Test Manual EEN00015-00

EEN00015-00
PPM REBUILD UNIT MANUAL

DISASSEMBLY & ASSEMBLY
Classification PUMP DISASSEMBLY & ASSEMBLY
Pump type LPV90
Name plate stamp DL0 DL6
Pump part number 708-1W-00111 708-1W-00131

Applicable machine PC60-7
Machine serial
52374 - 58000 58001 and up
number
Application Work equipment, Swing, Travel pump

2003/03/11: First edition (00)
Issue record
Remarks
1
DISASSEMBLY & ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79OT-OOO-OOOO cannot be supplied (they are items to be locally manufactured).
a Necessity: t ..........Cannot be substituted, should always be installed (used)
q ..........Extremely useful if available, can be substituted with commercially available part
a New/remodel: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, used without any modification
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
New/remodel
Necessity
Component Symbol Part No. Part Name Nature of work, remarks
Sketch
Q'ty
Unit repair stand
790-501-5000 (for 100V)
t 1
790-501-5200 Unit repair stand
(for 220V, 240V) Disassembly, assembly of
A pump
790-901-2110 Bracket t 1
790-901-1410 Plate t 1
B 796-267-1260 Nut t 1 Securing PC valve
1 01017-31650 Bolt t 1
2 796T-267-1120 Washer t 1 N Q
Disassembly, assembly of
C 3 01643-32060 Washer t 1 cylinder block assembly
Disassembly of hydraulic 4 01643-31645 Washer t 1
pump assembly
5 01580-01613 Nut t 1
790-201-2620 Plate t 1
D Press fitting of needle
bearing
790-201-2820 Spacer t 1
790-201-2720 Spacer t 1
E Press fitting of roller bearing
790-445-3870 Push tool t 1
01435-00816 Bolt t 1
Measuring shaft rotation
F torque
795-630-1803 Torque wrench t 1
1 796T-267-1110 Push tool t 1 N Q
G Press fitting oil seal
2 790-201-2730 Spacer t 1
LPV90 2
DISASSEMBLY & ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
C2 Washer
G1 Push tool
LPV90 3
DISASSEMBLY & ASSEMBLY HYDRAULIC PUMP
DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY

1. Hydraulic pump assembly
Set hydraulic pump assembly (1) on tool A.
2. LS valve assembly
1) Remove LS valve assembly (2).
a Use a felt pen to make a counter mark
from the pump case to the tip of the valve.
2) Disassemble LS valve assembly as follows.

a Before disassembling, measure the
amount that the plug is screwed in di-
mension (a).
i) Remove spool (3) from sleeve (4).

ii) Remove nut (5), then remove plug (6).
iii) Remove O-ring (7) and back-up ring (8)
from plug (6).
iv) Remove seat (9), spring (10) and seat
(11).
v) Remove seal (12) from sleeve (4).
LPV90 4
3. PC valve assembly
3 Tool B: 9.8 29.4 Nm {1 3 kgm}

1) Install tool B to PC valve.
2) Remove PC valve assembly (13).

from the pump case to the tip of the valve.
3) Disassemble PC valve assembly as follows.

a Before disassembling, measure the
amount that plug is screwed in dimension
(b).
i) Remove piston (14), spring (15), seat

(16), spring (17), and seat (18) from
sleeve (19).
ii) Remove spool (20).
iii) Remove tool B.
iv) Remove nut (21) and washer (22).
v) Remove nipple (23) from sleeve (19).
vi) Remove pin (24) from nipple (23).
4. Orifice plug
Remove nut (25), then remove orifice plug (26).
LPV90 5
5. Servo piston stopper

a Before disassembling, measure the mini-
mum swash plate angle adjustment dimen-
sion (c) and the maximum swash plate
adjustment dimension (d).
1) Loosen nut (27) and remove adjustment bolt

(28).
from the pump case to the tip of the ad-
justment bolt.
a The nut and bolt form a pair, so be careful
not to change the pairing.
2) Remove spring (29).
3) Loosen nut (30) and remove adjustment bolt

(31).
from the pump case to the tip of the ad-
justment bolt.
a The nut and bolt form a pair, so be careful
not to change the pairing.
LPV90 6
6. Lever assembly
1) Remove plug (32).
2) Remove lever assembly (33).
3) Disassemble lever assembly as follows.

