SM PC228US-2 SEBM015903
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Description
SEBM015903
1
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
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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
}
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. 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.
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): 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
123
Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
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.
s
4 3 2 5 6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
¤ •
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
4
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
kN
tons
10 11.5 12.5 14 16 18 20 22.4 30 40 50 60
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
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.
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.
¤
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
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) ★ The adapter can be pushed in about 3.5 mm. ★ Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) ★ Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) ★ Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) ★ When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
Type 1
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
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 and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
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 the hexagonal portion at the male end.
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 and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
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 to connect it.
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS ★ ★
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category
Komatsu code
Part No.
Q'ty
Container
LT-1A
790-129-9030
150 g
Tube
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
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
Can
LT-4
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
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
LG-5
790-129-9070
1 kg
Can
Main applications, featuresr •
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out.
•
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.
• •
Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs.
•
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.
• • •
Resistance to heat, chemicals Used at joint portions subject to high temperatures.
•
Used as adhesive or sealant for gaskets and packing of power train case, etc.
•
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
LM-P
09940-00040
200 g
•
Used as heat-resisting sealant for repairing engine.
•
Used as lubricant for sliding portion (to prevent from squeaking).
•
Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
Tube •
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI
G2-CA
SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA
Various
Various
Molybdenum disulphide lubricant
SYG2-400M
400 g (10 per case)
Belows type
Grease
Various
Ftures: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil an, thermostat housing, etc.
•
General purpose type
•
Used for normal temperature, light load bearing at places in contact with water or steam.
•
Used for places with heavy load
Various
00-11
FOREWORD
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) ★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter of bolt
Width across flats
mm
mm
6 8 10 12 14
10 13 17 19 22
16 18 20 22 24
24 27 30 32 36
27 30 33 36 39
41 46 50 55 60
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 0.15 0 0.3 0 0.7 01 02 28.5 0 3 39 0 4 56 0 6 76 0 8.5 94.5 0 10.5 135 0 15 175 0 20 225 0 25 280 0 30 335 0 35
0 1.4 03 07 0 10 0 19 279 0 30 382 0 39 549 0 59 745 0 83 927 0 103 1320 0 140 1720 0 190 2210 0 240 2750 0 290 3290 0 340
1.35 3.2 6.7 11.5 18
13.2 31 66 113 177
kgm
0 0 0 0
0.8 1.9 4.1 8.4
0 0.2 0 0.5 0 0.6 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS ★ In the case of flared nuts for which there is no special instruction, tighten to the torque given in 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
00-12
Tightening torque
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
FOREWORD
STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS ★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
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
0 0 0
6.7 0.7 11.5 1 28.5 3
0
0 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS ★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
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.
02 03, 04 05, 06 10, 12 14
kgm
0 0 0 0 0
0 0.5 01 02 06 0 13.5
3.5 9.5 14.5 43 89.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS ★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
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 0 0 0 0 0 0 0 0 0 0 0 0
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.
08 10 12 14 16 18 20 24 30 33 36 42 52
0 0 0 0 0 0 0 0 0 0 0 0 0
00-13
FOREWORD
STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS) Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6 8 10 12
10 2 24 4 43 6 77 12
kgm
0 0 0 0
1.02 2.45 4.38 7.85
0 0.20 0 0.41 0 0.61 0 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS) Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter
Tightening torque
mm
Nm
6 8 10 12 14
8 2 10 2 12 2 24 4 36 5
kgm
0 0 0 0 0
0.81 1.02 1.22 2.45 3.67
0 0.20 0 0.20 0 0.20 0 0.41 0 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS) Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter
00-14
Tightening torque
mm
Nm
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
kgm 0.31 0.81 1.22 1.53 2.45 3.67 6.12
0 0.10 0 0.20 0 0.20 0 0.41 0 0.41 0 0.51 0 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
2
26
5
CLASSIFICATION BY COLOR AND CODE Circuits Priority Classification
1
Primary
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
BW
RW
YR
GW
LW
2 Color White & Red Code
WB
3 Color White & Black Code 4
Auxiliary
WL
Color White & Blue Code
WG
5 Color White & Green Code 6 Color
n n
n n n n n n n n n n
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
n n n n
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 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.
A B
C
C
A
B
B Millimeters to inches 1 mm = 0.03937 in
A
00-16
0
1
2
3
4
5
6
7
8
9
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
2.165 2.559 2.953 3.346 3.740
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
C
FOREWORD
CONVERSION TABLE
Millimeters to Inches 1 mm = 0.03937 in
0
1
2
3
4
5
6
7
8
9
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram to Pound 1 kg = 2.2046 lb
0 0
0
1
2
3
4
5
6
7
8
9
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
l
1 = 0.2642 U.S. Gal
0
1
2
3
4
5
6
7
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
Liter to U.K. Gallon
l
1 = 0.21997 U.K. Gal
0
1
2
3
4
5
6
7
8
9
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2 1kg/cm2 = 14.2233 lb/in2
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-20
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. 1°C = 33.8°F
°C
°F
°C
°F
°C
°F
°C
°F
–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 PC228USLC-1
Serial Number
11001 and up
Bucket capacity
m3
0.8
Operating weight
kg
22,900
Max. digging depth
mm
6,810
Max. vertical wall depth
mm
5,910
Max. digging reach
mm
9,850
Max. reach at ground level
mm
9,670
Max. digging height
mm
10,700
Max. dumping height
mm
7,765
Max. digging force (using power max. function)
kN {kg}
125 {12,800} (137 {14,000})
Swing speed
rpm
11.0
Swing max. slope angle
deg.
16
Travel speed
km/h
Lo: 3.4 Mi: 4.1 Hi: 5.1
Gradeability
deg.
35
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
Working ranges Performance
Machine model
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
2 on each side
Track roller
9 on each side
Track shoe
Triple grouser, 49 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: 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
Carrier roller
Hydraulic pump
Undercarriage
Radiator core type
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
Arm
CFT-1 (Air cooled)
PC228USLC-1
GENERAL
Machine model
PC228US-2
Serial Number
15001 and up
Bucket capacity
m3
0.8
Operating weight
kg
21,800
Max. digging depth
mm
6,810
Max. vertical wall depth
mm
5,910
Max. digging reach
mm
9,850
Max. reach at ground level
mm
9,670
Max. digging height
mm
10,640
Max. dumping height
mm
7,720
Max. digging force (using power max. function)
kN {kg}
125 {12,800} (137 {14,000})
Swing speed
rpm
11.0
Swing max. slope angle
deg.
