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PC1250SP-8 Sen00889-02d PDF
PC1250SP-8 Sen00889-02d PDF
Shop
Manual
PC1250-8
PC1250SP-8
PC1250LC-8
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC1250-8 30001 and up
PC1250SP-8 30001 and up
PC1250LC-8 30001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00891-02 00 Index and foreword
01 Specification SEN00893-00
Specification and technical data SEN00894-00
2 PC1250-8
00 Index and foreword SEN00891-02
40 Troubleshooting SEN00907-00
General information on troubleshooting SEN01637-00 Q
Failure code table and fuse locations SEN01638-00 Q
Troubleshooting by failure code (Display of code), Part 1 SEN01639-00 Q
Troubleshooting by failure code (Display of code), Part 2 SEN01640-00 Q
Troubleshooting by failure code (Display of code), Part 3 SEN01641-00 Q
Troubleshooting by failure code (Display of code), Part 4 SEN01642-00 Q
Troubleshooting of electrical system (E-mode) SEN01643-00 Q
Troubleshooting of hydraulic and mechanical system (H-mode) SEN01644-00 Q
Troubleshooting of engine (S-mode) SEN01645-00 Q
PC1250-8 3
SEN00891-02 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN00891-02
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
01 Specification
Specification and technical data SEN00894-00
Specification and technical data .................................................................................................. 2
Specification drawings ............................................................................................................. 2
Working range drawing............................................................................................................ 4
Specifications........................................................................................................................... 6
Weight table ............................................................................................................................. 14
Table of fuel, coolant and lubricants ........................................................................................ 20
4 PC1250-8
00 Index and foreword SEN00891-02
PC1250-8 5
SEN00891-02 00 Index and foreword
6 PC1250-8
00 Index and foreword SEN00891-02
40 Troubleshooting
General information on troubleshooting SEN01637-00
General information on troubleshooting ...................................................................................... 2
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Checks before troubleshooting................................................................................................ 4
Classification and troubleshooting steps ................................................................................. 5
Information in troubleshooting table ........................................................................................ 9
Wiring table for connector pin numbers ................................................................................... 11
T-adapter box and T-adapter table .......................................................................................... 35
Failure code table and fuse locations SEN01638-00
Failure code table and fuse locations.......................................................................................... 2
Failure code table .................................................................................................................... 2
Fuse locations ......................................................................................................................... 7
Troubleshooting by failure code (Display of code), Part 1 SEN01639-00
Troubleshooting by failure code (Display of code), Part 1........................................................... 3
Failure code [A000N1] Eng. Hi Out of Std ............................................................................... 3
Failure code [AA10NX] Aircleaner Clogging............................................................................ 4
Failure code [AB00KE] Charge Voltage Low ........................................................................... 6
Failure code [B@BAZG] Eng. Oil Press. Low ......................................................................... 8
Failure code [B@BAZK] Eng. Oil Level Low ........................................................................... 10
Failure code [B@BCNS] Eng. Water Overheat ....................................................................... 12
Failure code [B@BCZK] Eng. Water Lvl Low .......................................................................... 14
Failure code [B@CBNS] High PTO temperature..................................................................... 16
Failure code [B@HANS] Hydr. Oil Overheat ........................................................................... 18
Failure code [CA111] ECM Critical Internal Failure ................................................................. 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................... 21
Failure code [CA122] Chg Air Press Sensor High Error.......................................................... 22
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........................................................... 30
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 31
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 33
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 34
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 36
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 36
Failure code [CA221] Ambient Press Sens High Error............................................................ 37
Failure code [CA222] Ambient Press Sens Low Error............................................................. 39
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 40
Failure code [CA234] Eng Overspeed..................................................................................... 42
Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 44
Failure code [CA263] Fuel Temp Sensor High Error ............................................................... 46
Failure code [CA265] Fuel Temp Sensor Low Error ................................................................ 48
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 49
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 50
Failure code [CA273] PCV2 Short Error .................................................................................. 52
Failure code [CA274] PCV2 Open Error.................................................................................. 53
Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 54
Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................... 56
Failure code [CA324] Inj #3 (L#3) Open/Short Error ............................................................... 58
Failure code [CA325] Inj #6 (L#6) Open/Short Error ............................................................... 60
Failure code [CA331] Inj #2 (L#2) Open/Short Error ............................................................... 62
Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................... 64
Failure code [CA342] Calibration Code Incompatibility ........................................................... 66
Failure code [CA351] Injectors Drive Circuit Error................................................................... 68
PC1250-8 7
SEN00891-02 00 Index and foreword
8 PC1250-8
00 Index and foreword SEN00891-02
PC1250-8 9
SEN00891-02 00 Index and foreword
10 PC1250-8
00 Index and foreword SEN00891-02
PC1250-8 11
SEN00891-02 00 Index and foreword
Removal and installation of fuel cooler and air conditioner condenser assembly ................... 17
Removal and installation of fan motor assembly ..................................................................... 19
Removal and installation of fuel tank assembly ....................................................................... 24
Engine and cooling system, Part 2 SEN01197-00
Engine and cooling system, Part 2.............................................................................................. 2
Removal and installation of fuel supply pump assembly ......................................................... 2
Removal and installation of cylinder head assembly ............................................................... 7
Removal and installation of fuel injector assembly .................................................................. 24
Removal and installation of engine front seal .......................................................................... 29
Removal and installation of engine rear seal........................................................................... 31
Power train SEN01198-00
Power train .................................................................................................................................. 2
Removal and installation of PTO assembly ............................................................................. 2
Disassembly and assembly of PTO assembly......................................................................... 4
Removal and installation of swing machinery assembly.......................................................... 8
Disassembly and assembly of swing machinery assembly ..................................................... 10
Removal and installation of swing circle assembly .................................................................. 17
Disassembly and assembly of final drive assembly................................................................. 18
Undercarriage and frame SEN01199-00
Undercarriage and frame ............................................................................................................ 2
Removal and installation of track shoe assembly.................................................................... 2
Removal and installation of idler assembly.............................................................................. 4
Disassembly and assembly of idler assembly ......................................................................... 5
Disassembly and assembly of idler adjustment cylinder assembly ......................................... 8
Removal and installation of recoil spring assembly ................................................................. 9
Disassembly and assembly of recoil spring assembly............................................................. 11
Removal and installation of track roller assembly.................................................................... 13
Disassembly and assembly of track roller assembly ............................................................... 14
Removal and installation of carrier roller assembly ................................................................. 17
Disassembly and assembly of carrier roller assembly............................................................. 18
Removal and installation of revolving frame assembly ............................................................ 20
Removal and installation of counterweight assembly .............................................................. 21
Hydraulic system SEN01200-00
Hydraulic system ......................................................................................................................... 3
Removal and installation of hydraulic tank assembly .............................................................. 3
Removal and installation of hydraulic pump assembly ............................................................ 5
Removal and installation of main pump input shaft oil seal ..................................................... 11
Removal and installation of 5-spool control valve assembly (No. 1) ....................................... 12
Removal and installation of 4-spool control valve assembly (No. 2) ....................................... 14
Removal and installation of 4-spool control valve assembly (No. 3) ....................................... 16
Disassembly and assembly of control valve assembly (No. 1)................................................ 18
Disassembly and assembly of control valve assembly (No. 2)................................................ 21
Disassembly and assembly of control valve assembly (No. 3)................................................ 25
Removal and installation of swing motor assembly ................................................................. 29
Removal and installation of center swivel joint assembly ........................................................ 31
Disassembly and assembly of center swivel joint assembly.................................................... 32
Removal and installation of travel motor assembly ................................................................. 33
Disassembly and assembly of work equipment PPC valve assembly..................................... 34
Disassembly and assembly of travel PPC valve assembly ..................................................... 36
Disassembly and assembly of hydraulic cylinder assembly .................................................... 38
Work equipment SEN01201-00
Work equipment .......................................................................................................................... 2
Removal and installation of bucket cylinder assembly ............................................................ 2
Removal and installation of bottom dump cylinder assembly .................................................. 6
Removal and installation of arm cylinder assembly ................................................................. 8
Removal and installation of boom cylinder assembly .............................................................. 12
12 PC1250-8
00 Index and foreword SEN00891-02
PC1250-8 13
SEN00892-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00892-00 00 Index and foreword
Safety notice 1
Important 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.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 PC1250LC-8
00 Index and foreword SEN00892-00
3) When disassembling or assembling, sup- 8) When removing piping, stop the fuel or oil
port the machine with blocks, jacks, or from spilling out. If any fuel or oil drips
stands before starting work. onto the floor, wipe it up immediately. Fuel
4) Remove all mud and oil from the steps or or oil on the floor can cause you to slip
other places used to get on and off the and can even start fires.
