Komatsu Pump

HYDRAULIC EXCAVATOR (and related) MODELS TESTING & ADJUSTING PROCEDURES BOOK Version 2001-21 …Ye Olde Tune Up Sheets, now compiled into… the

H.E. TuneUp Book Table of Contents Section No

Model

Starting Page

1

Sheets to books: Background & Purpose

2

2 3 4 5 6 7 8 9 10 11

BR350JG-1 PC128uu-1 and –2 PC228USLC-3 PC150-6LK Pre and Minor Change PC200 to 250-6 PRE Minor Change PC200 to 270-6 Minor Change PC300 and 400-6 Minor Change PC300 and 400-6 PRE - Minor Change PC600/750/1100-6 (E-OLSS) PC200/220/270 as TimberJack 635SL/735SL/835SL PC200Z-6LE (no monitor panel) D39Ex / Px – 21 KomStat Dozer

3 9 13 21 27 33 39 45 51 53

12 13

59 Coming Soon

2

… from loose Sheets to a Book! BACKGROUND

Begun in the 1990’s as an aid to Komatsu Hydraulic Excavator Shop Manual’s Te sting & Adjusting sections, these popular documents have also been widely used as training aids and exercises to teach the proper methods and sequence for H/E T&A. Due to their wide use in initial and recurrent training, their convenience and purposeful organization toward product PERFORMANCE, these documents are now popularly used to perform and document product performance at ALL stages of product life. These ‘sheets’ are used from PDI to PM Tune Up’s to Repair and Troubleshooting. In Training, no machine can be understood properly without first “MEASURING” the product’s condition and performance according to its intended design. Consolidating elements of Structure, Function, STD Values, Testing, Adjusting & Troubleshooting this format is brief yet complete – to OUR BEST KNOWLEDGE! Watch for revisions as we STRIVE TO IMPROVE in both PRODUCT KNOWLEDGE and COMMUNICATION of same. ~ Komatsu America Service Training, 2001

PURPOSE (by approximate element No.) 1.

Engine Speeds – vital health criteria in a diesel powered hydraulically operated product such as Hyd/Exc etc. Failure to verify proper Diesel performance wastes time on ANY further element (in operational diagnostics). 2. Cycle Times – these confirm the “FLOW” constituent of Hydraulic HP while “PRESSUR ES” usually remain constant. Therefore, any +/- in flow is a direct Hyd.HP result. Be certain to benchmark these BOTH prior to and AFTER any adjusting. 3. PPC or ‘pilot’ pressure – confirming the controls work before use! 4. Main Pressures – While adjustable, these must be verified and ‘balanced’ (multi-pump product) before adjusting other ‘pressure’ sensitive control devices (such as LS or PC/TCC/TVC). 5. LS-EPC (if equipped) – must verify operation correct PRIOR to any attempt to verify or adjust the LS Valve(s). 6. Servo In Pressure Ratio (to main) is only a TEST. Nothing can be adjusted here because the very items being tested (LS & PC/TCC/TVC) are, in subsequent elements, going to be TESTED & ADJUSTED, provided this step reveals they are operating as designed, in GENERAL. 7. LS Valve(s) adjustment – resulting in proper LS Differential Pressure(s) and that multipump product have as CLOSE a BALANCE as possible, giving product best possible pump synergy for best Hyd. HP and best possible combination of POWER and FINE CONTROL. 8. PC-EPC (if equipped) operation verified prior to PC adjusting. 9. HP Valve (PC/TCC/TVC) adjustment – results in BEST ENGINE USE for both power and most efficient use of fuel. This sets pump(s) limits. 10. RECHECK Cycle times (Element 2). This documents performance results or reveals any error(s) in adjusting which may be corrected for the best possible product.

H.E TuneUP Book.PDF

3 Date

Technician

Customer

Serial Model BR350JG-1 Mobile Crusher TESTING & ADJUSTMENT PROCEDURE

Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu BR350JG-1 machines serial number 1005 & higher. NOTE! Hydraulic adapters must be FITTED prior to using this procedure. See diagrams on last pages. Always ensure that any known abnormalities are resolved and are normal before continuing with this procedure. See the “Points to Remember when Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following steps..

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds. Compare these with the specified values. Adjust the engine speed if necessary. See page 20-103 in the Testing and Adjusting section of the Shop Manual for directions on how to connect a tachometer, required for Step 8 also. Actual Value After Standard Value Measurement conditions Adjusting BR350JG-1 a. Low Idle 920 – 1020 b. High Idle, all motors 2130 – 2270 running no load full speed c. High Idle+Tvl ‘touch’ 2230 – 2370 d. BOTH tracks relief 2000 – 2200 e. Left Trk (FP) Relief 2000 – 2200 f. Right Trk (RP) Relief 2000 – 2200 g. High FREE Idle 2230 – 2370

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Use same photoTach as in Step 1, above. Measurement Actual Values After Adjusting Standard Value conditions: BR350JG-1 CRUSHER F/Wheel Maximum Dial Spd CRUSHER F/Wheel Minimum Dial Spd Conveyor belt speed Conveyor, roller Magnetic Sep. Travel 20 meter running start 10m.

3)

245 – 255 RPM 160 – 170 RPM 70 – 110 RPM 70 – 110 RPM 90 – 100 RPM 24 SECONDS

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the EPC valve block. Adjust if necessary. Step 3 Actual value Adjusted Value Standard Value, kg/cm2 Pilot Oil Pressure 31 –38

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4) Measure the Main Relief and Unload valve pressures using a 400 kg/cm2 gauge connected to the test ports on top of the main pump assembly. Compare with the standard values listed below, and adjust if necessary. Note - BR350JG-1 remains “Pumps DIVIDED” all the time. Item

Measurement conditions

Unload Pressure Conveyor Lift Magnetic Sep. OPT 2 OPT 3 OPT 4 Travel Left

Hi Idle, Neutral Hi Idle, Relief Hi Idle, Blocked/Uncoupled Hi Idle, Uncoupled Hi Idle, Uncoupled Hi Idle, Uncoupled Hi Idle, Relief

Travel Right

Hi Idle, Relief

Front pump

Rear pump

Unload Pres Unload Pres Unload Pres Unload Pres Unload Pres Unload Pres Unload Pres

Standard value kg/cm2 30 - 50 170 - 180 170 - 180 170 - 180 170 - 180 170 - 180 345 - 370 LH relief 345 - 370 RH relief

WHEN SETTING THE RELIEF PRESSURE: Use the Left track to set the Left Relief valve, and the Right Track to set the right relief valve.

5) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) Engine Hi Idle Measurement Conditions Neutral Crusher set at HALF DIAL GRIZZLY at HALF DIAL

Front Pump Servo Input

Unload Pressure

Front Pump Main Pressure

Rear Pump Servo Input

Rear Pump Main Pressure

Unload Pressure

Unload pressure

Standard Value Servo vs. Main Almost the same Servo 1/2 of main Servo 1/2 of main

Unload Pressure

6) Measure the LS Differential pressure using the functions with EPC Dial at FULL. Adjust LS Valve if the Difference between the Load Sense pressure and the Main pressure is outside the standard value. ( Main – LS ) Kg / CM2 Measurement conditions Actual Value Standard Value Hi Idle, Neutral, Front Pump 20 - 40 Hi Idle, CRUSHER rotating at FULL DIAL, Front Pump 21 - 23 Hi Idle, Neutral, Rear Pump 20 - 40 Hi Idle, GRIZZLY rotating at FULL DIAL, Rear Pump 21 - 23

7) PC EPC output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the PC EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Start the engine, High Idle, track over relief and measure the oil pressure at the outlet of the valve at this time. The pressure should be within the standard values below. FUNCTION TEST – OK if engine NOT stalled when tracks relieved AT LOW IDLE. Item PC EPC output pressure – TRK stall

BR350JG-1 Crusher

Actual value

Standard Value BR350JG-1 5-10 kg/cm2

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5

8) PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You can use engine rpm over relief to determine if the PC valves are adjusted correctly. If the rpm with the track over relief is not within the standard value range, adjust the PC valve on each pump (DIVIDED!) to give you the correct rpm. Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. Measurement conditions

Actual value

After Adjustment

BOTH Tracks stalled

Standard Value

BR350JG-1 RPM 2000 - 2200

LH Track 2000 – 2200 (within 20 rpm of rear Relief (Front pump) pump) RH Track 2000 – 2200 (within 20 rpm of Relief front pump) (Rear Pump) Note: Adjust the PC valves to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel.

9)

Recheck all cycle times, and note in the table under #2 the new measurements.

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SIDE VIEW OF THE MAIN HYDRAULIC PUMP

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7 SELF PRESSURE REDUCING VALVE The Self-Pressure Reducing Valve is located on the rear of the main control valve. The outlet hose for the front pump attaches to this valve. To access the Control Pressure Relief valve remove the partition between the engine and the main control valve. As you can see below, the relief valve is located on the bottom of the Self-Pressure Reducing valve.

(PC220-6) BR350 Main Control Valve

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BLANK PAGE

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9 Date

Customer

Model PC128uu-1 -2

Technician

Serial

TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC128uu-1 machine s/ number 2347+ and DASH 2 s/n 5001 +. Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “Electrical Resets and Troubleshooting Procedure” sections in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1 – 10 because skipping one step will affect the measurements in the following steps. DO NOT OMIT STEP 9 - SAFETY CHECK! APD: Accident Prevention Device.

1) Warm machine and HYD OIL up to operating temperature (swing over relief is possible with CN-K29 swing release solenoid disconnected -1). Record all of the following Engine Speeds using a photo tach. Compare these with the specified values. Adjust the engine speed if necessary. **MAY REQUIRE REMOVAL OF ENTIRE COUNTERWEIGHT!** ‘X’ out model NOT testing! Actual After Standard Value Standard Value Measurement conditions Value Adjusting PC128uu-1 PC128uu-2 a. High Idle, no load 2040 - 2160 2340 – 2460 b. Low Idle 900 – 950 900 – 950 c. High Idle with Arm Relief 1880 – 1920 2120 – 2320

2) Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions High Idle Boom Raise Boom Down Arm In Arm Out Offset Right Offset Left Bucket Curl Bucket Dump LH Swing, 5 turns RH Swing, 5 turns LH Travel, Hi, 5 turns LH Travel, Lo, 5 turns RH Travel, Hi, 5 turns RH Travel, Lo, 5 turns Blade Raise Blade Lower

Actual Values seconds

After Adjusting seconds

Standard Value PC128uu - 1

Standard Value PC128uu - 2

3.5 - 4.9 2.9 – 4.3 2.8 – 3.4 2.3 – 3.4 4.8 – 6.1 4.9 – 6.2 2.7 – 3.6 2.2 – 2.9 28 – 36 28 - 36 35 - 40 54 - 62 35 - 40 54 - 62 1.2 – 2.7 1.1 – 2.2

3.5 - 4.3 3.2 – 3.9 3.3– 3.9 2.3 – 2.9 5.0 – 6.2 4.9 – 6.1 2.4 – 3.0 2.0 – 2.4 28 – 32 28 – 32 29 max 39 max 29 max 39 max 1.0 – 1.6 1.1 – 1.5

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the solenoid block. Adjust charge pump relief if necessary on -1. Dash 2 – adjust self-pressure reducing valve. Charge Pump Relief Pilot Oil Pressure

PC128uu1/uu2

Actual value

Adjusted Value

Standard Value, kg/cm2 31 - 35

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4) Measure the Main Relief and Unload valve pressures. Compare with the standard values listed below, and adjust relief or safety if necessary. Disconnect SWING BRAKE solenoid to lock swing.

