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PC300/400-7 Pm Tune Up Sheet & FST Exercise PC400-7

Spectune400_300_7.doc

12/17/2003

BLANK PAGE

Spectune400_300_7.doc

12/17/2003

MODEL

SERIAL No.

PUMP TQ. CODE ( = 224 ?)

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitoring code (01002) 010. Compare these with the specified values. Adjust the engine speed (governor – throttle linkage) if necessary. “Touch” means slight PPC operation to close PPC switch only.

“X” out Std. Value Measurement conditions a. High Idle, E mode + touch b. High Idle, A, Travel Touch c. High Idle, A mode + Touch d. Low Idle e. Arm Relief, A f. Arm Relief, A + P/Max g. AUTO DECEL Hi Idle h. RH Track Relief, A i. LH Track Relief, A j. Low Idle @ LH Track Relief

“NOT” in use Actual/ Adjusted Value

“ X” ? Standard Value PC300-7 1800 2090 - 2230 2090 - 2230 850 - 925 1880 - 2080 1840 - 1880 1300 - 1500 1770 - 1970 1770 - 1970 PEMC Test

“X“? Standard Value PC400-7’ref’ n/p n/p 1880 - 1980 975 - 1025 1830 - 2030 1730 - 1930 1200 - 1400 1730 - 1930 1730 - 1930 PEMC Test

2)

Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Standard Value Standard Value A mode, High Idle seconds Adjusting PC300LC-7 PC400LC-7 Boom Raise 3.3 – 4.1 3.6 – 4.4 Arm In 3.4 – 4.2 3.9 – 4.7 Arm Out 2.6 – 3.2 3.2 – 4.0 Bucket Curl 2.9 – 3.5 3.2 – 4.0 Bucket Dump 2.0 – 2.6 2.6 – 3.2 LH Swing, 5 turns 28.7 – 34.5 30 - 36 RH Swing, 5 turns 28.7 – 34.5 30 - 36 LH Travel, Hi, 5 turns 32.0 – 36.0 33 - 40 LH Travel, Mi, 5 turns 35.5 – 47.5 41 - 55 LH Travel, Lo, 5 turns 46.5 – 69.5 54 - 80 RH Travel, Hi, 5 turns 32.0 – 36.0 33 - 40 RH Travel, Mi, 5 turns 35.5 – 47.5 41 - 55 RH Travel, Lo, 5 turns 46.5 – 69.5 54 - 80

3)

Measure, record (and re-record, if adjusted) the Pilot Oil pressure. PPC TEST port; PPC ADJUST. Adjust Self Pressure Reducing Valve if necessary. (High Idle) (PC400LC-7 shows PPC Track rotating at Full PPC stroke, Rear pump +/- 0.5 SEC A MODE, Hi Idle, Mi Travel speed, Left 41.5 < 48.1> Track rotating at Full PPC stroke, Front Pump +/- 0.5 SEC Adjust LS Valve on each pump separately to achieve NO MORE than ½ second difference in Mi TVL cycle time. Each FLAT will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

Spectune400_300_7.doc

12/17/2003

8) PC EPC command current & function:. Bring up monitoring code 13 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, A mode, High Idle, Auto Decel “OFF”, arm over relief, Power Max, and measure the current. NO ADJUSTMENT HERE. Pressure was checked @ STEP 4.8 • Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment: The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to determine if the PC valves are adjusted correctly. Test (2 pump load) rpm with the Arm over relief Power Max “ON”. If not within the standard value range, adjust the PC valve on each pump to give you the correct rpm over relief using the stalled track (ensures both high relief pressure and divided pumps when travel operated WITHOUT any other function). Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. ( Numbers in GREY are for SEQUENCE to follow) Measurement Actual value After Adjustment Standard Value Standard Value conditions PC300-7, rpm PC400-7, rpm Arm Relief, 1840 – 1880 1730 - 1930 “A”+P/Max LH Track Relief, 1770 - 1970 (within 20 (+/- 20 rpm rear pump) Hi Travel speed rpm of rear pump) (Front pump) RH Track Relief 1770 - 1970 (within 20 (+/- 20 rpm front pump) Hi Travel speed rpm of front pump) (Rear Pump) BOOST Pressure No Code on PC300

11 22

66 55

33

44

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

10)

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

PC-7 MAIN PUMP CONTROLS SIDE (200 shown)

8

•

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

6 – 13mm PC locknuts 7 – 4mm hex PC Valve Adjust Screws 8 - LS Valve(s) 22mm locknut, 6mm hex LS Adjust Screw Spectune400_300_7.doc

