SM PC228US-2 SEBM015903
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Transcript of SM PC228US-2 SEBM015903
SEBM015903
© 2003 1All Rights ReservedPrinted in Japan 05-03(01)
1
00-1(3)
MACHINE MODEL SERIAL NUMBER
PC228USLC-1 11001 and upPC228US-2 15001 and upPC228USLC-2 15001 and up
• This shop manual may contain attachments and optional equipment that are not availablein your area. Please consult your local Komatsu distributor for those items you mayrequire.Materials and specifications are subject to change without notice.
• PC228US, PC228USLC mount the S6D102E-1 engine.For details of the engine, see the 102 Series Engine Shop Manual.
PC228US-2
PC228USLC-1, 2
00-2 PC228USLC-11
CONTENTS
No. of page
01 GENERAL ........................................................................ 01-1
10 STRUCTURE AND FUNCTION ...................................... 10-1
20 TESTING AND ADJUSTING .......................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................. 30-1
40 MAINTENANCE STANDARD......................................... 40-1
90 OTHERS........................................................................... 90-1
00-2-1(3)
PC228USLC-1
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Mark Indication Action required
fi Page to be newly added Add
‡ Page to be replaced Replace
( ) Page to be deleted Discard
The affected pages are indicated by the use of thefollowing marks. It is requested that necessary actionsbe taken to these pages according to the table below.
Pages having no marks are those previously revisedor made additions.
LIST OF REVISED PAGE
Time ofMark Page revisionTime ofMark Page revision
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LIST OF REVISED PAGES
01- 101- 2 (1)01- 2-1 (1)01- 301- 4 (2)01- 4-1 (1)01- 4-2 (2)01- 4-3 (1)01- 4-4 (1)01- 501- 601- 6-1 (1)01- 6-2 (1)01- 6-3 (1)01- 6-4 (1)01- 701- 8
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00-2-2(3)
PC228USLC-1
20-35120-35220-35420-35520-35620-35720-35820-35920-36020-36120-36220-36320-36420-36520-36620-36720-36820-36920-37020-37120-37220-37320-37420-37520-37620-37720-37820-37920-38020-38120-38220-38320-38420-38520-38620-38720-38820-38920-39020-391
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LIST OF REVISED PAGES
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20-10120-10220-10320-10420-10520-10620-10720-10820-10920-11020-11120-11220-11320-11420-11520-11620-11720-11820-11920-12020-12120-12220-12320-12420-12520-12620-12720-12820-12920-13020-13120-13220-13320-13420-135
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PC228USLC-1
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LIST OF REVISED PAGES
30-56-6 (2)30-56-7 (2)30-56-8 (2)30-56-9 (2)30-56-10 (2)30-56-11 (2)30-56-12 (2)30-56-13 (2)30-56-14 (2)30-56-15 (2)30-56-16 (2)30-56-17 (2)30-56-18 (2)30-56-19 (2)30-56-20 (2)30-56-21 (2)30-56-22 (2)30-56-23 (2)30-56-24 (2)30-56-25 (2)30-56-26 (2)30-56-27 (2)30-56-28 (2)30-56-29 (2)30-56-30 (2)30-56-31 (2)30-56-32 (2)30-56-33 (2)30-56-34 (2)30-56-35 (2)30-56-36 (2)30-56-37 (2)30-56-38 (2)30-56-39 (2)30-56-40 (2)30-56-41 (2)30-56-42 (2)30-56-43 (2)30-56-44 (2)30-56-45 (2)
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PC228USLC-1
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LIST OF REVISED PAGES
30-91 (1)30-92 (1)30-93 (1)30-94 (1)30-95 (1)30-96 (1)30-97 (1)30-98 (1)30-99 (1)30-100 (1)30-101 (1)30-102 (1)30-103 (1)30-104 (1)30-105 (1)30-106 (1)30-107 (1)30-108 (1)30-109 (1)30-110 (1)30-111 (1)30-112 (1)30-113 (1)30-114 (1)30-115 (1)30-116 (1)30-117 (1)30-118 (1)30-119 (1)30-120 (1)30-121 (1)30-122 (1)30-123 (1)30-124 (1)30-125 (1)30-126 (1)30-127 (1)30-128 (1)30-129 (1)30-130 (1)
30-131 (1)30-132 (1)30-133 (1)30-134 (1)30-135 (1)30-136 (1)30-137 (1)30-138 (1)30-139 (1)30-140 (1)30-141 (1)30-142 (1)30-144 (1)30-146 (1)30-147 (1)30-148 (1)30-149 (1)30-150 (1)30-151 (1)30-152 (1)30-153 (1)30-155 (1)30-156 (1)30-157 (1)30-158 (1)30-159 (1)30-160 (1)30-161 (1)30-162 (1)30-163 (1)30-164 (1)30-165 (1)30-166 (1)30-168 (1)30-170 (1)30-171 (1)30-172 (1)30-173 (1)30-174 (1)30-175 (1)
30-176 (1)30-177 (1)30-178 (1)30-179 (1)30-180 (1)
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40-3740-3840-4040-4140-4240-4340-4440-4540-4640-47
90- 1 (1)90- 390- 3-2 (1)90- 590- 7 (1)
SAFETY SAFETY NOTICE
00-3
SAFETYSAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service andrepair techniques recommended by Komatsu and described in this manual are both effectiveand safe. Some of these techniques require the use of tools specially designed by Komatsu forthe specific purpose.
To prevent injury to workers, the symbol¤ is used to mark safety precautions in this manual.The cautions accompanying these symbols should always be followed carefully. If any danger-ous situation arises or may possibly arise, first consider safety, and take the necessary actionsto deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.Read the Operation and Maintenance Manual care-fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, readall the precautions given on the decals which arefixed to the machine.
2. When carrying out any operation, alwayswear safety shoes and helmet. Do not wearloose work clothes, or clothes with buttonsmissing.
• Always wear safety glasses when hittingparts with a hammer.
• Always wear safety glasses when grindingparts with a grinder, etc.
3. If welding repairs are needed, always have atrained, experienced welder carry out the work.When carrying out welding work, always wearwelding gloves, apron, hand shield, cap andother clothes suited for welding work.
4. When carrying out any operation with two ormore workers, always agree on the operatingprocedure before starting. Always inform yourfellow workers before starting any step of theoperation. Before starting work, hang UNDERREPAIR signs on the controls in the operator'scompartment.
5. Keep all tools in good condition and learn thecorrect way to use them.
6. Decide a place in the repair workshop to keeptools and removed parts. Always keep the toolsand parts in their correct places. Always keepthe work area clean and make sure that there isno dirt or oil on the floor. Smoke only in the areasprovided for smoking. Never smoke while work-ing.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park themachine on hard, level ground, and block thewheels or tracks to prevent the machine frommoving.
8. Before starting work, lower blade, ripper, bucketor any other work equipment to the ground. Ifthis is not possible, insert the safety pin or useblocks to prevent the work equipment from fall-ing. In addition, be sure to lock all the controllevers and hang warning signs on them.
9. When disassembling or assembling, support themachine with blocks, jacks or stands beforestarting work.
10.Remove all mud and oil from the steps or otherplaces used to get on and off the machine.Always use the handrails, ladders or steps whengetting on or off the machine. Never jump on oroff the machine. If it is impossible to use thehandrails, ladders or steps, use a stand to pro-vide safe footing.
SAFETY SAFETY NOTICE
00-4
PRECAUTIONS DURING WORK
11.When removing the oil filler cap, drain plug orhydraulic pressure measuring plugs, loosenthem slowly to prevent the oil from spurting out.Before disconnecting or removing componentsof the oil, water or air circuits, first remove thepressure completely from the circuit.
12.The water and oil in the circuits are hot when theengine is stopped, so be careful not to getburned.Wait for the oil and water to cool before carry-ing out any work on the oil or water circuits.
13.Before starting work, remove the leads from thebattery. Always remove the lead from the nega-tive (–) terminal first.
14.When raising heavy components, use a hoist orcrane.Check that the wire rope, chains and hooks arefree from damage.Always use lifting equipment which has amplecapacity.Install the lifting equipment at the correct places.Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.Do not work with any part still raised by the hoistor crane.
15.When removing covers which are under internalpressure or under pressure from a spring,always leave two bolts in position on oppositesides. Slowly release the pressure, then slowlyloosen the bolts to remove.
16.When removing components, be careful not tobreak or damage the wiring. Damaged wiringmay cause electrical fires.
17.When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips onto the floor,wipe it up immediately. Fuel or oil on the floorcan cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to washparts. In particular, use only the minimum ofgasoline when washing electrical parts.
19.Be sure to assemble all parts again in their origi-nal places.Replace any damaged parts with new parts.• When installing hoses and wires, be sure
that they will not be damaged by contactwith other parts when the machine is beingoperated.
20.When installing high pressure hoses, make surethat they are not twisted. Damaged tubes aredangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, checkthat connecting parts are correctly installed.
21.When assembling or installing parts, always usethe specified tightening torques. When installingprotective parts such as guards, or parts whichvibrate violently or rotate at high speed, be par-ticularly careful to check that they are installedcorrectly.
22.When aligning two holes, never insert your fin-gers or hand. Be careful not to get your fingerscaught in a hole.
23.When measuring hydraulic pressure, check thatthe measuring tool is correctly assembled beforetaking any measurements.
24.Take care when removing or installing the tracksof track-type machines.When removing the track, the track separatessuddenly, so never let anyone stand at eitherend of the track.
FOREWORD GENERAL
00-5
FOREWORDGENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman anaccurate understanding of the product and by showing him the correct way to perform repairs and make judge-ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a serviceworkshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.
STRUCTURE AND FUNCTIONThis section explains the structure and function of each component. It serves not only to give an under-standing of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-nance standards.
TESTING AND ADJUSTINGThis section explains checks to be made before and after performing repairs, as well as adjustments tobe made at completion of the checks and repairs.Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-ponent, as well as precautions for them.
MAINTENANCE STANDARDThis section gives the judgment standards for inspection of disassembled parts.The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERSThis section mainly gives hydraulic circuit diagrams and electric circuit diagrams.In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without anyadvance notice. Use the specifications given in the book with the latest date.
FOREWORD HOW TO READ THE SHOP MANUAL
00-6
HOW TO READ THE SHOP MANUAL
VOLUMESShop manuals are issued as a guide to carrying outrepairs. They are divided as follows:
Chassis volume: Issued for every machine modelEngine volume: Issued for each engine series
Electrical volume:Attachments volume:
These various volumes are designed to avoid dupli-cating the same information. Therefore, to deal withall repairs for any model , it is necessary that chas-sis, engine, electrical and attachment volumes beavailable.
DISTRIBUTION AND UPDATINGAny additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-date information before you start any work.
FILING METHOD1. See the page number on the bottom of the page.
File the pages in correct order.2. Following examples show how to read the page
number.Example 1 (Chassis volume):
10 - 3
Item number (10. Structure andFunction)Consecutive page number for eachitem.
Example 2 (Engine volume):
12 - 5
Unit number (1. Engine)Item number (2. Testing and Adjust-ing)Consecutive page number for eachitem.
3. Additional pages: Additional pages are indicatedby a hyphen (-) and number after the pagenumber. File as in the example.Example:10-410-4-110-4-210-5
REVISED EDITION MARK
When a manual is revised, an edit ion mark(123....) is recorded on the bottom of the pages.
REVISIONS
Revised pages are shown in the LIST OF REVISEDPAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practicaluse, important safety and quality portions aremarked with the following symbols.
Symbol Item Remarks
¤ SafetySpecial safety precautionsare necessary when per-forming the work.
s Caution
Special technical precau-tions or other precautionsfor preserving standardsare necessary when per-forming the work.
4 Weight
Weight of parts of sys-tems. Caution necessarywhen selecting hoistingwire, or when working pos-ture is important, etc.
3 Tighteningtorque
Places that require specialattention for the tighteningtorque during assembly.
2 CoatPlaces to be coated withadhesives and lubricants,etc.
5 Oil, waterPlaces where oil, water orfuel must be added, andthe capacity.
6 DrainPlaces where oil or watermust be dra ined, andquantity to be drained.
}·
Each issued as onevolume to cover allmodels
12-20312-203-112-203-212-204
Added pages
FOREWORD HOISTING INSTRUCTIONS
00-7
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be liftedwith a hoist, etc. In the DISASSEMBLYAND ASSEMBLY section, every partweighing 25 kg or more is indicated clearlywith the symbol4
• If a part cannot be smoothly removed from themachine by hoisting, the following checksshould be made:1) Check for removal of all bolts fastening the
part to the relative parts.2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES1) Use adequate ropes depending on the
weight of parts to be hoisted, referring tothe table below:
Wire ropes(Standard "Z" or "S" twist ropes
without galvanizing)
★ The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength ofthe rope used.
2) Sling wire ropes from the middle portion of thehook.
Slinging near the edge of the hook may causethe rope to slip off the hook during hoisting, anda serious accident can result. Hooks have max-imum strength at the middle portion.
3) Do not sling a heavy load with one rope alone,but sling with two or more ropes symmetricallywound onto the load.¤ Slinging with one rope may cause turning
of the load during hoisting, untwisting ofthe rope, or slipping of the rope from itsoriginal winding position on the load, whichcan result in a dangerous accident.
