pc200 7 Main Pump Test Method

SEBH801100 1/26
PPM REBUILT UNIT MANUAL II

TESTING METHOD
Category Testing method for pumps

Type of the Pump HPV95+95 (112+112 cc/rev specification)
Stamping
Stamping on the nameplate DZJ
Part No. of the Pump 708-2L-00300
Machine model installing PC200/200LC-7 PC210/210LC-7
these motors GALEO GALEO
Serial No. of the machines
#200001~ #400001~
installing these motors
Applications Main pump
2004/5/20
Issuance history
Remarks
SEBH
SEBH80
8011
1100
00 2/
2/26
26
INTRODUCTION
• This document is organized into the following parts
1. Test Method ···························································· Pages 3 - 11
2. Test Hydraulic Circuit Diagram ············

························
························
············ Page 12
3. Performance Diagram and Standard Value Table ········

··········
·· Pages 13 - 23
4. Names of Sections and Related Dimension ················· Page 24 - 26
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.
• Applicable bench
1) Converted value test: Use the Komatsu general-purpose hydraulic test stand (KHT75-3) or its equivalent.
2) Standard value test: Hydraulic test stand having the same performance as the production plant hydraulic
test stand.
 Use Komatsu genuine

genuine engine oil E010-CD or equivalent. Discoloration of oil during
during test is managed
managed for
Class NAS10.
• Scope
This document is adopted for quality verification testing of the remanufactured main pump,
pump, HPV95 + 95 (1
(112
12
+ 112 cc/rev specifications), which is installed on PC200/210 series-7.
2
SEBH801100 3/26
1. Test Method
1-1) Since high pressure is produced during this HST 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 installa-
tion 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
Pump type HPV95+95
Specifications Standard Conversion
Piston pump capacity

13~112 ←
(cc/rev)
150mAp-p
EPC current dither ←
40Hz
Direction of rotation
Right hand ←
(input shaft)
Maximum revolution of input shaft

1950 1500
(rpm)
Maximum hydraulic pressure of pump 37.3 34.3
(MPa{kg/cm2}) {380} {350}
Pump suction pressure 0.98 ± 0.05

←
(MPa{kg/cm2}) {1.0 ± 0.5}
Pump drain pressure 0.98 or less

←
2
(MPa{kg/cm }) {1.0}
EPC valve original pressure 3.1

←
2
(MPa{kg/cm }) {32}
Maximum flow (L/min) 220 (23) 168 {19}
3
SEBH801100 4/26
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:  Conduct • ∆ Conduct, if possible. • × Don’t test
y
r t
Performance check i
o l
Test e a
n
i c m
Items - Flow check PQT control characteristics LS control characteristics n r
e o
g s n
n
i m n s r b
e
n u m e d e
i e
e e 6.9{70} 19.6 293 34.3 a
p f
n u c o d d d r o
u m i
i m n m o o o 9.8{100} {200} {200} {350} o
f e
k c
Test R x n
e
r 3
i f m m m Fine control c n
a e
f w STD
H S L mode mode ← ← ←
e e
s
h b
M M D l
i o
Method f
C a
Standard       
        
Conversion * × * × × × ×
 Carry out the converted value test marked with an asterisk (*) to the extent that hydraulic setting is
allowed.
1-4) Test Basic Hydraulic Circuit Diagram
• See Appendix Figure 1 in “Section 3 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.”
1-6) Test Equipment, Device, and Jig
1) Equipment to be used: Have the equipment listed in Table 1-3 ready.
Table1-3 Pressure Gauge and Device

 For information as to how to install pressure gauges, see Test Hydraulic Circuit Diagram.
Part Number
Part Name Quantity Specifications Measuring Points and Application
(or Manufacturer’s Type)
0~39.2MPa Pump discharge port (P1f, P1r)
799-101-5120 Gauge 4
{400kg/cm2) LS input port (PLS)
0~5.9MPa EPC original pressure sensing port
799-101-5130 Gauge 2 2
{60kg/cm ) (CEPC)
0~2.5MPa PC mode switching pressure sensing port (CPC)
799-101-5140 Gauge 2
{25kg/cm2) LS mode switching pressure sensing port (CLS)
0~0.4MPa
– Gauge 1 Pump suction (PS) section
{4kg/cm2)
Differential 0~49MPa Between pump discharge port (PP1) and
1
799-401-2700 pressure gauge {500kg/cm2) LS input port (PLS)
799-401-2810 Power supply: 100VAC Power supply for differential pressure
Transformer unit 1
input, 12VDC output gauge
799-552-3050  Dither signal generator Adjusts the following dither signal.
Controller module 2set
799-552-3930 Dither signal adjuster 40Hz · 150mAp-p
4
SEBH801100 5/26
Table 4 List of Devices (Continuation)

