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 BR350JG-1 3
3 PC128uu-1 and –2 9
4 PC228USLC-3 13
5 PC150-6LK Pre and Minor Change 21
6 PC200 to 250-6 PRE Minor Change 27
7 PC200 to 270-6 Minor Change 33
8 PC300 and 400-6 Minor Change 39
9 PC300 and 400-6 PRE - Minor Change 45
10 PC600/750/1100-6 (E-OLSS) 51
11 PC200/220/270 as 53
TimberJack 635SL/735SL/835SL
12 PC200Z-6LE (no monitor panel) 59
13 D39Ex / Px – 21 KomStat Dozer 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 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.PDF

3
Date Customer
Technician Model BR350JG-1 Serial
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 photo-
Tach as in Step 1, above.
Measurement Actual Values After Adjusting Standard Value
conditions: BR350JG-1
CRUSHER F/Wheel 245 – 255 RPM

Maximum Dial Spd
CRUSHER F/Wheel 160 – 170 RPM
Minimum Dial Spd
Conveyor belt speed 70 – 110 RPM
Conveyor, roller 70 – 110 RPM
Magnetic Sep. 90 – 100 RPM
Travel 20 meter 24 SECONDS

running start 10m.
3) 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
BR350JG-1 Crusher 07/ 06/ 01

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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 Front pump Rear pump Standard

value
kg/cm2
Unload Pressure Hi Idle, Neutral 30 - 50
Conveyor Lift Hi Idle, Relief Unload Pres 170 - 180
Magnetic Sep. Hi Idle, Blocked/Uncoupled Unload Pres 170 - 180
OPT 2 Hi Idle, Uncoupled Unload Pres 170 - 180
Travel Left Hi Idle, Relief Unload Pres 345 - 370
LH relief
Travel Right Hi Idle, Relief Unload Pres 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 Front Pump Front Pump Rear Pump Rear Pump Standard Value
Conditions Servo Input Main Servo Input Main Servo vs. Main
Pressure Pressure
Neutral Almost the same
Crusher set at Unload Unload Servo 1/2 of
HALF DIAL Pressure pressure main
GRIZZLY at Unload Unload Servo 1/2 of
HALF DIAL Pressure Pressure main
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 Actual value Standard Value

BR350JG-1
PC EPC output pressure 5-10 kg/cm2
– TRK stall
BR350JG-1 Crusher 07/ 06/ 01

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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 Actual value After Adjustment Standard Value

conditions BR350JG-1
RPM
BOTH Tracks 2000 - 2200
stalled
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.
BR350JG-1 Crusher 07/ 06/ 01

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SIDE VIEW OF THE MAIN HYDRAULIC PUMP
BR350JG-1 Crusher 07/ 06/ 01

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
BR350JG-1 Crusher 07/ 06/ 01

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BLANK PAGE
BR350JG-1 Crusher 07/ 06/ 01

9
Date Customer
Technician Model PC128uu-1 -2 Serial

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
PC128uu1/uu2 07/06/2001
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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
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
PC128uu1/uu2 07/06/2001
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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 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 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” 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?___)
PC128uu1/uu2 07/06/2001
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BLANK PAGE
PC128uu1/uu2 07/06/2001
13
Date Customer
Technician Model PC228USLC-3 Serial

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.
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”.
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)
Pilot Oil Pressure 31 -35
PC228us3 07/06/2001
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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 condi tions 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 07/06/2001
15
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!
circuit, LS valve, and the PC valve are working properly.)
Measurement Front Pump Front Pump Rear Pump Rear Pump Approx.STD Ratio
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 07/06/2001
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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 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
CHECK THESE also:

Arm @ relief Hi Idle Arm @ relief Lo Idle
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
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 07/06/2001
17
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
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 07/06/2001
18
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 07/06/2001
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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 07/06/2001
20
• 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 07/06/2001
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Date Customer
Technician Model Serial
PC150LC-6 S/N: K30001 & up PLUS K32000m/c

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>.
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
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)

PC150LC-6LK 07/06/2001
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 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
Travel , Hi, half Servo 1/2 of main
stroke
Travel, Hi, full Servo 1/2 of main
stroke
PC150LC-6LK 07/06/2001
23
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.