Actual compared to standard values Measurement conditions Actual

Item Unload Pressure Boom Up Arm In Arm Out Offset Right Offset Left Bucket Curl Bucket Dump Blade Raise Blade Lower Swing Left Swing Right Travel Left Travel Right

Hi Idle, Neutral (Unload Vlv. ) Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Safety Valve Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Safety Valve Hi Idle, Safety Valve Hi Idle, Main Relief Hi Idle, Main Relief

kg/cm2 PC128uu - 1

PC128uu - 2

25 - 45 300 - 350 300 - 350 300 - 350 250 - 300 250 - 300 300 - 350 300 - 350 300 - 350 300 - 350 245 - 295 245 - 295 300 - 350 300 - 350

25 - 45 325 - 345 325 - 345 325 - 345 260 - 290 325 - 345 325 - 345 325 - 345 325 - 345 325 - 345 310 - 330 310 - 330 345 - 365 345 - 365

5) ** NOT used on uu-2**LS EPC input voltage: Using the harness checker, breakout box and multimeter, check for controller input voltage at the EPC connector at the pump. Operation

Fuel Dial

Neutral All levers except tvl Swing only Swing only

MIN MAX MIN MAX

LS EPC input voltage

6) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) NOT ADJUSTABLE!! Measurement Conditions Neutral Arm Relief Travel , Hi, FULL stroke

PC128uu1/uu2

Servo Input

Main Pressure

Standard Value Servo vs. Main Kg / cm2 Almost the same (25 – 45) Servo 1/2 of main Servo 3/5 of main

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7) Measure and adjust the LS Differential Pressure using the tracks as outlined in the Shop Manual. Raise one side of the machine, ( HI travel speed, Full Throttle) and move the travel lever of the raised track Half - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Standard Value, kg/cm2 Measurement conditions Hi Idle, Neutral Travel , Hi, half stroke

Actual Value

After Adjusting

PC128uu - 1 25 - 45 21 – 23

PC128uu - 2 18 - 38 21 – 23

* LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at some steady speed roughly at ½ or less as long as main pressure is kept steady for the most repeatable and reliable reading of MAIN – LS = LS Differential.

8)

PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to determine if the PC valves are adjusted correctly. Test rpm with the Arm over relief at high idle. If not within the standard value range, adjust the PC valve on the main pump to give you the correct rpm over relief using the arm or bucket over relief. Measurement conditions High Idle, Arm Relief

•

Actual value

After Adjustment

PC128uu-1 RPM 1880 - 1920*

PC128uu-2 RPM 2120 - 2320*

Note: Adjust the PC valve to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel. PC Valves can “hide” a sick engine! Always ensure the engine care and health is verified prior to making hydraulic system adjustments.

9) Test 4 SYSTEM for Depth “Zero” feature s, Depth, Height, Offset & APD Stops: OK þ ___ Check Depth of bucket from level ground (raise track) - VERIFY READOUT. þ ___ Check Depth "Zero" feature from a set imaginary datum (top of blade, etc). þ ___ Check Depth STOP SET - at LOW IDLE. þ ___ Check Depth STOP SET - at HIGH IDLE. (cushion or slowdown?____) þ ___ Check Height STOP SET - at HIGH IDLE. (cushion or slowdown?____) þ ___ Check Offset LEFT STOP SET - at LOW IDLE. þ ___ Check Offset LEFT STOP SET - at HIGH IDLE. (cushion or slowdown?___) þ ___ Check APD Offset LEFT to cab side - at LOW IDLE. þ ___ Check APD ARM STOP to cab front - at LOW IDLE. þ ___ Check APD ARM STOP to cab front - at HI IDLE. (cushion/slowdown?___) 10)

Recheck all cycle times, and note in the table under #2 the new measurements.

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BLANK PAGE

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13 Date

Technician

Customer

Model PC228USLC-3

Serial

TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC228us -3 machines serial number 20001 & higher. Also, see MONITOR operation instructions at end of this document. Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-10 because skipping one step will affect the measurements in the following steps.

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitoring code 10. Compare these with the specified values. Adjust the engine speed (governor – throttle linkage) if necessary. “Touch” means slight PPC operation to close PPC switch. Actual/ Adjusted Standard Value Measurement conditi ons Value PC228US -3 a. High Idle, E mode + touch 1800 b. High Idle, A, Travel Touch 2080 - 2220 c. High Idle, A mode + Touch 2080 - 2220 d. Low Idle 980 - 1080 e. Arm Relief, A 1900 - 2100 f. Arm Re lief, A + P/Max 1800 - 2000 g. AUTO DECEL Hi Idle 1300 - 1500 h. RH Track Relief, A ?1900 - 2100 i. LH Track Relief, A ?1900 - 2100 j. Low Idle @ LH Track Relief PEMC Test ** Prior to 12-99 Active “droop” was 200-300RPM lower than PMax“droop”.

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Standard Value A mode, High Idle seconds Adjusting PC228USLC-3 Boom Raise 3.4 – 4.2 Arm In 3.2 – 3.8 Arm Out 2.5 – 3.1 Bucket Curl 2.3 – 2.9 Bucket Dump 1.7 – 2.3 LH Swing, 5 turns 25.6 – 30.9 RH Swing, 5 turns 25.6 – 30.9 LH Travel, Hi, 5 turns 29.4 – 32.9 LH Travel, Lo, 5 turns 50.8 – 62.1 RH Travel, Hi, 5 turns 29.4 – 32.9 RH Travel, Lo, 5 turns 50.8 – 62.1

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure. TEST port (3); ADJUST at (4).

Adjust Self Pressure Reducing Valve if necessary. (High Idle)

Step 3 Pilot Oil Pressure

PC228us3

Actual value

Adjusted Value

Standard Value, kg/cm2 31 -35

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4) Measure the Main Relief and Unload valve pressures using the machine monitor panel codes 11 & 12. Compare with the standard values listed below, and adjust if necessary. Item Unload Pressure Boom Up Arm In Arm Out Bucket Dump Bucket Curl Swing Left Swing Right Travel Left Travel Right

Measurement condi tions A, Hi Idle, Neutral A, Hi Idle, Relief (PMax) NO BOOM UP CUSHION A, Hi Idle, Relief (PMax) A, Hi Idle, Relief (PMax) A, Hi Idle, Relief (PMax) A, Hi Idle, Relief (PMax) A, Hi Idle, Swing Lock, Relief A, Hi Idle, Swing Lock, Relief A, Hi Idle, Relief A, Hi Idle, Relief

Front pump (code 11)

Rear pump (code 12)

Unload Pres Unload Pres

standard value kg/cm2 PC228 30 – 50 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 300 – 330 300 – 330 380 - 400 LH relief 380 – 400 RH relief

WHEN SETTING THE RELIEF PRESSURE: Set the high pressure setting (380 - 400) with the track FIRST, then set the low pressure setting (345 - 360) second. Use the Left track to set the (2) TOP Relief valve, and the Right Track to set the (1) BOTTOM relief valve.

3

4

To set the low pressure setting disconnect the 2 Stage Relief Solenoid valve (connector V__), then use the track to measure the low pressure setting. Using this procedure set the relief valve 10 kg/cm2 higher than you want it to be. Example: If you want the arm, boom, & bucket pressure to be 355 kg/cm2. Set low-pressure setting of the relief valve using the track with the 2-stage relief solenoid disconnected to 365 kg/cm2.

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5) LS EPC output pressure: Connect a coupler nipple to the LS EPC solenoid check port. Attach a 60kg/cm2 gauge to the nipple. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, A mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item Actual value All levers in neutral Any work eq. lever moved LS EPC current (code 15) * 870 - 930 mA 0 - 10 mA LS EPC output pressure ** 30 kg/cm2 0 LS EPC output pressure Hi TVL = 0 kg/cm2 LS EPC output pressure Lo TVL = ___ kg/cm2 * Connector corrosion (even slight) can lower current readout even though function is normal. ** FUNCTION TEST = is Lo Tvl normal? Then LS EPC is also!

6) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) Measurement Front Pump Front Pump Conditions Servo Input Main Neutral Arm Relief Arm Relief + Pmax RH Travel , Hi, half stroke - SPINNING LH Travel, Hi, half Unload Unload stroke - SPINNING Pressure Pressure

Rear Pump Servo Input

Rear Pump Main

Unload Pressure

Unload pressure

Approx.STD Ratio Servo vs. Main Almost the same Servo 3/5 of main Servo 3/5 of main Servo 3/5 of main Servo 3/5 of main

PC-EPC pressure

LS-EPC pressure

3 – FRONT pump Servo In

PC228us3

4 – REAR pump Servo In

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7) LS Differential - TIME Method: Using LOW TRAVEL (Std. 5 turn spec with NO tolerances); A mode; Hi Idle; Raise track, set travel lever at FULL STROKE Measurement conditions Actual Value After Adjusting Standard Value, Seconds A MODE, Hi Idle, Lo Travel speed, Right 56.0 Track rotating at Full PPC stroke,Front pump +/- 0.5 sec A MODE, Hi Idle, Lo Travel speed, Left 56.0 Track rotating at Full PPC stroke, Rear Pump +/- 0.5 sec Adjust LS Valve on each pump separately to achieve NO MORE than ½ second difference in Lo TVL cycle time. Each FLAT will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

8) PC EPC output pressure: Connect the coupler nipple to the PC EPC pressure check port on top of rear pump. Attach a 60kg/cm2 gauge to the nipple. Bring up monitoring code 13 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, A mode, High Idle, Auto Decel “OFF”, arm over relief, Power Max, and measure the oil pressure at the outlet of the valve at this time. The pressure and current should be within the standard values below. Item Actual value Std value PC228USLC-3 PC EPC current (code 13) * 480 - 680 mA PC EPC output pressure 5-10 kg/cm2 CHECK THESE also: Arm @ relief Hi Idle Arm @ relief Lo Idle * Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to determine if the PC valves are adjusted correctly. Test rpm with the Arm over relief Power Max “ON”. If not within the standard value range, adjust the PC valve on each pump to give you the correct rpm over relief using the stalled track (ensures both high relief pressure and divided pumps when travel operated WITHOUT any other function). Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. Measurement Actual value After Adjustment Standard Value conditions PC228USLC-6, rpm Arm Relief, 1800 - 2000* H/O+P/Max RH Track Relief, 1800 - 2000 (within 20 Hi Travel speed rpm of rear pump) (Front pump) LH Track Relief 1800 - 2000 (within 20 Hi Travel speed rpm of front pump) (Rear Pump)

•

Note: Adjust the PC valves to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel. PC Valves can “hide” a sick engine! Always ensure the engine care and health is verified prior to making hydraulic system adjustments. Divided pump target RPM’s will need to be about 50 – 100 higher than the merged, 2 pump values.

