EEN00022-00

PPM REBUILD UNIT MANUAL

DISASSEMBLY & ASSEMBLY

Classification MOTOR DISASSEMBLY & ASSEMBLY

Motor type KMF125ABE-5
Name plate stamp EF1 EF3
Motor part number 706 - 7G - 01040 706 - 7G - 01010 706 - 7G - 01011
PC200,200LC-7
Applicable machine PC228US,228USLC-3
PC220,220LC-7
PC200,200LC:
Machne serial 200001 and up PC228US,USLC: PC228US,USLC:
number PC220,220LC: 20001 - 20004 20005 and up
60001 and up
Application Swing motor
2005/03/31:First edition(00)

Issue record

Remarks

KMF125ABE-5 1
DISASSEMBLY AND ASSEMBLY LIST OF SPECIAL TOOLS

List of Special Tools

 Tools with part number 79 K T - KKK - KKKKK cannot be supplied (they are items to be locally manufactured).
 Necessity : „ ........ Cannot be substituted, must always be installed (used)

z ........ Extremely useful if available or can be substituted with commercially available part

 New/Revised : N ........ Tools with new part numbers, newly developed for this model

R ........ Tools with upgraded part numbers, remodeled from items already available for other models

Blank ... Tools already available for other models, can be used without any modification

 Tools marked K in the Sketch column are tools introduced in the sketches of the special tools (See SKETCHES OF
SPECIAL TOOLS).

Nes
Q’ty
N/R
Dwg
Equipment Symbol Number Name Work • Remarks

Unit repair stand

790-501-5000 (for 100 V)
z 1
Unit repair stand
790-501-5200 (for 110 V, 220 V) Disassembly and assembly
1
of motor assembly
790-901-2110 Bracket z 1
796T-466-1210 Plate z 1 N K
796-730-2120 Screwdriver z 1

2 796-720-2220 z 1 Removal installation of screw

Socket
795-630-1803 Torque wrench assembly z 1

3 799-301-1600 Oil leak tester kit „ 1 Removal of brake piston

790-201-2000 Push tool kit „ 1

4 Press-fitting of main bearing
790-201-2740 •Spacer 1
790-201-2000 Push tool kit „ 1
5 Press-fitting of sub bearing
790-201-2730 •Spacer „ 1
796-751-1500 Wrench assembly „ 1 Measurement of shaft
6
rotating torques
Disassembly and assembly 795-630-1803 Torque wrench assembly z 1
of swing motor assembly Y 796T-466-1220 Push tool „ 1 N K

7 790-201-2000 Push tool kit „ 1 Press-fitting of oil seal

790-201-2730 •Spacer 1
8 796T-660-1120 Push tool „ 1 K Press-fitting of dowel pin

796T-660-1510 Pump adapter „ 1 K

790-101-1430 •Coupler assembly 1

796-660-1490 •Nipple 1
799-101-5130 •Gauge 1
799-101-5160 •Nipple 1
Open of brake
9 790-301-1190 •Nipple 1
790-301-1660 •Tee 1
205-70-51390 •Nipple 1
790-301-1210 •Joint 1
07002-01432 •O-ring 1

790-101-1102 Hydraulic Pumps „ 1

KMF125ABE-5 2
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

SKETCHES OF SPECIAL TOOLS

Note : Komatsu cannot accept any responsibility for special
Y1 : Plate(796T-466-1210) tools manufactured according to these sketches.

KMF125ABE-5 3
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

Y7 : Push tool (796T-466-1220)

Y8 : Push tool (796T-660-1120)

KMF125ABE-5 4
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS

Y9 : Pump adapter (796T-660-1510)

KMF125ABE-5 5
DISASSEMBLY AND ASSEMBLY MAIN PUMP

DISASSEMBLY OF SWING MOTOR ASSEMBLY

1. Swing motor assembly

Set swing motor assembly (1) to tool Y1.

4 hydraulic motor assembly : 60kg

2. Simultaneous bleed control, valve assembly

1) Remove simultaneous bleed control valve assembly

(2).

2) Disassemble simultaneous bleed control valve assem-

bly as follows.

i) Remove 2 plugs (3), from body (4).

ii) Remove 2 springs (5)

iii) Remove 2 spools (6).

iv) Remove seal (7) from spool (6).

3. Safety valve assembly

1) Remove safety valve assembly (8).

KMF125ABE-5 6
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Remove O-ring (9) and backup ring (10) from safety

valve assembly (8).

