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KOMATSU PC1250-8 PC1250SP-8 PC1250LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00889-28 – PDF DOWNLOAD
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KOMATSU PC1250-8 PC1250SP-8 PC1250LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00889-28 – PDF DOWNLOAD
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KOMATSU PC1250-8 PC1250SP-8 PC1250LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00889-28 – PDF DOWNLOAD
Language : English
Pages : 1338
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC1250-8 PC1250SP-8 PC1250LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00889-28 – PDF DOWNLOAD
Cover.......................................................................................................................... 1 00 Index and foreword...................................................................................................... 3 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........................................................................................................... 59 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............................................................................ 91 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 Hydraulic system, Part 1............................................................................................... 125 Hydraulic piping drawing........................................................................................... 126 Hydraulic tank..................................................................................................... 129 Hydraulic pump..................................................................................................... 131 Line oil filter.................................................................................................... 172 Pilot oil filter................................................................................................... 173 Return oil filter.................................................................................................. 174 Drain oil filter................................................................................................... 175 Cooling fan pump................................................................................................... 176 Cooling fan motor.................................................................................................. 190 Aftercooler fan motor.............................................................................................. 196 Hydraulic system, Part 2............................................................................................... 203 Control valve...................................................................................................... 204 Swing motor........................................................................................................ 219 Center swivel joint................................................................................................ 228 Travel motor....................................................................................................... 229 PPC control relief valve........................................................................................... 239 Accumulator........................................................................................................ 240 Valve control...................................................................................................... 241 PPC valve.......................................................................................................... 242 Solenoid valve..................................................................................................... 252 Hydraulic cylinder................................................................................................. 260 Work equipment......................................................................................................... 265 Work equipment..................................................................................................... 266 Dimensions of work equipment....................................................................................... 270 Cab and its attachments................................................................................................ 275 Cab and its attachments............................................................................................ 276 Air conditioner................................................................................................ 276 Electrical system...................................................................................................... 279 Engine control..................................................................................................... 280 Electric control system............................................................................................ 287 Monitor system..................................................................................................... 323 Sensor............................................................................................................. 346 20 Standard value table.................................................................................................... 353 Standard service value table........................................................................................... 353 Standard value table for engine related parts...................................................................... 354 Standard value table for chassis related parts..................................................................... 355 30 Testing and adjusting................................................................................................... 377 Testing and adjusting, Part 1.......................................................................................... 377 Tools for testing, adjusting, and troubleshooting.................................................................. 379 Sketch of special tool............................................................................................. 384 Testing engine speed............................................................................................... 385 Testing air supply pressure (Boost pressure)....................................................................... 386 Testing exhaust temperature........................................................................................ 387 Testing exhaust color.............................................................................................. 388 Testing and adjusting valve clearance.............................................................................. 390 Testing compression pressure....................................................................................... 392 Testing blow-by pressure........................................................................................... 395 Testing engine oil pressure........................................................................................ 396 Testing EGR valve and bypass valve drive oil pressure.............................................................. 397 Adjusting engine speed sensor...................................................................................... 