22
Travel speed
km/h
Lo: 3.0 Hi: 5.3
Gradeability
deg.
35
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
Working ranges Performance
SPECIFICATIONS
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
STRUCTURE AND FUNCTION
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
STRUCTURE AND FUNCTION
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
STRUCTURE AND FUNCTION
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
STRUCTURE AND FUNCTION
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
TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
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 – 60°C 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
8
Min. 10 Max. 6
5–8
5–8
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
°C
Fan-tension mm Fan– air conditioner compressor
20-3
TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
‡ FOR CHASSIS Applicable model Category
Item
PC228USLC-1
Measurement conditions
Unit
· Hydraulic oil temperature: 45 – 55°C At TRAVEL · Coolant temperature: Within operating range · 2-pump relief: Arm relief At WORK
Engine speed
High idling Low idling
Permissible value
2,200 ± 70
—
2,200 ± 70
—
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
a
a
Boom control valve
Spool stroke
Standard value
b
b
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 – 55°C · 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
TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
PC228USLC-1
Boom
↔
Bucket teeth in contact with ground · Engine at high idling · Hydraulic oil temperature: 45 – 55°C
Arm
Permissible value
4.4 ± 0.5
Max. 5.2
4.0 ± 0.4
Max. 4.4
3.6 ± 0.4 Max. 4.5 (To Just before cushion) (To Just before cushion)
2.9 ± 0.3 Max. 3.5 (To Just before cushion) (To Just before cushion)
Cylinder fully retracted · Engine at high idling · Hydraulic oil temperature: 45 – 55°C
CURL
Fully extended
Bucket
Work equipment
Unit
↔
Work equipment speed
Cylinder fully extended
Standard value
RAISE
Measurement conditions
IN
Item
OUT
Category
LOWER
Applicable model
2.6 ± 0.4
Max. 3.3
2.1 ± 0.3
Max. 2.7
Max. 1.0
Max. 1.2
Max. 1.0
Max. 2.8
Fully extended
Boom
· Engine at high idling · Hydraulic oil temperature: 45 – 55°C
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 · Hydraulic oil temperature: 45 – 55°C
Arm BKP00115
· Stop arm suddenly and measure time taken for arm to stop · Engine at low idling · Hydraulic oil temperature: 45 – 55°C
PC228USLC-1
20-9 (3)
TESTING AND ADJUSTING
TABLE OF JUDGEMENT STANDARD VALUE
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
· Hydraulic oil temperature: 45 – 55°C cc/min · Engine at high idling · Relieve circuit to be measured · Engine at high idling · Hydraulic oil temperature: 45 – 55°C fl Use a hard horizontal surface.
Travel deviation when work equipment + travel are operated
20m
mm
10m
BKP00107
fl Measure dimension χ.
Hydraulic pump delivery
Performance in compound operation Performance of hydraulic pump
Measurement conditions
· Stop bucket suddenly and measure time taken for bucket to stop at bottom and then start again. · Engine at low idling · Hydraulic oil temperature: 45 – 55°C
Internal leakage
Work equipment
Category
20-10
Piston pump
See next page
See next page
PC228USLC-1
30
DISASSEMBLY AND ASSEMBLY
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 Removal and Installation ...................... 30-13 ENGINE OIL COOLER CORE Removal and Installation ...................... 30-14 FUEL INJECTION PUMP Removal .................................................. 30-15 Installation .............................................. 30-18 WATER PUMP Removal and Installation ...................... 30-20 NOZZLE HOLDER Removal and Installation ...................... 30-21 TURBOCHARGER Removal and Installation ...................... 30-22 THERMOSTAT Removal and Installation ...................... 30-23 CYLINDER HEAD Removal .................................................. 30-24 Installation .............................................. 30-28 ENGINE, MAIN PUMP Removal .................................................. 30-31 Installation .............................................. 30-34 DAMPER Removal and Installation ...................... 30-35 ENGINE FRONT SEAL Removal and Installation ...................... 30-36 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 Removal and Installation ...................... 30-47 FINAL DRIVE, TRAVEL MOTOR Removal and Installation ...................... 30-48 FINAL DRIVE Disassembly ........................................... 30-49 Assembly ................................................ 30-52 TRAVEL MOTOR Disassembly and Assembly .............. 30-56-1 SWING MOTOR, SWING MACHINERY Removal and Installation ...................... 30-57 SWING MACHINERY Disassembly ........................................... 30-58 Assembly ................................................ 30-62 SWING MOTOR Removal and Installation ...................... 30-67 REVOLVING FRAME Removal .................................................. 30-68 Installation .............................................. 30-69 SWING CIRCLE Removal .................................................. 30-70 Installation .............................................. 30-71 IDLER, RECOIL SPRING Removal and Installation ...................... 30-72 RECOIL SPRING Disassembly ........................................... 30-73 Assembly ................................................ 30-74 IDLER Disassembly ........................................... 30-75 Assembly ................................................ 30-76 TRACK ROLLER Removal and Installation ...................... 30-78 Disassembly ........................................... 30-79 Assembly ................................................ 30-80 CARRIER ROLLER Removal and Installation ...................... 30-82 Disassembly ........................................... 30-83 Assembly ................................................ 30-84 TRACK SHOE Removal and Installation ...................... 30-86 HYDRAULIC TANK Removal and Installation ...................... 30-87 MAIN PUMP Removal ................................................ 30- 88 Installation ............................................ 30- 89
30-1 2
