EEN00057-00 1/15

PPM REBUILD UNIT MANUAL

TESTING METHOD

Category Testing method for motor

Type of the motor LMF28 (28 cc/rev specification)

Stamping on the nameplate

Part No. of the motor 708-7S-00550

Machine model installing these motors and WA380-6

Serial No. of the machines installing these motors # 65001 and up

Applications FAN MOTOR

2007/7/20

Issuance history

Remarks
 EEN00057-00 2/15

INTRODUCTION

• Matters That Require Attention

1) The electromagnetic selector valve is used to change rotation direction. So, be sure to stop the
rotation before changing the rotation direction.
a Do not apply abnormal voltage to the electromagnetic selector valve: voltage range = DC24 ± 4 V.
2) Carry out this test both in the clockwise direction and in the counterclockwise direction after
changing the rotation direction with the electromagnetic selector valve.
a Clockwise rotation: Normal rotation direction.
a Counterclockwise rotation: Only in the cleaning mode.
• This document is organized into following parts:
1. Testing Method ..............................................................Pages 3 – 7
2. Test Hydraulic Circuit Diagrms .....................................Pages 8 – 10
3. Performance Standard Value Table..............................Pages 11 – 13
4. Names of Components and Related Dimensions .......Pages 14 – 15
5. Schematic Diagram of Test Jigs (Reference)...............(None)

• This document mainly provides the testing method using KHT75-3 hydraulic test stand or equivalent.

• Applicable Bench
1) Conversion value test: Use the Komatsu general-purpose hydraulic test stand (KHT75-3) or its
equivalent.
a The input-output shaft drive motor must be changed to a variable motor.
a When this test is conducted with KHT75 hydraulic test stand, care should be taken to pre-
vent cavitation (*) in the main pump on the hydraulic test stand side.
*When the main pump supply flow is approximately 160 l/min or more.
2) Standard value test: Hydraulic test stand having the same performance as the production plant
hydraulic test stand

a Use Komatsu genuine engine oil TO10-CD or its equivalent. Discoloration of oil during test
is managed for Class NAS10.

• Scope
This document is adopted for quality verification test of the remanufactured Fan motor (LMF28 •
28 cc/rev specification) installed on WA380-6.

2
 EEN00057-00 3/15

1. Testing Methods

1-1) This motor test is conducted while the output shaft rotates at a high speed. So, pay special attention to
installation of facilities, equipment, test jigs, parts and the motor, configuration of hydraulic circuits
and connection of the universal joint.
1-2) Test Specification
This document applies to the quality check test of rebuilt products of the Fan motor assembly for
LMF28, mounted on the WA380-6
• Sample test specifications (See Table 1-1.)
Table 1-1 Test specification list
Item Specifications
Maximum hydraulic pressure 14.2
(MPa {kg/cm2}) {145}
Maximum flow rate (l/min) Approx. 43
Motor displacement (cc/rev) 28 ± 0.5
Maximum speed (rpm) 1,500
Solenoid voltage (V) DC 24 ± 4
[Reference]
Safety performance 20.6 +1.47 +15
–0.49 {210 –5 }
(MPa {kg/cm2})

1-3) Testing Items

1) For test items and contents, see Tabel 1-2 below.
a For converted value test, conduct tests as limited by the capacity of the KHT75-3 hydraulic
test stand.
a The converted value test determines pass or fail after converting the results of measure-
ments into standard values.
a 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 Testing Items Legend: Q Test, E Test, if possible, × Not testable
Test Performance check
item
Motor Checking for
Running-in Motor case
Displacement volumetric Selector valve Pilot valve abnormalities
sealing
volume efficiency, working check valve
Testing property
drain volume
Methods
Standard
Q Q Q Q E Q Q
Conversion

1-4) Test Basic Hydraulic Circuit Diagram

• See Appendix 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”.