399 Handling fuel system parts......................................................................................... 400 Releasing residual pressure in fuel system......................................................................... 400 Testing fuel pressure.............................................................................................. 401 Testing fuel return rate and fuel leakage.......................................................................... 402 Bleeding air from fuel circuit..................................................................................... 405 Testing fuel system for leakage.................................................................................... 407 Procedure for checking alternator and replacing belt............................................................... 408 Testing and adjusting, Part 2.......................................................................................... 411 Testing swing circle bearing clearance............................................................................. 412 Testing wear of sprocket........................................................................................... 413 Testing and adjusting track shoe tension........................................................................... 414 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit.................................. 415 Testing and adjusting control circuit oil pressure................................................................. 429 Testing and adjusting piston pump control pressure................................................................. 431 Testing servo piston stroke........................................................................................ 438 Testing and adjusting, Part 3.......................................................................................... 441 Measuring PPC valve output pressure and testing swing PPC shuttle valve............................................ 442 Measuring solenoid valve output pressure........................................................................... 446 Adjusting work equipment, swing PPC valve.......................................................................... 448 Testing travel deviation........................................................................................... 449 Testing locations causing hydraulic drift of work equipment........................................................ 450 Measuring oil leakage.............................................................................................. 451 Measurement of fan speed........................................................................................... 459 Measurement of fan circuit oil pressure............................................................................ 460 Measuring fan pump EPC solenoid valve output pressure.............................................................. 462 Bleeding air....................................................................................................... 463 Releasing remaining pressure in hydraulic circuit.................................................................. 465 Testing procedures for diode....................................................................................... 466 Testing and adjusting, Part 4.......................................................................................... 469 Special function of machine monitor................................................................................ 470 Handling controller voltage circuit................................................................................ 510 Testing and adjusting, Part 5.......................................................................................... 513 VHMS controller initial setting procedure.......................................................................... 514 Precautions for replacing VHMS controller.......................................................................... 529 Testing and adjusting, Part 6.......................................................................................... 537 Pm-clinic service.................................................................................................. 538 40 Troubleshooting......................................................................................................... 553 Failure code table and fuse locations.................................................................................. 553 Failure code table................................................................................................. 554 Fuse locations..................................................................................................... 559 General information on troubleshooting................................................................................. 563 Points to remember when troubleshooting............................................................................ 564 Sequence of events in troubleshooting.............................................................................. 565 Checks before troubleshooting...................................................................................... 566 Classification and troubleshooting steps........................................................................... 567 Information in troubleshooting table............................................................................... 571 Connection table for connector pin numbers......................................................................... 573 T- branch box and T- branch adapter table.......................................................................... 609 Troubleshooting by failure code (Display of code), Part 1.............................................................. 613 Failure code [A000N1] Eng. Hi Out of Std........................................................................... 615 Failure code [AA10NX] Aircleaner Clogging.......................................................................... 616 Failure code [AB00KE] Charge Voltage Low........................................................................... 618 Failure code [B@BAZG] Eng. Oil Press. Low.......................................................................... 620 Failure code [B@BAZK] Eng. Oil Level Low........................................................................... 622 Failure code [B@BCNS] Eng. Water Overheat.......................................................................... 624 Failure code [B@BCZK] Eng. Water Lvl Low........................................................................... 626 Failure code [B@CBNS] High PTO temperature......................................................................... 628 Failure code [B@HANS] Hydr. Oil Overheat........................................................................... 630 Failure code [CA111] ECM Critical Internal Failure................................................................. 631 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.............................................................. 633 Failure code [CA122] Chg Air Press Sensor High Error............................................................... 634 Failure code [CA123] Chg Air Press Sensor Low Error................................................................ 636 Failure code [CA131] Throttle Sensor High Error.................................................................... 