10) Recheck Boom Raise and Arm out to determine results in oil flow (Hy HP).

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8

PC228US-3 MAIN PUMP FRONT SIDE

6 – 13mm locknut 7 – 4mm hex PC Valve Adjust Screw 8 - LS Valve(s) 22mm locknut, 6mm hex LS Adjust Screw

LS Differential - PRESSURE Method: Measure and adjust the LS Differential Pressure using the tracks as outlined in the Shop Manual. Raise one side of the machine, (A mode, HI travel speed, Full Throttle) and move the travel lever of the raised track Partial - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Repeat this procedure for the opposite track and pump. Measurement conditions Actual Value After Adjusting Standard Value, kg/cm2 A, Hi Idle, Neutral, Front Pump 30 - 50 A, Hi Idle, Hi Travel speed, Right Track 23 - 25 rotating at half stroke, Front Pump A, Hi Idle, Neutral, Rear Pump 30 – 50 A, Hi Idle, Hi Travel speed, Left Track 23 - 25 rotating at half stroke, Rear Pump * LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at a steady speed roughly at 50-80% as long as main pressure (codes 11, 12) is kept steady for the most repeatable and reliable reading of MAIN – LS = LS Differential.

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PC228US-3 Main Control Valve

_ Measurement positions a. Bucket CURL b. Bucket DUMP c. L.H. travel FORWARD d. L.H. travel REVERSE e. Boom LOWER f. Boom RAISE g. Left swing h. Right swing i. R.H. travel FORWARD j. R.H. travel REVERSE k. Arm IN l. Arm OUT

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MONITOR PANEL OPERATION PC228USLC-3

WIPER INDICATORS (above switch)

Auto Decel SW

Travel Speed SW

MODE SELECT “UP”/“DOWN SWITCHES

“BLACK BUTTON”

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• Key on……self test w/in 3 seconds

• ENTERING Monitor’s CODE MENU: 1. Hold BUZZER CANCEL + AUTO-DECEL switches for 3 secs. 2. Display “ 01 to 07 ” will appear 3. Hold BUZZER CANCEL + “Touch” MODE SELECT (up/dn) for choice of Monitor Codes “01, 02, 03, 04, 05, 06, 07” 4. When chosen CODE is displayed, touch “BLACK” button to select 5. To scroll within selection use BUZR CANCEL + “touch” MODE SELECT 6. To cancel a selection (“GETTING OUT”) use STEP #1 above. • CODES MENU: 01 – SERVICE (Failure) CODES + Hours (like PC-6) 02 - MONITORING (Data) CODES (01 to 201) (like PC-6) 03 - Governor Set ( “G-SET” ) Mode (like PC-6) 04 - Default WORK MODE Setting ( “d SET” ) 05 - Oil Change Reminder INTERVAL SET 06 - (unknown feature) ( “ 1 SET ” ) 07 - (unknown feature) ( “ 2 SET ” )

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Technician

Date

Customer

Model

Serial

PC150LC-6 S/N: K30001 & up PLUS K32000m/c TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC150LC6K machines serial number K30001 to K32000 or . Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following steps.

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitor panel code 10. Compare these with the specified values. Adjust the engine speed if necessary. Measurement Conditions Actual Value After Standard Value RPM Adjusting K30000-K32000 a. High Idle, H/O mode 2350 - 2510 Aa. High Idle, Active mode N/A b Low Idle 900- 1000 c Arm Relief, H/O 2000 - 2200 d Arm Relief, H/O + P/Max 2000 - 2200

Standard Value K32001 up 2250 - 2450 2500 - 2600 900- 1000 2000 – 2200 2000 – 2200

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement Conditions Actual Values After Adjusting Standard Value Standard Value H/O mode, High Idle Seconds K30000-K32000 K32001 up Boom Raise 3.3 - 4.1 3.1 – 3.9 Arm In 3.3 - 4.1 3.0 – 3.8 Arm Out 2.7 - 3.3 2.7 - 3.3 Bucket Curl 3.2 - 4.0 2.9 – 3.7 Bucket Dump 1.9 - 2.5 1.7 – 2.3 LH Swing, 5 turns 23.5 - 26.5 24.5 - 26.5 RH Swing, 5 turns 23.5 - 26.5 24.5 - 26.5 LH Travel, Hi, 5 turns* 26.5 - 32.5 29.1 – 35.1 LH Travel, Mi, 5 turns* 32.5 - 40.5 35.7 – 43.7 LH Travel, Lo, 5 turns* 53.0 - 65.0 58.2 – 70.2 RH Travel, Hi, 5 turns* 26.5 - 32.5 29.1 – 35.1 RH Travel, Mi, 5 turns* 32.5 - 40.5 35.7 – 43.7 RH Travel, Lo, 5 turns* 53.0 - 65.0 58.2 – 70.2 *travel cycles for PC150LC. STD track cycles are about 90% of LC seconds (2 to 6 secs FASTER)

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the solenoid block. Adjust if necessary. Step 3 Pilot Oil Pressure

PC150LC-6LK

Actual value

Adjusted Value

Standard Value, kg/cm2 32 - 33

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22

4) Measure the Main Relief and Unload valve pressures using the machine monitor panel code 11. Compare with the standard values listed below, and adjust if necessary. Item

Measurement Conditions

Unload Pressure

H/O, Hi Idle, Neutral

Boom Up Arm In Arm Out Bucket Dump Bucket Curl Swing Left Swing Right Travel Left Travel Right

H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Relief H/O, Hi Idle, Relief

Main Pump (code 11)

After Adjusting not adjustable

Standard Value kg/cm2 30 - 50 315-335 (345-370) 315-335 (345-370) 315-335 (345-370) 315-335 (345-370) 315-335 (345-370) 315 – 335 315 – 335 345-370 LH relief 345-370 RH relief

WHEN SETTING THE RELIEF PRESSURE: Set the high pressure setting (345-370) with the lower portion of the relief valve FIRST, then set the low pressure setting (315-335) second.

5) LS EPC current & output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the LS EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item

Actual value

LS EPC current (code 15) LS EPC output pressure

All levers in neutral 870 - 930 mA 30 kg/cm2

Actual value

Any work eq. lever moved 0 - 10 mA 0

6) Measure the Servo Input Pressure, and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the TVC valve are working properly.) Measurement Conditions Neutral Arm Relief Arm Relief + Pmax Travel , Hi, half stroke Travel, Hi, full stroke

PC150LC-6LK

Main Pump Servo Input

Main Pump Main Pressure

Standard Value Servo vs. Main Servo 1/2 of main Servo 1/3 of main Servo 1/3 of main Servo 1/2 of main Servo 1/2 of main

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7) Measure the LS Differential pressure using the tracks. Adjust if the Difference between the Load Sense pressure and the Main pressure is outside the standard value while rotating the raised track in Hi travel speed at half stroke. Measurement conditions H/O, Hi Idle, Neutral H/O, Hi Idle, Hi Travel speed, Either Track rotating at full stroke

Actual Value

Standard Value 30 - 50 kg/cm2 28 - 30 kg/cm2 24.7-25.7** **Refers to s/n K32000 up

8) TVC Valve adjustment: You can use engine rpm over relief to determine if the TVC valve is adjusted correctly. If the rpm with the Arm over relief Power Max “ON” is not within the standard value range, adjust the TVC valve to give you the correct rpm. Measurement Actual Value After Adjustment After Adjustment Standard Value Conditions RPM (if needed) PC150LC-6, rpm Arm Relief, 2000 - 2200* H/O+P/Max * Note: Adjust the TVC valve to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel.

9)

Recheck all cycle times, and note in the table under #2 the new measurements.

TOP VIEW OF PC150LC-6 MAIN CONTROL VALVE

Use Quick Coupler 799-101-5220 with O-Ring 07002-11023. 10 x 1.25mm thread

PC150LC-6LK

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24 FRONT VIEW OF PC150LC-6 MAIN CONTROL VALVE

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Technician

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Customer

Model

Serial

PC200, 210, 220, 250-6; Serial Numbers A80001 - A82999 TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC200 to 250-6 excavators. ** PRE-Minor Change Machines!!** Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following steps.

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitor panel code 10. Compare these with the specified values. Adjust the engine speed if necessary. Measurement Actual Value PC200, 210 PC200, 210 PC220, 250 conditions Komatsu Cummins Komatsu engine engine engine Low idle 920 - 1020 1000 - 1120 920 - 1020 High idle, H/O mode 2130 - 2270 2070 - 2190 2330 - 2470 High Idle, H/O, Travel 2330 - 2470 2360 - 2480 2430 - 2570 lever moved slightly ? Boom Relief, H/O 2050 - 2250 2000 - 2200 2250 - 2450 Boom Relief, H/O, + 2100 - 2300 2050 - 2250 2200 - 2400 Pmax

2)

PC220, 250 Cummins engine 1000 - 1120 2240 - 2360 2460 - 2580 ? 2150 - 2350 2150 - 2350

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedure and times. Measurement conditions Actual Values After Adjusting Standard Value Standard Value H/O mode, High Idle seconds PC200-6 PC220LC-6 ** (PC200LC-6) * Boom Raise Arm In Arm Out Bucket Dump Bucket Curl LH Swing, 5 turns (20.5 - 27.5) RH Swing, 5 turns (20.5 - 27.5) LH Travel, Hi, 5 turns (27.5 - 32.5) LH Travel, Mi, 5 turns (34.0 - 45.0) LH Travel, Lo, 5 turns (46.5 - 62.5) RH Travel, Hi, 5 turns (27.5 - 32.5) RH Travel, Mi, 5 turns (34.0 - 45.0) RH Travel, Lo, 5 turns (46.5 - 62.5)

* Note: See the Shop Manual for the Cycle times on the PC210LC-6. ** Note: See the Shop Manual for the Cycle times on the PC250LC-6.

