Komatsu PC1250-11R PC1250SP-11R Hydraulic Excavator Shop Manual PDF

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Komatsu PC1250-11R PC1250SP-11R Hydraulic Excavator Shop Manual SEN06824-06 – PDF DOWNLOAD

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Komatsu PC1250-11R PC1250SP-11R Hydraulic Excavator Shop Manual SEN06824-06 – PDF DOWNLOAD

Language : English
Pages : 2516
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC1250-11R PC1250SP-11R Hydraulic Excavator Shop Manual SEN06824-06 – PDF DOWNLOAD

SERIAL NUMBERS

• PC1250- 50090        and up
  PC1250SP- 50090   and up

Cover 1
00 Index and Foreword . 3
Index . 4
Abbreviation List . 19
Foreword, Safety, Basic Information . 22
How to Read the Shop Manual . 22
Safety Notice for Operation . 24
Precautions to Prevent Fire . 32
Procedures If Fire Occurs . 34
Precautions When You Discard Waste Materials 35
Precautions When You Handle Hydraulic Equipment . 36
Precautions When You Disconnect and Connect Pipings . 39
Precautions When You Handle Electrical Equipment 45
Precautions When You Handle Fuel System Equipment . 47
Precautions When You Handle Intake System Equipment . 48
Practical Use of KOMTRAX 49
Disconnect and Connect Push-Pull Type Coupler . 50
How to Disconnect and Connect Type 1 Push-Pull Type Coupler . 50
How to Disconnect and Connect Type 2 Push-Pull Type Coupler . 51
How to Disconnect and Connect Type 3 Push-Pull Type Coupler . 52
Precautions for Disconnection and Connection of Connectors 54
How to Disconnect and Connect Deutsch Connector . 58
How to Disconnect and Connect Slide Lock Type Connector . 59
How to Disconnect and Connect Connector with Lock to Pull . 61
How to Disconnect and Connect Connector with Lock to Push . 62
How to Disconnect and Connect Connector with Housing to Rotate 64
How to Read the Codes for Electric Cable 65
Explanation of Terms for Maintenance Standard . 69
Standard Tightening Torque Table 72
Conversion Table 79
01 Specifications . 85
Table of Contents . 86
Specifications 87
Specification Drawing . 87
Specification Drawing: PC1250-11R . 87
Specification Drawing: PC1250SP-11R . 88
Specification Drawing: PC1250-11R(Loading Shovel specification) . 89
Working Range Drawings 90
Working Range: PC1250-11R . 90
Working Range: PC1250SP-11R . 91
Working Range: PC1250-11R(Loading Shovel specification) . 92
Specifications 93
Specifications: PC1250-11R 93
Specifications: PC1250SP-11R 95
Specifications: PC1250-11R(Loading Shovel specification) 99
Weight Table 103
Weight Table: PC1250-11R 103
Weight Table: PC1250SP-11R 104
Weight Table: PC1250-11R (Loading Shovel Specification) . 106
Fuel, Coolant and Lubricant to Meet Ambient Temperature . 108
10 Structure and Function . 111
Table of Contents . 112
Boot-up System 115
Layout Drawing of Boot-up System 115
System Operating Lamp System 116
System Diagram of System Operating Lamp System 116
Function of Operation Lamp System . 116
Battery Disconnect Switch . 118
Function of Battery Disconnect Switch . 118
Engine System . 119
Layout Drawing of Engine System . 119
Engine Control System . 121
System Diagram of Engine Control 121
Function of Engine Control System . 121
Auto-Deceleration System 124
System Diagram of Auto-Deceleration System 124
Function of Auto-Deceleration System 124
Operation of Auto-Deceleration System . 125
Automatic Low Idle System . 126
Automatic Low Idle System Diagram . 126
Function of Automatic Low Idle System . 126
Operation of Automatic Low Idle System 127
Engine Automatic Warm-up System . 128
System Diagram of Engine Automatic Warm-up System . 128
Function of Engine Automatic Warm-up System . 128
Overheat Prevention System 130
Overheat Prevention System Diagram 130
Function of Overheat Prevention System 130
Turbocharger Protection System 131
System Diagram of Turbocharger Protection System 131
Function of Turbocharger Protection System 131
Automatic Idle Stop System 132
System Diagram of Automatic Idle Stop System 132
Function of Automatic Idle Stop System 132
Component Parts of Engine System 135
PTO . 135
PTO Lubrication System 136
Cooling System 138
Layout Drawing of Cooling System 138
Specifications of Cooling System 139
Fan Speed Control System of Hydraulic Fan . 140
Fan Speed Control System Diagram of Hydraulic Fan . 140
Function of Fan Speed Control System of Hydraulic Fan . 141
Engine Output Control System of Hydraulic Fan . 142
Engine Output Control System Diagram of Hydraulic Fan . 142
Function of Engine Output Control System of Hydraulic Fan . 142
Fan Reverse Rotation System of Hydraulic Fan 144
Fan Reverse Rotation System Diagram of Hydraulic Fan 144
Function of Fan Reverse Rotation System of Hydraulic Fan 144
Component Parts of Cooling System . 145
Cooling Fan Pump 145
Cooling Fan Motor . 159
Control System 166
Layout Drawing of Control System 166
Machine Monitor System 168
System Diagram of Machine Monitor System 168
KomVision System 169
Layout Drawing of KomVision System 169
System Diagram of KomVision System 171
Function of KomVision System 171
KOMTRAX Plus System . 173
System Diagram of KOMTRAX Plus System . 173
Function of KOMTRAX Plus System . 173
Component Parts of Control System . 177
Machine Monitor . 177
KomVision Controller 189
KomVision Camera 193
KOMTRAX Terminal 194
KOMTRAX Plus Controller . 196
Wireless LAN Unit . 200
Pump Controller . 201
Resistor for TVC Valve 205
CAN Terminating Resistor 206
Engine Controller . 207
Fuel Control Dial . 219
Fuel Feed Pump 220
Fuel Feed Pump Switch . 221
Hydraulic System 222
Layout Drawing of Hydraulic System 222
OLSS 225
Structure of OLSS . 225
Function of OLSS 225
Pump Swash Plate Angle (Oil Flow) Control . 226
Engine and Pump Combined Control System . 237
Engine and Pump Combined Control System Diagram . 237
Function of Engine and Pump Combined Control System . 238
Component Parts of Hydraulic System . 241
Hydraulic Tank 241
Main Pump . 243
Control Valve . 287
Variable Back Pressure Valve 308
Work Equipment System . 311
Layout Drawing of Work Equipment System . 311
Machine Push-up System 317
Machine Push-up System Diagram 317
Function of Machine Push-up System 318
Heavy Lift System . 319
Heavy Lift System Diagram . 319
Function of Heavy Lift System . 320
Operation of Heavy Lift System 320
Boom Shockless Control System . 322
Boom Shockless Control Function System Diagram 322
Function of Boom Shockless Control System . 322
Operation of Boom Shockless Control System 322
PPC Lock System . 324
System Diagram of PPC Lock 324
Function of PPC Lock System . 324
Work Equipment and Travel Automatic Lock System . 325
System Diagram of Lock Lever Automatic Lock System 325
Function of Work Equipment and Travel Automatic Lock System . 325