4) Do not sling a heavy load with ropes forming awide hanging angle from the hook.When hoisting a load with two or more ropes,the force subjected to each rope will increasewith the hanging angles. The table belowshows the variation of allowable load kN {kg}when hoisting is made with two ropes, each ofwhich is allowed to sling up to 9.8 kN {1000 kg}vertically, at various hanging angles.When two ropes sling a load vertically, up to19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}when two ropes make a 120° hanging angle.On the other hand, two ropes are subjected toan excessive force as large as 39.2 kN {4000kg} if they sling a 19.6 kN {2000 kg} load at alifting angle of 150°.
Rope diameter Allowable load
mm kN tons
1011.512.514161820
22.430405060
9.813.715.721.627.535.343.154.998.1176.5274.6392.2
1.01.41.62.22.83.64.45.6
10.018.028.040.0
SAD00479
41%71%79%88%100%
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
00-8
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, releasethe residual pressure from the hydraulic tank.For details, see TESTING AND ADJUSTING,Releasing residual pressure from hydraulictank.
¤ Even if the residual pressure is released fromthe hydraulic tank, some hydraulic oil flows outwhen the hose is disconnected. Accordingly,prepare an oil receiving container.
Disconnection1) Release the residual pressure from the hydrau-
l ic tank. For detai ls , see TESTING ANDADJUSTING, Releasing residual pressure fromhydraulic tank.
2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)★ The adapter can be pushed in about 3.5
mm.★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),press rubber cap portion (4) against (3) until itclicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.(See Fig. 3)★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with eachother. (See Fig. 4)★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapterperfectly, pull it back to check its connectingcondition. (See Fig. 5)★ When the hose is pulled back, the rubber
cap portion moves toward the hose about3.5 mm. This does not indicate abnormality,however.
Type 1
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
00-9
Type 2 Type 3D
isas
sem
bly
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turnlever (4) to the right (clockwise).
3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end.
2) Hold in the condition in Step 1), and pushuntil cover (3) contacts contact surface a ofthe hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), andpull out whole body (2) to disconnect it.
Con
nect
ion
• Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.
• Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-vention ring (1) contacts contact surface a ofthe hexagonal portion at the male end to con-nect it.
FOREWORD COATING MATERIALS
00-10
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Adhesives
LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets,
rubber cushions, and cock plugfrom coming out.
LT-1B 790-129-9050 20 g(2 pcs.)
Polyethylenecontainer
• Used in places requiring an imme-diately effective, strong adhesive.Used for plastics (except polyeth-ylene, polyprophylene, tetrafluor-oethlene and vinyl chlor ide),rubber, metal and non-metal.
LT-2 09940-00030 50 g Polyethylenecontainer
• Features: Resistance to heat andchemicals
• Used for anti-loosening and seal-ant purpose for bolts and plugs.
LT-3
790-129-9060(Set of
adhesive andhardening
agent)
Adhesive:1 kg
Hardening
agent:500 g
Can
• Used as adhesive or sealant formetal, glass and plastic.
LT-4 790-129-9040 250 g Polyethylenecontainer
• Used as sealant for machinedholes.
HoltzMH 705 790-126-9120 75 g Tube
• Used as heat-resisting sealant forrepairing engine.
Three bond1735 790-129-9140 50 g Polyethylene
container
• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of met-
als, rubbers, plastics and woods.
Aron-alpha201 790-129-9130 2 g Polyethylene
container
• Quick hardening type adhesive• Quick cure type (max. strength af-
ter 30 minutes)• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite648-50 79A-129-9110 50 cc Polyethylene
container
• Resistance to heat, chemicals• Used at joint portions subject to
high temperatures.
Gasketsealant
LG-1 790-129-9010 200 g Tube• Used as adhesive or sealant for
gaskets and packing of powertrain case, etc.
LG-5 790-129-9070 1 kg Can
• Used as sealant for variousthreads, pipe joints, flanges.
• Used as sealant for taperedplugs, elbows, nipples of hydrau-lic piping.
LG-6 790-129-9020 200 g Tube
• Features: Silicon based, resist-ance to heat, cold
• Used as sealant for flange sur-face, tread.
• mab Used as sealant for oil pan,final drive case, etc.
FOREWORD COATING MATERIALS
00-11
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Adhesives
LG-7 790-129-9070 1 g Tube
• Ftures: Silicon based, quick hard-ening type
• Used as sealant for flywheelhousing, intake manifold, oil an,thermostat housing, etc.
Three bond1211 790-129-9090 100 g Tube
• Used as heat-resisting sealant forrepairing engine.
Molybdenumdisulphidelubricant
LM-G 09940-00051 60 g Can • Used as lubricant for sliding por-tion (to prevent from squeaking).
LM-P 09940-00040 200 g Tube
• Used to prevent seizure or scuf-fling of the thread when press fit-ting or shrink fitting.
• Used as lubricant for linkage,bearings, etc.
Grease
G2-LI
SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LISYGA-160CNLI
Various Various
• General purpose type
G2-CA
SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA
Various Various
• Used for normal temperature,light load bearing at places in con-tact with water or steam.
Molybdenumdisulphidelubricant
SYG2-400M400 g
(10 percase)
Belows type• Used for places with heavy load
FOREWORD STANDARD TIGHTENING TORQUE
00-12
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given inthe table below.
Thread diameterof bolt
Width acrossflats
mm mm Nm kgm
68101214
1013171922
13.2 0 1.431 0 366 0 7
113 0 10177 0 19
1.35 0 0.153.2 0 0.36.7 0 0.711.5 0 118 0 2
1618202224
2427303236
279 0 30382 0 39549 0 59745 0 83927 0 103
28.5 0 339 0 456 0 6
76 0 8.594.5 0 10.5
2730333639
4146505560
1320 0 1401720 0 1902210 0 2402750 0 2903290 0 340
135 0 15175 0 20225 0 25280 0 30335 0 35
Thread diameterof bolt
Width acrossflats
mm mm Nm kgm
681012
10131427
7.85 0 1.9518.6 0 4.940.2 0 5.9
82.35 0 7.85
0.8 0 0.21.9 0 0.54.1 0 0.68.4 0 0.8
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
1418222430333642
1924273236414655
24.5 0 4.949 0 19.6
78.5 0 19.6137.3 0 29.4176.5 0 29.4196.1 0 49245.2 0 49294.2 0 49
2.5 0 0.55 0 28 0 2
14 0 318 0 320 0 525 0 530 0 5
SAD00483
Sealing surface
FOREWORD STANDARD TIGHTENING TORQUE
00-13
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
101216
141722
65.7 0 6.8112 0 9.8279 0 29
6.7 0 0.711.5 0 128.5 0 3
Norminal No.Thread diameter Width across flat Tightening torque
mm mm Nm kgm
0203, 0405, 0610, 12
14
1420243342
Varies dependingon type ofconnector.
34.3 0 4.993.1 0 9.8
142.1 0 19.6421.4 0 58.8877.1 0 132.3
3.5 0 0.59.5 0 114.5 0 243 0 6
89.5 0 13.5
Norminal No.Thread diameter Width across flat Tightening torque
mm mm Nm kgm
08101214161820243033364252
08101214161820243033364252
141719222427303232n36nn
7.35 0 1.4711.27 0 1.4717.64 0 1.9622.54 0 1.96
29.4 0 4.939.2 0 4.949 0 4.9
68.6 0 9.8107.8 0 14.7127.4 0 19.6151.9 0 24.5210.7 0 29.4323.4 0 44.1
0.75 0 0.151.15 0 0.15
1.8 0 0.22.3 0 0.23 0 0.54 0 0.55 0 0.57 0 1
11 0 1.513 0 2
15.5 0 2.521.5 0 333 0 4.5
FOREWORD STANDARD TIGHTENING TORQUE
00-14
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)Use these torques for eye joints (unit: mm) of Cummins Engine.
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
681012
10 0 224 0 443 0 6
77 0 12
1.02 0 0.202.45 0 0.414.38 0 0.617.85 0 1.22
Thread diameter Tightening torque
mm Nm kgm
68101214
8 0 210 0 212 0 224 0 436 0 5
0.81 0 0.201.02 0 0.201.22 0 0.202.45 0 0.413.67 0 0.51
Thread diameter Tightening torque
mm Nm kgm
1 / 161 / 81 / 43 / 81 / 23 / 4
1
3 0 18 0 212 0 215 0 224 0 436 0 560 0 9
0.31 0 0.100.81 0 0.201.22 0 0.201.53 0 0.412.45 0 0.413.67 0 0.516.12 0 0.92
FOREWORD ELECTRIC WIRE CODE
00-15
ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
Norminalnumber
Copper wire
Cable O.D.(mm)
Currentrating
(A)Applicable circuit
Number ofstrands
Dia. ofstrands(mm2)
Crosssection(mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Priori-ty
Circuits
Classi-fication
Charging Ground Starting Lighting Instrument Signal Other
1 Pri-mary
Code W B B R Y G L
Color White Black Black Red Yellow Green Blue
2
Auxi-liary
Code WR n BW RW YR GW LW
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
3Code WB n BY RB YB GR LR
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
4
Code WL n BR RY YG GY LY
Color White & Blue n Black & Red Red & Yellow Yellow &Green
Green &Yellow Blue & Yellow
5Code WG n n RG YL GB LB
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
6Code n n n RL YW GL n
Color n n n Red & Blue Yellow & White Green & Blue n
FOREWORD CONVERSION TABLE
00-16
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of themethod of using the Conversion Table, see the example given below.
EXAMPLE• Method of using the Conversion Table to convert from millimeters to inches1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal linefromA.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line downfromB.