637 Failure code [CA132] Throttle Sensor Low Error..................................................................... 639 Failure code [CA135] Eng Oil Press Sensor High Error............................................................... 640 Failure code [CA141] Eng Oil Press Sensor Low Error................................................................ 642 Failure code [CA144] Coolant Temp Sens High Error.................................................................. 643 Failure code [CA145] Coolant Temp Sens Low Error................................................................... 645 Failure code [CA153] Chg Air Temp Sensor High Error................................................................ 646 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................. 648 Failure code [CA187] Sens Supply 2 Volt Low Error.................................................................. 649 Failure code [CA212] Oil Temp. Sensor High Error................................................................... 650 Failure code [CA213] Oil Temp. Sensor Low Error.................................................................... 652 Failure code [CA221] Ambient Press Sens High Error................................................................. 653 Failure code [CA222] Ambient Press Sens Low Error.................................................................. 655 Failure code [CA227] Sens Supply 2 Volt High Error................................................................. 656 Failure code [CA234] Eng Overspeed................................................................................. 658 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................... 660 Failure code [CA263] Fuel Temp Sensor High Error................................................................... 662 Failure code [CA265] Fuel Temp Sensor Low Error.................................................................... 664 Failure code [CA271] IMV/PCV1 Short Error.......................................................................... 665 Failure code [CA272] IMV/PCV1 Open Error........................................................................... 666 Failure code [CA273] PCV2 Short Error.............................................................................. 668 Failure code [CA274] PCV2 Open Error............................................................................... 669 Failure code [CA322] Inj #1 (L#1) Open/Short Error................................................................. 670 Failure code [CA323] Inj #5 (L#5) Open/Short Error................................................................. 672 Failure code [CA324] Inj #3 (L#3) Open/Short Error................................................................. 674 Failure code [CA325] Inj #6 (L#6) Open/Short Error................................................................. 676 Failure code [CA331] Inj #2 (L#2) Open/Short Error................................................................. 678 Failure code [CA332] Inj #4 (L#4) Open/Short Error................................................................. 680 Failure code [CA342] Calibration Code Incompatibility.............................................................. 682 Failure code [CA351] Injectors Drive Circuit Error................................................................. 684 Troubleshooting by failure code (Display of code), Part 2.............................................................. 687 Failure code [CA352] Sens Supply 1 Volt Low Error.................................................................. 689 Failure code [CA386] Sensor Sup. 1 Volt. High Error................................................................ 690 Failure code [CA441] Battery Voltage Low Error..................................................................... 692 Failure code [CA442] Battery Voltage High Error.................................................................... 692 Failure code [CA449] Rail Press Very High Error.................................................................... 693 Failure code [CA451] Rail Press Sensor High Error.................................................................. 694 Failure code [CA452] Rail Press Sensor Low Error................................................................... 696 Failure code [CA553] Rail Press High Error......................................................................... 696 Failure code [CA554] Rail Press Sensor In Range Error.............................................................. 697 Failure code [CA559] Rail Press Low Error.......................................................................... 698 Failure code [CA689] Eng Ne Speed Sensor Error..................................................................... 702 Failure code [CA731] Eng Bkup Speed Sens Phase Error............................................................... 704 Failure code [CA757] All Persistent Data Lost Error................................................................ 705 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................... 706 Failure code [CA1228] EGR Valve Servo Error 1...................................................................... 708 Failure code [CA1625] EGR Valve Servo Error 2...................................................................... 709 Failure code [CA1626] BP Valve Sol Current High Error.............................................................. 710 Failure code [CA1627] BP Valve Sol Current Low Error............................................................... 712 Failure code [CA1628] Bypass Valve Servo Error 1................................................................... 713 Failure code [CA1629] Bypass Valve Servo Error 2................................................................... 714 Failure code [CA1631] BP Valve Pos Sens High Error................................................................. 715 Failure code [CA1632] BP Valve Pos Sens Low Error.................................................................. 717 Failure code [CA1633] KOMNET Datalink Timeout Error................................................................ 718 Failure code [CA2185] Throt Sens Sup Volt High Error............................................................... 720 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................ 722 Failure code [CA2249] Rail Press Very Low Error.................................................................... 723 Failure code [CA2271] EGR Valve Pos Sens High Error................................................................ 724 Failure code [CA2272] EGR Valve Pos Sens Low Error................................................................. 726 Failure code [CA2351] EGR Valve Sol Current High Error............................................................. 728 Failure code [CA2352] EGR Valve Sol Current Low Error.............................................................. 730 Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................ 731 Failure code [CA2556] Grid Htr Relay Volt High Error............................................................... 