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the solenoid block. Adjust if necessary. Step 3 Actual value Adjusted Value Standard Value, kg/cm2 Pilot Oil Pressure 31 -35

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4)

Measure the Main Relief and Unload valve pressures using the machine monitor panel codes 11 & 12. Compare with the standard values listed below, and adjust if necessary. Item Measurement conditions Front pump Rear pump Standard value (code 11) (code 12) kg/cm2 Unload Pressure H/O, Hi Idle, Neutral 30 - 50 non-adjustable Boom Up H/O, Hi Idle, Swing Accel ON, 315-335 LS Relief (345-370) Relief then (PMax) RH Main Relief or Safety Arm In H/O, Hi Idle, Swing Accel ON, 315-335 LS Relief (345-370) Relief then (PMax) LH Main Relief or Safety Arm Out H/O, Hi Idle, Swing Accel ON, 315-335 LS Relief (345-370) Relief then (PMax) LH Main Relief or Safety Bucket Dump H/O, Hi Idle, Swing Accel ON, 315-335 LS Relief (345-370) Relief then (PMax) RH Main Relief or Safety Bucket Curl H/O, Hi Idle, Swing Accel ON, 315-335 LS Relief (345-370) Relief then (PMax) RH Main Relief or Safety Swing Left H/O, Hi Idle, Swing Lock, Relief 305 - 330 Swing relief Swing Right H/O, Hi Idle, Swing Lock, Relief 305 - 330 Swing relief Travel Left H/O, Hi Idle, Relief Right 345 - 370 Left Main relief Sub-Unload Travel Safety valve Pressure 50-70 Travel Right H/O, Hi Idle, Relief Left 345 - 370 Right Main relief Sub-Unload Travel Safety valve Pressure 50-70 Adjust the Main Relief valves using the travel, then adjust the LS Relief using the work equipment. It is normal to see a 2-6 kg/cm2 difference between the pressures of the work equipment.

5) LS EPC output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the LS EPC solenoid valve. Attach a 60kg/cm2gauge to the adapter. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item Actual value All levers in neutral Any work eq. lever moved LS EPC current (code 15) 870 - 930 mA 0 - 10 mA LS EPC output pressure 30 kg/cm2 0

6) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the TVC valve are working properly.) Measurement Front Pump Front Pump Conditions Servo Input Main Pressure Neutral Arm Relief Left Track Relief Right Track Unload Unload Relief Pressure Pressure

PC200 to 250-6 Pre-m/c

Rear Pump Servo Input

Unload Pressure

Rear Pump Main Pressure

Unload pressure

Standard Value Servo vs. Main Almost the same Almost the same Servo approximately 1/2of main Servo approximately 1/2of main

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7) Measure the LS Differential pressure using the tracks. Adjust if the Difference between the Load Sense pressure and the Main pressure is outside the standard value while rotating the raised track in Hi travel speed at half stroke. Measurement conditions Actual Value Standard Value H/O, Hi Idle, Neutral, Front Pump 30 - 50 kg/cm2 H/O, Hi Idle, Hi Travel speed, Left Track rotating at half 21 - 23 kg/cm2 stroke, Front Pump H/O, Hi Idle, Neutral, Rear Pump 30 -50 kg/cm2 H/O, Hi Idle, Hi Travel speed, Right Track rotating at half 21 - 23 kg/cm2 stroke, Rear Pump

8) TVC Valve adjustment: You can use engine rpm over relief to determine if the TVC valves are adjusted correctly. If the rpm with the Arm over relief Power Max “ON” is not within the standard value range, adjust the TVC valve on each pump to give you the correct rpm. Use the Travel over relief to inform you if the TVC valve for each pump is adjusted within 20 rpm of the other. Measurement Actual After Standard Standard Standard Standard conditions value Adjustment Value Value Value Value PC200,210 PC200,210 PC220, 250 PC220,250 Komatsu, Cummins, Komatsu, Cummins, rpm rpm rpm rpm Arm Relief, 2100 - 2300 2050 -2250 2200 - 2400 2150 - 2350 H/O+P/Max ** ** ** ** LH Track Must be Must be Must be Must be Relief (Front within 20 within 20 within 20 within 20 pump) rpm of the rpm of the rpm of the rpm of the RH track RH track RH track RH track RH Track Must be Must be Must be Must be Relief (Rear within 20 within 20 within 20 within 20 Pump) rpm of the rpm of the rpm of the rpm of the LH track LH track LH track LH track NOTE: The TVC valves will mask a weak engine, so make certain you check the engine thoroughly prior to adjusting the TVCs. ** You may not be able to adjust the TVC’s to get the engine to the lower end of this range. The lower the engine rpm the faster the machine will be, but it will consume more fuel and run warmer. The optimum setting is the midpoint of the ranges given.

9)

Recheck all cycle times, and note in the table under #2 the new measurements.

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Technician

Date

Customer

Model

Serial

PC200/210/220/270-6 S/N: A83001 & up (“Minor Chg”) TESTING & ADJUSTMENT PROCEDURE v 2.7+ Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC200/210/220/270-6 machines serial number A83001 & higher. Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-10 because skipping one step will affect the measurements in the following steps. ** HINT – “X” OUT UNUSED MODELS! **

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitoring code 10. Comp are these with the specified values. Adjust the engine speed (governor – throttle linkage) if necessary. “Touch” means slight PPC operation to close PPC switch. Actual/ Adjusted Standard Standard Value Standard Value Measurement conditions Value Value PC220/250LC-6 PC270LC-6 PC200LC-6 a. High Idle, H/O mode 1930 - 2070 2130 - 2270 2230 - 2370 b. High Idle, H/O, Traveling 2130 - 2270 2230 - 2370 2330 - 2470 c. High Idle, Active + Touch 2130 - 2270 2230 - 2370 2330 - 2470 d. Low Idle 920 - 1020 920 - 1020 920 - 1020 e. Arm Relief, H/O 1850 - 2050 2050 - 2250 2010 - 2210 f. Arm Relief, H/O + P/Max 1900 - 2100 2000 - 2200 2100 - 2300 g. Arm Relief, H/O+ Active ** 1900 - 2100 2000 - 2200 2100 - 2300 h. RH Track Relief, H/O 1900 - 2100 2000 – 2200 2000 – 2200 i. LH Track Relief, H/O 1900 - 2100 2000 – 2200 2000 – 2200 j. Low Idle @ LH Track Relief PEMC Test PEMC Test PEMC Test ** Prior to 12-99 Active “droop” was 200-300RPM lower than Pmax “droop”. 2) Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Standard Value Standard Value Standard Value H/O mode, High Idle seconds Adjusting PC200LC-6LE PC220LC(250LC)-6 PC270LC-6L Boom Raise 3.6 - 4.4 3.5 - 4.3 3.4 – 4.2 Arm In 3.2 - 4.0 3.4 - 4.2 3.4 - 4.2 Arm Out 2.6 - 3.2 2.8 - 3.4 2.8 - 3.4 Bucket Curl 2.4 - 3.2 2.5 - 3.3 3.1 – 3.9 Bucket Dump 1.8 - 2.4 1.9 - 2.5 2.3 – 2.9 LH Swing, 5 turns 20.5 - 27.5 20.5 - 27.5 24 – 30 RH Swing, 5 turns 20.5 - 27.5 20.5 - 27.5 24 - 30 LH Travel, Hi, 5 turns 27.5 - 32.5 28.5 - 33.5 (34-38) 33 - 37 LH Travel, Mi, 5 turns 34.0 - 45.0 36.0 - 47.0 (42-48) 41.5 – 47.5 LH Travel, Lo, 5 turns 46.5 - 62.5 48.5 - 64.5 (78-88) 67 - 77 RH Travel, Hi, 5 turns 27.5 - 32.5 28.5 - 33.5 (34-38) 33 - 37 RH Travel, Mi, 5 turns 34.0 - 45.0 36.0 - 47.0 (42-48) 41.5 – 47.5 RH Travel, Lo, 5 turns 46.5 - 62.5 48.5 - 64.5 (78-88) 67 - 77

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the LS-EPC solenoid block.

Adjust Self Pressure Reducing Valve if necessary. (High Idle)

Step 3 Pilot Oil Pressure PC200 to 270-6 m/c

Actual value

Adjusted Value

Standard Value, kg/cm2 31 -35 07/06/2001

34

4)

Measure the Main Relief and Unload valve pressures using the machine monitor panel codes 11 & 12. Compare with the standard values listed below, and adjust if necessary. Item Unload Pressure Boom Up Arm In Arm Out Bucket Dump Bucket Curl Swing Left Swing Right Travel Left Travel Right

Measurement conditions H/O, Hi Idle, Neutral Divided H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Relief H/O, Hi Idle, Relief

Front pump (code 11)

Rear pump (code 12)

Unload Pres Unload Pres

standard value kg/cm2 30 – 50 315-335 (345-370) 315-335 (345-370) 315-335 (345-370) 315-335 (345-370) 315-335 (345-370) 305 – 330<275-300> 305 – 330<275-300> 345-370 LH relief 345-370 RH relief

WHEN SETTING THE RELIEF PRESSURE: Set the high pressure setting (345-370) with the track FIRST, then set the low pressure setting (315-335) second. Use the Left track to set the Left Relief valve, and the Right Track to set the right relief valve.

To set the low pressure setting disconnect the 2 Stage Relief Solenoid valve (connector V05), then use the track to measure the low pressure setting. Using this procedure set the relief valve 10 kg/cm2 higher than you want it to be. Example: If you want the arm, boom, & bucket pressure to be 325 kg/cm2. Set low-pressure setting of the relief valve using the track with the 2-stage relief solenoid disconnected to 335 kg/cm2.

5) LS EPC output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the LS EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item Actual value All levers in neutral Any work eq. lever moved LS EPC current (code 15) * 870 - 930 mA 0 - 10 mA LS EPC output pressure ** 30 kg/cm2 0 * Connector corrosion (even slight) can lower current readout even though function is normal. ** FUNCTION TEST = is Mi Tvl normal? Then LS EPC is also!

6) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) Measurement Front Pump Frnt Front Conditions Servo Input LS Pump Main

Rear Pump Servo Input

Rear LS

Rear Pump Main

Neutral Arm Relief Arm Relief + Pmax LH Travel , Hi, half stroke RH Travel, Hi, half stroke

PC200 to 270-6 m/c

Unload Pressure Unload Pressure

Unload pressure

Unload Pressure

07/06/2001

Approx.STD Ratio Servo vs. Main Almost the same Servo 1/2 of main Servo 1/2 of main Servo 1/2 of main Servo 1/2 of main

35

7) LS Differential - TIME Method: Using MEDIUM TRAVEL (Std. 5 turn spec with NO tolerances); H/O; Hi Idle; Active OFF; Raise track, set travel lever at FULL STROKE: PC200 (PC220)[250]<270> Measurement conditions Actual Value After Adjusting Standard Value, Seconds H/O, Hi Idle, Mi Travel speed, Left Track 39.5 (41.5)[45]<44.5> rotating at Full stroke, Front Pump max diff to opposite 0.5 H/O, Hi Idle, Mi Travel speed, Right Track 39.5 (41.5)[45]<44.5> rotating at Full stroke, Rear Pump max diff to opposite 0.5 Adjust LS Valve on each pump separately to achieve NO MORE than ½second difference in Mi TVL cycle time. Each FLA T will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

8) PC EPC output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the PC EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 13 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, arm over relief, Power Max, and measure the oil pressure at the outlet of the valve at this time. The pressure and current should be within the standard values below. Item Actual value Std value PC200LC-6 Std value PC220-270LC-6 PC EPC current (code 13) * 480 - 680 mA 470 - 670 mA PC EPC output pressure 5-10 kg/cm2 5-10 kg/cm2 * Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to determine if the PC valves are adjusted correctly. Test rpm with the Arm over relief Power Max “ON”. If not within the standard value range, adjust the PC valve on each pump to give you the correct rpm over relief using the stalled track (ensures both high relief pressure and divided pumps when travel operated WITHOUT any other function). Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. Measurement Actual value After Standard Value Standard Value Standard Value conditions Adjustment PC200LC-6, rpm PC220/250LC-6, PC270LC-6, rpm rpm Arm Relief, 1900 - 2100* 2000 - 2200* 2100 – 2300* H/O+P/Max LH Track Relief, 1900 - 2100 (within 20 2000 - 2200 2100 – 2300 Hi Travel speed rpm of rear pump) (within 20 rpm of (within 20 rpm of rear (Front pump) rear pump) pump) RH Track Relief 1900 - 2100 (within 20 2000 - 2200 2100 - 2300 Hi Travel speed rpm of front pump) (within 20 rpm of (within 20 rpm of (Rear Pump) front pump) front pump)

•

Note: Adjust the PC valves to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel. PC Valves can “hide” a sick engine! Always ensure the engine care and health is verified prior to making hydraulic system adjustments. Divided pump target RPM’s will need to be about 50 – 100 higher than the merged, 2 pump values. 10) Recheck all cycle times, and note in the table under #2 the new measurements.