(3) Take the point where the two lines cross asC. This pointC gives the value when converting from mil-limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
010203040
5060708090
00.3940.7871.1811.575
1.9692.3622.7563.1503.543
0.0390.4330.8271.2201.614
2.0082.4022.7953.1893.583
0.0790.4720.8661.2601.654
2.0472.4412.8353.2283.622
0.1180.5120.9061.2991.693
2.0872.4802.8743.2683.661
0.1570.5510.9451.3391.732
2.1262.5202.9133.3073.701
0.1970.5910.9841.3781.772
2.1652.5592.9533.3463.740
0.2360.6301.0241.4171.811
2.2052.5982.9923.3863.780
0.2760.6691.0631.4571.850
2.2442.6383.0323.4253.819
0.3150.7091.1021.4961.890
2.2832.6773.0713.4653.858
0.3540.7481.1421.5361.929
2.3232.7173.1103.5043.898
B
A
C
FOREWORD CONVERSION TABLE
00-17
Millimeters to Inches1 mm = 0.03937 in
Kilogram to Pound1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
3.622
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
3.661
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
3.701
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
3.780
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
3.819
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
3.858
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
3.898
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
22.05
44.09
66.14
88.18
110.23
132.28
154.32
176.37
198.42
2.20
24.25
46.30
68.34
90.39
112.44
134.48
156.53
178.57
200.62
4.41
26.46
48.50
70.55
92.59
114.64
136.69
158.73
180.78
202.83
6.61
28.66
50.71
72.75
94.80
116.85
138.89
160.94
182.98
205.03
8.82
30.86
51.91
74.96
97.00
119.05
141.10
163.14
185.19
207.24
11.02
33.07
55.12
77.16
99.21
121.25
143.30
165.35
187.39
209.44
13.23
35.27
57.32
79.37
101.41
123.46
145.51
167.55
189.60
211.64
15.43
37.48
59.53
81.57
103.62
125.66
147.71
169.76
191.80
213.85
17.64
39.68
61.73
83.78
105.82
127.87
149.91
171.96
194.01
216.05
19.84
41.89
63.93
85.98
108.03
130.07
152.12
174.17
196.21
218.26
FOREWORD CONVERSION TABLE
00-18
Liter to U.S. Gallon1l = 0.2642 U.S. Gal
Liter to U.K. Gallon1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
2.642
5.283
7.925
10.567
13.209
15.850
18.492
21.134
23.775
0.264
2.906
5.548
8.189
10.831
13.473
16.115
18.756
21.398
24.040
0.528
3.170
5.812
8.454
11.095
13.737
16.379
19.020
21.662
24.304
0.793
3.434
6.076
8.718
11.359
14.001
16.643
19.285
21.926
24.568
1.057
3.698
6.340
8.982
11.624
14.265
16.907
19.549
22.190
24.832
1.321
3.963
6.604
9.246
11.888
14.529
17.171
19.813
22.455
25.096
1.585
4.227
6.869
9.510
12.152
14.795
17.435
20.077
22.719
25.361
1.849
4.491
7.133
9.774
12.416
15.058
17.700
20.341
22.983
25.625
2.113
4.755
7.397
10.039
12.680
15.322
17.964
20.605
23.247
25.889
2.378
5.019
7.661
10.303
12.944
15.586
18.228
20.870
23.511
26.153
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
2.200
4.399
6.599
8.799
10.998
13.198
15.398
17.598
19.797
0.220
2.420
4.619
6.819
9.019
11.281
13.418
15.618
17.818
20.017
0.440
2.640
4.839
7.039
9.239
11.438
13.638
15.838
18.037
20.237
0.660
2.860
5.059
7.259
9.459
11.658
13.858
16.058
18.257
20.457
0.880
3.080
5.279
7.479
9.679
11.878
14.078
16.278
18.477
20.677
1.100
3.300
5.499
7.969
9.899
12.098
14.298
16.498
18.697
20.897
1.320
3.520
5.719
7.919
10.119
12.318
14.518
16.718
18.917
21.117
1.540
3.740
5.939
8.139
10.339
12.528
14.738
16.938
19.137
21.337
1.760
3.950
6.159
8.359
10.559
12.758
14.958
17.158
19.357
21.557
1.980
4.179
6.379
8.579
10.778
12.978
15.178
17.378
19.577
21.777
FOREWORD CONVERSION TABLE
00-19
kgm to ft. lb1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
0
72.3
144.7
217.0
289.3
361.7
434.0
506.3
578.6
651.0
723.3
795.6
868.0
940.3
1012.6
1084.9
1157.3
1129.6
1301.9
1374.3
7.2
79.6
151.9
224.2
296.6
368.9
441.2
513.5
585.9
658.2
730.5
802.9
875.2
947.5
1019.9
1092.2
1164.5
1236.8
1309.2
1381.5
14.5
86.8
159.1
231.5
303.8
376.1
448.5
520.8
593.1
665.4
737.8
810.1
882.4
954.8
1027.1
1099.4
1171.7
1244.1
1316.4
1388.7
21.7
94.0
166.4
238.7
311.0
383.4
455.7
528.0
600.3
672.7
745.0
817.3
889.7
962.0
1034.3
1106.6
1179.0
1251.3
1323.6
1396.0
28.9
101.3
173.6
245.9
318.3
390.6
462.9
535.2
607.6
679.9
752.2
824.6
896.9
969.2
1041.5
1113.9
1186.2
1258.5
1330.9
1403.2
36.2
108.5
180.8
253.2
325.5
397.8
470.2
542.5
614.8
687.1
759.5
831.8
904.1
976.5
1048.8
1121.1
1193.4
1265.8
1338.1
1410.4
43.4
115.7
188.1
260.4
332.7
405.1
477.4
549.7
622.0
694.4
766.7
839.0
911.4
983.7
1056.0
1128.3
1200.7
1273.0
1345.3
1417.7
50.6
123.0
195.3
267.6
340.0
412.3
484.6
556.9
629.3
701.6
773.9
846.3
918.6
990.9
1063.2
1135.6
1207.9
1280.1
1352.6
1424.9
57.9
130.2
202.5
274.9
347.2
419.5
491.8
564.2
636.5
708.8
781.2
853.5
925.8
998.2
1070.5
1142.8
1215.1
1287.5
1359.8
1432.1
65.1
137.4
209.8
282.1
354.4
426.8
499.1
571.4
643.7
716.1
788.4
860.7
933.1
1005.4
1077.7
1150.0
1222.4
1294.7
1367.0
1439.4
FOREWORD CONVERSION TABLE
00-20
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
0
142.2
284.5
426.7
568.9
711.2
853.4
995.6
1138
1280
1422
1565
1707
1849
1991
2134
2276
2418
2560
2702
2845
2987
3129
3271
3414
14.2
156.5
298.7
440.9
583.2
725.4
867.6
1010
1152
1294
1437
1579
1721
1863
2005
2148
2290
2432
2574
2717
2859
3001
3143
3286
3428
28.4
170.7
312.9
455.1
597.4
739.6
881.8
1024
1166
1309
1451
1593
1735
1877
2020
2162
2304
2446
2589
2731
2873
3015
3158
3300
3442
42.7
184.9
327.1
469.4
611.6
753.8
896.1
1038
1181
1323
1465
1607
1749
1892
2034
2176
2318
2460
2603
2745
2887
3030
3172
3314
3456
56.9
199.1
341.4
483.6
625.8
768.1
910.3
1053
1195
1337
1479
1621
1764
1906
2048
2190
2333
2475
2617
2759
2901
3044
3186
3328
3470
71.1
213.4
355.6
497.8
640.1
782.3
924.5
1067
1209
1351
1493
1636
1778
1920
2062
2205
2347
2489
2631
2773
2916
3058
3200
3343
3485
85.3
227.6
369.8
512.0
654.3
796.5
938.7
1081
1223
1365
1508
1650
1792
1934
2077
2219
2361
2503
2646
2788
2930
3072
3214
3357
3499
99.6
241.8
384.0
526.3
668.5
810.7
953.0
1095
1237
1380
1522
1664
1806
1949
2091
2233
2375
2518
2660
2802
2944
3086
3229
3371
3513
113.8
256.0
398.3
540.5
682.7
825.0
967.2
1109
1252
1394
1536
1678
1821
1963
2105
2247
2389
2532
2674
2816
2958
3101
3243
3385
3527
128.0
270.2
412.5
554.7
696.9
839.2
981.4
1124
1266
1408
1550
1693
1835
1977
2119
2262
2404
2546
2688
2830
2973
3115
3257
3399
3542
FOREWORD CONVERSION TABLE
00-21
TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.These figures refer to the temperature in either Fahrenheit or Centigrade degrees.If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table ofFahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table ofCentigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4–37.2–34.4–31.7–28.9
–28.3–27.8–27.2–26.7–26.1
–25.6–25.0–24.4–23.9–23.3
–22.8–22.2–21.7–21.1–20.6
–20.0–19.4–18.9–18.3–17.8
–17.2–16.7–16.1–15.6–15.0
–14.4–13.9–13.3–12.8–12.2
–40–35–30–25–20
–19–18–17–16–15
–14–13–12–11–10
–9–8–7–6–5
–4–3–2–1
0
12345
6789
10
–40.0–31.0–22.0–13.0
–4.0
–2.2–0.4
1.43.25.0
6.88.6
10.412.214.0
15.817.619.421.223.0
24.826.628.430.232.0
33.835.637.439.241.0
42.844.646.448.250.0
–11.7–11.1–10.6–10.0
–9.4
–8.9–8.3–7.8–7.2–6.7
–6.1–5.6–5.0–4.4–3.9
–3.3–2.8–2.2–1.7–1.1
–0.600.61.11.7
2.22.83.33.94.4
5.05.66.16.77.2
1112131415
1617181920
2122232425
2627282930
3132333435
3637383940
4142434445
51.853.655.457.259.0
60.862.664.466.268.0
69.871.673.475.277.0
78.880.682.484.286.0
87.889.691.493.295.0
96.898.6
100.4102.2104.0
105.8107.6109.4111.2113.0
7.88.38.99.4
10.0
10.611.111.712.212.8
13.313.914.415.015.6
16.116.717.217.818.3
18.919.420.020.621.1
21.722.222.823.323.9
24.425.025.626.126.7
4647484950
5152535455
56575859
0
6162636465
6667686970
7172737475
7677787980
114.8116.6118.4120.2122.0
123.8125.6127.4129.2131.0
132.8134.6136.4138.2140.0
141.8143.6145.4147.2149.0
150.8152.6154.4156.2158.0
159.8161.6163.4165.2167.0
168.8170.6172.4174.2176.0
27.227.828.328.929.4
30.030.631.131.732.2
32.833.333.934.435.0
35.636.136.737.237.8
40.643.346.148.951.7
54.457.260.062.765.6
68.371.173.976.779.4
8182838485
8687888990
9192939495
96979899
100
105110115120125
130135140145150
155160165170175
117.8179.6181.4183.2185.0
186.8188.6190.4192.2194.0
195.8197.6199.4201.2203.0
204.8206.6208.4210.2212.0
221.0230.0239.0248.0257.0
266.0275.0284.0293.0302.0
311.0320.0329.0338.0347.0
FOREWORD UNITS
00-22
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:N {kg}Nm {kgm}MPa {kg/cm2}kPa {mmH2O}kPa {mmHg}kW/rpm {HP/rpm}g/kWh {g/HPh}
01-3PC228USLC-1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Wor
king
ran
ges
Perfo
rman
ceDi
men
sion
s
Machine model PC228USLC-1
Serial Number 11001 and up
Bucket capacity m3 0.8
Operating weight kg 22,900
Max. digging depth mm 6,810
Max. vertical wall depth mm 5,910
Max. digging reach mm 9,850
Max. reach at ground level mm 9,670
Max. digging height mm 10,700
Max. dumping height mm 7,765
Max. digging force(using power max. function) kN {kg} 125 {12,800} (137 {14,000})
Swing speed rpm 11.0
Swing max. slope angle deg. 16
Travel speed km/h Lo: 3.4 Mi: 4.1 Hi: 5.1
Gradeability deg. 35
Ground pressure(triple grouser shoe width: 700 mm) kPa {kg/cm2} 41 {0.42}
Overall length (for transport) mm 8,890
Overall width mm 2,980
Overall width of track mm 3,080
Overall height (for transport) mm 2,990
Overall height to chassis mm 2,990
Ground clearance to bottom of upper structure mm 1,050
Min. ground clearance mm 440
Tail swing radius mm 1,625
Min. swing radius of work equipment mm 2,310
Height of work equipment at min. swing radius mm 8,290
Length of track on ground mm 3,640
Track gauge mm 2,380
Height of machine cab mm 2,280
GENERAL SPECIFICATIONS
Machine model PC228USLC-1
Serial Number 11001 and up
Engi
neHy
drau
lic s
yste
m
Perfo
rman
ce
Und
er-
carr
iage
Cont
rol
valve
Hydr
aulic
cyl
inde
rHy
drau
licpu
mp
Hydr
aulic
mot
or
+70–40
Model S6D102E-1-AType 4-cycle, water-cooled, in-line, vertical,
direct injection, with turbocharger
No. of cylinders – bore × stroke mm 6 – 102 × 120Piston displacement ¬ {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 96/2,000 {128/2,000}Max. torque Nm/rpm {kgm/rpm} 545.3/1,350 {55.6/1,350}Max. speed at no load rpm 2,170Min. speed at no load rpm 970 ± 60Min. fuel consumption g/kWh {g/HPh} 218 {160}