machine. Always use the handrails, lad- 9) As a general rule, do not use gasoline to
ders or steps when getting on or off the wash parts. Do not use it to clean electri-
m a c h i n e . N e v e r j u m p o n o r o ff t h e cal parts, in particular.
machine. If it is impossible to use the 10) Be sure to assemble all parts again in their
handrails, ladders or steps, use a stand to original places. Replace any damaged
provide safe footing. parts and parts which must not be reused
with new parts. When installing hoses and
3. Precautions during work wires, be sure that they will not be dam-
1) Before disconnecting or removing compo- aged by contact with other parts when the
nents of the oil, water, or air circuits, first machine is operated.
release the pressure completely from the 11) When installing high pressure hoses,
circuit. When removing the oil filler cap, a make sure that they are not twisted. Dam-
drain plug, or an oil pressure pickup plug, aged tubes are dangerous, so be
loosen it slowly to prevent the oil from extremely careful when installing tubes for
spurting out. high pressure circuits. In addition, check
2) The coolant and oil in the circuits are hot t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
when the engine is stopped, so be careful installed.
not to get scalded. Wait for the oil and 12) When assembling or installing parts,
coolant to cool before carrying out any always tighten them to the specified
work on the oil or water circuits. torques. When installing protective parts
3) Before starting work, stop the engine. such as guards, or parts which vibrate vio-
When working on or around a rotating lently or rotate at high speed, be particu-
part, in particular, stop the engine. When larly careful to check that they are
checking the machine without stopping installed correctly.
the engine (measuring oil pressure, 13) When aligning 2 holes, never insert your
revolving speed, temperature, etc.), take fingers or hand. Be careful not to get your
extreme care not to get rolled or caught in fingers caught in a hole.
rotating parts or moving parts. 14) When measuring hydraulic pressure,
4) Before starting work, remove the leads check that the measuring tools are cor-
from the battery. Always remove the lead rectly assembled.
from the negative (–) terminal first. 15) Take care when removing or installing the
5) When raising a heavy component (heavier tracks of track-type machines. When
than 25 kg), use a hoist or crane. Before removing the track, the track separates
starting work, check that the slings (wire suddenly, so never let anyone stand at
ropes, chains, and hooks) are free from either end of the track.
damage. Always use slings which have 16) If the engine is operated for a long time in
ample capacity and install them to proper a place which is not ventilated well, you
places. Operate the hoist or crane slowly may suffer from gas poisoning. Accord-
to prevent the component from hitting any ingly, open the windows and doors to ven-
other part. Do not work with any part still tilate well.
raised by the hoist or crane.
6) When removing a cover which is under
internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
7) When removing components, be careful
not to break or damage the electrical wir-
ing. Damaged wiring may cause electrical
fires.
PC1250-8 3
SEN00892-00 00 Index and foreword
4 PC1250-8
00 Index and foreword SEN00892-00
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven-
18 28.6 2.9
tion earth leakage breaker, crane collision
20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
2) Observe the signs for sling work. 30 79.6 8.1
3) Operate the hoist at a safe place. 40 141.6 14.4
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
PC1250-8 5
SEN00892-00 00 Index and foreword
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
6 PC1250-8
00 Index and foreword SEN00892-00
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
PC1250-8 7
SEN00892-00 00 Index and foreword
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
8 PC1250-8
00 Index and foreword SEN00892-00
PC1250-8 9
SEN00892-00 00 Index and foreword
10 PC1250-8
00 Index and foreword SEN00892-00
3) 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.
PC1250-8 11
SEN00892-00 00 Index and foreword
12 PC1250-8
00 Index and foreword SEN00892-00
2) Connecting connectors
1] 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.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this 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 connectors with lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
3) Connecting DT connectors
Since the DT 8-pin and 12-pin heavy duty
wire connectors have 2 latches respec-
tively, push them in until they click 2 times.
1. Male connector
2. Female connector
q Normal locking state (Horizontal): a,
b, d
q Incomplete locking state (Diagonal): c
PC1250-8 13
SEN00892-00 00 Index and foreword
14 PC1250-8
00 Index and foreword SEN00892-00
4. Handling controller
1) 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.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
PC1250-8 15
SEN00892-00 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
16 PC1250-8
00 Index and foreword SEN00892-00
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
PC1250-8 17
SEN00892-00 00 Index and foreword
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
18 PC1250-8
00 Index and foreword SEN00892-00
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
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 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
PC1250-8 19
SEN00892-00 00 Index and foreword
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & 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
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
20 PC1250-8
00 Index and foreword SEN00892-00
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (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)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
PC1250-8 21
SEN00892-00 00 Index and foreword
Type 2
1. Disconnection
1) 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)
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 discon-
nect it. (Fig. 8)
2. Connection
q 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. 9)
22 PC1250-8
00 Index and foreword SEN00892-00
Type 3
1. Disconnection
1) 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)
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), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
PC1250-8 23
SEN00892-00 00 Index and foreword
a Fig. A a Fig. B
24 PC1250-8
00 Index and foreword SEN00892-00
PC1250-8 25
SEN00892-00 00 Index and foreword
5. 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.
6. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolt BANJO bolt
mm Nm kgm Nm kgm
6 10 ± 2 1.02 ± 0.20 8± 2 0.81 ± 0.20
8 24 ± 4 2.45 ± 0.41 10 ± 2 1.02 ± 0.20
10 43 ± 6 4.38 ± 0.61 12 ± 2 1.22 ± 0.20
12 77 ± 12 7.85 ± 1.22 24 ± 4 2.45 ± 0.41
14 – – 36 ± 5 3.67 ± 0.51
7. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
26 PC1250-8
00 Index and foreword SEN00892-00
8. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
PC1250-8 27
SEN00892-00 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
28 PC1250-8
00 Index and foreword SEN00892-00
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
PC1250-8 29
SEN00892-00 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
30 PC1250-8
00 Index and foreword SEN00892-00
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
PC1250-8 31
SEN00892-00 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
32 PC1250-8
00 Index and foreword SEN00892-00
PC1250-8 33
SEN00894-00
PC1250-8
PC1250SP-8
PC1250LC-8
01 Specification 1
Specification and technical data
Specification and technical data
Specification drawings.......................................................................................................................... 2
Working range drawing ........................................................................................................................ 4
Specifications ....................................................................................................................................... 6
Weight table ....................................................................................................................................... 14
Table of fuel, coolant and lubricants ................................................................................................... 20
PC1250-8 1
SEN00894-00 01 Specification
PC1250LC-8
Item Unit PC1250-8 PC1250SP-8
(Only North America)
A Overall length mm 16,020 14,790 16,020
B Overall height mm 16,040 16,265 16,040
C Overall width mm 15,600 15,600 15,750
D Track shoe width mm 14,700 14,700 11,000
E Height of cab mm 14,120 14,120 14,120
F Tail swing radius mm 14,870 14,870 14,870
G Track overall length mm 16,425 16,425 17,400
H Length of track on ground mm 14,995 14,995 15,970
I Min. ground clearance mm 14,990 14,990 14,990
2 PC1250-8
01 Specification SEN00894-00
PC1250-8 3
SEN00894-00 01 Specification
PC1250LC-8
Item Unit PC1250-8 PC1250SP-8
(Only North America)
A Max. digging reach mm 15,350 14,070 15,350
B Max. digging depth mm 19,350 17,900 19,350
C Max. digging height mm 13,400 13,000 13,400
D Max. vertical wall depth mm 17,610 15,025 17,610
E Max. dumping height mm 18,680 18,450 18,680
F Max. reach at ground level mm 15,000 13,670 15,000
4 PC1250-8
01 Specification SEN00894-00
PC1250-8 5
SEN00894-00 01 Specification
Specifications 1
Backhoe specification
PC1250-8
Machine model PC1250-8
Serial number 30001 and up
Bucket capacity m 3
5.0
Weight of machine kg 105,600
Max. digging depth mm 9,350
Working range
6 PC1250-8
01 Specification SEN00894-00
*1: Head side with cushion *2: Bottom side with cushion
PC1250-8 7
SEN00894-00 01 Specification
PC1250SP-8
Machine model PC1250SP-8
Serial number 30001 and up
Bucket capacity m3 6.7
Weight of machine kg 110,700
Max. digging depth mm 7,900
Working range
8 PC1250-8
01 Specification SEN00894-00
*1: Head side with cushion *2: Bottom side with cushion
PC1250-8 9
SEN00894-00 01 Specification
PC1250LC-8
Machine model PC1250LC-8
Serial number 30001 and up
Bucket capacity m3 5.0
Weight of machine kg 112,600
Max. digging depth mm 9,350
Working range
10 PC1250-8
01 Specification SEN00894-00
*1: Head side with cushion *2: Bottom side with cushion
PC1250-8 11
SEN00894-00 01 Specification
PC1250-8
Machine model PC1250-8 (Loading shovel specification)
Serial number 30001 and up
Bucket capacity m 3
6.5
Weight of machine kg 110,000
Max. digging depth mm 3,650
Working range
12 PC1250-8
01 Specification SEN00894-00
*1: Head side with cushion *2: Bottom side with cushion
PC1250-8 13
SEN00894-00 01 Specification
Weight table 1
k This weight table is a guide for use when transporting or handling components.
Backhoe specification
PC1250, 1250SP-8
Unit: kg
Machine model PC1250-8 PC1250SP-8
Serial number 30001 and up 30001 and up
Engine assembly 4,229 4,229
q Engine 3,140 3,140
q PTO (incl. lubricating piping) 505 505
q No. 1 pump 157 157
q No. 2 pump 148 148
q No. 3 pump 191 191
q Control pump (for control and fan drive) 88 88
Radiator assembly 283 283
Oil cooler assembly 251.5 251.5
Hydraulic tank (excl. hydraulic oil) 776 776
Revolving frame (incl. left and right decks) 10,700 10,700
Operator’s cab 323 323
Swing machinery 488 × 2 488 × 2
Swing motor assembly 126 × 2 126 × 2
Travel motor assembly 130 × 2 130 × 2
L.H. 5-spool control valve 260 260
R.H. 4-spool control valve 253 253
Swing 4-spool control valve 240 240
Center swivel joint 69 69
Counterweight 18,000 18,000
Track frame assembly 28,374 28,374
q Center frame 7,400 7,400
q Track frame 4,390 × 2 4,390 × 2
q Carrier roller 80 × 6 80 × 6
q Track roller 190 × 16 190 × 16
q Idler cushion assembly 1,000 × 2 1,000 × 2
q Idler 788 × 2 788 × 2
q Final drive assembly 1,869 × 2 1,869 × 2
q Swing circle assembly 2,165 2,165
Track shoe assembly
q Standard shoe (700 mm) 10,630 10,630
q Wide shoe (1,000 mm) 12,940 12,940
q Wide shoe (1,200 mm) — —
Boom assembly (excl. piping) 10,380 10,275
Arm assembly (excl. piping) 3,520 3,915
Bucket assembly (excl. piping) 4,579 6,191
Boom cylinder assembly 1,174 × 2 1,174 × 2
Arm cylinder assembly 1,538 1,538
Bucket cylinder assembly 436 × 2 454 × 2
Boom foot pin 72 × 2 72 × 2
Boom cylinder foot pin 43.8 × 2 43.8 × 2
14 PC1250-8
01 Specification SEN00894-00
Unit: kg
Machine model PC1250-8 PC1250SP-8
Serial number 30001 and up 30001 and up
Boom cylinder top pin 43.2 × 2 43.2 × 2
Boom-arm connecting pin 168.6 168.6
Arm cylinder foot pin 92.9 101.3
Arm cylinder top pin 97.9 97.9
Link-arm connecting pin 103 103
Link-bucket connecting pin 110.4 110.4
Bucket cylinder top pin 37.9 37.9
Bucket cylinder foot pin 37.9 37.9
Arm-bucket connecting pin 120.4 120.4
Link assembly 817 878
Link connecting pin 103 103
PC1250-8 15
SEN00894-00 01 Specification
PC1250LC-8
Unit: kg
Machine model PC1250LC-8
Serial number 30001 and up
Engine assembly 4,229
q Engine 3,140
q PTO (incl. lubricating piping) 505
q No. 1 pump 157
q No. 2 pump 148
q No. 3 pump 191
q Control pump (for control and fan drive) 88
Radiator assembly 283
Oil cooler assembly 251.5
Hydraulic tank (excl. hydraulic oil) 776
Revolving frame (incl. left and right decks) 10,700
