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Komatsu PC1250-8, PC1250SP-8, PC1250LC-8 Excavator Service Manual – PDF DOWNLOAD
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Komatsu PC1250-8, PC1250SP-8, PC1250LC-8 Excavator Service Manual
SERIAL NUMBERS:
PC1250- 30001 and up
PC1250SP- 30001 and up
PC1250LC- 30001 and up
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Description
Komatsu PC1250-8, PC1250SP-8, PC1250LC-8 Excavator Service Manual
FILE DETAILS:
Komatsu PC1250-8, PC1250SP-8, PC1250LC-8 Excavator Service Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC1250-8, PC1250SP-8, PC1250LC-8
Serial Number: 30001 and up
Book Code: SEN00889-17
Language: English
Pages: 1301
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC1250-8, PC1250SP-8, PC1250LC-8 Excavator Service Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC1250-8, PC1250SP-8, PC1250LC-8 Excavator Service Manual
COVER ......................................................................................................................... 1 00 Index and foreword.......................................................................................................... 0 Index...................................................................................................................... 3 Composition of shop manual............................................................................................. 4 Table of contents...................................................................................................... 6 Foreword and general information........................................................................................... 17 Safety notice.......................................................................................................... 18 How to read the shop manual............................................................................................ 23 Explanation of terms for maintenance standard.......................................................................... 25 Handling of electric equipment and hydraulic component................................................................. 27 Handling of connectors newly used for engines.......................................................................... 36 How to read electric wire code......................................................................................... 39 Precautions when carrying out operation................................................................................ 42 Method of disassembling and connecting push-pull type coupler.......................................................... 45 Standard tightening torque table....................................................................................... 48 Conversion table....................................................................................................... 52 01 Specification............................................................................................................... 0 Specification and technical data........................................................................................... 59 Backhoe specification.................................................................................................. 60 Loading shovel specification........................................................................................... 62 Specifications......................................................................................................... 64 Weight table........................................................................................................... 80 Table of fuel, coolant and lubricants.................................................................................. 88 10 Structure, function and maintenance standard................................................................................ 0 Engine and cooling system.................................................................................................. 91 Engine and cooling system.............................................................................................. 92 PTO................................................................................................................ 92 PTO lubrication system............................................................................................. 94 Radiator and oil cooler............................................................................................ 96 Power train................................................................................................................ 99 Power train............................................................................................................ 100 Swing machinery........................................................................................................ 102 Swing circle........................................................................................................... 106 Final drive............................................................................................................ 107 Sprocket............................................................................................................... 110 Undercarriage and frame.................................................................................................... 113 Track frame, recoil spring............................................................................................. 114 Idler.................................................................................................................. 116 Carrier roller......................................................................................................... 118 Track roller........................................................................................................... 119 Track shoe............................................................................................................. 120 Air system................................................................................................................. 125 Air system............................................................................................................. 126 Air piping drawing................................................................................................. 126 Air circuit diagram................................................................................................ 127 Air governor....................................................................................................... 128 Air tank........................................................................................................... 129 Safety valve....................................................................................................... 130 Horn valve......................................................................................................... 131 Grease pump........................................................................................................ 132 Hydraulic system, Part 1................................................................................................... 135 Hydraulic system, Part 1............................................................................................... 136 Hydraulic piping drawing........................................................................................... 136 Hydraulic tank..................................................................................................... 139 Hydraulic pump..................................................................................................... 141 Line oil filter.................................................................................................... 182 Pilot oil filter................................................................................................... 183 Return oil filter.................................................................................................. 184 Drain oil filter................................................................................................... 185 Cooling fan pump................................................................................................... 186 Cooling fan motor.................................................................................................. 