Operation of Lock Lever Automatic Lock System . 326
Component Parts of Work Equipment System 327
Work Equipment and Swing PPC Valve 327
Solenoid Valve 332
Pilot Circuit Accumulator . 337
Swing System 339
Layout Drawing of Swing System 339
Swing Control System Diagram 342
Function of Swing Control System 343
Swing Priority System Diagram . 346
Function of Swing Priority System . 347
Swing Compensation System Diagram . 349
Function of Swing Compensation System . 349
Operation of Swing Compensation System 349
Component Parts of Swing System . 350
Swing Motor . 350
Swing Machinery . 361
Swing Circle 363
Travel System . 364
Layout Drawing of Travel System . 364
System Diagram of Travel Control System . 368
Function of Travel Control System . 369
Component Parts of Travel System 371
Travel Motor 371
Final Drive . 381
Travel PPC Valve 382
Center Swivel Joint . 386
Lifting System 388
Hydraulically Operated Stairway System 388
Layout Drawing of Hydraulically Operated Stairway System 388
Hydraulically Operated Stairway System Diagram 389
Function of Hydraulically Operated Stairway System 389
Component Parts of Lifting System . 391
Switch Box 391
Proximity Switch Part . 391
Control Valve Assembly 392
Undercarriage and Frame . 394
Layout Drawing of Undercarriage . 394
SPECIFICATIONS OF UNDERCARRIAGE . 394
Work Equipment 395
Structure of Work Equipment . 395
Function of Work Equipment 396
Work Equipment Clearance Adjustment Shim 397
Function of Work Equipment Clearance Adjustment Shim 397
Bucket Clearance Adjustment Shim 398
Function of Bucket Clearance Adjustment Shim 398
CAB Related Parts . 399
CAB . 399
Structure of CAB 399
CAB Mount . 400
Structure of CAB Mount 400
Function of CAB Mount . 400
CAB Tipping Stopper . 401
Structure of CAB Tipping Stopper 401
Function of CAB Tipping Stopper . 401
20 Standard Value Table . 403
Table of Contents . 404
Standard Value Table for Engine . 405
Standard Value Table for Engine: PC1250-11R . 405
Standard Value Table for Engine: PC1250SP-11R . 410
Standard Value Table for Machine 415
Standard Value Table for Machine: PC1250-11R 415
Standard Value Table for Machine: PC1250-11R (Loading Shovel Specification) . 429
Standard Value Table for Machine: PC1250SP-11R 444
Machine Posture and Procedures to Measure Performance . 458
Machine Posture and Procedures to Measure Performance (Loading Shovel Specification) 462
30 Testing and Adjusting 467
Table of Contents . 468
Precautions Before Work . 472
Related Information on Testing and Adjusting 473
Tools for Testing and Adjusting . 473
Sketch of Tools for Testing and Adjusting . 483
Engine and Cooling System . 484
Examine Engine Speed 484
How to Examine Engine Speed . 484
Examine Boost Pressure 487
How to Examine Boost Pressure on Machine Monitor 487
How to Examine Boost Pressure by Testing Tool . 488
Examine Exhaust Gas Temperature . 489
How to Examine Exhaust Gas Temperature 489
Examine Exhaust Gas Color . 491
How to Examine Exhaust Gas Color with the Handy Smoke Checker . 491
How to Examine Exhaust Gas Color with Smoke Meter . 492
Examine and Adjust Valve Clearance 495
How to Examine Valve Clearance 495
How to Adjust Valve Clearance . 496
Examine Compression Pressure 498
How to Examine Compression Pressure . 498
Examine Blowby Pressure . 502
How to Examine Blowby Pressure 502
Examine Engine Oil Pressure . 504
How to Examine Engine Oil Pressure on Machine Monitor . 504
How to Examine Engine Oil Pressure by Testing Tool 504
Examine Fuel Pressure . 506
How to Examine Fuel Pressure 506
Examine Fuel Return Rate and Leakage 508
How to Examine Fuel Return Rate and Leakage . 509
Bleed Air from Fuel System 513
How to Bleed Air from Fuel System . 513
Examine Fuel Circuit for Leakage 515
How to Examine Fuel System for Leakage 515
Examine Supply Pump . 517
How to Examine Supply Pump 517
Handle Cylinder Cut-out Mode Operation 520
Examine Alternator 521
How to Examine Alternator . 521
Handle No-Injection Cranking Operation 522
Write Injector Compensation Value to Engine Controller 523
How to Write Injector Compensation Value 523
Power Train . 529
Examine Swing Circle Bearing Clearance 529
How to Examine Swing Circle Bearing Clearance . 529
Undercarriage and Frame . 531
Examine Sprocket Wear . 531
How to Examine Sprocket Wear 531
Examine and Adjust Track Tension 532
How to Examine Track Tension 532
How to Adjust Track Tension . 532
Hydraulic System 534
Release Remained Pressure in Hydraulic Circuit 534
How to Release Remained Pressure in Hydraulic System 534
How to Release Remained Pressure from Swing Motor Circuit . 537
How to Release Remained Pressure from Travel Motor Circuit 537
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . 539
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits . 542
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 549
Examine and Adjust Oil Pressure in Control Circuit 553
How to Examine Oil Pressure in Control Circuit 553
How to Adjust Oil Pressure in Control Circuit . 554
Examine and Adjust Piston Pump Control Oil Pressure . 555
How to Examine TVC Valve Outlet Pressure 555
How to Examine CO Valve + NC Valve Outlet Pressure of No. 1 and No. 2 Pumps . 556
How to Examine CO Valve + NC Valve Outlet Pressure of No. 3 Pump 557
How to Examine Jet Sensor Outlet Differential Pressure of 4-Spool Control Valve on the Right Side and 5-Spool Control Valve on the Left Side 558
How to Examine Jet Sensor Outlet Differential Pressure of 4-Spool Control Valve for Swing . 559
How to Adjust TVC Valve . 560
How to Adjust CO Valve + NC Valve of No. 1 and No. 2 Pumps 561
How to Adjust CO Valve + NC Valve of No. 3 Pump . 562
How to Adjust Jet Sensor of 4-Spool Control Valve on the Right Side and 5-Spool Control Valve on the Left Side 562
How to Adjust Jet Sensor of 4-Spool Control Valve for Swing . 563
Examine Servo Piston Stroke . 564
How to Examine Servo Piston Stroke 564
Examine Outlet Pressure of Solenoid Valve . 566
How to Examine Outlet Pressure of Solenoid Valve 566
Operating Condition of Solenoid Valve . 568
Examine PPC Valve Outlet Pressure . 571
How to Examine Outlet Pressure in PPC Valve . 571
Examine Swing PPC Shuttle Valve Outlet Pressure . 573
How to Examine Swing PPC Shuttle Valve Outlet Pressure 573
Adjust Play of Work Equipment and Swing PPC Valves 575
How to Adjust Play of Work Equipment and Swing PPC Valves . 575
Examine Travel Deviation 576
How to Examine Travel Deviation . 576
Examine Cooling Fan Speed . 577
How to Examine Cooling Fan Speed 577
Examine Aftercooler Fan Speed . 578
How to Examine Aftercooler Fan Speed 578
Examine Oil Pressure in Fan Pump Circuit 579
How to Examine Oil Pressure in Fan Pump Circuit . 579
Examine Aftercooler Fan Pump Circuit Oil Pressure . 580
