PPM20-037-00 1/15

PPM REBUILD UNIT MANUAL

TESTING METHOD
Category Testing method motors
Type of the
HMV120（120 cc/rev specification）
Pump
Stamping on
-
the nameplate
Part No. of the 708-8F-00360(R.H.)
pump 708-8F-00370(L.H.)
Machine model
installing these PC170LC-10 PC170LC-11
pumps
Serial No. of
the machines
#30001-30925 #35001-35345
installing these
pumps
Applications Travel motor
2020/7/31
Issuance
history

Remarks

Group manager/Team manager Person

Authorizer,
Issuer

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INTRODUCTION
・ This document is organized into the following parts

1. Test Method ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ Page 3 - 7

2. Test Hydraulic Circuit Diagram ・・・・・・・・・・・・・・・・・・・・・・ Page 8 - 9
3. Performance and Standard Value Table ・・・・・・・・・・・・・・・ Page 10 - 13
4. Names of Components and Related Dimension ・・・・・・・・・ Page 14 - 15
5. Schematic Diagram of Test Jig (Reference) ・・・・・・・・・・・・ No indication

・ This document mainly provides the test method using the KHT75-3 hydraulic test stand or equivalent.
　★ When this test is conducted with the KHT75 hydraulic test stand, care should be taken to prevent
　 cavitation (*) in the main pump on the hydraulic test stand side
　 * When the main pump supply flow is approximately 160 L/min or more.

・ Applicable bench
1)　Converted value test: Use the Komatsu general-purpose hydraulic test stand (KHT75-3) or
its equivalent. The input-output shaft drive motor must be changed to a variable motor.
2)　Standard value test: Hydraulic test stand having the same performance as the production
plant hydraulic test stand.
★ Use Komatsu genuine engine oil TO10-CD or equivalent. Discoloration of oil during test is
managed for Class NAS10.

・ Scope
This document is adopted for quality verification testing of the remanufactured main pump,
HMV (120 cc/rev specifications), which is installed on the following machine.
・PC170LC-10/11

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1. Test Method

1-1) Since high pressure is produced during this Main pump test, great care should be taken when
selecting the equipment, device, test jigs and components. Also, great attention should be given
to the pump installation condition, the hydraulic circuit configuration, and the universal joint connection.

1-2) Test Specifications

See the following Table 1-1.

Table 1-1 List of Test Specifications

Type of the motor and
Machine model Standard
Specifications

maximum 95.4
Motor capacity (cc/rev)
minimum 55

Clockwise
PMA port inflow
Direction of rotation of rotation
output shaft Counterclockw
PMB port inflow
ise rotation
Maximum rotation of out put shaft
2600
(rpm)
Maximum hydraulic pressure
37.3
(MPa {kg/cm2})
Maximun supply flow
143
(L/min)
Reference:
0.85 ± 0.2 {8.7 ± 2}
Conter balance valce performance
(Change over pressure)
(MPa {kg/cm2})
Reference:
37.3 {380}
Safety valve performance
(Set pressure)
(MPa {kg/cm2})

1-3) Test Items

1)　For test items and contents, see Table 1-2 below.
　　　　★　For converted value test, conduct tests as limited by the capacity of the KHT75-3 hydraulic test stand.
　　　　★　The converted value test determines pass or fail after converting the results of measurements into standard values.
　　　　★　The test standard values to be adopted are:
・ Standard value test: Standard of performance standard value table
・ Converted value test: Conversion of performance standard value table

Table 1-2 Test item Legend: 〇 Conduct, △ Conduct, if possible, × Don't test
Test items Performance check
Checking
Volumetric
Running-in Morot Regulator Parking brake pressure or
efficiency Amount absence of
Test displacement performance torque
(or amount of of slip test
Method volume check check caoacity check abrnormality
drain)

Standard 〇 〇 〇 〇 〇 〇 〇

1-4) Test Basic Hydraulic Circuit Diagram

・ See Appemdix Figure 1 in " Section 2 Test Hydraulic Circuit Diagram".
1-5) Functions and Conditions of Sample Sections
・ See Appendix Table 1 in " Section 4 Names of Sections and Related Dimensions".