12/17/2003

LS Differential - PRESSURE Method: Measure and adjust the LS Differential Pressure using the tracks as outlined in the Shop Manual. Raise one side of the machine, (A mode, HI travel speed, Full Throttle) and move the travel lever of the raised track Partial - Lever Stroke (easily held steady at a chosen value such as 85 kg/cm2 of Main Pressure). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Repeat this procedure for the opposite track and pump. 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 24-26 rotating at half stroke, Rear Pump A, Hi Idle, Neutral, Rear Pump 30-50 A, Hi Idle, Hi Travel speed, Left Track 24-26 rotating at half stroke, Front Pump • LS Verification: Since track operation may cause erratic readings on the more sensitive digital DIFFERENTIAL PRESSURE GUAGES, another method of final verification is to use BOOM UP or ARM OUT functions to get a “final, steady LS Differential” reading. Operate the chosen function at a steady speed roughly at 50-80% as long as main pressure (codes 011,012) is kept steady for the most repeatable and reliable reading of • MAIN – LS = LS Differential.

REFERENCE to PUMP TORQUE ADJ on Multi-Monitor Only.

Spectune400_300_7.doc

12/17/2003

(PC220, 220, 270LC-7)

PC220-7

SPEC200/220/270-7.DOC

PC270-7

6/18/2003

MODEL

SERIAL No.

PUMP TQ. CODE ( = 224 ?)

1) Warm the machine up to operating temperature, and record all of the following Engine Speeds using the machine monitoring code 010. Compare these with the specified values. Adjust the engine speed (governor – throttle linkage) if necessary. “Touch” means slight PPC operation to close PPC switch only. “ X” ? “X“? “X” out Std. Value “NOT” in use Measurement conditions a. High Idle, E mode + touch b. High Idle, A, Travel Touch c. High Idle, A mode + Touch d. Low Idle e. Arm Relief, A f. Arm Relief, A + P/Max g. AUTO DECEL Hi Idle h. RH Track Relief, A i. LH Track Relief, A j. Low Idle @ LH Track Relief

Actual/ Adjusted Value

Standard Value PC200-7 1800 2080 - 2220 2080 - 2220 980 - 1080 1900 - 2100 1800 - 2000 1300 - 1500 ?1900 - 2100 ?1900 - 2100 PEMC Test

Standard Value PC220-7 1800 2080 - 2220 2080 - 2220 980 - 1080 1900 - 2100 1800 - 2000 1300 - 1500 ?1900 - 2100 ?1900 - 2100 PEMC Test

Standard Value PC270-7 1850 2180 - 2320 2180 - 2320 950 - 1050 2000 - 2200 1900 - 2100 1300 - 1500 1900 - 2100 1900 - 2100 PEMC Test

2) Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement conditions Actual Values After Standard Value Standard Value Standard Value A mode, High Idle seconds Adjusting PC200-7 PC220-7 PC270-7 Boom Raise 3.4 – 4.2 3.1 - 3.9 3.5 - 4.3 Arm In 3.2 – 3.8 3.4 - 4.2 2.9 - 3.5 Arm Out 2.5 – 3.1 2.7 - 3.3 3.6 - 4.4 Bucket Curl 2.3 – 2.9 2.6 - 3.2 2.1 - 2.5 Bucket Dump 1.7 – 2.3 1.9 - 2.5 2.7 - 3.3 LH Swing, 5 turns 25.6 – 30.9 23.3 - 28.5 25.6 - 31.6 RH Swing, 5 turns 25.6 – 30.9 23.3 - 28.5 25.6 - 31.6 LH Travel, Hi, 5 turns 29.4 – 32.9 28.9 - 31.9 27.2 - 37.2 LH Travel, Mi, 5 turns 36.7 - 44.9 38.6 - 47.2 35.5 - 55.5 LH Travel, Lo, 5 turns 50.8 – 62.1 52.8 - 64.6 52.2 - 72.2 RH Travel, Hi, 5 turns 29.4 – 32.9 28.9 - 31.9 27.2 - 37.2 RH Travel, Mi, 5 turns 36.7 - 44.9 38.6 - 47.2 35.5 - 55.5 RH Travel, Lo, 5 turns 50.8 – 62.1 52.8 - 64.6 52.2 - 72.2 3) Measure, record (and re-record, if adjusted) the Pilot Oil pressure. TEST port (3); ADJUST at (4). Adjust Self Pressure Reducing Valve if necessary. (High Idle)

