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KOMATSU PC1250-7 PC1250SP-7 PC1250LC-7 SHOP MANUAL SEBM027312 – PDF DOWNLOAD
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Description
KOMATSU PC1250-7 PC1250SP-7 PC1250LC-7 SHOP MANUAL SEBM027312 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC1250-7 PC1250SP-7 PC1250LC-7 SHOP MANUAL SEBM027312 – PDF DOWNLOAD
Language : English
Pages : 970
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC1250-7 PC1250SP-7 PC1250LC-7 SHOP MANUAL SEBM027312 – PDF DOWNLOAD
COVER................................................................................................................... 1 CONTENTS................................................................................................................ 2 LIST OF REVISED PAGES................................................................................................... 3 SAFETY.................................................................................................................. 9 SAFETY NOTICE....................................................................................................... 9 FOREWORD................................................................................................................ 11 GENERAL............................................................................................................. 11 HOW TO READ THE SHOP MANUAL......................................................................................... 12 HOISTING INSTRUCTIONS............................................................................................... 13 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.......................................................... 14 COATING MATERIALS................................................................................................... 16 STANDARD TIGHTENING TORQUE.......................................................................................... 18 ELECTRIC WIRE CODE.................................................................................................. 21 CONVERSION TABLE.................................................................................................... 22 UNITS............................................................................................................... 28 01 GENERAL.............................................................................................................. 29 SPECIFICATION DIMENSION DRAWINGS.................................................................................... 30 SPECIFICATIONS...................................................................................................... 34 WEIGHT TABLE........................................................................................................ 38 FUEL, COOLANT AND LUBRICANTS........................................................................................ 42 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD......................................................................... 43 PTO................................................................................................................. 44 PTO LUBRICATION SYSTEM.............................................................................................. 46 RADIATOR, OIL COOLER, AFTERCOOLER AND FUEL COOLER................................................................... 48 POWER TRAIN......................................................................................................... 50 SWING MACHINERY..................................................................................................... 52 SWING CIRCLE........................................................................................................ 54 FINAL DRIVE......................................................................................................... 55 SPROCKET............................................................................................................ 58 TRACK FRAME......................................................................................................... 60 IDLER............................................................................................................... 62 CARRIER ROLLER...................................................................................................... 64 TRACK ROLLER........................................................................................................ 65 TRACK SHOE.......................................................................................................... 66 AIR PIPING DIAGRAM.................................................................................................. 70 AIR CIRCUIT DIAGRAM................................................................................................. 71 AIR GOVERNOR........................................................................................................ 72 AIR TANK............................................................................................................ 72 SAFETY VALVE........................................................................................................ 73 HORN VALVE.......................................................................................................... 73 GREASE PUMP......................................................................................................... 74 HYDRAULIC EQUIPMENT LAYOUT DRAWING.................................................................................. 76 HYDRAULIC TANK...................................................................................................... 81 HYDRAULIC PUMP...................................................................................................... 82 NO. 1 PUMP.......................................................................................................... 83 NO. 2 PUMP..........................................................................................................106 NO. 3 PUMP..........................................................................................................111 LINE OIL FILTER.....................................................................................................120 PILOT OIL FILTER....................................................................................................121 RETURN OIL FILTER...................................................................................................122 DRAIN OIL FILTER....................................................................................................123 L.H. 5-SPOOL CONTROL VALVE..........................................................................................124 R.H. 4-SPOOL CONTROL VALVE..........................................................................................128 SWING 4-SPOOL CONTROL VALVE.........................................................................................132 STRAIGHT-TRAVEL VALVE...............................................................................................138 SWING MOTOR.........................................................................................................141 CENTER SWIVEL JOINT.................................................................................................143 TRAVEL MOTOR........................................................................................................144 PPC CONTROL RELIEF VALVE............................................................................................154 ACCUMULATOR.........................................................................................................156 VALVE CONTROL.......................................................................................................157 WORK EQUIPMENT, SWING PPC VALVE.....................................................................................158 TRAVEL PPC VALVE....................................................................................................164 