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1-6) Test Equipment, Device, and Jig

1)　Equipment to be used: Have the equipmet listed in Table 1-3 ready.
Table 1-3 Pressure Gauge and Device
　　　　★　For information as to how to install pressure gauges, see Test Hydraulic Circuit Diagram.
　　　　★　For equipment market with *, you may select equivalents of any makers if they if they satisfy their specifications.
　　　　★　To measure the quantity of drain, use the flow meter when the quantity is large (10 L/min or more).
Part Number
Equip
(or Manufacturer's Part Name Q'ty Specifications Measuring Points and Application
ment
Type)
0～39.2 MPa Motor inlet section (High pressure side)
799-101-5120 Gauge 1
{400 kg/c㎡) (PMA or PMB)
pressure gauge
Related to

Motor outlet section (Low pressure side)

0～5.9 MPa
799-101-5130 Gauge 2 (PMB or PMA)
{60 kg/c㎡)
Regulator pilot pressure inlet port section (P1)
0～0.4 MPa
- Gauge 1 Pump suction port (PS), drain port (PD)
{4 kg/c㎡)

Measuring
Measuring flow: 0 - 20 L/min
cylinder or 1
*- (Working pressure; 0.98 MPa {kg/cm2} Measurement of slow of motor drain
Related equipment

flowmeter and (1 set)

・Measuring slow: 10 L/min or more)
display meter

799-552-3710 Stopwatch 1 - Measurement of flow of motor drain

Measuring torque range:

799-610-1410 Torque wrench 1 For measurement of Parking brake torque
686 Nm {70 kgm} or more

2)　Test Jigs and Parts: Prepare the jigs listed in Table 1-4.
Table 1-4, List of Test Jigs
No. Part Number Part Name Q'ty Measuring Points and Applications
1 - Plate 1 For instllation of motor
2 - Coupling 1 For connecting output shaft
　　　　★　For manufacturing of jigs, refer to "section 4 Names of section and Related Dimensions."
　　　　★　Piston pump discharge port PA must be provided the safety valve.

3 ) In addition to those listed in Table 1-4, prepare flange, hose and other parts necessary to continue the
hydraulic circuit for the test.
4 ) Prepare penetrant (developer for color check).

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1-7) Preparation Steps for Test Fig. 7-1 Travel Motor Hydraulic Circuit Diagram
Make the following arrangements before the test:
1)　Installation of Hydraulic Test Stand
　 Install the stand so that the drain port (PD) of the
DUT faces upward.(See Figure 7-2, 7-3.)
★　When connecting the universal joint, use
the bolt hole for the output shaft section of the
travel motor and fasten the connection using
a bolt so that the coupling may not be disengaged.
2)　Piping Configuration according to Test Hydraulic
Circuit Diagram (See Attached diagram 1 and 2 motor Fig. 7-2 Motor Assembly Mounting Direction
hydraulic circuit.)
(1) See Figure 7-1 for travel motor hydraulic circuit
(2) For the port positions, refer to Attached Table 1 in
"Section 4 Names of Section and Related Diagram".
★ Common to port section of all machine
(3) Attached Diagram 1 to 2 should be selectively
used according to the teat carried out.
・ Attached diagram1: For Running-in and
Performance check
・ Attached diagram 2: For Slip volume check Fig. 7-3 Port Motor Position (PMA, PMB, PD)
★ Test hydraulic circuit of Attached diagram
1 and 2 are for tests conducted while turning
the motor clockwise. In case of counterclockwise
rotation tests, connect PMA and PMB ports in reverse.
3)　The rotating directions are as follows when you
look at the output shaft (M2):
・ Flow through the PMA port :
Clockwise rotation (C.W)
・ Flow through the PMB port :
Counterclockwise rotation (C.C.W)
(See Figure 7-3 and 7-4.) Fig. 7-4 Output Shaft (M2) Rotating Direction
• Fig. 7-2 to 7-4
PMA : MA side inlet and outlet port
PMB : MB side inlet and outlet port
PD : Drain port
PB : Parking brake pressure inlet port
P1 : Requlator pilot pressure inlet port
M2 : Output shaft