200 Aftercooler fan motor.............................................................................................. 206 Hydraulic system, Part 2................................................................................................... 213 Control valve.......................................................................................................... 214 Swing motor............................................................................................................ 229 Center swivel joint.................................................................................................... 238 Travel motor........................................................................................................... 239 PPC control relief valve............................................................................................... 249 Accumulator............................................................................................................ 250 Valve control.......................................................................................................... 251 PPC valve.............................................................................................................. 252 Solenoid valve......................................................................................................... 262 Hydraulic cylinder..................................................................................................... 270 Work equipment............................................................................................................. 275 Work equipment......................................................................................................... 276 Work equipment..................................................................................................... 276 Dimensions of work equipment....................................................................................... 280 Cab and its attachments.................................................................................................... 285 Cab and its attachments................................................................................................ 286 Air conditioner.................................................................................................... 286 Electrical system.......................................................................................................... 288 Engine control......................................................................................................... 289 Electric control system................................................................................................ 296 Monitor system......................................................................................................... 332 Sensor................................................................................................................. 355 20 Standard value table........................................................................................................ 0 Standard service value table............................................................................................... 362 Standard value table for engine related parts.......................................................................... 363 Standard value table for chassis related parts......................................................................... 364 30 Testing and adjusting....................................................................................................... 0 Testing and adjusting, Part 1.............................................................................................. 386 Tools for testing, adjusting, and troubleshooting...................................................................... 388 Sketch of special tool................................................................................................. 393 Testing engine speed................................................................................................... 394 Testing air supply pressure (Boost pressure)........................................................................... 395 Testing exhaust temperature............................................................................................ 396 Testing exhaust color.................................................................................................. 397 Testing and adjusting valve clearance.................................................................................. 399 Testing compression pressure........................................................................................... 401 Testing blow-by pressure............................................................................................... 404 Testing engine oil pressure............................................................................................ 405 Testing EGR valve and bypass valve drive oil pressure.................................................................. 406 Adjusting engine speed sensor.......................................................................................... 408 Handling fuel system parts............................................................................................. 409 Releasing residual pressure in fuel system............................................................................. 409 Testing fuel pressure.................................................................................................. 410 Testing fuel return rate and fuel leakage.............................................................................. 411 Bleeding air from fuel circuit......................................................................................... 414 Testing fuel system for leakage........................................................................................ 416 Procedure for checking alternator and replacing belt................................................................... 417 Testing and adjusting, Part 2.............................................................................................. 420 Testing swing circle bearing clearance................................................................................. 421 Testing wear of sprocket............................................................................................... 422 Testing and adjusting track shoe tension............................................................................... 423 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit...................................... 424 Testing and adjusting control circuit oil pressure..................................................................... 438 Testing and adjusting piston pump control pressure..................................................................... 440 Testing servo piston stroke............................................................................................ 447 Testing and adjusting, Part 3.............................................................................................. 450 Measuring PPC valve output pressure and testing swing PPC shuttle valve................................................ 451 Measuring solenoid valve output pressure............................................................................... 455 Adjusting work equipment, swing PPC valve.............................................................................. 457 Testing travel deviation............................................................................................... 458 Testing locations causing hydraulic drift of work equipment............................................................ 459 Measuring oil leakage.................................................................................................. 460 Measurement of fan speed............................................................................................... 468 Measurement of fan circuit oil pressure................................................................................ 469 Measuring fan pump EPC solenoid valve output pressure.................................................................. 