EPC VALVE Removal and Installation .................... 30- 90 PC VALVE Removal and Installation .................... 30- 91 LS VALVE Removal and Installation .................... 30- 92 CONTROL VALVE Removal ................................................ 30- 93 Installation ............................................ 30- 95 Disassembly ......................................... 30- 96 Assembly .............................................. 30-101 LS SELECT VALVE Disassembly and Assembly ................ 30-107 PRESSURE COMPENSATION VALVE Disassembly ......................................... 30-108 Assembly .............................................. 30-109 MAIN RELIEF VALVE Removal and Installation .................... 30-110 Disassembly and Assembly ................ 30-111 SOLENOID VALVE Removal and Installation .................... 30-112 PUMP MERGE/DIVIDER SOLENOID VALVE Removal and Installation .................... 30-113 2-STAGE RELIEF, TRAVEL HI/LO SOLENOID VALVE Removal and Installation .................... 30-114 INTERFERENCE PREVENTION SOLENOID VALVE Removal and Installation .................... 30-115 LEFT WORK EQUIPMENT PPC VALVE (FOR SWING, ARM CONTROL) Removal and Installation .................... 30-116 RIGHT WORK EQUIPMENT PPC VALVE (FOR BOOM, BUCKET CONTROL) Removal and Installation .................... 30-117 WORK EQUIPMENT PPC VALVE (PPC VALVE FOR BOOM, BUCKET, ARM, SWING CONTROL) Disassembly ......................................... 30-118 Assembly .............................................. 30-119 TRAVEL PPC VALVE Removal and Installation .................... 30-120 Disassembly and Assembly ................ 30-121 PPC VALVE FOR OFFSET CONTROL Removal and Installation .................... 30-122 BOOM LOCK VALVE Removal and Installation .................... 30-123 BOOM CYLINDER Removal ................................................ 30-124 Installation ............................................ 30-125 ARM CYLINDER Removal ................................................ 30-126 Installation ............................................ 30-127 BUCKET CYLINDER Removal ................................................ 30-128 Installation ............................................ 30-129
30-2 1
OFFSET CYLINDER Removal ................................................ 30-130 Installation ............................................ 30-131 HYDRAULIC CYLINDER FOR OFFSET Disassembly ......................................... 30-132 Assembly .............................................. 30-134 HYDRAULIC CYLINDER FOR BOOM, ARM, BUCKET Disassembly ......................................... 30-136 Assembly .............................................. 30-139 BUCKET Removal ................................................ 30-144 Installation ............................................ 30-145 ARM Removal ................................................ 30-146 Installation ............................................ 30-147 BUCKET, ARM Removal ................................................ 30-150 Installation ............................................ 30-151 OFFSET BRACKET Removal and Installation .................... 30-155 SECOND BOOM Removal ................................................ 30-156 Installation ............................................ 30-157 FIRST BOOM Removal ................................................ 30-158 Installation ............................................ 30-160 SECOND, FIRST BOOM Removal ................................................ 30-161 Installation ............................................ 30-163 OFFSET BRACKET, SECOND, FIRST BOOM Removal ................................................ 30-164 Installation ............................................ 30-166 BOOM Removal ................................................ 30-168 Installation ............................................ 30-169 OPERATOR’S CAB Removal ................................................ 30-170 Installation ............................................ 30-171 FLOOR FRAME Removal ................................................ 30-172 Installation ............................................ 30-173 AIR CONDITIONER COMPRESSOR Removal and Installation .................... 30-174 AIR CONDITIONER CONDENSER Removal and Installation .................... 30-175 AIR CONDITIONER UNIT Removal ................................................ 30-176 Installation ............................................ 30-177 COUNTERWEIGHT Removal and Installation .................... 30-178 CONTROLLER Removal and Installation .................... 30-179 MONITOR Removal and Installation .................... 30-180
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR GM38VL CONTENTS ASSEMBLY DRAWINGS .................................................................................................................... 30-56- 2 PARTS LIST ......................................................................................................................................... 30-56- 8 TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY ........................................................................ 30-56-10 1. Standard tools ....................................................................................................................... 30-56-10 2. Manufactured tools ............................................................................................................... 30-56-11 DISASSEMBLY PROCEDURE ............................................................................................................ 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
DISASSEMBLY AND ASSEMBLY
30-56-2 2
TRAVEL MOTOR
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
PC228USLC-1
TRAVEL MOTOR
30-56-3 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
REDUCTION GEAR
30-56-4 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
PC228USLC-1
TRAVEL MOTOR
30-56-5 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
HYDRAULIC MOTOR RELIEF VALVE CONTROL VALVE
30-56-6 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
PC228USLC-1
TRAVEL MOTOR
30-56-7 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
PARTS LIST No.
Part name
Q’ty
37
REDUCTION GEAR Hub Spindle kit • Spindle ass’y • • Spindle • • Hold flange • Hexagon socket head bolt • Parallel pin (select one from 3 kinds) • Plain washer
3
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
6
Input gear
1
7
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 ↓ 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
1 2
33 35 36 42 43
Hexagon socket head plug Hexagon socket head bolt Ball Parallel pin O-ring
3 12 1 2 3
1
2 3 19 34
8 13
30-56-8 2
1 1 1 1 1 1 3 6
No.
Part name
Q’ty
HYDRAULIC MOTOR
1
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 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
DISASSEMBLY AND ASSEMBLY
No.
201 202 203 204 205 206 208 209 210 211 217 219 220
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
Part name
TRAVEL MOTOR
Q’ty
No.
RELIEF VALVE
2
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
• Hexagon socket head plug • Name plate • Square head plug
4 1 2
341 343
• Parallel pin • Hexagon socket head bolt
1 12
CONTROL VALVE
1
Rear flange assembly • Rear flange kit • • Rear flange • • Spool • • Piston • Plug • Plug • Stopper • Plug • Valve • Spring • Spring • O-ring • O-ring • Plug • Hexagon socket head 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
Q’ty
30-56-9 2
DISASSEMBLY AND ASSEMBLY
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
Q’ty
1
Hexagonal wrench
2
Socket wrench (Ratchet handle)
3
Torque wrench
Dial type for about 280 N Dial type for about 850 N
4
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
5
Extension bar
150 mm
1
6
Hammer
Nominal size: 12
1
7
Plastic hammer
L = About 300
1
8
Flat-head screwdriver
About 150 mm
1
9
Snap ring pliers
For shaft 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. 100°C 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
1
18
Thickness gauge
Measurement range: 0.04 – 0.3 mm
1
19
Rotary bar
For cutting cast iron
1
20
Air chisel
BRH-8 (Compressed air: 0.5 – 0.6 MPa {5 – 6 kg/cm2})
1
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
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
2. Manufactured tools No.
Name and major dimensions
Q’ty
No.
