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SEN00892-04

00 Index and foreword

4

PC1250-8

12) When assembling or installing parts,

always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate vio-
lently or rotate at high speed, be particu-
l a r l y   c a r e f u l   t o   c h e c k   t h a t   t h e y   a r e
installed correctly.

13) When aligning 2 holes, never insert your

fingers or hand. Be careful not to get your
fingers caught in a hole.

14) When measuring hydraulic pressure,

check that the measuring tools are cor-
rectly assembled.

15) Take care when removing or installing the

tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.

16) If the engine is operated for a long time in

a place which is not ventilated well, you
may suffer from gas poisoning. Accord-
ingly, open the windows and doors to ven-
tilate well.

4.

Precautions for sling work and making
signs

1)

Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.

q

Do not stand under the load.

q

Do not step on the load.

2)

Check the slings before starting sling
work.

3)

Keep putting on gloves during sling work.
(Put on leather gloves, if available.)

4)

Measure the weight of the load by the eye
and check its center of gravity.

5)

Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.

6)

Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.

k

Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.

7)

Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120°. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150°, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.

8)

When installing wire ropes to an angular
load, apply pads to protect the wire ropes.
If the load is slippery, apply proper mate-
rial to prevent the wire rope from slipping.

9)

Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.

10) Apply wire ropes to the middle portion of

the hook.

q

Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle por-
tion.

Summary of Contents for PC1250 -8

Page 1: ...HYDRAULIC EXCAVATOR SEN00889 19 PC1250 8 PC1250SP 8 PC1250LC 8 SERIAL NUMBERS PC1250 30001 PC1250SP 30001 PC1250LC 30001 and up...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...NUAL PC1250 8 PC1250SP 8 PC1250LC 8 Machine model Serial number PC1250 8 30001 and up PC1250SP 8 30001 and up PC1250LC 8 30001 and up 00 Index and foreword 1 Index Composition of shop manual 2 Table o...

Page 4: ...on Title Form Number Shop Manual contents binder binder label and tabs SEN00889 19 00 Index and foreword SEN00890 19 Index SEN00891 19 q Foreword and general information SEN00892 04 01 Specification S...

Page 5: ...system E mode SEN01643 01 Troubleshooting of hydraulic and mechanical system H mode SEN01644 00 Troubleshooting of engine S mode SEN01645 02 50 Disassembly and assembly SEN00908 06 General informatio...

Page 6: ...ing torque table 32 Conversion table 36 01 Specification Specification and technical data SEN00894 02 Backhoe specification 2 Loading shovel specification 4 Specifications 6 Weight table 22 Table of f...

Page 7: ...tem 9 Monitor system 45 Sensor 68 20 Standard value table Standard service value table SEN01631 04 Standard value table for engine related parts 2 Standard value table for chassis related parts 3 30 T...

Page 8: ...monitor 2 Handling controller voltage circuit 42 Testing and adjusting Part 5 SEN01636 01 VHMS controller initial setting procedure 2 Precautions for replacing VHMS controller 17 Testing and adjustin...

Page 9: ...Open Short Error 66 Failure code CA332 Inj 4 L 4 Open Short Error 68 Failure code CA342 Calibration Code Incompatibility 70 Failure code CA351 Injectors Drive Circuit Error 72 Troubleshooting by failu...

Page 10: ...or change of VHMS LED display from n8 to 02 14 Failure code DGE5KB Ambi Temp Sensor S C 16 Failure code DGH2KB Hydr Oil Temp Sensor S C 17 Failure code DGT3KZ PTO Temp Sensor Failure or change of VHMS...

Page 11: ...R cyl Exhaust Temp 1 or change of VHMS LED display from n3 to 71 46 Failure code F HCMA Swing Pump Pres Sen Abnormality 48 Failure code F HCZL Swing Pump Relief Pres Abnormality 50 Failure code J100KA...

Page 12: ...low 9 H 2 Engine speed lowers remarkably or engine stalls 11 H 3 All work equipment travel and swing systems do not work 12 H 4 Abnormal sound is heard from around pump 14 H 5 Speed or power of boom i...

Page 13: ...n of radiator and hydraulic oil cooler assembly 11 Removal of air aftercooler assembly 15 Removal and installation of fuel cooler and air conditioner condenser assembly 17 Removal and installation of...

