PC300/400-7 Pm Tune Up Sheet & FST Exercise

PC400-7

Spectune400_300_7.doc 12/17/2003
 BLANK PAGE

Spectune400_300_7.doc 12/17/2003
 MODEL SERIAL No. PUMP TQ. CODE ( = 224 ?)

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine
monitoring code (01002) 010. Compare these with the specified values. Adjust the engine speed (governor – throttle
linkage) if necessary. “Touch” means slight PPC operation to close PPC switch only.
“X” out Std. “NOT” “ X” ? “X“?
Value in use
Actual/ Adjusted Standard Value Standard Value
Measurement conditions Value PC300-7 PC400-7’ref’
a. High Idle, E mode + touch 1800 n/p
b. High Idle, A, Travel Touch 2090 - 2230 n/p
c. High Idle, A mode + Touch 2090 - 2230 1880 - 1980
d. Low Idle 850 - 925 975 - 1025
e. Arm Relief, A 1880 - 2080 1830 - 2030
f. Arm Relief, A + P/Max 1840 - 1880 1730 - 1930
g. AUTO DECEL Hi Idle 1300 - 1500 1200 - 1400
h. RH Track Relief, A 1770 - 1970 1730 - 1930
i. LH Track Relief, A 1770 - 1970 1730 - 1930
j. Low Idle @ LH Track Relief PEMC Test PEMC Test

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
A mode, High Idle seconds Adjusting PC300LC-7 PC400LC-7
Boom Raise 3.3 – 4.1 3.6 – 4.4
Arm In 3.4 – 4.2 3.9 – 4.7
Arm Out 2.6 – 3.2 3.2 – 4.0
Bucket Curl 2.9 – 3.5 3.2 – 4.0
Bucket Dump 2.0 – 2.6 2.6 – 3.2
LH Swing, 5 turns 28.7 – 34.5 30 - 36
RH Swing, 5 turns 28.7 – 34.5 30 - 36
LH Travel, Hi, 5 turns 32.0 – 36.0 33 - 40
LH Travel, Mi, 5 turns 35.5 – 47.5 41 - 55
LH Travel, Lo, 5 turns 46.5 – 69.5 54 - 80
RH Travel, Hi, 5 turns 32.0 – 36.0 33 - 40
RH Travel, Mi, 5 turns 35.5 – 47.5 41 - 55
RH Travel, Lo, 5 turns 46.5 – 69.5 54 - 80

3) Measure, record (and re-record, if adjusted) the Pilot Oil pressure. PPC TEST port; PPC ADJUST.
Adjust Self Pressure Reducing Valve if necessary. (High Idle) (PC400LC-7 shows PPC <bucket=07300 on Monitor)
Step 3 Actual value Adjusted Value Standard Value, kg/cm2
Pilot Oil Pressure 31 -35

PPC Test

PPC Adj

Spectune400_300_7.doc 12/17/2003
 Adjustment Section ~ be certain Pump TQ = 224
4) Measure the Main Unload, Safety & Relief valve pressures using the machine monitor panel codes (01100)011 &
012(01101). Compare with the standard values listed below, and adjust if necessary. “Balance” mains +/- 1.0 Kg/cm2.

Item Measurement conditions Front pump Rear pump standard value

(code 011) (code 012) kg/cm2
<01100> <01101> PC300<400>7
Unload Pressure A, Hi Idle, Neutral Also divided! 30 – 50 <32-52>
Boom Up A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Arm In A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Arm Out A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Bucket Dump A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Bucket Curl A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Swing Left A, Hi Idle, Swing Lock Safety V. 290 - 330
Swing Right A, Hi Idle, Swing Lock Safety V. 290 - 330
Travel Left A, Hi Idle, Relief Unload Pres 380 - 400 LH relief
Travel Right A, Hi Idle, Relief Unload Pres 380 – 400 RH relief

WHEN SETTING THE RELIEF PRESSURE: Set the high pressure setting (380 - 400) with the track.
Use the Left track to set the (3) TOP Relief valve, and the Right Track to set the (4) BOTTOM relief valve.