1
Preload adjustment jig for main bearing
1
6
Holder (III)
1
7
Holder (IV)
1
8
Pointed punch
1
2
Clamp
Name and major dimensions
Q’ty
2
3
Press fitting jig
1
9
Steel rod
1
4
Holder (I)
1
10
Aluminum rod
1
11
Sling jig
1
5
Holder (II)
1
PC228USLC-1
30-56-11 2
DISASSEMBLY AND ASSEMBLY
No.
Name and major dimensions
TRAVEL MOTOR
Q’ty
No. 17
12
Floating seal fitting jig (I)
1
13
Floating seal fitting jig (II)
1
14
Floating seal fitting jig (III)
1
15
Sling jig
1
16
Pulling jig
1
30-56-12 2
Name and major dimensions Bending jig
Q’ty 1
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
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
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
2. DISASSEMBLY PROCEDURE fl fl fl fl fl
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). fl Necessary tools • Impact wrench or ratchet handle • Wrench adapter, socket of size 32
1) Remove hexagon socket head bolts (343) (12 pieces). fl Necessary tools • Socket wrench • Extension bar • Wrench adapter, rod of size 14
(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. 2) Remove hexagon socket head plugs (33) (3 pieces). 3) Remove hexagon socket head bolts (35) (12 pieces). fl Necessary tools • Ratchet handle • Wrench adapter, rod of size 10
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). Do not reuse removed O-ring (30). 4) Drain oil from the reduction gear assembly. fl Necessary tools • Sling: 1 set • Eyebolt (for PF 1/2): 2 pieces • Plastic hammer • Container (for 8 liters)
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
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
DISASSEMBLY AND ASSEMBLY
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). fl Loosen the plug when the motor is on the turning work table for the ease of work. fl Do not reuse removed O-ring (336). fl Necessary tools • Socket wrench • Wrench adapter, socket of size 41
2) Remove 2 springs (328), 2 stoppers (325), and spool (323) from rear flange (301). fl Take care not to damage the periphery of spool (323) and sliding surface of rear flange (301). fl Slant rear flange (301) with either plug port down, and spool (323) slides down. Hold the end of the spool and take it out.
2. Removal of check valve 1) Take plugs (326) (2 pieces) out of rear flange (301). fl Loosen the plugs when the motor is on the turning work table for the ease of work. fl Necessary tools • Socket wrench • Wrench adapter, rod of size 14
2) Take 2 springs (330) and 2 valves (327) out of rear flange (301). fl Take care not to damage the seats of valve (327) and rear flange (301). 3) Take O-ring (337) out of plug (326). fl Do not reuse removed O-ring (337).
30-56-16 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
3. Disassembly of 2nd travel speed selection valve 1) Remove plug (357) from rear flange (301). fl Loosen the plug when the motor is on the turning work table for the ease of work. fl Necessary tools • Hexagonal wrench of size 10
2) Remove spool (363) and spring (366) from rear flange (301). 3) Remove O-ring (355) from plug (357). fl Do not reuse removed O-ring (355).
4. Disassembly of internal parts (SRV) 1) Remove plugs (380) (2 pieces). fl Necessary tools • Hexagonal wrench of size 8
2) Remove O-ring (359) from plug (380). fl Do not reuse removed O-ring (359). 3) Remove rear flange (301) from piston (381). fl Take care not to damage the piston hole. fl Since rear flange (301) and piston (381) are matched to each other in the field, keep them coupled.
PC228USLC-1
30-56-17 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
4) Remove plugs (382) (2 pieces). fl Necessary tools • Hexagonal wrench of size 5 5) Remove O-rings (383) and (384) from plug (382). fl Do not reuse removed O-rings (383) and (384).
6) Remove steel balls (385) (2 pieces) from rear flange (301).
5. Disassembly of relief valve 1) Remove plug (204) from sleeve (202). fl Since shim (205) of the internal parts of sleeve (202) is decided after relief pressure is set, keep those parts as a valve kit separately from other parts. fl Necessary tools • Hexagonal wrench of size 10 2) Remove O-ring (210) from plug (204). fl Do not reuse removed O-ring (210).
3) Take shim (205) out of plug (204).
30-56-18 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
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
DISASSEMBLY AND ASSEMBLY
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). fl Necessary tools • Compressed air (0.3 – 0.5 MPa {3 – 5 kg/cm2}) • Nozzle
2) Remove O-rings (135) and (139) from piston (112). fl Do not reuse removed O-rings (135) and (139).
2. Taking internal parts out of motor 1) Lay the travel motor on its side. (Turn the travel motor by 90 degrees.) fl When the travel motor is laid on its side, oil spills. Place a container under the motor to receive the oil. fl Necessary tools • Container 2) Drain the oil from the travel motor. 3) Hold cylinder block (104) with both hands and take it out of spindle (2). fl Before pulling out cylinder block (104), hold it with the hands and rotate it in both directions by 2 - 3 turns to separate shoe (106) from swash plate (103). If cylinder block (104) is pulled out 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
DISASSEMBLY AND ASSEMBLY
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). fl 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). fl 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
DISASSEMBLY AND ASSEMBLY
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). fl Since piston (161) and shoe (162) are set in 1 unit, if either of them needs to be replaced, replace both of them. If compressed air is supplied quickly, the 2nd travel speed selection valve 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} fl Necessary tools • Compressed air (0.3 – 0.5 MPa {3 – 5 kg/cm2}) • Nozzle
3. Disassembly of internal parts of cylinder block 1) Place cylinder block (104) on a press stand. Apply holder (I) to washer (110) and take out C-type hole snap ring (145) with snap ring pliers. fl Press load: Min. 1,961 N {200 kg} fl When removing the spring, align holder (I) with the washer and protect the cylinder block from washer and spring. fl Cover the sliding surfaces of the cylinder block with vinyl sheet for protection. fl Remove spring (114) only when it needs to be replaced. fl Necessary tools • Press stand • Holder (I) • Snap ring pliers 2) Loosen the press slowly until the spring force is reduced to zero. If the press is loosened quickly, the spring may jump out to hurt you. Loosen it slowly. 3) Take C-type hole snap ring (145), washer (110), spring (114), and washer (110) out of cylinder block (104).