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4) Pour oil from the DUT drain port (PD) to drain air
and to fill the case with oil.
★ Be sure to fill the case with oil to prevent the
motor inside from being damaged.
5) Clean the motor assembly and spray dye penetrant
to each connection and the safety valve connection.
6) Set the oil temperature of the hydraulic test
stand to 50 ± 5°C.
7) Rotate the motor slowly and check the rotating
direction, flowmeter indication and other troubles.

1-8) Confirming test method

For the details of test conditions and standard values for confirming tests, refer to "Section 3 Performance
Standard Volue Table"
1) Running-in : During the operation, check if any trouble (abnormal pressure, sound, etc.) occurs and if oil leaks.
2) Check of Motor Displacement Volume
Measure outlet flow (Q) and motor drain volume (EQ), and calculate the motor displacement volume [qm (cc/rev.)].

3) Performance tests of the regulator

This is a test to check the changeover pressure between the 1st speed (Lo) and the 2nd speed (Hi) of themotor
and, by changing the regulator changeover pilot pressure under the specified conditions, measure
the pilot pressure at the revolution speed changing (Rising • N1, Dropping • N2) point. (Refer to Fig. 8-1.)
i) 1st speed (F1 = Lo) o 2nd speed (F2 = Hi): The
pressure level when the changeover is started: Fig. 8-1 Method of pilot pressure check (P1H, P1L)
Raising the (P1H) pilot pressure (P1) gradually
from 0 MPa {0kg/cm²}, measure the pilot pressure
(P1H) when the revolution speed starts rising.
ii) 2nd speed (F2 = Hi) o 1st speed (F1 = Lo):
The pressure level when the changeover is
started:
Lowering the (PL) pilot pressure (P1) gradually
from 1.96 MPa {20kg/cm²}, measure the pilot
pressure (P1L) when the revolution speed starts
dropping.

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4) Check of Volumetric Efficiency (or Drain Volume)

When the motor is loaded, measure outlet flow (Q), motor drain volume (EQ) and calculate the volumetric
efficiency η(%) or drain volume (L/min.).
★ For converted value test, measure the drain volume [L/min.]

5) Check of Torque Efficiency (Measured output shaft torque)

Applying specified load to the motor [Pm (MPa {kg/cm²})], measure the displacement capacity of the motor
[qm (cc/rev)] and the torque level [Tt (Nm{kgm})] to calculate the torque efficiency [ηt (%)].
★ Use the actual measurement value as the displacement capacity of the motor for the calculation.
Refer to 1-8 Section 3) for the calculation formula.

6) Check of slip volume (See Attached Diagram 2)

Closed the motor outlet side, than drive the motor from the hydraulic test stand to determine the output
shaft slip volume (revolution, rpm) under the specified circuit pressure.
★ A specified pressure can fluctate due to the motor ratation, thus you need to control the pressure
so that it may not go beyond the "Set pressure + 0.98 MPa {10 kg/cm²}" level.
7) Parking Brake Torque Capacity Check
Rotate the motor output shaft using a torque wrench and measure the torque (Nm (kgm)).
★ Disconnect the universal joint, hose, etc.
8) Check for Abnormalities
Check for abnormalities during the tset such as heating, vibrations, noise and oil leakage.
1-9) Operation requred after the test
When removing and restoring the DUT after the test, the following operations are required.
1) Drain residual oil inside the DUT, then check if the oil is contaminated by foreign substance.
2) Remove all jigs and parts used in the test.
3) Using nylon plugs or equivalent, close all ports so that entry of dusts may be prevented.
4) Enter the test results to the record sheets and maintain them for later reference (retention period is three
years).