2Nut Main Relief 1 LS Valve

2

6mm

22mm

Spectune400_300_7.doc 12/17/2003
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<01500> 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 Rear Pump Rear Pump Approx.STD Ratio
Conditions Servo Input Main Servo Input Main Servo vs. Main
Neutral Almost the same
Arm Relief Servo 3/5 of main
Arm Relief + Pmax Servo 3/5 of main
LH Travel , Hi, half Unload Unload Servo 3/5 of main
stroke - SPINNING Pressure pressure
RH Travel, Hi, half Unload Unload Servo 3/5 of main
stroke - SPINNING Pressure Pressure

F. Servo-In
R. Servo - In

Spectune400_300_7.doc 12/17/2003
 3

PPC Test

PPC Adj

4
LS V.
PC Valve

4mm

13mm

7) LS Differential - TIME Method: ‘A’ M ode; Mi 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
PC300LC-7 <PC400LC-7>
A MODE, Hi Idle, Mi Travel speed, Right 41.5 < 48.1>
Track rotating at Full PPC stroke, Rear pump +/- 0.5 SEC
A MODE, Hi Idle, Mi Travel speed, Left 41.5 < 48.1>
Track rotating at Full PPC stroke, Front Pump +/- 0.5 SEC
Adjust LS Valve on each pump separately to achieve NO MORE than ½ second 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

Spectune400_300_7.doc 12/17/2003
 8) PC EPC command current & function:. Bring up monitoring code 13 <01300> 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 current. NO ADJUSTMENT HERE. Pressure was checked @ STEP 4.8
• 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 (2 pump load) 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. ( Numbers in GREY are
for SEQUENCE to follow)
Measurement Actual value After Adjustment Standard Value Standard Value
conditions PC300-7, rpm PC400-7, rpm
Arm Relief,
“A”+P/Max
11 66 1840 – 1880 1730 - 1930

LH Track Relief,
Hi Travel speed
22 55 1770 - 1970 (within 20 (+/- 20 rpm rear pump)
rpm of rear pump)
(Front pump)
RH Track Relief
Hi Travel speed
33 44 1770 - 1970 (within 20 (+/- 20 rpm front pump)
rpm of front pump)
(Rear Pump)
BOOST Pressure No Code on PC300 <Min 107kPa>
<code 36500> <Min 800 mm Hg>
* 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.
10) Recheck Boom Raise and Arm out to determine results in oil flow (Hyd HP).

PC-7 MAIN PUMP CONTROLS SIDE (200 shown)

• *** SAME TOOLING for NEW PC200/ ~ /400-7

6 – 13mm PC locknuts 7 – 4mm hex PC Valve Adjust Screws

8 - LS Valve(s) 22mm locknut, 6mm hex LS Adjust Screw

Spectune400_300_7.doc 12/17/2003
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.
<PC400-7 only>
Measurement conditions Actual Value After Adjusting Standard Value, kg/cm2
A, Hi Idle, Neutral, Front Pump 30-50 <32 – 52>
A, Hi Idle, Hi Travel speed, Right Track 24-26 <26 - 28>
rotating at half stroke, Rear Pump
A, Hi Idle, Neutral, Rear Pump 30-50 <32 – 52>
A, Hi Idle, Hi Travel speed, Left Track 24-26 <26 - 28>
rotating at half stroke, Front 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 011,012) <01100/01101> is kept steady for the most repeatable and reliable reading of
• MAIN – LS = LS Differential.

REFERENCE to PUMP TORQUE ADJ on Multi-Monitor Only.

Spectune400_300_7.doc 12/17/2003
 (PC220, 220, 270LC-7)

PC220-7 PC270-7

SPEC200/220/270-7.DOC 6/18/2003
 MODEL SERIAL No. PUMP TQ. CODE ( = 224 ?)

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the
machine monitoring code 010. Compare these with the specified values. Adjust the engine speed
(governor – throttle linkage) if necessary. “Touch” means slight PPC operation to close PPC switch only.
“X” out Std. Value “NOT” in use “ X” ? “X“?