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.
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 07/06/2001
24
FRONT VIEW OF PC150LC-6 MAIN CONTROL VALVE
PC150LC-6LK 07/06/2001
25
PC150LC-6LK 07/06/2001
26
BLANK PAGE
PC150LC-6LK 07/06/2001
27
Date Customer
PC200, 210, 220, 250-6; Serial Numbers A80001 - A82999

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!!**
Measurement Actual Value PC200, 210 PC200, 210 PC220, 250 PC220, 250
conditions Komatsu Cummins Komatsu Cummins
engine engine engine engine
Low idle 920 - 1020 1000 - 1120 920 - 1020 1000 - 1120
High idle, H/O mode 2130 - 2270 2070 - 2190 2330 - 2470 2240 - 2360
High Idle, H/O, Travel 2330 - 2470 2360 - 2480 2430 - 2570 2460 - 2580
lever moved slightly ? ?
Boom Relief, H/O 2050 - 2250 2000 - 2200 2250 - 2450 2150 - 2350
Boom Relief, H/O, + 2100 - 2300 2050 - 2250 2200 - 2400 2150 - 2350
Pmax
2) 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.
PC200 to 250-6 Pre-m/c 07/ 06/ 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 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)
Bucket Curl H/O, Hi Idle, Swing Accel ON, 315-335 LS Relief (345-370)
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
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.
circuit, LS valve, and the TVC valve are working properly.)
Measurement Front Pump Front Pump Rear Pump Rear Pump Standard Value Servo
Conditions Servo Input Main Servo Input Main vs. Main
Pressure Pressure
Arm Relief Almost the same
Left Track Unload Unload Servo approximately
Relief Pressure pressure 1/2of main
Right Track Unload Unload Servo approximately
Relief Pressure Pressure 1/2of main
PC200 to 250-6 Pre-m/c 07/ 06/ 2001

29
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.
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.
PC200 to 250-6 Pre-m/c 07/ 06/ 2001

30
PC200 to 250-6 Pre-m/c 07/ 06/ 2001

31
PC200 to 250-6 Pre-m/c 07/ 06/ 2001

32
BLANK PAGE
PC200 to 250-6 Pre-m/c 07/ 06/ 2001

33
Date Customer
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.
will affect the measurements in the following steps. ** HINT – “X” OUT UNUSED
MODELS! **
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”.
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)
PC200 to 270-6 m/c 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 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
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.
** FUNCTION TEST = is Mi Tvl normal? Then LS EPC is also!
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
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 07/06/2001

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>
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
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
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)
PC200 to 270-6 m/c 07/06/2001

36
PC200 to 270-6 m/c 07/06/2001

37
CONTROL SIDE VIEW OF THE MAIN HYDRAULIC PUMP
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 07/06/2001

38
PC200/210/220/250/270/290/300/350/400/450-6 Main Control Valve
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.
H/O, Hi Idle, Neutral, Front Pump 30 - 50
H/O, Hi Idle, Hi Travel speed, Left Track 21 – 23
H/O, Hi Idle, Neutral, Rear Pump 30 – 50
H/O, Hi Idle, Hi Travel speed, Right Track 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 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 07/06/2001

39
Date Customer
PC300/400-6LK
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
will affect the measurements in the following ste ps. ** HINT – “X” OUT MODEL NOT BEING USED! **
panel code 10. Compare these with the specified values. Adjust the engine speed if necessary. “Touch” means slight PPC

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. max 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.
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.
PC300 to 400-6 m/c 07/06/2001

40
4) Measure the Main Relief and Unload valve pressures using the machine mo nitor panel codes 11 & 12. Compare with the
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.
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.
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 Front Pump Frnt Front Rear Pump Rear Rear Pump Approx. Ratio
Conditions Servo Input LS Pump Main Servo Input LS Main Servo vs. Main
RH Travel , Hi, Unload Unload Servo 2/5 of main
half stroke Pressure pressure
stroke Pressure Pressure
PC300 to 400-6 m/c 07/06/2001

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>
H/O, Hi Idle, Mi Travel speed, Left Track Med [42]<44.5>
H/O, Hi Idle, Mi Travel speed, Right Track Med [42]<44.5>
Adjust LS Valve on each pump separately to achieve NO MORE than ½second difference in Mi TVL cycle time. Each FLAT
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
(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 to 400-6 m/c 07/06/2001

42
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
PC300 to 400-6 m/c 07/06/2001

43
PC300 to 400-6 m/c 07/06/2001

44
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.

