Related Manuals for Komatsu PC1250 -8
Summary of Contents for Komatsu PC1250 -8
- Page 1 SEN00889-19 HYDRAULIC PC1250 EXCAVATOR PC1250SP PC1250LC PC1250- 30001 PC1250SP- 30001 SERIAL NUMBERS and up PC1250LC- 30001...
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- Page 3 SEN00891-19 HYDRAULIC EXCAVATOR 1SHOP MANUAL 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 Index Composition of shop manual .......................... 2 Table of contents ............................. 4 PC1250-8 Find manuals at https://best-manuals.com...
- Page 4 SEN00891-19 00 Index and foreword Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
- Page 5 00 Index and foreword SEN00891-19 40 Troubleshooting ......................SEN00907-05 Failure code table and fuse locations ................SEN01638-02 q General information on troubleshooting................SEN01637-04 Troubleshooting by failure code (Display of code), Part 1 ..........SEN01639-01 Troubleshooting by failure code (Display of code), Part 2 ..........SEN01640-02 Troubleshooting by failure code (Display of code), Part 3 ..........
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Page 6: Table Of Contents
SEN00891-19 00 Index and foreword Table of contents 00 Index and foreword Index SEN00891-19 Composition of shop manual ....................Table of contents........................Foreword and general information SEN00892-04 Safety notice ..........................How to read the shop manual....................Explanation of terms for maintenance standard ..............Handling of electric equipment and hydraulic component ............ - Page 7 00 Index and foreword SEN00891-19 Hydraulic system, Part 1 SEN00900-01 Hydraulic piping drawing ......................Hydraulic tank.......................... Hydraulic pump........................Line oil filter ..........................48 Pilot oil filter ..........................49 Return oil filter ......................... 50 Drain oil filter..........................51 Cooling fan pump ........................52 Cooling fan motor ........................
- Page 8 SEN00891-19 00 Index and foreword Testing fuel system for leakage ....................31 Procedure for checking alternator and replacing belt .............. 32 Testing and adjusting, Part 2 SEN01633-02 Testing swing circle bearing clearance ..................Testing wear of sprocket ......................Testing and adjusting track shoe tension................. Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ....
- Page 9 00 Index and foreword SEN00891-19 Failure code [CA123] Chg Air Press Sensor Low Error............24 Failure code [CA131] Throttle Sensor High Error ..............25 Failure code [CA132] Throttle Sensor Low Error..............27 Failure code [CA135] Eng Oil Press Sensor High Error ............28 Failure code [CA141] Eng Oil Press Sensor Low Error............
- Page 10 SEN00891-19 00 Index and foreword Failure code [CA2271] EGR Valve Pos Sens High Error............38 Failure code [CA2272] EGR Valve Pos Sens Low Error ............40 Failure code [CA2351] EGR Valve Sol Current High Error ............42 Failure code [CA2352] EGR Valve Sol Current Low Error............44 Failure code [CA2555] Grid Htr Relay Volt Low Error..............
- Page 11 00 Index and foreword SEN00891-19 Failure code [DW45KB] Swing Brake Sol. S/C................ 58 Failure code [DW48KA] CO Cancel Sol. Disc................. 60 Failure code [DW48KB] CO Cancel Sol. S/C ................62 Troubleshooting by failure code (Display of code), Part 4 SEN01642-00 Failure code [DW7BKA] Fan Reverse Sol.
- Page 12 SEN00891-19 00 Index and foreword E-11 Fuel level monitor red lamp lights up while engine is running ......... 25 E-12 Hydraulic oil temperature gauge does not display correctly..........26 E-13 Fuel gauge does not display correctly................27 E-14 Swing lock monitor does not display correctly ..............28 E-15 When the monitor switch is operated, no display appears..........
- Page 13 00 Index and foreword SEN00891-19 S-5 Engine does not rotate smoothly ..................14 S-6 Engine lacks output (or lacks power) ................15 S-7 Exhaust smoke is black (incomplete combustion) ............16 S-8 Oil consumption is excessive (or exhaust smoke is blue)..........17 S-9 Oil becomes contaminated quickly ...................
- Page 14 SEN00891-19 00 Index and foreword Hydraulic system SEN01200-03 Removal and installation of hydraulic tank assembly .............. Removal and installation of hydraulic pump assembly ............Removal and installation of main pump input shaft oil seal ............. 10 Removal and installation of 5-spool control valve assembly (No. 1) ........11 Removal and installation of 4-spool control valve assembly (No.
- Page 15 00 Index and foreword SEN00891-19 PC1250-8...