471 Bleeding air........................................................................................................... 472 Releasing remaining pressure in hydraulic circuit...................................................................... 474 Testing procedures for diode........................................................................................... 475 Testing and adjusting, Part 4.............................................................................................. 478 Special function of machine monitor.................................................................................... 479 Handling controller voltage circuit.................................................................................... 519 Testing and adjusting, Part 5.............................................................................................. 522 VHMS controller initial setting procedure.............................................................................. 523 Precautions for replacing VHMS controller.............................................................................. 538 Testing and adjusting, Part 6.............................................................................................. 546 Pm-clinic service...................................................................................................... 547 40 Troubleshooting............................................................................................................. 0 Failure code table and fuse locations...................................................................................... 562 Failure code table..................................................................................................... 563 Fuse locations......................................................................................................... 568 General information on troubleshooting..................................................................................... 572 Points to remember when troubleshooting................................................................................ 573 Sequence of events in troubleshooting.................................................................................. 574 Checks before troubleshooting.......................................................................................... 575 Classification and troubleshooting steps............................................................................... 576 Information in troubleshooting table................................................................................... 580 Connection table for connector pin numbers............................................................................. 582 T- branch box and T- branch adapter table.............................................................................. 618 Troubleshooting by failure code (Display of code), Part 1.................................................................. 622 Failure code [A000N1] Eng. Hi Out of Std............................................................................... 624 Failure code [AA10NX] Aircleaner Clogging.............................................................................. 625 Failure code [AB00KE] Charge Voltage Low............................................................................... 627 Failure code [B@BAZG] Eng. Oil Press. Low.............................................................................. 629 Failure code [B@BAZK] Eng. Oil Level Low............................................................................... 631 Failure code [B@BCNS] Eng. Water Overheat.............................................................................. 633 Failure code [B@BCZK] Eng. Water Lvl Low............................................................................... 635 Failure code [B@CBNS] High PTO temperature............................................................................. 637 Failure code [B@HANS] Hydr. Oil Overheat............................................................................... 639 Failure code [CA111] ECM Critical Internal Failure..................................................................... 640 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.................................................................. 642 Failure code [CA122] Chg Air Press Sensor High Error................................................................... 643 Failure code [CA123] Chg Air Press Sensor Low Error.................................................................... 645 Failure code [CA131] Throttle Sensor High Error........................................................................ 646 Failure code [CA132] Throttle Sensor Low Error......................................................................... 648 Failure code [CA135] Eng Oil Press Sensor High Error................................................................... 649 Failure code [CA141] Eng Oil Press Sensor Low Error.................................................................... 651 Failure code [CA144] Coolant Temp Sens High Error...................................................................... 652 Failure code [CA145] Coolant Temp Sens Low Error....................................................................... 654 Failure code [CA153] Chg Air Temp Sensor High Error.................................................................... 655 Failure code [CA154] Chg Air Temp Sensor Low Error..................................................................... 657 Failure code [CA187] Sens Supply 2 Volt Low Error...................................................................... 658 Failure code [CA212] Oil Temp. Sensor High Error....................................................................... 659 Failure code [CA213] Oil Temp. Sensor Low Error........................................................................ 661 Failure code [CA221] Ambient Press Sens High Error..................................................................... 662 Failure code [CA222] Ambient Press Sens Low Error...................................................................... 664 Failure code [CA227] Sens Supply 2 Volt High Error..................................................................... 665 Failure code [CA234] Eng Overspeed..................................................................................... 667 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................................... 669 Failure code [CA263] Fuel Temp Sensor High Error....................................................................... 671 Failure code [CA265] Fuel Temp Sensor Low Error........................................................................ 673 Failure code [CA271] IMV/PCV1 Short Error.............................................................................. 674 Failure code [CA272] IMV/PCV1 Open Error............................................................................... 675 Failure code [CA273] PCV2 Short Error.................................................................................. 677 Failure code [CA274] PCV2 Open Error................................................................................... 678 Failure code [CA322] Inj #1 (L#1) Open/Short Error..................................................................... 679 Failure code [CA323] Inj #5 (L#5) Open/Short Error..................................................................... 681 Failure code [CA324] Inj #3 (L#3) Open/Short Error..................................................................... 683 Failure code [CA325] Inj #6 (L#6) Open/Short Error..................................................................... 685 Failure code [CA331] Inj #2 (L#2) Open/Short Error..................................................................... 687 Failure code [CA332] Inj #4 (L#4) Open/Short Error..................................................................... 689 Failure code [CA342] Calibration Code Incompatibility.................................................................. 691 Failure code [CA351] Injectors Drive Circuit Error..................................................................... 693 Troubleshooting by failure code (Display of code), Part 2.................................................................. 696 Failure code [CA352] Sens Supply 1 Volt Low Error...................................................................... 