SOLENOID VALVE......................................................................................................168 HYDRAULIC CYLINDER..................................................................................................176 WORK EQUIPMENT......................................................................................................180 DIMENSIONS OF WORK EQUIPMENT........................................................................................184 AIR CONDITIONER.....................................................................................................188 ENGINE CONTROL......................................................................................................189 HPI ENGINE CONTROL SYSTEM...........................................................................................195 MACHINE CONTROL SYSTEM..............................................................................................197 MONITOR SYSTEM......................................................................................................225 SENSOR..............................................................................................................248 20 TESTING AND ADJUSTING................................................................................................251 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.......................................................................252 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS......................................................................256 TESTING AND ADJUSTING...............................................................................................275 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING................................................................276 MEASURING ENGINE SPEED..........................................................................................280 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)..................................................................281 MEASURING EXHAUST TEMPERATURE...................................................................................282 TROUBLESHOOTING FOR INJECTOR....................................................................................283 MEASURING EXHAUST COLOR.........................................................................................284 ADJUSTING VALVE CLEARANCE.......................................................................................285 ADJUSTING INJECTOR SET LOAD.....................................................................................286 MEASURING COMPRESSION PRESSURE..................................................................................288 MEASURING BLOW-BY PRESSURE......................................................................................290 MEASURING ENGINE OIL PRESSURE...................................................................................291 HANDLING EQUIPMENT IN FUEL SYSTEM...............................................................................292 MEASURING FUEL CIRCUIT PRESSURE.................................................................................293 VISUAL INSPECTION OF RETURN FUEL................................................................................295 ARRANGEMENT OF CONTROL DEVICES FOR HPI..........................................................................296 BLEEDING AIR FROM FUEL CIRCUIT..................................................................................299 ADJUSTING ENGINE SPEED SENSOR...................................................................................301 REPLACING AND ADJUSTING FAN BELT................................................................................302 TESTING AND ADJUSTING ALTERNATOR AND AIR COMPRESSOR BELT TENSION................................................303 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................305 MEASURING WEAR OF SPROCKET......................................................................................306 TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................307 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................308 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE..............................................................315 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE..............................................................316 TESTING SERVO PISTON STROKE.....................................................................................323 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTINGS WING PPC SHUTTLE VALVE.........................................324 MEASURING SOLENOID VALVE OUTPUT PRESSURE........................................................................328 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................330 TESTING TRAVEL DEVIATION........................................................................................331 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................332 MEASURING OIL LEAKAGE...........................................................................................333 MEASURING FAN SPEED.............................................................................................337 MEASURING FAN CIRCUIT OIL PRESSURE..............................................................................337 BLEEDING AIR....................................................................................................339 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................341 INSPECTION PROCEDURES FOR DIODE.................................................................................342 SPECIAL FUNCTION OF MONITOR PANEL...............................................................................343 INITIALIZATION PROCEDURES FOR VHMS CONTROLLER...................................................................373 SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER................................................................386 TESTING AND ADJUSTING DEVICES RELATED TO VHMS...................................................................401 PM-CLINIC SERVICE...............................................................................................405 TROUBLESHOOTING.....................................................................................................419 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................420 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................421 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................422 CHECKS BEFORE TROUBLESHOOTING...................................................................................430 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING....................................................................431 CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM.....................................435 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................458 T-BRANCH BOX AND T-BRANCH TABLE.................................................................................482 TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (1/2)....485 INFORMATION IN TROUBLESHOOTING TABLE........................................................................486 Error code in Electrical System C111 (ECM Microprocessor)...................................................488 Error code in Electrical System C112 (Timing Actuator Stuck)................................................488 Error code in Electrical System C113 (Timing Actuator Current)..............................................489 Error code in Electrical System C115 (Engine Speed Sensor (2))..............................................490 Error code in Electrical System C116 (Timing Rail P. Sensor)................................................492 Error code in Electrical System C117 (Timing Rail P. Sensor)................................................493 