30-56-22 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
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. fl 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
DISASSEMBLY AND ASSEMBLY
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. fl 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. fl Necessary tools • Clamp • Hexagonal wrench of size 14 3) Turn over the travel motor. 4) Remove 3 snap rings (20) and distance pieces (13) from hold flange (3). fl Make match marks on the snap rings and hold flange so that they will be installed to the original positions. fl 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. fl Necessary tools • Rotary bar 6) Install the jig to pull out parallel pin (34) and pull out the parallel pin to the end of hold flange (3). (6 places) fl Necessary tools • Wrench adapter, socket of size 22
30-56-24 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
7) Loosen hexagon socket head bolts (19). fl Since the threaded parts of the hexagon socket head bolts (19) are coated with adhesive, those bolts may be difficult to remove. Accordingly, loosen the bolts as slowly as possible. (Loosening torque: Min. 686 Nm {70 kgm}) fl Necessary tools • Torque wrench • Wrench adapter, rod of size 19
8) Remove hold flange (3) from spindle (2). fl Make match marks on the hold flange and spindle so that they will be installed to the original positions.
5. Removal of clamps 1) Turn over the travel motor. 2) Remove the clamps (2 pieces). fl 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). fl Lift up spindle (2) slowly so that it will not damage the retainer of ball bearing (21). fl Necessary tools • 1 set of sling • 2 eyebolts • Plastic hammer
PC228USLC-1
30-56-25 2
DISASSEMBLY AND ASSEMBLY
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. fl When removing ball bearing (21), hit 3 4 points on the periphery of the pin end lightly so that the bearing will not be slanted. fl If the outer race of ball bearing (21) is removed from hub (1), ball bearing (21), RV gear assembly, and pin (17) fall from hub (1). Accordingly, place a container and a rubber mat on it under the work table to protect the falling parts. fl The RV gear assembly is the minimum parts unit. If any part of this assembly needs to be replaced, replace the whole assembly. (See parts classification in the parts list.) fl Necessary tools • Pin punch [1] • Hammer [2] 8. Removal of ball bearing 1) Take floating seal (31) out of hub (1). 2) Turn over the travel motor. 3) Hit ball bearing (21) with a pin punch [1] and hammer [2] from the cover (8) side of hub (1) to remove the ball bearing from hub (1). fl If ball bearing (21) is removed, it falls from hub (1). Accordingly, place a rubber mat under the work table to protect it. fl Necessary tools • Pin punch [1] • Hammer [2]
30-56-26 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
9. Removal of spindle parts 1) Take floating seal (31) out of spindle (2). fl Necessary tools • Flat-head screwdriver 2) Take the outer race of tapered roller bearing (22) out of spindle (2).
10. Taking outer race out of tapered roller bearing (22) 1) Take the outer race of tapered roller bearing (22) out of hold flange (3). fl Necessary tools • Aluminum rod • Hammer
11. Removal of oil seal 1) Apply a flat-head screwdriver to the rim of oil seal (132) in spindle (2) and hit it with a hammer [1] to take out oil seal (132). fl Remove oil seal (132) only when it needs to be replaced. Do not reuse the removed oil seal. fl Remove the oil seal after the reduction gear assembly is disassembled and spindle (2) is separated. fl Necessary tools • Flat-head screwdriver • Hammer [1] 12. Removal of deep groove ball bearing (149) Remove deep groove ball bearing (149) only when it needs to be replaced. 1) Place holder [II] on the press stand and put shaft (102) in it. Do not reuse the removed deep groove ball bearing. fl Necessary tools • Press stand • Holder [II] 2) Press the tip of shaft with press [1] and remove deep groove ball bearing (149).
PC228USLC-1
30-56-27 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
MAINTENANCE STANDARD Disassemble and inspect the travel motor according to the following standard. Handle its parts carefully. In particular, take care not to damage the moving parts and sliding parts. 1. Seals Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, even if they are free from damage. 2. Maintenance standard for worn parts 1) Replace all the parts which have visible extreme damages. 2) Replace the parts which have the following trouble (phenomenon). Part No.
Part name Spindle kit Spindle Hold flange Hexagon socket head bolt Parallel pin Plain washer
(2) (3) (19) (34) (37)
RV gear assembly RV gear (A) RV gear (B) Crankshaft Spacer bearing Tapered roller bearing Needle roller bearing with retainer
(4) (5) (9) (12) (22) (23) 13
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. • Periphery and end faces are 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 µ 25 µ
Outside surface has flaw. Outside surface is worn unevenly. Outside surface has flaw. Outside surface is worn unevenly.
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
Part No.
Part name
TRAVEL MOTOR
Trouble
102
Shaft
• Contact face against oil seal (132) is worn. • Spline is worn.
103
Swash plate
• Swash plate is seized.
104
Cylinder block
• Spline is worn. • Inside of bore is worn remarkably. • Sliding surface against timing plate (109) is scratched and worn unevenly.
(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
• Periphery and end faces are 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
Deep groove ball bearing Deep groove ball bearing
• There is bruise. • Surface is flaked. • Surface is worn unevenly.
363
Spool
• Outside surface has flaw. • Outside surface is worn unevenly.
201
Valve
• Outside surface has flaw. • Outside surface is worn unevenly.
202
Sleeve
• Seat has flaw. • Clearance between sleeve and valve (201) is large.
