Handle its parts
carefully. In particular, take care not to damage the moving parts and sliding parts.
1. Seals
Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, even if they are
free from damage.
2. Maintenance standard for worn parts
1) Replace all the parts which have visible extreme damages.
2) Replace the parts which have the following trouble (phenomenon).
Part
No.
Part name
Spindle kit
Spindle
Hold flange
Parallel pin
Plain washer
(2)
(3)
(19)
(34)
(37)
RV gear assembly
RV gear (A)
RV gear (B)
Crankshaft
Spacer bearing
Tapered roller bearing
Needle roller bearing with
retainer
(4)
(5)
(9)
(12)
(22)
(23)
13
Distance piece (Rank)
20
Snap ring
21
Ball bearing
(301)
Rear flange kit

Rear flange
(323)
Spool
(381)
Piston
30-56-28
2
Trouble
Standard value
(Standard dimension)
Allowable value
(Criterion)
Part surface has visible serious

damage.
Part surface is scuffed or worn
easily.
RV gear tooth surface is worn

unevenly.
When crankshafts (9) are
revolved, each part does not
move smoothly.
Periphery and end faces are

worn abnormally.
worn abnormally.
There is bruise.
Surface is flaked.
Surface is worn unevenly.
Moving part against spool (323)
has flaw.
Clearance between rear flange
and spool is large.
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.
Diameter clearance Diameter clearance

10 20
25
Outside surface has flaw.

Outside surface is worn unevenly.
PC228USLC-1
Part
No.
Part name
TRAVEL MOTOR
Trouble
102
Shaft
Swash plate
Cylinder block
Clearance:
0.05 mm
Clearance:
0.15 mm
Braking torque:
Min. 398 Nm
{40.6 kgm}
Braking torque:
Max. 398 Nm
{40.6 kgm}
Swash plate is seized.
104
Allowable value
(Criterion)
Contact face against oil seal

(132) is worn.
Spline is worn.
103
Standard value
(Standard dimension)
Spline is worn.
Inside of bore is worn remarkably.
Sliding surface against timing
plate (109) is scratched and
worn unevenly.
(105)
(106)
Piston assembly
Piston
Shoe
There is axial clearance between

piston (105) and shoe (106).
Shoe is worn abnormally.
Shoe is worn unevenly.
107
Retainer plate

worn unevenly.
108
Thrust ball
109
Timing plate
Spherical sliding parts against

retainer plate (107) is worn
unevenly.
Sliding surface is seized and
worn unevenly.
115
116
Friction plate
Mating plate
Both end faces are worn