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2.Test Hydraulic Circuit Diagram
Appendix Figure 1：Moror Test Basic Circuit Diagram

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Appendix Figure 2：Slip volume check test circuit diagram

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Performance Standard Value Table

1） This document contains the Table Standard Value Table.
2 ）When conducting a test, select the applicable model from the following table.
3 ）PC170LC-10/11

List of Standard Value Tables

Chart and Standard

Remarks
Value Table No.

Table 1 Running-in, Moror displacement volume

Table 2 Performance check (Volumetric and Touque efficiency)

Table 3 Performance check (Requlator performance, Slip volume check)

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 Motor displacement
Test items Running-in
capacity measurement

Sym 1st speed 2nd speed Max. (1st Min. (2nd

Category
Condition and Standard Value Items Unit Tolerance
bol 1 2 3 4 5 6 1 2 3 4 speed) speed)

Output shaft revolution speed Standard M2 rpm ±10 500 1500 500 1000 ← 1500 1000 1500 ← ← 1000 ←

Direction of input shaft rotation - - - Clockwise ← ← ← ← ← ← ← ← ← Clockwise ←

4.9 4.9 9.8 14.7 9.8 14.7 2.4 {25}

Inlet PA No load ← No load ← ←
{50} {50} {100} {150} {100} {150} or less
Main port pressure
0.29 {3}
Outlet PB No-load ← ← ← ← ← ← ← ← ← ←
±0.5 or less
{±5}
Inlet PA
MPa
Main port puressure (circuit pressure) - - - - - - - - - - - -
{kg/cm2}

Test Condition
Outlet PB

±0.1 1.96
Regulatror changing pilot pressure P1 0 ← ← ← ← ← ← ← ← ← 0
{±1} {20}

Parking brake release pressure P2 or more - - - - - - - - - - - -

2 tiimes or
operating time, number of measuring times - min times - 2 min 1 min ← ← ← ← 2 min ← 1 min ← ←
more
Within
Motor displacement volume qm cc/rev - - - - - - - - - - 93.5 - 98 52.9 - 57.2
range

Drain amount △Q l/min or less - - - - - - - - - - - -

Volumetric effeciency η % or more - - - - - - - - - - - -

Torque efficiency ηt % or more - - - - - - - - - - - -

[Refence] Caluculation torque valve Tt Nm{kgm} or more - - - - - - - - - - - -

Standard Value
Slip amount (outlet shaft revolution speed) M2 rpm or less - - - - - - - - - - - -
(PC170-10/11) [1/3]

MPa Within
Regulator changing pilot pressure P1 - - - - - - - - - - - -
{kg/cm2} range
Within
Parking brake torque capacity TB Nm{kgm} - - - - - - - - - - - -
range

Motor displacement capacity qm cc/rev - - - - - - - - - - -

Slip amount (outlet shaft revolution speed) M2 rpm - - - - - - - - - - - [ ] [ ]

Table 1 : Performance Standard Value Table

Inlet (outlet) flow rate Q l/min - - - - - - - - - - - [ ] [ ]

Drain amount △Q l/min - - - - - - - - - - - [ ] [ ]

Volumetric effeciency η % - - - - - - - - - - - ( ) ( )

Torque efficiency ηt % - - - - - - - - - - - - -

Measurement Value
Torque value Tt Nm{kgm} - - - - - - - - - - - - -

MPa
Regulator changing pressure P1 - - - - - - - - - - - - -
{kg/cm2}

Parking brake torque capacity TB Nm{kgm} - - - - - - - - - - - - -

Oil leakage, abnormal noise, and heat generation check - - OK/NG OK/NG OK/NG OK/NG OK/NG OK/NG OK/NG OK/NG OK/NG OK/NG - OK/NG

Determination　(　〇　)