PC228USLC-1
Standard value (Standard dimension)
Allowable value (Criterion)
Clearance: 0.05 mm
Clearance: 0.15 mm
Braking torque: Min. 398 Nm {40.6 kgm}
Braking torque: Max. 398 Nm {40.6 kgm}
30-56-29 2
DISASSEMBLY AND ASSEMBLY
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
Q’ty
Tightening torque 709 ± 108 Nm {72.3 ± 11 kgm}
19
Hexagon socket head bolt
M24 (P3.0)
3
33
Hexagon socket head plug
PF 1/2
3
98.1 ± 19.6 Nm {10 ± 2 kgm}
35
Hexagon socket head bolt
M12 (P1.75)
12
102 ± 15.7 Nm {10.4 ± 1.6 kgm}
202
Sleeve
PF 1
2
245 ± 49 Nm {25 ± 5 kgm}
204
Plug
PF 1/2
2
98.1 ± 19.6 Nm {10 ± 2 kgm}
324
Plug
M36 (P1.5)
2
255 ± 39.2 Nm {26 ± 4 kgm}
326
Plug
M36 (P1.5)
2
441 ± 88.3 Nm {45 ± 9 kgm}
343
Hexagon socket head bolt
M16 (P2.0)
12
252 ± 39.2 Nm {25.7 ± 4 kgm}
346
Plug
PT 1/4
2
29.4 ± 4.9 Nm {3 ± 0.5 kgm}
352
Plug
PF 1/4
2
29.4 ± 4.9 Nm {3 ± 0.5 kgm}
354
Hexagon socket head plug
NPTF 1/16
8
9.81 ± 2.45 Nm {1.0 ± 0.25 kgm}
357
Plug
PF 1/2
2
98.1 ± 19.6 Nm {10 ± 2 kgm}
380
Plug
PF 3/8
2
58.8 ± 9.81 Nm {6 ± 1 kgm}
382
Plug
PF 1/8
2
14.7 ± 2.45 Nm {1.5 ± 0.25 kgm}
398
Hexagon socket head plug
PT 1/8
4
12.3 ± 2.45 Nm {1.25 ± 0.25 kgm}
30-56-30 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
2. ASSEMBLY PROCEDURE 2-1. ASSEMBLY OF BRAKE VALVE 1. Installation of check valve 1) Fit O-ring (337) to plug (326). fl Apply grease to O-ring (337). fl Necessary tools • Torque wrench • Wrench adapter, rod of size 14 2) Put spring (330) and valve (327) in plug (326). Apply grease to valve (327) and spring (330) and fix spring (330) temporarily. fl Apply HERMSEAL to the threads of plug (326). fl Tighten plug (326) with torque wrench. 3 Plug: 255 ± 39.2 Nm {26 ± 4 kgm} 3) Put assembled plug (326) in rear flange (301) and tighten to the specified torque.
2. Installation of spool 1) Insert spool (323) in rear flange (301). fl Apply hydraulic oil to spool (323) and insert it in rear flange (301). When inserting the spool, align it with rear flange hole. A flaw on the rear flange hole or outside of the spool can cause internal leakage and lowering of performance of the travel motor. Take care. fl Necessary tools • Torque wrench • Wrench adapter, socket of size 41 2) Fit O-ring (336) to plug (324). fl Apply grease to O-ring (336). 3) Install stopper (325) and spring (328) to plug (324) and tighten plugs (324) (2 pieces) into rear flange (301) to the specified torque. 3 Plug: 441 ± 88.3 Nm {45 ± 9 kgm} fl Rear flange (301) and spool (323) are 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
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
3. Assembly of 2nd travel speed selection valve 1) Fit O-ring (355) to plug (357). fl Apply grease to O-ring (355). 2) Fit spring (366) to spool (363) and insert them in rear flange (301). fl When inserting spool (363) in rear flange (301), apply hydraulic oil to it. fl A flaw on the hole of rear flange (301) or outside of spool (363) can cause internal leakage and lowering of performance of the travel motor. Take care. fl When inserting spool (163), align it with the hole of rear flange (301) to prevent contact damage on the inside of rear flange and outside of the spool. 3) Install plug (357) to rear flange (301) and tighten it to the specified torque. 3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm} fl Necessary tools • Torque wrench • Wrench adapter, rod of size 10
4. Assembly of internal parts (SRV) 1) Put steel balls (385) (2 pieces) in rear flange (301).
2) Fit O-rings (383) and (384) to plug (382). (2 pieces) fl Apply grease to O-rings (383) and (384). 3) Install plugs (382) (2 pieces) to rear flange (301) and tighten them to the specified torque. 3 Plug: 14.7 ± 2.45 {1.5 ± 0.25 kgm} fl Necessary tools • Torque wrench • Wrench adapter, rod of size 5
30-56-32 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
4) Put piston (381) in rear flange (301). fl 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.
5) Fit O-ring (359) to plug (380). fl Apply grease to O-ring (359). 6) Install plug (380) to rear flange (301) and tighten it to the specified torque. 3 Plug: 58.8 ± 9.81 Nm {6 ± 1 kgm} fl Use a vise for the ease of work. fl Necessary tools • Torque wrench • Wrench adapter, rod of size 8
5. Assembly of relief valve 1) Fit O-rings (208), (209), and (219), and backup rings (211) and (217) (2 pieces) to sleeve (202). fl Apply grease to O-rings (208) and (209). 2) Fit O-ring (210) to plug (204). fl Apply grease to O-ring (210). 3) Put shim (205) in plug (204). fl Since the relief pressure is adjusted with the shim, install the removed shim as it is.
4) Install piston seal (220) to valve (201). fl Piston seal (220) consists of an O-ring and a Teflon ring. Apply grease to both of them. Put in the O-ring first, then put in the Teflon ring.
PC228USLC-1
30-56-33 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
5) Insert valve (201), spring (206), and spring retainer (203) in sleeve (202) and tighten plug (204) having shim (205). fl Apply hydraulic oil to valve (201) and insert it in sleeve (202). fl When inserting valve (201), align it with the hole of sleeve (202) (to prevent contact damage on the hole of the sleeve and outside of the valve). fl Since the internal parts of the sleeve are adjusted for each combination, take care not to mistake in combination. 3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm} fl Necessary tools • Torque wrench • Wrench adapter, rod of size 10 fl 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
DISASSEMBLY AND ASSEMBLY
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
Was any part replaced?