Part Number
Part Name Quantity Specifications Measuring Points and Application
(or Manufacturer’s Type)
Flowmeter 1 Working pressure: For measuring LS drain (Q3)
*FSC-750
Flow display 1 34.3MPa{350kg/cm2}
*DRM-100
Measuring flow:
Made by Flowtec
0~100L/min
Stop valve (S1) 1 Working pressure: For generating differential pressure at LS
*GNT-3
34.3MPa{350kg/cm2} (S1)
(PT 3/8 thread)
or more
Made by Hirose
Maximum flow:
Valve Industry
30(L/min) or more
Relief valve 2 Set pressure: For safety valve
– 2
34.3MPa{350kg/cm }
or more
Maximum flow:
160(L/min) or more
 For information as to how to install the above devices, see Hydraulic Circuit Diagram (Appendix Figure
1).
 The connector for the controller must be changed to a German type connector.
 Any device with an asterisk (*) is not included in the supplies; their manufacturer’s names are en-
closed in parenthesis. (Part number registration not set) You can choose a product of any manufacturer
that satisfies the specifications.
2) Jigs and components to be used: Have jigs and components listed in Table 1-4 ready.
Table 1-4 Test Jigs
No. Part Number Part Name Quantity Specifications and Application
1 799-404-2980 Plate 1 For installing pump
2 799-404-2970 Coupling 1 For connecting input shaft
3 799-404-2910 Adapter 1 1.6 mm diameter fixed throttle valve
 The jigs are the same as those used for testing HPV95 + 95 pumps.
 Piston pump discharge port (P1) must be provided with a port for introducing LS pressure, the one for
introducing pump pressure, the one for removing the differential pressure gauge, and the one installing
the safety valve.
3) In addition to those listed in Table 1-4, have components such as an adapter and hose ready, which are
required for configuring a test hydraulic circuit.

 For information on manufacturing of jigs and components, see “Section 4 Names of Sections and
Related Dimensions.”
4) Have a penetrant testing agent (e.g. developer such as color check) ready.
5
SEBH801100 6/26
1-7) Preparatory Steps for Test

7-1 Installation Condition of Pump
Perform the following steps prior to this test.
1) Installing hydraulic test stand (see Fig. 7-1)
Install the test stand so that the sample bleeder
(PDa) turns up.

• Fig . 7-1
P1f : Pump discharge port on the F side
P 1r: Pump discharge port on the R side
PDr: Air bleeder (used for air bleeding)
PD1f: Pump case drain port on the F side
2) Installing universal joint Fig.7-2 Pump Hydraulic Circuit Diagram
Since the universal joint rotates rapidly, install it in a
level position when connecting, and take action not
to cause run-out. Protect the coupling from becom-
ing detached from the shaft.
3) Configuring test hydraulic circuit (see Appendix Fig-
ure 1)
i) Configure as per test hydraulic circuit diagram in
the Appendix Figure 1.

 For the main pump hydraulic circuit diagram, Fig.7-3 R Pump Drain Hydraulic Circuit Diagram
see Fig. 7-2.

ii) Set up circuits for bleeding air and force-feed
lubrication on the rear pump. (See Fig. 7-3.)

 Use drain port (PD2r) for air bleeding of the rear
pump. (See Fig. 7-3.)
• Set the drain discharge port higher than the
pump discharge port (P1r), because the drain
port tends to point downward.
• Drain pressure: 0.98/ MPa{1kg/cm 2} or less
 Use the plug (PT) for forced-feed lubrication of
Fig. 7-4 Locations of R Pump Case Drain Plugs
the rear pump. (See Fig. 7-4.)
• Flow of forced-feed lubrication:40(L/min) or less
iii) Install pressure gauges on hydraulic detection
ports.
 For specifications of the pressure gauge to be
installed, see Appendix Figure 1.
 For details of port and adjustment sections, see
Appendix Table 1.
6
SEBH801100 7/26
4) Filling the pump case with oil
Pour oil into the pump case (PS port), bleed the air
(P Da, P D1f, and P D2r ports), and fill the pump
case with oil.

