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00 Index and foreword

SEN00891-19

PC1250-8

S-5 Engine does not rotate smoothly ......................................................................................

S-6 Engine lacks output (or lacks power) ................................................................................

S-7 Exhaust smoke is black (incomplete combustion) ............................................................

S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................

S-9 Oil becomes contaminated quickly ...................................................................................

S-10 Fuel consumption is excessive .......................................................................................

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..............................

S-12 Oil pressure drops...........................................................................................................

S-13 Oil level rises (Entry of coolant or fuel) ...........................................................................

S-14 Coolant temperature becomes too high (overheating)....................................................

S-15 Abnormal noise is made .................................................................................................

S-16 Vibration is excessive .....................................................................................................

S-17 Air cannot be bled from fuel circuit..................................................................................

50 Disassembly and assembly

General information on disassembly and assembly

SEN01195-03

How to read this manual..........................................................................................................

Coating materials list ...............................................................................................................

Special tools list .......................................................................................................................

Sketches of special tools .........................................................................................................

Engine and cooling system, Part 1

SEN01197-03

Removal and installation of fuel supply pump assembly .........................................................

Removal and installation of cylinder head assembly ...............................................................

Removal and installation of fuel injector assembly ..................................................................

Removal and installation of engine front seal ..........................................................................

Removal and installation of engine rear seal...........................................................................

Engine and cooling system, Part 2

SEN01196-02

Removal and installation of engine, PTO and hydraulic pump assembly................................

Removal and installation of radiator and hydraulic oil cooler assembly ..................................

Removal of air aftercooler assembly .......................................................................................

Removal and installation of fuel cooler and air conditioner condenser assembly ...................

Removal and installation of fan motor assembly .....................................................................

Removal and installation of fuel tank assembly.......................................................................

Power train

SEN01198-03

Removal and installation of PTO assembly .............................................................................

Disassembly and assembly of PTO assembly.........................................................................

Removal and installation of swing machinery assembly .........................................................

Removal and installation of swing motor and swing machinery assembly ..............................

Disassembly and assembly of swing machinery assembly .....................................................

Disassembly and assembly of swing motor and swing machinery assembly..........................

Removal and installation of swing circle assembly..................................................................

Disassembly and assembly of final drive assembly ................................................................

Undercarriage and frame

SEN01199-04

Removal and installation of track shoe assembly....................................................................

Disassembly and assembly of one link in field ........................................................................

Removal and installation of idler assembly .............................................................................

Disassembly and assembly of idler assembly .........................................................................

Disassembly and assembly of idler adjustment cylinder assembly .........................................

Removal and installation of recoil spring assembly .................................................................

Disassembly and assembly of recoil spring assembly ............................................................

Removal and installation of track roller assembly ...................................................................

Disassembly and assembly of track roller assembly ...............................................................

Removal and installation of carrier roller assembly .................................................................

Disassembly and assembly of carrier roller assembly.............................................................

Removal and installation of revolving frame assembly............................................................

Removal and installation of counterweight assembly ..............................................................

Содержание PC1250 -8

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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