Step 3 Pilot Oil Pressure

SPEC200/220/270-7.DOC

Actual value

Adjusted Value

Standard Value, kg/cm2 31 -35

6/18/2003

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

Measurement conditions

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

A, Hi Idle, Neutral Also divided! A, Hi Idle, Safety V. (PMax) A, Hi Idle, Safety V. (PMax) A, Hi Idle, Safety V. (PMax) A, Hi Idle, Safety V. (PMax) A, Hi Idle, Safety V. (PMax) A, Hi Idle, Swing Lock Safety V. A, Hi Idle, Swing Lock Safety V. A, Hi Idle, Relief A, Hi Idle, Relief

Front pump (code 11)

Rear pump (code 12)

Unload Pres Unload Pres

standard value kg/cm2 PC200-270-7 30 – 50 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 313 – 316 313 – 316 380 - 400 LH relief 380 – 400 RH relief

WHEN SETTING THE RELIEF PRESSURE: Set the high pressure setting (380 - 400) with the track FIRST, then set the low pressure setting (345 - 360) second. Use the Left track to set the (2) TOP Relief valve, and the Right Track to set the (1) BOTTOM relief valve. **New PC-7 may have ‘single’ adjustment only!**

3

4

To set the low pressure setting disconnect the 2 Stage Relief Solenoid valve (connector V06), then use the track to measure the low pressure setting. Using this procedure set the relief valve 10 kg/cm2 higher than you want it to be. Example: If you want the arm, boom, & bucket pressure to be 355 kg/cm2. Set low-pressure setting of the relief valve using the track with the 2-stage relief solenoid disconnected to 365 kg/cm2.

SPEC200/220/270-7.DOC

6/18/2003

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

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

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

PC-EPC pressure

LS-EPC pressure

3 – FRONT pump Servo In SPEC200/220/270-7.DOC

4 – REAR pump Servo In 6/18/2003

7) LS Differential - TIME Method: Using Mi TRAVEL (Std. 5 turn spec with NO tolerances); A mode; Hi Idle; Raise track, set travel lever at FULL STROKE PC200 {PC270} Measurement conditions Actual Value After Adjusting Standard Value, Seconds A MODE, Hi Idle, Mi Travel speed, Right 40.8 < 43.0 >{45.5} Track rotating at Full PPC stroke, Frnt pump +/- 0.5 sec A MODE, Hi Idle, Mi Travel speed, Left 40.8 < 43.0 >{45.5} Track rotating at Full PPC stroke, Rear Pump +/- 0.5 sec Adjust LS Valve on each pump separately to achieve NO MORE than ½ second difference in Mi TVL cycle time. Each FLAT will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

8) PC EPC output pressure: Connect the coupler nipple to the PC EPC pressure check port on top of rear pump. Attach a 60kg/cm2 gauge to the nipple. Bring up monitoring code 013 on the monitor panel to view the current flowing to the solenoid while testing. Start the engine, A mode, High Idle, Auto Decel “OFF”, arm over relief, Power Max, and measure the oil pressure at the outlet of the valve at this time. The pressure and current should be within the standard values below. Item Actual value Std value Arm Relief + P.Max PC EPC current (code 013) * 480 - 680 mA PC EPC output pressure 5-10 kg/cm2 CHECK THESE also: Arm @ relief Lo Idle “L” No Eng stall BKT @ relief Lo Idle “L” No Eng stall * Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment: Be certain Pump Torque Adjustment (Monitor) = 224! You use engine rpm over relief to determine if the PC valves are adjusted correctly. Test rpm with the Arm over relief Power Max “ON”. If not within the standard value range, adjust the PC valve on each pump to give you the correct rpm over relief using the stalled track (ensures both high relief pressure and divided pumps when travel operated WITHOUT any other function). Use the Travel over relief to inform you if the PC valve for each pump is adjusted within 20 rpm of the other. Best pump “balance/power” is attained when rpm’s match Front to Rear pump. Measurement Actual value After Standard Value PC200-7, Standard Value PC220-7, Std Value PC270-7, conditions Adjustment rpm rpm rpm 1800 - 2000* 1850 - 2050* 1900 - 2100* Arm Relief, “A”+P/Max 1800 - 2000 (within 20 1850 - 2050 (within 20 1900 - 2100 (within RH Track Relief, rpm of rear pump) rpm of rear pump) 20 rpm of rear pump) Hi Travel speed (Front pump) 1800 - 2000 (within 20 1850 - 2050 (within 20 1900 - 2100 (within LH Track Relief rpm of front pump) rpm of rear pump) 20 rpm of rear pump) Hi Travel speed (Rear Pump)