Error code in Electrical System C118 (Fuel Pump P. Sensor)..................................................494 Error code in Electrical System C119 (Fuel Pump P. Sensor)..................................................496 Error code in Electrical System C121 (Engine Speed Sensor (1))..............................................496 Error code in Electrical System C122 (Boost P. Sensor)......................................................498 Error code in Electrical System C123 (Boost P. Sensor)......................................................499 Error code in Electrical System C131 (Throttle Sensor)......................................................500 Error code in Electrical System C132 (Throttle Sensor)......................................................501 Error code in Electrical System C135 (Oil P. Sensor)........................................................502 Error code in Electrical System C141 (Oil P. Sensor)........................................................504 Error code in Electrical System C143 (Oil P. Low)...........................................................504 Error code in Electrical System C144 (Coolant T. Sensor)....................................................505 Error code in Electrical System C145 (Coolant T. Sensor)....................................................507 Error code in Electrical System C151 (Coolant T. High)......................................................507 Error code in Electrical System C153 (Intake Manifold T. Sensor)............................................508 Error code in Electrical System C154 (Intake Manifold T. Sensor)............................................509 Error code in Electrical System C222 (Ambient Air P. Sensor)................................................512 Error code in Electrical System C234 (Engine Overspeed).....................................................512 Error code in Electrical System C254 (FSOV Circuit).........................................................513 Error code in Electrical System C259 (FSOV Circuit).........................................................514 Error code in Electrical System C261 (Fuel T. High).........................................................514 Error code in Electrical System C263 (Fuel T. Sensor).......................................................515 Error code in Electrical System C265 (Fuel T. Sensor).......................................................516 Error code in Electrical System C316 (Fuel Pump Actuator Current)...........................................517 Error code in Electrical System C318 (Fuel Pump Actuator Stuck).............................................518 Error code in Electrical System C346 (ECM Powerdown)........................................................520 Error code in Electrical System C423 (Timing Rail P. In Range Error)........................................522 Error code in Electrical System C441 (Battery Voltage)......................................................524 Error code in Electrical System C442 (Battery Voltage)......................................................524 Error code in Electrical System C451 (Fuel Rail P. Sensor)..................................................525 Error code in Electrical System C452 (Fuel Rail P. Sensor)..................................................526 Error code in Electrical System C455 (Fuel Rail Actuator Current)...........................................527 Error code in Electrical System C467 (Timing Actuator Control)..............................................528 Error code in Electrical System C468 (Rail Actuator Control)................................................528 Error code in Electrical System C514 (Rail Actuator Stuck)..................................................529 Error code in Electrical System C554 (Fuel Rail P. In Range Error)..........................................530 TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (2/2)....533 Error Code in Electrical System E101 (Abnormality Error Record).............................................536 Error Code in Electrical System E112 (Wiper Drive (For) S/C)................................................538 Error Code in Electrical System E113 (Wiper Drive (Rev) S/C)................................................542 Error Code in Electrical System E114 (Washer Drive S/C).....................................................544 Error Code in Electrical System E115 (Wiper Working Abnormality)............................................546 Error Code in Electrical System E116 (Wiper Parking Abnormality)............................................548 Error Code in Electrical System E201 (CO Cancel Sol. S/C)...................................................552 Error Code in Electrical System E202 (Travel Junction Sol. S/C).............................................554 Error Code in Electrical System E203 (Swing Brake Sol. S/C).................................................556 Error Code in Electrical System E204 (2-stage Relief Sol. S/C)User Code.....................................558 Error Code in Electrical System E205 (Swing Priority Sol. S/C)User Code.....................................560 Error Code in Electrical System E206 (Travel Speed Sol. S/C)................................................562 Error Code in Electrical System E207 (Flash Light Relay S/C)................................................564 Error Code in Electrical System E211 (CO Cancel Sol. Disc.).................................................566 Error Code in Electrical System E212 (Travel Junction Sol. Disc.)...........................................568 Error Code in Electrical System E213 (Swing Brake Sol. Disc.)...............................................570 Error Code in Electrical System E214 (2-stage Relief Sol. Disc.)............................................572 Error Code in Electrical System E215 (Swing Priority Sol. Disc.)............................................574 Error Code in Electrical System E216 (Travel Speed Sol. Disc.)..............................................576 Error Code in Electrical System E217 (Model selection Abnormality)..........................................578 Error Code in Electrical System E218 (S-Net Comm. Disc.)....................................................580 Error Code in Electrical System E221 (J1939 Comm. Error)....................................................582 Error Code in Electrical System E222 (Working Mode Output S/C (1))..........................................584 Error Code in Electrical System E223 (Working Mode Output Disc. (1))........................................585 Error Code in Electrical System E224 (Working Mode Output S/C (2))..........................................586 Error Code in Electrical System E225 (Working Mode Output Disc. (2))........................................587 Error Code in Electrical System E226 (Auto-deceleration Output Disc.).......................................588 Error Code in Electrical System E227 (Engine Speed Sensor Abnormality)......................................589 Error Code in Electrical System E228 (Auto-deceleration Output S/C).........................................590 Error Code in Electrical System E232 (TVC Sol. S/C).........................................................592 Error Code in Electrical System E233 (TVC Sol. Disc.).......................................................594 Error Code in Electrical System E234 (Lever Neutral Output S/C).............................................596 Error Code in Electrical System E235 (Lever Neutral Output Disc.)