3
 EEN00057-00 4/15

1-6) Test Facility, Equipment and Jigs

1) Applicable Equipment: Prepare the equipment indicated in Table 1-3.
Table 1-3, Equipment list
Device Part No. Measuring section
Part name Q'ty Specifications
name (or maker model) and use
799-101-5120 Gauge 1 0 – 39.2 MPa {400 kg/cm2} Motor inlet port sides (PMA)
manometer
Related

799-101-5130 Gauge 1 0 – 5.9 MPa {60 kg/cm2} Select pressure sensing port section (CV)

— Gauge 1 0 – 0.98 MPa {10 kg/cm2} Motor outlet port sides (PMB)

Measuring flow rate:

— Female cylinder 1 For measurement of drain volume
0 – 5 l/min
equipment
*Related

— Stopwatch 1 — For measurement of drain volume

Generation device Power supply output:
* 1 For voltage of select valve
for DC power supply DC 24 ± 4V
Measured flow rate: For measurement of leakage through
* Flow meter 1
Max. 1 l/min pilot check valve

a For installation of each manometer and device, refer to the hydraulic circuit diagrams
(Appendix Figure 1).
a For equipment marked *, So, you may select equivalents of any makers if they satisty their
specification.
a When the pilot valve check valve performance needs to be checked, prepare the tools
marked with *.

2) Jigs and Parts: Prepare the jigs listed in Table 1-4.

Table 1-4, List of Jigs used in Test
No. Part No. Part name Q'ty Use and specifications
1 — Plate 1 For mounting the motor.
2 — Coupling 1 For connecting the output shaft. (Taper and key type)

a When manufacturing them, refer to "Section 4 Names of Sections and Related Dimensions."

3) In addition to the jigs and parts listed in Table 1-4, prepare flange, hose, etc. that are necessary
to constitute the test hydraulic circuit.

4) Prepare a dye penetrant (developer used for color check).

4
 EEN00057-00 5/15

1-7) Preparation for Test

The following procedures shall be done Fig. 7-1 Fan motor assembly
before the test:
1) Install the sample case port (PD2) upward as
shown in Fig. 7-1.
PD2 : Case port (with plug)
PMA: Motor inlet port
M2 : Output shaft (Taper)
2) When connecting the universal joint, make
sure that it is horizontal and free from radial
runout.
a The coupling is of taper connection. So,
be sure to fix it firmly so that it does not
come off.
3) Construct piping referencing the hydraulic
circuit diagram Fig. 7-2 Fan motor circuit diagram
i) Configure the piping according to the
hydraulic circuit diagrams for Appendix
Figure 1.
a For Fan motor hydraulic circuit dia-
grams, see Fig. 7-2.
ii) For port and adjuster positions, refer to
Appendix Table 1.
iii) Connect a piping adapter and a pressure
gauge takeoff plug to each port.
4) Filling motor case with oil
Pour oil into the motor case, bleed air (PD2)
and fill the motor case with oil.
a Case port plug tightening torque
9.8 – 12.7 Nm {1.0 – 1.3 kgm} Fig. 7-3 Motor output shaft rotation direction
5) Cleaning motor assembly
Clean the motor assembly to check for oil
leakage and apply penetrant testing agent to
each of valve, plug and output shaft oil seal.
6) Rotation Direction (See Fig. 7-3)
Run the sample by low speed, then check the
rotation direction.
i) Judge the rotation direction when facing
the output axis (M2).
• Clockwise direction (C.W) : (The normal
rotation direction)
• Counterclockwise direction (C.C.W) :
(Only in the cleaning mode)
ii) To change rotation direction, use the elec-
tromagnetic selector valve.
a Be sure to stop the output shaft before
changing the rotation direction.
iii) For the rotation direction, see Table 1-5.
Table 1-5 How to Operate Rotation Direction
of Motor
Counter-
Rotation direction of Clockwise
clockwise
motor rotation
rotation
Inlet port PMA PMA
Solenoid voltage (V) 0 24