unevenly.
Specified torque is not produced.
Plate is seized.
149
150

There is bruise.
Surface is flaked.
Surface is worn unevenly.
363
Spool

201
Valve

202
Sleeve
Seat has flaw.

Clearance between sleeve and
valve (201) is large.
PC228USLC-1
30-56-29
2
TRAVEL MOTOR
ASSEMBLY PROCEDURE
1. GENERAL PRECAUTIONS
1) Work in a clean place.
2) When assembling, do not put on cloth gloves. (Prevention of entry of fibers)
3) Repair the parts damaged during disassembly and be sure to prepare new oil seals and Orings.
4) Be sure to replace removed hexagon socket head bolts (19) with new ones.
5) Clean each part in kerosene and dry it with compressed air. Never use cloths to wipe the parts.
(Prevention of entry of fibers)
(1) Clean the hub, spindle, cover, and rear flange in a cleaning tank.
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
Qty
Tightening torque
709 108 Nm {72.3 11 kgm}
19
M24 (P3.0)
33
PF 1/2
98.1 19.6 Nm {10 2 kgm}
35
M12 (P1.75)
12
102 15.7 Nm {10.4 1.6 kgm}
202
Sleeve
PF 1
245 49 Nm {25 5 kgm}
204
Plug
PF 1/2
98.1 19.6 Nm {10 2 kgm}
324
Plug
M36 (P1.5)
255 39.2 Nm {26 4 kgm}
326
Plug
M36 (P1.5)
441 88.3 Nm {45 9 kgm}
343
M16 (P2.0)
12
252 39.2 Nm {25.7 4 kgm}
346
Plug
PT 1/4
29.4 4.9 Nm {3 0.5 kgm}
352
Plug
PF 1/4
29.4 4.9 Nm {3 0.5 kgm}
354
NPTF 1/16
9.81 2.45 Nm {1.0 0.25 kgm}
357
Plug
PF 1/2
98.1 19.6 Nm {10 2 kgm}
380
Plug
PF 3/8
58.8 9.81 Nm {6 1 kgm}
382
Plug
PF 1/8
14.7 2.45 Nm {1.5 0.25 kgm}
398
PT 1/8
12.3 2.45 Nm {1.25 0.25 kgm}
30-56-30
2
PC228USLC-1
TRAVEL MOTOR
2. ASSEMBLY PROCEDURE
2-1. ASSEMBLY OF BRAKE VALVE
1. Installation of check valve
1) Fit O-ring (337) to plug (326).
Apply grease to O-ring (337).
Necessary tools
Torque wrench
2) Put spring (330) and valve (327) in plug (326).
Apply grease to valve (327) and spring (330)
and fix spring (330) temporarily.
Apply HERMSEAL to the threads of plug
(326).
Tighten plug (326) with torque wrench.
3 Plug: 255 39.2 Nm {26 4 kgm}
3) Put assembled plug (326) in rear flange (301)
and tighten to the specified torque.
2. Installation of spool
1) Insert spool (323) in rear flange (301).
Apply hydraulic oil to spool (323) and
insert it in rear flange (301).
When inserting the spool, align it with
rear flange hole.
A flaw on the rear flange hole or outside
of the spool can cause internal leakage
and lowering of performance of the travel
motor. Take care.
Necessary tools
Torque wrench
3) Install stopper (325) and spring (328) to plug
(324) and tighten plugs (324) (2 pieces) into
rear flange (301) to the specified torque.
3 Plug: 441 88.3 Nm {45 9 kgm}
Rear flange (301) and spool (323) are handles as a kit. If either of them needs to
be replaced, be sure to replace both of
them.
PC228USLC-1
30-56-31
2
TRAVEL MOTOR
3. Assembly of 2nd travel speed selection valve

2) Fit spring (366) to spool (363) and insert them
in rear flange (301).
When inserting spool (363) in rear flange
(301), apply hydraulic oil to it.
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.
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}
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)
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}
Necessary tools
Torque wrench
30-56-32
2
PC228USLC-1
TRAVEL MOTOR
4) Put piston (381) in rear flange (301).

Apply hydraulic oil to piston (381) and
insert it in rear flange (301). Align piston (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}
Use a vise for the ease of work.
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).
3) Put shim (205) in plug (204).
Since the relief pressure is adjusted with
the shim, install the removed shim as it
is.
4) Install piston seal (220) to valve (201).

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
TRAVEL MOTOR
5) Insert valve (201), spring (206), and spring

retainer (203) in sleeve (202) and tighten plug
(204) having shim (205).
Apply hydraulic oil to valve (201) and
insert it in sleeve (202).
When inserting valve (201), align it with
the hole of sleeve (202) (to prevent contact damage on the hole of the sleeve
and outside of the valve).
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}
Necessary tools
Torque wrench
Stick shim (205) to plug (204) with hydraulic oil or grease to prevent it from
falling.
6) Install the other sleeve similarly.
30-56-34
2
PC228USLC-1
TRAVEL MOTOR
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
(page 30-56-36)
No
<Replaced part>
Hub (1)
Spindle kit
Ball bearing (21)
[B] PROCEDURE FOR

ADJUSTING THICKNESS OF
HOLD FLANGE (3)
(page 30-56-45)
<Replaced part>
Spindle kit
RV gear assembly
Was any part replaced?
[C] PROCEDURE FOR

SELECTING THICKNESS OF
DISTANCE PIECE (13)
(page 30-56-47)
Yes
When assembling after replacing the above parts, be sure to adjust each part. If the parts are put
together without adjustment, the travel motor will malfunction and will be broken soon.
PC228USLC-1
30-56-35
2
TRAVEL MOTOR
[A] ASSEMBLY
1. Assembly of hub (1)
1) Install hub (1) to the turning work table.
2) Press fit the outer race of ball bearing (21)
to hub (1) with press fitting jig [2] and
hammer [1].
Necessary tools
Press fitting jig
Hammer
3) Install floating seal (31) to hub (1).

