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KOMATSU PC1250-8R PC1250SP-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02048-26 – PDF DOWNLOAD
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KOMATSU PC1250-8R PC1250SP-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02048-26 – PDF DOWNLOAD
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KOMATSU PC1250-8R PC1250SP-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02048-26 – PDF DOWNLOAD
Language : English
Pages : 1312
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC1250-8R PC1250SP-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02048-26 – 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....................................................................................................... 76 Table of fuel, coolant and lubricants.............................................................................. 84 10 Structure, function and maintenance standard............................................................................ 87 Engine and cooling system.............................................................................................. 87 PTO................................................................................................................ 88 PTO lubrication system............................................................................................. 90 Radiator and oil cooler............................................................................................ 92 Power train............................................................................................................ 95 Power train........................................................................................................ 96 Swing machinery.................................................................................................... 98 Swing circle....................................................................................................... 102 Final drive........................................................................................................ 103 Sprocket........................................................................................................... 106 Undercarriage and frame................................................................................................ 109 Track frame, recoil spring......................................................................................... 110 Idler.............................................................................................................. 112 Carrier roller..................................................................................................... 114 Track roller....................................................................................................... 115 Track shoe......................................................................................................... 116 Hydraulic system, Part 1............................................................................................... 121 Hydraulic piping drawing........................................................................................... 122 Hydraulic tank..................................................................................................... 125 Hydraulic pump..................................................................................................... 127 Line oil filter.................................................................................................... 168 Pilot oil filter................................................................................................... 169 Return oil filter.................................................................................................. 170 Drain oil filter................................................................................................... 171 Cooling fan pump................................................................................................... 172 Cooling fan motor.................................................................................................. 186 Aftercooler fan motor.............................................................................................. 192 Hydraulic system, Part 2............................................................................................... 199 Control valve...................................................................................................... 200 Swing motor........................................................................................................ 215 Center swivel joint................................................................................................ 224 Travel motor....................................................................................................... 225 PPC control relief valve........................................................................................... 235 Accumulator........................................................................................................ 236 Valve control...................................................................................................... 237 PPC valve.......................................................................................................... 238 Solenoid valve..................................................................................................... 248 Hydraulic cylinder................................................................................................. 256 Work equipment......................................................................................................... 261 Work equipment..................................................................................................... 262 Dimensions of work equipment....................................................................................... 266 Cab and its attachments................................................................................................ 271 Air conditioner.................................................................................................... 272 Electrical system...................................................................................................... 275 Engine control..................................................................................................... 276 Electric control system............................................................................................ 283 Monitor system..................................................................................................... 319 Sensor............................................................................................................. 342 20 Standard value table.................................................................................................... 349 Standard service value table........................................................................................... 349 Standard value table for engine related parts...................................................................... 350 Standard value table for chassis related parts..................................................................... 351 30 Testing and adjusting................................................................................................... 