5
 EEN00057-00 6/15

1-8) Confirming Test Method

For the details of test conditions and standard values for confirming tests, refer to “Section 3 Perfor-
mance Diagram and Standard Value Table.”
1) Running-in
During the operation, check if any trouble (abnormal pressure, sound, etc.) occurs and if oil leaks.
a Operate the transfer valve to check clockwise and counterclockwise rotations.
2) Check of Motor Displacement Volume
Measure outlet flow (Qout) and motor drain volume (dQ), and calculate the motor displacement
volume [qm (cc/rev)].
3) Check of Volumetric Efficiency (or Drain Volume) and Torque
(1) When the motor is loaded, measure outlet flow (Qout) and motor drain volume (dQ) and calcu-
late the volumetric efficiency η(%). (When it is for converted value test, measure the drain vol-
ume [l/min])
(2) Measure the torque value when the specified load is applied to the motor.
a Use the actual measurement value of the motor displacement value for calculating effi-
ciency.
4) Check of Operation of Selector Valve
Confirmation test [1]
i) When the minimum operating pressure and the specified rotation are set and the solenoid volt-
age is set to 24V, check that the rotation direction is smoothly switched (from clockwise to
counterclockwise).
a Minimum operating voltage: 19.6 ± 0.49 MPa (20 ± 5kg/cm2)
ii) After checking the above, conduct the test Volumetric Efficiency (or Drain Volume) and Torque
Check in 3).
5) Check of pilot valve check valve performance (Perform if possible)
i) Set the solenoid voltage to 24 V, apply the specified pressure to pilot selector pressure pickup
port (Cv), and measure leakage (Qc) through the check valve.
a See figure 2 attached to the motor test circuit diagram.
a Start the check after the pilot valve is warmed up sufficiently.
a Disconnect the universal joint, hose, etc. and open each port.
6) Test of Motor Case Sealing Property
Apply the specified pressure (0.5 MPa {5 kg/cm2}) to the specified time and check oil leak and ooze
from the following positions:
• Oil sealing part
• Oil seal housing
• Mating case and end cap
• Fitted portion of each valve
• Thveaded portion of plug
a Disconnect the universal joint, hose, etc. and open all ports other than the drain port (PD)
7) Checking Troubles
Check if abnormal overheat, vibration, sound and oil leak occur during the test.

6
 EEN00057-00 7/15

1-9) Procedures After Test

Follow the precautions below when removing the sample and restoring the motor.
1) Discharge the residual oil from inside the sample and check it for foreign matter.
2) Remove all the jigs and parts which were installed before the test.
3) Seal all the ports with nylon plugs to prevent invasion of contaminants.
4) The test result shall be written and stored in the report form (storage period: 3 years).

7
8
Note 1 This circuit diagram shows the circuit for the performance test of the pilot valve check valve of fan motor (LMF28).
Note 2 Apply the specified pressure (0.69 ± 0.1 MPa {7 ± 1 kg/cm2} and voltage of 24 ± 4 V to pilot selector pressure pickup port (Cv).
Note 3 The gauge used is for 10 k = 0.98 MPa {10 kg/cm2}.

Part No.: 708-7S-00550

PPM model: LMF28: Fan motor
2. Test Hydraulic Circuit Diagram

(For Fan motor test hydraulic circuit diagram)

Appendix Figure 1: Test basic hydraulic circuit diagram

All test
EEN00057-00 8/15

Test Item
Machine model: WA380-6
 Note 1 This circuit diagram shows the circuit for the performance test of the pilot valve check valve of fan motor (LMF28).
Note 2 Apply the specified pressure (0.69 ± 0.1 MPa {7 ± 1 kg/cm2} and voltage of 24 ± 4 V to pilot selector pressure pickup port (Cv).
Note 3 The gauge used is for 10 k = 0.98 MPa {10 kg/cm2}.