Starting motor 24V, 4.5 kWAlternator 24V, 50ABattery 12V, 110 Ah × 2Radiator core type Corrugated CWX-4Carrier roller 2 on each sideTrack roller 9 on each sideTrack shoe Triple grouser, 49 on each side
Type × no. HPV95+95, variable displacementpiston type × 2
Delivery ¬/min Piston type: 206 × 2Set pressure MPa {kg/cm2} Piston type: 34.8 {355}Type × No. 6-spool type × 1Control method HydraulicTravel motor GM38VL, Piston type
(with brake valve, parking brake: × 2
Swing motor KMF90AEL-3, Piston type(with safety valve, parking brake): × 1
Boom Arm BucketType Double acting Double acting Double acting
piston piston pistonInside diameter of cylinder mm 120 135 130Diameter of piston rod mm 85 95 90Stroke mm 1,285 1,490 1,020Max. distance between pins mm 3,155 3,565 2,625Min. distance between pins mm 1,870 2,075 1,605
Hydraulic tank Box-shaped, sealedHydraulic filter Tank return sideHydraulic cooler CFT-1 (Air cooled)
PC228USLC-101-42
PC228USLC-1 01-4-11
GENERAL SPECIFICATIONS
Wor
king
ran
ges
Perfo
rman
ceDi
men
sion
s
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
Ground pressure(triple grouser shoe width: 700 mm) kPa {kg/cm2} 51 {0.52}
Overall length (for transport) mm 8,700
Overall width mm 2,995
Overall width of track mm 2,800
Overall height (for transport) mm 2,965
Overall height to chassis mm 2,990
Ground clearance to bottom of upper structure mm 1,050
Min. ground clearance mm 440
Tail swing radius mm 1,680
Min. swing radius of work equipment mm 2,380
Height of work equipment at min. swing radius mm 8,210
Length of track on ground mm 3,270
Track gauge mm 2,200
Height of machine cab mm 2,280
GENERAL SPECIFICATIONS
Machine model PC228US-2
Serial Number 15001 and up
Engi
neHy
drau
lic s
yste
m
Perfo
rman
ce
Und
er-
carr
iage
Cont
rol
valve
Hydr
aulic
cyl
inde
rHy
drau
licpu
mp
Hydr
aulic
mot
or
+70–40
Model S6D102E-1-FType 4-cycle, water-cooled, in-line, vertical,
direct injection, with turbocharger
No. of cylinders – bore × stroke mm 6 – 102 × 120Piston displacement ¬ {cc} 5.883 {5,883}
Flywheel horsepower kW/rpm {HP/rpm} 96/2,000 {128/2,000}Max. torque Nm/rpm {kgm/rpm} 545.3/1,350 {55.6/1,350}Max. speed at no load rpm 2,170Min. speed at no load rpm 970 ± 60Min. fuel consumption g/kWh {g/HPh} 218 {160}
Starting motor 24V, 4.5 kWAlternator 24V, 35ABattery 12V, 110 Ah × 2Radiator core type Corrugated CWX-4Carrier roller 2 on each sideTrack roller 7 on each sideTrack shoe Triple grouser, 45 on each side
Type × no. HPV95+95, variable displacementpiston type × 2
Delivery ¬/min Piston type: 206 × 2Set pressure MPa {kg/cm2} Piston type: 37.2 {380}Type × No. 6-spool type × 1Control method HydraulicTravel motor GM38VL, Piston type
(with brake valve, parking brake): × 2
Swing motor KMF90ABE-3, Piston type(with safety valve, parking brake): × 1
Boom Arm BucketType Double acting Double acting Double acting
piston piston pistonInside diameter of cylinder mm 120 135 130Diameter of piston rod mm 85 95 90Stroke mm 1,285 1,490 1,020Max. distance between pins mm 3,155 3,565 2,625Min. distance between pins mm 1,870 2,075 1,605
Hydraulic tank Box-shaped, sealedHydraulic filter Tank return sideHydraulic cooler CFT-1 (Air cooled)
PC228USLC-101-4-22
10-65PC228USLC-1
STRUCTURE AND FUNCTION TRAVEL MOTOR
3) When starting travel (or during normaltravel)
• When the travel lever is operated, the pres-sure oil from the pump moves counterbal-ance valve spool (19) to the right. When thishappens, the passage to the suction-safetyvalve becomes the circuit flowing throughthe small notch in the counterbalance valvespool. As a result, a big difference in pres-sure is created, and the pump pressure risesto provide a powerful drawbar pull. (Fig. 7)
10-65-12
PC228USLC-1
STRUCTURE AND FUNCTION TRAVEL MOTOR
PC228USLC-1, 2GM38VL
A. From control valveB. From control valveD1. Drain port (to tank) (L.H. travel motor)D2. Drain port (to tank) (R.H. travel motor)
SpecificationsType : GM38VLTheoretical delivery : 140.5 cc/revBrake releasing pressure : 0.59 MPa {6.0 kg/cm2}Travel speed switching pressure: 1.96 – 6.86 MPa
{20 – 70 kg/cm2}Reduction ratio : 66
PC228USLC-1
STRUCTURE AND FUNCTION TRAVEL MOTOR
10-65-22
12. Spring13. Plate14. Disc15. Swash plate16. Pivot17. Spindle18. Floating seal19. Hub20. RV gear A21. RV gear B22. Crankshaft
23. Cover24. spur gear25. Input gear26. Hold flange27. Piston28. Shoe29. Shaft30. Shoe31. Piston32. Spring33. Timing plate
1. Plug2. Spring3. Valve4. Spool5. Spring6. Valve7. Spring8. Sleeve9. End cover
10. Cylinder block11. Piston
PC228USLC-110-66
STRUCTURE AND FUNCTION VALVE CONTROL
VALVE CONTROL
1. Travel PPC valve2. L.H. travel lever3. R.H. travel lever4. Solenoid block5. Accumulator6. R.H. PPC valve7. R.H. work equipment
lever
8. Control valve9. Hydraulic pump
10. L.H. work equipmentlever
11. L.H. PPC valve12. Safety lock lever
Lever positions1 HOLD2 Boom RAISE3 Boom LOWER4 Bucket DUMP5 Bucket CURL6 HOLD7 Arm IN8 Arm OUT
9 Swing RIGHT0 Swing LEFTA NEUTRALB Travel REVERSEC Travel FORWARDD LOCKE FREE
20-3PC228USLC-1
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
TABLE OF JUDGEMENT STANDARD VALUE
‡ FOR ENGINE
Machine model PC228USLC-1
Engine S6D102-1
Item Measurement condition Unit Standard value Permissible value
Working
TravelingRated 1,800 —
Engine speed rpmspeed 2,000 —
At sudden acceleration Bosch Max. 1.0 2.0Exhaust gas color
At high idling index Max. 0.5 1.5
(normal temperature)Valve clearance Intake valve mm 0.25 —
Exhaust valve 0.51 —
Oil temperature: Difference betweenCompression pressure 40 – 60°C MPa Min. 2.4 cylinders
(engine speed: 250rpm) {kg/cm2} {Min. 24.6} Min. 1.0(SAE15W-40 oil) {Min. 10.3}
(Coolant temperature:Blow-by pressure operating range) kPa Max. 1.2 5.1
At rated output (mmH2O) {Max. 123} {520}(SAE30 oil)
(Coolant temperature: operating range)(Measure at top of oil filter)
At high idling MPa 0.39 – 0.52 0.25Oil pressure (SAE15W-40) {kg/cm2} {4.0 – 5.3} {2.6}
At low idling Min. 0.12 0.09(SAE15W-40) {Min. 1.2} {0.9}
Oil temperature Whole speed range°C 80 – 110 120(inside oil pan)
Fuel injection timing Before top dead center °(B.T.D.C.) (degree) 18 ± 1 18 ± 1
Min. 108 Max. 6Belt tension mm
5 – 8 5 – 8
Fan-tension
Fan–air conditionercompressor
Deflectionwhenpressedwith fingerforce ofapprox.58.8N{6kg}
PC228USLC-120-4
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
‡ FOR CHASSIS
Applicable model
Cate- Item Measurement conditions Unit Standard value Permissible valuegory
PC228USLC-1
Low idling
1,850 ± 100 —
At TRAVEL
rpm
High idlingAt WORK
Trav
el o
f con
trol l
ever
s
1,400 ± 120 1,400 ± 120
2 pumps at relief
Speed when auto-deceleration is operated
Boom control valve
Arm control valve
Bucket control valve
Swing control valve
Travel control valve
Boom control lever
Arm control lever
Bucket control lever
Swing control lever
Travel control lever
Play of control lever
Boom control lever
Arm control lever
Bucket control lever
Swing control lever
Travel control lever
a b a b
100 ± 10
100± 10
100± 10
100 ± 10
115 ± 12
Max. 10
· Hydraulic oil temperature:45 – 55°C
· Coolant temperature:Within operating range
· 2-pump relief: Arm relief
· Fuel control dial at MAX.· Control lever at neutral
Engi
ne s
peed
9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5 9.5 ± 0.5
Max. 110Min. 90
Max. 110Min. 90
Max. 110Min. 90
Max. 110Min. 90
Max. 127Min. 103
Max. 15
Spoo
l stro
ke
15.7 ± 3.9 Max. 24.5{1.6 ± 0.4} {Max. 2.5}15.7 ± 3.9 Max. 24.5{1.6 ± 0.4} {Max. 2.5}13.7 ± 2.9 Max. 22.6{1.4 ± 0.3} {Max. 2.3}13.7 ± 2.9 Max. 22.6{1.4 ± 0.3} {Max. 2.3}24.5 ± 5.9 Max. 39.2{2.5 ± 0.6} {Max. 4.0}74.5 ± 18.6 Max. 107.6{7.6 ± 1.9} {Max. 11}
· Engine at high idling· Oil temperature: 45 – 55°C· Fit push-pull scale to center
of control lever knob tomeasure
· Measure max. value to endof travel
Lever
PedalOpe
ratin
g fo
rce
of c
ontro
l lev
ers
N{kg}
mm· Center of lever knob· Read max. value to end of
travel· Engine stopped· Excluding neutral play
2,200 ± 70 —
2,200 ± 70 —
970 ± 50
(3)
20-9PC228USLC-1
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Applicable model
Cate- Item Measurement conditions Unit Standard value Permissible valuegory
RAIS
E
Wor
k eq
uipm
ent s
peed
· Lower boom and measure timetaken from point where bucketcontacts ground to point wherechassis rises from ground
· Engine at low idling· Hydraulic oil temperature:
45 – 55°C
· Stop arm suddenly and measuretime taken for arm to stop
· Engine at low idling· Hydraulic oil temperature:
45 – 55°C
Arm Max. 1.0 Max. 2.8
Boom Max. 1.0 Max. 1.2
Arm
Cylinder fullyretracted
Fully extended
↔
LOW
ERIN
OU
TCU
RLDU
MP
Wor
k eq
uipm
ent
Tim
e la
g
sec
Boom
Bucket teeth incontact with ground
Cylinder fullyextended
↔
Bucket
Cylinder fullyretracted
Fully extended
↔
BKP00114
BKP00115
· Engine at high idling· Hydraulic oil temperature:
45 – 55°C
· Engine at high idling· Hydraulic oil temperature:
45 – 55°C
· Engine at high idling· Hydraulic oil temperature:
45 – 55°C
2.6 ± 0.4 Max. 3.3
2.1 ± 0.3 Max. 2.7
PC228USLC-1
4.4 ± 0.5 Max. 5.2
4.0 ± 0.4 Max. 4.4
(3)
3.6 ± 0.4 Max. 4.5(To Just before cushion) (To Just before cushion)
2.9 ± 0.3 Max. 3.5(To Just before cushion) (To Just before cushion)
PC228USLC-120-10
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Applicable model
Cate- Item Measurement conditions Unit Standard value Permissible valuegory
Cylinders 4.5 20cc/min
Inter
nal l
eaka
ge
· Engine at high idling· Hydraulic oil temperature:
45 – 55°C
fl Use a hard horizontal surface.
· Stop bucket suddenly andmeasure time taken for bucketto stop at bottom and thenstart again.
· Engine at low idling· Hydraulic oil temperature:
45 – 55°C
· Hydraulic oil temperature:45 – 55°C
· Engine at high idling· Relieve circuit to be measuredCenter swivel joint
Wor
k eq
uipm
ent
Tim
e la
g
Bucket sec. Max. 1.0 Max. 3.6
10 50
20m
10m BKP00107
fl Measure dimension χ.