i) Remove pin (34), then remove lever as-
sembly (35) from cover (36).
ii) Remove nut (37) and washer (38), then
remove slider (39).
iii) Remove pin (40) from lever (41).
7. Inner parts assembly

a The inner parts assembly consists of all parts
from the shaft and cradle assembly to the
rocker cam, cylinder block and piston assem-
bly.
1) Remove 8 mounting bolts (42) of cradle.
2) Set 3 guide bolts and 2 forcing screws

in position.
3) Pull out inner parts assembly (43) slowly and
remove.
a Set the shaft end of facing slightly down
so that the cylinder block and piston as-
sembly come out as one unit when re-
moving.
LPV90 7
4) Separate inner parts assembly as follows.

i) Remove cylinder block and piston as-
sembly (44) and rocker cam (45) from
shaft and cradle assembly (58) as one
unit and turn over.
ii) Remove rocker cam (45) from cylinder
block and piston assembly (44).
8. Rocker cam
Remove slider (46) from rocker cam (45).
9. Cylinder block, piston assembly

Disassemble cylinder block and piston assembly
as follows.
1) Remove piston assembly (47).
2) Remove 9 pistons (48) from shoe retainer
(49).
3) Remove retainer guide (50) from cylinder

block assembly (51).
4) Remove 3 pins (52).
LPV90 8
5) Set tool C to cylinder block assembly (51)

and compress spring.
6) Remove snap ring (53), then remove tool C.
7) Remove seat (54), spring (55), and seat (56)
from cylinder block (57).
10. Shaft, cradle assembly

Disassemble shaft and cradle assembly as fol-
lows.
1) Remove snap ring (59).
2) Using press, remove shaft (60) from cradle

(61).
a Wash the spline portion of the shaft to
protect the oil seal and prevent it from be-
ing damaged.
3) Remove snap ring (62), then remove washer

(63).
a Check the thickness of the washer.
4) Remover roller bearing (64) from shaft (60).
LPV90 9
5) Remove snap ring (65), then remove spacer

(66).
6) Remove oil seal (67) from cradle (61).
11. Servo piston

Remove servo piston (68).
12. Valve plate

Remove valve plate (69).
LPV90 10
13. Pump case

1) Remove cover (70).
2) Remove plug (71).
3) Remove drain plug (72).
4) Remove needle bearing (73).
LPV90 11
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY

a Clean all parts, remove all burrs, and be particu-
larly careful to completely clean the oil passage
in the drill hole.
a Coat the rotating and sliding surfaces of all parts
with engine oil (EO10-CD) before assembling.
a Always check the contact of the following parts
before assembling. For details, see CHECKING
CONTACT BETWEEN PARTS.
1) Cradle and rocker cam
2) Cylinder block and pump case
3) Valve plate and pump case
1. Pump case
1) Set pump case (74) to tool A.
2) Using tool D, press fit needle bearing (73) to
2 Outer circumference of bearing:

case (74).
Grease (G2-LI)
3 Drain plug :
3) Fit O-ring and install drain plug (72).
58.8 78.4 Nm {6 8 kgm}
3 Plug : 58.8 73.5 Nm {6 7.5 kgm}

4) Fit O-ring and install plug (71).
3 Mounting bolt :
5) Fit O-ring and install cover (70).
98 123 Nm {10 12.5 kgm}
2. Valve plate
Install valve plate (69).
a Align the pin at the pump case end with the
pin groove in the valve plate, and check that
the valve plate and pump case are in tight
contact.
LPV90 12
3. Servo piston
Assemble servo piston (68).
a Set so that the mating groove with the rocker
cam slider is near the center of the case
(pump swash plate angle 0).
4. Shaft, cradle assembly