373 Testing and adjusting, Part 1.......................................................................................... 373 Tools for testing, adjusting, and troubleshooting.................................................................. 375 Sketch of special tool............................................................................................. 380 Measuring engine speed............................................................................................. 381 Measuring air supply pressure (Boost pressure)..................................................................... 382 Measuring exhaust temperature...................................................................................... 383 Measuring exhaust color............................................................................................ 384 Adjustment of valve clearance...................................................................................... 386 Measurement of compression pressure................................................................................ 388 Measuring blow-by pressure......................................................................................... 391 Measurement of engine oil pressure................................................................................. 392 Adjusting engine speed sensor...................................................................................... 393 Handling fuel system parts......................................................................................... 394 Releasing residual pressure in fuel system......................................................................... 394 Testing fuel pressure.............................................................................................. 395 Measurement of fuel return rate and fuel leakage................................................................... 396 Bleeding air from fuel circuit..................................................................................... 400 Testing fuel system for leakage.................................................................................... 402 Procedure for checking alternator and replacing belt............................................................... 403 Testing and adjusting, Part 2.......................................................................................... 405 Testing swing circle bearing clearance............................................................................. 406 Testing wear of sprocket........................................................................................... 407 Testing and adjusting track shoe tension........................................................................... 408 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit.................................. 409 Testing and adjusting control circuit oil pressure................................................................. 423 Testing and adjusting piston pump control pressure................................................................. 425 Testing servo piston stroke........................................................................................ 432 Testing and adjusting, Part 3.......................................................................................... 435 Measuring PPC valve output pressure and testing swing PPC shuttle valve............................................ 436 Measuring solenoid valve output pressure........................................................................... 440 Adjusting work equipment, swing PPC valve.......................................................................... 442 Testing travel deviation........................................................................................... 443 Testing locations causing hydraulic drift of work equipment........................................................ 444 Measuring oil leakage.............................................................................................. 445 Measurement of fan speed........................................................................................... 453 Measurement of fan circuit oil pressure............................................................................ 454 Measuring fan pump EPC solenoid valve output pressure.............................................................. 456 Bleeding air....................................................................................................... 457 Releasing remaining pressure in hydraulic circuit.................................................................. 459 Testing procedures for diode....................................................................................... 460 Testing and adjusting, Part 4.......................................................................................... 463 Special function of machine monitor................................................................................ 464 Handling controller voltage circuit................................................................................ 504 Testing and adjusting, Part 5.......................................................................................... 507 VHMS controller initial setting procedure.......................................................................... 508 Precautions for replacing VHMS controller.......................................................................... 523 Testing and adjusting, Part 6.......................................................................................... 531 Pm-clinic service.................................................................................................. 532 40 Troubleshooting......................................................................................................... 549 Failure code table and fuse locations.................................................................................. 549 Failure code table................................................................................................. 550 Fuse locations..................................................................................................... 554 General information on troubleshooting................................................................................. 557 Points to remember when troubleshooting............................................................................ 558 Sequence of events in troubleshooting.............................................................................. 559 Checks before troubleshooting...................................................................................... 560 Classification and troubleshooting steps........................................................................... 561 Information in troubleshooting table............................................................................... 565 Connection table for connector pin numbers......................................................................... 567 T- branch box and T- branch adapter table.......................................................................... 603 Troubleshooting by failure code (Display of code), Part 1.............................................................. 607 Failure code [A000N1] Eng. Hi Out of Std........................................................................... 609 Failure code [AA10NX] Aircleaner Clogging.......................................................................... 