 Be sure to perform this to prevent the possibility
of damage inside the pump.
 Be sure to release air from the rear pump.
 Specified torque for air bleeder:
7.8~9.8 Nm(0.8~1 kgm)
 PT port plug specified torque:
58.8~78.4 Nm (6~8kgm)
Fig. 8-1 Maximum Flow Adjustment Section
5) Cleaning pump assembly
Clean the pump assembly to check for oil leakage
and apply penetrant testing agent to each of valve,
plug and input shaft oil seal.
1-8) Verification Test and Adjustment Methods

 Prior to conducting a test, check connections of
piping (PA and PB ports), hose and adapters.
 For more information on conditions and standard
values during testing, see the “Performance Standard
Value Table” in Section 3. Fig. 8-2 Detail of Maximum Flow Adjustment Sec-
1) Running-in tion
Check for abnormality (pressure, vibration, sound,
etc) and oil leakage while the pump is running.
2) How to check and adjust maximum and minimum
pump flow
(1) Check piston pumps P 1f and P 1r delivery for the
maximum and minimum flow under the
predetermined conditions.
 DFor the measurement of minimum flow, add
the amount of drain at LS pressure port (amount
of oil flowing when the stop valve S1 is open =
Q3).
• Q T = Q1 + Q3 (L/min)
(2) How to adjust pump flow
 Before making adjustments, place alignment mark.
i) Adjust the maximum flow using the adjustment screw (Ma). (See Fig. 8-1.)
 The maximum flow adjustment section has been mounted to reference dimensions when the pump
was assembled (see Fig. 8-2).
[Reference] L2 = 12.6 ± 0.1 mm
7
SEBH801100 8/26
ii) Adjust the minimum flow using the adjustment

Fig.8-3 Minimum Flow Adjustment Section
screw (Mb). (See Fig. 8-3.)
 Since the minimum flow adjustment section
has been mounted with the pre-adjusted PC
valve assembly, be sure to check the
performance of PC valve assembly (PQT
performance) after you make adjustments (see
Fig. 8-4).
[Reference] L1 = 19.1 ± 0.1 mm
• Fig . 8-1 ~ 8.4
Ma : Maximum flow adjustment screw
Mb : Minimum flow adjustment screw Fig. 8-4 Detail of Minimum Flow Adjustment Sec-
MPC : PC valve adjustment screw tion
1 : Cover
A : Locknut
(3) How to adjust maximum and minimum flow (see
Fig. 8-5)
 Symbol enclosed in parenthesis indicates the
method of adjusting the minimum flow.
 Prior to adjustment, measure the length between
the alignment mark and the screw head, L3 and
L4.
i) Loosen the locknut A. Fig. 8-5 Details of Maximum and Minimum Flow
Adjustment Sections
ii) Adjust the screw Ma (Mb).
iii) After adjustment, temporarily tighten locknut A

and measure the flow.
iv) When the measured value is within the standard
value, fully tighten locknut A. (See Table 8-1.)
 Locknut A: 568 ~ 676 Nm (58 ~ 69 kgm)
• Fig . 7-5, 7-6
Ma : Maximum flow adjustment screw
Mb : Minimum flow adjustment screw
MPC : PC valve adjustment screw
PC : PC valve assembly
1 : Cover Table 8-1 Procedure for Adjusting Maximum and
2 : Cover Minimum Flow
A : Locknut
Phenomenon Large Small
Locations of standard standard
adjustment flow flow
Maximum flow adjustment
Turn cw Turn ccw
screw (Ma)
Minimum flow adjustment
Turn ccw Turn cw
screw (Mb)
8
SEBH801100 9/26
3) How to test and adjust PQT control characteristics Fig. 8-6 P-Q-T Characteristics Chart and Difference
in Flow (∆Q) Check
(1) Testing PQT control characteristics (see Fig. 7-6)
Measure the flow caused by the pressure fluctuation
and check that the values plot on PC characterist ics
chart (P-Q) and torque characteristics chart (P-T) are
within the standard value.
i) H mode: E PC current - 350 mA (without P-Q-T
chart)
ii) S mode: E PC current - 460 mA (with P-Q-T
chart)
iii) L mode: E PC current - 710 mA (P-Q-T without
chart)
 For more information on the PQT control cha-
racteristics (P-Q-T chart), see “Table of
Performance Standard Values and Fig.1” in
Section 3.
 Measure PQT control characteristics at both
pressure rise and pressure drop and, then, adopt
the value at pressure rise.
 Close stop valve S1.
(2) Checking difference in flow of pump discharge
amounts
 Use three modes.
Check that the difference in flow (∆Q) between P 1f
pump delivery (Q f) and P 1r pump delivery (Qr) under
the same conditions is below the predetermined value.
(See Fig. 8-6.)
 Be sure to make this check to prevent travel
deviation when installed on an actual machine.
 Check this when testing PQT control chara-
cteristics.
 Predetermined pressure: P A1 = P A2 (same
pressure)
∆Q = Less than 7.3 L/min: When making standard
value test
• Both Q 1f > Q 1r and Q 1f < Q 1r are acceptable.
9
SEBH801100 10/26
(3) How to adjust PC control characteristics
1) For locations of adjustment sections, see Fig. 8-7.