How to Examine Aftercooler Fan Pump Circuit Oil Pressure 580
Examine Fan Pump EPC Electric Current . 581
How to Examine Fan Pump EPC Electric Current 581
Examine Fan Pump EPC Solenoid Valve Outlet Pressure . 582
How to Examine Fan Pump EPC Solenoid Valve Outlet Pressure 582
Examine Parts Which Cause Hydraulic Drift of Work Equipment . 583
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder . 583
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 583
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 584
Examine Oil Leakage . 585
How to Examine Oil Leakage from Boom Cylinder . 585
How to Examine Oil Leakage from Arm Cylinder 586
How to Examine Oil Leakage from Bucket Cylinder . 586
How to Examine Oil Leakage from Swing Motor . 587
How to Examine Oil Leakage from Travel Motor 587
How to Examine Oil Leakage of Swivel Joint 588
Bleed Air from Hydraulic System . 590
How to Bleed Air from Hydraulic System 591
CAB Related Parts . 595
Examine CAB Tipping Stopper . 595
How to Examine Cab Tipping Stopper 595
How to Adjust Mirrors . 596
Procedure to Adjust Machine Left Front Mirror (A) . 596
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) . 597
Procedure to Adjust Machine Right Front Mirror (B) 598
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) 599
Procedure to Adjust Machine Right Front Mirror (C) 600
Procedure to Adjust Regular Position of Machine Right Front Mirror (C) 601
Electrical System . 603
Set and Operate Machine Monitor . 603
Operator Mode . 606
Function to Show Technician Identification Status Screen 606
Function to Show Operator Identification Input Screen . 606
Examine Function by LCD (Liquid Crystal Display) 607
Examine Function of Service Meter . 608
Usage Limitation and Maintenance Password Change Function . 608
Service Mode 610
How to Operate Service Mode . 610
How to See Pre-defined Monitoring Information . 612
How to Examine Self-Define Monitor Information 616
Abnormality Record Menu . 625
How to See Maintenance Record . 630
Maintenance Mode Setting 631
How to Set Phone Number Entry . 635
Default Menu 636
Diagnostic Tests Menu . 644
Adjustment Menu . 646
No-Injection Cranking Operation . 653
KOMTRAX Settings Menu . 654
How to Show Service Message . 656
How to Operate Snap Shot 657
How to Start Up KOMTRAX Terminal 659
Default Setting of KOMTRAX Plus Controller 665
Default Setting of KOMTRAX Plus Controller 665
Default Setting of Wireless LAN Modem . 668
Default Setting of Wireless LAN Modem . 668
How to Examine Wireless LAN Modem Communication . 669
Download Data from KOMTRAX Plus Controller 670
How to Download Data from KOMTRAX Plus Controller . 670
How to Download Data from Service Connector . 670
How to Download Data from Wireless LAN (Wireless LAN Spec) 672
Adjust After Replacement of KOMTRAX Plus Controller . 673
How to Adjust After Replacement of KOMTRAX Plus Controller 673
Adjust After Replacement of Wireless LAN Modem 676
How to Adjust After Replacement of Wireless LAN Modem . 676
Adjust KomVision Camera Angle . 679
How to Adjust KomVision Camera Angle 680
Adjust KomVision Related Function . 682
Setting of KomVision (Main Setting) . 682
Setting of KomVision (Camera Setting) . 684
Setting of KomVision (Camera Calibration) . 684
KomVision screen – Check 12 m visibility 698
Set Region of Bluetooth(R) Compatible Radio . 701
How to Set Region of Bluetooth(R) Compatible Radio 701
Handle Voltage Circuit of Engine Controller . 703
Handle Battery Disconnect Switch 704
Examine Diodes 705
How to Examine Diodes by Digital Tester . 705
How to Examine Diodes by Analog Tester 705
Pm Clinic . 706
Pm Clinic Service . 706
Pm Clinic Check Sheet: PC1250-11R . 711
Pm Clinic Check Sheet: PC1250SP-11R . 725
Perform Quick Pm 739
How to Perform Quick Pm . 739
40 Troubleshooting 745
Table of Contents . 746
Precautions Before Work . 754
Related Information to Troubleshooting 755
General Troubleshooting Points 755
Sequence of Events in Troubleshooting . 756
Checks Before Troubleshooting . 758
Inspection Procedure Before Troubleshooting . 760
Walk-Around Check . 760
Test in Accordance with Testing Procedure . 762
Examine Fuel Level and Type . 762
Examine for Impure Ingredient in Fuel . 763
Examine Fuel Prefilter 763
Examine Water Separator, Drain Water and Sediment . 764
Replace Fuel Prefilter Cartridge 764
Examine Fuel Main Filter 765
Examine Engine Oil Level (Oil Quantity in Oil Pan) 767
Examine Coolant Level (Reservoir Tank) 768
Examine Air Cleaner Clogging 769
Clean Outer Element . 769
Replace Element . 772
Examine Hydraulic Oil Level . 772
Examine Hydraulic Oil Strainer 774
Examine Hydraulic Oil Filter 775
Examine Oil Level in Swing Machinery Case . 776
Examine Oil Level in PTO Case . 778
Examine PTO Lubrication Filter Strainer . 778
Examine Oil Level in Final Drive Case . 779
Bleed Air from Fuel System 779
Bleed Air from Hydraulic System . 779
How to Examine Electric Equipment . 779
Preparation for Troubleshooting of Electrical System 785
Preparation for Troubleshooting of Machine Monitor 785
Preparation for Troubleshooting of Engine Controller 785
Preparation for Troubleshooting of Pump Controller 785
Preparation for Troubleshooting of KOMTRAX Terminal . 786
Preparation for Troubleshooting of KOMTRAX Plus Controller 786
Preparation for Troubleshooting of KomVision Controller . 786
How to Disconnect and Connect Connector with a Special Lock . 786
Procedure for Troubleshooting . 791
Symptom and Troubleshooting Numbers . 794
Information Shown in Troubleshooting Table 798
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness . 800
Connector List and Layout . 803
Connector Contact Connection Table 820
T-Branch Box and T-Branch Adapter Table . 867
Fuse Location Table . 873
Failure Code Table 876
Troubleshooting by Failure Code (Display of Code) . 889
Failure Code [879AKA] . 889
Failure Code [879AKB] . 890
Failure Code [879BKA] . 891
Failure Code [879BKB] . 893
Failure Code [879CKA] . 895
Failure Code [879CKB] . 896
Failure Code [879DKZ] . 897
Failure Code [879EMC] . 899
Failure Code [879FMC] . 900
Failure Code [879GKX] . 901
Failure Code [8800L8] . 903
Failure Code [8800ZG] . 904
Failure Code [989L00] . 905
Failure Code [989M00] . 906
Failure Code [989N00] . 907
Failure Code [A900FR] . 908
Failure Code [A900N6] . 909
Failure Code [A900NY] . 910
Failure Code [AA10NX] . 911
Failure Code [AB00KE] . 913
Failure Code [B@BAZG] . 915
Failure Code [B@BAZK] . 916
Failure Code [B@BCNS] . 918
Failure Code [B@BCZK] . 919
Failure Code [B@CBNS] . 921
Failure Code [B@BCQA] . 923
Failure Code [B@HAMB] . 925
Failure Code [B@HANS] . 926
Failure Code [CA115] 927
Failure Code [CA122] 931
Failure Code [CA123] 933
Failure Code [CA131] 935
Failure Code [CA132] 937