Part No.: 708-7S-00550

PPM model: LMF28: Fan motor
2. Test Hydraulic Circuit Diagram

(Circuit diagram for test of pilot valve check valve)

Appendix Figure 2: Test basic hydraulic circuit diagram

Test of pilot valve check valve

EEN00057-00 9/15

Test Item

9
Machine model: WA380-6
10
Note 1 Pressure applied to the drain port (PD1) must not exceed 0.5 MPa {5 kg/cm2}
Note 2 Open all other ports than the drain port (PD1). Disconnect the universal joint before the test.
Note 3 The gauge symbols used represents the following; 10 K = 0.98 MPa {10 kg/cm2}

Part No.: 708-7S-00550

PPM model: LMF28: Fan motor
2. Test Hydraulic Circuit Diagram

(Circuit diagram for test of motor case sealing capacity)

Appendix Figure 3: Test basic hydraulic circuit diagram

Test of more case

EEN00057-00 10/15

Test Item
Machine model: WA380-6
 EEN00057-00 11/15

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) ( ): Measured for reference.
[ ]: Must be measured to obtain a standard value.

Table 3-1) List of Standard Value Tables

Standard value
Remarks
table list No.
Table 1 Running-in, Motor displacement volume
Volumetric and Torque efficiency, Selector valve work check, Check valve of pilot valve and
Table 2
Motor case sealing capacity check

11
12
Motor displacement
Test item Run-in operation
Condition volume
standard value item

Category
Symbol Unit Tolerance 1 2 3 4 5 6 7 8 9 10 1 2 Part No.: 708-7S-00550

Output shaft revolution speed M2 rpm ±10 300 500 i 1000 1500 300 500 i 1000 1500 500 i
Counter- Counter-
Direction of output shaft revolution — — — Clockwise i i i i i i i i Clockwise
clockwise clockwise
PPM model: LMF28: Fan motor

Supply voltage of solenoid EV V ±4 0 i i i i 24 i i i i 0 24

±0.5 2.45 or less 4.9 6.9 14.2 2.45 or less 4.9 6.9 16.7 2.45 or less
Inlet PMA i i i
Main port pressure {±5} {25 or less} {50} {70} {145} {25 or less} {50} {70} {170} {25 or less}
Outlet PMB MPa 0.2 {2} i i i i 0.2 {2} i i i i 0.2 {2} i
Motor case drain pressure PD1 {kg/cm2} — — — — — — — — — — — —

Test condition
or less
± 0.1
Pick-up port pressure of pilot valve CV
{± 13}
Operating time, number of min. 2 time or
— — 2 min i 1 min i i 2 min i 1 min i i i
measuring times times more
within the 27.5 –
Motor displacement volume qm cc/rev — — — — — — — — — — i
range 28.5
Drain amount dQ l/min or less — — — — — — — — — — — —
Volumetric effeciency η % or more — — — — — — — — — — — —
Torque efficiency ηt % or more — — — — — — — — — — — —
[Reference] Nm
Tt or more — — — — — — — — — — — —
Theonetical torque value {kgm}

Standard value
Leakage of check valve QC cc/min or less — — — — — — — — — — — —
[Standard Values (1/2)]

Revolution direction check — — —

Motor displacement volume qm cc/rev — — — — — — — — — — —
Inlet (outlet) flow rate Q — — — — — — — — — — — [ ] [ ]
l/min
Drain amount dQ — — — — — — — — — — — [ ] [ ]
Output shaft revolution speed M2 rpm — — — — — — — — — — — [ ] [ ]
Table 1: Performance Standard Value Table

Volumetric efficiency η % — — — — — — — — — — — — —
Torque efficiency ηt % — — — — — — — — — — — — —
Nm
Torque value Tt — — — — — — — — — — — — —

Measured value
{kgm}
Revolution (speed and) direction check MZ (rpm) — — — — — — — — — — — [ ] [ ]
Leakage of check valve QC cc/min —
Oil leak, abnormal noise, 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 OK/NG
Judgement (O)
EEN00057-00 12/15

Machine model: WA380-6

 Volumetric and torque efficiency Performance
Test item Select valve work check
Condition (Drain volume check) check of pilot Check for motor case
standard value item valve check sealing capacity