...........................................597 Error Code in Electrical System E241 (Pre. Sens Voltage Failure)............................................598 Error Code in Electrical System E242 (F Pump Pre. Sens Failure).............................................600 Error Code in Electrical System E243 (R Pump Pre. Sens Failure).............................................602 Error Code in Electrical System E244 (Swing Pre. Sens Failure)..............................................604 Error Code in Electrical System E245 (High relief press F Pump).............................................606 Error Code in Electrical System E246 (High relief press R Pump).............................................607 Error Code in Electrical System E247 (High relief press pump swing).........................................608 Error Code in Electrical System E302 (Step Light Relay S/C).................................................610 Error Code in Electrical System E304 (Step Light Power Drive Relay S/C).....................................612 Error Code in Electrical System E315 (Battery Relay Drive S/C)..............................................614 Failure Code in VHMS System A000N1 (Engine Over Speed)......................................................616 Failure Code in Mechanical System AA10NX (Aircleaner Clogging)..............................................618 Failure Code in Mechanical System AB00KE (Charge Voltage Low)...............................................620 Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)..............................................622 Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low)...............................................623 Failure Code in Mechanical System B@BCNS (Eng. Water Overheat)..............................................624 Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low)...............................................626 Failure Code in VHMS System B@CBNS (High PTO temperature)...................................................628 Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat)...............................................629 Failure Code in VHMS System DBB0KK (VHMS source voltage Error)..............................................630 Failure Code in VHMS System DBB5KP (VHMS 5V source sys Error)...............................................632 Failure Code in VHMS System DBB6KP (VHMS 24V source sys Error)..............................................633 Failure Code in VHMS System DBBQKR (KOM-NET/c error)........................................................634 Failure Code in VHMS System DBBRKR (CAN-NET sys (J1939) Error)..............................................636 Failure Code in VHMS System DGE1KB (Eng Oil Temp. Sensor Failure)...........................................638 Failure Code in VHMS System DGE1KY (Eng Oil Temp. Sensor Failure)...........................................640 Failure Code in VHMS System DGE5KX (Ambient Air Temp Sensor Failure)........................................642 Failure Code in VHMS System DGT3KZ (PTO Temp Sensor Failure)................................................644 Failure Code in VHMS System DGT4KA (F Exhaust Temp. Sensor Failure).........................................646 Failure Code in VHMS System DGT4KB (F Exhaust Temp. Sensor Failure).........................................648 Failure Code in VHMS System DGT5KA (R Exhaust Temp. Sensor Failure).........................................650 Failure Code in VHMS System DGT5KB (R Exhaust Temp. Sensor Failure).........................................652 Failure Code in VHMS System DHE5KB (Blowby Pres. Sensor Failure)............................................654 Failure Code in VHMS System DHE5KY (Blowby Pres. Sensor Failure)............................................656 Failure Code in VHMS System F@BBZL (High Blowby Pressure)...................................................658 Failure Code in VHMS System F@BYNR (High F cyl. Exhaust Temp. 2)............................................659 Failure Code in VHMS System F@BYNS (High F cyl. Exhaust Temp. 1)............................................660 Failure Code in VHMS System F@BZNR (High R cyl. Exhaust Temp. 2)............................................661 Failure Code in VHMS System F@BZNS (High R cyl. Exhaust Temp. 1)............................................662 Failure Code in VHMS System J100KA (Cnt. Pump Pre. Sens Failure)............................................664 Failure Code in VHMS System j100KA (Fan Pump Pre. Sens Failure).............................................666 Failure Code in VHMS System J100KB (Cnt. Pump Pre. Sens Failure)............................................668 Failure Code in VHMS System j100KB (Fan Pump Pre. Sens Failure).............................................670 Failure Code in VHMS System J100L6 (Abnomal Cnt. gear pump press)...........................................672 Failure Code in VHMS System j100L6 (Abnomal Fan gear pump press)............................................674 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...................................................................677 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................678 E-1 Engine does not start (Engine does not rotate)..........................................................679 E-2 Auto-decelerator does not work..........................................................................682 E-3 Auto engine warm-up device does not work................................................................683 E-4 Preheater does not work.................................................................................684 E-5 All work equipment, swing and travel do not move........................................................686 E-6 Machine push-up circuit does not work...................................................................688 E-7 Boom shockless circuit cannot be reset..................................................................690 E-8 No display in monitor panel at all......................................................................692 E-9 Part of display on monitor panel is missing.............................................................693 E-10 Monitor panel displays contents irrelevant to the model................................................693 E-11 Fuel level monitor red lamp lights up while engine is running..........................................694 E-12 Hydraulic oil temperature gauge does not display correctly.............................................695 E-13 Fuel gauge does not display correctly..................................................................696 E-14 Swing lock monitor does not display correctly..........................................................697 E-15 When the monitor switch is operated, no display appears................................................698 E-16 Windshield wiper does not work.........................................................................699 E-17 Alarming buzzer cannot be cancelled....................................................................702 E-18 "Boom RAISE" is not correctly displayed in monitor function............................................703 E-19 "Boom LOWER" is not correctly displayed in monitor function............................................704 E-20 "Arm DIGGING" is not correctly displayed in monitor function...........................................705 E-21 "Arm DUMPING" is not correctly displayed in monitor function...........................................706 E-22 "Bucket DIGGING" is not correctly displayed in monitor function........................................707 E-23 "Bucket DUMPING" is not correctly displayed in monitor function........................................708 E-24 "SWING" is not correctly displayed in monitor function.................................................710 E-25 "TRAVEL" is not correctly displayed in monitor function................................................712 E-26 Air Conditioner does not work..........................................................................714 E-27 Travel alarm does not sound............................................................................715 E-28 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up...............716 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)........................................................721 BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS.................................................722 INFORMATION IN TROUBLESHOOTING TABLE........................................................................727 H-1 Speed or power of all work equipment, travel, and swing is low..........................................728 H-2 Engine speed lowers remarkably or engine stalls.........................................................730 H-3 All work equipment, travel, and swing systems do not work...............................................731 H-4 Abnormal sound is heard from around pump................................................................732 H-5 Speed or power of boom is low...........................................................................733 H-6 Speed or power of arm is low............................................................................735 H-7 Speed or power of bucket is low.........................................................................736 H-8 Boom does not move......................................................................................737 H-9 Arm does not move.......................................................................................737 H-10 Bucket does not move...................................................................................737 H-11 Hydraulic drift of work equipment is large.............................................................738 H-12 Time lag of work equipment is large....................................................................739 H-13 Boom shockless function cannot be turned ON or OFF.....................................................740 H-14 Machine deviates in one direction......................................................................740 H-15 Machine deviates largely at start......................................................................742 H-16 Machine deviates largely during compound ope...........................................................743 H-17 Travel speed or power is low...........................................................................743 H-18 Machine does not travel (only one track)...............................................................744 H-19 Travel speed does not change...........................................................................745 H-20 Machine does not swing.................................................................................746 H-21 Swing speed or acceleration is low.....................................................................747 H-22 Swing speed or power is low in compound operation of travel and bucket.................................748 H-23 Swing speed or power is low in compound operation of travel and boom in swing priority mode............748 H-24 Upper structure overruns largely.......................................................................749 H-25 Large shocks are made when upper structure stops swingi................................................750 H-26 Large abnormal sounds are made when upper structure stops swinging.....................................751 H-27 Hydraulic drift of swing is large......................................................................751 TROUBLESHOOTING OF ENGINE BODY (S MODE).........................................................................753 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................754 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................755 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...............................................758 S-2 ENGINE DOES NOT START...................................................................................760 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....................................................766 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................768 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...............................................................770 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)....................................................................772 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)..........................................................774 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................776 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................777 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................778 S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN..................................779 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................................780 S-13 OIL LEVEL RISES........................................................................................781 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................782 S-15 ABNORMAL NOISE IS MADE.................................................................................783 S-16 VIBRATION IS EXCESSIVE.................................................................................784 30 DISASSEMBLY AND ASSEMBLY.............................................................................................785 HOW TO READ THIS MANUAL.............................................................................................789 REMOVAL AND INSTALLATIONOF ASSEMBLIES...........................................................................789 DISASSEMBLY AND ASSEMBLYOF ASSEMBLIES...........................................................................790 PRECAUTIONS WHEN PERFORMING OPERATION...............................................................................791 SPECIAL TOOL LIST...................................................................................................793 SKETCHES OF SPECIAL TOOLS.......................................................................................797 REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY......................................................................803 REMOVAL.........................................................................................................803 INSTALLATION....................................................................................................803 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.......................................................................804 SPECIAL TOOLS...................................................................................................804 REMOVAL.........................................................................................................804 INSTALLATION....................................................................................................804 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL........................................................................806 SPECIAL TOOLS...................................................................................................806 REMOVAL.........................................................................................................806 INSTALLATION....................................................................................................806 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..................................................................808 SPECIAL TOOLS...................................................................................................808 REMOVAL.........................................................................................................808 INSTALLATION....................................................................................................811 REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER ASSEMBLY................................................813 SPECIAL TOOLS...................................................................................................813 REMOVAL.........................................................................................................813 INSTALLATION....................................................................................................814 