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PC200 to 270-6 m/c

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37 CONTROL SIDE VIEW OF THE MAIN HYDRAULIC PUMP

SELF PRESSURE REDUCING VALVE The Self-Pressure Reducing Valve is located on the rear of the main control valve. The outlet hose for the front pump attaches to this valve. To access the Control Pressure Relief valve remove the partition between the engine and the main control valve. As you can see below, the relief valve is located on the bottom of the Self-Pressure Reducing valve. ** PC300 to 450-6 Installation is 90 Degrees Rotated CCW from this!!**

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PC200/210/220/250/270/290/300/350/400/450-6 Main Control Valve

LS Differential - PRESSURE Method: Measure and adjust the LS Differential Pressure using the tracks as outlined in the Shop Manual. Raise one side of the machine, (HO mode, HI travel speed, Full Throttle) and move the travel lever of the raised track Partial - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Repeat this procedure for the opposite track and pump. Measurement conditions Actual Value After Adjusting Standard Value, kg/cm2 H/O, Hi Idle, Neutral, Front Pump 30 - 50 H/O, Hi Idle, Hi Travel speed, Left Track 21 – 23 rotating at half stroke, Front Pump H/O, Hi Idle, Neutral, Rear Pump 30 – 50 H/O, Hi Idle, Hi Travel speed, Right Track 21 – 23 rotating at half stroke, Rear Pump • LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at a steady speed roughly at 50-80% as long as main pressure (codes 11, 12) is kept steady for the most repeatable and reliable reading of MAIN – LS = LS Differential.

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Model

Serial

PC300/400-6LK TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC300 & PC400-6”LK” machines. (Minor Change ) s/n A83001 & up. Always ensure that all Service Codes and Controller Input and Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following ste ps. ** HINT – “X” OUT MODEL NOT BEING USED! **

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitor panel code 10. Compare these with the specified values. Adjust the engine speed if necessary. “Touch” means slight PPC Measurement conditions a. High Idle, H/O mode b. High Idle, H/O (+Touch) c. High Idle, Active (+Touch) d. Low Idle, H/O mode e. Low Idle, H/O mode(+Touch) f. Arm in relief g. Arm in relief & P. max h. Auto-Decel ON i. RH Track Relief, H/O j. LH Track Relief, H/O k. Low Idle @ Track Relief operation to close PPC switch.

2)

Actual RPM

After Adjusting

Standard Value PC300LC-6mc 1900-2000 2000-2100 2100-2200 850-950 N/A 1830-2030 1690-1790 1300-1500 1690 - 1790 1690 - 1790 PEMC Test

Standard Value PC400LC-6LK 2000-2100 2100-2200 2200-2300 610-710 900-1080 1920-2120 1850-2050 1300-1500 1850 - 2050 1850 - 2050 PEMC Test

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Adjusting Standard Value Standard Value H/O mode, High Idle Seconds PC300LC-6mc PC400LC-6LK Boom Raise 3.5 - 4.3 3.8 - 4.6 Arm In 3.5 - 4.3 4.4 - 5.2 Arm Out 3.1 - 3.7 3.5 - 4.3 Bucket Curl 2.9 - 3.5 3.2 - 4.0 Bucket Dump 2.0 - 2.6 2.5 - 3.1 LH Swing, 5 turns 28.5 - 31.5 31.0 - 35.0 RH Swing, 5 turns 28.5 - 31.5 31.0 - 35.0 LH Travel, Hi, 5 turns 30.4 - 37.8 32.8 - 40.2 LH Travel, Mi, 5 turns 37.3 - 45.9 38.0 - 50.0 LH Travel, Lo, 5 turns 44.8 - 56.6 57.0 - 70.0 RH Travel, Hi, 5 turns 30.4 - 37.8 32.8 - 40.2 RH Travel, Mi, 5 turns 37.3 - 45.9 38.0 - 50.0 RH Travel, Lo, 5 turns 44.8 - 56.6 57.0 - 70.0

3)

Measure, record (and re-record, if adjusted) the Pilot pressure, and adjust at the Self Pressure Reducing Valve if necessary. Step 3 Actual value Adjusted Value Standard Value, kg/cm2 Pilot Oil Pressure 31 - 35 PC300 to 400-6 m/c

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4) Measure the Main Relief and Unload valve pressures using the machine mo nitor panel codes 11 & 12. Compare with the standard values listed below, and adjust if necessary. Item

Measurement conditions

Rear pump (code 12)

Unload Pressure

H/O, Hi Idle, Neutral Divided

Boom Up Boom DOWN(Low) Arm In Arm Out Bucket Dump Bucket Curl Swing Left Swing Right Travel Left Travel Right

H/O, Hi Idle, Relief (PMax) Machine “Push-Up” feature H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Relief H/O, Hi Idle, Relief

Front pump (code 11)

Standard Value PC 300LC-6 Kg/cm2 30 - 50 non-adjustable 335-355 (345-365) 175 - 195 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 300 - 325 300 - 325 345-365 LH relief 345-365 RH relief

Unload Pres Unload Pres

Standard Value PC 400LC-6 kg/cm2 30 - 50 non-adjustable 335-355 (345-365) 175 - 195 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 295 – 320 295 – 320 345-365 LH relief 345-365 RH relief

WHEN SETTING THE RELIEF PRESSURE: Stall each track individually and measure the pressure (HO mode, Full Throttle, Swing Lock “OFF.”) This will give you the power max pressure setting with the pumps divided. The left track is using the rear pump and left main relief valve and the right track is using the front pump and right main relief valve. Adjust to 355 +/- 10 kg/cm2 using the track. Verify the settings using the work equipment independently in HO mode, Swing Lock “OFF,” over relief. Readings should be 345 +/- 10 kg/cm2. Note: The PC 300 and PC 400 utilize a single stage relief valve. The higher Power Max setting is simply achieved by sending more flow through the same size relief valve. For this reason, the higher setting should be used to set the relief valves as described above.

5) LS EPC current & output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the LS EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item Actual value All levers in neutral LS EPC current (code 15) 870 - 930 mA LS EPC output pressure 30 kg/cm2 ** FUNCTION TEST = is Mi Tvl normal? Then LS EPC is also!

Any work eq. lever moved 0 - 10 mA 0

6) Measure the TVC valve output pressure (Servo Input Pressure), as outlined in the Testing and Adjusting section of the Shop Manual. Verify that you have 2/5 of main pressure at the servo input with the Arm in over relief, Swing Lock “ON”, and Power Max “ON.” (This verifies that the LS circuit, LS Valve, and the TVC Valve are working properly.) Measurement Conditions Neutral Arm Relief + Pmax RH Travel , Hi, half stroke LH Travel, Hi, half stroke

PC300 to 400-6 m/c

Front Pump Servo Input

Frnt LS

Front Pump Main

Rear Pump Servo Input

Unload Pressure Unload Pressure

Rear LS

Rear Pump Main

Unload pressure

Unload Pressure

Approx. Ratio Servo vs. Main Almost the same Servo 2/5 of main Servo 2/5 of main Servo 2/5 of main

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41 7) LS Differential - TIME Method: Using MEDIUM TRAVEL (Std. 5 turn spec with N O tolerances); H/O; Hi Idle; Active OFF; Raise track, set travel lever at FULL STROKE: [300]<400> Measurement conditions Actual Value After Adjusting Standard Value, Seconds H/O, Hi Idle, Mi Travel speed, Left Track Med [42]<44.5> rotating at Full stroke, Rear Pump max diff to opposite 0.5 H/O, Hi Idle, Mi Travel speed, Right Track Med [42]<44.5> rotating at Full stroke, Front Pump max diff to opposite 0.5 Adjust LS Valve on each pump separately to achieve NO MORE than ½second difference in Mi TVL cycle time. Each FLAT will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

8) TVC Valve adjustment: Measure the TVC valve adjustment using engine RPM. The engine RPM at 2-pump relief and power max is the best judge of how well the TVC’s are loading the engine (Step A below). If the 2-pump/power max relief RPM is not within specifications, use the following procedure to adjust them.

Note: See “EXAMPLE” below Measurement Conditions

Actual Value (engine rpm)

After Adjusting

A) Arm Relief, H/O+ P/Max (2 pumps) B) Arm Relief, H/O, Move Travel pedal slightly (Rear Pump) C) Boom Up Relief, H/O, Move Travel pedal slightly (Front Pump)

Standard Value PC300LC-6mc (rpm) 1690 - 1790

Standard Value PC400LC-6LK (rpm) 1850 - 2050

Within 20 rpm of front pump

Within 20 rpm of front pump

Within 20 rpm of rear pump

Within 20 rpm of rear pump

NOTE: The Pump Merge/Divide valve is not actuated with the Active Mode switch, so you cannot divide the pumps with this switch to set the TVC valves individually. To set the TVC valves individually, check the RPM drop of each by doing Steps B & C above. Adjust each pump to within 20 rpm of each other, and to give you a 2 pump rpm within the Standard Value. Alternate Procedure: A)

Switch the connector (CN-VO5) for the Boom High/Low solenoid with the connector (CN-VO3) for the pump Merge/Divide solenoid. Then you can turn the Boom High/Low switch “ON” to activate the merge/divide valve, and divide the pumps.

B)

Rear Pump: With the pumps divided, Hold the Arm IN over relief and measure the engine rpm.

C)

Front Pump: With the pumps divided, Hold the Boom UP over relief and measure the engine rpm.

EXAMPLE: PC 300LC-6, RPM at 2-pump power max relief 1850. Spec is 1690 - 1790. 8A) Rear pump rpm drop 1870, adjust rear pump TVC to 1830. 8B) Front pump rpm drop 1880, adjust front pump TVC to 1830. RECHECK 2 PUMP / POWER MAX RELIEF, after adjustment it is 1730 (within spec.)