732 Failure code [D110KB] Battery Relay Drive S/C...................................................................... 734 Failure code [D163KB] Flash Light Relay S/C........................................................................ 736 Failure code [D195KB] Step Light Relay S/C......................................................................... 738 Failure code [DA22KK] Solenoid: Source voltage reduction........................................................... 740 Failure code [DA25KP] Press. Sensor Power Abnormality.............................................................. 742 Failure code [DA2SKQ] Model selection Abnormality.................................................................. 744 Failure code [DA80MA] Auto. Lub. Abnormal.......................................................................... 746 Failure code [DA2RMC] Pump Comm. Abnormality....................................................................... 748 Failure code [DAFRMC] Monitor Comm. Abnormality.................................................................... 750 Troubleshooting by failure code (Display of code), Part 3.............................................................. 753 Failure code [DBB0KK] VHMS source voltage Error (or change of VHMS- LED display from n9 to 01)..................... 756 Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nf to 11)........................ 758 Failure code [DBB3KK] Abnormality in VBAT voltage (or change of VHMS-LED display from n9 to 05).................... 760 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS- LED display from n9 to 04)...................... 762 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)...................... 764 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)................................ 766 Failure code [DGE5KB] Ambi. Temp. Sensor S/C....................................................................... 768 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C................................................................... 769 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS- LED display from n5 to 01)....................... 770 Failure code [DGT4KA] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 12)................. 772 Failure code [DGT4KB] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 11)................. 774 Failure code [DGT5KA] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 22)................. 776 Failure code [DGT5KB] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 21)................. 778 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32).................... 780 Failure code [DHE5KY] Blowby Pres. Sensor Failure) (or change of VHMS-LED display from n3 to 31)................... 782 Failure code [DHPAMA] F Pump P. Sensor Abnormality................................................................. 784 Failure code [DHPAZL] F Pump Relief Pressure Abnormality........................................................... 786 Failure code [DHPBMA] R Pump P. Sensor Abnormality................................................................. 788 Failure code [DHPBZL] R Pump Relief Pressure Abnormality........................................................... 790 Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 23)..................... 792 Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 24)..................... 794 Failure code [DLE2MA] Engine Speed Sensor Error.................................................................... 796 Failure code [DV20KB] Travel Alarm S/C............................................................................. 798 Failure code [DW41KA] Swing Priority Sol. Disc..................................................................... 800 Failure code [DW41KB] Swing Priority Sol. S/C...................................................................... 802 Failure code [DW43KA] Travel Speed Sol. Disc....................................................................... 804 Failure code [DW43KB] Travel Speed Sol. S/C........................................................................ 806 Failure code [DW45KA] Swing Brake Sol. Disc........................................................................ 808 Failure code [DW45KB] Swing Brake Sol. S/C......................................................................... 810 Failure code [DW48KA] CO Cancel Sol. Disc.......................................................................... 812 Failure code [DW48KB] CO Cancel Sol. S/C........................................................................... 814 Troubleshooting by failure code (Display of code), Part 4.............................................................. 817 Troubleshooting by failure code (Display of code), Part 4.......................................................... 820 Failure code [DW7BKA] Fan Reverse Sol. Disc.................................................................... 820 Failure code [DW7BKB] Fan Reverse Sol. S/C..................................................................... 822 Failure code [DW91KA] Travel Junction Sol. Disc................................................................ 824 Failure code [DW91KB] Travel Junction Sol. S/C................................................................. 826 Failure code [DWK0KA] 2-stage Relief Sol. Disc................................................................. 828 Failure code [DWK0KB] 2-stage Relief Sol. S/C.................................................................. 830 Failure code [DX16KA] Fan Pump EPC Sol. Disc................................................................... 832 Failure code [DX16KB] Fan Pump EPC Sol. S/C.................................................................... 834 Failure code [DXA0KA] TVC Sol. Disc............................................................................ 836 Failure code [DXA0KB] TVC Sol. S/C............................................................................. 838 Failure code [DY20KA] Wiper Working Abnormality................................................................ 840 Failure code [DY20MA] Wiper Parking Abnormality................................................................ 842 Failure code [DY2CKB] Washer Drive S/C......................................................................... 846 Failure code [DY2DKB] Wiper Drive (For) S/C.................................................................... 848 Failure code [DY2EKB] Wiper Drive (Rev) S/C.................................................................... 852 Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)....................... 854 Failure code [F@BYNR] High F cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 62)................ 856 Failure code [F@BYNS] High F cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 61)................ 858 Failure code [F@BZNR] High R cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 72)................ 860 Failure code [F@BZNS] High R cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 71)................ 862 Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality........................................................ 864 Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality...................................................... 866 Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 11)................ 868 Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 21)................. 870 Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 12)................ 872 Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 22)................. 874 Failure code [J100L6] Abnormal Cnt. gear pump press (or change of VHMS-LED display from n5 to 71).............. 