HYDRAULIC EXCAVATOR (and related) MODELS

TESTING & ADJUSTING PROCEDURES BOOK

Version 2001-22

…Ye Olde Tune Up Sheets, now compiled into…

the

H.E. TuneUp Book 1

Table of Contents - Book 1of 3 – CURRENT H/E PRODUCT

Section No Model Starting Page

1 Sheets to books: Background & Purpose 2

2 BR350JG-1 See Book 3

3 PC128uu-1 and –2 3
4 PC228USLC-3 7
5 PC150-6LK Pre and Minor Change 15
6 PC200 to 250-6 PRE Minor Change See Book 2
7 PC200 to 270-6 Minor Change 21
8 PC300 and 400-6 Minor Change 27
9 PC300 and 400-6 PRE - Minor Change See Book 2
10 PC600/750/1100-6 (E-OLSS) See Book 2
11 PC200/220/270 as See Book 3
TimberJack 635SL/735SL/835SL
12 PC200Z-6LE (no monitor panel) See Book 2
13 D39Ex / Px – 21 KomStat Dozer See Book 3
2
… from loose Sheets to a Book!

BACKGROUND

Begun in the 1990’s as an aid to Komatsu Hydraulic Excavator Shop Manual’s Testing &
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
“PRESSURES” 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 multi-
pump 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 1 current prods .PDF

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Date Customer

Technician Model PC128uu-1 -2 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 Actual Values After Adjusting Standard Value Standard Value
conditions Seconds seconds PC128uu - 1 PC128uu - 2
High Idle
Boom Raise 3.5 - 4.9 3.5 - 4.3
Boom Down 2.9 – 4.3 3.2 – 3.9
Arm In 2.8 – 3.4 3.3– 3.9
Arm Out 2.3 – 3.4 2.3 – 2.9
Offset Right 4.8 – 6.1 5.0 – 6.2
Offset Left 4.9 – 6.2 4.9 – 6.1
Bucket Curl 2.7 – 3.6 2.4 – 3.0
Bucket Dump 2.2 – 2.9 2.0 – 2.4
LH Swing, 5 turns 28 – 36 28 – 32
RH Swing, 5 turns 28 - 36 28 – 32
LH Travel, Hi, 5 turns 35 - 40 29 max
LH Travel, Lo, 5 turns 54 - 62 39 max
RH Travel, Hi, 5 turns 35 - 40 29 max
RH Travel, Lo, 5 turns 54 - 62 39 max
Blade Raise 1.2 – 2.7 1.0 – 1.6
Blade Lower 1.1 – 2.2 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 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. 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 kg/cm2

Item Measurement conditions Actual PC128uu - 1 PC128uu - 2

Unload Pressure Hi Idle, Neutral (Unload Vlv. ) 25 - 45 25 - 45

Boom Up Hi Idle, Main Relief 300 - 350 325 - 345
Arm In Hi Idle, Main Relief 300 - 350 325 - 345
Arm Out Hi Idle, Main Relief 300 - 350 325 - 345
Offset Right Hi Idle, Safety Valve 250 - 300 260 - 290
Offset Left Hi Idle, Main Relief 250 - 300 325 - 345
Bucket Curl Hi Idle, Main Relief 300 - 350 325 - 345
Bucket Dump Hi Idle, Main Relief 300 - 350 325 - 345
Blade Raise Hi Idle, Main Relief 300 - 350 325 - 345
Blade Lower Hi Idle, Main Relief 300 - 350 325 - 345
Swing Left Hi Idle, Safety Valve 245 - 295 310 - 330
Swing Right Hi Idle, Safety Valve 245 - 295 310 - 330
Travel Left Hi Idle, Main Relief 300 - 350 345 - 365
Travel Right Hi Idle, Main Relief 300 - 350 345 - 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 LS EPC input voltage

Neutral MIN
All levers except tvl MAX
Swing only MIN
Swing only MAX

6) Measure the (Servo Input Pressure), and comp are 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 Servo Input Main Standard Value Servo vs. Main

Conditions Pressure Kg / cm2
Neutral Almost the same (25 – 45)
Arm Relief Servo 1/2 of main
Travel , Hi, FULL Servo 3/5 of main
stroke

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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 Actual Value After Adjusting PC128uu - 1 PC128uu - 2

Hi Idle, Neutral 25 - 45 18 - 38
Travel , Hi, half stroke 21 – 23 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 ½or 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 Actual value After Adjustment PC128uu-1 PC128uu-2

conditions RPM RPM
High Idle, Arm 1880 - 1920* 2120 - 2320*
Relief
• 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” features, 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.