698 Failure code [CA386] Sensor Sup. 1 Volt. High Error.................................................................... 699 Failure code [CA441] Battery Voltage Low Error......................................................................... 701 Failure code [CA442] Battery Voltage High Error........................................................................ 701 Failure code [CA449] Rail Press Very High Error........................................................................ 702 Failure code [CA451] Rail Press Sensor High Error...................................................................... 703 Failure code [CA452] Rail Press Sensor Low Error....................................................................... 705 Failure code [CA553] Rail Press High Error............................................................................. 705 Failure code [CA554] Rail Press Sensor In Range Error.................................................................. 706 Failure code [CA559] Rail Press Low Error.............................................................................. 707 Failure code [CA689] Eng Ne Speed Sensor Error......................................................................... 711 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................................... 713 Failure code [CA757] All Persistent Data Lost Error.................................................................... 714 Failure code [CA778] Eng Bkup Speed Sensor Error....................................................................... 715 Failure code [CA1228] EGR Valve Servo Error 1.......................................................................... 717 Failure code [CA1625] EGR Valve Servo Error 2.......................................................................... 718 Failure code [CA1626] BP Valve Sol Current High Error.................................................................. 719 Failure code [CA1627] BP Valve Sol Current Low Error................................................................... 721 Failure code [CA1628] Bypass Valve Servo Error 1....................................................................... 722 Failure code [CA1629] Bypass Valve Servo Error 2....................................................................... 723 Failure code [CA1631] BP Valve Pos Sens High Error..................................................................... 724 Failure code [CA1632] BP Valve Pos Sens Low Error...................................................................... 726 Failure code [CA1633] KOMNET Datalink Timeout Error.................................................................... 727 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................... 729 Failure code [CA2186] Throt Sens Sup Volt Low Error.................................................................... 731 Failure code [CA2249] Rail Press Very Low Error........................................................................ 732 Failure code [CA2271] EGR Valve Pos Sens High Error.................................................................... 733 Failure code [CA2272] EGR Valve Pos Sens Low Error..................................................................... 735 Failure code [CA2351] EGR Valve Sol Current High Error................................................................. 737 Failure code [CA2352] EGR Valve Sol Current Low Error.................................................................. 739 Failure code [CA2555] Grid Htr Relay Volt Low Error.................................................................... 740 Failure code [CA2556] Grid Htr Relay Volt High Error................................................................... 741 Failure code [D110KB] Battery Relay Drive S/C.......................................................................... 743 Failure code [D163KB] Flash Light Relay S/C............................................................................ 745 Failure code [D195KB] Step Light Relay S/C............................................................................. 747 Failure code [DA22KK] Pump controller solenoid: Source voltage reduction............................................... 749 Failure code [DA25KP] Press. Sensor Power Abnormality.................................................................. 751 Failure code [DA2SKQ] Model selection Abnormality...................................................................... 753 Failure code [DA80MA] Auto. Lub. Abnormal.............................................................................. 755 Failure code [DA2RMC] Pump Comm. Abnormality........................................................................... 757 Failure code [DAFRMC] Monitor Comm. Abnormality........................................................................ 759 Troubleshooting by failure code (Display of code), Part 3.................................................................. 762 Troubleshooting by failure code (Display of code), Part 3.............................................................. 764 Failure code [DBB0KK] VHMS source voltage Error (or change of VHMS-LED display from n9 to 01)...................... 764 Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nf to 11)........................ 766 Failure code [DBB3KK] Abnormality in VBAT voltage (or change of VHMS-LED display from n9 to 05).................... 768 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-LED display from n9 to 04)....................... 770 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)...................... 772 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)................................ 774 Failure code [DGE5KB] Ambi. Temp. Sensor S/C....................................................................... 776 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C................................................................... 777 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01)......................... 778 Failure code [DGT4KA] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 12)................. 780 Failure code [DGT4KB] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 11)................. 782 Failure code [DGT5KA] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 22)................. 784 Failure code [DGT5KB] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 21)................. 786 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32).................... 788 Failure code [DHE5KY] Blowby Pres. Sensor Failure) (or change of VHMS-LED display from n3 to 31)................... 790 Failure code [DHPAMA] F Pump P. Sensor Abnormality................................................................. 792 Failure code [DHPAZL] F Pump Relief Pressure Abnormality........................................................... 794 Failure code [DHPBMA] R Pump P. Sensor Abnormality................................................................. 796 Failure code [DHPBZL] R Pump Relief Pressure Abnormality........................................................... 798 Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 23)..................... 799 Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 24)..................... 801 Failure code [DV20KB] Travel Alarm S/C............................................................................. 803 Failure code [DW41KA] Swing Priority Sol. Disc..................................................................... 805 Failure code [DW41KB] Swing Priority Sol. S/C...................................................................... 807 Failure code [DW43KA] Travel Speed Sol. Disc....................................................................... 809 Failure code [DW43KB] Travel Speed Sol. S/C........................................................................ 811 Failure code [DW45KA] Swing Brake Sol. Disc........................................................................ 813 Failure code [DW45KB] Swing Brake Sol. S/C......................................................................... 815 Failure code [DW48KA] CO Cancel Sol. Disc.......................................................................... 817 Failure code [DW48KB] CO Cancel Sol. S/C........................................................................... 819 Troubleshooting by failure code (Display of code), Part 4.................................................................. 