Komatsu Pump

H YDR YD R AUL I C EXCA E XCA VA TOR (an (and rel related) MODE LS TESTING & ADJ USTI USTI NG PROCEDURE PROCEDURE S BO BOO OK V er sio si on 2001-21 2001-21 … Y e Olde Olde Tune Up Sheets, Sheets, now compiled compiled into… the

H .E . Tu T uneUp B ook Table of Contents Section No

Model Mode l

Starting Page

1

Sheets to books: Background & Purpose

2

2 3 4 5 6 7 8 9 10 11

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

3 9 13 21 27 33 39 45 51 53

12 13

59 Coming Soon

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2

… from loose Sheets to a Book!

BACKGROUND Begun in the 1990’s as an aid to Komatsu Hydraulic Excavator Shop Manual’s Testing 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! KNOWLEDGE! Watch for revisions as we STRIVE TO IMPROVE in both PRODUCT PRODUCT KNOWLEDGE and COMMUNICATION of same. ~ Komatsu America Service Training, 2001

P UR P OSE OS E ( by app pprr ox i mate elem lement N o.) 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 wastes time on ANY further element (in operational diagnostics). 2. Cycle Times – these confirm the “FLOW” constituent of Hydraulic HP while “PRESSUR “PRESSURES” ES” usually remain 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 thes e 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 multimultipump 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.















3 Date

Customer

Model BR350JG-1

Technician

Serial

Mobile Crusher

TESTI TESTI NG & ADJUSTMENT ADJUSTMENT PRO PROCEDURE CEDURE Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu BR350JG-1 machines serial number 1005 & higher. N OTE ! H ydr ydr aulic ad adapter s must be F I TTE TT E D pr pr i or to using this this

proc proce edure. ure. See See diagram iagrams on last last pages. ges. 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. F ollow ollow thi thiss procedure procedure in or der fr om 1-9 because because ski sk i ppi ppi ng one step will will affect aff ect the measur easur ements ements i n the following ollowing ste steps ps..

1) Warm the machine up to operating temperature, and record all of the followingE ngi ne Spee Speeds. Compare these with the specified values. Adjust the engine speed if necessary. See page 20-103 in the Testing and Adjusting sec tion of the Shop Manual for directions on how to connect a tachometer, required for Step Step 8 also. also. Actual Value Measurement Measurement conditions a. Low Idle b. High Idle, Id le, all motors running no load full speed c. High Idle+Tvl ‘touch’ d. BOTH tracks relief e. Left Trk (FP) Relief f. Right Trk (RP) Relief g. High FREE Idle

After Adjusting

Standard Value BR350JG-1 920 – 1020 2130 – 2270

2230 – 2000 – 2000 – 2000 – 2230 –

2370 2200 2200 2200 2370

2)

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

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















4

Relief and and Unloa Unload valve valve pressures using a 400 kg/cm2 gauge connected to the test ports on top of the 4) Measure the Main Relief main pump assembly. Compare with the standard values listed below, and adjust if necessary. Note - BR350 JG-1 JG-1 remains “Pumps DIVIDED” all the time. Ite m

Measurement conditions condition s

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

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

Travel Right

Hi Idle, Relief

Front pump

Rear pump

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

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

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

Se nput Pressure Pressure), and compare with the main pressure at the same time. (This test verifies that the LS ( rvo I nput 5) Measure the Servo circuit, LS valve, and the PC valve are working properly.) Engine Hi Idle Measurement Conditions

Neutral Crusher set at HALF DIAL GRIZZLY at HALF DIAL

Front Pump Servo Input

Front Pump Main Pressure

Rear Pump Servo Input

Unload Pressure

Unload Pressure Unload Pressure

Rear Pump Main Pressure

Unload pressure

Standard Value Servo vs. Main

Almost the same Servo 1/2 of main Servo 1/2 of main

FULL. Adjust LS Valve if the Difference 6) Measure the LS Differential pressure using the functions with EPC Dial at FULL. between betwe en the Loa d Sense pr essure and a nd the M ain pressure pres sure is out side the s tandard tandar d 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 - 23 790-261- 1311 to the outlet hose from the PC EPC s olenoid valve. Attach 7) PC E PC outp output ut pressure ressure : Connect the adapter P/N 790-261a 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 It em