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY....................................................................815 REMOVAL.........................................................................................................815 INSTALLATION....................................................................................................815 REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY.....................................................816 REMOVAL.........................................................................................................816 INSTALLATION....................................................................................................817 REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....................................................818 REMOVAL.........................................................................................................818 INSTALLATION....................................................................................................821 REMOVAL AND INSTALLATION OF PTO ASSEMBLY............................................................................822 REMOVAL.........................................................................................................822 INSTALLATION....................................................................................................823 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY............................................................................824 DISASSEMBLY.....................................................................................................824 ASSEMBLY........................................................................................................825 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY......................................................................828 REMOVAL.........................................................................................................828 INSTALLATION....................................................................................................828 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY....................................................................829 SPECIAL TOOLS...................................................................................................829 DISASSEMBLY.....................................................................................................829 ASSEMBLY........................................................................................................833 SKETCHES OF SPECIAL TOOLS.......................................................................................839 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY................................................................840 REMOVAL.........................................................................................................840 INSTALLATION....................................................................................................840 REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY................................................................841 REMOVAL.........................................................................................................841 INSTALLATION....................................................................................................841 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY................................................................842 SPECIAL TOOLS...................................................................................................842 DISASSEMBLY.....................................................................................................842 ASSEMBLY........................................................................................................845 SKETCHES OF SPECIAL TOOLS.......................................................................................849 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...................................................................851 REMOVAL.........................................................................................................851 INSTALLATION....................................................................................................851 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.....................................................................852 SPECIAL TOOLS...................................................................................................852 REMOVAL.........................................................................................................852 INSTALLATION....................................................................................................853 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY..........................................................................854 REMOVAL.........................................................................................................854 INSTALLATION....................................................................................................854 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY..........................................................................855 SPECIAL TOOLS...................................................................................................855 DISASSEMBLY.....................................................................................................855 ASSEMBLY........................................................................................................856 DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY......................................................858 DISASSEMBLY.....................................................................................................858 ASSEMBLY........................................................................................................858 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY..................................................................859 REMOVAL.........................................................................................................859 INSTALLATION....................................................................................................859 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY..................................................................861 SPECIAL TOOLS...................................................................................................861 DISASSEMBLY.....................................................................................................861 INSTALLATION....................................................................................................862 SKETCHES OF SPECIAL TOOLS.......................................................................................863 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.................................................................864 REMOVAL.........................................................................................................864 INSTALLATION....................................................................................................864 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.................................................................865 SPECIAL TOOLS...................................................................................................865 DISASSEMBLY.....................................................................................................865 ASSEMBLY........................................................................................................866 SKETCHES OF SPECIAL TOOLS.......................................................................................867 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY...................................................................868 