Komatsu PC1250 -8 Shop Manual Download Page 7

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00 Index and foreword

SEN00891-19

PC1250-8

Hydraulic system, Part 1

SEN00900-01

Hydraulic piping drawing .........................................................................................................

Hydraulic tank..........................................................................................................................

Hydraulic pump........................................................................................................................

Line oil filter .............................................................................................................................

Pilot oil filter .............................................................................................................................

Return oil filter .........................................................................................................................

Drain oil filter............................................................................................................................

Cooling fan pump ....................................................................................................................

Cooling fan motor ....................................................................................................................

Aftercooler fan motor ...............................................................................................................

Hydraulic system, Part 2

SEN00901-02

Control valve............................................................................................................................

Swing motor.............................................................................................................................

Center swivel joint ...................................................................................................................

Travel motor.............................................................................................................................

PPC control relief valve ...........................................................................................................

Accumulator.............................................................................................................................

Valve control ............................................................................................................................

PPC valve................................................................................................................................

Solenoid valve .........................................................................................................................

Hydraulic cylinder ....................................................................................................................

Work equipment

SEN00902-00

Work equipment ......................................................................................................................

Dimensions of work equipment ...............................................................................................

Cab and its attachments

SEN00903-00

Air conditioner..........................................................................................................................

Electrical system

SEN00904-05

Engine control..........................................................................................................................

Electric control system.............................................................................................................

Monitor system ........................................................................................................................

Sensor .....................................................................................................................................

20 Standard value table

Standard service value table

SEN01631-04

Standard value table for engine related parts ..........................................................................

Standard value table for chassis related parts.........................................................................

30 Testing and adjusting

Testing and adjusting, Part 1

SEN01632-04

Tools for testing, adjusting, and troubleshooting .....................................................................

Sketch of special tool...............................................................................................................

Testing engine speed...............................................................................................................

Testing air supply pressure (Boost pressure) ..........................................................................

Testing exhaust temperature ...................................................................................................

Testing exhaust color...............................................................................................................

Testing and adjusting valve clearance.....................................................................................

Testing compression pressure.................................................................................................

Testing blow-by pressure .........................................................................................................

Testing engine oil pressure......................................................................................................

Testing EGR valve and bypass valve drive oil pressure ..........................................................

Adjusting engine speed sensor ...............................................................................................

Handling fuel system parts ......................................................................................................

Releasing residual pressure in fuel system .............................................................................

Testing fuel pressure ...............................................................................................................

Testing fuel return rate and fuel leakage .................................................................................

Bleeding air from fuel circuit ....................................................................................................

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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 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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