H/O, Hi Idle, Neutral, Front Pump 30 – 50
LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL
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 07/06/2001

45
Date Customer
PC300/400-6
Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC300 &
PC400-6 machines. **( Pre-Minor Change )
Measurement conditions RPM Adjusting PC300LC-6 PC400LC-6
b. High Idle, G/O mode 1790 - 1930 1810 - 1990
c. High Idle, F/O mode 1790 - 1930 1810 - 1990
d. High Idle, L/O mode 1590 - 1730 1500 - 1700
e. Low Idle, H/O mode 850 - 950 650 - 750
f. Arm in relief 1830 - 2030 1910 - 2060
g. Arm in relief & P. max 1690 - 1790 1940- 2030
h. Auto-Decel ON 1300 - 1500 1300 - 1400
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.

PC300 to 400-6 PRE - m/c 07/06/2001

46
4) Measure the Main Relief and Unload valve pressures using the machine monitor panel codes 11 & 12. Compare with the
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 30 - 50 30 - 50
Boom Up H/O, Hi Idle, Relief (PMax) 335-355 (345-365) 335-355 (345-365)
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.
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.
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.)
Pressure Pressure
RH Travel , Hi, half Unload Unload Servo 2/5 of main
stroke Pressure pressure
PC300 to 400-6 PRE - m/c 07/06/2001

47
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.

H/O, Hi Idle, Hi Travel speed, Right Track 24 - 26
H/O, Hi Idle, Neutral, Rear Pump 30 - 50
H/O, Hi Idle, Hi Travel speed, Left Track 24 - 26
• LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL
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
(engine rpm) Adjusting PC300LC-6 PC400LC-6
(rpm) (rpm)
A) Arm Relief, H/O+ 1690 - 1790 1940 - 2040
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 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 07/06/2001

48
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
PC300 to 400-6 PRE - m/c 07/06/2001

49
PC300 to 400-6 PRE - m/c 07/06/2001

50
BLANK PAGE
PC300 to 400-6 PRE - m/c 07/06/2001

51
Date Customer
PC600/750/1100-6
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! )
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).
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.
Pilot Oil Pressure 32.0 – 35.5
PC600 / 750 / 1100-6 E-OLSS 07/06/2001

52
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 Front/R4 Rear/L5 #3 / S4 Standard Value Standard Value
Right 4 Left 5 Swing 4 [PC750]/ 1100LC -6
PC 600LC- Kg/cm2
6
Kg/cm2
Rlf DropPress Lo Idle, Relief NO Hvy Lft NO NO NO 295 300
Boom UP Hi Idle, Relief NO Hvy Lft ADJ ADJ ADJ 315 320
Boom Up Hi Idle, Relief + Hvy Lift = High 340-365 340
Boom Up Hi Idle, Relief = Low 315-340 320
Boom Down Lo Idle Relief “Push-Up=LOW” N/A 175-215 [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 Standard Value Standard Value
PC 600LC-6 PC 750LC-6 PC 1100LC -6
Kg/cm2 Kg/cm2 kg/cm2
Neutral 21-25 20-26
Boom Up Relief 12.5 – 16.5 9.5 – 13.5
BmUp Rlf+HvyLift 10.5 – 14.5 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
Right 4 Left 5 Swing 4 PC 600LC-6 [PC750]PC 1100LC-6
Kg/cm2 kg/cm2
FRONT Pair CO fully engaged N/A N/A 310 310