Assemble shaft and cradle assemble as follows.
1) Using tool E, press fit roller bearing (64) to
2 Inner circumference of bearing :

shaft (60).
Grease (G2-LI)
a Insert the flange of the bearing on to the
shaft first, then assemble the inner race
and outer race and press fit.
2) Select thickness of washer as follows.
i) Temporarily assemble washer (63) of
any thickness.
ii) Measure distance (e) from top surface of
washer to top of snap ring groove.
iii) Calculate dimension (e) and temporarily
assembled washer (63), then select
washer so that dimension (e) is 1.20 -
1.30 mm.
Washer thickness : 2.5, 2.6, 2.7, 2.8 mm
3) Fit selected washer (63) and secure snap
ring (62).
4) Using press, press fit shaft (60) to cradle
2 Outer circumference of bearing :

(61).
Grease (G2-LI)
LPV90 13
5) Install snap ring (59).
a Install the snap ring so that the opening is

at the ring groove portion of the cradle, as
shown in the diagram on the right.
5. Cylinder block, piston assembly

Assemble cylinder block and piston assembly as
follows.
1) Assemble seat (56), spring (55), and seat
(54) to cylinder block (57).
a Assemble so that the chamfered inside
diameter portion of seat (56) is at the bot-
tom.
2) Set tool C to cylinder block assembly (51)
and compress spring.
3) Install snap ring (53).
4) Assemble 3 pins (52) to cylinder block as-

sembly (51).
5) Install retainer guide (50).
LPV90 14
6) Set 9 pistons (48) to shoe retainer (49).

7) Assemble piston assembly (47) to cylinder
block assembly.
6. Rocker cam
Install slider (46) to rocker cam (45).
a Install the slider so that the chamfered inside
diameter portion is facing the rocker cam.
7. Inner parts assembly

a The inner parts assembly consists of all parts
from the shaft and cradle assembly to the
rocker cam, cylinder block and piston assem-
bly.
1) Assemble inner parts assembly as follows.
i) Set rocker cam (45) to cylinder block and
piston assembly (44).
ii) Turn over cylinder block and piston as-
sembly (44) and rocker cam (45) as one
unit, and assemble to shaft and cradle
assembly (58).
a Check that the sliding portion of the
cradle and rocker cam are securely
fitted.
2) Set 3 guide bolts to pump case.
3) Fit O-ring and assemble inner parts assem-
bly (43).
a Be careful not to drop the valve plate. Be
sure to install the slider facing in the cor-
2 Mating surface :Gasket Sealant

rect direction.
(LG-5 or LG-7)
LPV90 15
4) Install 8 mounting bolts (42) of cradle.

a Tighten the mounting bolts alternatively
3 Mounting bolt :
on diagonally opposite sides.
58.8 73.5 Nm {6 7.5 kgm}
5) Using tool F, measure shaft rotating torque.

a When measuring, rotate the shaft at a
constant speed of approx. 3 5 sec/1
turn.
Rotating torque: 24.5 Nm {2.5 kgm}
(Width of torque variation:
Max. 2.94 Nm {Max. 0.3 kgm})
a If the rotating torque is not normal, disas-
semble again and investigate the cause.
8. Oil seal
1) Using tool G, press fit oil seal (67).
a Wash the spline portion of the shaft to protect
the oil seal and prevent it from being dam-
2 Seal lip portion : Grease (G2-LI)

aged.
2) Fit spacer (68) and install snap ring (65).
LPV90 16
9. Lever assembly
1) Assemble lever assembly as follows.
i) Install pin (40) to lever (41).
ii) Fit slider (39) and install washer (38) and
2 Thread portion :
nut (37).
Adhesive
3 Nut :
(Loctite #638 or equivalent)
11.8 14.7 Nm {1.2 1.5 kgm}

iii) Fit lever assembly (35) to cover (36) and
3 Pin :
install pin (34).
27.5 34.3 Nm {2.8 3.5 kgm}
2 Mating surface :
2) Fit O-ring and install lever assembly (33).
3 Mounting bolt :
Gasket sealant (LG-5 or LG-7)
27.5 34.3 Nm {2.8 3.5 kgm}
3 Plug :
3) Fit O-ring and install plug (32).
14.7 19.6 Nm {1.5 2.0 kgm}
10. Servo piston stopper

1) Fit O-ring and install adjustment bolt (31),
then secure with nut (30).
a Align with the counter mark and maximum
swash plate angle adjustment dimension
(d) measured when disassembling.
Standard adjustment dimension (d):
3 Nut : 196 245 Nm {20 25 kgm}