•

11 22

66 55

33

44

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

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

SPEC200/220/270-7.DOC

6/18/2003

8

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

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

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

SPEC200/220/270-7.DOC

6/18/2003

SpecTune160_7.doc

10/27/2003

PC160LC-7 TESTING & ADJUSTMENT PROCEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC160LC-7 (-7K) machines serial number 10001 up. Be certain pump torque code = 224. Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. See the “MultiMonitor” section in the Shop manual for instructions on checking the inputs and outputs. Follow this procedure in order from 1-8 because skipping one step will affect the measurements in the following steps.

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

2) Measure and record all of the Cycle Times listed below. See the Shop Manual for procedural details. Measurement Conditions Actual Values After Adjusting Standard Value A mode, High Idle Seconds Boom Raise 3.1 - 3.9 Arm In 3.1 - 3.7 Arm Out 2.5 - 3.1 Bucket Curl 2.5 - 3.1 Bucket Dump 2.0 - 2.4 LH Swing, 5 turns 22.5 - 27.5 RH Swing, 5 turns 22.5 - 27.5 LH Travel, Hi, 5 turns* 26.0 - 28.8 LH Travel, Lo, 5 turns* 39.9 - 48.7 RH Travel, Hi, 5 turns* 26.0 - 28.8 RH Travel, Lo, 5 turns* 39.9 - 48.7 Cycle times begin with PPC movement; End at cushion portion of cylinder stroke.

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

SpecTune160_7.doc

Actual value

Adjusted Value

Standard Value, kg/cm2 32 – 33

10/27/2003

4) Measure the Main Relief and Unload valve pressures using the machine monitor panel code 011 or 012. Compare with the standard values listed below, and adjust if necessary. Item Unload Pressure

Measurement Conditions

Main Pump (code 11)

After Adjusting not adjustable

A, Hi Idle, Neutral

Standard Value kg/cm2 34 - 60

Boom Up A, Hi Idle, Relief (PMax) 355 (380) Arm In A, Hi Idle, Relief (PMax) 355 (380) Arm Out A, Hi Idle, Relief (PMax) 355 (380) Bucket Dump A, Hi Idle, Relief (PMax) 355 (380) Bucket Curl A, Hi Idle, Relief (PMax) 355 (380) Swing Left A, Hi Idle, Swing Lock, SsafetyV 315 Swing Right A, Hi Idle, Swing Lock, SsafetyV 315 Travel Left A, Hi Idle, Relief 380 Travel Right A, Hi Idle, Relief 380 WHEN SETTING THE (4nut) RELIEF PRESSURE: Set the high pressure setting (380) with the lower portion of the relief valve FIRST, then set the low pressure setting (355) second. On PC7 style (2nut) do HIGH only.

5) Measure the Servo Input Pressure, and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) No Adjustments here! Measurement Conditions Neutral

Main Pump Servo Input

Main Pump Main Pressure

Standard Value Servo vs. Main Servo 100% of main Servo 3/5 of main Servo 3/5 of main

Arm Relief Travel , Hi, half stroke Travel, Hi, full stroke

Servo 3/5 of main

2Nut Main Relief

1

2

PC Valve

LS Valve

6mm

4mm

22mm 13mm

SpecTune160_7.doc

10/27/2003

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

7) PC Valve adjustment: You can use engine rpm over relief to determine if the PC valve is adjusted correctly. If the rpm with the Arm Out over relief is not within the standard value range, adjust the PC valve to give you the correct rpm. BE SURE PUMP TORQUE CODE = 224 Measurement Actual Value After Adjustment After Adjustment Standard Value Conditions RPM (if needed) PC160LC-7, rpm Arm Out Relief 2045 - 2245 Arm Out+P.Max 1955 – 2155 * Note: Adjust the PC valve to the midpoint of this range. If you adjust to the low end of the range the machine will not go much faster, but will use a lot more fuel.

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

Test Locations B

1) PA1C: P1 Pump discharge pressure pick up port 2) PA2C: P2 Pump discharge pressure pick up port 3) PLSC: LS pressure pick up port. 4) PEN: Servo piston pick up port 5A) PPC pressure pick up point 5B)PM: PC-EPC pressure pick up point

A

Part No Nipple 799-101-5220 are 10 x 1.25 mm ‘O’ Ring 07002-11023 PC160-7-1

SpecTune160_7.doc

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10/27/2003