Travel deviation whenwork equipment +travel are operated
mm Max. 200 Max. 220
Perfo
rman
ce in
com
poun
d op
erat
ion
Perfo
rman
ce o
f hyd
raul
ic pu
mp
Hydr
aulic
pum
p de
liver
y
Piston pump See next page See next page
BKP00116
PC228USLC-1
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................... 30- 3PRECAUTIONS WHEN CARRYING
OUT OPERATION ................................... 30- 5SPECIAL TOOL LIST ..................................... 30- 7SKETCHES OF SPECIAL TOOLS ................. 30- 9STARTING MOTOR
Removal and Installation ......................30-12ALTERNATOR
Removal and Installation ......................30-13ENGINE OIL COOLER CORE
Removal and Installation ......................30-14FUEL INJECTION PUMP
Removal .................................................. 30-15Installation .............................................. 30-18
WATER PUMPRemoval and Installation ......................30-20
NOZZLE HOLDERRemoval and Installation ......................30-21
TURBOCHARGERRemoval and Installation ......................30-22
THERMOSTATRemoval and Installation ......................30-23
CYLINDER HEADRemoval .................................................. 30-24Installation .............................................. 30-28
ENGINE, MAIN PUMPRemoval .................................................. 30-31Installation .............................................. 30-34
DAMPERRemoval and Installation ......................30-35
ENGINE FRONT SEALRemoval and Installation ......................30-36
ENGINE REAR SEALRemoval .................................................. 30-38Installation .............................................. 30-39
RADIATOR, HYDRAULIC COOLERRemoval .................................................. 30-40Installation .............................................. 30-41
FUEL TANKRemoval .................................................. 30-42Installation .............................................. 30-43
CENTER SWIVEL JOINTRemoval .................................................. 30-44Installation .............................................. 30-45
CENTER SWIVEL JOINTDisassembly and Assembly ..................30-46
SPROCKETRemoval and Installation ......................30-47
FINAL DRIVE, TRAVEL MOTORRemoval and Installation ......................30-48
FINAL DRIVEDisassembly ........................................... 30-49Assembly ................................................ 30-52
TRAVEL MOTORDisassembly and Assembly .............. 30-56-1
SWING MOTOR, SWING MACHINERYRemoval and Installation ......................30-57
SWING MACHINERYDisassembly ........................................... 30-58Assembly ................................................ 30-62
SWING MOTORRemoval and Installation ......................30-67
REVOLVING FRAMERemoval .................................................. 30-68Installation .............................................. 30-69
SWING CIRCLERemoval .................................................. 30-70Installation .............................................. 30-71
IDLER, RECOIL SPRINGRemoval and Installation ......................30-72
RECOIL SPRINGDisassembly ........................................... 30-73Assembly ................................................ 30-74
IDLERDisassembly ........................................... 30-75Assembly ................................................ 30-76
TRACK ROLLERRemoval and Installation ......................30-78Disassembly ........................................... 30-79Assembly ................................................ 30-80
CARRIER ROLLERRemoval and Installation ......................30-82Disassembly ........................................... 30-83Assembly ................................................ 30-84
TRACK SHOERemoval and Installation ......................30-86
HYDRAULIC TANKRemoval and Installation ......................30-87
MAIN PUMPRemoval ................................................ 30- 88Installation ............................................ 30- 89
PC228USLC-1 30-12
PC228USLC-130-21
OFFSET CYLINDERRemoval ................................................ 30-130Installation ............................................ 30-131
HYDRAULIC CYLINDER FOR OFFSETDisassembly ......................................... 30-132Assembly .............................................. 30-134
HYDRAULIC CYLINDER FOR BOOM,ARM, BUCKETDisassembly ......................................... 30-136Assembly .............................................. 30-139
BUCKETRemoval ................................................ 30-144Installation ............................................ 30-145
ARMRemoval ................................................ 30-146Installation ............................................ 30-147
BUCKET, ARMRemoval ................................................ 30-150Installation ............................................ 30-151
OFFSET BRACKETRemoval and Installation .................... 30-155
SECOND BOOMRemoval ................................................ 30-156Installation ............................................ 30-157
FIRST BOOMRemoval ................................................ 30-158Installation ............................................ 30-160
SECOND, FIRST BOOMRemoval ................................................ 30-161Installation ............................................ 30-163
OFFSET BRACKET, SECOND,FIRST BOOMRemoval ................................................ 30-164Installation ............................................ 30-166
BOOMRemoval ................................................ 30-168Installation ............................................ 30-169
OPERATOR’S CABRemoval ................................................ 30-170Installation ............................................ 30-171
FLOOR FRAMERemoval ................................................ 30-172Installation ............................................ 30-173
AIR CONDITIONER COMPRESSORRemoval and Installation .................... 30-174
AIR CONDITIONER CONDENSERRemoval and Installation .................... 30-175
AIR CONDITIONER UNITRemoval ................................................ 30-176Installation ............................................ 30-177
COUNTERWEIGHTRemoval and Installation .................... 30-178
CONTROLLERRemoval and Installation .................... 30-179
MONITORRemoval and Installation .................... 30-180
EPC VALVERemoval and Installation .................... 30- 90
PC VALVERemoval and Installation .................... 30- 91
LS VALVERemoval and Installation .................... 30- 92
CONTROL VALVERemoval ................................................ 30- 93Installation ............................................ 30- 95Disassembly ......................................... 30- 96Assembly .............................................. 30-101
LS SELECT VALVEDisassembly and Assembly ................30-107
PRESSURE COMPENSATION VALVEDisassembly ......................................... 30-108Assembly .............................................. 30-109
MAIN RELIEF VALVERemoval and Installation .................... 30-110Disassembly and Assembly ................30-111
SOLENOID VALVERemoval and Installation .................... 30-112
PUMP MERGE/DIVIDERSOLENOID VALVERemoval and Installation .................... 30-113
2-STAGE RELIEF, TRAVEL HI/LOSOLENOID VALVERemoval and Installation .................... 30-114
INTERFERENCE PREVENTIONSOLENOID VALVERemoval and Installation .................... 30-115
LEFT WORK EQUIPMENT PPC VALVE(FOR SWING, ARM CONTROL)Removal and Installation .................... 30-116
RIGHT WORK EQUIPMENT PPC VALVE(FOR BOOM, BUCKET CONTROL)Removal and Installation .................... 30-117
WORK EQUIPMENT PPC VALVE(PPC VALVE FOR BOOM, BUCKET,
ARM, SWING CONTROL)Disassembly ......................................... 30-118Assembly .............................................. 30-119
TRAVEL PPC VALVERemoval and Installation .................... 30-120Disassembly and Assembly ................30-121
PPC VALVE FOR OFFSET CONTROLRemoval and Installation .................... 30-122
BOOM LOCK VALVERemoval and Installation .................... 30-123
BOOM CYLINDERRemoval ................................................ 30-124Installation ............................................ 30-125
ARM CYLINDERRemoval ................................................ 30-126Installation ............................................ 30-127
BUCKET CYLINDERRemoval ................................................ 30-128Installation ............................................ 30-129
PC228USLC-1 30-56-12
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTORGM38VLCONTENTS
ASSEMBLY DRAWINGS .................................................................................................................... 30-56- 2PARTS LIST ......................................................................................................................................... 30-56- 8TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY........................................................................ 30-56-10
1. Standard tools ....................................................................................................................... 30-56-102. Manufactured tools ............................................................................................................... 30-56-11
DISASSEMBLY PROCEDURE ............................................................................................................ 30-56-131. General precautions .............................................................................................................. 30-56-132. Disassembly procedure ........................................................................................................ 30-56-14
2-1. Disassembly of brake valve .......................................................................................... 30-56-162-2. Disassembly of hydraulic motor .................................................................................. 30-56-202-3. Disassembly of reduction gear assembly ................................................................... 30-56-23
MAINTENANCE STANDARD ............................................................................................................. 30-56-281. Seals ....................................................................................................................................... 30-56-282. Maintenance standard for worn parts ................................................................................. 30-56-28
ASSEMBLY PROCEDURE .................................................................................................................. 30-56-301. General precautions .............................................................................................................. 30-56-302. Assembly procedure ............................................................................................................. 30-56-31
2-1. Assembly of brake valve .............................................................................................. 30-56-312-2. Assembly of reduction gear assembly and hydraulic motor .................................... 30-56-35
PERFORMANCE TEST ........................................................................................................................ 30-56-50LIST OF CLEARANCE ADJUSTMENT PARTS .................................................................................. 30-56-51
PC228USLC-130-56-22
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC228USLC-1 30-56-32
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC228USLC-130-56-42
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
REDUCTION GEAR
PC228USLC-1 30-56-52
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PC228USLC-130-56-62
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
HYDRAULIC MOTORRELIEF VALVECONTROL VALVE
PC228USLC-1 30-56-72
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
PARTS LISTNo. Part name Q’ty
REDUCTION GEAR 11 Hub 1
Spindle kit 1• Spindle ass’y 1
2 • • Spindle 13 • • Hold flange 1
19 • Hexagon socket head bolt 334 • Parallel pin 6
(select one from 3 kinds)37 • Plain washer 3
RV gear assembly kit 1• RV gear kit 1
4 • • RV gear A 15 • • RV gear B 19 • Crankshaft 3
12 • Spacer 622 • Tapered roller bearing 623 • Needle roller bearing 6
6 Input gear 1
Spur gear kit 17 • Spur gear 3
8 Cover 113 Distance piece 3
t: Above 3.30, up to 3.15↓ <at interval of 0.05>
t: Above 4.10 up to 4.1515 Coupling 117 Pin 2420 C-type snap ring for hole 321 Ball bearing 225 C-type snap for shaft 327 O-ring 229 O-ring 130 O-ring 1
Floating seal kit 131 • Floating seal 2
33 Hexagon socket head plug 335 Hexagon socket head bolt 1236 Ball 142 Parallel pin 243 O-ring 3
No. Part name Q’tyHYDRAULIC MOTOR 1
Cylinder & piston kit 1• Piston kit 1• • Piston assembly 9
105 • • Piston 1106 • • • Shoe 1104 • Cylinder block 1107 • Retainer plate 1108 • Thrust ball 1110 • Washer 2111 • Washer 1114 • Spring 1145 • C-type snap ring for hole 1151 • Needle roller 5
Piston assembly 1161 • Piston 1162 • Shoe 1
102 Shaft 1103 Swash plate 1109 Timing plate 1112 Piston 1113 Spring 12115 Friction plate 2116 Mating plate 2132 Oil seal 1135 O-ring 1139 O-ring 1149 Deep groove ball bearing 1150 Deep groove ball bearing 1167 Pivot 2171 Parallel pin 2173 Spring 1
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No. Part name Q’tyRELIEF VALVE 2
Valve kit 1201 • Valve 1202 • Sleeve 1203 • Spring retainer 1204 • Plug 1205 • Shim 1206 • Spring 1208 • O-ring 1209 • O-ring 1210 • O-ring 1211 • Back-up ring 2217 • Back-up ring 2219 • O-ring 1220 • Piston seal 1
CONTROL VALVE 1
Rear flange assembly 1• Rear flange kit 1
301 • • Rear flange 1323 • • Spool 1381 • • Piston 1321 • Plug 1324 • Plug 2325 • Stopper 2326 • Plug 2327 • Valve 2328 • Spring 2330 • Spring 2336 • O-ring 2337 • O-ring 2352 • Plug 2354 • Hexagon socket head plug 7355 • O-ring 1357 • Plug 1358 • O-ring 2359 • O-ring 2363 • Spool 1366 • Spring 1368 • Ball 2373 • O-ring 1379 • Filter 1380 • Plug 2382 • Plug 2383 • O-ring 2384 • O-ring 2385 • Ball 2397 • Orifice 1
No. Part name Q’ty398 • Hexagon socket head plug 4399 • Name plate 1400 • Square head plug 2
341 • Parallel pin 1343 • Hexagon socket head bolt 12
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
No. Name Model/Dimensions Q’ty
1 Hexagonal wrench 6 (For M8) (PF 1/4) 5 (PF 1/8) 1 each10 (For M12) (PF 1/2) 8 (PF 3/8) 1 each14 (For M16) 1 each
2 Socket wrench 1(Ratchet handle)
3 Torque wrench Dial type for about 280 N 1Dial type for about 850 N 1
4 Torque wrench adapter Nominal size of socket: 22, 30, 32, 41 1 each(12.7 mm square drive) Nominal size of rod: 5, 6, 8, 10, 14 1 each(19.0 mm square drive) Nominal size of rod: 19 1 each
5 Extension bar 150 mm 1
6 Hammer Nominal size: 12 1
7 Plastic hammer L = About 300 1
8 Flat-head screwdriver About 150 mm 1
9 Snap ring pliers For shaft 1For hole 1
10 Sling parts Sling load: Min. 2,942 N {300 kg} 1 setEyebolt (For M16) (2)Eyebolt (For PF 1/2) (2)Wire with hook (1)
11 Press stand Press capacity: Min. 1,961 N {200 kg} 1 set
12 Compressed air For 0.3 – 0.5 MPa {3 – 5 kg/cm2} 1 set
13 Container Vat for general use, W450 x D300 x H120 2
14 Heating tank Heating ability: Min. 100°C 1 setCapacity: Min. 500 mm x 500 mm x 500 mm
15 Leather gloves 1 pair
16 Sealing tape 1
17 Depth micrometer Measurement range: About 30 mm 1Min. division: 0.01 mm
18 Thickness gauge Measurement range: 0.04 – 0.3 mm 1
19 Rotary bar For cutting cast iron 1
20 Air chisel BRH-8 1(Compressed air: 0.5 – 0.6 MPa {5 – 6 kg/cm2})
TOOLS LIST FOR DISASSEMBLY AND ASSEMBLY1. Standard tools
• Necessary tools for disassembly and assembly of GM38VL are shown below.
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No. Name and major dimensions Q’ty1 Preload adjustment jig for main bearing 1
2. Manufactured tools
No. Name and major dimensions Q’ty6 Holder (III) 1
2 Clamp 2
3 Press fitting jig 1
4 Holder (I) 1
5 Holder (II) 111 Sling jig 1
10 Aluminum rod 1
9 Steel rod 1
8 Pointed punch 1
7 Holder (IV) 1
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No. Name and major dimensions Q’ty12 Floating seal fitting jig (I) 1
No. Name and major dimensions Q’ty17 Bending jig 1
13 Floating seal fitting jig (II) 1
14 Floating seal fitting jig (III) 1
15 Sling jig 1
16 Pulling jig 1
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
DISASSEMBLY PROCEDURE
1. GENERAL PRECAUTIONS1) Before disassembling the travel motor, consider the inspection items, characteristics of the
detected trouble, etc. and then review the given disassembly procedure.
2) Disassemble the travel motor in a clean place according to the procedure in 2. Disassemblyprocedure.
3) Spread a rubber sheet, vinyl sheet, etc. on the worktable.
4) When disassembling, make match marks on the mating faces of the parts.
5) Arrange the removed parts well so that they will not be damaged or lost.
6) Replace each seal once the travel motor is disassembled, as a rule. Accordingly, prepare theall replacement seals before disassembling.
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2. DISASSEMBLY PROCEDUREfl When inspecting or repairing the travel motor, disassemble it according to the following procedure.fl The number in ( ) after each part name refers to the part No. in Parts list.fl Before disassembling the travel motor, install it to a turning work table.fl Prepare a container to collect lubricating oil (for 8 liters).fl Prepare a container to collect hydraulic oil (for 4 liters).
(Disassembly of hydraulic motor on brake valve side)
(Disassembly of shaft and oil seals of reduction gear assembly and hydraulic motor)
1) Remove the relief valve from rear flange (301).
2) Remove O-rings (208), (209), and (210) and backup rings (211) (2 pieces), and (217) (2 pieces) from the relief valve.
Do not reuse removed O-ring (138).fl Necessary tools
• Impact wrench or ratchet handle• Wrench adapter, socket of size 32
1) Remove hexagon socket head bolts (343) (12 pieces).
fl Necessary tools• Socket wrench• Extension bar• Wrench adapter, rod of size 14
1) Turn the work table 180 degrees so that cover (8) of the travel motor will be directed up.
2) Remove hexagon socket head plugs (33) (3 pieces).
3) Remove hexagon socket head bolts (35) (12 pieces).
fl Necessary tools• Ratchet handle• Wrench adapter, rod of size 10
1) Install eyebolts (2 pieces) to threaded plug holes (PF 1/2).
2) Install hooks to the eyebolts and lift off cover (8).
If the cover is not removed be-cause of resistance of O-ring (30), hit the rim of the cover with a plastic hammer.
3) Remove O-ring (30) from cover (8).Do not reuse removed O-ring (30).4) Drain oil from the reduction gear
assembly.fl Necessary tools
• Sling: 1 set• Eyebolt (for PF 1/2): 2 pieces• Plastic hammer• Container (for 8 liters)
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1) Remove rear flange (301) from spindle (2).Take care, since shaft (102) may be removed, too.