Actual value

Standard Value BR350JG-1















5

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

Actual value

After Adjustment

BOTH Tracks stalled

Standard Value

BR350JG-1 RPM 2000 - 2200

LH Track 2000 – 2200 (within 20 rpm of rear Relief (Front pump) pump) RH Track 2000 – 2200 (within 20 rpm of Relief front pump) (Rear Pump) Note: Adjust the PC valves va lves to the th e midpoint mid point of this t his range. r ange. If you y ou adjust ad just to the t he low lo w end of the t he range ra nge the t he machine ma chine will not go much mu ch faster, but will use a lot more fuel.

9)

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















6

SIDE VIEW OF THE MAIN HYDRAULIC PUMP

















7 SELF PRESSURE REDUCING VALVE The Self-Pressure 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

















8

BLANK PAGE

















9

Technician

Date

Customer

Mod Model PC PC12 128u 8uuu-1 1 -2

Serial

TESTI TESTI NG & ADJUSTMENT ADJUSTMENT PRO PROCEDURE CEDURE 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. procedure. See the “Electrical Resets and Troubleshooting Procedure” sections in the Shop manual for instructions on checking the inputs and outputs. F ollow ollow thi thiss procedure procedure in in order order fr om 1 – 10 beca because use ski ski ppi ppi ng one step step will will STEP 9 - SAFETY CHECK ! APD: Accident affect the measurements in the following steps. DO NOT OMIT STEP Prevention Device.

1) Warm machine and HYD OIL up to operating temperature (swing over relief is possible with CN-K29 swing release Speeds using a photo tach. Compare these with the specified solenoid disconnected -1). Record all of the following E ngi ne Spee values. Adjust the engine speed if necessary. **MAY RE QUIRE REMOVAL OF OF E NTIRE CO COUN UNTERWEI TERWEI GHT!** ‘X’ ‘X ’ out mode modell NOT N OT testin testingg ! Measurement Measurement conditions a. High Idle, no load b. Low Idle c. High Idle with Arm Relief

Actual Value

After Adjusting

Standard Value PC128uu-1 2040 - 2160 900 – 950 1880 – 1920

Standard Value PC128uu-2 2340 – 2460 900 – 950 2120 – 2320

2) Measure and record all of the C ycle T i mes listed below. See the Shop Manual for procedural details. Measurement conditions High Idle Boom Raise Boom Down Arm In Arm Out Offset Right Offset Left Bucket Curl Bucket Dump

Actual Values seconds seconds

After Adjusting seconds seconds

Standard Value PC128uu - 1

Standard Value PC128uu - 2

3.5 - 4.9 2.9 – 4.3 2.8 – 3.4 2.3 – 3.4 4.8 – 6.1 4.9 – 6.2 2.7 – 3.6 2.2 2.9

3.5 - 4.3 3.2 – 3.9 3.3– 3.9 2.3 – 2.9 5.0 – 6.2 4.9 – 6.1 2.4 – 3.0 2.0 2.4

















10

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

Actual compared to standard values Measurement Measurement conditions Actual Actual

Item

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

Hi Idle, Neutral (Unload Vlv. ) Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Safety Valve Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief Hi Idle, Main Relief alve Hi Idle, Safe ty V alve Hi Idle, Safety Valve Hi Idle, Main Relief Relie f Hi Idle, Main Relief Relie f

kg/cm2 PC128uu - 1

PC128uu - 2

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

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

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

Fuel Dial

Neutral All levers except tvl Swing only Swing only

MIN MAX MIN MAX

LS EPC input voltage

( 6) Measure the Servo I nput nput Pressure Pressure), and compare with the main pressure at the same time. (This test verifies that the LS circuit, LS valve, and the PC valve are working properly.) NOT NOT ADJUST ADJUSTABLE ABLE ! ! Measurement Conditions