SPECIAL TOOLS...................................................................................................868 REMOVAL.........................................................................................................868 INSTALLATION....................................................................................................868 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...................................................................869 SPECIAL TOOLS...................................................................................................869 DISASSEMBLY.....................................................................................................869 ASSEMBLY........................................................................................................870 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.................................................................872 REMOVAL.........................................................................................................872 INSTALLATION....................................................................................................873 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.................................................................874 REMOVAL.........................................................................................................874 INSTALLATION....................................................................................................874 REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL..........................................................875 REMOVAL.........................................................................................................875 INSTALLATION....................................................................................................875 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY..............................................................876 DISASSEMBLY.....................................................................................................876 ASSEMBLY........................................................................................................876 REMOVAL AND INSTALLATION OF 5-SPOOL CONTROL VALVE ASSEMBLY (NO. 1)..................................................877 REMOVAL.........................................................................................................877 INSTALLATION....................................................................................................878 REMOVAL AND INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY (NO. 2)..................................................879 REMOVAL.........................................................................................................879 INSTALLATION....................................................................................................880 REMOVAL AND INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY (NO. 3)..................................................881 REMOVAL.........................................................................................................881 INSTALLATION....................................................................................................882 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 1)..........................................................883 DISASSEMBLY.....................................................................................................883 ASSEMBLY........................................................................................................884 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 2)..........................................................886 DISASSEMBLY.....................................................................................................886 ASSEMBLY........................................................................................................887 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 3)..........................................................890 DISASSEMBLY.....................................................................................................890 ASSEMBLY........................................................................................................891 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY....................................................................893 REMOVAL.........................................................................................................893 INSTALLATION....................................................................................................894 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY............................................................895 REMOVAL.........................................................................................................895 INSTALLATION....................................................................................................895 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY............................................................896 DISASSEMBLY.....................................................................................................896 ASSEMBLY........................................................................................................896 REMOVAL AND INSTALLATIONOF TRAVEL MOTOR ASSEMBLY....................................................................897 SPECIAL TOOLS...................................................................................................897 REMOVAL.........................................................................................................897 INSTALLATION....................................................................................................897 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.......................................................898 DISASSEMBLY.....................................................................................................898 ASSEMBLY........................................................................................................899 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...............................................................900 DISASSEMBLY.....................................................................................................900 ASSEMBLY........................................................................................................901 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY................................................................902 REMOVAL.........................................................................................................902 INSTALLATION....................................................................................................903 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)...............................................904 REMOVAL.........................................................................................................904 INSTALLATION....................................................................................................905 REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)..........................................906 REMOVAL.........................................................................................................906 INSTALLATION....................................................................................................907 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACKHOE SPECIFICATION)...........................................908 SPECIAL TOOLS...................................................................................................908 REMOVAL.........................................................................................................908 INSTALLATION....................................................................................................909 SKETCHES