 Do not assemble the safety valve assembly.

4. Suction valve

1) Remove 2 plugs (11).

2) Remove 2 springs (12) and 2 valves (13).

5. Check valve

1) Remove 2 plugs (14), together with spring.

2) Remove valve (15) and spring (16) from plug (14).

6. Turning motor assembly by 180 degrees

1) Turn motor assembly (1) by 180 degrees, then mount it

onto tool Y1.

2) Tilt motor assembly (1) toward T port side.

 To pull out piston and center shaft vertically for motor

inclined by 35 degrees, tilt piston and center shaft by

approximately 35 degrees toward T port side.

7. Case assembly

Remove 10 mounting bolts, then remove case assembly

(17).

 When mounting bolts are removed, case is lifted by

4mm by spring.

 Lift case gently while checking that piston and center

shaft come off from cylinder block smoothly.

KMF125ABE-5 7
DISASSEMBLY AND ASSEMBLY MAIN PUMP

8. Brake spring

Remove 6 brake springs (18).

9. Cylinder block

1) Remove center ring (19).

2) Remove spring (20).

3) Remove cylinder block (21).

10. Valve plate

Remove valve plate (22).

KMF125ABE-5 8
DISASSEMBLY AND ASSEMBLY MAIN PUMP

11. Housing

1) Remove needle bearing (23).

2) Remove housing (24) from tool Y1.

12. Case assembly

Set case assembly (17) to tool Y1.

13. Piston, center shaft assembly

1) Using tool Y2, remove 7 screws.

2) Remove piston and center shaft assembly (25).

KMF125ABE-5 9
DISASSEMBLY AND ASSEMBLY MAIN PUMP

3) Remove 7 pistons (26) and center shaft (27) from re-

tainer (28).

 Do not remove the piston ring.

14. Brake piston, plate, disc

1) Using tool Y3, remove brake piston (29).

 Air pressure : 0.2MPa (2kg/cm2).

 If the air is high pressure, the brake piston my fly

out, be careful the operation.

2) Remove 5 plates (30) and 4 discs (31) by tuns.

15. Drive shaft assembly

1) Remove case assembly (32) to tool Y1.

KMF125ABE-5 10
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Using press remove drive shaft assembly (33) from

case (34).

 To protect drive shaft from damage in case of drop-

ping, put some cushion under drive shaft assem-

bly.

3) Disassemble drive shaft assembly as follows.

i) Remove snap ring (35), then remove spacer (36).

ii) Using push tool [1] and press, separate press fit-

ting portion of sub bearing inner race (37).

 The Push tool supports only the lower face of the

main bearing outer race.

 To protect drive shaft from damage in case of

dropping, put some cushion under drive shaft

assembly.

iii) Remove sub bearing inner race (37) and outer race

(38).

iv) Remove seat (39) and 2 springs (40).

KMF125ABE-5 11
DISASSEMBLY AND ASSEMBLY MAIN PUMP

v) Remove spacer (41) and main bearing outer race

(42).

vi) Remove main bearing inner race (43) from drive

shaft (44).

16. Oil seal

1) Remove snap ring (45), then remove spacer (46).

2) Remove oil seal (47).

KMF125ABE-5 12
DISASSEMBLY AND ASSEMBLY MAIN PUMP

ASSEMBLY OF SWING MOTOR ASSEMBLY

 Clean all parts and correct any burrs.

 Coat the rotating surfaces and sliding surfaces of all parts

with engine oil (EO10-CD) before assembling.

 Using chromic oxide for lapped portion, remove lapping

particles completely.

1. Drive shaft assembly

1) Assemble drive shaft assembly as follows.

i) Using press and tool Y4, press fit main bearing inner

race (43) to drive shaft (44).

2 Bearing press fitting portion :

Engine oil (EO10-CD)

 Press fit until the end face of the bearing inner

race is in tight contact with the drive shaft.

 Press fitting load :

5.12 ~ 26.1kN {522 ~ 2,660kg}

ii) Assemble main bearing outer race (42).

iii) Install spacer (41), 2 springs (40) and seat (39).

 Install the two springs so that they both face the

outside.

iv) Assemble sub bearing outer race (38).

v) Using press and tool Y5, press fit sub bearing inner

race (37) to drive shaft (44).

2 Bearing press fitting portion :

Engine oil (EO10-CD)

 Within specified press fitting load, press fit it until

lower face of seat is in tight contact with upper

face of spacer.