• Hub (1) • Spindle kit • Ball bearing (21)
[B] PROCEDURE FOR ADJUSTING THICKNESS OF HOLD FLANGE (3) (page 30-56-45)
• Spindle kit • RV gear assembly
[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
DISASSEMBLY AND ASSEMBLY
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]. fl 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). fl Place floating seal fitting jig [I], floating seal, and floating seal fitting jig [II] in order and press them until jig [II] comes in contact with jig [I]. Remove the jigs and check that the parallelism error of the end face of the hub and floating seal surface is less than 1 mm. fl Necessary tools • Floating seal fitting jig [I] • Floating seal fitting jig [II] 2. Assembly of spindle (2) 1) Fit floating seal (31) to the floating seal groove of spindle (2). Do not apply grease to the O-ring of floating seal (31). fl Place floating seal fitting jig [III], floating seal, and floating seal fitting jig [II] in order and press them until jig [II] comes in contact with jig [III]. Remove the jigs and check that the parallelism error of the end face of the spindle groove and floating seal surface is less than 1 mm. fl Necessary tools • Floating seal fitting jig [II] • Floating seal fitting jig [III]
30-56-36 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
3. Assembly of hub (1) and spindle (2) 1) Install eyebolts (for M16) (2 pieces) symmetrically to spindle (2). fl Necessary tools • Eyebolt, 2 pieces 2) Install hooks to the eyebolts and put spindle (2) in hub (1) slowly. If spindle (2) is inserted in hub (1) quickly, it may be slanted and scratched in main bearing (21). Insert it slowly. When spindle (2) is inserted, if it is slanted, separate it from hub (1) and insert it again slowly. fl Necessary tools • Set of sling 3) Install clamps (2 pieces) to hub (1) and spindle (2) to secure. Set the clamps symmetrically. fl Necessary tools • Clamp • Hexagonal wrench of size 14 4) Turn over the travel motor to bring the cover side to the top. fl Turn the travel motor 180 degrees. 5) Fit outer races (3 pieces) of tapered roller bearing (22) to the outer race fitting holes in spindle (2). 4. Assembly of RV gear assembly 1) Install a sling [1] to the RV gear assembly. fl Necessary tools • Sling (RV gear assembly) 2) Install a hook to the sling and put it in 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. fl Apply lubricating oil to pins (17) before inserting them.
PC228USLC-1
30-56-37 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
5. Assembly of ball bearing 1) Insert ball bearing (21) in hub (1). fl Ball bearing (21) is to be press fitted to hub (1). Fit it evenly little by little by hitting it lightly with a hammer. Put ball bearing (21) in hub (1) securely. fl Necessary tools • Hammer [1] • Press fitting jig [2]
2) Install the outer races of 3 tapered roller bearings (22).
6. Installation of hold flange 1) Install spindle (2) to hold flange (3). Check the match marks of spindle (2) and hold flange (3).
30-56-38 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
7. Installation of hexagon socket head bolts (19) and parallel pin (34) 1) Apply LOCTITE #638 to the threads of spindle (2). fl Necessary tools • Torque wrench • Wrench adapter, rod of size 19 2) Put plain washers (37) (3 pieces) on the bolt seats of hold flange (3). 3) Tighten hexagon socket head bolts (19) (3 pieces) to about 19.6 Nm {20 kgm}. fl Degrease hexagon socket head bolts (19) thoroughly. 4) Drive parallel pins (34) (6 pieces) with an air chisel (BRH-8) until they reach the pin hole bottoms of spindle (2). fl Degrease parallel pins (34) thoroughly. Set air pressure to 49 – 58.8 Nm {5 – 6 kg/cm2}. Take care not to mistake the fitting 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.) fl Necessary tools • Air chisel (BRH-8) 5) After installing parallel pins (34), bend the pin hole edge of hold flange (3). fl Apply the bending jig around the pin hole of hold flange (3) and hit it with a hammer. fl Necessary tools • Bending jig • Hammer
6) Tighten hexagon socket head bolts (19) to the specified torque. 3 Bolt: 709 ± 108 Nm {72.3 ± 11 kgm} fl If any parts (spindle kit and/or RV gear assembly) are replaced, refer to [C] PROCEDURE FOR SELECTING THICKNESS OF DISTANCE PIECE (13) (page 30-56-47). fl If no parts are replaced, go to item 8. below.
PC228USLC-1
30-56-39 2
DISASSEMBLY AND ASSEMBLY
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). fl Fit 3 snap rings (20) and 3 distance pieces (13) to their original positions, matching the match marks. fl 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. fl Necessary tools • Snap ring pliers
Match marks on spur gears (7) fl When fitting spur gear (7), set their match marks a (punch marks) as shown here.
2) Fit C-type shaft snap rings (25) to the snap ring grooves of crankshafts (9). Snap ring (25) may come off the pliers and fly off. Hold it securely with the pliers. fl Necessary tools • Snap ring pliers
30-56-40 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
fl Take care of the direction of each snap ring. Fit it with its square side a up.
10. Fitting of oil seal 1) Turn over the travel motor. 2) Fit oil seal (132) to the oil seal hole of spindle (2). fl Apply lithium grease to the lip of oil seal (132). fl Necessary tools • Hammer • Holder [III]
11. Installation of shaft (102) 1) Install deep groove ball bearing (149) to shaft (102) by shrink fit. fl When installing, put on leather gloves and take care not to get burned. fl If deep groove ball bearing (149) was removed during disassembly, replace it with new one. fl Shrink fit temperature: 100 ± 10°C When installing the bearing, take care that it will not slant from shaft (2). fl Necessary tools • Heating oven • Leather gloves • Holder [II]
PC228USLC-1
30-56-41 2
DISASSEMBLY AND ASSEMBLY
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). fl Put washers (110) as shown in the figure at right.