Failure Code [CA135] 939
Failure Code [CA141] 941
Failure Code [CA144] 943
Failure Code [CA145] 945
Failure Code [CA153] 947
Failure Code [CA154] 949
Failure Code [CA212] 951
Failure Code [CA213] 953
Failure Code [CA221] 955
Failure Code [CA222] 957
Failure Code [CA234] 959
Failure Code [CA238] 960
Failure Code [CA239] 962
Failure Code [CA271] 964
Failure Code [CA272] 966
Failure Code [CA273] 967
Failure Code [CA274] 969
Failure Code [CA322] 970
Failure Code [CA323] 972
Failure Code [CA324] 974
Failure Code [CA325] 976
Failure Code [CA331] 978
Failure Code [CA332] 980
Failure Code [CA343] 982
Failure Code [CA351] 984
Failure Code [CA352] 986
Failure Code [CA386] 988
Failure Code [CA441] 990
Failure Code [CA442] 992
Failure Code [CA449] 994
Failure Code [CA451] 995
Failure Code [CA452] 997
Failure Code [CA515] 999
Failure Code [CA516] 1000
Failure Code [CA553] 1001
Failure Code [CA559] 1002
Failure Code [CA689] 1007
Failure Code [CA691] 1009
Failure Code [CA692] 1011
Failure Code [CA697] 1013
Failure Code [CA698] 1014
Failure Code [CA731] 1015
Failure Code [CA778] 1019
Failure Code [CA1117] .1021
Failure Code [CA1135] .1023
Failure Code [CA1257] .1026
Failure Code [CA1843] .1027
Failure Code [CA1844] .1029
Failure Code [CA1942] .1031
Failure Code [CA2185] .1033
Failure Code [CA2186] .1034
Failure Code [CA2249] .1036
Failure Code [CA2555] .1041
Failure Code [CA2556] .1043
Failure Code [CA2765] .1045
Failure Code [CA4952] .1046
Failure Code [CB115] 1048
Failure Code [CB238] 1051
Failure Code [CB239] 1053
Failure Code [CB271] 1055
Failure Code [CB272] 1057
Failure Code [CB273] 1058
Failure Code [CB274] 1060
Failure Code [CB343] 1061
Failure Code [CB352] 1063
Failure Code [CB386] 1065
Failure Code [CB441] 1067
Failure Code [CB442] 1069
Failure Code [CB689] 1071
Failure Code [CB697] 1073
Failure Code [CB698] 1074
Failure Code [CB731] 1075
Failure Code [CB778] 1079
Failure Code [CB1117] .1081
Failure Code [CB1257] .1083
Failure Code [CB4952] .1084
Failure Code [D110KB] .1086
Failure Code [D163KB] .1088
Failure Code [D195KA] .1090
Failure Code [D195KB] .1092
Failure Code [D19JKZ] .1094
Failure Code [D1F0KA] .1096
Failure Code [D1F0KB] .1098
Failure Code [D1F0KY] .1100
Failure Code [D1R1KA] .1101
Failure Code [D1R1KB] .1103
Failure Code [D1R1KY] .1105
Failure Code [D862KA] .1106
Failure Code [DA20MC] .1107
Failure Code [DA22KK] .1108
Failure Code [DA25KP] .1110
Failure Code [DA26KP] .1112
Failure Code [DA29KQ] .1114
Failure Code [DA2LKA] .1116
Failure Code [DA2LKB] .1118
Failure Code [DA2QKR] .1120
Failure Code [DA2RKR] .1125
Failure Code [DAF0KM] .1130
Failure Code [DAF0MB] .1131
Failure Code [DAF0MC] .1132
Failure Code [DAF8KB] .1133
Failure Code [DAF9KQ] .1134
Failure Code [DAFGMC] .1135
Failure Code [DAFLKA] .1136
Failure Code [DAFLKB] .1139
Failure Code [DAFQKR] .1141
Failure Code [DAZ9KQ] .1145
Failure Code [DAZQKR] .1146
Failure Code [DB2QKR] .1149
Failure Code [DB2RKR] .1156
Failure Code [DBP0KM] .1162
Failure Code [DBP0KT] .1163
Failure Code [DBP5KB] .1164
Failure Code [DBP5KY] .1166
Failure Code [DBPQKR] .1168
Failure Code [DBV0MC] .1173
Failure Code [DBV1KK] .1174
Failure Code [DBV5KB] .1176
Failure Code [DBV6KB] .1180
Failure Code [DBVLKA] .1182
Failure Code [DBVLKB] .1184
Failure Code [DBVQKR] .1186
Failure Code [DBVRKR] .1190
Failure Code [DBVVKR] .1194
Failure Code [DBVWKR] .1195
Failure Code [DDNRKA] .1196
Failure Code [DDNRKY] .1198
Failure Code [DDNS00] .1200
Failure Code [DDXAL4] .1202
Failure Code [DGE5KB] .1204
Failure Code [DGH2KA] .1205
Failure Code [DGH2KB] .1207
Failure Code [DGT3KB] .1209
Failure Code [DGT4KA] .1211
Failure Code [DGT4KB] .1213
Failure Code [DGT5KA] .1215
Failure Code [DGT5KB] .1217
Failure Code [DHA4KA] .1219
Failure Code [DHPAMA] .1221
Failure Code [DHPAZL] .1223
Failure Code [DHPBMA] .1224
Failure Code [DHPBZL] .1226
Failure Code [DHPGMA] .1227
Failure Code [DHPGZL] .1229
Failure Code [DHPSMA] .1230
Failure Code [DHPZMA] .1232
Failure Code [DHS3MA] .1234
Failure Code [DHS4MA] .1237
Failure Code [DHS8MA] .1240
Failure Code [DHS9MA] .1243
Failure Code [DHSAMA] .1246
Failure Code [DHSBMA] .1249
Failure Code [DHSCMA] .1252
Failure Code [DHSDMA] .1255
Failure Code [DHSFMA] .1258
Failure Code [DHSGMA] .1261
Failure Code [DHSHMA] .1264
Failure Code [DHSJMA] .1267
Failure Code [DKR2KA] .1270
Failure Code [DKR2KB] .1272
Failure Code [DKR2NX] .1274
Failure Code [DKR3KA] .1276
Failure Code [DKR3KB] .1278
Failure Code [DKR3NX] .1280
Failure Code [DKULKA] .1282
Failure Code [DKULKB] .1284
Failure Code [DKULKY] .1286
Failure Code [DLM3KA] .1288
Failure Code [DLM3KB] .1290
Failure Code [DLM3MB] .1292
Failure Code [DMU6KB] .1293
Failure Code [DR10KA] .1295
Failure Code [DR12KA] .1298
Failure Code [DR20KA] .1300
Failure Code [DR21KX] .1302
Failure Code [DR30KA] .1304
Failure Code [DR31KX] .1306
Failure Code [DR40KA] .1308
Failure Code [DUMBKA] .1310
Failure Code [DUMBKB] .1313
Failure Code [DV20KB] .1315
Failure Code [DW41KA] .1317
Failure Code [DW41KB] .1319
Failure Code [DW41KY] .1321
Failure Code [DW43KA] .1322
Failure Code [DW43KB] .1324
Failure Code [DW43KY] .1325
Failure Code [DW45KA] .1326
Failure Code [DW45KB] .1329
Failure Code [DW45KY] .1332
Failure Code [DW48KA] .1334
Failure Code [DW48KB] .1336
Failure Code [DW48KY] .1338
Failure Code [DW4CKY] .1339
Failure Code [DW7BKA] .1341
Failure Code [DW7BKB] .1343
Failure Code [DW7BKY] .1345
Failure Code [DW91KA] .1346
Failure Code [DW91KB] .1348
Failure Code [DW91KY] .1349
Failure Code [DWK0KA] .1350
Failure Code [DWK0KB] .1352
Failure Code [DWK0KY] .1354
Failure Code [DWK2KA] .1355
Failure Code [DWK2KB] .1357
Failure Code [DWK2KY] .1359
Failure Code [DWK8KA] .1360
Failure Code [DWK8KB] .1362
Failure Code [DWK8KY] .1364
Failure Code [DWNRKA] .1365
Failure Code [DWNRKB] .1367
Failure Code [DWNRKY] .1369
Failure Code [DX16KA] .1370
Failure Code [DX16KB] .1372
Failure Code [DXA0KA] .1374
Failure Code [DXA0KB] .1376
Failure Code [DXAXKA] .1378
Failure Code [DXAXKB] .1380
Failure Code [DY20KA] .1382
Failure Code [DY20KA] .1384
Failure Code [DY20MA] .1387
Failure Code [DY20MA] .1389
Failure Code [DY2CKA] .1392
Failure Code [DY2CKB] .1394
Failure Code [DY2CKY] .1396
Failure Code [DY2DKB] .1398
Failure Code [DY2DKB] .1400
Failure Code [DY2EKB] .1403
Failure Code [DY2EKB] .1405
Failure Code [DY2FMA] .1408
Failure Code [F7FQKR] .1410
Failure Code [F7G0MC] .1414
Failure Code [F@BYNR] .1415
Failure Code [F@BYNS] .1416
Failure Code [F@BZNR] .1417
Failure Code [F@BZNS] .1418
Failure Code [F@HCZL] .1419
Failure Code [J100KA] .1420
Failure Code [J100KB] .1422
Failure Code [J100L6] .1424
Failure Code [J190KA] .1425
Failure Code [J190KB] .1427
Failure Code [J190L6] .1429
Failure Code [LA10ZL] .1430