11.8 mm
2) Assemble spring (29).
LPV90 17
3) Fit O-ring and install adjustment bolt (28),

then secure with nut (27).
a Align with the counter mark and minimum
swash plate angle adjustment dimension
(c) measured when disassembling.
Standard adjustment dimension (c):
3 Nut :
26.0 mm
156.8 186.2 Nm {16 19 kgm}
11. Orifice plug

Fit O-ring and install orifice plug (26), then secure
with nut (25).
a Screw in with a screwdriver until the tip of the
orifice plug contacts the pump case, turn
back until the slit in the end face is parallel
with the shaft, then lock in position with the
3 Nut : 27.4 34.3 Nm {2.8 3.5 kgm}

nut.
12. PC valve assembly

1) Assemble PC valve assembly as follows.
i) Assemble pin (24) to nipple (23).
ii) Fit O-ring and install nipple (23) to sleeve
3 Nipple :
(19).
29.4 39.2 Nm {3 4 kgm}

iii) Fit washer (22) and nut (21) and secure
with tool B.
a Install the washer so that the side
with the machined V-notch is facing
3 Tool B :
the nut.
9.8 29.4 Nm {1 3 kgm}

a When determining the amount that
the nut is screwed in dimension (b),
set to the measurement made when
disassembling.
Amount that nut is screwed in di-
mension (b): 119.8 mm
iv) Assemble spool (20) to sleeve (19).
v) Assemble seat (18), spring (17), seat
(16), spring (15), and piston (14).
a Set the seat facing in the direction
LPV90 18
3 Tighten the PC valve assembly as

2) Fit O-ring and install PC valve assembly (13).
follows.
i) Tighten sleeve (width across flats:
22mm) with 49 78.4 nm {5 8 kgm}.
ii) Tighten nut (width across flats: 41mm)
with 98 Nm {10 kgm}.
iii) Loosen tool B (width across flats:
36mm) and remove.
iv) Tighten nut (width across flats: 41mm)
to 88.2 - 113 Nm {9 - 11.5 kgm} again.
13. LS valve assembly

1) Assemble LS valve assembly as follows.
i) Install seal (12) to sleeve (4).
ii) Assemble seat (11), spring (10), and seat
(9).
a Set the seat facing in the direction
iii) Assemble O-ring (7) and backup ring (8)
to plug (6).
a Set the O-ring and backup ring
mounting position as shown in the di-
agram on the right.
iv) Fit plug (6) and secure with nut (5).
a When determining the amount that
the plug is screwed in dimension (a),
set to the measurement made when
disassembling.
Amount that plug is screwed in di-
3 Nut : 49 63.7 Nm {5 6.5 kgm}

mension (a): 2.4 mm
v) Assemble spool (3) to sleeve (4).

a Assemble the spool so that the part
with less oil groove (spherical por-
tion) faces the inside.
3 LS valve assembly :
2) Fit O-ring and install LS valve assembly (7).
132.3 156.8 Nm {13.5 16 kgm}
LPV90 19
CHECKING CONTACT BETWEEN PARTS

a Check the contact as follows if the one of the set
of following sliding parts has been repaired or re-
placed with a supplied part (new part).
This is not necessary if both sliding parts have
been replaced by supplied parts (new parts).
1) Cradle and rocker cam
2) Cylinder block and valve plate
3) Valve plate and pump case
1. Cradle and rocker cam

1) Remove all oil and grease from the parts to
be checked.
a Do not wipe with a cloth.
2) Paint the cradle with inspection paint, then
put the rocker cam on top.
a Coat thinly with paint.
3) Push the rocker cam with a force of 39.2
49.0 N {4 5 kg} and move it between the
maximum swash plate angle position and the
minimum swash plate angle position on the
opposite side. Repeat this process two or
three times.
4) Remove the rocker cam, transfer the contact
surface to a tape, and check the contact sur-
face.
a The standard for the contact is as given
below.
(1) Within 30 40 mm of center portion:
Contact of more than 90%
(2) Range from center portion
(30 40 mm) 55 mm:
Contact of 50 90%
(3) Outside width of 55 mm:
Contact of less than 50%
The parts cannot be used if there is
no contact at the center portion and
the contact is only at the outside.
a If the contact is defective and lapping is
carried out, it must always be carried out
for both parts together.
LPV90 20
2. Cylinder block and valve plate