Actual/ Adjusted Standard Value Standard Value Standard Value

Measurement conditions Value PC200-7 PC220-7 PC270-7
a. High Idle, E mode + touch 1800 1800 1850
b. High Idle, A, Travel Touch 2080 - 2220 2080 - 2220 2180 - 2320
c. High Idle, A mode + Touch 2080 - 2220 2080 - 2220 2180 - 2320
d. Low Idle 980 - 1080 980 - 1080 950 - 1050
e. Arm Relief, A 1900 - 2100 1900 - 2100 2000 - 2200
f. Arm Relief, A + P/Max 1800 - 2000 1800 - 2000 1900 - 2100
g. AUTO DECEL Hi Idle 1300 - 1500 1300 - 1500 1300 - 1500
h. RH Track Relief, A ?1900 - 2100 ?1900 - 2100 1900 - 2100
i. LH Track Relief, A ?1900 - 2100 ?1900 - 2100 1900 - 2100
j. Low Idle @ LH Track Relief PEMC Test PEMC Test PEMC Test

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
A mode, High Idle seconds Adjusting PC200-7 PC220-7 PC270-7
Boom Raise 3.4 – 4.2 3.1 - 3.9 3.5 - 4.3
Arm In 3.2 – 3.8 3.4 - 4.2 2.9 - 3.5
Arm Out 2.5 – 3.1 2.7 - 3.3 3.6 - 4.4
Bucket Curl 2.3 – 2.9 2.6 - 3.2 2.1 - 2.5
Bucket Dump 1.7 – 2.3 1.9 - 2.5 2.7 - 3.3
LH Swing, 5 turns 25.6 – 30.9 23.3 - 28.5 25.6 - 31.6
RH Swing, 5 turns 25.6 – 30.9 23.3 - 28.5 25.6 - 31.6
LH Travel, Hi, 5 turns 29.4 – 32.9 28.9 - 31.9 27.2 - 37.2
LH Travel, Mi, 5 turns 36.7 - 44.9 38.6 - 47.2 35.5 - 55.5
LH Travel, Lo, 5 turns 50.8 – 62.1 52.8 - 64.6 52.2 - 72.2
RH Travel, Hi, 5 turns 29.4 – 32.9 28.9 - 31.9 27.2 - 37.2
RH Travel, Mi, 5 turns 36.7 - 44.9 38.6 - 47.2 35.5 - 55.5
RH Travel, Lo, 5 turns 50.8 – 62.1 52.8 - 64.6 52.2 - 72.2

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 Actual value Adjusted Value Standard Value, kg/cm2
Pilot Oil Pressure 31 -35

SPEC200/220/270-7.DOC 6/18/2003
4) Measure the Main Unload, Safety & Relief valve pressures using the machine monitor panel codes 011 &
012. Compare with the standard values listed below, and adjust if necessary. “Balance” mains +/- 1.0
Kg/cm2.

Item Measurement conditions Front pump Rear pump standard value

(code 11) (code 12) kg/cm2 PC200-270-7
Unload Pressure A, Hi Idle, Neutral Also divided! 30 – 50
Boom Up A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Arm In A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Arm Out A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Bucket Dump A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Bucket Curl A, Hi Idle, Safety V. (PMax) 345 - 365 (370 - 390)
Swing Left A, Hi Idle, Swing Lock Safety V. 313 – 316
Swing Right A, Hi Idle, Swing Lock Safety V. 313 – 316
Travel Left A, Hi Idle, Relief Unload Pres 380 - 400 LH relief
Travel Right A, Hi Idle, Relief Unload Pres 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. **New PC-7 may have ‘single’ adjustment only!**

To set the low pressure setting disconnect the 2 Stage Relief Solenoid valve (connector V06), 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.