 Prior to adjustment, measure the length be-tween the alignment mark and the screw head, L5.
• Fig. 8-7
MPC: PC valve adjustment screw
Mb: Minimum flow adjustment screw
PC: PC valve assembly
B: Locknut
2) Make adjustments in the following order (see Fig. 8-7).
(i) Loosen lock nut B.
(ii) Adjust the PC control characteristics using the adjustment plug (M PC).
q To adjust the PC control characteristics to a value below the standard → tighten the plug (turn cw)
w To adjust the PC control characteristics to a value above the standard → loosen the plug (turn ccw)
(iii) After adjustment, temporarily tighten locknut B and measure the PC control characteristics.
(iv) When the measured value is within the standard value, fully tighten locknut B to the specified torque.
 Locknut B: 27 ~ 34 Nm {2.8 ~ 3.5 kgm}
4) How to test and adjust LS control characteristics
(1) Testing LS control characteristics (see Fig. 8-8)
Measure the flow caused by fluctuation in LS differ-
ential pressure under a constant control pump

Fig. 8-7 Details of PC Control Section
pressure and check that it is within the LS control
characteristics chart.
 Use normal mode (A) and fine control mode ( B).
• Control pressure (pump pressure)
* i) 6.9 MPa{ 70{kg/cm2}): without LS chart
* ii) 9.8 MPa{100 kg/cm2}): (without LS chart)
iii) 19.6 MPa{200kg/cm2}): (with LS chart)
iv) 29.4 MPa{300kg/cm 2}): (without LS chart)
v) 34.3 MPa{350kg/cm2}): (without LS chart)
 For more information on the LS control chara-
cteristics (LS), see “Performance Standard Value Fig. 8-8 Details of LS Characteristics Chart
Table - Fig.2” in Section 3.
 The same standard value is applied to control
pressure of 6.9 MPa (70 kg/cm 2) and 9.8 MPa
(100 kg/cm2).
 Adopt the value when LS differential pressure is
reduced.
 For the overall pump capacity (QT), add the am-
ount of drain at LS pressure port (amount of oil
flowing when stop valve S1 is open = Q3).
• Q T = Q1 + Q3 (L/min)
 Be sure to slowly open and close stop valve S1.
10
SEBH801100 11/26
(2) How to adjust LS control characteristics (see Figs.

Fig. 8-9 LS Adjustment Section
8-9 and 8-10)
Make adjustments in the following order.

 Prior to adjustment, measure the length, L6. (See
Fig. 8-10.)
• Figs. 8-9 and 8-10
MLSf: LS adjustment plug on the front pump
MLSr: LS adjustment plug on the rear pump
C: Locknut
i) Loosen locknut C.
ii) Adjust the LS control characteristics using the