PC128uu1/uu2 08/01/2001
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BLANK PAGE

PC128uu1/uu2 08/01/2001
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Date Customer

Technician 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 instructio ns 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 conditions 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 Relief, 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 Actual value Adjusted Value Standard Value, kg/cm2
Pilot Oil Pressure 31 -35

PC228us3 08/01/2001
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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 PC228
Unload Pressure A, Hi Idle, Neutral 30 – 50
Boom Up A, Hi Idle, Relief (PMax) NO 345 - 365 (370 - 390)
BOOM UP CUSHION
Arm In A, Hi Idle, Relief (PMax) 345 - 365 (370 - 390)
Arm Out A, Hi Idle, Relief (PMax) 345 - 365 (370 - 390)
Bucket Dump A, Hi Idle, Relief (PMax) 345 - 365 (370 - 390)
Bucket Curl A, Hi Idle, Relief (PMax) 345 - 365 (370 - 390)
Swing Left A, Hi Idle, Swing Lock, Relief 300 – 330
Swing Right A, Hi Idle, Swing Lock, Relief 300 – 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 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.

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.

PC228us3 08/01/2001
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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 pres sure 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

PC228us3 08/01/2001
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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 ½second 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).

PC228us3 08/01/2001
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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.

PC228us3 08/01/2001
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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

PC228us3 08/01/2001
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MONITOR PANEL OPERATION PC228USLC-3

Auto Decel SW WIPER

INDICATORS
(above switch)

Travel
Speed SW
MODE SELECT
“UP”/“DOWN
SWITCHES

“BLACK
BUTTON”

PC228us3 08/01/2001
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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 ” )

PC228us3 08/01/2001
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Date Customer

Technician 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 PC150LC-
6K machines serial number K30001 to K32000 or <K32001 & 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 1-9 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 Standard Value
RPM Adjusting K30000-K32000 K32001 up
a. High Idle, H/O mode 2350 - 2510 2250 - 2450
Aa. High Idle, Active mode N/A 2500 - 2600
b Low Idle 900- 1000 900- 1000
c Arm Relief, H/O 2000 - 2200 2000 – 2200
d Arm Relief, H/O + P/Max 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 Actual value Adjusted Value Standard Value, kg/cm2

Pilot Oil Pressure 32 - 33

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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 Main Pump After Standard Value
(code 11) Adjusting kg/cm2
Unload Pressure H/O, Hi Idle, Neutral not 30 - 50
adjustable
Boom Up H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Arm In H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Arm Out H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Bucket Dump H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Bucket Curl H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Swing Left H/O, Hi Idle, Swing Lock, Relief 315 – 335
Swing Right H/O, Hi Idle, Swing Lock, Relief 315 – 335
Travel Left H/O, Hi Idle, Relief 345-370 LH relief
Travel Right H/O, Hi Idle, 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 All levers in Actual value Any work eq.
neutral 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 Main Pump Main Pump Standard Value

Conditions Servo Input Main Pressure Servo vs. Main
Neutral Servo 1/2 of main
Arm Relief Servo 1/3 of main
Arm Relief + Pmax Servo 1/3 of main
Travel , Hi, half Servo 1/2 of main
stroke
Travel, Hi, full Servo 1/2 of main
stroke

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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 30 - 50 kg/cm2
H/O, Hi Idle, Hi Travel speed, Either Track rotating at full 28 - 30 kg/cm2
stroke 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 08/01/2001
18

FRONT VIEW OF PC150LC-6 MAIN CONTROL VALVE

PC150LC-6LK 08/01/2001
 19

PC150LC-6LK 08/01/2001
20

BLANK PAGE

PC150LC-6LK 08/01/2001
 21
Date Customer

Technician 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. 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 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 Actual value Adjusted Value Standard Value, kg/cm2
Pilot Oil Pressure 31 -35
PC200 to 270-6 m/c 08/01/2001
22

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<PC270>
Unload Pressure H/O, Hi Idle, Neutral Divided 30 – 50
Boom Up H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Arm In H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Arm Out H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Bucket Dump H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Bucket Curl H/O, Hi Idle, Relief (PMax) 315-335 (345-370)
Swing Left H/O, Hi Idle, Swing Lock, Relief 305 – 330<275-300>
Swing Right H/O, Hi Idle, Swing Lock, Relief 305 – 330<275-300>
Travel Left H/O, Hi Idle, Relief Unload Pres 345-370 LH relief
Travel Right H/O, Hi Idle, Relief Unload Pres 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 dis connected 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 Rear Pump Rear Rear Pump Approx.STD
Conditions Servo Input LS Pump Main Servo Input LS Main Ratio Servo vs.
Main
Neutral Almost the same
Arm Relief Servo 1/2 of
main
Arm Relief + Pmax Servo 1/2 of
main
LH Travel , Hi, Unload Unload Servo 1/2 of
half stroke Pressure pressure main
RH Travel, Hi, half Unload Unload Servo 1/2 of
stroke Pressure Pressure main

PC200 to 270-6 m/c 08/01/2001

 23

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 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 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.