SPEC200/220/270-7.DOC 6/18/2003
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 Rear Pump Rear Pump Approx.STD Ratio
Conditions Servo Input Main Servo Input Main Servo vs. Main
Neutral Almost the same
Arm Relief Servo 3/5 of main
Arm Relief + Pmax Servo 3/5 of main
RH Travel , Hi, half Unload Unload Servo 3/5 of main
stroke - SPINNING Pressure pressure
LH Travel, Hi, half Unload Unload Servo 3/5 of main
stroke - SPINNING Pressure Pressure

PC-EPC
pressure
LS-EPC
pressure

3 – FRONT pump Servo In 4 – REAR pump Servo In

SPEC200/220/270-7.DOC 6/18/2003
 7) LS Differential - TIME Method: Using Mi TRAVEL (Std. 5 turn spec with NO tolerances);
A mode; Hi Idle; Raise track, set travel lever at FULL STROKE PC200 <PC220> {PC270}
Measurement conditions Actual Value After Adjusting Standard Value, Seconds
A MODE, Hi Idle, Mi Travel speed, Right 40.8 < 43.0 >{45.5}
Track rotating at Full PPC stroke, Frnt pump +/- 0.5 sec
A MODE, Hi Idle, Mi Travel speed, Left 40.8 < 43.0 >{45.5}
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 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 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 013 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 Arm Relief + P.Max
PC EPC current (code 013) * 480 - 680 mA
PC EPC output pressure 5-10 kg/cm2
CHECK THESE also:
Arm @ relief Lo Idle “L” No Eng stall
BKT @ relief Lo Idle “L” No Eng stall
* Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment: Be certain Pump Torque Adjustment (Monitor) = 224! 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. Best pump “balance/power” is attained when rpm’s match Front to Rear pump.
Measurement Actual value After Standard Value PC200-7, Standard Value PC220-7, Std Value PC270-7,
conditions Adjustment rpm rpm rpm
Arm Relief, 1800 - 2000* 1850 - 2050* 1900 - 2100*
“A”+P/Max 11 66
RH Track Relief, 1800 - 2000 (within 20 1850 - 2050 (within 20 1900 - 2100 (within
Hi Travel speed 22 55 rpm of rear pump) rpm of rear pump) 20 rpm of rear pump)
(Front pump)
LH Track Relief 1800 - 2000 (within 20 1850 - 2050 (within 20 1900 - 2100 (within
Hi Travel speed 33 44 rpm of front pump) rpm of rear pump) 20 rpm of rear 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

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

SPEC200/220/270-7.DOC 6/18/2003
 8

PC200/220//270-7//228-3//300-7 MAIN PUMP ADJUST SIDE (200’s FRONT)

6 – 13mm PC 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 21 - 23
rotating at half stroke, Front Pump
A, Hi Idle, Neutral, Rear Pump 30 – 50
A, Hi Idle, Hi Travel speed, Left 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.

SPEC200/220/270-7.DOC 6/18/2003
SpecTune160_7.doc 10/27/2003
 PC160LC-7
TESTING & ADJUSTMENT PROCEDURE
Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu
PC160LC-7 (-7K) machines serial number 10001 up. Be certain pump torque code = 224.

Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing
with this procedure. See the “MultiMonitor” section in the Shop manual for instructions on checking the
inputs and outputs. Follow this procedure in order from 1-8 because skipping one step will affect the
measurements in the following steps.

1) Warm the machine up to operating (50C) hyd oil temperature, and record all of the following Engine Speeds
using the machine monitor panel code 010. Compare these with the specified values. Adjust the engine speed if
necessary.
Measurement Conditions Actual Value After Standard Value
RPM Adjusting
a. High Idle, A mode 2280 - 2420
b Low Idle 1000 - 1100
c Arm Out @Relief, A mode 2045 - 2245
d A+Arm Out Relief+P.Max 1955 - 2155
e. Auto-Decel “ON” neutral 1300 - 1500

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
A mode, High Idle Seconds
Boom Raise 3.1 - 3.9
Arm In 3.1 - 3.7
Arm Out 2.5 - 3.1
Bucket Curl 2.5 - 3.1
Bucket Dump 2.0 - 2.4
LH Swing, 5 turns 22.5 - 27.5
RH Swing, 5 turns 22.5 - 27.5
LH Travel, Hi, 5 turns* 26.0 - 28.8
LH Travel, Lo, 5 turns* 39.9 - 48.7
RH Travel, Hi, 5 turns* 26.0 - 28.8
RH Travel, Lo, 5 turns* 39.9 - 48.7
Cycle times begin with PPC movement; End at cushion portion of cylinder stroke.