Troubleshooting of Electrical System (E-Mode) .1431
E-1 Engine Does Not Start (Engine Does Not Crank) .1431
E-2 Manual Preheating System Does Not Operate .1438
E-3 Automatic Preheating System Does Not Operate 1441
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On .1443
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1445
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow .1448
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow .1449
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 1450
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs .1451
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 1452
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 1453
E-12 Fuel Level Monitor Comes On in Red While Engine Runs .1454
E-13 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1455
E-14 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation .1456
E-15 Hydraulic Oil Temperature Monitor Comes on in Red While Engine is in Operation .1457
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum .1458
E-17 Display of Fuel Gauge is Different from Actual Fuel Level 1460
E-18 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 1461
E-19 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 1462
E-20 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 1463
E-21 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1465
E-22 Some Areas of Machine Monitor Screen are Not Shown .1466
E-23 Function Switch Does Not Operate .1467
E-24 Automatic Warm-up System Does Not Work (in Cold Weather) .1468
E-25 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out .1469
E-26 Auto-Decelerator is Not Operated or Canceled with Lever 1470
E-27 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown .1471
E-28 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 1472
E-29 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change .1473
E-30 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 1474
E-31 Alarm Buzzer Cannot be Canceled 1475
E-32 Service Meter is Not Shown, While Starting Switch is in OFF Position .1476
E-33 Service Mode Cannot be Selected 1477
E-34 All of Work Equipment, Swing, and Travel Mechanism Do Not Move .1478
E-35 All Work Equipment, Swing and Travel Do Not Lock .1481
E-36 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing .1483
E-37 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate .1486
E-38 Alarm Does Not Sound During Travel .1488
E-39 Travel Alarm Does Not Stop When Machine Stops 1490
E-40 Horn Does Not Sound 1491
E-41 Horn Does Not Stop .1494
E-42 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 1496
E-43 Wiper Does Not Operate When Wiper Switch is Operated (Single Wiper Specification) 1497
E-44 Wiper Does Not Operate When Wiper Switch is Operated (Double Wiper Specification) 1499
E-45 Fuel Feed Pump Does Not Operate or Stop Automatically 1501
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated .1504
E-47 “Boom RAISE” is Not Shown Correctly with Monitoring Function .1505
E-48 “Boom LOWER” is Not Shown Correctly with Monitoring Function .1506
E-49 “Arm OUT” is Not Shown Correctly with Monitoring Function 1507
E-50 “Arm IN” is Not Shown Correctly with Monitoring Function .1508
E-51 “Bucket DUMP” is Not Shown Correctly with Monitoring Function 1509
E-52 “Bucket CURL” is Not Shown Correctly with Monitoring Function 1510
E-53 “Swing” is Not Shown Correctly with Monitoring Function 1511
E-54 “Travel” is Not Shown Correctly with Monitoring Function .1512
E-55 KOMTRAX System Does Not Operate Correctly 1513
E-56 Machine Push-Up Function Cannot be Canceled 1514
E-57 Machine Push-Up Function Does Not Operate 1516
E-58 Step Light Does Not Come On 1517
E-59 Step Light Does Not Go Out .1520
E-60 Boom Shockless Function Cannot be Canceled .1522
E-61 Boom Shockless Function Does Not Work 1524
E-62 Bottom Dump Cannot be Operated .1525
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) .1528
H-1 All Work Equipment, Travel, and Swing Speed or Power is Low .1528
H-2 Engine Speed Drops Significantly or Engine Stalls .1530
H-3 All Work Equipment, Swing and Travel Do Not Work 1531
H-4 Unusual Noise is Heard from Around Work Equipment Pump 1533
H-5 Boom Speed or Power is Low in Normal Mode .1534
H-6 Boom RAISE Speed or Power is Low in Heavy Lift Mode .1535
H-7 Boom LOWER Speed or Power is Low in Machine Push Up Mode 1536
H-8 Arm Speed or Power is Low .1537
H-9 Bucket Speed or Power is Low 1538
H-10 Boom Does Not Operate 1539
H-11 Arm Does Not Operate .1540
H-12 Bucket Does Not Operate 1541
H-13 Hydraulic Drift of Boom is Large .1542
H-14 Hydraulic Drift of Arm is Large 1543
H-15 Hydraulic Drift of Bucket is Large .1544
H-16 Time Lag of Boom is Large 1545
H-17 Time Lag of Arm is Large .1546
H-18 Time Lag of Bucket is Large 1547
H-19 Boom Shockless Function Does Not Work or Cannot be Released 1548
H-20 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Same Direction When Traveling Forward and Reverse) 1549
H-21 Machine Accidentally Turns to One Side When Machine Travels (It Turns in the Different Directions When Traveling Forward and Reverse) 1551
H-22 Travel Deviation is Large at Start of Travel Only When Travel Lever is Fully Moved .1552
H-23 Regardless of the Stroke of the Travel Lever, Travel Deviation is Large at Start of Traveling 1553
H-24 Travel Deviation is Large at Mixed Operation .1554
H-25 Travel Speed or Power is Low .1555
H-26 Only the One Side Track Can Operate (Machine Does Not Travel FORWARD or REVERSE) .1556
H-27 Only the One Side Track Can Operate (in Either Forward or Reverse Direction) .1557
H-28 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1558
H-29 Upper Structure Does Not Swing to Right and Left .1559
H-30 Upper Structure Swings Only to Right or Left .1560
H-31 Swing Acceleration or Swing Speed is Low in Lateral Directions (Right and Left) 1561
H-32 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Slow in Only One Direction 1562
H-33 In Mixed Operation of Work Equipment, Swing Speed or Power is Low 1563
H-34 Swing Acceleration or Swing Speed is Low During Mixed Operation with Boom in Swing Priority Mode .1564
H-35 Upper Structure Overruns Too Much When It Stops Swing Operation in Lateral Directions of Right and Left 1565
H-36 Upper Structure Speed is High When It Stops Swing Operation (on One Side) 1566
H-37 Shock is Large When Upper Structure Stops Swing Operation (Right and Left) .1567
H-38 Shock is Large When Upper Structure Stops Swing Operation (in Only Right of Left Direction) 1568
H-39 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation (in Right and Left Directions) .1569
H-40 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation in Only One Direction 1570