876 Failure code [j100L6] Abnormal Fan gear pump press (or change of VHMS-LED display from n5 to 81)............... 878 Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change of VHMS-LED display from n5 to 25).......... 880 Troubleshooting of electrical system (E-mode).......................................................................... 883 Before carrying out troubleshooting of electrical system........................................................... 885 Information contained in troubleshooting table..................................................................... 887 E-1 Engine does not start (Engine does not rotate)................................................................. 888 E-2 Auto-decelerator does not work................................................................................. 892 E-3 Auto engine warm-up device does not work....................................................................... 894 E-4 Preheater does not work........................................................................................ 896 E-5 All work equipment, swing and travel do not move............................................................... 898 E-6 Machine push-up circuit does not work.......................................................................... 900 E-7 Boom shockless circuit cannot be reset......................................................................... 902 E-8 No display in machine monitor at all........................................................................... 904 E-9 Part of display on machine monitor is missing.................................................................. 906 E-10 Machine monitor displays contents irrelevant to the model..................................................... 906 E-11 Fuel level monitor red lamp lights up while engine is running................................................. 907 E-12 Hydraulic oil temperature gauge does not display correctly.................................................... 908 E-13 Fuel gauge does not display correctly......................................................................... 909 E-14 Swing lock monitor does not display correctly................................................................. 910 E-15 When the monitor switch is operated, no display appears....................................................... 912 E-16 Windshield wiper does not work................................................................................ 914 E-17 “Boom RAISE” is not correctly displayed in monitor function................................................... 916 E-18 “Boom LOWER” is not correctly displayed in monitor function................................................... 917 E-19 “Arm DIGGING” is not correctly displayed in monitor function.................................................. 918 E-20 “Arm DUMPING” is not correctly displayed in monitor function.................................................. 919 E-21 “Bucket CURL” is not correctly displayed in monitor function.................................................. 920 E-22 “Bucket DUMPING” is not correctly displayed in monitor function............................................... 921 E-23 “SWING” is not correctly displayed in monitor function........................................................ 922 E-24 “TRAVEL” is not correctly displayed in monitor function....................................................... 924 E-25 Air conditioner does not work................................................................................. 926 E-26 Travel alarm does not sound................................................................................... 928 E-27 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up...................... 929 E-28 Step light does not light up or go off........................................................................ 933 E-29 Electric priming pump does not operate or does not stop automatically......................................... 936 Troubleshooting of hydraulic and mechanical system (H-mode)............................................................ 939 Before troubleshooting for hydraulic and mechanical systems........................................................ 941 H-1 Speed or power of all work equipment, travel, and swing is low................................................. 947 H-2 Engine speed lowers remarkably or engine stalls................................................................ 949 H-3 All work equipment, travel, and swing systems do not work...................................................... 950 H-4 Abnormal sound is heard from around pump....................................................................... 952 H-5 Speed or power of boom is low.................................................................................. 953 H-6 Speed or power of arm is low................................................................................... 955 H-7 Speed or power of bucket is low................................................................................ 956 H-8 Boom does not move............................................................................................. 957 H-9 Arm does not move.............................................................................................. 958 H-10 Bucket does not move.......................................................................................... 959 H-11 Hydraulic drift of work equipment is large.................................................................... 960 H-12 Time lag of work equipment is large........................................................................... 961 H-13 Boom shockless function cannot be turned ON or OFF............................................................ 962 H-14 Machine deviates in one direction............................................................................. 962 H-15 Machine deviates largely at start............................................................................. 964 H-16 Machine deviates largely during compound operation............................................................ 965 H-17 Travel speed or power is low.................................................................................. 965 H-18 Machine does not travel (only one track)...................................................................... 966 H-19 Travel speed does not change.................................................................................. 967 H-20 Machine does not swing........................................................................................ 968 H-21 Swing speed or acceleration is low............................................................................ 969 H-22 Swing speed or power is low in compound operation of travel and bucket........................................ 970 H-23 Swing speed or power is low in compound operation of travel and boom in swing priority mode................... 970 H-24 Upper structure overruns largely.............................................................................. 971 H-25 Large shocks are made when upper structure stops swinging..................................................... 972 H-26 Large abnormal sounds are made when upper structure stops swinging............................................ 