REAR Pair CO fully engaged N/A N/A 310 310
7) Test and Adjust NC OUT pressures, DH Mode, HIGH Idle, Swing Lock OFF
Right 4 Left 5 Swing 4 PC 600LC-6 [PC750]/1100LC-6
Kg/cm2 kg/cm2
Pump #3 Swing, NO Load N/A N/A [N/A] MIN 17
FRONT Pair RIGHT TRACK – No load N/A N/A MIN 18 MIN 17
REAR Pair LEFT TRACK – No Load N/A N/A MIN 18 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 Actual Adjusted Standard Value Standard Value Standard Value

PC 600LC-6 PC 750LC-6 PC 1100LC -6
Kg/cm2 Kg/cm2 kg/cm2
FRONT pair àR4 (neutral) 4.0 – 5.5 MAX 2.6-4.1 MAX
(Travel-NO Load) 18 MIN 17 MIN
REAR pair àL5 (neutral) 4.0 – 5.5 MAX 2.6-4.1 MAX
(Travel – NO Load) 18 MIN 17 MIN
PUMPS #3 àS4 (neutral) N/A N/A 6.9 – 8.4MAX
(Swing – NO load) 17 MIN
9) Recheck ALL CYCLE TIMES. Re-Adjust as needed, record results.

PC600 / 750 / 1100-6 E-OLSS 07/06/2001
53
Date Customer
TimberJack
635 / 735 SHOVEL LOGGER

Use the following procedure as a supplement to the Shop Manual when testing & adjusting.
** Minor Change Machines!!**
will affect the measurements in the following steps. ** Helpful HINT – LINE THROUGH MODEL(s) NOT BEING
USED!!
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.
Actual/ Adjusted Standard Value Standard Value

Measurement conditions Value 635 735
b. High Idle, H/O, Traveling 2130 - 2270 2230 - 2370
B+ High Idle, Active + Touch 2130 - 2270 2230 - 2370
c. Low Idle 920 - 1020 920 - 1020
d. Boom Relief, H/O 1850 - 2050 2050 - 2250
e. Boom Relief, H/O + P/Max 1900 - 2100 2000 - 2200
f. Boom Relief, H/O+ Active * 1650 – 1850 1940 – 2140
g. RH Track Relief, H/O 1900 – 2100 2000 – 2200
h. LH Track Relief, H/O 1900 – 2100 2000 – 2200
* 1999 machines may revert to Line “e” RPM’s.
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 07/06/2001

54
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
Pressure 50-70
Travel Right H/O, Hi Idle, Relief Left 345 - 370 Right Main relief
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
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.

55
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
LH Travel , Hi, half Unload Unload Servo 1/2 of main
stroke Pressure pressure
RH Travel, Hi, half Unload Unload 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>
H/O, Hi Idle, Mi Travel speed, Left Track 42 <54>
H/O, Hi Idle, Mi Travel speed, Right Track 42 <54>
Adjust LS Valve on each pump separately to achieve NO MORE than ½second difference in Mi TVL cycle time. Each FLAT
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
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)

56

57

58
635SL / 735SL / 835SL Main Control Valve
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
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.

59
Date Customer
PC200Z-6LE S/N: A83001 & up (“Minor Chg “Z” or “Custom”)

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
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.

PC200’Z’-6 ‘Custom’ 07/ 06/ 2001

60
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 Measurement conditions Front pump Rear pump Standard

value
kg/cm2
Unload Hi Idle, Neutral 30 - 50
Pressure
Boom Up Hi Idle, Relief Unload Pres 315-335
Arm In Hi Idle, Relief Unload Pres 315-335
Arm Out Hi Idle, Relief Unload Pres 315-335
Bucket Hi Idle, Relief Unload Pres 315-335
Dump
Bucket Curl Hi Idle, Relief Unload Pres 315-335
Swing Left Hi Idle, Swing Lock, Relief Unload Pres 285 - 310
Swing Right Hi Idle, Swing Lock, Relief Unload Pres 285 - 310
Travel Left Hi Idle, Relief Unload Pres 315-335 LH
relief
Travel Right Hi Idle, Relief Unload Pres 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”).
Pressure Pressure
Arm Relief Servo 1/2 of
main
LH Travel Unload Unload Servo 1/2 of
half stroke Pressure pressure main
RH Travel Unload Unload Servo 1/ 2 of
half stroke Pressure Pressure 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
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
STEP 6 CONTINUED….Next Page…
PC200’Z’-6 ‘Custom’ 07/ 06/ 2001