See disassembly procedure for brake valve
See disassembly procedure for hydraulic motor
See disassembly procedure for reduction gear assembly
1) Remove timing plate (109), parallel pin (341) (1 piece), springs (113) (12 pieces), and deep groove ball bearing (150) from rear flange (301) and hydraulic motor.
2) Remove O-rings (27) (2 pieces) and (29) from spindle (2).
Do not reuse removed O-rings (27) and (29).
Removal of hydraulic motor shaft
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2-1. DISASSEMBLY OF BRAKE VALVE1. Removal of spool
1) Remove plug (324) from rear flange (301).Remove O-ring (336) from plug (324).fl Loosen the plug when the motor is on
the turning work table for the ease ofwork.
fl Do not reuse removed O-ring (336).fl Necessary tools
• Socket wrench• Wrench adapter, socket of size 41
2) Remove 2 springs (328), 2 stoppers (325),and spool (323) from rear flange (301).fl Take care not to damage the periphery
of spool (323) and sliding surface of rearflange (301).
fl Slant rear flange (301) with either plugport down, and spool (323) slides down.Hold the end of the spool and take itout.
2. Removal of check valve1) Take plugs (326) (2 pieces) out of rear flange
(301).fl Loosen the plugs when the motor is on
the turning work table for the ease ofwork.
fl Necessary tools• Socket wrench• Wrench adapter, rod of size 14
2) Take 2 springs (330) and 2 valves (327) outof rear flange (301).fl Take care not to damage the seats of
valve (327) and rear flange (301).
3) Take O-ring (337) out of plug (326).fl Do not reuse removed O-ring (337).
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3. Disassembly of 2nd travel speed selection valve1) Remove plug (357) from rear flange (301).
fl Loosen the plug when the motor is onthe turning work table for the ease ofwork.
fl Necessary tools• Hexagonal wrench of size 10
2) Remove spool (363) and spring (366) fromrear flange (301).
3) Remove O-ring (355) from plug (357).fl Do not reuse removed O-ring (355).
4. Disassembly of internal parts (SRV)1) Remove plugs (380) (2 pieces).
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.
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4) Remove plugs (382) (2 pieces).fl Necessary tools
• Hexagonal wrench of size 5
5) Remove O-rings (383) and (384) from plug(382).fl Do not reuse removed O-rings (383) and
(384).
6) Remove steel balls (385) (2 pieces) from rearflange (301).
5. Disassembly of relief valve1) Remove plug (204) from sleeve (202).
fl Since shim (205) of the internal parts ofsleeve (202) is decided after relief pres-sure is set, keep those parts as a valvekit separately from other parts.
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).
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4) Take spring retainer (203), spring (206), andvalve (201) in order out of sleeve (202).
5) Remove piston seal (220) from valve (201).
6) Disassemble the other sleeve similarly. The parts other than O-ring (210) and
piston seal (221) in sleeve (202) cannotbe replaced singly, since relief pressuremust be set again. If those parts needto be replaced, replace the whole reliefvalve.
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
2-2. DISASSEMBLY OF HYDRAULIC MOTOR1. Removal of parking brake parts
1) Supply compressed air through the parkingbrake passage of spindle (2) to take out pis-ton (112). If compressed air is supplied quickly, pis-
ton (112) may jump out to hurt you. Toprevent this, place a proper cover on pis-ton (112).
fl Necessary tools• Compressed air (0.3 – 0.5 MPa {3 – 5
kg/cm2})• Nozzle
2) Remove O-rings (135) and (139) from piston(112).fl Do not reuse removed O-rings (135) and
(139).
2. Taking internal parts out of motor1) Lay the travel motor on its side.
(Turn the travel motor by 90 degrees.)fl When the travel motor is laid on its side,
oil spills. Place a container under themotor to receive the oil.
fl Necessary tools• Container
2) Drain the oil from the travel motor.
3) Hold cylinder block (104) with both handsand take it out of spindle (2).fl Before pulling out cylinder block (104),
hold it with the hands and rotate it inboth directions by 2 - 3 turns to separateshoe (106) from swash plate (103).
If cylinder block (104) is pulled out with-out performing the above action, theshoe is left on the swash plate and theparts sticking to the cylinder block (pis-ton, shoe, etc.) come off the cylinderblock and fall in the spindle.
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4) Remove 2 mating plates (116) and 2 frictionplates (115) from the periphery of cylinderblock (104).
5) Remove the piston assembly (piston (105)and shoe (106)), retainer plate (107), thrustball (108), collar (111), and needle rollers(151) (5 pieces) from removed cylinder block(104).fl Cylinder block (104), piston assembly
(piston (105) and shoe (106)), retainerplate (107), etc. are the cylinder and pis-ton kit, which is the minimum parts unit.If any part of this kit needs to be re-placed, replace the whole kit. (See partsclassification in the parts list.)
6) Take swash plate (103) out of spindle (2).
7) Take out shaft (102).fl Oil seal (132) cannot be taken out. The shaft can be pulled out easily by
hitting its end on reduction gear assem-bly side lightly with a plastic hammer. Ifit is hit strongly it may jump out.
8) Take pivots (167) (2 pieces) and parallel pins(171) (2 pieces) out of spindle (2).
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9) Take out 2nd travel speed selection valveassembly (piston (161) and shoe (162)) andspring (193) by supplying compressed airthrough the passage of spindle (2).fl Since piston (161) and shoe (162) are set
in 1 unit, if either of them needs to bereplaced, replace both of them.
If compressed air is supplied quickly, the2nd travel speed selection valve assem-bly may jump out to hurt you. To pre-vent this, place a proper cover on valveassembly.Compressed air: 0.3 – 0.5 MPa
{3 – 5 kg/cm2}fl Necessary tools
• Compressed air (0.3 – 0.5 MPa {3 – 5kg/cm2})
• Nozzle
3. Disassembly of internal parts of cylinder block1) Place cylinder block (104) on a press stand.
Apply holder (I) to washer (110) and take outC-type hole snap ring (145) with snap ringpliers.fl Press load: Min. 1,961 N {200 kg}fl When removing the spring, align holder
(I) with the washer and protect the cylin-der block from washer and spring.
fl Cover the sliding surfaces of the cylin-der block with vinyl sheet for protection.
fl Remove spring (114) only when it needsto be replaced.
fl Necessary tools• Press stand• Holder (I)• Snap ring pliers
2) Loosen the press slowly until the spring forceis reduced to zero. If the press is loosened quickly, the
spring may jump out to hurt you. Loosenit slowly.
3) Take C-type hole snap ring (145), washer(110), spring (114), and washer (110) out ofcylinder block (104).
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2-3. DISASSEMBLY OF REDUCTION GEARASSEMBLY
1. Removal of input gear1) Remove steel ball (36) and input gear (6)
from coupling (15).
2. Removal of spur gears1) Remove C-type shaft snap rings (25)
(3 pieces) from crankshafts (9). When the snap ring is removed, it may
come off the pliers nose and fly out. Takecare.
fl Necessary tools• Snap ring pliers
3. Removal of coupling1) Remove coupling (15) from shaft (102).
2) Remove spur gear (7) (3 pieces) from crank-shaft (9).
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
4. Removal of hold flange1) Turn over the travel motor.2) Install clamps (2 pieces) to hub (1) and spin-
dle (2) to secure. Set the clamps symmetri-cally.fl If hold flange (3) is removed without set-
ting the clamps, hub (1) and spindle (2)will separate from each other and spin-dle (2) will fall from the work table.
fl Necessary tools• Clamp• Hexagonal wrench of size 14
3) Turn over the travel motor.4) Remove 3 snap rings (20) and distance pieces
(13) from hold flange (3).fl Make match marks on the snap rings
and hold flange so that they will be in-stalled to the original positions.
fl Necessary tools• Snap ring pliers
5) Cut the bent part of the top of the parallelpin hole. When the bent part is cut with a rotary
bar, metal chips are scattered. Put onprotective goggles, mask, etc.
fl Necessary tools• Rotary bar
6) Install the jig to pull out parallel pin (34) andpull out the parallel pin to the end of holdflange (3). (6 places)fl Necessary tools
• Wrench adapter, socket of size 22
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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 withadhesive, those bolts may be difficult toremove. Accordingly, loosen the boltsas slowly as possible.(Loosening torque:
Min. 686 Nm {70 kgm})fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 19
8) Remove hold flange (3) from spindle (2).fl Make match marks on the hold flange
and spindle so that they will be installedto the original positions.
5. Removal of clamps1) Turn over the travel motor.
2) Remove the clamps (2 pieces).fl Necessary tools
• Clamp
6. Separation of hub and spindle1) Install eyebolts (for M16) to spindle (2). In-
stall hooks to the eyebolts and sling themwith a crane to remove spindle (2) from hub(1).fl Lift up spindle (2) slowly so that it will
not damage the retainer of ball bearing(21).
fl Necessary tools• 1 set of sling• 2 eyebolts• Plastic hammer
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
7. Removal of ball bearing, RV gear assembly, andpin1) Hit the end of pin (17) with a pin punch [1]
and hammer [2] to remove ball bearing (21)from hub (1). At this time, RV gear assem-bly (RV gear A (4), RV gear B (5), crankshafts(9), tapered roller bearing (22), and needleroller bearing with retainer (23)) and pin (17)are removed, too.fl When removing ball bearing (21), hit 3 -
4 points on the periphery of the pin endlightly so that the bearing will not beslanted.
fl If the outer race of ball bearing (21) isremoved from hub (1), ball bearing (21),RV gear assembly, and pin (17) fall fromhub (1). Accordingly, place a containerand a rubber mat on it under the worktable to protect the falling parts.
fl The RV gear assembly is the minimumparts unit. If any part of this assemblyneeds to be replaced, replace the wholeassembly. (See parts classification in theparts list.)
fl Necessary tools• Pin punch [1]• Hammer [2]
8. Removal of ball bearing1) Take floating seal (31) out of hub (1).2) Turn over the travel motor.3) Hit ball bearing (21) with a pin punch [1] and
hammer [2] from the cover (8) side of hub(1) to remove the ball bearing from hub (1).fl If ball bearing (21) is removed, it falls
from hub (1). Accordingly, place a rub-ber mat under the work table to protectit.
fl Necessary tools• Pin punch [1]• Hammer [2]
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9. Removal of spindle parts1) Take floating seal (31) out of spindle (2).
fl Necessary tools• Flat-head screwdriver
2) Take the outer race of tapered roller bearing(22) out of spindle (2).
10. Taking outer race out of tapered roller bearing(22)1) Take the outer race of tapered roller bearing
(22) out of hold flange (3).fl Necessary tools
• Aluminum rod• Hammer
11. Removal of oil seal1) Apply a flat-head screwdriver to the rim of
oil seal (132) in spindle (2) and hit it with ahammer [1] to take out oil seal (132).fl Remove oil seal (132) only when it needs
to be replaced. Do not reuse the removedoil seal.
fl Remove the oil seal after the reductiongear assembly is disassembled and spin-dle (2) is separated.
fl Necessary tools• Flat-head screwdriver• Hammer [1]
12. Removal of deep groove ball bearing (149) Remove deep groove ball bearing (149) only
when it needs to be replaced.1) Place holder [II] on the press stand and put
shaft (102) in it. Do not reuse the removed deep groove
ball bearing.fl Necessary tools
• Press stand• Holder [II]
2) Press the tip of shaft with press [1] and re-move deep groove ball bearing (149).
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MAINTENANCE STANDARDDisassemble and inspect the travel motor according to the following standard. Handle its partscarefully. In particular, take care not to damage the moving parts and sliding parts.1. Seals
Replace the all seals (O-rings, oil seals, and floating seals) once they are removed, even if they arefree from damage.
2. Maintenance standard for worn parts1) Replace all the parts which have visible extreme damages.2) Replace the parts which have the following trouble (phenomenon).
Part Part name Trouble Standard value Allowable valueNo. (Standard dimension) (Criterion)
Spindle kit(2) Spindle • Part surface has visible serious(3) Hold flange damage.
(19) Hexagon socket head bolt • Part surface is scuffed or worn(34) Parallel pin easily.(37) Plain washer
RV gear assembly(4) RV gear (A) • RV gear tooth surface is worn(5) RV gear (B) unevenly.(9) Crankshaft • When crankshafts (9) are
(12) Spacer bearing revolved, each part does not(22) Tapered roller bearing move smoothly.(23) Needle roller bearing with
retainer
13 Distance piece (Rank) • Periphery and end faces areworn abnormally.
20 Snap ring • Periphery and end faces areworn abnormally.
21 Ball bearing • There is bruise.• Surface is flaked.• Surface is worn unevenly.
Rear flange kit(301) Rear flange • Moving part against spool (323)
has flaw.• Clearance between rear flange Diameter clearance Diameter clearance
and spool is large. 10 – 20 µ 25 µ• Sliding surface against piston
(381) has flaw.• Clearance between rear flange
and piston is large.• Contact face against valve (327)
has flaw.• Depth to contact face against
valve (327) is large.
(323) Spool • Outside surface has flaw.• Outside surface is worn unevenly.