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PPM20-037-00 11/15
 Test items Drain amount, Torque efficiency measurement (*For converted value test, measure the drain volume)

Sym 1st speed 2nd speed

Category
Condition and Standard Value Items Unit Tolerance
bol 1 2 3 4 5 1 2 3 4 5

Output shaft revolution speed Standard M2 rpm ±10 1400 1050 840 430 430 2600 1600 1240 650 650

Direction of input shaft rotation - - - Clockwise ← ← ← ← ← ← ← ← ←

9.8 19.6 24.5 34.3 37.3 9.8 19.6 24.5 34.3 37.3
Inlet PA
{100} {200} {250} {350} {380} {100} {200} {250} {350} {380}
Main port pressure
Outlet PB (No-load) ← ← ← ← ← ← ← ← ←
±0.5
{±5}
Inlet PA
MPa
Main port puressure (circuit pressure) - - - - - - - - - -
{kg/cm2}

Test Condition
Outlet PB

±0.1 2.94
Regulatror changing pilot pressure P1 0 ← ← ← ← ← ← ← ←
{±1} {30}

Parking brake release pressure P2 or more - - - - - - - - - -

2 times
operating time, number of measuring times - min times - ← ← ← ← ← ← ← ← ←
or more
Within
Motor displacement volume qm cc/rev - - - - - - - - - -
range

Drain amount △Q l/min or less *6.7 *10 - - - *(12.9) *11.4 *10.9 - -

Volumetric effeciency η % or more 95 90 86 81 76 91 87 84 71 66

Torque efficiency ηt % or more 65 84 85 86 86 57 75 80 80 80

(96.7) (250) (316) (447) (486) (48.9) (128) (171) (240) (260)
[Refence] Caluculation torque valve Tt Nm{kgm} or more
({9.9}) ({25.5}) ({32.3}) ({45.7}) ({49.6}) ({5}) ({13.1}) ({17.5}) ({24.5}) ({26.6})

Standard Value
Slip amount (outlet shaft revolution speed) M2 rpm or less - - - - - - - - - -
(PC170-10/11) [2/3]

MPa Within
Regulator changing pilot pressure P1 - - - - - - - - - -
{kg/cm2} range
Within
Parking brake torque capacity TB Nm{kgm} - - - - - - - - - -
range

Motor displacement capacity qm cc/rev - [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

Slip amount (outlet shaft revolution speed) M2 rpm - [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

Table 2 : Performance Standard Value Table

Inlet (outlet) flow rate Q l/min - [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

Drain amount △Q l/min - [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

Volumetric effeciency η % -

Torque efficiency ηt % -

Measurement Value
Torque value Tt Nm{kgm} - [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ] [ ]

MPa
Regulator changing pressure P1 - - - - - - - - - - -
{kg/cm2}

Parking brake torque capacity TB Nm{kgm} - - - - - - - - - - -

Oil leakage, abnormal noise, and heat generation check - - - - - - OK/NG - - - - OK/NG

Determination　(　〇　)

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PPM20-037-00 12/15
 Regulator performance check
Test items Slip amount test
(1st speed [Lo] ⇔ 2nd speed [Hi}
Parking brake torque capacity
Sym Run in 1st speed → 2nd speed → Condition measurement

Category
Condition and Standard Value Items Unit Tolerance 1st speed 2nd speed
bol operation 2nd speed 1st speed

500
Output shaft revolution speed Standard M2 rpm ±10 ← (at 2nd speed) - - -
(at 1st speed)
Clockwise (Drive Clockwise
Direction of input shaft rotation - - - Clockwise ← ← ←
from the bench side) (Drive with torque wrench)
9.8 0.098 {1}
Inlet PA ← ← ← Open port
{100} or less
Main port pressure
Outlet PB (No-load) ← ← Close port ← Open port
±0.5
{±5}
Inlet PA - - - - - -
MPa
Main port puressure (circuit pressure)
{kg/cm2} 4.9