973 H-27 Hydraulic drift of swing is large............................................................................. 974 H-28 Fan revolution is abnormal (Sound and vibration of the fan is abnormally large, and the fan is overheated).... 975 Troubleshooting of engine (S-mode)..................................................................................... 977 Method of using troubleshooting chart.............................................................................. 979 S-1 Starting performance is poor................................................................................... 982 S-2 Engine does not start.......................................................................................... 984 S-3 Engine does not pick up smoothly............................................................................... 988 S-4 Engine stops during operations................................................................................. 989 S-5 Engine does not rotate smoothly................................................................................ 990 S-6 Engine lacks output (or lacks power)........................................................................... 991 S-7 Exhaust smoke is black (incomplete combustion)................................................................. 992 S-8 Oil consumption is excessive (or exhaust smoke is blue)........................................................ 993 S-9 Oil becomes contaminated quickly............................................................................... 994 S-10 Fuel consumption is excessive................................................................................. 995 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......................................... 996 S-12 Oil pressure drops............................................................................................ 997 S-13 Oil level rises (Entry of coolant or fuel).................................................................... 998 S-14 Coolant temperature becomes too high (overheating)............................................................1000 S-15 Abnormal noise is made........................................................................................1001 S-16 Vibration is excessive........................................................................................1002 S-17 Air cannot be bled from fuel circuit..........................................................................1004 50 Disassembly and assembly................................................................................................1007 General information on disassembly and assembly........................................................................1007 How to read this manual............................................................................................1008 Coating materials list.............................................................................................1010 Special tools list.................................................................................................1013 Sketches of special tools..........................................................................................1022 Engine and cooling system, Part 1......................................................................................1037 Removal and installation of fuel supply pump assembly..............................................................1038 Removal and installation of cylinder head assembly.................................................................1044 Removal and installation of fuel injector assembly.................................................................1062 Removal and installation of engine front seal......................................................................1067 Engine and cooling system, Part 2......................................................................................1075 Removal and installation of engine, PTO and hydraulic pump assembly................................................1076 Removal and installation of radiator and hydraulic oil cooler assembly.............................................1085 Removal of air aftercooler assembly................................................................................1089 Removal and installation of fuel cooler and air conditioner condenser assembly.....................................1091 Removal and installation of fan motor assembly.....................................................................1093 Removal and installation of fuel tank assembly.....................................................................1098 Power train............................................................................................................1101 Removal and installation of PTO assembly...........................................................................1102 Disassembly and assembly of PTO assembly...........................................................................1104 Removal and installation of swing machinery assembly...............................................................1108 Removal and installation of swing motor and swing machinery assembly...............................................1110 Disassembly and assembly of swing machinery assembly...............................................................1113 Disassembly and assembly of swing machinery assembly...............................................................1120 Removal and installation of swing circle assembly..................................................................1128 Disassembly and assembly of final drive assembly...................................................................1129 Undercarriage and frame................................................................................................1141 Removal and installation of track shoe assembly....................................................................1142 Disassembly and assembly of one link in field......................................................................1144 Removal and installation of idler assembly.........................................................................1148 Disassembly and assembly of idler assembly.........................................................................1149 Disassembly and assembly of idler adjustment cylinder assembly.....................................................1152 Removal and installation of recoil spring assembly.................................................................1153 Disassembly and assembly of recoil spring assembly.................................................................1155 Removal and installation of track roller assembly..................................................................1157 Disassembly and assembly of track roller assembly..................................................................1158 Removal and installation of carrier roller assembly................................................................1161 Disassembly and assembly of carrier roller assembly................................................................1162 Removal and installation of revolving frame assembly...............................................................1164 Removal and installation of counterweight assembly.................................................................1165 Hydraulic system.......................................................................................................1169 