Operator’s cab 323
Swing machinery 488 × 2
Swing motor assembly 126 × 2
Travel motor assembly 130 × 2
L.H. 5-spool control valve 260
R.H. 4-spool control valve 253
Swing 4-spool control valve 240
Center swivel joint 69
Counterweight 18,000
Track frame assembly 30,814
q Center frame 7,400
q Track frame 5,230 × 2
q Carrier roller 80 × 6
q Track roller 190 × 16
q Idler cushion assembly 1,000 × 2
q Idler 788 × 2
q Final drive assembly 1,869 × 2
q Swing circle assembly 2,165
Track shoe assembly
q Standard shoe (700 mm) —
q Wide shoe (1,000 mm) 14,820
q Wide shoe (1,200 mm) 16,350
Boom assembly (excl. piping) 10,380
Arm assembly (excl. piping) 3,520
Bucket assembly (excl. piping) 4,579
Boom cylinder assembly 1,174 × 2
Arm cylinder assembly 1,538
Bucket cylinder assembly 436 × 2
Boom foot pin 72 × 2
Boom cylinder foot pin 43.8 × 2
Boom cylinder top pin 43.2 × 2
Boom-arm connecting pin 168.6
Arm cylinder foot pin 92.9
Arm cylinder top pin 97.9
Link-arm connecting pin 103
Link-bucket connecting pin 110.4
16 PC1250-8
01 Specification SEN00894-00
Unit: kg
Machine model PC1250LC-8
Serial number 30001 and up
Bucket cylinder top pin 37.9
Bucket cylinder foot pin 37.9
Arm-bucket connecting pin 120.4
Link assembly 817
Link connecting pin 103
PC1250-8 17
SEN00894-00 01 Specification
PC1250-8
Unit: kg
Machine model PC1250-8 (Loading shovel specification)
Serial number 30001 and up
Engine assembly 4,229
q Engine 3,140
q PTO (incl. lubricating piping) 505
q No. 1 pump 157
q No. 2 pump 148
q No. 3 pump 191
q Control pump (for control and fan drive) 88
Radiator assembly 283
Oil cooler assembly 251.5
Hydraulic tank (excl. hydraulic oil) 776
Revolving frame (incl. left and right decks) 10,700
Operator’s cab 323
Swing machinery 488 × 2
Swing motor assembly 126 × 2
Travel motor assembly 130 × 2
L.H. 5-spool control valve 260
R.H. 4-spool control valve 253
Swing 4-spool control valve 240
Center swivel joint 69
Counterweight 18,000
Track frame assembly 28,374 (29,724)
q Center frame 7,400
q Track frame 4,390 × 2
q Carrier roller 80 × 6
q Track roller 190 × 16
q Idler cushion assembly 1,000 × 2
q Idler 788 × 2
q Final drive assembly 1,869 × 2
q Swing circle assembly 2,165
Track shoe assembly
q Standard shoe (700 mm) 10,630
q Wide shoe (1,000 mm) 12,940
q Wide shoe (1,200 mm) —
Boom assembly (excl. piping) 6,190
Arm assembly (excl. piping) 4,970
Bucket assembly (excl. piping) 9,730
Boom cylinder assembly 1,073 × 2
Arm cylinder assembly 602 × 2
Bottom dump cylinder assembly 194 × 2
Bucket cylinder assembly 845 × 2
Boom foot pin 72 × 2
Boom cylinder foot pin 43.8 × 2
Boom cylinder top pin 43.8 × 2
Boom-arm connecting pin 80.6 × 2
Arm cylinder foot pin 24.2 × 2
18 PC1250-8
01 Specification SEN00894-00
Unit: kg
Machine model PC1250-8 (Loading shovel specification)
Serial number 30001 and up
Arm cylinder top pin 24.2 × 2
Bottom dump cylinder top pin 15.2 × 2
Bottom dump cylinder foot pin 23.1 × 2
Bucket cylinder top pin 50 × 2
Bucket cylinder foot pin 42.9 × 2
Arm-bucket connecting pin 67.9 × 2
Bucket connecting pin 33.1 × 2
PC1250-8 19
SEN00894-00 01 Specification
20 PC1250-8
01 Specification SEN00894-00
Unit: l
PC1250-8, PC1250SP-8, PC1250LC-8
Reservoir
Specified capacity Refill capacity
Engine oil pan 97 86
PTO case 13.5 13.5
Swing machinery case (each) 24.3 24.3
Final drive case (each) 22 21
Hydraulic system 1,180 670
Fuel tank 1,360 —
Cooling system 142 —
PC1250-8 21
SEN00896-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00896-00 10 Structure, function and maintenance standard
2 PC1250-8
10 Structure, function and maintenance standard SEN00896-00
Unit: mm
No. Check Item Criteria Remedy
Backlash between drive gear Standard clearance Clearance limit Replace
9 and driven shaft
(for HPV160+160) 0.07 – 0.18 —
Backlash between drive gear
10 and driven gear 0.273 – 0.374 —
(for HPV95+SAR100)
Adjust
Backlash between drive gear
11 0.2 – 0.74 —
and driven gear
Backlash between drive gear
12 and driven shaft 0.07 – 0.18 —
(for HPV95+95)
Specifications
Lubricating oil : 13.5 l
Reduction ratio : HPV95+SAR100 = 1
PC1250-8 3
SEN00896-00 10 Structure, function and maintenance standard
4 PC1250-8
10 Structure, function and maintenance standard SEN00896-00
1. PTO case
2. Divider block
3. Lubricating pipe
4. PTO lubricating pump (SAL008)
5. PTO lubricating strainer
6. PTO cooler
Outline
The lubricating oil inside PTO case (1) from PTO
lubricating pump (4) passes through PTO lubricat-
ing strainer (5) and PTO cooler (6), is sent to top
divider block (2), and is then divided to various
parts of the PTO to lubricate and cool the gears.
PC1250-8 5
SEN00896-00 10 Structure, function and maintenance standard
6 PC1250-8
10 Structure, function and maintenance standard SEN00896-00
1. Aftercooler Specifications
2. Reservoir tank 1. Fan
3. Aftercooler fan Outside diameter:1,450 mm
4. Fan guard No. of vanes: 6
5. Radiator inlet tube Rotating speed: Standard 975 rpm
6. Fan (At rated engine speed of
7. Radiator upper tank 1,800 rpm)
8. Oil cooler 2. Radiator
9. Radiator outlet tube Core type: ALW-4
10. Fuel cooler Fin pitch: 4.5 mm
11. Radiator cap Cracking pressure for pressure valve:
70 ± 15 kPa
{0.7 ± 0.15 kg/cm2}
Cracking pressure for vacuum valve:
0 – 5 kPa
{0 – 0.05 kg/cm2}
3. Oil cooler
Core type: J5
Fin pitch: 3 mm
4. Aftercooler fan
Outside diameter:850 mm
No. of vanes: 6
Rotating speed: Standard 1,060 rpm
(At rated engine speed of
1,800 rpm)
5. Fuel cooler
Core type: XXXXXXXXX
Fin pitch: 4.0 mm
PC1250-8 7
SEN00897-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00897-00 10 Structure, function and maintenance standard
Power train 1
Power train 1
2 PC1250-8
10 Structure, function and maintenance standard SEN00897-00
PC1250-8 3
SEN00897-00 10 Structure, function and maintenance standard
Swing machinery 1
4 PC1250-8
10 Structure, function and maintenance standard SEN00897-00
Specification
Reduction ratio: (20 + 97)/20 × (19 + 97)/19 = 35.716
Unit: mm
No. Check Item Criteria Remedy
Backlash between swing motor Standard clearance Clearance limit
16
shaft and No. 1 sun gear 0.19 – 0.29 —
Backlash between No. 1 sun
17 0.19 – 0.51 0.90
gear and No. 1 planetary gear
Backlash between No. 1
18 0.24 – 0.70 0.90
planetary gear and ring gear
Backlash between No. 2
19 0.06 – 0.24 —
planetary carrier and coupling
Backlash between No. 1 plane- Replace
20 0.38 – 0.78 1.10
tary gear and No. 2 sun gear
Backlash between No. 2 sun
21 0.17 – 0.52 1.00
gear and No. 2 planetary gear
Backlash between No. 2
22 0.21 – 0.64 1.10
planetary gear and ring gear
Backlash between coupling and
23 0.08 – 0.25 —
swing pinion