Servo Input

Main Pressure

Standard Value Servo vs. Mai n Kg / cm2

















11

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 asi ly held h eld ste steady at a chose chosen n va value such such as as 85 85 kg/cm kg/cm2 2 of of Ma M ain Pres P ressure sure)). At this point the Main pressure should be 80 - 100 kg/cm2. Adjust the LS Differential pressure to within standard values. Standard Value, kg/cm2 Measurement conditions Hi Idle, Neutral Travel , Hi, half stroke

Actual Value

After Adjusting

PC128uu - 1 25 - 45 21 – 23

PC128uu - 2 18 - 38 21 – 23

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

8)

PC Valve adjustment : The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to

determine if the PC valves are adjusted correctly. Test rpm with the Arm over relief at high idle. If not within the standard value range, adjust the PC valve on the main pump to give you the correct rpm over relief using the arm or bucket over relief. Measurement conditions

High Idle, Arm Relief •

Actual value

After Adjustment

PC128uu-1 RPM

PC128uu-2 RPM

1880 - 1920* 1920*

2120 - 2320* 2320*

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

9) Test 4 SYSTEM for Depth “Zero” features, feature s, Depth, Height, Height , Offset & APD Stops: OK READOUT. 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). IDLE. þ ___ Check Depth STOP SET - at LOW IDLE. þ ___ Check Depth STOP SET - at HIGH IDLE. (cushion or slowdown?____) SET - at HIGH IDLE. (cushion or slowdown?____) slowdown?____) þ ___ Check Height STOP SET Check Offset LEFT LEFT STOP SET - at LOW IDLE. IDLE. þ



















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BLANK PAGE



















13

Technician

Date

Customer

Mo M odel PC PC2 228USLC USL C -3

Serial

TESTING & ADJUSTMENT ADJUSTMENT PROCEDURE PROCEDURE Komatsu PC228us -3 Use the following procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu machines serial number 20001 & higher. Also, see MONITOR operation instructions at end of this document. Always ensure that all Service Codes and Controller Input & Output signals are normal before continuing with this procedure. procedure. See the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. F ollow this thi s procedur procedure e i n order fr f r om 1-10 because because ski sk i ppi ppi ng one step step will affect the measurements in the following steps . Speeds using the machine monitoring 1) Warm the machine up to operating temperature, and record all of the following E ngi ne Spee code 10. Compare these with the specified values. Adjust the engine speed (governor – throttle linkage) linkage) if necessary. “Touch” means slight PPC operation to close PPC switch. Actual/ Adjusted Standard Value Measurement Measurement conditi ons Value PC228US PC228US -3 a. b. c. d. e. f.

High Idle, E mode + touch High Idle, Id le, A, T ravel Touch T ouch High Idle, A mode + Touch Low Idle Arm Relief, A Arm Re li l i ef , A + P / Ma x

1800 2080 - 2220 2080 - 2220 980 - 1080 108 0 1900 - 2100 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 PEM C Tes t ** Prior to 12-99 Active “droop” was 200-300RPM 200-300RPM low er than P Max“droop”.



















14

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

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

Measureme Measurement nt condi tions

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

Front pump (code 11)

Rear pump (code 12)

standard value kg/cm2 PC228

30 – 50 345 - 365 (370 - 390)

Unload Pres Unload Pres

345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 345 - 365 (370 - 390) 300 – 330 300 – 330 380 - 400 LH relief reli ef 380 – 400 RH relief

WHE N SETTING SETTING THE RELI EF PRESSURE: PRESSURE: Set the high pressure setting (380 - 400) with the track F I R S T , 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.



















15

output pr pr essure : Connect a coupler nipple to the LS EPC solenoid check port. port. Attach a 60kg/cm2 gauge to the 5) LS E PC outp 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 valv e atneutral and while moving a work equipment lever. The pres sure and current should be within the standard values below. Ite m

Actual value

All levers in neutral

Any work eq. lever moved

LS EPC current curren t (code 15) * 870 - 930 930 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!