Fig. 8-10 Details of LS Adjustment Section
adjustment screw (M LS). (See Table 8-2.)
q To adjust the LS control characteristics to a
pressure lower than the standard, tighten the
screw (turn cw)
w To adjust the LS control characteristics to a
pressure higher than the standard, loosen the
screw (turn ccw).
iii) After adjustment, temporarily tighten locknut C
and measure the control characteristics.
iv) When the measured value is within the standard
value, fully tighten locknut C to the specified
torque.
 Locknut C: 49 ~ 68.6 Nm(5 ~ 7 kgm)
5) Checking for Abnormality
Check the following items for abnormality during the test and after the test and determine pass/fail results.
(1) Oil leakage from the following sections
i) Input shaft oil seal
ii) Valve connections
iii) Plug connections
iv) End cap connections
(2) Abnormal sound, vibration, or temperature
(3) Other abnormalities
6) POST-TEST TASKS
To remove the sample and restore to the original state, keep the following in mind.
1) Drain the residual oil out of the sample and check the oil for a foreign substance.
2) Remove all the jigs installed for testing.
3) Seal off all ports with nylon plugs or the like to prevent the ingress of dirt and dust.
4) Record the test results on appropriate report forms. (Retention period: 3 years)
11
SEBH801100 12/26
Appendix Figure 1: Pump Test Basic Circuit Diagram
.
)
2
m
c
/ s s
t m
g
k s t
e
4 e I
t t
( l
l s
a e
A T
P
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4
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0
=
K
4
d
n
a
,
)
2
m
c
/
g
k
5
2
(
a
P
M
5
.
2
=
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5
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,
)
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) t
s f (
a a
n h
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s =
e t
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/
c d 2
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2 w / g
1 e
1 i
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2 a 4
(
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( i
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o 2
+ l .
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9 i
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e :
g l s
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i p w
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s m l o
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T T T
: : :
1 2 3
e t
t e e
o o t
o
N N N
12
SEBH801100 13/26
3. Performance Standard Value Table
1) This document contains the Table 3-1) Standard Value Table.
2) When conducting a test, select the applicable model from the following table.
3) PC200-7, PC200LC-7, PC210-7, and PC210LC-7 Common to all models.

 This standard value table is common to PC228US-3, too.
Table 3-1) List of Standard Value Tables

Chart and Standard
Remarks
Value Table No.
Fig. 1 PQT characteristics performance chart (S mode)
Fig. 2 LS characteristics chart (control pressure: 19.6 MPa{200 kg/cm 2})
Table 1 Running-in
Table 2 PQT characteristics (H mode)
Table 3 PQT characteristics (S mode)
Table 4 PQT characteristics (L mode)
LS characteristics ([normal and fine control modes] Control pressure: 9.8

Table 5
MPa{100 kg/cm2})

Table 6
MPa{200kg/cm2})

Table 7
MPa{300kg/cm2})

Table 8
MPa{350kg/cm2})
13
SEBH801100 14/26
Fig. 1 Pump Assembly Performance Specification Chart

(Standard Value)
Model PC200-7(#200001~) Test item: PQT characteristics (S mode)

s
(application serial number) PC210-7(# 40001~) n Direction of rotation Right-handed rotation Pump pressures (P1f and P1r) See chart
o
i
t
i
Pump type HPV95+95 d Number of revolu- Standard 1950rpm EPC original pressure (P EPC) 3.14{32}MPa{kg/cm2}
n
(Pump capacity) (112+112cc/rev) o c
tions of input shaft Conversion 1500rpm LS differential pressure ( ∆PLS) 0 MPa{kg/cm2}
t
s t
Part number 708-2L-00300 e n
e
PC mode (Epc) 460mA PC mode selection pressure (Pm) (0.90{9.2})MPa{kg/cm2}
T r
r
Applicable chart Values at pressure rise are applied
u
LS set (ELS)
C 0 mA LS set switching pressure (Psig) 0 MPa{kg/cm2}
Pump absorption torque T
r
1
P
+ 2
f
1
P
=
1
P
e
r
u
s
s
e
r
p
: e
e p
o
g
r
g
r r a
a
h
d ) h
c
c e
r
2
s
s m
u / i
i
d s c
g d
s k p
R e
r
d p 0
2 m
n )
2 t (
a a a a u
F s m P
s P /
f l c d P
e
o M k g r
a M
w r
o 0 n 6
6
. d
o
l . 1 2 a 9
f n .
i 2 2 t 1 :
n d d s )
i
e m n n s e
/
c L a a i s c
n 3 8 r n
i
e . . 0
r 7 1 2 t e e
r
e
e
f 1 1 s f
f t ( y e
i r
D a H (
. .
1 2
Miscellaneous
Pump delivery 1 QT
14
SEBH801100 15/26
Fig. 2 Pump Assembly Performance Specification Chart