 Press fitting load : 14.8 kN {1,505kg}

KMF125ABE-5 13
DISASSEMBLY AND ASSEMBLY MAIN PUMP

vi) Assemble snap ring (35) temporarily.

vii) Measure clearance a between end face of sub bear-

ing inner race (37) and snap ring (35) groove of

shaft, and select thickness of spacer.

 Dimensions a and thickness of spacer

Dimensions a Thickness of spacer

[Measured value] (mm) (mm)
~ 3.45 3.1
3.45 ~ 3.85 3.4
3.85 ~ 3.7

viii) Fit selected spacer (36), and secure with snap ring

(35).

 Check that the snap ring is fitted securely in the

ring groove of drive shaft.

ix) Using push tool [1] and press, push down drive shaft
(44).

 Push tool support lower face of main bearing in-

ner race only.

 Within specified pushing down load, push down

it until spacer becomes unable to be rotated by

hand due to tight contact among snap ring, spacer

and sub bearing inner race.

 Pushing down load:

4.19 ~ 16.0 kN {427 ~ 1,630kg}

2) Using push tool [2] and press, press fit drive shaft as-

sembly (33) to case (34).

 Case supports circumference of oil seal fitting por-

tion.

3 Drive shaft fitting portion :

Engine oil (EO10-CD)

 Within specified press fitting load, press fit it until

end face b of main bearing outer race is in tight con-

tact with stepped portion of case.

 Press fit load : 10.2 kN {1,037kg}

KMF125ABE-5 14
DISASSEMBLY AND ASSEMBLY MAIN PUMP

3) Set case assembly (32) to tool Y1.

4) Using tool Y6, measure shaft rotating torque.

 Rotate shaft at a constant speed (1 turn / 5 sec) and

measure shaft rotating torque.

 Rotating torque : 0.98 ~ 1.57 Nm {0.1 ~ 0.16kgm}

 If rotating torque is abnormal, replace main bearing

with new one, then reassemble them.

2. Oil seal

1) Using tool Y7, press fit Oil seal (47) to case.

 Put a drop of Lithium grease on each of 4 points on

circumference of oil seal lip portion, spread it over

whole surface with fingertip.

3 Oil seal lip portion :

Lithium grease (G2-L1-S)

 Press fitting depth c of oil seal : 10 ± 0.1mm

2) Fit spacer (46) and secure with snap ring (45).

KMF125ABE-5 15
DISASSEMBLY AND ASSEMBLY MAIN PUMP

3. Brake piston, plate, disc

1) Assemble 5 plates (30) and 4 discs (31) in order to

case.

 Do not wash the discs in trichloroethylene or blow

strongly with air.

2 Face of disc : Engine oil (EO10-CD)

 Align crenas (indicated by arrow) of internal gears of

all 4 discs when mounting them together (no restric-

tion in relationship between disc and plate).

2) Fit O-ring and install brake piston (29).

 For brake piston, locate groove for dowel pin at bolt

hole position indicated by arrow.

4. Piston, center shaft assembly

1) Assemble center shaft (27) and 7 pistons (26) to re-

tainer (28).

 Assemble them so that retainer identification groove

d of retainer will face outside.

KMF125ABE-5 16
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Assemble piston and center shaft assembly (25) to drive

shaft.

3) Using tool Y2, tighten 7 screws.

 Screw cannot be reused. Replace with new one.

 After degreasing and drying threaded portion (male

and female), put two drops (approximately 0.04 g) of

adhesive on threaded portion.

2 Threaded portion:

Adhesive(LOCKTITE #262)

 Tighten up screw in order shown in diagram on the

right.

3 Screw : (First time : temporary tightening)

First time : (0.98Nm {0.1kgm or less})

Second time :
3.92 ~ 5.88 Nm {0.4 ~ 0.6kgm}

Third time :
11.77 ~ 14.71 Nm {1.2 ~ 1.5kgm}
(target value : 13.24 Nm {1.35kgm})

 After tightening up screw, check that adhesive does

not come out.

 After tightening screw, leave them for 30 minutes.

4) Set dial gage [3] on spherical portion of cylinder, and

check axial play of piston.

 Play of piston 0.50 mm max.

 If play is abnormal, reassembly them.

5. Case assembly

Remove case assembly (17) from tool Y1.

KMF125ABE-5 17
DISASSEMBLY AND ASSEMBLY MAIN PUMP

6. Housing

1) Set housing (24) to tool Y1.

2) Install needle bearing (23) to housing.