Test Condition
Outlet PB - - - ← -
{50}
±0.1 0⇔2.94 2.94
Regulatror changing pilot pressure P1 ← ← 0 Open port
{±1} {0⇔30} {30}
1.96
Parking brake release pressure P2 or more - - - ← Open port
{20}
5 times 2 times 2 times 2 times
operating time, number of measuring times - min times - ← ←
or more or more or more or more
Within
Motor displacement volume qm cc/rev - - - - - -
range

Drain amount △Q l/min or less - - - - - -

Volumetric effeciency η % or more - - - - - -

Torque efficiency ηt % or more - - - - - -

[Refence] Caluculation torque valve Tt Nm{kgm} or more - - - - - -

Standard Value
Slip amount (outlet shaft revolution speed) M2 rpm or less - - - 7 12.4 -
(PC170-10/11) [3/3]

MPa Within 0.69 - 1.18 0.29 - 0.78

Regulator changing pilot pressure P1 - - - -
{kg/cm2} range {7 - 12} {3 - 8}
Within 333 - 637
Parking brake torque capacity TB Nm{kgm} - - - - -
range {34 - 65}

Motor displacement capacity qm cc/rev - - - - - - -

Slip amount (outlet shaft revolution speed) M2 rpm - - - - -

Table : Performance Standard Value Table

Inlet (outlet) flow rate Q l/min - - - - - - -

Drain amount △Q l/min - - - - - - -

Volumetric effeciency η % - - - - - - -

Torque efficiency ηt % - - - - - - -

Measurement Value
Torque value Tt Nm{kgm} - - - - - - -

MPa
Regulator changing pressure P1 - - - - -
{kg/cm2}

Parking brake torque capacity TB Nm{kgm} - - - - - -

Oil leakage, abnormal noise, and heat generation check - - OK/NG - - OK/NG OK/NG -

Determination　(　〇　)

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4. Names of Components and Related Dimensions
Appendix Table 1 Names of Sample Components and Port Size

1. Names of Components and Port Size

Symbol representing Presece or
port or adjustmnet Name of port and adjustment sections absence of Port size Remarks
section connection

M1 Installed position of motor Connected - See dimentional drawing

M2 Spline section of output shaft Connected - See spline specification

PMA Motor inlet and outlet port (PMA side) Connected M33 x 1.5

PMB Motor inlet and outlet port (PMB side) Connected M33 x 1.5

PD Motor case drain port Connected M20 x 1.5 For drain

Pda Air bleeder Closed - For motor case air drain

P1 Pilot pressure inlet port Connected M14 x 1.5 For regulator change over
Parking brake release pressure
PB Parking brake purssure inlet port Connected (M10 x 1.25)
(with plug)
Installation of pressure gauge
CMA Motor inlet and outlet checking port (PMA side) Connected (M14 x 1.5)
(with plug)
Installation of pressure gauge
CMB Motor inlet and outlet checking port (PMB side) Connected (M14 x 1.5)
(with plug)

2. Spline Specifications (M2)

Details of involute spline (M2)
33.333 x 18 x 1.667 involute spline hole
Amount of addendum modification +1.334
Tooth prlfile Tooth bottom
Module 1.667
Tool Pressure angle 20.00°
Number of teeth 18.000
Reference pitch circle diameter 30.000
-0.182
Over-pin dimension '36.244 -0.273 (Φ3.0)
Tooth thickness Base tangent length
(reference)
-

Alignment Alignment of tooth

Mating part number -

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Appendix Figure 1 Dimensions of Sample Sections
Applicable Models：PC170-10/11

3. Related positions of pump and ports

86
8° 20°
M1

M2 18xM16x2 xMIN29
X (Circumference
equary spaced)

105
94.5
P
-0.2
-0.3

Φ390
Φ328
Φ390

135
CMA
130 CMB
0
183.4 9 -0.5

(12) PDa
210.4 146 146

222.4 126

4. Details of inlet and outlet port (PMA and PMB)

PD
PMB

PMA

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