61
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 Actual value Std value PC200”Z”-6LE

PC EPC input current 240 - 400 mA
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 Actual value After Adjustment Standard Value PC200”Z”-6LE

conditions RPM
Arm Relief 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.
PC200’Z’-6 ‘Custom’ 07/ 06/ 2001

62
PC200’Z’-6 ‘Custom’ 07/ 06/ 2001

63
PC200/210/220/250-6 Main Control Valve
PC200’Z’-6 ‘Custom’ 07/ 06/ 2001

64
PC200’Z’-6 ‘Custom’ 07/ 06/ 2001

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HYDRAULIC EXCAVATOR (and related) MODELS

TESTING & ADJUSTING PROCEDURES BOOK

…Ye Olde Tune Up Sheets, now compiled into…

H.E. TuneUp Book

Section No Model Starting Page

1 Sheets to books: Background & Purpose 2

~ Komatsu America Service Training, 2001

PURPOSE (by approximate element No.)

H.E TuneUP Book.PDF

Technician Model BR350JG-1 Serial

CRUSHER F/Wheel 245 – 255 RPM

Travel 20 meter 24 SECONDS

BR350JG-1 Crusher 07/ 06/ 01

Item Measurement conditions Front pump Rear pump Standard

Item Actual value Standard Value

BR350JG-1 Crusher 07/ 06/ 01

Measurement Actual value After Adjustment Standard Value

LH Track 2000 – 2200 (within 20 rpm of rear

BR350JG-1 Crusher 07/ 06/ 01

SIDE VIEW OF THE MAIN HYDRAULIC PUMP

BR350JG-1 Crusher 07/ 06/ 01

(PC220-6) BR350 Main Control Valve

BR350JG-1 Crusher 07/ 06/ 01

BR350JG-1 Crusher 07/ 06/ 01

Technician Model PC128uu-1 -2 Serial

TESTING & ADJUSTMENT PROCEDURE

Actual compared to standard values kg/cm2

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

Operation Fuel Dial LS EPC input voltage

Measurement Servo Input Main Standard Value Servo vs. Main

Measurement conditions Actual Value After Adjusting PC128uu - 1 PC128uu - 2

Measurement Actual value After Adjustment PC128uu-1 PC128uu-2

Technician Model PC228USLC-3 Serial

TESTING & ADJUSTMENT PROCEDURE

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

CHECK THESE also:

PC228US-3 MAIN PUMP FRONT SIDE

6 – 13mm locknut 7 – 4mm hex PC Valve Adjust Screw

Auto Decel SW WIPER

• ENTERING Monitor’s CODE MENU:

1. Hold BUZZER CANCEL + AUTO-DECEL switches for 3 secs.

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 ” )

Technician Model Serial

PC150LC-6 S/N: K30001 & up PLUS K32000m/c

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

Measurement Main Pump Main Pump Standard Value

Measurement conditions Actual Value Standard Value

Measurement Actual Value After Adjustment After Adjustment Standard Value

TOP VIEW OF PC150LC-6 MAIN CONTROL VALVE

Use Quick Coupler 799-101-5220 with

FRONT VIEW OF PC150LC-6 MAIN CONTROL VALVE

Technician Model Serial

PC200, 210, 220, 250-6; Serial Numbers A80001 - A82999

PC200 to 250-6 Pre-m/c 07/ 06/ 2001

PC200 to 250-6 Pre-m/c 07/ 06/ 2001

PC200 to 250-6 Pre-m/c 07/ 06/ 2001

PC200 to 250-6 Pre-m/c 07/ 06/ 2001

PC200 to 250-6 Pre-m/c 07/ 06/ 2001