9) Recheck all cycle times, and compare with those recorded in step 1.

PC300 to 400-6 m/c

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Merge / Divide valve

Right Main Relief Adjust to 345 - 365 kg/cm2 using Right track

Right Sub- unload valve non-adjustable

PC300 to 400-6 m/c

Left Main Relief Adjust to 345 - 365 kg/cm2 using Left track

Left Sub-unload valve non-adjustable

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PC300 to 400-6 m/c

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LS Differential – Pressure Method Using the tracks as outlined in the Shop Manual. Raise one side of the machine, (HO mode, HI travel speed, Full Throttle) and move the travel lever of the raised track Half - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Repeat this procedure for the opposite track and pump. Measurement conditions Actual Value After Adjusting Standard Value, kg/cm2 H/O, Hi Idle, Neutral, Front Pump 30 – 50 H/O, Hi Idle, Hi Travel speed, Right Track 24 – 26 rotating at half stroke, Front Pump H/O, Hi Idle, Neutral, Rear Pump 30 – 50 H/O, Hi Idle, Hi Travel speed, Left Track 24 – 26 rotating at half stroke, Rear Pump LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at some steady speed roughly at ½or less as long as main pressure (codes 11, 12) is kept steady for the most repeatable and reliable reading of MAIN – LS = LS Differential.

PC300 to 400-6 m/c

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Technician

Date

Customer

Model

Serial

PC300/400-6 TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC300 & PC400-6 machines. **( Pre-Minor Change ) Always ensure that all Service Codes and Controller Input and Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following steps.

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitor panel code 10. Compare these with the specified values. Adjust the engine speed if necessary. Actual After Standard Value Measurement conditions RPM Adjusting PC300LC-6 a. High Idle, H/O mode 2000 - 2100 b. High Idle, G/O mode 1790 - 1930 c. High Idle, F/O mode 1790 - 1930 d. High Idle, L/O mode 1590 - 1730 e. Low Idle, H/O mode 850 - 950 f. Arm in relief 1830 - 2030 g. Arm in relief & P. max 1690 - 1790 h. Auto-Decel ON 1300 - 1500

Standard Value PC400LC-6 2050 - 2150 1810 - 1990 1810 - 1990 1500 - 1700 650 - 750 1910 - 2060 1940- 2030 1300 - 1400

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Adjusting Standard Value Standard Value H/O mode, High Idle seconds PC300LC-6 * PC400LC-6 * Boom Raise 3.5 - 4.3 3.8 - 4.6 Arm In 3.5 - 4.3 4.4 - 5.2 Arm Out 3.1 - 3.7 3.5 - 4.3 Bucket Curl 2.9 - 3.5 3.4 - 4.2 Bucket Dump 2.0 - 2.6 2.6 - 3.2 LH Swing, 5 turns 28.5 - 31.5 32.0 - 35.4 RH Swing, 5 turns 28.5 - 31.5 32.0 - 35.4 LH Travel, Hi, 5 turns 30.4 - 37.8 32.8 - 40.2 LH Travel, Mi, 5 turns 37.3 - 45.9 39.7 - 49.3 LH Travel, Lo, 5 turns 44.8 - 56.6 56.0 - 69.0 RH Travel, Hi, 5 turns 30.4 - 37.8 32.8 - 40.2 RH Travel, Mi, 5 turns 37.3 - 45.9 39.7 - 49.3 RH Travel, Lo, 5 turns 44.8 - 56.6 56.0 - 69.0 * See the Shop Manual for the cycle times of the PC300HD-6 and PC400HD-6.

3)

Measure, record (and re-record, if adjusted) the Control Pump pressure, and adjust if necessary. Step 3 Pilot Oil Pressure

PC300 to 400-6 PRE - m/c

Actual value

Adjusted Value

Standard Value, kg/cm2 30 - 36

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4) Measure the Main Relief and Unload valve pressures using the machine monitor panel codes 11 & 12. Compare with the standard values listed below, and adjust if necessary. Item

Measurement conditions

Rear pump (code 12)

Unload Pressure

H/O, Hi Idle, Neutral

Boom Up Arm In Arm Out Bucket Dump Bucket Curl Swing Left Swing Right Travel Left Travel Right

H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Relief (PMax) H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Swing Lock, Relief H/O, Hi Idle, Relief H/O, Hi Idle, Relief

Front pump (code 11)

Unload Pres Unload Pres

Standard Value PC 300LC-6 Kg/cm2 30 - 50 non-adjustable 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 300 - 325 300 - 325 345-365 LH relief 345-365 RH relief

Standard Value PC 400LC-6 kg/cm2 30 - 50 non-adjustable 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 335-355 (345-365) 295 - 320 295 - 320 345-365 LH relief 345-365 RH relief

WHEN SETTING THE RELIEF PRESSURE: Stall each track individually and measure the pressure (HO mode, Full Throttle, Swing Lock “OFF.”) This will give you the power max pressure setting with the pumps divided. The left track is using the rear pump and left main relief valve and the right track is using the front pump and right main relief valve. Adjust to 355 +/- 10 kg/cm2 using the track. Verify the settings using the work equipment independently in HO mode, Swing Lock “OFF,” over relief. Readings should be 345 +/- 10 kg/cm2. Note: The PC 300 and PC 400 utilize a single stage relief valve. The higher Power Max setting is simply achieved by sending more flow through the same size relief valve. For this reason, the higher setting should be used to set the relief valves as described above.

5) LS EPC current & output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the LS EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item LS EPC current (code 15) LS EPC output pressure

Actual value

All levers in neutral 870 - 930 mA 30 kg/cm2

Any work eq. lever moved 0 - 10 mA 0

6) Measure the TVC valve output pressure (Servo Input Pressure), as outlined in the Testing and Adjusting section of the Shop Manual. Verify that you have 2/5 of main pressure at the servo input with the Arm in over relief, Swing Lock “ON”, and Power Max “ON.” (This test verifies that the LS circuit, LS Valve, and the TVC Valve are working properly.) Measurement Conditions Neutral Arm Relief Arm Relief + Pmax RH Travel , Hi, half stroke LH Travel, Hi, half stroke

PC300 to 400-6 PRE - m/c

Front Pump Servo Input

Front Pump Main Pressure

Rear Pump Servo Input

Unload Pressure Unload Pressure

Unload Pressure

Rear Pump Main Pressure

Unload pressure

Standard Value Servo vs. Main Almost the same Servo 2/5 of main Servo 2/5 of main Servo 2/5 of main Servo 2/5 of main

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7) Measure and adjust the LS Differential Pressure using the tracks as outlined in the Shop Manual. Raise one side of the machine, (HO mode, HI travel speed, Full Throttle) and move the travel lever of the raised track Half - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Diffe rential pressure to within standard values. Repeat this procedure for the opposite track and pump.

•

Measurement conditions Actual Value After Adjusting Standard Value, kg/cm2 H/O, Hi Idle, Neutral, Front Pump 30 - 50 H/O, Hi Idle, Hi Travel speed, Right Track 24 - 26 rotating at half stroke, Front Pump H/O, Hi Idle, Neutral, Rear Pump 30 - 50 H/O, Hi Idle, Hi Travel speed, Left Track 24 - 26 rotating at half stroke, Rear Pump LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at some steady speed roughly at ½or le ss as long as main pressure (codes 11, 12) is kept steady for the most repeatable and reliable reading of MAIN – LS = LS Differential.

8) TVC Valve adjustment: Measure the TVC valve adjustment using engine RPM. The engine RPM at 2-pump relief and power max is the best judge of how well the TVC’s are loading the engine (Step A below). If the 2-pump/power max relief RPM is not within specifications, use the following procedure to adjust them.

Note: See “EXAMPLE” below Measurement Conditions

Actual Value (engine rpm)

After Adjusting

A) Arm Relief, H/O+ P/Max (2 pumps) B) Arm Relief, H/O, Move Travel pedal slightly (Rear Pump) C) Boom Up Relief, H/O, Move Travel pedal slightly (Front Pump)

Standard Value PC300LC-6 (rpm) 1690 - 1790

Standard Value PC400LC-6 (rpm) 1940 - 2040

Within 20 rpm of front pump

Within 20 rpm of front pump

Within 20 rpm of rear pump

Within 20 rpm of rear pump

NOTE: The Pump Merge/Divide valve is not actuated with the Swing Accel (Priority) switch, so you cannot divide the pumps with this switch to set the TVC valves individually. To set the TVC valves individually, check the RPM drop of each by doing Steps B & C above. Adjust each pump to within 20 rpm of each other, and to give you a 2 pump rpm within the Standard Value. Alternate Procedure: A)

Switch the connector (CN-VO5) for the Boom High/Low solenoid with the connector (CN-VO3) for the pump Merge/Divide solenoid. Then you can turn the Boom High/Low switch “ON” to activate the merge/divide valve, and divide the pumps.

B)

Rear Pump: With the pumps divided, Hold the Arm IN over relief and measure the engine rpm.

C)

Front Pump: With the pumps divided, Hold the Boom UP over relief and measure the engine rpm.

EXAMPLE: PC 300LC-6, RPM at 2-pump power max relief 1850. Spec is 1690 - 1790. 8A) Rear pump rpm drop 1870, adjust rear pump TVC to 1830. 8B) Front pump rpm drop 1880, adjust front pump TVC to 1830. RECHECK 2 PUMP / POWER MAX RELIEF, after adjustment it is 1730 (within spec.)

9) Recheck all cycle times, and comp are with those recorded in step 1. PC300 to 400-6 PRE - m/c

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Merge / Divide valve

Right Main Relief Adjust to 345 - 365 kg/cm2 using Right track

Right Sub- unload valve non-adjustable

PC300 to 400-6 PRE - m/c

Left Main Relief Adjust to 345 - 365 kg/cm2 using Left track

Left Sub-unload valve non-adjustable

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PC300 to 400-6 PRE - m/c

07/06/2001

50

BLANK PAGE

PC300 to 400-6 PRE - m/c

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51

Technician

Date

Customer

Model

Serial

PC600/750/1100-6 TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC600, PC750 & PC1100-6 machines. **( OPEN-CENTER “E-OLSS” Machines! ) Always ensure that all Service Codes and Controller Input and Output signals are normal before continuing with this procedure. See the “Details (Order) of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following steps.

1)

Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitor panel code 10. “Touch” means PPC only open enough to close pressure switches, but NOT move the machine. Compare these with the specified values. Adjust the engine speed if necessary. SM = Shop Manual spec (SVT) ** Actual After Standard Standard Standard Measurement conditions RPM Adjusting Value Value Value PC600LC-6 PC750LC-6 PC1100LC-6 a. High Idle, DH mode+touch 1850-1950 SM 1950-2050 b. High Idle, H mode+touch 1750-1850 SM 1940-2040 approx c. High Idle, G mode+touch 1550-1650 SM 1850-1950 approx e. Low Idle 750-850 SM 705 - 755 f. Boom UP relief 1700-1900 SM 1750 - 1950 g. Boom UP relief & Hvy Lift 1650-1850 SM 1700 - 1900 h. Auto-Decel OFF;Hi Idle; NO 1720-1750 Touch i. Auto-Decel ON 1300-1500 SM 1200 - 1400 ** PC1100-6 Engine speeds are NON-Adjustable, at present (5/99).