OF SPECIAL TOOLS.......................................................................................910 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL)..................................................911 REMOVAL.........................................................................................................911 INSTALLATION....................................................................................................912 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACKHOE SPECIFICATION)..........................................913 SPECIAL TOOLS...................................................................................................913 REMOVAL.........................................................................................................913 INSTALLATION....................................................................................................914 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL).................................................915 REMOVAL.........................................................................................................915 INSTALLATION....................................................................................................916 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (BACKHOE SPECIFICATION).....................................917 SPECIAL TOOLS...................................................................................................917 DISASSEMBLY.....................................................................................................917 ASSEMBLY........................................................................................................921 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACKHOE SPECIFICATION).................................................925 REMOVAL.........................................................................................................925 INSTALLATION....................................................................................................926 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL)........................................................927 REMOVAL.........................................................................................................927 INSTALLATION....................................................................................................928 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACKHOE SPECIFICATION)....................................................929 REMOVAL.........................................................................................................929 INSTALLATION....................................................................................................929 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL)...........................................................930 REMOVAL.........................................................................................................930 INSTALLATION....................................................................................................931 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACKHOE SPECIFICATION)...................................................932 REMOVAL.........................................................................................................932 INSTALLATION....................................................................................................933 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL)..........................................................934 REMOVAL.........................................................................................................934 INSTALLATION....................................................................................................935 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.................................................................936 REMOVAL.........................................................................................................936 INSTALLATION....................................................................................................937 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)......................................................938 SPECIAL TOOLS...................................................................................................939 REMOVAL.........................................................................................................939 INSTALLATION....................................................................................................940 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...................................................................948 REMOVAL.........................................................................................................948 INSTALLATION....................................................................................................950 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY..................................................................954 REMOVAL.........................................................................................................954 INSTALLATION....................................................................................................954 REMOVAL AND INSTALLATION OF RECEIVER TANKASSEMBLY...................................................................955 SPECIAL TOOLS...................................................................................................955 REMOVAL.........................................................................................................955 INSTALLATION....................................................................................................955 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................956 SPECIAL TOOLS...................................................................................................956 REMOVAL.........................................................................................................956 INSTALLATION....................................................................................................956 REMOVAL AND INSTALLATION OF VHMS CONTROLLER.........................................................................957 REMOVAL.........................................................................................................957 INSTALLATION....................................................................................................957 90 OTHERS...............................................................................................................959 HYDRAULIC CIRCUIT DIAGRAM (1/3).....................................................................................961 HYDRAULIC CIRCUIT DIAGRAM (2/3).....................................................................................962 HYDRAULIC CIRCUIT DIAGRAM (3/3).....................................................................................963 ELECTRICAL CIRCUIT DIAGRAM (1/7)....................................................................................964 ELECTRICAL CIRCUIT DIAGRAM (2/7)....................................................................................965 ELECTRICAL CIRCUIT DIAGRAM (3/7)....................................................................................966 ELECTRICAL CIRCUIT DIAGRAM (4/7)....................................................................................967 ELECTRICAL CIRCUIT DIAGRAM (5/7)....................................................................................968 ELECTRICAL CIRCUIT DIAGRAM (6/7)....................................................................................969 ELECTRICAL CIRCUIT DIAGRAM (7/7)....................................................................................970
DESCRIPTION:
KOMATSU PC1250-7 PC1250SP-7 PC1250LC-7 SHOP MANUAL SEBM027312 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
S.S 26/12/24