H-41 Swing Drift on a Slope is Large 1571
H-42 Fan Rotation is Abnormal (Such as Excessive Noise or Vibration of Fan, or Overheating) .1572
Troubleshooting of Engine (S-Mode) 1573
Information Shown in Troubleshooting Table (S-Mode) .1573
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 1574
S-2 Engine Cranks but No Exhaust Smoke Comes Out 1575
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 1576
S-4 Engine Startability is Unsatisfactory .1577
S-5 Engine Does Not Pick Up Smoothly 1579
S-6 Engine Stops During Operation .1581
S-7 Engine Runs Rough or is Not Stable 1583
S-8 Engine Lacks Power 1584
S-9 Engine Oil Consumption is Excessive .1586
S-10 Oil Becomes Dirty Quickly 1587
S-11 Fuel Consumption is Excessive 1588
S-12 Oil is in Coolant (or Coolant Spurts Back or Coolant Level Goes Down) 1589
S-13 Oil Pressure Drops .1590
S-14 Fuel Mixes Into Engine Oil .1591
S-15 Water Mixes Into Engine Oil (Milky) 1592
S-16 Coolant Temperature Increases Too High (Overheat) 1593
S-17 There is an Unusual Noise 1594
S-18 Vibration is Excessive .1595
S-19 Air Cannot be Bled from Fuel Circuit .1596
50 Disassembly and Assembly .1597
Table of Contents .1598
Precautions Before Work .1603
Related Information on Disassembly and Assembly .1604
How to Read This Manual .1604
Coating Materials List 1606
Special Tool List .1611
Sketches of Special Tools .1630
Engine and Cooling System .1638
Remove and Install Supply Pump Assembly .1638
How to Remove Supply Pump Assembly 1638
How to Install Supply Pump Assembly .1650
Remove and Install Injector Assembly 1663
How to Remove Injector Assembly .1664
How to Install Injector Assembly 1685
Remove and Install Cylinder Head Assembly .1711
How to Remove Cylinder Head Assembly 1712
How to Install Cylinder Head Assembly .1746
Remove and Install Starter Assembly .1793
How to Remove Starting Motor Assembly .1793
How to Install Starting Motor Assembly 1793
Remove and Install Alternator Belt 1795
How to Remove Alternator Belt .1795
How to Install Alternator Belt 1796
Remove and Install Radiator Assembly 1798
How to Remove Radiator Assembly .1798
How to Install Radiator Assembly 1802
Remove and Install Hydraulic Oil Cooler Assembly 1807
How to Remove Hydraulic Oil Cooler Assembly .1807
How to Install Hydraulic Oil Cooler Assembly 1812
Remove and Install Aftercooler Assembly .1818
How to Remove Aftercooler Assembly 1818
How to Install Aftercooler Assembly .1824
Remove and Install Cooling Fan Motor Assembly .1830
How to Remove Cooling Fan Motor Assembly 1830
How to Install Cooling Fan Motor Assembly .1843
Remove and Install Engine, PTO, and Hydraulic Pump Assembly .1855
How to Remove Engine, PTO, and Hydraulic Pump Assembly 1855
How to Install Engine, PTO, and Hydraulic Pump Assembly .1871
Remove and Install Engine Front Oil Seal 1888
How to Remove Engine Front Oil Seal .1888
How to Install Engine Front Oil Seal 1891
Remove and Install Engine Rear Oil Seal .1895
How to Remove Engine Rear Oil Seal 1895
How to Install Engine Rear Oil Seal .1896
Remove and Install Fuel Cooler Assembly .1900
How to Remove Fuel Cooler Assembly 1900
How to Install Fuel Cooler Assembly .1901
Remove and Install Engine Hood Assembly .1903
How to Remove Engine Hood Assembly 1903
How to Install Engine Hood Assembly .1908
Remove and Install Fuel Tank Assembly .1914
How to Remove Fuel Tank Assembly 1914
How to Install Fuel Tank Assembly .1919
Remove and Install Muffler Assembly .1924
How to Remove Muffler Assembly 1924
How to Install Muffler Assembly .1928
Remove and Install Bellows Pipe Assembly 1933
How to Remove Bellows Pipe Assembly .1933
How to Install Bellows Pipe Assembly 1937
Remove and Install Air Cleaner Assembly .1941
How to Remove Air Cleaner Assembly 1941
How to Install Air Cleaner Assembly .1942
Remove and Install Air Conditioner Compressor Assembly 1943
How to Remove Air Conditioner Compressor Assembly .1943
How to Install Air Conditioner Compressor Assembly 1944
Remove and Install Air Conditioner Condenser Assembly .1946
How to Remove Air Conditioner Condenser Assembly 1946
How to Install Air Conditioner Condenser Assembly .1947
Power Train .1950
Disassemble and Assemble PTO Assembly .1950
How to Disassemble PTO Assembly .1950
How to Assemble PTO Assembly 1952
Remove and Install PTO Assembly .1956
How to Remove PTO Assembly 1956
How to Install PTO Assembly .1958
Remove and Install Travel Motor and Final Drive Assembly 1961
How to Remove Travel Motor and Final Drive Assembly .1961
How to Install Travel Motor and Final Drive Assembly 1962
Disassemble and Assemble Final Drive Assembly .1963
How to Disassemble Final Drive Assembly .1963
How to Assemble Final Drive Assembly 1968
Remove and Install Swing Motor and Swing Machinery Assembly .1976
How to Remove Swing Motor and Swing Machinery Assembly 1976
How to Install Swing Motor and Swing Machinery Assembly .1978
Disassemble and Assemble Swing Machinery Assembly .1981
How to Disassemble Swing Machinery Assembly .1981
How to Assemble Swing Machinery Assembly 1985
Remove and Install Swing Circle Assembly 1991
How to Remove Swing Circle Assembly .1991
How to Install Swing Circle Assembly 1992
Undercarriage and Frame .1993
Remove and Install Idler Assembly .1993
How to Remove Idler Assembly 1993
How to Install Idler Assembly .1994
Disassemble and Assemble Recoil Spring Assembly .1995
How to Disassemble Recoil Spring Assembly .1995
How to Assemble Recoil Spring Assembly 1996
Remove and Install Track Roller Assembly 1997
How to Remove Track Roller Assembly .1997
How to Install Track Roller Assembly 1998
Remove and Install Carrier Roller Assembly 2000
How to Remove Carrier Roller Assembly .2000
How to Install Carrier Roller Assembly 2001
Disassemble and Assemble One Track Link Assembly in Field .2002
How to Disassemble One Track Link Assembly in Field .2004
How to Assemble One Track Link Assembly in Field 2005
Separate and Connect Track Assembly .2008
How to Separate Track Assembly 2009
How to Install Track Assembly .2010
Disassemble and Assemble Idler Assembly .2011
How to Disassemble Idler Assembly .2011
How to Assemble Idler Assembly 2013
Disassemble and Assemble Idler Adjustment Cylinder Assembly .2016
How to Disassemble Idler Adjustment Cylinder Assembly .2016
How to Assemble Idler Adjustment Cylinder Assembly 2017
Disassemble and Assemble Track Roller Assembly 2018
How to Disassemble Track Roller Assembly 2018
How to Assemble Track Roller Assembly .2019
Disassemble and Assemble Carrier Roller Assembly 2022
How to Disassemble Carrier Roller Assembly 2022
How to Assemble Carrier Roller Assembly .2023
Remove and Install Revolving Frame Assembly .2025
How to Remove Revolving Frame Assembly 2025