Do not apply grease to the O-ring of floating seal (31).
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.
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 floating seal (31).
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.
Necessary tools
Floating seal fitting jig [II]
Floating seal fitting jig [III]
30-56-36
2
PC228USLC-1
TRAVEL MOTOR
3. Assembly of hub (1) and spindle (2)

1) Install eyebolts (for M16) (2 pieces) symmetrically to spindle (2).
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 insert it again slowly.
Necessary tools
Set of sling
3) Install clamps (2 pieces) to hub (1) and spindle (2) to secure. Set the clamps symmetrically.
Necessary tools
Clamp
4) Turn over the travel motor to bring the cover
side to the top.
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.
Necessary tools
Sling (RV gear assembly)
2) Install a hook to the sling and put it in spindle (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.
Apply lubricating oil to pins (17) before
inserting them.
PC228USLC-1
30-56-37
2
TRAVEL MOTOR
5. Assembly of ball bearing

1) Insert ball bearing (21) in hub (1).
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.
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
2
PC228USLC-1
TRAVEL MOTOR
7. Installation of hexagon socket head bolts (19)

and parallel pin (34)
1) Apply LOCTITE #638 to the threads of spindle (2).
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}.
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).
Degrease parallel pins (34) thoroughly.
Set air pressure to 49 58.8 Nm {5 6
kg/cm2}.
Take care not to mistake the fitting directions 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.)
Necessary tools
Air chisel (BRH-8)
5) After installing parallel pins (34), bend the
pin hole edge of hold flange (3).
Apply the bending jig around the pin
hole of hold flange (3) and hit it with a
hammer.
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}
If any parts (spindle kit and/or RV gear assembly) are replaced, refer to [C] PROCEDURE FOR SELECTING THICKNESS OF DISTANCE PIECE (13) (page 30-56-47).
If no parts are replaced, go to item 8. below.
PC228USLC-1
30-56-39
2
TRAVEL MOTOR
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).
Fit 3 snap rings (20) and 3 distance pieces
(13) to their original positions, matching
the match marks.
Necessary tools
Snap ring pliers
9. Assembly of spur gears (7)

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

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.
Necessary tools
Snap ring pliers
30-56-40
2
PC228USLC-1
TRAVEL MOTOR
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 spindle (2).
Apply lithium grease to the lip of oil seal
(132).
Necessary tools
Hammer
Holder [III]
11. Installation of shaft (102)

1) Install deep groove ball bearing (149) to shaft
(102) by shrink fit.
When installing, put on leather gloves
and take care not to get burned.
If deep groove ball bearing (149) was
removed during disassembly, replace it
with new one.
Shrink fit temperature: 100 10C
When installing the bearing, take care
that it will not slant from shaft (2).
Necessary tools
Heating oven
Leather gloves
Holder [II]
PC228USLC-1
30-56-41
2
TRAVEL MOTOR
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 piston 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).
Put washers (110) as shown in the figure
at right.
30-56-42
2
PC228USLC-1
TRAVEL MOTOR
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).
Cover the sliding surfaces of cylinder
block with a vinyl sheet for protection.
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.
Necessary tools
Press stand
Holder [I]
Snap ring pliers
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 retainer 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
TRAVEL MOTOR
5) Install swash plate (103), thrust ball (108),

collar (111), retainer plate (107), needle rollers (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.
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).
Match the pivot hole of swash plate (103)
to pivot (167) and install the motor assembly slowly, taking care not to damage spindle (2), etc. with the motor assembly.
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.
After installing the motor assembly, revolve 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
2
PC228USLC-1
TRAVEL MOTOR
[B] PROCEDURE FOR ADJUSTING THICKNESS