822 Troubleshooting by failure code (Display of code), Part 4.............................................................. 824 Failure code [DW7BKA] Fan Reverse Sol. Disc........................................................................ 824 Failure code [DW7BKB] Fan Reverse Sol. S/C......................................................................... 826 Failure code [DW91KA] Travel Junction Sol. Disc.................................................................... 828 Failure code [DW91KB] Travel Junction Sol. S/C..................................................................... 830 Failure code [DWK0KA] 2-stage Relief Sol. Disc..................................................................... 832 Failure code [DWK0KB] 2-stage Relief Sol. S/C...................................................................... 834 Failure code [DX16KA] Fan Pump EPC Sol. Disc....................................................................... 836 Failure code [DX16KB] Fan Pump EPC Sol. S/C........................................................................ 838 Failure code [DXA0KA] TVC Sol. Disc................................................................................ 840 Failure code [DXA0KB] TVC Sol. S/C................................................................................. 842 Failure code [DY20KA] Wiper Working Abnormality.................................................................... 844 Failure code [DY20MA] Wiper Parking Abnormality.................................................................... 846 Failure code [DY2CKB] Washer Drive S/C............................................................................. 850 Failure code [DY2DKB] Wiper Drive (For) S/C........................................................................ 852 Failure code [DY2EKB] Wiper Drive (Rev) S/C........................................................................ 856 Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)........................... 858 Failure code [F@BYNR] High F cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 62).................... 860 Failure code [F@BYNS] High F cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 61).................... 862 Failure code [F@BZNR] High R cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 72).................... 864 Failure code [F@BZNS] High R cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 71).................... 866 Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality............................................................ 868 Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality.......................................................... 870 Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 11).................... 871 Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 21)..................... 873 Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 12).................... 875 Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 22)..................... 877 Failure code [J100L6] Abnormal Cnt. gear pump press (or change of VHMS-LED display from n5 to 71).................. 879 Failure code [j100L6] Abnormal Fan gear pump press (or change of VHMS-LED display from n5 to 81)................... 881 Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change of VHMS-LED display from n5 to 25).............. 883 Troubleshooting of electrical system (E-mode).............................................................................. 886 Before carrying out troubleshooting of electrical system............................................................... 888 Information contained in troubleshooting table......................................................................... 890 E-1 Engine does not start (Engine does not rotate)..................................................................... 891 E-2 Auto-decelerator does not work..................................................................................... 895 E-3 Auto engine warm-up device does not work........................................................................... 897 E-4 Preheater does not work............................................................................................ 899 E-5 All work equipment, swing and travel do not move................................................................... 901 E-6 Machine push-up circuit does not work.............................................................................. 903 E-7 Boom shockless circuit cannot be reset............................................................................. 905 E-8 No display in machine monitor at all............................................................................... 907 E-9 Part of display on machine monitor is missing...................................................................... 909 E-10 Machine monitor displays contents irrelevant to the model......................................................... 909 E-11 Fuel level monitor red lamp lights up while engine is running..................................................... 910 E-12 Hydraulic oil temperature gauge does not display correctly........................................................ 911 E-13 Fuel gauge does not display correctly............................................................................. 912 E-14 Swing lock monitor does not display correctly..................................................................... 913 E-15 When the monitor switch is operated, no display appears........................................................... 915 E-16 Windshield wiper does not work.................................................................................... 917 E-17 “Boom RAISE” is not correctly displayed in monitor function....................................................... 919 E-18 “Boom LOWER” is not correctly displayed in monitor function....................................................... 920 E-19 “Arm DIGGING” is not correctly displayed in monitor function...................................................... 921 E-20 “Arm DUMPING” is not correctly displayed in monitor function...................................................... 922 E-21 “Bucket CURL” is not correctly displayed in monitor function...................................................... 923 E-22 “Bucket DUMPING” is not correctly displayed in monitor function................................................... 924 E-23 “SWING” is not correctly displayed in monitor function............................................................ 925 E-24 “TRAVEL” is not correctly displayed in monitor function........................................................... 927 E-25 Air conditioner does not work..................................................................................... 929 E-26 Travel alarm does not sound....................................................................................... 931 E-27 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up.......................... 932 E-28 Step light does not light up or go off............................................................................ 936 E-29 Electric priming pump does not operate or does not stop automatically............................................. 939 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................ 942 Troubleshooting of hydraulic and mechanical system (H-mode)............................................................ 944 Before troubleshooting for hydraulic and mechanical systems........................................................ 944 H-1 Speed or power of all work equipment, travel, and swing is low................................................. 950 H-2 Engine speed lowers remarkably or engine stalls................................................................ 