3) Measure, record (and re-record, if adjusted) the Pilot Oil pressure at the Pump PPC test port.
Adjust if necessary.

Step 3 Actual value Adjusted Value Standard Value, kg/cm2

Pilot Oil Pressure 32 – 33

SpecTune160_7.doc 10/27/2003
 4) Measure the Main Relief and Unload valve pressures using the machine monitor panel code 011 or 012.
Compare with the standard values listed below, and adjust if necessary.

Item Measurement Conditions Main Pump After Standard Value

(code 11) Adjusting kg/cm2
Unload Pressure A, Hi Idle, Neutral not 34 - 60
adjustable
Boom Up A, Hi Idle, Relief (PMax) 355 (380)
Arm In A, Hi Idle, Relief (PMax) 355 (380)
Arm Out A, Hi Idle, Relief (PMax) 355 (380)
Bucket Dump A, Hi Idle, Relief (PMax) 355 (380)
Bucket Curl A, Hi Idle, Relief (PMax) 355 (380)
Swing Left A, Hi Idle, Swing Lock, SsafetyV 315
Swing Right A, Hi Idle, Swing Lock, SsafetyV 315
Travel Left A, Hi Idle, Relief 380
Travel Right A, Hi Idle, Relief 380
WHEN SETTING THE (4nut) RELIEF PRESSURE: Set the high pressure setting (380) with the lower
portion of the relief valve FIRST, then set the low pressure setting (355) second. On PC7 style (2nut) do HIGH
only.

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.) No Adjustments here!

Measurement Main Pump Main Pump Standard Value

Conditions Servo Input Main Pressure Servo vs. Main
Neutral Servo 100% of
main
Arm Relief Servo 3/5 of main
Travel , Hi, half Servo 3/5 of main
stroke
Travel, Hi, full Servo 3/5 of main
stroke

2Nut Main Relief 1

2

PC Valve
LS Valve

6mm 4mm

22mm
13mm

SpecTune160_7.doc 10/27/2003
6) Measure the LS Differential pressure using the tracks with Bucket “Touch”. 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 full stroke when bucket PPC switch just closes (“touch”).This causes the controller to cancel
Merge-Divider solenoid so a ‘true’ LS pressure can be read since (in travel only)the M/D valve blocks LS while
feeding the LS signal circuit to the pump with main oil from the higher of the two P1, P2 pumps.
Measurement conditions Actual Value Standard Value
A, Hi Idle, Neutral 34 - 60 kg/cm2
A, Hi Idle, Hi Travel speed, Either Track rotating at full 21.5 – 23.5
stroke + Bucket CURL “TOUCH” only (speedup)

7) PC Valve adjustment: You can use engine rpm over relief to determine if the PC valve is adjusted correctly. If
the rpm with the Arm Out over relief is not within the standard value range, adjust the PC valve to give you the
correct rpm. BE SURE PUMP TORQUE CODE = 224

Measurement Actual Value After Adjustment After Adjustment Standard Value

Conditions RPM (if needed) PC160LC-7, rpm
Arm Out Relief 2045 - 2245
Arm Out+P.Max 1955 – 2155
* 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.

8) Recheck all cycle times, and note in the table under #2 the new measurements. Try altering PUMP TQ. CODE at
this time, if needed. Note FINAL CODE HERE _______________________.

Test Locations
B

1) PA1C: P1 Pump discharge pressure pick up port

2) PA2C: P2 Pump discharge pressure pick up port
3) PLSC: LS pressure pick up port.
4) PEN: Servo piston pick up port
5A) PPC pressure pick up point
5B)PM: PC-EPC pressure pick up point

Part No Nipple 799-101-5220 are 10 x 1.25 mm

‘O’ Ring 07002-11023 PC160-7-1 4

SpecTune160_7.doc 10/27/2003