610 Failure code [AB00KE] Charge Voltage Low........................................................................... 612 Failure code [B@BAZG] Eng. Oil Press. Low.......................................................................... 614 Failure code [B@BAZK] Eng. Oil Level Low........................................................................... 616 Failure code [B@BCNS] Eng. Water Overheat.......................................................................... 618 Failure code [B@BCZK] Eng. Water Lvl Low........................................................................... 620 Failure code [B@CBNS] High PTO temperature......................................................................... 622 Failure code [B@HANS] Hydr. Oil Overheat........................................................................... 624 Failure code [CA111] ECM Critical Internal Failure................................................................. 625 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.............................................................. 627 Failure code [CA122] Chg Air Press Sensor High Error............................................................... 628 Failure code [CA123] Chg Air Press Sensor Low Error................................................................ 630 Failure code [CA131] Throttle Sensor High Error.................................................................... 631 Failure code [CA132] Throttle Sensor Low Error..................................................................... 633 Failure code [CA135] Eng Oil Press Sensor High Error............................................................... 634 Failure code [CA141] Eng Oil Press Sensor Low Error................................................................ 636 Failure code [CA144] Coolant Temp Sens High Error.................................................................. 637 Failure code [CA145] Coolant Temp Sens Low Error................................................................... 639 Failure code [CA153] Chg Air Temp Sensor High Error................................................................ 640 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................. 642 Failure code [CA187] Sens Supply 2 Volt Low Error.................................................................. 642 Failure code [CA221] Ambient Press Sens High Error................................................................. 643 Failure code [CA222] Ambient Press Sens Low Error.................................................................. 645 Failure code [CA227] Sens Supply 2 Volt High Error................................................................. 646 Failure code [CA234] Eng Overspeed................................................................................. 648 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................... 650 Failure code [CA263] Fuel Temp Sensor High Error................................................................... 652 Failure code [CA265] Fuel Temp Sensor Low Error.................................................................... 654 Failure code [CA271] IMV/PCV1 Short Error.......................................................................... 655 Failure code [CA272] IMV/PCV1 Open Error........................................................................... 656 Failure code [CA273] PCV2 Short Error.............................................................................. 658 Failure code [CA274] PCV2 Open Error............................................................................... 659 Failure code [CA322] Inj #1 (L#1) Open/Short Error................................................................. 660 Failure code [CA323] Inj #5 (L#5) Open/Short Error................................................................. 662 Failure code [CA324] Inj #3 (L#3) Open/Short Error................................................................. 664 Failure code [CA325] Inj #6 (L#6) Open/Short Error................................................................. 666 Failure code [CA331] Inj #2 (L#2) Open/Short Error................................................................. 668 Failure code [CA332] Inj #4 (L#4) Open/Short Error................................................................. 670 Failure code [CA342] Calibration Code Incompatibility.............................................................. 672 Failure code [CA351] Injectors Drive Circuit Error................................................................. 674 Troubleshooting by failure code (Display of code), Part 2.............................................................. 677 Failure code [CA352] Sens Supply 1 Volt Low Error.................................................................. 679 Failure code [CA386] Sensor Sup. 1 Volt. High Error................................................................ 680 Failure code [CA441] Battery Voltage Low Error..................................................................... 682 Failure code [CA442] Battery Voltage High Error.................................................................... 682 Failure code [CA449] Rail Press Very High Error.................................................................... 683 Failure code [CA451] Rail Press Sensor High Error.................................................................. 684 Failure code [CA452] Rail Press Sensor Low Error................................................................... 686 Failure code [CA553] Rail Press High Error......................................................................... 686 Failure code [CA554] Rail Press Sensor In Range Error.............................................................. 687 Failure code [CA559] Rail Press Low Error.......................................................................... 688 Failure code [CA689] Eng Ne Speed Sensor Error..................................................................... 692 Failure code [CA731] Eng Bkup Speed Sens Phase Error............................................................... 694 Failure code [CA757] All Persistent Data Lost Error................................................................ 695 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................... 696 Failure code [CA1633] KOMNET Datalink Timeout Error................................................................ 698 Failure code [CA2185] Throt Sens Sup Volt High Error............................................................... 700 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................ 702 Failure code [CA2249] Rail Press Very Low Error.................................................................... 703 Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................ 704 Failure code [CA2556] Grid Htr Relay Volt High Error............................................................... 706 Failure code [D110KB] Battery Relay Drive S/C...................................................................... 708 Failure code [D163KB] Flash Light Relay S/C........................................................................ 710 Failure code [D195KB] Step Light Relay S/C......................................................................... 712 Failure code [DA22KK] Pump controller solenoid: Source voltage reduction........................................... 