How to Install Revolving Frame Assembly .2026
Remove and Install Counterweight Assembly .2028
How to Remove Counterweight Assembly 2028
How to Install Counterweight Assembly .2030
Hydraulic System 2032
Remove and Install Center Swivel Joint Assembly .2032
How to Remove Center Swivel Joint Assembly 2032
How to Install Center Swivel Joint Assembly .2033
Disassemble and Assemble Center Swivel Joint Assembly .2035
How to Disassemble Center Swivel Joint Assembly .2036
How to Assemble Center Swivel Joint Assembly 2037
Remove and Install Hydraulic Tank Assembly 2038
How to Remove Hydraulic Tank Assembly .2038
How to Install Hydraulic Tank Assembly 2042
Remove and Install Hydraulic Pump Assembly 2047
How to Remove Hydraulic Pump Assembly .2047
How to Install Hydraulic Pump Assembly 2058
Remove and Install Control Valve Assembly .2068
How to Remove Control Valve Assembly 2068
How to Install Control Valve Assembly .2073
Remove and Install Swing Motor Assembly .2080
How to Remove Swing Motor Assembly 2080
How to Install Swing Motor Assembly .2081
Disassemble and Assemble Work Equipment PPC Valve Assembly 2083
How to Disassemble Work Equipment PPC Valve Assembly 2083
How to Assemble Work Equipment PPC Valve Assembly .2084
Disassemble and Assemble Travel PPC Valve Assembly 2086
How to Disassemble Travel PPC Valve Assembly 2086
How to Assemble Travel PPC Valve Assembly .2087
Disassemble and Assemble Grease Gun Assembly 2089
How to Disassemble Grease Gun Assembly 2089
How to Assemble Grease Gun Assembly .2089
Work Equipment 2090
Remove and Install Bucket Cylinder Assembly .2090
How to Remove Bucket Cylinder Assembly 2090
How to Install Bucket Cylinder Assembly .2091
Remove and Install Bucket Cylinder Assembly (Loading Shovel Specification) 2093
How to Remove Bucket Cylinder Assembly (Loading Shovel Specification) .2093
How to Install Bucket Cylinder Assembly (Loading Shovel Specification) 2094
Remove and Install Arm Cylinder Assembly 2096
How to Remove Arm Cylinder Assembly .2096
How to Install Arm Cylinder Assembly 2098
Remove and Install Arm Cylinder Assembly (Loading Shovel Specification) .2100
How to Remove Arm Cylinder Assembly (Loading Shovel Specification) 2100
How to Install Arm Cylinder Assembly (Loading Shovel Specification) .2102
Remove and Install Boom Cylinder Assembly .2104
How to Remove Boom Cylinder Assembly 2104
How to Install Boom Cylinder Assembly .2105
Remove and Install Boom Cylinder Assembly (Loading Shovel Specification) 2107
How to Remove Boom Cylinder Assembly (Loading Shovel Specification) .2107
How to Install Boom Cylinder Assembly (Loading Shovel Specification) 2108
Remove and Install Bucket Assembly 2111
How to Remove Bucket Assembly .2112
How to Install Bucket Assembly 2113
Remove and Install Bucket Assembly (Loading Shovel Specification) .2115
How to Remove Bucket Assembly (Loading Shovel Specification) 2115
How to Install Bucket Assembly (Loading Shovel Specification) .2116
Remove and Install Arm Assembly .2118
How to Remove Arm Assembly 2118
How to Install Arm Assembly .2119
Remove and Install Arm Assembly (Loading Shovel Specification) 2121
How to Remove Arm Assembly (Loading Shovel Specification) .2121
How to Install Arm Assembly (Loading Shovel Specification) 2122
Remove and Install Boom Assembly 2124
How to Remove Boom Assembly .2124
How to Install Boom Assembly 2126
Remove and Install Boom Assembly (Loading Shovel Specification) .2128
How to Remove Boom Assembly (Loading Shovel Specification) 2128
How to Install Boom Assembly (Loading Shovel Specification) .2130
Disassemble and Assemble Work Equipment Cylinder Assembly .2132
How to Disassemble Work Equipment Cylinder Assembly .2133
How to Assemble Work Equipment Cylinder Assembly 2135
Disassemble and Assemble Bottom Dump Cylinder Assembly (Loading Shovel Specification) .2140
How to Disassemble Bottom Dump Cylinder Assembly (Loading Shovel Specification) .2140
How to Assemble Bottom Dump Cylinder Assembly (Loading Shovel Specification) 2146
CAB Related Parts .2151
Remove and Install Top Guard Assembly .2151
How to Remove Top Guard Assembly 2151
How to Install Top Guard Assembly .2153
Remove and Install Operator Cab Assembly 2156
How to Remove Operator Cab Assembly .2156
How to Install Operator Cab Assembly 2165
Remove and Install Operator Cab Glass (Adhered Glass) .2175
How to Remove Operator Cab Glass (Adhered Glass) 2177
How to Install Operator Cab Glass (Adhered Glass) .2177
Remove and Install Front Window Assembly 2187
How to Remove Front Window Assembly .2187
How to Install Front Window Assembly 2190
Remove and Install Floor Frame Assembly .2196
How to Remove Floor Frame Assembly 2196
How to Install Floor Frame Assembly .2202
Remove and Install Air Conditioner Unit Assembly 2209
How to Remove Air Conditioner Unit Assembly .2209
How to Install Air Conditioner Unit Assembly 2214
Remove and Install Operator Seat 2221
How to Remove Operator Seat .2221
How to Install Operator Seat 2223
How to Remove and Install Seat Belt .2226
How to Remove Seat Belt .2226
How to Install Seatbelt .2226
Remove and Install Work Equipment Control Lever Assembly 2228
How to Remove Work Equipment Control Lever Assembly .2228
How to Install Work Equipment Control Lever Assembly 2234
Remove and Install Front Wiper Assembly .2242
How to Remove Front Wiper Assembly 2242
How to Install Front Wiper Assembly .2247
Electrical System .2256
Remove and Install Engine Controller Assembly .2256
How to Remove Engine Controller Assembly 2256
How to Install Engine Controller Assembly .2258
Remove and Install Pump Controller Assembly .2261
How to Remove Pump Controller Assembly 2261
How to Install Pump Controller Assembly .2263
Remove and Install KomVision Controller Assembly 2266
How to Remove KomVision Controller Assembly .2266
How to Install KomVision Controller Assembly 2267
Remove and Install Machine Monitor Assembly .2269
How to Remove Machine Monitor Assembly 2269
How to Install Machine Monitor Assembly .2271
Remove and Install Crankcase Pressure Sensor 2275
How to Remove Crankcase Pressure Sensor .2275
How to Install Crankcase Pressure Sensor 2276
Remove and Install KomVision Camera .2278
How to Remove KomVision Camera 2278
How to Install KomVision Camera .2279
Remove and Install KOMTRAX Terminal Assembly 2281
How to Remove KOMTRAX Terminal Assembly .2281
How to Install KOMTRAX Terminal Assembly 2283
Remove And Install KOMTRAX Plus Controller Assembly .2285
How to Remove KOMTRAX Plus Controller Assembly 2285
How to Install KOMTRAX Plus Controller Assembly .2287
Remove and Install Wireless LAN Unit Assembly .2289
How to Remove Wireless LAN Unit Assembly 2289
How to Install Wireless LAN Unit Assembly .2290
60 Maintenance Standard .2293