(381) Piston • Outside surface has flaw.• Outside surface is worn unevenly.
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Part Part name Trouble Standard value Allowable valueNo. (Standard dimension) (Criterion)
102 Shaft • Contact face against oil seal(132) is worn.
• Spline is worn.
103 Swash plate • Swash plate is seized.
104 Cylinder block • Spline is worn.• Inside of bore is worn remarkably.• Sliding surface against timing
plate (109) is scratched andworn unevenly.
Piston assembly(105) Piston • There is axial clearance between Clearance: Clearance:(106) Shoe piston (105) and shoe (106). 0.05 mm 0.15 mm
• Shoe is worn abnormally.• Shoe is worn unevenly.
107 Retainer plate • Periphery and end faces areworn unevenly.
108 Thrust ball • Spherical sliding parts againstretainer plate (107) is wornunevenly.
109 Timing plate • Sliding surface is seized andworn unevenly.
115 Friction plate • Both end faces are worn Braking torque: Braking torque:116 Mating plate unevenly. Min. 398 Nm Max. 398 Nm
• Specified torque is not produced. {40.6 kgm} {40.6 kgm}• Plate is seized.
149 Deep groove ball bearing • There is bruise.150 Deep groove ball bearing • Surface is flaked.
• Surface is worn unevenly.
363 Spool • Outside surface has flaw.• Outside surface is worn unevenly.
201 Valve • Outside surface has flaw.• Outside surface is worn unevenly.
202 Sleeve • Seat has flaw.• Clearance between sleeve and
valve (201) is large.
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ASSEMBLY PROCEDURE1. GENERAL PRECAUTIONS
1) Work in a clean place.
2) When assembling, do not put on cloth gloves. (Prevention of entry of fibers)
3) Repair the parts damaged during disassembly and be sure to prepare new oil seals and O-rings.
4) Be sure to replace removed “hexagon socket head bolts (19)” with new ones.
5) Clean each part in kerosene and dry it with compressed air. Never use cloths to wipe the parts.(Prevention of entry of fibers)(1) Clean the hub, spindle, cover, and rear flange in a cleaning tank.
Remove all sand and dirt from each part. Kerosene is flammable. Take care of a fire extremely.
(2) Clean the other parts in a container with kerosene. If dirty parts are washed in kerosene from first, they may be scratched. Wait until dirt
and grease are dissolved sufficiently.
6) Be sure to apply clean hydraulic oil (NAS Grade 9 or equivalent) to the moving and slidingparts of the hydraulic motor valves before assembling.
7) Tighten each mounting bolt and plug to the specified torque with a torque wrench, etc.
Tightening torque table
Part No. Part name Thread size Q’ty Tightening torque
19 Hexagon socket head bolt M24 (P3.0) 3 709 ± 108 Nm {72.3 ± 11 kgm}
33 Hexagon socket head plug PF 1/2 3 98.1 ± 19.6 Nm {10 ± 2 kgm}
35 Hexagon socket head bolt M12 (P1.75) 12 102 ± 15.7 Nm {10.4 ± 1.6 kgm}
202 Sleeve PF 1 2 245 ± 49 Nm {25 ± 5 kgm}
204 Plug PF 1/2 2 98.1 ± 19.6 Nm {10 ± 2 kgm}
324 Plug M36 (P1.5) 2 255 ± 39.2 Nm {26 ± 4 kgm}
326 Plug M36 (P1.5) 2 441 ± 88.3 Nm {45 ± 9 kgm}
343 Hexagon socket head bolt M16 (P2.0) 12 252 ± 39.2 Nm {25.7 ± 4 kgm}
346 Plug PT 1/4 2 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
352 Plug PF 1/4 2 29.4 ± 4.9 Nm {3 ± 0.5 kgm}
354 Hexagon socket head plug NPTF 1/16 8 9.81 ± 2.45 Nm {1.0 ± 0.25 kgm}
357 Plug PF 1/2 2 98.1 ± 19.6 Nm {10 ± 2 kgm}
380 Plug PF 3/8 2 58.8 ± 9.81 Nm {6 ± 1 kgm}
382 Plug PF 1/8 2 14.7 ± 2.45 Nm {1.5 ± 0.25 kgm}
398 Hexagon socket head plug PT 1/8 4 12.3 ± 2.45 Nm {1.25 ± 0.25 kgm}
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2. ASSEMBLY PROCEDURE2-1. ASSEMBLY OF BRAKE VALVE1. Installation of check valve
1) Fit O-ring (337) to plug (326).fl Apply grease to O-ring (337).fl Necessary tools
• 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 spool1) Insert spool (323) in rear flange (301).
fl Apply hydraulic oil to spool (323) andinsert it in rear flange (301).
When inserting the spool, align it withrear flange hole.
A flaw on the rear flange hole or outsideof the spool can cause internal leakageand lowering of performance of the travelmotor. Take care.
fl Necessary tools• Torque wrench• Wrench adapter, socket of size 41
2) Fit O-ring (336) to plug (324).fl Apply grease to O-ring (336).
3) Install stopper (325) and spring (328) to plug(324) and tighten plugs (324) (2 pieces) intorear flange (301) to the specified torque.3 Plug: 441 ± 88.3 Nm {45 ± 9 kgm}fl Rear flange (301) and spool (323) are han-
dles as a kit. If either of them needs tobe replaced, be sure to replace both ofthem.
PC228USLC-130-56-322
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3. Assembly of 2nd travel speed selection valve1) Fit O-ring (355) to plug (357).
fl Apply grease to O-ring (355).
2) Fit spring (366) to spool (363) and insert themin rear flange (301).fl When inserting spool (363) in rear flange
(301), apply hydraulic oil to it.fl A flaw on the hole of rear flange (301) or
outside of spool (363) can cause internalleakage and lowering of performance ofthe travel motor. Take care.
fl When inserting spool (163), align it withthe hole of rear flange (301) to preventcontact damage on the inside of rearflange and outside of the spool.
3) Install plug (357) to rear flange (301) andtighten it to the specified torque.3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}fl Necessary tools
• 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). (2pieces)fl Apply grease to O-rings (383) and (384).
3) Install plugs (382) (2 pieces) to rear flange(301) and tighten them to the specifiedtorque.3 Plug: 14.7 ± 2.45 {1.5 ± 0.25 kgm}fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 5
PC228USLC-1 30-56-332
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 pis-ton (381) with the hole of rear flange(301) (to prevent contact damage on thebody hole and outside of the piston).
Since the clearance between piston (381)and rear flange (301) is adjusted for eachcombination, take care not to mistake incombination.
5) Fit O-ring (359) to plug (380).fl Apply grease to O-ring (359).
6) Install plug (380) to rear flange (301) andtighten it to the specified torque.3 Plug: 58.8 ± 9.81 Nm {6 ± 1 kgm}fl Use a vise for the ease of work.fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 8
5. Assembly of relief valve1) Fit O-rings (208), (209), and (219), and backup
rings (211) and (217) (2 pieces) to sleeve(202).fl Apply grease to O-rings (208) and (209).
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 itis.
4) Install piston seal (220) to valve (201).fl Piston seal (220) consists of an O-ring
and a Teflon ring. Apply grease to bothof them. Put in the O-ring first, then putin the Teflon ring.
PC228USLC-130-56-342
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
5) Insert valve (201), spring (206), and springretainer (203) in sleeve (202) and tighten plug(204) having shim (205).fl Apply hydraulic oil to valve (201) and
insert it in sleeve (202).fl When inserting valve (201), align it with
the hole of sleeve (202) (to prevent con-tact damage on the hole of the sleeveand outside of the valve).
fl Since the internal parts of the sleeve areadjusted for each combination, take carenot to mistake in combination.
3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 10
fl Stick shim (205) to plug (204) with hy-draulic oil or grease to prevent it fromfalling.
6) Install the other sleeve similarly.
PC228USLC-1 30-56-352
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/orProcedure for selecting thickness of distance piece (13) must be performed. Before startingassembly, see if the following parts have been replaced.
When assembling after replacing the above parts, be sure to adjust each part. If the parts are puttogether without adjustment, the travel motor will malfunction and will be broken soon.
Was any part replaced? <Replaced part>• Hub (1)• Spindle kit• Ball bearing (21)
<Replaced part>• Spindle kit• RV gear assembly
Yes
[A] ASSEMBLY(page 30-56-36)
[B] PROCEDURE FOR ADJUSTING THICKNESS OF HOLD FLANGE (3)(page 30-56-45)
[C] PROCEDURE FOR SELECTING THICKNESS OF DISTANCE PIECE (13)(page 30-56-47)
No
PC228USLC-130-56-362
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
[A] ASSEMBLY1. Assembly of hub (1)
1) Install hub (1) to the turning work table.2) Press fit the outer race of ball bearing (21)
to hub (1) with press fitting jig [2] andhammer [1].fl Necessary tools
• Press fitting jig• Hammer
3) Install floating seal (31) to hub (1). Do not apply grease to the O-ring of float-
ing seal (31).fl Place floating seal fitting jig [I], floating
seal, and floating seal fitting jig [II] inorder and press them until jig [II] comesin contact with jig [I]. Remove the jigsand check that the parallelism error ofthe end face of the hub and floating sealsurface is less than 1 mm.
fl Necessary tools• Floating seal fitting jig [I]• Floating seal fitting jig [II]
2. Assembly of spindle (2)1) Fit floating seal (31) to the floating seal
groove of spindle (2). Do not apply grease to the O-ring of float-
ing seal (31).fl Place floating seal fitting jig [III], floating
seal, and floating seal fitting jig [II] inorder and press them until jig [II] comesin contact with jig [III]. Remove the jigsand check that the parallelism error ofthe end face of the spindle groove andfloating seal surface is less than 1 mm.
fl Necessary tools• Floating seal fitting jig [II]• Floating seal fitting jig [III]
PC228USLC-1 30-56-372
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3. Assembly of hub (1) and spindle (2)1) Install eyebolts (for M16) (2 pieces) symmetri-
cally to spindle (2).fl Necessary tools
• Eyebolt, 2 pieces2) Install hooks to the eyebolts and put spindle
(2) in hub (1) slowly. If spindle (2) is inserted in hub (1) quickly,
it may be slanted and scratched in mainbearing (21). Insert it slowly.
When spindle (2) is inserted, if it isslanted, separate it from hub (1) and in-sert it again slowly.
fl Necessary tools• Set of sling
3) Install clamps (2 pieces) to hub (1) and spin-dle (2) to secure. Set the clamps symmetri-cally.fl Necessary tools
• Clamp• Hexagonal wrench of size 14
4) Turn over the travel motor to bring the coverside to the top.fl Turn the travel motor 180 degrees.
5) Fit outer races (3 pieces) of tapered rollerbearing (22) to the outer race fitting holes inspindle (2).
4. Assembly of RV gear assembly1) Install a sling [1] to the RV gear assembly.
fl Necessary tools• Sling (RV gear assembly)
2) Install a hook to the sling and put it in spin-dle (2) slowly. Match the inner race of the tapered roller
bearing of the crankshaft to the outerrace hole of tapered roller bearing (22)fitted to spindle (2), and install the RVgear assembly to the spindle slowly.
If the RV gear assembly is loweredquickly, the tapered roller bearing willbe damaged and the travel motor willmalfunction.
3) Insert pins (17) (24 pieces) between the pingrooves of hub (1) and tooth grooves of thegear.fl Apply lubricating oil to pins (17) before
inserting them.
PC228USLC-130-56-382
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
5. Assembly of ball bearing1) Insert ball bearing (21) in hub (1).
fl Ball bearing (21) is to be press fitted tohub (1). Fit it evenly little by little byhitting it lightly with a hammer. Put ballbearing (21) in hub (1) securely.
fl Necessary tools• Hammer [1]• Press fitting jig [2]
2) Install the outer races of 3 tapered rollerbearings (22).
6. Installation of hold flange1) Install spindle (2) to hold flange (3).
Check the match marks of spindle (2)and hold flange (3).
PC228USLC-1 30-56-392
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 spin-
dle (2).fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 19
2) Put plain washers (37) (3 pieces) on the boltseats of hold flange (3).
3) Tighten hexagon socket head bolts (19) (3pieces) to about 19.6 Nm {20 kgm}.fl Degrease hexagon socket head bolts (19)
thoroughly.4) Drive parallel pins (34) (6 pieces) with an air
chisel (BRH-8) until they reach the pin holebottoms of spindle (2).fl Degrease parallel pins (34) thoroughly.
Set air pressure to 49 – 58.8 Nm {5 – 6kg/cm2}.
Take care not to mistake the fitting di-rections and positions of parallel pins(34).
When driving parallel pins (34), take carenot to slant them. (Slanting them cancause burrs and sharp fins.)
fl Necessary tools• Air chisel (BRH-8)
5) After installing parallel pins (34), bend thepin hole edge of hold flange (3).fl Apply the bending jig around the pin
hole of hold flange (3) and hit it with ahammer.
fl Necessary tools• Bending jig• Hammer
6) Tighten hexagon socket head bolts (19) tothe specified torque.3 Bolt: 709 ± 108 Nm {72.3 ± 11 kgm}
fl If any parts (spindle kit and/or RV gear as-sembly) are replaced, refer to [C] PROCE-DURE FOR SELECTING THICKNESS OF DIS-TANCE PIECE (13) (page 30-56-47).
fl If no parts are replaced, go to item 8. below.