OF HOLD FLANGE (3)
Assembly processes to be finished before adjustment
Finish assembly procedures 1 5 (on pages 3056-36 to 30-56-38) before adjusting the thickness of the hold flange.
1. Install the preload adjustment jig [2] for main
bearing to spindle (2).
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}
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].
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=AB
PC228USLC-1
A: Measured value
B: Dimension of jig
C: Clearance
30-56-45
2
TRAVEL MOTOR
5. Obtain dimension D of hold flange (3).

6. From the result of procedures 1 5 above, adjust hold flange (3) according to the following
procedure. Dimension C is the standard dimension 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 adjustment allowance.
Carry out disassembly and assembly
again.
7. Remove the preload adjustment jig for main
bearing from spindle (2).
30-56-46
2
PC228USLC-1
TRAVEL MOTOR
[C] PROCEDURE FOR SELECTING THICKNESS

OF DISTANCE PIECE (13)
Assembly processes to be finished before selection
Finish assembly procedures 1 7 (on pages 3056-36 to 30-56-39) before selecting the thickness
of the distance piece.
1. Lightly hit the outer race of tapered roller bearing (22) installed to crankshaft (9) of the RV gear
assembly with holder [IV] and hammer.
Perform this procedure to insert the RV gear
assembly in spindle (2) securely.
Necessary tools
Holder [IV]
Hammer
Thickness gauge
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.
Perform this procedure to check that the RV
gear assembly is inserted in spindle (2) securely.
4. Insert thickness gauge between snap ring (20)
and distance piece (13) to measure the clearance.
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.
See clearance adjustment parts list (on page
30-56-51).
PC228USLC-1
30-56-47
2
TRAVEL MOTOR
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

plate (116) to the peripheral groove of cylinder
block (104) with friction plate (115) ahead.
When fitting friction plates (115), dip them in
hydraulic oil.
Take care not to mistake the fitting order of the
friction plates and mating plates. If it is mistaken,
the braking force of the parking brake may lower.
1) Put piston (112) having O-rings (135) and

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

brake valve
(pages 30-56-31 to 30-56-33)
1) Install deep groove ball bearing (150), timing

plate (109), parallel pin (341) (1 piece), and
springs (113) (12 pieces) to rear flange (301).
Apply sufficient amount of grease to spring (113)
and timing plate (109) so that they will not fall
from rear flange (301).
Apply hydraulic oil to deep groove ball bearing (150).
Necessary tools
Grease
Hydraulic oil
1) Add hydraulic oil.

5 Hydraulic oil (1.7 liters)
2) Install O-rings (29) and (27) (2 pieces) and parallel
pins (42) (2 pieces) to spindle (2) side and install
rear flange (301) to the spindle.
Do not apply grease to O-ring (29) on the mating face
(since oozing grease can be mistaken for oil leakage).
When installing rear flange (301), match the pin
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.
Match the bolt holes of cover (8) to the tap holes of hub (1).
Necessary tools
Grease Plastic hammer Eyebolts (2 pieces), PF 1/2 1 set of sling
30-56-48
2
PC228USLC-1
TRAVEL MOTOR
1) Install the relief valve to rear flange (301).

1) Tighten hexagon socket head bolts (343)
(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
Necessary tools
a drain port which will not be used.
Torque wrench
3 Plug: 98.1 19.6Nm {10 2 kgm}
Necessary tools
Torque wrench
Wrench adapter, rods of sizes 10 and 14
1) Tighten hexagon socket head bolts (35)