Removal and installation of hydraulic tank assembly................................................................1170 Removal and installation of hydraulic pump assembly................................................................1172 Removal and installation of main pump input shaft oil seal.........................................................1178 Removal and installation of 5-spool control valve assembly (No. 1).................................................1179 Removal and installation of 4-spool control valve assembly (No. 2).................................................1181 Removal and installation of 4-spool control valve assembly (No. 3).................................................1183 Disassembly and assembly of control valve assembly (No. 1).........................................................1185 Disassembly and assembly of control valve assembly (No. 2).........................................................1188 Disassembly and assembly of control valve assembly (No. 3).........................................................1192 Removal and installation of swing motor assembly...................................................................1196 Removal and installation of center swivel joint assembly...........................................................1200 Disassembly and assembly of center swivel joint assembly...........................................................1201 Removal and installation of travel motor assembly..................................................................1203 Disassembly and assembly of work equipment PPC valve assembly......................................................1204 Disassembly and assembly of travel PPC valve assembly..............................................................1206 Disassembly and assembly of hydraulic cylinder assembly............................................................1209 Work equipment.........................................................................................................1219 Removal and installation of bucket cylinder assembly...............................................................1220 Removal and installation of bottom dump cylinder assembly..........................................................1224 Removal and installation of arm cylinder assembly..................................................................1226 Removal and installation of boom cylinder assembly.................................................................1230 Removal and installation of bucket assembly........................................................................1234 Removal and installation of arm assembly...........................................................................1238 Removal and installation of boom assembly..........................................................................1241 Cab and its attachments................................................................................................1247 Removal and installation of operator cab assembly..................................................................1248 Removal and installation of operator’s cab glass (Stuck glass).....................................................1251 Removal and installation of front window assembly..................................................................1261 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY...........................................................1267 Electrical system......................................................................................................1279 Removal and installation of air conditioner unit assembly..........................................................1280 Removal and installation of monitor assembly.......................................................................1283 Removal and installation of pump controller assembly...............................................................1284 Removal and installation of Orbcomm terminal assembly for VHMS.....................................................1285 Removal and installation of VHMS controller assembly...............................................................1286 Removal and installation of engine controller assembly.............................................................1287 90 Diagrams and drawings...................................................................................................1289 Hydraulic circuit diagrams.............................................................................................1289 Hydraulic circuit diagram (1/2) Serial number 35001 – 35016........................................................1291 Hydraulic circuit diagram (2/2) Serial number 35001 – 35016........................................................1293 Hydraulic circuit diagram (1/3) Serial number 35017 and up.........................................................1295 Hydraulic circuit diagram (2/3) Serial number 35017 and up.........................................................1297 Hydraulic circuit diagram (3/3) Serial number 35017 and up.........................................................1299 Electrical diagrams and drawings.......................................................................................1303 Electrical diagrams and drawings...................................................................................1305 Electrical circuit diagram (1/7) Serial number 30001 - 30604...................................................1305 Electrical circuit diagram (2/7) Serial number 30001 - 30604...................................................1307 Electrical circuit diagram (3/7) Serial number 30001 - 30604...................................................1309 Electrical circuit diagram (4/7) Serial number 30001 - 30604...................................................1311 Electrical circuit diagram (5/7) Serial number 30001 - 30604...................................................1313 Electrical circuit diagram (6/7) Serial number 30001 - 30604...................................................1315 Electrical circuit diagram (7/7) Serial number 30001 - 30604...................................................1317 Electrical circuit diagram (1/8) Serial number 30605 and up....................................................1319 Electrical circuit diagram (2/8) Serial number 30605 and up....................................................1321 Electrical circuit diagram (3/8) Serial number 30605 and up....................................................1323 Electrical circuit diagram (4/8) Serial number 30605 and up....................................................1325 Electrical circuit diagram (5/8) Serial number 30605 and up....................................................1327 Electrical circuit diagram (6/8) Serial number 30605 and up....................................................1329 Electrical circuit diagram (7/8) Serial number 30605 and up....................................................1331 Electrical circuit diagram (8/8) Serial number 30605 and up....................................................1333 Connector arrangement diagram..................................................................................1335
DESCRIPTION:
KOMATSU PC1250-8 PC1250SP-8 PC1250LC-8 HYDRAULIC EXCAVATOR SHOP MANUAL SEN00889-28 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 28/12/24