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

Rear Pump Servo Input

Rear Pump Main

Unload Pressure

Unload pressure

Approx.STD Ratio Servo Se rvo 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



















16

with NO tolerances); tolerances); 7) LS Differential - TIME Method: Method: Using LOW TRAVEL (Std. 5 turn spec with NO A mode; Hi Idle; Raise track, track, set travel lever at FULL STROKE Actual Value Measurement conditions A MODE, Hi Idle, Lo Travel speed, Right Track rotating at Full PPC stroke,Front stroke,Front pump A MODE, Hi Idle, Lo Travel speed, Left Track rotating rotating at Full PPC stroke, Rear Pump

After Adjusting

Standard Value, Seconds 56.0 +/- 0.5 sec 56.0 +/- 0.5 sec

Adjust LS Valve on each pump separately to achieve NO MORE than ½second ½second difference in Lo TVL cycle time. Each FLAT will change cycle approximately 2 seconds (5 turns, running start). LS Differential - PRESSURE Method: Consult LAST PAGE

8) PC E PC output utput pr essure: 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 press ure at the th e outlet outle t of the val ve at this t ime. The Th e pressure press ure and c urrent urren t should shoul d be withi n the sta ndard values below. Ite m Actual value Std value PC228USLCPC228US LC-3 3 PC EPC current (code 13) PC EPC output pressure

*

480 - 680 680 mA 5-10 kg/cm2

CHECK THESE al so: Arm @ relief Hi Idle Arm @ relief Lo Idle * Connector corrosion (even slight) can lower current readout even though function is normal.

9) PC Valve adjustment : The PC valve functions similar to the previous TVC valve. You use engine rpm over relief to





















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8





















18

PC228US-3 PC228US-3 Main Control Valve





















19

MONITOR PANEL OPERATION PC228USLC-3





















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 Displa y “ 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.





















21

Technician

Date

Customer

Model

Serial

PC 150LC PC15 0LC -6 S/N S/N : K 3000 30001 1 & up PL US K 3200 32000m 0m//c TESTI TESTI NG & ADJUSTMENT ADJUSTMENT PRO PROCEDURE CEDURE Use the following procedure procedure as a supplement to the Shop Manual when testing & adjusting the Komatsu PC150LC machines serial number K30001 to K32000 or . 6K machines Always ensure that all Service Codes and Controller Input & Output signals are nor mal before continuing with this procedure procedure.. See the the “Details of Troubleshooting and Troubleshooting Procedure” section in the Shop manual for instructions on checking the inputs and outputs. F ollow this this procedur procedure e i n or or der der fr om 1-9 beca because use ski ski ppi ppi ng one step step will affect the measurements in the following steps . Speeds using the machine monitor 1) Warm the machine up to operating temperature, and record all of the followingE ngi ne Spee























22

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

Unload Pressure

Measurement Measurement Conditions

H/O, Hi Idle, Neutral

Main Pump (code 11 )

After Adjusting not adjustable

Standard Value kg/cm2 30 - 50























23

7) Measure the LS L S Di D i ffe ff erential rential press pressure ure using the tracks. Adjust if the Difference between the Load Sense pressure and the Main pressure is outside the standard value while rotating the raised track in Hi travel speed at half stroke. Measurement conditions

H/O, Hi Idle, Neutral Neutr al H/O, Hi Idle, Hi Travel speed, Either Track rotating at full stroke

Actual Value

Standard Value

30 - 50 kg/cm2 28 - 30 kg/cm2 24.7-25.7**























24 FRONT VIEW OF PC150LC-6 MAIN CONTROL VALVE























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62















63 SIDE VIEW OF THE MAIN HYDRAUL IC PUMP

SELF PRESSURE REDUCING VALVE The Self-Pressure 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.















64

Komatsu Pump

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