714 Failure code [DA25KP] Press. Sensor Power Abnormality.............................................................. 716 Failure code [DA2SKQ] Model selection Abnormality.................................................................. 718 Failure code [DA80MA] Auto. Lub. Abnormal.......................................................................... 720 Failure code [DA2RMC] Pump Comm. Abnormality....................................................................... 722 Failure code [DAFRMC] Monitor Comm. Abnormality.................................................................... 724 Troubleshooting by failure code (Display of code), Part 3.............................................................. 727 Failure code [DBB0KK] VHMS source voltage Error (or change of VHMS- LED display from n9 to 01)..................... 730 Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nf to 11)........................ 732 Failure code [DBB3KK] Abnormality in VBAT voltage (or change of VHMS-LED display from n9 to 05).................... 734 Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS- LED display from n9 to 04)...................... 736 Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)...................... 738 Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)................................ 740 Failure code [DGE5KB] Ambi. Temp. Sensor S/C....................................................................... 742 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C................................................................... 743 Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS- LED display from n5 to 01)....................... 744 Failure code [DGT4KA] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 12)................. 746 Failure code [DGT4KB] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 11)................. 748 Failure code [DGT5KA] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 22)................. 750 Failure code [DGT5KB] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 21)................. 752 Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32).................... 754 Failure code [DHE5KY] Blowby Pres. Sensor Failure) (or change of VHMS-LED display from n3 to 31)................... 756 Failure code [DHPAMA] F Pump P. Sensor Abnormality................................................................. 758 Failure code [DHPAZL] F Pump Relief Pressure Abnormality........................................................... 760 Failure code [DHPBMA] R Pump P. Sensor Abnormality................................................................. 762 Failure code [DHPBZL] R Pump Relief Pressure Abnormality........................................................... 764 Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 23)..................... 766 Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 24)..................... 768 Failure code [DLE2MA] Engine Speed Sensor Error.................................................................... 770 Failure code [DV20KB] Travel Alarm S/C............................................................................. 772 Failure code [DW41KA] Swing Priority Sol. Disc..................................................................... 774 Failure code [DW41KB] Swing Priority Sol. S/C...................................................................... 776 Failure code [DW43KA] Travel Speed Sol. Disc....................................................................... 778 Failure code [DW43KB] Travel Speed Sol. S/C........................................................................ 780 Failure code [DW45KA] Swing Brake Sol. Disc........................................................................ 782 Failure code [DW45KB] Swing Brake Sol. S/C......................................................................... 784 Failure code [DW48KA] CO Cancel Sol. Disc.......................................................................... 786 Failure code [DW48KB] CO Cancel Sol. S/C........................................................................... 788 Troubleshooting by failure code (Display of code), Part 4.............................................................. 791 Failure code [DW7BKA] Fan Reverse Sol. Disc........................................................................ 794 Failure code [DW7BKB] Fan Reverse Sol. S/C......................................................................... 796 Failure code [DW91KA] Travel Junction Sol. Disc.................................................................... 798 Failure code [DW91KB] Travel Junction Sol. S/C..................................................................... 800 Failure code [DWK0KA] 2-stage Relief Sol. Disc..................................................................... 802 Failure code [DWK0KB] 2-stage Relief Sol. S/C...................................................................... 804 Failure code [DX16KA] Fan Pump EPC Sol. Disc....................................................................... 806 Failure code [DX16KB] Fan Pump EPC Sol. S/C........................................................................ 808 Failure code [DXA0KA] TVC Sol. Disc................................................................................ 810 Failure code [DXA0KB] TVC Sol. S/C................................................................................. 812 Failure code [DY20KA] Wiper Working Abnormality.................................................................... 814 Failure code [DY20MA] Wiper Parking Abnormality.................................................................... 816 Failure code [DY2CKB] Washer Drive S/C............................................................................. 820 Failure code [DY2DKB] Wiper Drive (For) S/C........................................................................ 822 Failure code [DY2EKB] Wiper Drive (Rev) S/C........................................................................ 826 Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)........................... 828 Failure code [F@BYNR] High F cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 62).................... 830 Failure code [F@BYNS] High F cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 61).................... 832 Failure code [F@BZNR] High R cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 72).................... 834 Failure code [F@BZNS] High R cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 71).................... 836 Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality............................................................ 838 Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality.......................................................... 840 Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 11).................... 842 Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMS- LED display from n5 to 21).................... 844 Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 12).................... 846 Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMS- LED display from n5 to 22).................... 848 Failure code [J100L6] Abnormal Cnt. gear pump press (or change of VHMS-LED display from n5 to 71).................. 850 Failure code [j100L6] Abnormal Fan gear pump press (or change of VHMS-LED display from n5 to 81)................... 