Backlash between swing pinion
24 0 – 1.13 2.00
and swing circle
Clearance between plate and
25 0.06 – 0.86 —
coupling Repair hard
Standard size Repair limit chrome plating
Wear of swing pinion oil seal or replace
26
contact surface –0
150 –0.100 —
PC1250-8 5
SEN00897-00 10 Structure, function and maintenance standard
Swing circle 1
1. Swing circle inner race (No. of teeth: 132) a. Inner race soft zone “S” position
2. Ball b. Outer race soft zone “plug” position
3. Swing circle outer race
Unit: mm
No. Check Item Criteria Remedy
Clearance of bearing in axial Standard clearance Clearance limit
4 direction (when mounted on Replace
0.5 – 2 4
machine)
Specifications
Reduction ratio: 132/13 = 10.154
Amount of grease: 65 l (G2-LI)
6 PC1250-8
10 Structure, function and maintenance standard SEN00897-00
Specifications
Reduction ratio: –(13 + 68)/13 × (19 + 69)/19 × 63/
13 = –139.852
PC1250-8 7
SEN00897-00 10 Structure, function and maintenance standard
8 PC1250-8
10 Structure, function and maintenance standard SEN00897-00
Unit: mm
No. Check Item Criteria Remedy
Backlash between No. 3 plane- Standard clearance Clearance limit
21
tary carrier and case 0.08 – 0.27 —
Backlash between No. 2 sun
22 0.47 – 0.97 —
gear and No. 2 planetary gear
Backlash between No. 3 sun
23 0.47 – 0.97 —
gear and No. 2 planetary carrier
Backlash between No. 3 sun
24 0.25 – 0.82 —
gear and No. 3 planetary gear
Backlash between No. 3 plane-
25 0.29 – 0.82 —
tary gear and No. 3 ring gear
Backlash between No. 1 plane-
26 0.38 – 0.72 —
tary carrier and No. 2 sun gear Replace
Backlash between No. 1 ring
27 0.08 – 0.26 —
gear and case
Backlash between No. 1 sun
28 0.07 – 0.85 —
gear and travel motor coupling
Backlash between No. 1 sun
29 0.15 – 0.53 —
gear and No. 1 planetary gear
Backlash between No.1 ring
30 0.19 – 0.62 —
gear and No. 1 planetary gear
Backlash between No.2 ring
31 0.19 – 0.62 —
gear and No. 2 planetary gear
32 Wear of sprocket tooth shape Repair limit: 6
Standard size Repair limit Rebuild or
33 Sprocket tooth width
114 108 replace
PC1250-8 9
SEN00897-00 10 Structure, function and maintenance standard
Sprocket 1
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1 Wear of tooth tip
430 418 Build-up
2 Thickness of tooth root 30.8 24.8 welding or
3 Width of tooth 114 108 replace
4 Wear of tooth shape Repair limit: 6 (measure with sprocket tooth shape)
10 PC1250-8
10 Structure, function and maintenance standard SEN00897-00
a The above drawing is reduced to 46%. Enlarge it to 217% to return it to the full scale and make a copy
on an OHP sheet.
PC1250-8 11
SEN00898-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00898-00 10 Structure, function and maintenance standard
2 PC1250-8
10 Structure, function and maintenance standard SEN00898-00
Track shoe
Standard shoe
Models
PC1250-8 PC1250SP-8 PC1250LC-8
Item
Shoe width (double shoe) 700 mm 700 mm 1,000 mm
Link pitch 280 mm 280 mm 280 mm
No. of shoes (each side) 48 48 55
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length Installed Installed Installed
Free length
9 Recoil spring × OD length load load Replace
578.2 kN 460.9 kN
1,508 × 351 1,280 —
{58,957 kg} {47,000 kg}
Standard size Tolerance Repair limit
Top-to-bottom width of idler
10 Track frame 200 200 ± 2 205
guide
Idler support 195 195 ± 1.2 185 Rebuild or
Track frame 395 395 ± 2 405 replace
11 Left-to-right width of idler guide 391
Idler support 391 383
(+1.4/–0.8)
PC1250-8 3
SEN00898-00 10 Structure, function and maintenance standard
Idler 1
4 PC1250-8
10 Structure, function and maintenance standard SEN00898-00
Unit: mm
No. Check item Criteria Remedy
Outside diameter of Standard size Repair limit
1
protruding part 962 —
Outside diameter of tread
2 920 908
surface Rebuild or
3 Depth of tread 21 27 replace
4 Thickness of tread 46.5 40.5
5 Width of tread 77 —
6 Overall width 290 —
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
7
bushing –0.080 +0.313 0.353 –
125 1.5
–0.120 +0.273 0.433
Standard Tolerance Standard Interference Replace bushing
Interference between idler and size Shaft Hole interference limit
8
bushing +0.096 –0.098 0.140 –
135 —
+0.042 –0.148 0.244
9 Play of shaft in axial direction 0.66 – 1.06
PC1250-8 5
SEN00898-00 10 Structure, function and maintenance standard
Carrier roller 1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
220 —
2 Outside diameter of tread 205 185
3 Width of tread 79 —
4 Thickness of tread 67.6 57.6
5 Width of flange 17 —
Standard Tolerance Standard Interference Replace
Interference between bearing size Shaft Hole interference limit
6
and roller –0.250 –0.250 –0.020 –
125 —
–0.020 –0.040 0.040
Interference between bearing +0.390 –0.250 0.020 –
7 70 —
and shaft +0.020 –0.015 0.054
Standard size Clearance limit
8 Play of roller in axial direction
0 – 0.110 0.3
6 PC1250-8
10 Structure, function and maintenance standard SEN00898-00
Track roller 1
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Outside diameter of flange
320 —
Outside diameter of tread
2 275 263
surface
3 Thickness of tread 77.5 71.5 Rebuild or
replace
4 Overall width 370 —
5 Inside width 136 —
6 Width of tread 82 —
7 Width of flange 35 —
Standard Tolerance Standard Clearance
Clearance between shaft and size Shaft Hole clearance limit
8
bushing –0.120 +0.360 0.380 –
110 1.5
–0.207 +0.260 0.567
Replace
Tolerance Standard
Standard Interference bushing
interfer-
Interference between roller and size Shaft Hole limit
9 ence
bushing
+0.087 +0.020 0.017 –
120 —
+0.037 –0.037 0.102
PC1250-8 7
SEN00898-00 10 Structure, function and maintenance standard
Track shoe 1
8 PC1250-8
10 Structure, function and maintenance standard SEN00898-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
1 Link pitch
280.3 283.3 Reverse or
Standard size When turned replace
2 Bushing outside diameter
98 93
Standard size Repair limit
3 Thickness of bushing metal Replace
18.8 13.8
4 Link height 181 168
Rebuild or
Thickness of link metal replace
5 56
(bushing press-fitting portion)
6 256.6
7 Shoe bolt pitch 183 Replace
8 79.5
Inside
9 135
width
Overall Repair or
10 Link 86.1
width replace
Tread
11 75
width
12 Protrusion of pin 4.5
13 Protrusion of regular bushing 8.7
Adjust or
14 Overall length of pin 324.4
replace
15 Overall length of bushing 225.6
16 Thickness of spacer 10.93
17 Bushing 215 – 304 kN {22 – 31 ton}
Regular
18 637 – 745 kN {65 – 76 ton}
Press-fitting force pin —
Master
*19 235 – 294 kN {24 – 30 ton}
pin
PC1250-8 9
SEN00898-00 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Tightening torque Additional tightening
a. Regular link (Nm {kgm}) angle (deg.)