(12 pieces) to the specified torque with a
torque wrench.
2) Add lubricating oil (5.4 liters).
3 Bolt: 102 15.7 Nm {10.4 1.6 kgm}
Necessary tools
Torque wrench
Lubricating oil: 5.4 liters
PC228USLC-1
1) Fit O-rings (43) to hexagon socket head

plugs (33).
2) Tighten hexagon socket head plugs (33)
(3 pieces) for cover (8).
3 Plug: 98.1 19.6 Nm {10 2 kgm}
Necessary tools
Torque wrench
30-56-49
2
TRAVEL MOTOR
PERFORMANCE TEST
After maintaining the travel motor, execute the performance test according to the following
procedure.
1) Necessary measuring tools
1
Pressure gauge
(For 3.4 MPa {35 kg/cm2})
2 pieces
Measuring cylinder (For 5 liters)
1 piece
Stopwatch
1 piece
2) Test procedure
1
Installation and piping of

travel motor
Install the travel motor to machine body and connect the

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 circuit) can be installed and the drainage from the hydraulic 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.
Speed of
travel motor
10 rpm
High
Pressure
Revolving
direction
Operation
time
No load
Run-in operation of travel

motor
Gear
speed
Low
Right and left
Min. 1 minute
each
20 rpm
Performance test of travel

motor
1) Preparatory operation for test ..... Operate until temperature rises to the following levels.
Hydraulic oil: 45 55C
Temperature of outside part of
reduction gear assembly hub: 40 80C
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
Install tracks.
30-56-50
2
Rejected
Disassemble and adjust again.
PC228USLC-1
TRAVEL MOTOR
LIST OF CLEARANCE ADJUSTMENT PARTS

Part name
Dimension
Distance piece (13)
Unit: mm
Classification
No.
E
Above 3.30 to 3.35
Above 3.35 to 3.40
Above 3.40 to 3.45
Above 3.45 to 3.50
Above 3.50 to 3.55
Above 3.55 to 3.60
Above 3.60 to 3.65
Above 3.65 to 3.70
Above 3.70 to 3.75
Above 3.75 to 3.80
Above 3.80 to 3.85
Above 3.85 to 3.90
Above 3.90 to 3.95
Above 3.95 to 4.00
Above 4.00 to 4.05
Above 4.05 to 4.10
PC228USLC-1
Dimension (T)
Above 4.10 to 4.15
30-56-51
2

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PC228US, PC228USLC mount the S6D102E-1 engine.

STRUCTURE AND FUNCTION ......................................

TESTING AND ADJUSTING ..........................................

DISASSEMBLY AND ASSEMBLY .................................

MAINTENANCE STANDARD .........................................

LIST OF REVISED PAGES

The affected pages are indicated by the use of the

Page to be newly added

Pages having no marks are those previously revised

LIST OF REVISED PAGE

LIST OF REVISED PAGES

LIST OF REVISED PAGES

LIST OF REVISED PAGES

To prevent injury to workers, the symbol

Always wear safety glasses when hitting

3. If welding repairs are needed, always have a

6. Decide a place in the repair workshop to keep

PRECAUTIONS DURING WORK

19.Be sure to assemble all parts again in their original places.

STRUCTURE AND FUNCTION

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

Chassis volume: Issued for every machine model

Special safety precautions

Special technical precautions or other precautions

Weight of parts of systems. Caution necessary

Places that require special

Places to be coated with

Places where oil, water or

Places where oil or water

So that the shop manual can be of ample practical

DISTRIBUTION AND UPDATING

Revised pages are shown in the LIST OF REVISED

If a part cannot be smoothly removed from the

3) Do not sling a heavy load with one rope alone,

Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause

4) Do not sling a heavy load with ropes forming a

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

1) Hold the mouthpiece of the tightening portion

1) Hold the mouthpiece of the tightening portion

2) Hold in the condition in Step 1), and turn

2) Hold in the condition in Step 1), and push

3) Hold in the condition in Steps 1) and 2), and

3) Hold in the condition in Steps 1) and 2), and

Hold the mouthpiece of the tightening portion

Hold the mouthpiece of the tightening portion

Main applications, featuresr

Used as adhesive or sealant for

Used as sealant for machined

Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Features: Resistance to heat and

Used in places requiring an immediately effective, strong adhesive.

Used to prevent rubber gaskets,

Used as adhesive or sealant for