852 Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change of VHMS-LED display from n5 to 25).............. 854 Troubleshooting of electrical system (E-mode).......................................................................... 857 Before carrying out troubleshooting of electrical system........................................................... 859 Information contained in troubleshooting table..................................................................... 861 E-1 Engine does not start (Engine does not rotate)................................................................. 862 E-2 Auto-decelerator does not work................................................................................. 866 E-3 Auto engine warm-up device does not work....................................................................... 868 E-4 Preheater does not work........................................................................................ 870 E-5 All work equipment, swing and travel do not move............................................................... 872 E-6 Machine push-up circuit does not work.......................................................................... 874 E-7 Boom shockless circuit cannot be reset......................................................................... 876 E-8 No display in machine monitor at all........................................................................... 878 E-9 Part of display on machine monitor is missing.................................................................. 880 E-10 Machine monitor displays contents irrelevant to the model..................................................... 880 E-11 Fuel level monitor red lamp lights up while engine is running................................................. 881 E-12 Hydraulic oil temperature gauge does not display correctly.................................................... 882 E-13 Fuel gauge does not display correctly......................................................................... 883 E-14 Swing lock monitor does not display correctly................................................................. 884 E-15 When the monitor switch is operated, no display appears....................................................... 886 E-16 Windshield wiper does not work................................................................................ 888 E-17 “Boom RAISE” is not correctly displayed in monitor function................................................... 890 E-18 “Boom LOWER” is not correctly displayed in monitor function................................................... 891 E-19 “Arm DIGGING” is not correctly displayed in monitor function.................................................. 892 E-20 “Arm DUMPING” is not correctly displayed in monitor function.................................................. 893 E-21 “Bucket CURL” is not correctly displayed in monitor function.................................................. 894 E-22 “Bucket DUMPING” is not correctly displayed in monitor function............................................... 895 E-23 “SWING” is not correctly displayed in monitor function........................................................ 896 E-24 “TRAVEL” is not correctly displayed in monitor function....................................................... 898 E-25 Air conditioner does not work................................................................................. 900 E-26 Travel alarm does not sound................................................................................... 902 E-27 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up...................... 903 E-28 Step light does not light up or go off........................................................................ 907 E-29 Electric priming pump does not operate or does not stop automatically......................................... 910 Troubleshooting of hydraulic and mechanical system (H-mode)............................................................ 913 Before troubleshooting for hydraulic and mechanical systems........................................................ 915 H-1 Speed or power of all work equipment, travel, and swing is low................................................. 921 H-2 Engine speed lowers remarkably or engine stalls................................................................ 923 H-3 All work equipment, travel, and swing systems do not work...................................................... 924 H-4 Abnormal sound is heard from around pump....................................................................... 926 H-5 Speed or power of boom is low.................................................................................. 927 H-6 Speed or power of arm is low................................................................................... 929 H-7 Speed or power of bucket is low................................................................................ 930 H-8 Boom does not move............................................................................................. 931 H-9 Arm does not move.............................................................................................. 932 H-10 Bucket does not move.......................................................................................... 933 H-11 Hydraulic drift of work equipment is large.................................................................... 934 H-12 Time lag of work equipment is large........................................................................... 935 H-13 Boom shockless function cannot be turned ON or OFF............................................................ 936 H-14 Machine deviates in one direction............................................................................. 936 H-15 Machine deviates largely at start............................................................................. 938 H-16 Machine deviates largely during compound operation............................................................ 939 H-17 Travel speed or power is low.................................................................................. 939 H-18 Machine does not travel (only one track)...................................................................... 940 H-19 Travel speed does not change.................................................................................. 941 H-20 Machine does not swing........................................................................................ 942 H-21 Swing speed or acceleration is low............................................................................ 943 H-22 Swing speed or power is low in compound operation of travel and bucket........................................ 944 H-23 Swing speed or power is low in compound operation of travel and boom in swing priority mode................... 944 H-24 Upper structure overruns largely.............................................................................. 945 H-25 Large shocks are made when upper structure stops swinging..................................................... 946 H-26 Large abnormal sounds are made when upper structure stops swinging............................................ 947 H-27 Hydraulic drift of swing is large............................................................................. 