1,372 ± 137 {140 ± 14} 150 ± 10
Shoe bolt Retighten
20 Tightening torque Additional tightening Lower limit torque
b. Master link (Nm {kgm}) angle (deg.) (Nm {kgm})
— — —
No. of shoes (each side) 48 —
Standard Tolerance Standard Interference
Interference between bushing size Shaft Hole interference limit
21
and link +0.622 +0.087 0.435 –
98 1.5
+0.522 +0.087 0.622
Interference between regular +0.042 –0.126 0.452 –
22 60 —
pin and link +0.326 –0.200 0.626
Standard Tolerance Standard Clearance
Clearance between regular pin size Shaft Hole clearance limit
23
and bushing –0.174 +0.666 0.340 – Adjust or
60.5 —
–0.074 +0.166 0.740 replace
Standard Tolerance Standard Interference
Interference between master size Shaft Hole interference limit
*24
pin and link +0.228 –0.126 0.324 –
60 —
+0.198 –0.200 0.428
Standard Tolerance Standard Clearance
Clearance between master pin size Shaft Hole clearance limit
*25
and bushing –0.51 +0.666 0.676 –
60.5 —
–0.61 +0.166 1.276
10 PC1250-8
10 Structure, function and maintenance standard SEN00898-00
Double shoe
Unit: mm
No. Check Item Criteria Remedy
Standard size Repair limit
1, 2 Height
50 25
Rebuild or
3 Thickness 25
replace
4 length at bottom 39
5, 6 length at top 30
PC1250-8 11
SEN00899-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00899-00 10 Structure, function and maintenance standard
Air system 1
Air piping drawing 1
2 PC1250-8
10 Structure, function and maintenance standard SEN00899-00
PC1250-8 3
SEN00899-00 10 Structure, function and maintenance standard
Specifications
q Cut-out pressure: 0.71 ± 0.03 MPa
{7.2 ± 0.3 kg/cm2})
q Cut-in pressure: 0.59 ± 0.03 MPa
{6.0 ± 0.3 kg/cm2})
1. Body
2. Spring
3. Exhaust stem
4. Piston
5. Inlet valve
6. Filter
4 PC1250-8
10 Structure, function and maintenance standard SEN00899-00
Air tank 1
Specifications
q Capacity: 15 l
PC1250-8 5
SEN00899-00 10 Structure, function and maintenance standard
1. Cover
2. Sleeve
3. Spring
4. Pin
5. Cap
6. Valve
7. Nipple
6 PC1250-8
10 Structure, function and maintenance standard SEN00899-00
Horn valve 1
PC1250-8 7
SEN00899-00 10 Structure, function and maintenance standard
Grease pump 1
8 PC1250-8
10 Structure, function and maintenance standard SEN00899-00
1. Silencer
2. Valve
3. Cover
4. Air chamber
5. Follow plate
6. Grease chamber
7. Grease tank
Function
q The pump is divided into air chamber (4) and
grease chamber (6). As the amount of grease
in grease chamber (6) goes down, follow plate
(5) is pulled down to push down the grease
stuck to the edge of grease chamber (6).
PC1250-8 9
SEN00900-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00900-00 10 Structure, function and maintenance standard
2 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 3
SEN00900-00 10 Structure, function and maintenance standard
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Cooling fan motor
6. Aftercooler fan motor
7. Line oil filter (for R.H. 4-spool control valve)
8. Oil cooler, radiator
9. Line oil filter (for L.H. 5-spool control valve)
10. Line oil filter (for swing 4-spool control valve)
11. Return oil filter
12. L.H. travel motor
13. Drain oil filter
14. Hydraulic tank
15. Center swivel joint
16. R.H. 4-spool control valve
17. L.H. 5-spool control valve
18. Swing 4-spool control valve
19. Swing priority selector solenoid valve
20. CO cancel solenoid valve
21. Straight-travel solenoid valve
22. Heavy lift solenoid valve
23. Machine push-up solenoid valve
24. Travel speed solenoid valve
25. Pilot oil filter
26. Swing holding brake solenoid valve
27. PPC lock valve
28. No. 3 pump
29. Control, PTO lubrication, aftercooler fan drive pump
30. No. 2 pump
31. Oil filter
32. No. 1 pump
33. PPC control relief valve
34. Accumulator
35. Boom control valve
36. L.H. PPC valve
37. Travel PPC valve
38. R.H. PPC valve
4 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Hydraulic tank 1
PC1250-8 5
SEN00900-00 10 Structure, function and maintenance standard
6 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Hydraulic pump 1
PC1250-8 7
SEN00900-00 10 Structure, function and maintenance standard
No.1 pump
Type: HPV95+95
8 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 9
SEN00900-00 10 Structure, function and maintenance standard
10 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 11
SEN00900-00 10 Structure, function and maintenance standard
12 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PA2 (IN) : Main pump pressure input port PDR (OUT) : Servo valve drain output port
PA2 (OUT) : Main pump pressure output port PSV1 : Servo basic pressure input port
PAC : Servo actuator port PECN : CO + NC valve output pressure input
PDR : CO + NC valve drain port port
PC1250-8 13
SEN00900-00 10 Structure, function and maintenance standard
14 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PA1 (IN) : Main pump pressure input port PDR : CO + NC valve drain port
PA1 (OUT) : Main pump pressure output port PDR (OUT) : Servo valve drain output port
PA2 (IN) : Main pump pressure input port PSV1 : Servo basic pressure input port
PA2 (OUT) : Main pump pressure output port PSV2 : Servo basic pressure output port
PAC : Servo actuator port PECN : CO + NC valve output pressure input
port
PC1250-8 15
SEN00900-00 10 Structure, function and maintenance standard
Function
q Discharge amounts (Q1) and (Q2) of main
pumps (PA1) and (PA2) are controlled individu-
ally by the respective servo valves.
q The relationship between pump delivery (Q)
and input signal (PECN) to the servo valve is
as shown in the graph. (Q) varies in proportion
to (PECN).
16 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Operation
(1) Operation in direction of increase of pump delivery (max. angle)
q The control pump pressure (PSV) is taken to q As a result, servo piston chamber (f) is also
port (a). interconnected with chamber (e) through port
Signal pressure (PECN) from the NC valve is (g) and port (d).
taken from port (b) to chamber (c). q At the same time, port (a) is interconnected
q When signal pressure (PECN) rises, control with port (h), so the oil flows through port (i) to
piston (8) is pushed to the left by the hydraulic servo piston chamber (j), pushes servo piston
pressure in chamber (c), and stops at a point (19) to the left, increases the swash plate
where it balances the pressure of springs (4) angle in the main piston pump and increases
and (4A). the pump delivery.
q At the same time, arm (6) uses servo piston q When servo piston (19) moves, arm (6) rotates
(19) as a fulcrum and sways to the left in the clockwise with its center at pin (7). Guide spool
same way as control piston (8). This moves (13) is moved to the right and closes port (a),
guide spool (13) to the left. p o r t ( d ) an d p o r t ( h ) , s o t h e d i s c h a r g e
q When guide spool (13) moves, port (a) and increases by an amount that matches signal
port (d) are closed and port (d) is connected to pressure (PECN).
drain chamber (e).
PC1250-8 17
SEN00900-00 10 Structure, function and maintenance standard
q When signal pressure (PECN) goes down, q At the same time, port (a) is interconnected
control piston (8) moves to the right and stops with port (d), so the oil flows through port (g) to
at a point where the hydraulic pressure in servo piston chamber (f), pushes servo piston
chamber (c) balances the pressure of springs (19) to the right, decreases the swash plate
(4) and (4A). angle in the main piston pump and decreases
q At the same time, arm (6) uses servo piston the pump delivery.