952 H-3 All work equipment, travel, and swing systems do not work...................................................... 953 H-4 Abnormal sound is heard from around pump....................................................................... 955 H-5 Speed or power of boom is low.................................................................................. 956 H-6 Speed or power of arm is low................................................................................... 958 H-7 Speed or power of bucket is low................................................................................ 959 H-8 Boom does not move............................................................................................. 960 H-9 Arm does not move.............................................................................................. 961 H-10 Bucket does not move.......................................................................................... 962 H-11 Hydraulic drift of work equipment is large.................................................................... 963 H-12 Time lag of work equipment is large........................................................................... 964 H-13 Boom shockless function cannot be turned ON or OFF............................................................ 965 H-14 Machine deviates in one direction............................................................................. 965 H-15 Machine deviates largely at start............................................................................. 967 H-16 Machine deviates largely during compound operation............................................................ 968 H-17 Travel speed or power is low.................................................................................. 968 H-18 Machine does not travel (only one track)...................................................................... 969 H-19 Travel speed does not change.................................................................................. 970 H-20 Machine does not swing........................................................................................ 971 H-21 Swing speed or acceleration is low............................................................................ 972 H-22 Swing speed or power is low in compound operation of travel and bucket........................................ 973 H-23 Swing speed or power is low in compound operation of travel and boom in swing priority mode................... 973 H-24 Upper structure overruns largely.............................................................................. 974 H-25 Large shocks are made when upper structure stops swinging..................................................... 975 H-26 Large abnormal sounds are made when upper structure stops swinging............................................ 976 H-27 Hydraulic drift of swing is large............................................................................. 977 H-28 Fan revolution is abnormal (Sound and vibration of the fan is abnormally large, and the fan is overheated).... 978 Troubleshooting of engine (S-mode)......................................................................................... 980 Method of using troubleshooting chart.................................................................................. 982 S-1 Starting performance is poor....................................................................................... 985 S-2 Engine does not start.............................................................................................. 987 S-3 Engine does not pick up smoothly................................................................................... 991 S-4 Engine stops during operations..................................................................................... 992 S-5 Engine does not rotate smoothly.................................................................................... 993 S-6 Engine lacks output (or lacks power)............................................................................... 994 S-7 Exhaust smoke is black (incomplete combustion)..................................................................... 995 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................................ 996 S-9 Oil becomes contaminated quickly................................................................................... 997 S-10 Fuel consumption is excessive..................................................................................... 998 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)............................................. 999 S-12 Oil pressure drops................................................................................................1000 S-13 Oil level rises (Entry of coolant or fuel)........................................................................1001 S-14 Coolant temperature becomes too high (overheating)................................................................1003 S-15 Abnormal noise is made............................................................................................1004 S-16 Vibration is excessive............................................................................................1005 S-17 Air cannot be bled from fuel circuit..............................................................................1007 50 Disassembly and assembly.................................................................................................... 0 General information on disassembly and assembly............................................................................1010 How to read this manual................................................................................................1011 Coating materials list.................................................................................................1013 Special tools list.....................................................................................................1016 Sketches of special tools..............................................................................................1024 Engine and cooling system, Part 1..........................................................................................1038 Removal and installation of fuel supply pump assembly..................................................................1039 Removal and installation of cylinder head assembly.....................................................................1045 Removal and installation of fuel injector assembly.....................................................................1063 Removal and installation of engine front seal..........................................................................1068 Engine and cooling system, Part 2..........................................................................................1076 Removal and installation of engine, PTO and hydraulic pump assembly....................................................1077 Removal and installation of radiator and hydraulic oil cooler assembly.................................................1086 Removal of air aftercooler assembly....................................................................................1090 Removal and installation of fuel cooler and air conditioner condenser assembly.........................................1092 Removal and installation of fan motor assembly.........................................................................1094 Removal and installation of fuel tank assembly.........................................................................1099 Power train................................................................................................................1102 Removal and installation of PTO assembly...............................................................................1103 Disassembly and assembly of PTO assembly...............................................................................1105 Removal and installation of swing machinery assembly...................................................................1109 Removal and installation of swing motor and swing machinery assembly...................................................1111 Disassembly and assembly of swing machinery assembly...................................................................1114 Disassembly and assembly of swing motor and swing machinery assembly...................................................1121 Removal and installation of swing circle assembly......................................................................1128 Disassembly and assembly of final drive assembly.......................................................................1129 Undercarriage and