(Standard Value)
Model PC200-7(#200001~) Test item: LS characteristics

s
(application serial number) PC210-7(# 40001~) n Direction of rotation Right-handed rotation Pump pressures (P1f and P1r) 19.6{200}MPa{kg/cm2}
o
i
t
i
Pump type HPV95+95 d Number of revolu- Standard 1950rpm EPC original pressure (P EPC) 3.14{32}MPa{kg/cm2}
n
(Pump capacity) (112+112cc/rev) o c
tions of input shaft Conversion 1200rpm LS differential pressure ( ∆PLS) See chart
t
s t PC mode (Epc) 310mA
Part number 708-2L-00300 e PC mode selection pressure (Pm) 0.34{3.5}MPa{kg/cm2}
T n
e
The values, when the LS differential pressu- r
r
u
A: 0 mA LS set switching pressure ( A :0) MPa{kg/cm 2 }
Applicable chart CLS set (ELS)
re is increased, must be within the range. B:1000mA (Psig) ( B :0.29{3})MPa{kg/cm 2}
1. A: Normal mode B: Fine control mode
2. The difference in the set pressures for pump pressure of 9.8MPa (100kg/cm 2) and 34.3MPa
(350kg/cm 2) must be within 0.3 MPa (3 kg/cm2) in terms of LS differential pressure.
Miscellaneous 3. Hysterisis standard (reference)
At 6.9 and 9.8 MPa (70 and 100 kg/cm 2) : 0.25 MPa (2.5 kg/cm2) or less
At 19.6 MPa (200kg/cm2) : 0.29 MPa (3.0kg/cm 2) or less
At 29.4 and 34.3 MPa (300 and 350 kg/cm 2) : 0.34 MPa (3.5kg/cm 2) or less
S
L
P
-
1
P
=
S
L
P
∆
e
r
u
s
s
e
r
p
l
a
i
t
n
e
r
e
f
f
i
d
S
L
Pump delivery 1 QT
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SEBH801100 16/26
Table 1: Performance Standard Value Table

(PC200/210-7· [1/8])
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k
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o
c
e
8 2
o
} } m } n

n s
b
e
h
t
i
9
. 0 9
. 0 5 e 2 2 a
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18
SEBH801100 19/26

(PC200/210-7 [4/8])
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19
SEBH801100 20/26

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SEBH801100 21/26

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21
SEBH801100 22/26

(PC200/210-7 [7/8])
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22
SEBH801100 23/26

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SEBH801100 24/26
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 represent- Presence or

ing port or adjust- Name of port and adjustment sections absence of Port size Remarks
ment section connection
M1 Installed position of pump Connected — See dimensional drawing
M2 Spline section of input shaft Connected — See spline specifications
P1f Piston pump discharge port (front) Connected — See dimensional drawing
P1r Piston pump discharge port (rear) Connected — See dimensional drawing
PP1 Pump pressure input port Connected 14 × 1.5
PEPC EPC original pressure input port Connected 14 × 1.5
PS Pump suction port Connected — See dimensional drawing
PLSf Load pressure input port (front LS pressure) Connected 14 × 1.5
PLSr Load pressure input port (rear LS pressure) Connected 14 × 1.5
PDa Air bleeder (used for bleeding air in the pump case)Closed — For bleeding air (with plug)
PD1f Pump case drain port (front) Closed 24 × 1.5 Installation of pressure gauge
PD2f Pump case drain port (front) Closed 24 × 1.5 With plug
PD2r Pump case drain port (rear) Connected 24 × 1.5 With plug (for bleeding air)
PT Plug (used for forced-feed lubrication) Connected 24 × 1.5 With plug
CP1f Front pump discharge pressure sensing port Connected 10 × 1.25 Installation of pressure gauge (with plug)
CP1r Rear pump discharge pressure sensing port Connected 10 × 1.25 Installation of pressure gauge (with plug)
Cenf Control pressure sensing port (front) Connected 10 × 1.25 Installation of pressure gauge (with plug)
Cenr Control pressure sensing port (rear) Connected 10 × 1.25 Installation of pressure gauge (with plug)
CLSf Load pressure sensing port (front) Connected 10 × 1.25 Installation of pressure gauge (with plug)
Clsr Load pressure sensing port (rear) Connected 10 × 1.25 Installation of pressure gauge (with plug)
CPm PC mode switching pressure sensing port Connected 10 × 1.25 Installation of pressure gauge (with plug)
Csig LS set switching pressure sensing port Connected 10 × 1.25 Installation of pressure gauge (with plug)
Maf Maximum flow adjusting section (front) Non-connected —
Mar Maximum flow adjusting section (rear) Non-connected —
Mbf Minimum flow adjusting section (front) Non-connected —
Mbr Minimum flow adjusting section (rear) Non-connected —
MPCf PC valve adjusting section (front) Non-connected —
MPCr PC valve adjusting section (rear) Non-connected —
MLSf LS valve adjusting section (front) Non-connected —
MLSr LS valve adjusting section (rear) Non-connected —
EPC PC mode switching current connector (2 poles) Connected —
ELS LS set switching current connector (2 poles) Connected —
SOL.A PC mode switching valve solenoid Non-connected —
SOL.B LS set switching valve solenoid Non-connected —
24
SEBH801100 25/26
Appendix Figure 1 Dimensions of Sample Sections
Applicable Models: PC200/210-7
1. Installed positions of pump and ports