948 H-28 Fan revolution is abnormal (Sound and vibration of the fan is abnormally large, and the fan is overheated).... 949 Troubleshooting of engine (S-mode)..................................................................................... 951 Method of using troubleshooting chart.............................................................................. 953 S-1 Starting performance is poor................................................................................... 956 S-2 Engine does not start.......................................................................................... 957 S-3 Engine does not pick up smoothly............................................................................... 960 S-4 Engine stops during operations................................................................................. 961 S-5 Engine does not rotate smoothly................................................................................ 962 S-6 Engine lacks output (or lacks power)........................................................................... 963 S-7 Exhaust smoke is black (incomplete combustion)................................................................. 964 S-8 Oil consumption is excessive (or exhaust smoke is blue)........................................................ 965 S-9 Oil becomes contaminated quickly............................................................................... 966 S-10 Fuel consumption is excessive................................................................................. 967 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)......................................... 968 S-12 Oil pressure drops............................................................................................ 969 S-13 Oil level rises (Entry of coolant or fuel).................................................................... 970 S-14 Coolant temperature becomes too high (overheating)............................................................ 971 S-15 Abnormal noise is made........................................................................................ 972 S-16 Vibration is excessive........................................................................................ 973 S-17 Air cannot be bled from fuel circuit.......................................................................... 974 50 Disassembly and assembly................................................................................................ 977 General information on disassembly and assembly........................................................................ 977 How to read this manual............................................................................................ 978 Coating materials list............................................................................................. 980 Special tools list................................................................................................. 983 Sketches of special tools.......................................................................................... 992 Engine and cooling system (SAA6D170E-5)................................................................................1005 Removal and installation of engine, PTO and hydraulic pump assembly................................................1006 Removal and installation of radiator and hydraulic oil cooler assembly.............................................1016 Removal of air aftercooler assembly................................................................................1021 Removal and installation of fuel cooler and air conditioner condenser assembly.....................................1024 Removal and installation of fan motor assembly.....................................................................1026 Removal and installation of fuel tank assembly.....................................................................1032 Engine (SAA6D170E-5)...................................................................................................1035 Removal and installation of fuel supply pump assembly..............................................................1036 Removal and installation of cylinder head assembly.................................................................1042 Removal and installation of fuel injector assembly.................................................................1061 Removal and installation of engine front seal......................................................................1066 Removal and installation of engine rear seal.......................................................................1068 Power train............................................................................................................1075 Removal and installation of PTO assembly...........................................................................1076 Disassembly and assembly of PTO assembly...........................................................................1078 Removal and installation of swing machinery assembly...............................................................1082 Removal and installation of swing motor and swing machinery assembly...............................................1084 Disassembly and assembly of swing machinery assembly...............................................................1087 Disassembly and assembly of swing machinery assembly...............................................................1094 Removal and installation of swing circle assembly..................................................................1102 Disassembly and assembly of final drive assembly...................................................................1103 Undercarriage and frame................................................................................................1115 Removal and installation of track shoe assembly....................................................................1116 Disassembly and assembly of one link in field......................................................................1118 Removal and installation of idler assembly.........................................................................1122 Disassembly and assembly of idler assembly.........................................................................1123 Disassembly and assembly of idler adjustment cylinder assembly.....................................................1126 Removal and installation of recoil spring assembly.................................................................1127 Disassembly and assembly of recoil spring assembly.................................................................1129 Removal and installation of track roller assembly..................................................................1131 Disassembly and assembly of track roller assembly..................................................................1132 Removal and installation of carrier roller assembly................................................................1135 Disassembly and assembly of carrier roller assembly................................................................1136 Removal and installation of revolving frame assembly...............................................................1138 Removal and installation of counterweight assembly.................................................................1139 Hydraulic system.......................................................................................................1143 