3) Using tool Y8, press fit dowel pin (48) to housing.

 In case that dowel pin is removed or replaced with

new one, use tool Y8 to press fit it.

 Install the dowel pin with the worked side of the groove

e directed toward the brake piston.

 Dowel pin press fitting dimension f : 8.5 ~ 9.9mm.

8. Valve plate

Install valve plate (22).

 Align pin of housing side with pin groove of valve plate

side, then check that valve plate and housing are in

tight contact.

KMF125ABE-5 18
DISASSEMBLY AND ASSEMBLY MAIN PUMP

9. Cylinder block

1) Install cylinder block (21).

2) Install spring (20).

3) Install center ring (19).

10. Brake spring

Install 6 brake springs (18).

11. Case assembly

1) Tilt housing assembly (49) toward T port side.

 To insert piston and center shaft vertically for motor

inclined by 35 degrees, tilt piston and center shaft

by approximately 35 degrees toward T port side to

horizontalize upper face of cylinder block.

KMF125ABE-5 19
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Fit O-ring, sling case assembly (17), and then set them

above housing assembly (49).

2 Case matching face :

Gasket sealant (LG-5 or LG-7)

 Tilt case assembly by approximately 35 degrees

as done for housing assembly, to align center of
cylinder block with center of center shaft.
3) Move down case assembly (17) gently to insert it into

housing assembly.

 Check that center shaft and piston are inserted into

cylinder block smoothly.
 Check that dowel pin is inserted into pin groove of
brake piston.
 When case assembly is at the bottom, clearance
between case and housing becomes approximately
4 mm.
 Tighten temporarily mounting bolt with less fitting
depth (indicated by arrow) first.
4) Install case assembly (17).

3 Mounting bolt :

98 ~ 123 Nm {10.0 ~ 12.5kgm}

5) Using tools Y9 and Y6, measure rotating torque of

shaft.

 Increase pressure inside brake circuit by using tool

Y9 to release brake, and then measure rotating
torque.
 Hydraulic pressure for brake :
2.94 ± 0.49MPa {30 ± 5kg/cm2}
 Perform measurement while rotating shaft at con-
stant speed of approximately 1 revolution per 5
seconds.
 Rotating torque : 4.9 ~ 14.7 Nm {0.5 ~ 1.5kgm}
(Range of torque variation : 1.47 Nm {0.15kgm})
 If rotating torque is abnormal, disassemble again,
then examine cause.

12. Motor assembly

Turn motor assembly (1) by 180 degrees, then mount it

onto tool Y1.

KMF125ABE-5 20
DISASSEMBLY AND ASSEMBLY MAIN PUMP

13. Check valve

1) Fit O-ring, assemble spring (16) and valve (15) to plug

(14).

2) Install 2 plugs (14) and install valve together with spring.

3 Plug : 59 ~ 78 Nm {6 ~ 8kgm}

14. Suction valve

1) Install 2 valves (13) and 2 springs (12).

2) Fit O-ring and install 2 springs (11).

 After degreasing and drying threaded portion (male

and female) sufficiently, put 2 drops (approximately

0.04 g) of adhesive on area 2 to 3 mm from tip of

plug.
2 Threaded portion of plug :

Adhesive (LOCKTITE #638 or #648)

 After tightening plug, leave them for 30 minutes or

more.
15. Safety valve assembly

1) Fit O-ring (9) and backup ring (10) to safety valve as-

sembly (8).

2) Fit O-ring, and install safety valve assembly (8).

3 Safety valve assembly:

226 ~ 284 Nm {23 ~ 29kgm}

16. Simultaneous bleed control valve assembly

1) Assemble simultaneous bleed control valve assem-

bly as follows.

i) Install seal (7) to spool (6).

ii) Assemble 2 spools (6) to body (4).

iii) Assemble 2 springs (5).

iv) Fit O-ring and install 2 plugs (3).

3 Plug : 19.6 ~ 24.5 Nm {2.0 ~ 2.5kgm}

KMF125ABE-5 21
DISASSEMBLY AND ASSEMBLY MAIN PUMP

2) Fit O-ring and install simultaneous bleed control valve

assembly (2).

 Pay attention not to drop O-ring on reverse rotation

prevention valve side when fitting.

 Tighten mounting bolts alternately.

3 Mounting bolt :

1st : 15 ~ 20 Nm {1.5 ~ 2.0kgm}

2st : 27 ~ 34 Nm {2.8 ~ 3.5kgm}

KMF125ABE-5 22