PC228USLC-130-56-402
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, matchingthe 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 shownbelow.fl Necessary tools
• Snap ring pliers
Match marks on spur gears (7)
2) Fit C-type shaft snap rings (25) to the snapring grooves of crankshafts (9). Snap ring (25) may come off the pliers
and fly off. Hold it securely with thepliers.
fl Necessary tools• Snap ring pliers
fl When fitting spur gear (7), set their matchmarks a (punch marks) as shown here.
PC228USLC-1 30-56-412
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
fl Take care of the direction of each snapring. Fit it with its square side a up.
10. Fitting of oil seal1) Turn over the travel motor.2) Fit oil seal (132) to the oil seal hole of spin-
dle (2).fl Apply lithium grease to the lip of oil seal
(132).fl Necessary tools
• Hammer• Holder [III]
11. Installation of shaft (102)1) Install deep groove ball bearing (149) to shaft
(102) by shrink fit.fl When installing, put on leather gloves
and take care not to get burned.fl If deep groove ball bearing (149) was
removed during disassembly, replace itwith new one.
fl Shrink fit temperature: 100 ± 10°C When installing the bearing, take care
that it will not slant from shaft (2).fl Necessary tools
• Heating oven• Leather gloves• Holder [II]
PC228USLC-130-56-422
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 pis-ton hole in spindle (2).
13. Installation of pivot (167)1) Insert pins (171) (2 pieces) in spindle (2) and
install pivots (167) (2 pieces).2) Apply grease to the hemisphere parts of the
pivots.
14. Assembly of internal parts of cylinder block1) Place cylinder block (104) on the press stand.
2) Put washer (110), spring (114), and washer(110) in cylinder block (104).fl Put washers (110) as shown in the figure
at right.
PC228USLC-1 30-56-432
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
3) Place the above cylinder block on the pressstand. Apply holder [I] to washer (110) topress spring (114) and fit C-type hole snapring (145).fl Cover the sliding surfaces of cylinder
block with a vinyl sheet for protection.fl Pressing force of spring (114):
Min. 1,961 N {200 kg} Snap C-type hole snap ring (145) may
come off the pliers and fly off. Hold itsecurely with the pliers.
fl Necessary tools• Press stand• Holder [I]• Snap ring pliers
15. Installation of motor assembly1) Fit needle rollers (151) (5 pieces) to cylinder
block (104) and place collar (111) and thrustball (108) on them.
2) Put piston assemblies (105) and (106) in re-tainer plate (107).
3) Apply hydraulic oil to the piston assembliesand install them to cylinder block (104).
4) Apply hydraulic oil to the sliding surface ofshoe (106) and spherical part of thrust ball(108).
PC228USLC-130-56-442
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
5) Install swash plate (103), thrust ball (108),collar (111), retainer plate (107), needle roll-ers (151), cylinder block (104), and pistonassemblies (105) and (106) to shaft (102) asshown at right, and then install a sling [I]and set the whole assembly vertically.fl Necessary tools
• 1 set of sling• Sling [I]
16. Installation of motor assembly1) Using sling [I], lift up the motor assembly
and install an insertion jig to the spline atthe end of shaft (102).fl Match the pivot hole of swash plate (103)
to pivot (167) and install the motor as-sembly slowly, taking care not to dam-age spindle (2), etc. with the motor as-sembly.
fl Necessary tools• Shaft insertion jig
2) Lift up the motor shaft slowly and install itto spindle (2).
3) After installing the motor assembly, removesling [I] and insertion jig.fl After installing the motor assembly, re-
volve the cylinder block with the hand tocheck that it does not have play. If thecylinder block has play, check it. Whenchecking, do not pull out the cylinderblock, however. If it is pulled out, collar(111) and thrust ball (108) will come offand the cylinder block will not revolvenormally.
PC228USLC-1 30-56-452
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
[B] PROCEDURE FOR ADJUSTING THICKNESSOF HOLD FLANGE (3)
Assembly processes to be finished before adjust-mentfl Finish assembly procedures 1 – 5 (on pages 30-
56-36 to 30-56-38) before adjusting the thick-ness of the hold flange.
1. Install the preload adjustment jig [2] for mainbearing to spindle (2).fl Necessary tools
• Preload adjustment jig [2] for main bearing
3. Obtain depth A through the measurement holeof the preload adjustment jig for main bearingwith depth micrometer [4].fl Necessary tools
• Depth micrometer [4]
4. Since dimension B of the preload adjustment jigfor main bearing is known, obtain clearance Cby the following formula.
C = A – B A: Measured valueB: Dimension of jigC: Clearance
2. Tighten special nut [3] of preload adjustment jig[2] for main bearing to the specified torque.3 Nut [3]: 118 ± 19.6 Nm {12 ± 2 kgm}fl Necessary tools
• Torque wrench [1]• Wrench adapter, socket of size 30
PC228USLC-130-56-462
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
5. Obtain dimension D of hold flange (3).
6. From the result of procedures 1 – 5 above, ad-just hold flange (3) according to the followingprocedure. Dimension C is the standard dimen-sion of the hold flange.Adjust to D = C ± 0.02.1) If dimension D of actual hold flange (3) is
less than the standard value, cut face E ofhold flange (3) with a lathe, etc. until thestandard value is obtained.
2) If dimension D of actual hold flange (3) is inthe tolerance of the standard value, use thehold flange as it is.
3) If dimension D of actual hold flange (3) islarger than the standard value, replace thespindle assembly with new one. Hold flange(3) of the new spindle assembly has adjust-ment allowance.fl Carry out disassembly and assembly
again.
7. Remove the preload adjustment jig for mainbearing from spindle (2).
PC228USLC-1 30-56-472
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
[C] PROCEDURE FOR SELECTING THICKNESSOF DISTANCE PIECE (13)
Assembly processes to be finished before selectionfl Finish assembly procedures 1 – 7 (on pages 30-
56-36 to 30-56-39) before selecting the thicknessof the distance piece.
1. Lightly hit the outer race of tapered roller bear-ing (22) installed to crankshaft (9) of the RV gearassembly with holder [IV] and hammer.fl Perform this procedure to insert the RV gear
assembly in spindle (2) securely.fl Necessary tools
• Holder [IV]• Hammer• Thickness gauge
2. Install thinnest distance piece (13) into holdflange (3) and fit snap ring (20) to the snap ringgroove inside hold flange (3).
3. Lightly hit the periphery of snap ring (20) withholder [IV] and hammer.fl Perform this procedure to check that the RV
gear assembly is inserted in spindle (2) se-curely.
4. Insert thickness gauge between snap ring (20)and distance piece (13) to measure the clear-ance.Measurement of thickness of distance piece
5. After deciding the thickness of the distance piece,select proper ones from 17 types and installthem.fl See clearance adjustment parts list (on page
30-56-51).
1 Set thickness of distance piece (Max.)Max. = Thickness of thickness gauge + Thickness of distance piece currently inserted
2 Set thickness of distance piece (Min.)Min. = Thickness of thickness gauge + Thickness of distance piece currently inserted – 0.05
PC228USLC-130-56-482
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
See assembly procedure forhydraulic motor parts
(pages 30-56-41 to 30-56-44)
See assembly procedure for brake valve
(pages 30-56-31 to 30-56-33)
See assembly procedure for reduction gear assembly and hydraulic motor shaft
(pages 30-56-35 to 30-56-41)
1) Fit 2 couples of friction plate (115) and mating plate (116) to the peripheral groove of cylinder block (104) with friction plate (115) ahead.
fl When fitting friction plates (115), dip them in hydraulic oil.
Take care not to mistake the fitting order of the friction plates and mating plates. If it is mistaken, the braking force of the parking brake may lower.
1) Put piston (112) having O-rings (135) and (139) in spindle (2).
2) Insert piston (112) into spindle (2) by hitting its end with a plastic hammer. Take care not to slant it.
fl Apply grease to O-rings (135) and (139).fl Necessary tools
• Plastic hammer
1) Install deep groove ball bearing (150), timing plate (109), parallel pin (341) (1 piece), and springs (113) (12 pieces) to rear flange (301).
Apply sufficient amount of grease to spring (113) and timing plate (109) so that they will not fall from rear flange (301).
fl Apply hydraulic oil to deep groove ball bearing (150).fl Necessary tools
• Grease • Hydraulic oil
1) Add hydraulic oil.5 Hydraulic oil (1.7 liters)
2) Install O-rings (29) and (27) (2 pieces) and parallel pins (42) (2 pieces) to spindle (2) side and install rear flange (301) to the spindle.
Do not apply grease to O-ring (29) on the mating face (since oozing grease can be mistaken for oil leakage).
fl When installing rear flange (301), match the pinholes to parallel pins (42) fitted in spindle (2).
1) Set coupling gear (15).2) Set input gear (6). Apply grease to the hollow of input gear (6) and steel ball (36), and then place steel ball (36).3) Fit O-ring (29) to cover (8).4) Install 2 eyebolts to the plug holes of cover (8). Lift up cover (8) and install it to hub (1).fl Apply grease to O-ring (30). When installing cover (8) into hub (1), take care not to damage the O-ring, etc.fl Match the bolt holes of cover (8) to the tap holes of hub (1).fl Necessary tools
• Grease • Plastic hammer • Eyebolts (2 pieces), PF 1/2 • 1 set of sling
PC228USLC-1 30-56-492
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
1) Tighten hexagon socket head bolts (343) (12 pieces) into spindle (2) to the specified torque.
3 Bolt: 252 ± 39.2 Nm {25.7 ± 4 kgm}2) Fit O-ring (355) to plug (357) and install them to
a drain port which will not be used. 3 Plug: 98.1 ± 19.6Nm {10 ±2 kgm}fl Necessary tools
• Torque wrench• Wrench adapter, rods of sizes 10 and 14
1) Install the relief valve to rear flange (301).2) Tighten the relief valve to the specified torque. 3 Bolt: 245 ± 49Nm {25 ± 5kgm}fl Necessary tools
• Torque wrench• Wrench adapter, socket of size 32
1) Tighten hexagon socket head bolts (35) (12 pieces) to the specified torque with a torque wrench.
2) Add lubricating oil (5.4 liters). 3 Bolt: 102 ± 15.7 Nm {10.4 ± 1.6 kgm}fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 10• Lubricating oil: 5.4 liters
1) Fit O-rings (43) to hexagon socket head plugs (33).
2) Tighten hexagon socket head plugs (33) (3 pieces) for cover (8).
3 Plug: 98.1 ± 19.6 Nm {10 ± 2 kgm}fl Necessary tools
• Torque wrench• Wrench adapter, rod of size 10
PC228USLC-130-56-502
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
1 Pressure gauge 2 pieces(For 3.4 MPa {35 kg/cm2})2 Measuring cylinder (For 5 liters) 1 piece
3 Stopwatch 1 piece
1 Installation and piping oftravel motor
PERFORMANCE TESTfl After maintaining the travel motor, execute the performance test according to the following
procedure.
1) Necessary measuring tools
2) Test procedureInstall the travel motor to machine body and connect thepipes. Do not install the tracks, however.(For the performance test (no-load operation) of the travelmotor)Note)1. Connect the pipes so that a pressure gauge (main cir-
cuit) can be installed and the drainage from the hydrau-lic motor can be measured.
2. When installing the travel motor, do not hit it with ahammer but fix it slowly by using the bolt holes.
Gear Speed of Pressure Revolving Operationspeed travel motor direction time
Low 10 rpmNo load Right and left Min. 1 minute
High 20 rpm each
1) Preparatory operation for test ..... Operate until temperature rises to the following levels.• Hydraulic oil: 45 – 55°C• Temperature of outside part of
reduction gear assembly hub: 40 – 80°C
2) Performance test ........................... Measure and judge the following items.Criteria for acceptance — Travel motor drive pressure
Max. 2.0 MPa {20 kg/cm2} in 1st gear speed at 10 rpmMax. 2.9 MPa {30 kg/cm2} in 2nd gear speed at 20 rpm
Drainage from hydraulic motorMax. 2 liters/min in both 1st and 2nd gears at 10 rpm
2 Run-in operation of travelmotor
3 Performance test of travelmotor
Accepted Rejected
Install tracks. Disassemble and adjust again.
PC228USLC-1 30-56-512
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
LIST OF CLEARANCE ADJUSTMENT PARTS
Classification Dimension (T)No.E Above 3.30 to 3.35F Above 3.35 to 3.40G Above 3.40 to 3.45H Above 3.45 to 3.50I Above 3.50 to 3.55J Above 3.55 to 3.60K Above 3.60 to 3.65L Above 3.65 to 3.70M Above 3.70 to 3.75N Above 3.75 to 3.80O Above 3.80 to 3.85P Above 3.85 to 3.90Q Above 3.90 to 3.95R Above 3.95 to 4.00S Above 4.00 to 4.05T Above 4.05 to 4.10U Above 4.10 to 4.15
Distance piece (13) Unit: mm
Part name Dimension