30-56-42 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
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). fl Cover the sliding surfaces of cylinder block with a vinyl sheet for protection. fl Pressing force of spring (114): Min. 1,961 N {200 kg} Snap C-type hole snap ring (145) may come off the pliers and fly off. Hold it securely with the pliers. fl Necessary tools • Press stand • Holder [I] • 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
DISASSEMBLY AND ASSEMBLY
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. fl Necessary tools • 1 set of sling • Sling [I]
16. Installation of motor assembly 1) Using sling [I], lift up the motor assembly and install an insertion jig to the spline at the end of shaft (102). fl Match the pivot hole of swash plate (103) to pivot (167) and install the motor assembly slowly, taking care not to damage spindle (2), etc. with the motor assembly. fl Necessary tools • Shaft insertion jig 2) Lift up the motor shaft slowly and install it to spindle (2). 3) After installing the motor assembly, remove sling [I] and insertion jig. fl After installing the motor assembly, 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
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
[B] PROCEDURE FOR ADJUSTING THICKNESS OF HOLD FLANGE (3) Assembly processes to be finished before adjustment fl 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). fl Necessary tools • Preload adjustment jig [2] for main bearing
2. Tighten special nut [3] of preload adjustment jig [2] for main bearing to the specified torque. 3 Nut [3]: 118 ± 19.6 Nm {12 ± 2 kgm} fl Necessary tools • Torque wrench [1] • Wrench adapter, socket of size 30
3. Obtain depth A through the measurement hole of the preload adjustment jig for main bearing with depth micrometer [4]. fl Necessary tools • Depth micrometer [4] 4. Since dimension B of the preload adjustment jig for main bearing is known, obtain clearance C by the following formula. C=A–B
PC228USLC-1
A: Measured value B: Dimension of jig C: Clearance
30-56-45 2
DISASSEMBLY AND ASSEMBLY
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. fl Carry out disassembly and assembly again. 7. Remove the preload adjustment jig for main bearing from spindle (2).
30-56-46 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
[C] PROCEDURE FOR SELECTING THICKNESS OF DISTANCE PIECE (13) Assembly processes to be finished before selection fl 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. fl Perform this procedure to insert the RV gear assembly in spindle (2) securely. fl Necessary tools • Holder [IV] • Hammer • Thickness gauge
2. Install thinnest distance piece (13) into hold flange (3) and fit snap ring (20) to the snap ring groove inside hold flange (3). 3. Lightly hit the periphery of snap ring (20) with holder [IV] and hammer. fl Perform this procedure to check that the RV gear assembly is inserted in spindle (2) 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. fl See clearance adjustment parts list (on page 30-56-51).
PC228USLC-1
30-56-47 2
DISASSEMBLY AND ASSEMBLY
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. fl When fitting friction plates (115), dip them in hydraulic oil. Take care not to mistake the fitting order of the friction plates and mating plates. If it is mistaken, the braking force of the parking brake may lower.
1) Put piston (112) having O-rings (135) and (139) in spindle (2). 2) Insert piston (112) into spindle (2) by hitting its end with a plastic hammer. Take care not to slant it. fl Apply grease to O-rings (135) and (139). fl Necessary tools • Plastic hammer
See assembly procedure for 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). fl Apply hydraulic oil to deep groove ball bearing (150). fl Necessary tools • Grease • Hydraulic oil
1) Add hydraulic oil. 5 Hydraulic oil (1.7 liters) 2) Install O-rings (29) and (27) (2 pieces) and parallel pins (42) (2 pieces) to spindle (2) side and install rear flange (301) to the spindle. Do not apply grease to O-ring (29) on the mating face (since oozing grease can be mistaken for oil leakage). fl When installing rear flange (301), match the pin holes to parallel pins (42) fitted in spindle (2).
See assembly procedure for 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). fl Apply grease to O-ring (30). When installing cover (8) into hub (1), take care not to damage the O-ring, etc. fl Match the bolt holes of cover (8) to the tap holes of hub (1). fl Necessary tools • Grease • Plastic hammer • Eyebolts (2 pieces), PF 1/2 • 1 set of sling
30-56-48 2
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
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 fl Necessary tools a drain port which will not be used. • Torque wrench 3 Plug: 98.1 ± 19.6Nm {10 ±2 kgm} • Wrench adapter, socket of size 32 fl Necessary tools • Torque wrench • Wrench adapter, rods of sizes 10 and 14
1) Tighten hexagon socket head bolts (35) (12 pieces) to the specified torque with a torque wrench. 2) Add lubricating oil (5.4 liters). 3 Bolt: 102 ± 15.7 Nm {10.4 ± 1.6 kgm} fl Necessary tools • Torque wrench • Wrench adapter, rod of size 10 • Lubricating oil: 5.4 liters
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} fl Necessary tools • Torque wrench • Wrench adapter, rod of size 10
30-56-49 2
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
PERFORMANCE TEST fl 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
2
Measuring cylinder (For 5 liters)
1 piece
3
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.
2
Run-in operation of travel motor
Gear speed
Speed of travel motor
Low
10 rpm
High
3
Pressure
Revolving direction
Operation time
No load
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 – 55°C • Temperature of outside part of reduction gear assembly hub: 40 – 80°C 2) Performance test ........................... Measure and judge the following items. Criteria for acceptance
— Travel motor drive pressure Max. 2.0 MPa {20 kg/cm2} in 1st gear speed at 10 rpm Max. 2.9 MPa {30 kg/cm2} in 2nd gear speed at 20 rpm Drainage from hydraulic motor Max. 2 liters/min in both 1st and 2nd gears at 10 rpm
30-56-50 2
Accepted
Rejected
Install tracks.
Disassemble and adjust again.
PC228USLC-1
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR
LIST OF CLEARANCE ADJUSTMENT PARTS Part name
Dimension
Distance piece (13)
PC228USLC-1
Unit: mm Classification No.
Dimension (T)
E
Above 3.30 to 3.35
F
Above 3.35 to 3.40
G
Above 3.40 to 3.45
H
Above 3.45 to 3.50
I
Above 3.50 to 3.55
J
Above 3.55 to 3.60
K
Above 3.60 to 3.65
L
Above 3.65 to 3.70
M
Above 3.70 to 3.75
N
Above 3.75 to 3.80
O
Above 3.80 to 3.85
P
Above 3.85 to 3.90
Q
Above 3.90 to 3.95
R
Above 3.95 to 4.00
S
Above 4.00 to 4.05
T
Above 4.05 to 4.10
U
Above 4.10 to 4.15
30-56-51 2
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