PC200 to 270-6 m/c 08/01/2001

24

PC200 to 270-6 m/c 08/01/2001

 25
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!!**

PC200 to 270-6 m/c 08/01/2001

26
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.

PC200 to 270-6 m/c 08/01/2001

 27
Date Customer

Technician 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 steps. ** 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

Actual After Standard Value Standard Value

Measurement conditions RPM Adjusting PC300LC-6mc PC400LC-6LK
a. High Idle, H/O mode 1900-2000 2000-2100
b. High Idle, H/O (+Touch) 2000-2100 2100-2200
c. High Idle, Active (+Touch) 2100-2200 2200-2300
d. Low Idle, H/O mode 850-950 610-710
e. Low Idle, H/O mode(+Touch) N/A 900-1080
f. Arm in relief 1830-2030 1920-2120
g. Arm in relief & P. ma x 1690-1790 1850-2050
h. Auto-Decel ON 1300-1500 1300-1500
i. RH Track Relief, H/O 1690 - 1790 1850 - 2050
j. LH Track Relief, H/O 1690 - 1790 1850 - 2050
k. Low Idle @ Track Relief PEMC Test PEMC Test
operation to close PPC switch.

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-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 / 400-6 m/c 08/ 01/ 2001

28

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 Front pump Standard Value Standard Value
(code 12) (code 11) PC 300LC-6 PC 400LC-6
Kg/cm2 kg/cm2
Unload Pressure H/O, Hi Idle, Neutral Divided 30 - 50 30 - 50
non-adjustable non-adjustable
Boom Up H/O, Hi Idle, Relief (PMax) 335-355 (345-365) 335-355 (345-365)
Boom DOWN(Low) Machine “Push-Up” feature 175 - 195 175 - 195
Arm In H/O, Hi Idle, Relief (PMax) 335-355 (345-365) 335-355 (345-365)
Arm Out H/O, Hi Idle, Relief (PMax) 335-355 (345-365) 335-355 (345-365)
Bucket Dump H/O, Hi Idle, Relief (PMax) 335-355 (345-365) 335-355 (345-365)
Bucket Curl H/O, Hi Idle, Relief (PMax) 335-355 (345-365) 335-355 (345-365)
Swing Left H/O, Hi Idle, Swing Lock, Relief 300 - 325 295 – 320
Swing Right H/O, Hi Idle, Swing Lock, Relief 300 - 325 295 – 320
Travel Left H/O, Hi Idle, Relief Unload Pres 345-365 LH relief 345-365 LH relief
Travel Right H/O, Hi Idle, Relief Unload Pres 345-365 RH 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 Any work eq. lever moved
LS EPC current (code 15) 870 - 930 mA 0 - 10 mA
LS EPC output pressure 30 kg/cm2 0
** FUNCTION TEST = is Mi Tvl normal? Then LS EPC is also!

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 ma in 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 Front Pump Frnt Front Rear Pump Rear Rear Pump Approx. Ratio
Conditions Servo Input LS Pump Main Servo Input LS Main Servo vs. Main
Neutral Almost the same
Arm Relief + Pmax Servo 2/5 of main
RH Travel , Hi, Unload Unload Servo 2/5 of main
half stroke Pressure pressure
LH Travel, Hi, half Unload Unload Servo 2/5 of main
stroke Pressure Pressure

PC300 / 400-6 m/c 08/ 01/ 2001

 29
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 appro ximately 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 After Standard Value Standard Value
(engine rpm) Adjusting PC300LC-6mc PC400LC-6LK
(rpm) (rpm)
A) Arm Relief, H/O+ 1690 - 1790 1850 - 2050
P/Max (2 pumps)
B) Arm Relief, H/O, Move Within 20 rpm of Within 20 rpm of
Travel pedal slightly front pump front pump
(Rear Pump)
C) Boom Up Relief, H/O, Within 20 rpm of Within 20 rpm of
Move Travel pedal slightly rear pump rear pump
(Front 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 / 400-6 m/c 08/ 01/ 2001

30

Merge / Divide valve

Right Main Relief

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

Right Sub- unload Left Sub-unload

valve valve
non-adjustable non-adjustable

PC300 / 400-6 m/c 08/ 01/ 2001

 31

PC300 / 400-6 m/c 08/ 01/ 2001

32

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 / 400-6 m/c 08/ 01/ 2001