- Page 16 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)
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Page 17: Table Of Contents
SEN00892-04 HYDRAULIC EXCAVATOR 1SHOP MANUAL 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 Foreword and general information Safety notice ..............................2 How to read the shop manual ......................... 7 Explanation of terms for maintenance standard ..................... -
Page 18: Safety Notice
Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. -
Page 19: Air Circuit Diagram
00 Index and foreword SEN00892-04 Preparations for work Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. -
Page 20: Table Of Contents
SEN00892-04 00 Index and foreword 12) When assembling or installing parts, Limit the hanging angle to 60°, as a rule. always tighten them to the specified Do not sling a heavy load with ropes form- torques. When installing protective parts ing a wide hanging angle from the hook. -
Page 21: Air Tank
00 Index and foreword SEN00892-04 Precautions for using overhead hoist crane When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disas- sembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over... -
Page 22: Specifications
SEN00892-04 00 Index and foreword Selecting wire ropes Connection Select adequate ropes depending on the When installing the air conditioner cir- weight of parts to be hoisted, referring to cuit hoses and tubes, take care that the table below. dirt, dust, water, etc. will not enter them. -
Page 23: How To Read The Shop Manual
Engine volume This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. PC1250-8... -
Page 24: Swing Circle
SEN00892-04 00 Index and foreword Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. -
Page 25: Explanation Of Terms For Maintenance Standard
00 Index and foreword SEN00892-04 Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another. - Page 26 SEN00892-04 00 Index and foreword Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
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Page 27: Handling Of Electric Equipment And Hydraulic Component
00 Index and foreword SEN00892-04 Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. -
Page 28: Sprocket
SEN00892-04 00 Index and foreword Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring may be broken. - Page 29 00 Index and foreword SEN00892-04 Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
- Page 30 SEN00892-04 00 Index and foreword Connecting connectors Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or dam- age to the connector pins. Check that there is no damage or breakage to the outside of the con- nector.
- Page 31 00 Index and foreword SEN00892-04 Heavy duty wire connector (DT 8-pole, 12- Disconnection Connection (Example of pole) incomplete setting of (a)) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) Push in female connector (2) horizon- tally until the lock clicks.
- Page 32 SEN00892-04 00 Index and foreword Drying wiring harness If there is any oil or dirt on the wiring har- ness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
- Page 33 00 Index and foreword SEN00892-04 Handling controller The controller contains a microcomputer and electronic control circuits. These con- trol all of the electronic circuits on the machine, so be extremely careful when handling the controller. Do not place objects on top of the control- ler.
- Page 34 SEN00892-04 00 Index and foreword Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
- Page 35 00 Index and foreword SEN00892-04 Change hydraulic oil when the temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm.
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Page 36: Handling Of Connectors Newly Used For Engines
SEN00892-04 00 Index and foreword Handling of connectors newly used for engines a Mainly, following engines are object for follow- Pull lock type (PACKARD-2) ing connectors. 95 – 170, 12V140 engines 95E-5 Various temperature sensors 107E-1 Example) 114E-3 Intake air temperature sensor in 125E-5 intake manifold: TIM 140E-5... - Page 37 00 Index and foreword SEN00892-04 Push lock type 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the fol- lowing procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. 114 engine 107, 114 engines Example)
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Page 38: Weight Table
SEN00892-04 00 Index and foreword 95, 125 – 170, 12V140 engines Turn-housing type (Round green connector) While pressing lock (E) of the connector, 140 engine pull out connector (5) in the direction of Example) the arrow. Intake air pressure sensor in intake mani- fold (CANNON-04): PIM etc. -
Page 39: How To Read Electric Wire Code
00 Index and foreword SEN00892-04 How to read electric wire code a The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting. In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym- bols. - Page 40 SEN00892-04 00 Index and foreword Dimensions (Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09...
- Page 41 00 Index and foreword SEN00892-04 Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Black Light green & White Brown Light green & Yellow Brown & Black Blue & Red Brown & Red Blue & White Brown &...
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Page 42: Precautions When Carrying Out Operation
SEN00892-04 00 Index and foreword Precautions when carrying out operation [When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. - Page 43 00 Index and foreword SEN00892-04 Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
- Page 44 SEN00892-04 00 Index and foreword Checking muffler and exhaust pipe for damage and looseness Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness.
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Page 45: Method Of Disassembling And Connecting Push-Pull Type Coupler
00 Index and foreword SEN00892-04 Method of disassembling and connecting push-pull type coupler Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. -
Page 46: Table Of Fuel, Coolant And Lubricants
SEN00892-04 00 Index and foreword Type 2 Disconnection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexag- onal portion at the male end. (Fig. 6) While holding the condition of Step 1), turn lever (8) to the right (clockwise). - Page 47 00 Index and foreword SEN00892-04 Type 3 Disconnection Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexag- onal portion at the male end. (Fig. 10) 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.
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Page 48: Standard Tightening Torque Table
SEN00892-04 00 Index and foreword Standard tightening torque table Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a The following table applies to the bolts in Fig. A. Thread diameter of bolt Width across flats Tightening torque... - Page 49 00 Index and foreword SEN00892-04 Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below. Thread diameter of bolt Width across flats Tightening torque 59 – 74 6.0 – 7.5 98 –...
- Page 50 SEN00892-04 00 Index and foreword Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil. Tightening torque Nm {kgm} Taper seal Face seal...
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