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement Actual After Standard Value Standard Value Standard Value conditions Values Adjusting PC600LC-6 PC750LC-6 PC1100LC-6 H/O mode, High Idle Seconds seconds Boom Raise 4.4 - 5.4 SM 5.5 – 6.9 Arm In 4.8 – 5.8 SM 4.5 – 5.5 Arm Out 3.5 – 4.3 SM 3.6 – 4.4 Bucket Curl 2.8 – 3.6 SM 2.9 – 3.7 Bucket Dump 3.1 – 3.9 SM 2.7 – 3.5 LH Swing, 5 turns 34-38 SM 49.4 – 54.6 RH Swing, 5 turns 34-38 SM 49.4 – 54.6 LH Travel, Hi, 5 turns 35-43 SM 65 – 80 LH Travel, Lo, 5 turns 54-66 SM 95 – 117 RH Travel, Hi, 5 turns 35-43 SM 65 – 80 RH Travel, Lo, 5 turns 54-66 SM 95 - 117 * SM = See the Shop Manual for the cycle times of the PC750-6.

3)

Measure, record (and re-record, if adjusted) the (Control Pump) PILOT pressure, and adjust if necessary. Step 3 Actual value Adjusted Value Standard Value, kg/cm2 Pilot Oil Pressure 32.0 – 35.5

PC600 / 750 / 1100-6 E-OLSS

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4) Measure the Main Relief valve pressures. Compare with the standard values listed below, and adjust if necessary. High Idle, DH Mode with Swing Lock OFF. Push-Up Switch “OFF” (2Stg Safety) Item

Measurement conditions

Rlf DropPress Boom UP Boom Up Boom Up Boom Down

Front/R4 Right 4

Rear/L5 Left 5

#3 / S4 Swing 4

NO ADJ

NO ADJ

NO ADJ

Lo Idle, Relief NO Hvy Lft Hi Idle, Relief NO Hvy Lft Hi Idle, Relief + Hvy Lift = High Hi Idle, Relief = Low Lo Idle Relief “Push-Up=LOW”

Standard Value

PC 600LC6

Standard Value [PC750]/ 1100LC -6 Kg/cm2

Kg/cm2 295 315 340-365 315-340 175-215

N/A

300 320 340 320 [150] 170-210

WHEN SETTING THE RELIEF PRESSURE: Relieve and measure the pressure (DH mode, Full Throttle, Swing Lock “OFF.”) Heavy Lift ON will give you the HIGH RELIEF for each valve and pump group. Then, set the LOW RELIEF with Heavy LIFT turned OFF. Always do HIGH first.

5) Measure the TVC Out (“Pe”) pressures. Compare with the standard value, and adjust if necessary. Configure machine at DH Mode; Hi Idle, Swing Lock “OFF” Item

Actual

Adjusted

Standard Value PC 600LC-6 Kg/cm2 21-25 12.5 – 16.5 10.5 – 14.5

Neutral Boom Up Relief BmUp Rlf+HvyLift

Standard Value PC 750LC-6 Kg/cm2

Standard Value PC 1100LC -6 kg/cm2 20-26 9.5 – 13.5 20.0 – 26.0

6) Test and Adjust ALL “CO VALVES” (Front & Rear Pumps – Remember on PC1100 #3 pump, the CO Valve is there, but is non-adjustable.) G Mode, Swing Lock OFF, High Idle Item

FRONT Pair REAR Pair

Measurement conditions

CO fully engaged CO fully engaged

Front/R4 Right 4

Rear/L5 Left 5

#3 / S4 Swing 4

Standard Value PC 600LC-6 Kg/cm2

Standard Value [PC750]PC 1100LC-6 kg/cm2

N/A

N/A N/A

310 310

310 310

N/A

7) Test and Adjust NC OUT pressures, DH Mode, HIGH Idle, Swing Lock OFF Item

Pump #3 FRONT Pair REAR Pair

Measurement conditions

Swing, NO Load RIGHT TRACK – No load LEFT TRACK – No Load

Front/R4 Right 4

Rear/L5 Left 5

N/A

N/A N/A

#3 / S4 Swing 4

Standard Value PC 600LC-6 Kg/cm2

N/A N/A

MIN 18 MIN 18

N/A

Standard Value [PC750]/1100LC-6 kg/cm2 [N/A] MIN 17 MIN 17 MIN 17

8) Measure & Adjust NC/CO OUT (“Pecn”) pressures in neutral. Compare with the standard value, and adjust (at the proper Jet Sensor Relief) if necessary. Configure machine at Hi Idle, Swing Lock “OFF”, all controls in NEUTRAL=Maximum; TRAVEL(P3 Swi ng on PC1100) NoLoad=Minimum Item FRONT pair àR4 (neutral) (Travel-NO Load) REAR pair àL5 (neutral) (Travel – NO Load) PUMPS #3 àS4 (neutral) (Swing – NO load)

Actual

Adjusted

Standard Value PC 600LC-6 Kg/cm2 4.0 – 5.5 MAX 18 MIN 4.0 – 5.5 MAX 18 MIN N/A

Standard Value PC 750LC-6 Kg/cm2

N/A

Standard Value PC 1100LC -6 kg/cm2 2.6-4.1 MAX 17 MIN 2.6-4.1 MAX 17 MIN 6.9 – 8.4MAX 17 MIN

9) Recheck ALL CYCLE TIMES. Re-Adjust as needed, record results. PC600 / 750 / 1100-6 E-OLSS

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TimberJack

Date

Customer

Technician

Model

Serial

635 / 735 SHOVEL LOGGER TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting. ** Minor Change Machines!!** Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-10 because skipping one step will affect the measurements in the following steps. ** Helpful HINT – LINE THROUGH MODEL(s) NOT BEING USED!!

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitoring code 10. Compare these with the specified values. Adjust the engine speed (governor – throttle linkage) if necessary. “Touch” means slight PPC operation to close PPC switch – NOT move it.

Measurement conditions a. High Idle, H/O mode b. High Idle, H/O, Traveling B+ High Idle, Active + Touch c. Low Idle d. Boom Relief, H/O e. Boom Relief, H/O + P/Max f. Boom Relief, H/O+ Active * g. RH Track Relief, H/O h. LH Track Relief, H/O * 1999 machines may revert to

Actual/ Adjusted Value

Standard Value 635 1930 - 2070 2130 - 2270 2130 - 2270 920 - 1020 1850 - 2050 1900 - 2100 1650 – 1850 1900 – 2100 1900 – 2100

Standard Value 735 2130 - 2270 2230 - 2370 2230 - 2370 920 - 1020 2050 - 2250 2000 - 2200 1940 – 2140 2000 – 2200 2000 – 2200

Line “e” RPM’s.

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Standard Value Standard Value Standard Value H/O mode, High Idle seconds Adjusting 635 735 PC270-6 (835) Boom Raise 6.91 7.2 3.4 – 4.2 Stick In 2.24 2.5 3.4 - 4.2 Stick Out 4.50 4.1 2.8 - 3.4 Heel OUT 3.37 3.1 3.1 – 3.9 Heel IN 2.77 2.8 2.3 – 2.9 Grapple OPEN 2.03 3.5 Grapple CLOSE 1.76 2.9 LH Swing, 5 turns 25.6(20.5 - 27.5) 25.6(20.5 - 27.5) 24 – 30 RH Swing, 5 turns 25.6(20.5 - 27.5) 25.6(20.5 - 27.5) 24 - 30 LH Travel, Hi, 5 turns 32.4(27.5 - 32.5) 42 33 - 37 LH Travel, Mi, 5 turns 42.1(34.0 - 45.0) 54 41.5 – 47.5 LH Travel, Lo, 5 turns 55.0(46.5 - 62.5) 78 67 - 77 RH Travel, Hi, 5 turns 32.4(27.5 - 32.5) 42 33 - 37 RH Travel, Mi, 5 turns 42.1(34.0 - 45.0) 54 41.5 – 47.5 RH Travel, Lo, 5 turns 55.0(46.5 - 62.5) 78 67 - 77

TJ 635 / 735 / 835 Shovel Loggers

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3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the solenoid block. Adjust if necessary. Step 3 Actual value Adjusted Value Standard Value, kg/cm2 Pilot Oil Pressure 31 -35

4)

Measure the Main Relief and Unload valve pressures using the machine monitor panel codes 11 & 12. Compare with the standard values listed below, and adjust if necessary. Item Measurement conditions Front pump Rear pump Standard value (code 11) (code 12) kg/cm2 Unload Pressure H/O, Hi Idle, Neutral 30 - 50 non-adjustable Boom Up H/O, Hi Idle, Relief then (PMax) 315-335 LS Relief (345-370) RH Main Relief or Safety Stick In H/O, Hi Idle, Relief then (PMax) 272-292 Port Relief Stick Out H/O, Hi Idle, Relief then (PMax) 272-292 Port Relief Heel Out H/O, Hi Idle, Relief then (PMax) 272-292 Port Relief Heel In H/O, Hi Idle, Relief then (PMax) 345 LO IDLE Port Relief Grapple Close H/O, Hi Idle, Relief 165-185 Port Relief Grapple Open H/O, Hi Idle, Relief 165-185 Port Relief Grapple Rotate Left H/O, Hi Idle, Relief 75-95 Port Relief Grapple Rotate Right H/O, Hi Idle, Relief 75-95 Port Relief Swing Left H/O, Hi Idle, Swing Lock, Relief 305 - 330 Swing relief Swing Right H/O, Hi Idle, Swing Lock, Relief 305 - 330 Swing relief Travel Left H/O, Hi Idle, Relief Right 345 - 370 Left Main relief Sub-Unload Travel Safety valve Pressure 50-70 Travel Right H/O, Hi Idle, Relief Left 345 - 370 Right Main relief Sub-Unload Travel Safety valve Pressure 50-70 WHEN SETTING THE RELIEF PRESSURE: Set the high pressure setting (345-370) with the track FIRST, then set the low pressure setting (315-335) second. Use the Left track to set the Left Relief valve, and the Right Track to set the right relief valve. To set the low pressure setting disconnect the 2 Stage Relief Solenoid valve (connector V05), then use the track to measure the low pressure setting. Using this procedure set the relief valve 10 kg/cm2 higher than you want it to be. Example: If you want the arm, boom, & bucket pressure to be 325 kg/cm2. Set low-pressure setting of the relief valve using the track with the 2-stage relief solenoid disconnected to 335 kg/cm2.