(19) as a fulcrum and sways to the right in the q When servo piston (19) moves, arm (6) rotates
same way as control piston (8). This moves counterclockwise with its center at pin (7).
guide spool (13) to the right. Guide spool (13) is moved to the left and
q When guide spool (13) moves, port (a) and closes port (a), port (d) and port (h), so the dis-
port (h) are closed and port (h) is connected to charge decreases by an amount that matches
drain chamber (e). signal pressure (PECN).
q As a result, servo piston chamber (j) is also
interconnected with chamber (e) through port
(i) and port (h).
18 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
4. TVC valve
PC1250-8 19
SEN00900-00 10 Structure, function and maintenance standard
Function Operation
q When the power mode is at P mode or E q The command current sent from the controller
mode, the pump delivery is controlled to the actuates solenoid push pin (9) and spool (2)
optimum amount by the command current sent moves.
from the controller in accordance with the vari- q When this happens, the piston stops at a point
ation in the engine speed. where it balances the total of the force of spring
q When the emergency pump drive switch is ON, (1), the force of push pin (9), and the force of
the pump delivery is controlled according to TVC output pressure (PE) acting on piston (3).
the pump discharge pressure (load) by hydrau- q The command current at this point is small, so
lic sensing which follows a constant pump spool (2) is balanced at the bottom.
absorption torque. q As a result, port (a) and port (b) are almost com-
pletely open, so the pressure oil from the control
a For details, see “Machine control system”. pump is almost all output as TVC output pres-
sure (PE).
In this way, the pump delivery becomes the max-
imum.
20 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
(2) When command current value from controller is large in P and E mode
Operation
q The command current sent from the controller
actuates solenoid push pin (9) and spool (2)
moves. When this happens, the piston stops at
a point where it balances the force of spring
(1).
q The command current at this point is large, so
spool (2) is balanced at the top.
q As a result, the flow of oil from the control
pump at port (a) and port (b) is throttled. At the
same time, the area of the opening at port (b)
and port (c) (drain port) becomes larger.
q In this way, TVC output pressure (PE) goes
down, and the pump delivery decreases.
PC1250-8 21
SEN00900-00 10 Structure, function and maintenance standard
(3) When pump load is small in emergency pump drive switch “ON”
q When emergency pump drive switch “ON” is q Main pump discharge pressures (PA1) and
selected, solenoid push pin (9) is pushed up, (PA2) are low, so spool (2) is pushed down
increases the set pressure of spring (1), and fully by spring (1).
this condition is maintained. q As a result, control pump discharge pressure
q As a result, the pump absorption torque (PSV) and TVC valve output pressure (PE) are
becomes constant, so TVC output pressure equal.
(PE) (= pump delivery) is controlled by the q At this point, TVC valve output pressure (PE)
pump discharge pressure. becomes the maximum, and the main pump
delivery is also the maximum.
22 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
(4) When pump load is large in emergency pump drive switch “ON”
PC1250-8 23
SEN00900-00 10 Structure, function and maintenance standard
24 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PA1I : Main pump pressure input port PE1 : TVC valve output pressure front, rear inter-
PA1O : Main pump pressure output port connection port
PA2I : Main pump pressure input port PE2 : TVC valve output pressure input port
PA2O : Main pump pressure output port PECN : CO + NC valve output pressure output port
PC : CO selector pilot port PSV1 : Servo basic pressure input port
PD : Jet sensor downstream pressure input port PSV2 : Servo basic pressure output port
PDR1 : TVC valve drain input port PT : Jet sensor upstream pressure input port
PDR2 : CO + NC valve drain output port
PC1250-8 25
SEN00900-00 10 Structure, function and maintenance standard
CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug
26 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Function Operation
q When the load becomes large during opera- q Spool (4) is being pushed down fully by spring
tions and the main pump discharge pressure (3).
rises to a point close to relief pressure, the cut- q As a result, port (a) and port (b) are fully open
off function of the CO valve acts to reduce the and TVC valve output pressure (PE) and CO
pump discharge in order to reduce relief loss. valve output pressure (PEC) are equal.
q At the same time, it has a cut-off cancel func- q In this way, CO valve output pressure (PEC)
tion actuated by the pilot pressure from the becomes the maximum and the main pump
heavy-lift solenoid valve. delivery also becomes the maximum.
q The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure (PA) and CO valve output pressure
(PEC).
PC1250-8 27
SEN00900-00 10 Structure, function and maintenance standard
(2) When main pump discharge pressure becomes close to relief pressure
28 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 29
SEN00900-00 10 Structure, function and maintenance standard
Function Operation
q The NC valve controls the main pump delivery q When control valve is at neutral, jet sensor dif-
according to the amount that the control valve ferential pressure [(PT) – (PD)] becomes the
spool is operated. This flow control function maximum, and the force of jet sensor output
reduces the neutral loss and fine control loss. pressure (PT) pushing piston (10) becomes
q The NC valve is controlled by balancing the larger than the total of the force of spring (12)
total of the jet sensor output pressure (PT) and and the force of jet sensor output pressure
the NC valve output pressure (PECN) with the (PD) pushing the bottom of spool (11).
total of the force of NC valve spring (12) and q As a result, spool (11) is pushed down, so the
the jet sensor output pressure (PD). flow to port (c) and port (b) is throttled, and the
q The jet sensor picks up the flow of oil returning area of the opening of port (b) and port (a)
to the tank through the control valve and takes (drain port) becomes larger.
them as (PT) and (PD) of the NC valve. q In this way, NC valve output pressure (PECN)
becomes the minimum, and the main pump
delivery also becomes the minimum.
30 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 31
SEN00900-00 10 Structure, function and maintenance standard
No. 2 pump
Type: HPV95+95
32 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
1. Front pump
2. Front servo valve
3. Rear servo valve
4. Rear pump
5. Gear pump
PC1250-8 33
SEN00900-00 10 Structure, function and maintenance standard
34 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 35
SEN00900-00 10 Structure, function and maintenance standard
36 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 37
SEN00900-00 10 Structure, function and maintenance standard
No. 3 pump
Type: HPV160+160
38 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
1. Front pump
2. Front servo valve
3. Front CO + NC valve
4. Rear servo valve
5. Rear pump
PC1250-8 39
SEN00900-00 10 Structure, function and maintenance standard
PA1 : Front pump discharge port PSV1A : Servo valve output port
PA2 : Rear pump discharge port PSV1B : Servo valve output port
PSV1 : Servo valve basic pressure port PSV2A : Servo valve output port
PSV2 : Servo valve basic pressure port PSV2B : Servo valve output port
40 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 41
SEN00900-00 10 Structure, function and maintenance standard
42 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 43
SEN00900-00 10 Structure, function and maintenance standard
44 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PA1I : Main pump pressure input port PE1 : TVC valve output pressure input port
PC : CO selector pilot port PE2 : TVC valve output pressure detection port
PD : Jet sensor downstream pressure input port PECN : CO + NC valve output pressure output port
PDR2 : TVC valve drain output port PT : Jet sensor upstream pressure input port
PC1250-8 45
SEN00900-00 10 Structure, function and maintenance standard
CO valve NC valve
1. Plug 8. Plug
2. Piston 9. Sleeve
3. Spool 10. Piston
4. Spring 11. Spool
5. Piston 12. Spring
6. Plate 13. Plug
7. Plug
46 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 47
SEN00900-00 10 Structure, function and maintenance standard
48 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 49
SEN00900-00 10 Structure, function and maintenance standard
1. Cover Outline
2. Spring There are two return oil filters installed to the rear
3. Bypass valve face of the hydraulic tank. They remove the dirt and
4. Bypass valve spring dust in the return oil.
5. Element
6. Housing Specifications
q Bypass valve set pressure:
A: From control valve 1.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}
B: To hydraulic tank
50 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
1. Bracket Outline
2. Safety valve The drain oil filters are installed between the
3. Cartridge hydraulic tank and the travel motor, swing motor,
4. Filter and aftercooler fan drive motor. They remove the
dirt and dust in the oil from each motor drain port.