Category
Efficiency valve
Symbol Unit Tolerance 1 2 3 Work check
check
Output shaft revolution speed M2 rpm ±10 1000 1500 ← 300 1500 [Max.] 300 —
Part No.: 708-7S-00550

Clockwise
Counter-Clock- Counter- Clock-
Direction of output shaft revolution — — — Clockwise ← ⇒ Counter- — —
wise wise
Clockwise
PPM model: LMF40: Fan motor

Supply voltage of solenoid EV V ±4 0 ← ← 0 ⇒ 24 24 24 —

±0.5 4.9 14.2 1.96 14.2
Inlet PMA ← Open Open
Main port pressure {±5} {50} {145} {20} {145}
MPa
Outlet PMB {kg/cm2} 0.2 {2} ← ← 0.2 {2} ← Open Open
or less

Test condition
Moter case drain pressure PD1 — — — — — — 0.39 – 0.49 {4 – 5}
Pick-up port pressure of pilot ±0.1
CV — — — — — 0.69{7}
valve {±13}
Operating time, number of min.
— — 2 time or more ← ← 5 time or more 2 time or more 2 time or more 3 min
measuring times times
within the
Motor displacement volume qm cc/rev — — — — — —
range
Drain amount dQ l/min or less 1.7 3 3 — 3 — After the test, the fol-
lowing portions shall be
Volumetric effeciency η % or more (94) (93) (93) — (93) — free from oil leakage:
1. Sealed position of
Torque efficiency ηt % or more (75) (84) (84) — (84) — output shaft
[Reference] Nm 2. Mating face of each
Tt or more (15.7{1.6}) (53{5.4}) (53{5.4}) — (53{5.4}) — positions
Theonetical torque value {kgm}

Standard value
3. Positions closed with
Leakage of check valve QC cc/min or less — — — — — 17 plug and screw
[Standard Values (2/2)]

Smooth to be
Revolution direction check — — — — — — — —
changing
Motor displacement volume qm cc/rev — [ ] [ ] [ ] — [ ] — —
Inlet (outlet) flow rate Q — [ ] [ ] [ ] — [ ] — —
l/min
Drain amount dQ — — —
Volumetric efficiency η % — [ ] [ ] [ ] — [ ] — —
Table 2: Performance Standard Value Table

Torque efficiency ηt % — [ ] [ ] [ ] — [ ] — —
Nm
Torque value Tt — [ ] [ ] [ ] — [ ] — —
{kgm}

Measured value
Revolution speed and direction check M2 (rpm) — [ ] [ ] [ ] [ ] —
Leakage of check valve QC cc/min — — — — — —
Oil leak, abnormal noise, heat generation
— — — — OK/NG — OK/NG OK/NG OK/NG
check
Judgement (O)
EEN00057-00 13/15

Machine model: WA380-6

13
 EEN00057-00 14/15

4. Names of Components and Related Dimensions

Appendix Table 1 Names of Sample Compenents and Port Size

(Applicable Model: WA380-6)

Applicable components: Fan motor

1. Names of Components and Port Size

Port and Presence or
adjustment Name of port and adjustment absence of
Port size Remarks
section sections connection for
symbol installation
M1 Installed position of motor Connection — See dimensional drawing.
M2 Output shaft (Taper) Connection — See dimensional drawing.
P MA Motor inlet port (Pressurization) Connection M24 x 1.5 Installation of pressure gauge
P MB Motor outlet port Connection M24 x 1.5 Installation of pressure gauge
P D1 Motor case drain port Connection M18 x 1.5
P D2 Motor case drain port Closed — With plug
CV Select valve pressure sensing port Connection — Installation of pressure gauge
EV Solenoid connector (2 poles) Connection — 2-pole connector (DT type)

2. 708-7T-00710: Fan motor

1) Output shaft (M2) and installation detail (M1)

Detail of output shaft (P) Detail of installation (Q)

14
 EEN00057-00 15/15

Attached Figure 1: Dimensions of Sample Sections

2) Names and dimensions of ports

15