Page 14: ...al and installation of boom cylinder assembly 12 Removal and installation of bucket assembly 16 Removal and installation of arm assembly 20 Removal and installation of boom assembly 23 Cab and its att...

Page 15: ...00 Index and foreword SEN00891 19 PC1250 8 13...

Page 16: ...14 SEN00891 19 PC1250 8 PC1250SP 8 PC1250LC 8 Hydraulic excavator Form No SEN00891 19 2017 KOMATSU All Rights Reserved Printed in Japan 09 17 01...

Page 17: ...d general information Safety notice 2 How to read the shop manual 7 Explanation of terms for maintenance standard 9 Handling of electric equipment and hydraulic component 11 Handling of connectors new...

Page 18: ...ty shoes and helmet Do not wear loose work clothes or clothes with buttons missing q Always wear safety glasses when hit ting parts with a hammer q Always wear safety glasses when grinding parts with...

Page 19: ...ng parts 4 For the machine equipped with a bat tery disconnct switch turn the battery disconnect switch to the OFF O posi tion and pull the switch key out before starting the work For machines without...

Page 20: ...5 Use proper sling according to the weight of the load and method of slinging If too thick wire ropes are used to sling a light load the load may slip and fall 6 Do not sling a load with 1 wire rope...

Page 21: ...opes brake clutch controller rails over wind stop device electric shock preven tion earth leakage breaker crane collision prevention device and power application warning lamp and check safety 2 Observ...

Page 22: ...your skin you may lose your sight and your skin may be frozen Accordingly put on safety glasses safety gloves and safety clothes when recover ing or adding the refrigerant Refrigerant gas must be rec...

Page 23: ...standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them The...

Page 24: ...ed with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are necess...

Page 25: ...is called the standard size and the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The...

Page 26: ...in the standard range 4 Repair limit and allowable value or allow able dimension q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the r...

Page 27: ...ore likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair operations they are frequently removed and installed again so they are likely t...

Page 28: ...r does enter it is difficult for it to be drained Therefore if water should get into the connector the pins will be short cir cuited by the water so if any water gets in immediately dry the connector...

Page 29: ...ll with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip pul...

Page 30: ...s will cause short circuits a If there is any damage or break age replace the connector 2 Fix the connector securely Align the position of the connector correctly and then insert it securely For conne...

Page 31: ...1 Push in female connector 2 horizon tally until the lock clicks Arrow 1 2 Since locks a and b may not be set completely push in female connector 2 while moving it up and down until the locks are set...

Page 32: ...he air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector use a...

Page 33: ...nnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the powe...

Page 34: ...assembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the perfor mance should be checked with special test equipment 3 Sealing openings A...

Page 35: ...oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge and ol...

Page 36: ...140 engines Ambient pressure sensor PAMB 125 170 12V140 engines Disconnect connector 1 according to the fol lowing procedure 1 Slide lock L1 to the right 2 While pressing lock L2 pull out connec tor 1...

Page 37: ...he direction of the arrow q 114 engine q 107 engine a If the lock is on the underside use flat head screwdriver 1 since you cannot insert your fingers 2 While pressing up lock C of the connec tor with...

Page 38: ...p 4 Turn housing type Round green connector q 140 engine Example Intake air pressure sensor in intake mani fold CANNON 04 PIM etc 1 Disconnect connector 6 according to the following procedure 1 Turn h...

Page 39: ...cates color of wire by color code Color codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and material of...

Page 40: ...d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Num...

Page 41: ...White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red White G...

Page 42: ...use lifting equipment of ample strength q When using forcing screws to remove any components tighten the forcing screws uniformly in turn q Before removing any unit clean the surrounding area and fit...

Page 43: ...cylinder 100 mm from the end of its stroke 3 Next operate the hydraulic cylinder 3 4 times to the end of its stroke 4 After doing this run the engine at normal speed a When using the machine for the...

Page 44: ...any part is damaged replace it 2 Check the mounting bolts and nuts of the muffler exhaust pipe and their mounting parts for looseness If any bolt or nut is loosened retighten it 5 Checking muffler fu...

Page 45: ...3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks Fig 2...

Page 46: ...hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to disco...

Page 47: ...ig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 and 2...

Page 48: ...bolts shown in Fig B Values of tightening torques shown in the table for Fig A are applied Thread diameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34...

Page 49: ...dth across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0 10...

Page 50: ...eries to the torque below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diameter mm...

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