5) LS EPC output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the LS EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 15 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, and measure the oil pressure at the outlet of the valve at neutral and while moving a work equipment lever. The pressure and current should be within the standard values below. Item Actual value All levers in neutral Any work eq. lever moved LS EPC current (code 15) * 870 - 930 mA 0 - 10 mA LS EPC output pressure ** 30 kg/cm2 0 * Connector corrosion (even slight) can lower current readout even though function is normal. ** FUNCTION TEST = is Mi Tvl normal? Then LS EPC is also!

TJ 635 / 735 / 835 Shovel Loggers

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6) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) Measurement Front Pump Front Pump Rear Pump Conditions Servo Input Main Servo Input Neutral Arm Relief Arm Relief + Pmax LH Travel , Hi, half Unload stroke Pressure RH Travel, Hi, half Unload Unload stroke Pressure Pressure

Rear Pump Main

Unload pressure

Approx.STD Ratio Servo vs. Main Almost the same Servo 1/2 of main Servo 1/2 of main Servo 1/2 of main Servo 1/2 of main

7) LS Differential - TIME Method: Using MEDIUM TRAVEL (Std. 5 turn spec with NO tolerances); H/O; Hi Idle; Active OFF; Raise track, set travel lever at FULL STROKE: 635 <735> Measurement conditions Actual Value After Adjusting Standard Value, Seconds H/O, Hi Idle, Mi Travel speed, Left Track 42 <54> rotating at Full stroke, Front Pump max diff to opposite 0.5 H/O, Hi Idle, Mi Travel speed, Right Track 42 <54> rotating at Full stroke, Rear Pump max diff to opposite 0.5 Adjust LS Valve on each pump separately to achieve NO MORE than ½second difference in Mi TVL cycle time. Each FLAT will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

8) PC EPC output pressure: Connect the adapter P/N 790-261-1311 to the outlet hose from the PC EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Bring up monitoring code 13 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, H/O mode, High Idle, Auto Decel “OFF”, arm over relief, Power Max, and measure the oil pressure at the outlet of the valve at this time. The pressure and current should be within the standard values below. Item Actual value Std value PC200LC-6 Std value PC220-270LC-6 PC EPC current (code 13) * 480 - 680 mA 470 - 670 mA PC EPC output pressure 5-10 kg/cm2 5-10 kg/cm2 * Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to determine if the PC valves are adjusted correctly. Test rpm with the Arm over relief Power Max “ON”. If not within the standard value range, adjust the PC valve on each pump to give you the correct rpm over relief using the stalled track (ensures both high relief pressure and divided pumps when travel operated WITHOUT any other function). Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. Measurement Actual value After Standard Value 635, Standard Value 735, conditions Adjustment rpm rpm Boom Relief, 1900 - 2100* 2000 - 2200* H/O+P/Max LH Track Relief, 1900 - 2100 2000 - 2200 (Front pump) (within 20 rpm of rear (within 20 rpm of rear pump) pump) RH Track Relief 1900 - 2100 2000 - 2200 (Rear Pump) (within 20 rpm of front (within 20 rpm of front pump) pump) • Note: Adjust the PC valves to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel. PC Valves can “hide” a sick engine! Always ensure the engine care and health is verified prior to making hydraulic system adjustments. Divided pump target RPM’s will need to be about 50 – 100 higher than the merged, 2 pump values. 10) Recheck all cycle times, and note in the table under #2 the new measurements.

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TJ 635 / 735 / 835 Shovel Loggers

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SELF PRESSURE REDUCING VALVE The Self-Pressure Reducing Valve is located on the rear of the main control valve. The outlet hose for the front pump attaches to this valve. To access the Control Pressure Relief valve remove the partition between the engine and the main control valve. As you can see below, the relief valve is located on the bottom of the Self-Pressure Reducing valve.

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635SL / 735SL / 835SL Main Control Valve

LS Differential - PRESSURE Method: Measure and adjust the LS Differential Pressure using the tracks as outlined in the Shop Manual. Raise one side of the machine, (HO mode, HI travel speed, Full Throttle) and move the travel lever of the raised track Partial - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Repeat this procedure for the opposite track and pump. Measurement conditions Actual Value After Adjusting “CALCULATED” Standard Value, kg/cm2 H/O, Hi Idle, Neutral, Front Pump 30 - 50 H/O, Hi Idle, Hi Travel speed, Left Track 21 – 23 rotating at half stroke, Front Pump H/O, Hi Idle, Neutral, Rear Pump 30 – 50 H/O, Hi Idle, Hi Travel speed, Right Track 21 – 23 rotating at half stroke, Rear Pump * LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at a steady speed roughly at 50-80% as long as main pressure (codes 11, 12) is kept steady for the most repeatable and reliable reading of MAIN – LS = LS Differential.

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Technician

Date

Customer

Model

Serial

PC200Z-6LE S/N: A83001 & up (“Minor Chg “Z” or “Custom”) TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC200”Z” 6LE machines serial number A83001 & higher. Always ensure that any known abnormalities are resolved and are normal before continuing with this procedure. See the “Points to Remember when Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions. Follow this procedure in order from 1-9 because skipping one step will affect the measurements in the following steps. Special note at Steps 4 & 6 to DIVIDE PUMPS!! Please read and understand.

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds. Compare these with the specified values. Adjust the engine speed if necessary. See page 20-18 in the Testing and Adjusting section of the Shop Manual for directions on how to connect a tachometer, required for Step 8 also. Actual Value After Standard Value Measurement conditions Adjusting PC200LC-6LE a. High Idle 2130 - 2270 b. Low Idle 920 - 1020

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement Actual Values After Adjusting Standard Value conditions: seconds PC200Z-6LE High Idle Boom Raise 3.6 - 4.4 Arm In 3.2 - 4.0 Arm Out 2.6 - 3.2 Bucket Curl 2.4 - 3.2 Bucket Dump 1.8 - 2.4 LH Swing, 5 turns 20.5 - 27.5 RH Swing, 5 turns 20.5 - 27.5 LH Travel, 5 turns 35.5 - 45.5 RH Travel, 5 turns 35.5 - 45.5

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the EPC valve block. Adjust if necessary. Step 3 Pilot Oil Pressure

PC200’Z’-6 ‘Custom’

Actual value

Adjusted Value

Standard Value, kg/cm2 31 -35

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4) Measure the Main Relief and Unload valve pressures using a 400 kg/cm2 gauge connected to the test ports on top of the main pump assembly. Compare with the standard values listed below, and adjust if necessary. Dividing PUMPS is recommended if possible, using divider drain hose connected to a pilot oil source temporarily only!! (See also Step 6 note***) Item

Unload Pressure Boom Up Arm In Arm Out Bucket Dump Bucket Curl Swing Left Swing Right Travel Left Travel Right

Measurement conditions

Front pump

Rear pump

Hi Idle, Neutral Hi Idle, Relief Hi Idle, Relief Hi Idle, Relief Hi Idle, Relief

Unload Pres

Hi Idle, Relief Hi Idle, Swing Lock, Relief Hi Idle, Swing Lock, Relief Hi Idle, Relief

Unload Pres

Hi Idle, Relief

Unload Pres

Unload Pres Unload Pres Unload Pres

Unload Pres Unload Pres Unload Pres

Standard value kg/cm2 30 - 50 315-335 315-335 315-335 315-335 315-335 285 - 310 285 - 310 315-335 LH relief 315-335 RH relief

WHEN SETTING THE RELIEF PRESSURE: Set the pressure setting (315-335) with the track while pumps are “Divided” see step above and at Step 6! Use the Left track to set the Left Relief valve, and the Right Track to set the right relief valve. Note: Travel is only ONE SPEED and only at LOW Relief pressures (CMO”Z”).

5) Measure the (Servo Input Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) Measurement Conditions

Front Pump Servo Input

Front Pump Main Pressure

Rear Pump Servo Input

Rear Pump Main Pressure

Neutral Arm Relief LH Travel half stroke RH Travel half stroke

Unload Pressure Unload Pressure

Unload Pressure

Unload pressure

Standard Value Servo vs. Main Almost the same Servo 1/2 of main Servo 1/2 of main Servo 1/ 2 of main

6) Measure the LS Differential pressure using the tracks and with the pump flow manually divided(***). Adjust if the Difference between the Load Sense pressure and the Main pressure is outside the standard value while rotating the raised track in Hi travel speed at half stroke. Attempt to “hold” a steady main pressure such as 85 to 100 kg/cm2. ( Main – LS ) Kg / CM2 Measurement conditions Actual Value Standard Value Hi Idle, Neutral, Front Pump 20 - 40 Hi Idle, Left Track rotating at half stroke, Front Pump 21 - 23 Hi Idle, Neutral, Rear Pump 20 - 40 Hi Idle, Right Track rotating at half stroke, Rear Pump 21 - 23

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6…(***) To manually divide the pump flow, disconnect the merge divide valve supply/drain line from the main oil drain for the solenoid block located on the bottom of the solenoid block under the main control valve. The lines can be connected with regular (600 kg/cm2) quick couplings, if desired. Then connect the merge divide valve supply/drain line to the output line of the swing lock solenoid. This is located on the front of the solenoid block and can also accomplished with quick couplings. The next step is to energize the swing lock solenoid, this means moving the swing lock switch to the OFF position. Return Divider signal line to DRAIN for NORMAL operations (ALLWAYS MERGED).

7) PC EPC current and output pressure: Measure the current between pins 7 & 13 of connector C01 using the harness checker or DMM. The current to the PC-EPC should be within the standard values below. Connect the adapter P/N 790-261-1311 to the outlet hose from the PC EPC solenoid valve. Attach a 60kg/cm2 gauge to the adapter. Start the engine, High Idle, arm over relief and measure the oil pressure at the outlet of the valve at this time. The pressure should be within the standard values below. Item PC EPC input current PC EPC output pressure

Actual value

Std value PC200”Z”-6LE 240 - 400 mA 5-10 kg/cm2

8) PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You can use engine rpm over relief to determine if the PC valves are adjusted correctly. If the rpm with the Arm over relief is not within the standard value range, adjust the PC valve on each pump (DIVIDED!) to give you the correct rpm. Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. Measurement conditions Arm Relief

Actual value

After Adjustment

Standard Value PC200”Z”-6LE RPM 1900 – 2100*

LH Track 1900 - 2100 (within 20 rpm of rear Relief (Front pump) pump) RH Track 1900 - 2100 (within 20 rpm of Relief front pump) (Rear Pump) Note: Adjust the PC valves to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel.

9)

Recheck all cycle times, and note in the table under #2 the new measurements.

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PC200’Z’-6 ‘Custom’

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SELF PRESSURE REDUCING VALVE The Self-Pressure Reducing Valve is located on the rear of the main control valve. The outlet hose for the front pump attaches to this valve. To access the Control Pressure Relief valve remove the partition between the engine and the main control valve. As you can see below, the relief valve is located on the bottom of the Self-Pressure Reducing valve.

PC200/210/220/250-6 Main Control Valve PC200’Z’-6 ‘Custom’

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PC200’Z’-6 ‘Custom’

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