Table of Contents .2294
Engine and Cooling System .2295
Maintenance Standard for Engine Mount .2295
Maintenance Standard for PTO 2296
Maintenance Standard for Cooling System .2297
Maintenance Standard for Cooling Fan Pump .2299
Maintenance Standard for EPC Valve of Cooling Fan Pump 2301
Maintenance Standard for Cooling Fan Motor 2302
Power Train .2304
Maintenance Standard for Swing Circle .2304
Maintenance Standard for Swing Machinery 2305
Maintenance Standard for Final Drive 2307
Maintenance Standard for Sprocket .2309
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 2310
Undercarriage and Frame .2311
Maintenance Standard for Track Frame and Idler Cushion 2311
Maintenance Standard for Idler 2313
Maintenance Standard for Track Roller .2315
Maintenance Standard for Carrier Roller .2316
Maintenance Standard for Track Shoes 2317
Maintenance Standard for Double Shoes .2320
Hydraulic System 2321
Maintenance Standard for Main Pump 2321
Maintenance Standard for Swing Motor 2325
Maintenance Standard for Control Valve 2328
Maintenance Standard for Straight Travel Valve of Control Valve .2339
Maintenance Standard for Variable Back Pressure Valve .2340
Maintenance Standard for Work Equipment and Swing PPC Valve .2341
Maintenance Standard for Travel PPC Valve .2344
Maintenance Standard for Solenoid Valve .2346
Maintenance Standard for Center Swivel Joint 2347
Work Equipment 2348
Maintenance Standard for Work Equipment Linkage .2348
Dimensions of Arm .2351
Dimensions of Bucket 2353
Maintenance Standard for Work Equipment Linkage (Loading Shovel Specification) 2355
Dimensions of Arm (Loading Shovel Specification) 2358
Dimensions of Bucket (Loading Shovel Specification) .2360
Maintenance Standard for Boom Cylinder 2362
Maintenance Standard for Boom Cylinder (Loading Shovel Specification) .2363
Maintenance Standard for Arm Cylinder .2364
Maintenance Standard for Arm Cylinder (Loading Shovel Specification) 2365
Maintenance Standard for Bucket Cylinder 2366
Maintenance Standard for Bucket Cylinder (Loading Shovel Specification) .2367
Maintenance Standard for Bottom Dump Cylinder (Loading Shovel Specification) 2368
80 Appendix .2369
Table of Contents .2370
Precautions Before Work .2372
Air Conditioner System 2373
Precautions for Refrigerant .2373
Air Conditioner Component .2374
Specifications of Air Conditioner .2376
Structure and Function of Refrigeration Cycle .2377
Outline of Refrigeration Cycle 2378
Component Parts of Air Conditioner System .2380
Air Conditioner Unit 2380
Configuration Diagram of Air Conditioner Unit .2380
Function of Air Conditioner Unit 2382
Component Parts of Air Conditioner Unit .2384
Function of Evaporator as Air Conditioner Unit Component 2385
Function of Heater Core as Air Conditioner Unit Component .2385
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component .2385
Function of Servo Motor as Air Conditioner Unit Component .2385
Structure of Expansion Valve as Air Conditioner Unit Component 2386
Function of Expansion Valve as Air Conditioner Unit Component .2386
Operate Expansion Valve as Air Conditioner Unit Component .2386
Function of Dual Pressure Switch 2387
Air Conditioner Controller 2388
Structure of Air Conditioner Controller .2388
Compressor 2389
Structure of Compressor .2389
Specifications of Compressor 2389
Function of Compressor 2389
Condenser .2390
Structure of Condenser 2390
Specifications of Condenser .2390
Function of Condenser .2390
Receiver Drier 2391
Structure of Receiver Dryer .2391
Specifications of Receiver Dryer 2391
Function of Receiver Dryer 2391
Air Conditioner Related Sensors .2392
Structure of Sunlight Sensor 2392
Function of Sunlight Sensor .2392
Structure of Outside Temperature Sensor .2392
Function of Outside Air Temperature Sensor 2392
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner .2394
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2396
System Diagram of Air Conditioner .2398
Input and Output Signals of Air Conditioner Controller 2399
Function of Air Conditioner Controller 2400
Locations of Air Conditioner Parts and Layout of Connectors .2401
Examine Air Leakage (Duct) 2405
How to Examine Air Leakage (Duct) .2405
Examine Air Conditioner with Self-Diagnosis Function 2406
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor .2407
Examine Vent (Mode) Changeover 2408
How to Examine Vent (Mode) Changeover .2408
Examine Fresh/Recirc Air Changeover .2409
How to Examine Fresh/Recirc Air Changeover 2409
Examine Sunlight Sensor .2410
How to Examine Sunlight Sensor 2410
Examine Refrigerant (Dual) Pressure Switch 2411
How to Examine Refrigerant (Dual) Pressure Switch .2411
Examine Relay .2412
How to Examine Relay 2412
Air Conditioner Troubleshooting Chart 1 .2413
Air Conditioner Troubleshooting Chart 2 .2414
Information Shown in Troubleshooting Table 2417
Failure Code [879AKA] .2418
Failure Code [879AKB] .2419
Failure Code [879BKA] .2420
Failure Code [879BKB] .2422
Failure Code [879CKA] .2424
Failure Code [879CKB] .2425
Failure Code [879DKZ] .2426
Failure Code [879EMC] .2428
Failure Code [879FMC] .2429
Failure Code [879GKX] .2430
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2432
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) .2434
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2437
A-4 Troubleshooting for Fresh/Recirc Air Changeover .2439
Troubleshooting by Gauge Pressure .2441
Connect Service Tool 2444
How to Connect Service Tool .2444
Precautions for Disconnection and Connection of Air Conditioner Piping 2446
Handle Compressor Oil .2448
90 Circuit Diagrams .2451
Table of Contents .2452
Hydraulic Circuit Diagram .2453
Symbols Used in Hydraulic Circuit Diagram .2453
Hydraulic Circuit Diagram(1/4) 2457
Hydraulic Circuit Diagram(2/4) 2459
Hydraulic Circuit Diagram(3/4) 2461
Hydraulic Circuit Diagram(4/4) 2463
Electrical Circuit Diagram 2465
Symbols Used in Electric Circuit Diagram 2465
Electrical Circuit Diagram (1/15) .2469
Electrical Circuit Diagram (2/15) .2471
Electrical Circuit Diagram (3/15) .2473
Electrical Circuit Diagram (4/15) .2475
Electrical Circuit Diagram (5/15) .2477
Electrical Circuit Diagram (6/15) .2479
Electrical Circuit Diagram (7/15) .2481
Electrical Circuit Diagram (8/15) .2483
Electrical Circuit Diagram (9/15) .2485
Electrical Circuit Diagram (10/15) 2487
Electrical Circuit Diagram (11/15) 2489
Electrical Circuit Diagram (12/15) 2491
Electrical Circuit Diagram (13/15) 2493
Electrical Circuit Diagram (14/15) 2495
Electrical Circuit Diagram (15/15) 2497
Index 2499

DESCRIPTION:

Komatsu PC1250-11R PC1250SP-11R Hydraulic Excavator Shop Manual SEN06824-06 – PDF DOWNLOAD

SERIAL NUMBERS

• PC1250- 50090        and up
  PC1250SP- 50090   and up

G.B 27/12/24