frame....................................................................................................1142 Removal and installation of track shoe assembly........................................................................1143 Disassembly and assembly of one link in field..........................................................................1145 Removal and installation of idler assembly.............................................................................1149 Disassembly and assembly of idler assembly.............................................................................1150 Disassembly and assembly of idler adjustment cylinder assembly.........................................................1153 Removal and installation of recoil spring assembly.....................................................................1154 Disassembly and assembly of recoil spring assembly.....................................................................1156 Removal and installation of track roller assembly......................................................................1158 Disassembly and assembly of track roller assembly......................................................................1159 Removal and installation of carrier roller assembly....................................................................1162 Disassembly and assembly of carrier roller assembly....................................................................1163 Removal and installation of revolving frame assembly...................................................................1165 Removal and installation of counterweight assembly.....................................................................1166 Hydraulic system...........................................................................................................1170 Removal and installation of hydraulic tank assembly....................................................................1171 Removal and installation of hydraulic pump assembly....................................................................1173 Removal and installation of main pump input shaft oil seal.............................................................1179 Removal and installation of 5-spool control valve assembly (No. 1).....................................................1180 Removal and installation of 4-spool control valve assembly (No. 2).....................................................1182 Removal and installation of 4-spool control valve assembly (No. 3).....................................................1184 Disassembly and assembly of control valve assembly (No. 1).............................................................1186 Disassembly and assembly of control valve assembly (No. 2).............................................................1189 Disassembly and assembly of control valve assembly (No. 3).............................................................1193 Removal and installation of swing motor assembly.......................................................................1197 Removal and installation of center swivel joint assembly...............................................................1201 Disassembly and assembly of center swivel joint assembly...............................................................1202 Removal and installation of travel motor assembly......................................................................1204 Disassembly and assembly of work equipment PPC valve assembly..........................................................1205 Disassembly and assembly of travel PPC valve assembly..................................................................1207 Disassembly and assembly of hydraulic cylinder assembly................................................................1210 Work equipment.............................................................................................................1220 Removal and installation of bucket cylinder assembly...................................................................1221 Removal and installation of bottom dump cylinder assembly..............................................................1225 Removal and installation of arm cylinder assembly......................................................................1227 Removal and installation of boom cylinder assembly.....................................................................1231 Removal and installation of bucket assembly............................................................................1235 Removal and installation of arm assembly...............................................................................1239 Removal and installation of boom assembly..............................................................................1242 Cab and its attachments....................................................................................................1248 Removal and installation of operator cab assembly......................................................................1249 Removal and installation of operator’s cab glass (Stuck glass).........................................................1252 Removal and installation of front window assembly......................................................................1262 Electrical system..........................................................................................................1270 Removal and installation of air conditioner unit assembly..............................................................1271 Removal and installation of monitor assembly...........................................................................1274 Removal and installation of pump controller assembly...................................................................1275 Removal and installation of Orbcomm terminal assembly for VHMS.........................................................1276 Removal and installation of VHMS controller assembly...................................................................1277 Removal and installation of engine controller assembly.................................................................1278 90 Diagrams and drawings....................................................................................................... 0 Hydraulic circuit diagrams.................................................................................................1280 Hydraulic circuit diagram (1/2) Serial number 30001 - 30051............................................................1282 Hydraulic circuit diagram (2/2) Serial number 30001 - 30051............................................................1283 Hydraulic circuit diagram (1/3) Serial number 30052 and up.............................................................1284 Hydraulic circuit diagram (2/3) Serial number 30052 and up.............................................................1285 Hydraulic circuit diagram (3/3) Serial number 30052 and up.............................................................1286 Electrical diagrams and drawings...........................................................................................1290 Electrical diagrams and drawings.......................................................................................1292 Electrical circuit diagram (1/7)...................................................................................1292 Electrical circuit diagram (2/7)...................................................................................1293 Electrical circuit diagram (3/7)...................................................................................1294 Electrical circuit diagram (4/7)...................................................................................1295 Electrical circuit diagram (5/7)...................................................................................1296 Electrical circuit diagram (6/7)...................................................................................1297 Electrical circuit diagram (7/7)...................................................................................1298 Connector arrangement diagram......................................................................................1299
KOMATSU PC1250-8, PC1250SP-8, PC1250LC-8 EXCAVATOR SERVICE MANUAL – PDF DOWNLOAD:
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