Details of Discharge Port (P 1f and P 1r)
 Locations of PT ports prior to change are shown.
(See Fig. BOZ11615.)
Details of Installed Position (M1)
Details of Suction Port (PS)
25
SEBH801100 26/26
Appendix Figure 2 Dimensions of Sample Sections
2. Splines and Ports
 Locations of PT ports prior to change are shown (See Fig.BOZ11617).
Details of spline
45 x 16 x 2.5 involute spline shaft

Amountof addendummodification +2000
Tooth profile Tooth bottom
Tool Module 2.5
Pressure angle 20.00°
Number of teeth 16
Reference pitch circle diameter 40.000
Tooth Over-pin dimension 49.277 -0.179
-0.267
(4.50)
thickness Base tangent length
—
(reference)
Alignment Alignment of tooth
Mating part number —
26

pc200 7 Main Pump Test Method

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SEBH801100 1/26

PPM REBUILT UNIT MANUAL II

Category Testing method for pumps

1. Test Method ···························································· Pages 3 - 11

2. Test Hydraulic Circuit Diagram ············

3. Performance Diagram and Standard Value Table ········

4. Names of Sections and Related Dimension ················· Page 24 - 26

5. Schematic Diagram of Test Jig (Reference) ······

 Use Komatsu genuine

+ 112 cc/rev specifications), which is installed on PC200/210 series-7.

1-2) Test Specifications

See the following Table 1-1.

Table 1-1 List of Test Specifications

Pump type HPV95+95

Specifications Standard Conversion

Piston pump capacity

Maximum revolution of input shaft

Maximum hydraulic pressure of pump 37.3 34.3

(MPa{kg/cm2}) {380} {350}

Pump suction pressure 0.98 ± 0.05

Pump drain pressure 0.98 or less

EPC valve original pressure 3.1

Maximum flow (L/min) 220 (23) 168 {19}

1-3) Test Items

1) For test items and contents, see Table 1-2 below.

1-4) Test Basic Hydraulic Circuit Diagram

• See Appendix Figure 1 in “Section 3 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.”

1-6) Test Equipment, Device, and Jig

1) Equipment to be used: Have the equipment listed in Table 1-3 ready.

Table1-3 Pressure Gauge and Device

Table 4 List of Devices (Continuation)

Table 1-4 Test Jigs

No. Part Number Part Name Quantity Specifications and Application

1 799-404-2980 Plate 1 For installing pump

2 799-404-2970 Coupling 1 For connecting input shaft

3 799-404-2910 Adapter 1 1.6 mm diameter fixed throttle valve

required for configuring a test hydraulic circuit.

1-7) Preparatory Steps for Test

1) Installing hydraulic test stand (see Fig. 7-1)

Install the test stand so that the sample bleeder

(PDa) turns up.

level position when connecting, and take action not

to cause run-out. Protect the coupling from becom-

ing detached from the shaft.

3) Configuring test hydraulic circuit (see Appendix Fig-

i) Configure as per test hydraulic circuit diagram in

the Appendix Figure 1.

see Fig. 7-2.

lubrication on the rear pump. (See Fig. 7-3.)

4) Filling the pump case with oil

(P Da, P D1f, and P D2r ports), and fill the pump

case with oil.

Clean the pump assembly to check for oil leakage

and apply penetrant testing agent to each of valve,

plug and input shaft oil seal.

1-8) Verification Test and Adjustment Methods

Check for abnormality (pressure, vibration, sound,

etc) and oil leakage while the pump is running.

2) How to check and adjust maximum and minimum

(1) Check piston pumps P 1f and P 1r delivery for the

maximum and minimum flow under the