1) Manufacture a centering tool for cylinder
block and valve plate.
a The tool cam be made of plastic, bakelite,
or any other soft material
be checked.
3) Paint the cylinder block with inspection paint,
then put the tool and valve plate on top.
4) Push the valve plate with a force of 39.2
49.0 N {4 5 kg} against the cylinder block,
turn the valve plate 90, then return it to its
original position. Repeat this process two or
three times.
5) Remove the valve plate, transfer the contact
face.
a The standard for the contact is as given
below.
(1) Seal portion (range of 82.9 mm):
Contact of more than 80% and no break
around whole circumference
(2) Land portion (range of 82.9 102 mm):
Contact of more than 60% and no break
around whole circumference
3. Valve plate and pump case

be checked.
2) Paint the pump case with inspection paint,
then put the valve plate on top.
3) Push the valve plate with a force of 39.2
49.0 N {4 5 kg} against the pump case, turn
the valve plate 90, then return it to its original
position. Repeat this process two or three
times.
4) Remove the valve plate, transfer the contact
face.
a The standard is contact of more than
80% with no play at the mating surface.
a If the contact is poor, use a surface plate
and correct by lapping.
LPV90 21

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EEN00015-00

PPM REBUILD UNIT MANUAL

Classification PUMP DISASSEMBLY & ASSEMBLY

Pump type LPV90

Name plate stamp DL0 DL6

Pump part number 708-1W-00111 708-1W-00131

Application Work equipment, Swing, Travel pump

SPECIAL TOOL LIST

SKETCHES OF SPECIAL TOOLS

DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY

2) Disassemble LS valve assembly as follows.

i) Remove spool (3) from sleeve (4).

3 Tool B: 9.8 29.4 Nm {1 3 kgm}

2) Remove PC valve assembly (13).

3) Disassemble PC valve assembly as follows.

i) Remove piston (14), spring (15), seat

5. Servo piston stopper

1) Loosen nut (27) and remove adjustment bolt

2) Remove spring (29).

3) Loosen nut (30) and remove adjustment bolt

3) Disassemble lever assembly as follows.

7. Inner parts assembly

2) Set 3 guide bolts and 2 forcing screws

4) Separate inner parts assembly as follows.

9. Cylinder block, piston assembly

3) Remove retainer guide (50) from cylinder

5) Set tool C to cylinder block assembly (51)

10. Shaft, cradle assembly

2) Using press, remove shaft (60) from cradle

3) Remove snap ring (62), then remove washer

5) Remove snap ring (65), then remove spacer

6) Remove oil seal (67) from cradle (61).

11. Servo piston

12. Valve plate

13. Pump case

4) Remove needle bearing (73).

ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY

2 Outer circumference of bearing:

58.8 78.4 Nm {6 8 kgm}

3 Plug : 58.8 73.5 Nm {6 7.5 kgm}

98 123 Nm {10 12.5 kgm}

4. Shaft, cradle assembly

2 Inner circumference of bearing :

4) Using press, press fit shaft (60) to cradle

2 Outer circumference of bearing :

5) Install snap ring (59).

a Install the snap ring so that the opening is

5. Cylinder block, piston assembly

4) Assemble 3 pins (52) to cylinder block as-

6) Set 9 pistons (48) to shoe retainer (49).

7. Inner parts assembly

2 Mating surface :Gasket Sealant

4) Install 8 mounting bolts (42) of cradle.

58.8 73.5 Nm {6 7.5 kgm}

5) Using tool F, measure shaft rotating torque.

2 Seal lip portion : Grease (G2-LI)

2) Fit spacer (68) and install snap ring (65).

11.8 14.7 Nm {1.2 1.5 kgm}

27.5 34.3 Nm {2.8 3.5 kgm}

27.5 34.3 Nm {2.8 3.5 kgm}

14.7 19.6 Nm {1.5 2.0 kgm}

10. Servo piston stopper

3 Nut : 196 245 Nm {20 25 kgm}

2) Assemble spring (29).