Removal and installation of hydraulic tank assembly................................................................1144 Removal and installation of hydraulic pump assembly................................................................1146 Removal and installation of main pump input shaft oil seal.........................................................1152 Removal and installation of 5-spool control valve assembly (No. 1).................................................1153 Removal and installation of 4-spool control valve assembly (No. 2).................................................1155 Removal and installation of 4-spool control valve assembly (No. 3).................................................1157 Disassembly and assembly of control valve assembly (No. 1).........................................................1159 Disassembly and assembly of control valve assembly (No. 2).........................................................1162 Disassembly and assembly of control valve assembly (No. 3).........................................................1166 Removal and installation of swing motor assembly...................................................................1170 Removal and installation of center swivel joint assembly...........................................................1174 Disassembly and assembly of center swivel joint assembly...........................................................1175 Removal and installation of travel motor assembly..................................................................1177 Disassembly and assembly of work equipment PPC valve assembly......................................................1178 Disassembly and assembly of travel PPC valve assembly..............................................................1180 Disassembly and assembly of hydraulic cylinder assembly............................................................1183 Work equipment.........................................................................................................1193 Removal and installation of bucket cylinder assembly...............................................................1194 Removal and installation of bottom dump cylinder assembly..........................................................1198 Removal and installation of arm cylinder assembly..................................................................1200 Removal and installation of boom cylinder assembly.................................................................1204 Removal and installation of bucket assembly........................................................................1208 Removal and installation of arm assembly...........................................................................1212 Removal and installation of boom assembly..........................................................................1215 Cab and its attachments................................................................................................1221 Removal and installation of operator cab assembly..................................................................1222 Removal and installation of operator’s cab glass (Stuck glass).....................................................1225 Removal and installation of front window assembly..................................................................1235 REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY...........................................................1241 Electrical system......................................................................................................1253 Removal and installation of air conditioner unit assembly..........................................................1254 Removal and installation of monitor assembly.......................................................................1257 Removal and installation of pump controller assembly...............................................................1258 Removal and installation of Orbcomm terminal assembly for VHMS.....................................................1259 Removal and installation of VHMS controller assembly...............................................................1260 Removal and installation of engine controller assembly.............................................................1261 90 Diagrams and drawings...................................................................................................1263 Hydraulic circuit diagrams.............................................................................................1263 Hydraulic circuit diagram (1/2) Serial number 35001 – 35016........................................................1265 Hydraulic circuit diagram (2/2) Serial number 35001 – 35016........................................................1267 Hydraulic circuit diagram (1/3) Serial number 35017 and up.........................................................1269 Hydraulic circuit diagram (2/3) Serial number 35017 and up.........................................................1271 Hydraulic circuit diagram (3/3) Serial number 35017 and up.........................................................1273 Electrical diagrams and drawings.......................................................................................1277 Electrical circuit diagram (1/7) Serial number 35001 - 36050.......................................................1279 Electrical circuit diagram (2/7) Serial number 35001 - 36050.......................................................1281 Electrical circuit diagram (3/7) Serial number 35001 - 36050.......................................................1283 Electrical circuit diagram (4/7) Serial number 35001 - 36050.......................................................1285 Electrical circuit diagram (5/7) Serial number 35001 - 36050.......................................................1287 Electrical circuit diagram (6/7) Serial number 35001 - 36050.......................................................1289 Electrical circuit diagram (7/7) Serial number 35001 - 36050.......................................................1291 Electrical circuit diagram (1/8) Serial number 36051 and up........................................................1293 Electrical circuit diagram (2/8) Serial number 36051 and up........................................................1295 Electrical circuit diagram (3/8) Serial number 36051 and up........................................................1297 Electrical circuit diagram (4/8) Serial number 36051 and up........................................................1299 Electrical circuit diagram (5/8) Serial number 36051 and up........................................................1301 Electrical circuit diagram (6/8) Serial number 36051 and up........................................................1303 Electrical circuit diagram (7/8) Serial number 36051 and up........................................................1305 Electrical circuit diagram (8/8) Serial number 36051 and up........................................................1307 Connector arrangement diagram......................................................................................1309
DESCRIPTION:
KOMATSU PC1250-8R PC1250SP-8R HYDRAULIC EXCAVATOR SHOP MANUAL SEN02048-26 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates 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 29/12/24