Specifications
q Safety valve set pressure:
0.10 MPa {1.05 kg/cm2}
PC1250-8 51
SEN00900-00 10 Structure, function and maintenance standard
52 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Outline
q This pump consists of 1 variable capacity
swash plate piston pump, PC valve, EPC valve
and gear pump.
1. Piston pump
2. Gear pump
3. EPC valve
4. PC valve
PC1250-8 53
SEN00900-00 10 Structure, function and maintenance standard
1. Shaft
2. Cradle
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve
54 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 55
SEN00900-00 10 Structure, function and maintenance standard
56 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Control of delivery
q If the swash plate angle (a) becomes larger,
the difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure
from the PC valve.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (10) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the PC valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship between the size of pressure
(PP) at the small diameter piston end and
pressure (PEN) at the large diameter piston
end, and the ratio between the area receiving
the pressure of the small diameter piston and
the large diameter piston controls the move-
ment of servo piston (10).
PC1250-8 57
SEN00900-00 10 Structure, function and maintenance standard
2. PC valve
Function
q The PC valve controls the pump delivery
according to the EPC valve output pressure.
q If the EPC valve output pressure rises, the PC
valve increases the pump delivery.
q If the EPC valve output pressure lowers, the
PC valve decreases the pump delivery.
58 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Operation
q PC mode selector current (IM) is being sent to
EPC valve solenoid (1) from the pump control-
ler.
q PC mode selector current (IM) acts on EPC
valve to output the signal pressure in order to
modify the force pushing piston (2).
q Spool (3) stops at a position where the force of
spring (4) is balanced with the force applied to
piston (2) according to the EPC valve signal
pressure.
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The level of PC mode selector current (IM) is
determined by the engine oil temperature,
hydraulic oil temperature, engine speed, and
set value of the hydraulic fan.
a The spring set force of spring (4) varies as
servo piston (9) expands and compresses
spring (4).
PC1250-8 59
SEN00900-00 10 Structure, function and maintenance standard
2) When PC mode selector current decreases (When EPC output pressure lowers)
60 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
3) When PC mode selector current increases (When EPC output pressure rises)
PC1250-8 61
SEN00900-00 10 Structure, function and maintenance standard
62 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
3. EPC valve
C : To PC valve
P : From pilot relief valve
T : To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
PC1250-8 63
SEN00900-00 10 Structure, function and maintenance standard
Function Operation
q The EPC valve consists of the proportional 1) When signal current is 0 (coil is de-energized)
solenoid portion and the hydraulic valve por- q When there is no signal current flowing from
tion. the controller to coil (2), coil (2) is de-ener-
q When it receives signal current (i) from the gized.
controller, it generates the EPC output pres- q Spool (5) is pushed to the left by spring (4).
sure in proportion to the size of the signal, and q Port (P) closes and the pressurized oil from the
outputs it to the LS (PC) valve. pilot relief valve does not flow to the PC valve.
q The pressurized oil from the PC valve is
drained to the tank through port (C) and port
(T).
64 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 65
SEN00900-00 10 Structure, function and maintenance standard
66 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
outside Free length
14 Spool return spring length load load If damaged or
diameter
deformed,
146 N 117 N replace spring
62.66 × 19.8 53.5 —
{14.9 kg} {11.9 kg}
13.7 N 11.0 N
15 Suction valve spring 16.4 × 8.9 11.5 —
{1.4 kg} {1.12 kg}
PC1250-8 67
SEN00900-00 10 Structure, function and maintenance standard
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center of the
stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) and generates force (F1)[F1
= P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°) to
the output shaft (1), the force is divided into
components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 x ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = ∑(F3 × ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
68 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Operation
1) When pump is started
q If the pressurized oil from the pump is supplied
to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor,
the motor starts revolution. The pressurized oil
on the motor outlet (MB) side of the motor
returns through port (T) to the tank.
PC1250-8 69
SEN00900-00 10 Structure, function and maintenance standard
70 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
PC1250-8 71
SEN00900-00 10 Structure, function and maintenance standard
72 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed If damaged or
outside Free length
12 Suction valve spring length load load deformed,
diameter
replace spring
1.96 N 1.57 N
13.0 × 6.5 9.5 —
{0.2 kg} {0.16 kg}
PC1250-8 73
SEN00900-00 10 Structure, function and maintenance standard
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y-Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces], and gener-
ates force (F1) [F1 = P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°) to
output shaft (1), the force is divided into com-
ponents (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 × ri] against the (Y-Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = ∑(F3 × ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
74 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
Operation
When starting
q If the pressurized oil from the gear pump is
supplied to port (P) and the pressure on (MA)
side rises and starting torque is generated in
the motor, the motor starts revolution. The oil
on motor outlet (MB) side of the motor returns
through port (T) to the tank.
PC1250-8 75
SEN00900-00 10 Structure, function and maintenance standard
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
76 PC1250-8
10 Structure, function and maintenance standard SEN00900-00
PC1250-8 77
SEN00901-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00901-00 10 Structure, function and maintenance standard
2 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
A1 : Plug
A2 : To boom cylinder
A3 : To arm cylinder
A4 : To bucket cylinder
A5 : To L.H. travel motor port (P2)
B1 : Plug
B2 : Plug
B3 : To arm cylinder
B4 : To bucket cylinder
B5 : To L.H. travel motor port (P1)
NCA : To NC valve at rear of No. 1 main pump
NCB : To NC valve at rear of No. 1 main pump
P : From No. 1, No. 2 main pump
P1 : To R.H. 4-spool valve port (P2)
PA1 : Plug
PA2 : From R.H. work equipment, swing PPC valve
PA3 : From L.H. work equipment, swing PPC valve
PA4 : From R.H. work equipment, swing PPC valve
PA5 : From L.H. travel PPC valve
PB1 : Plug
PB2 : From R.H. work equipment, swing PPC valve
PB3 : From L.H. work equipment, swing PPC valve
PB4 : From R.H. work equipment, swing PPC valve
PB5 : From L.H. travel PPC valve
PP : From 2-stage main relief solenoid valve
T : To hydraulic tank
PC1250-8 3
SEN00901-00 10 Structure, function and maintenance standard
Sectional view
4 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
outside Free length
14 Spool return spring length load load
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
402 N 322 N
15 Spool return spring 75 × 37 71.5 — If damaged or
{41 kg} {32.8 kg}
deformed,
370 N 296 N replace spring
16 Spool return spring 83.4 × 35 78.5 —
{37.7 kg} {30.2 kg}
0.98 N 0.78 N
17 Throttle valve spring 31.8 × 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
18 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.54 kg}
6.86 N 5.49 N
19 Suction valve spring 27.9 × 13 18 —
{0.7 kg} {0.56 kg}
PC1250-8 5
SEN00901-00 10 Structure, function and maintenance standard
6 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 7
SEN00901-00 10 Structure, function and maintenance standard
Sectional view
8 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
outside Free length
14 Spool return spring length load load
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
If damaged or
402 N 322 N
15 Spool return spring 75 × 37 71.5 — deformed,
{41 kg} {32.8 kg}
replace spring
18.8 N 15.1 N
16 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
17 Check valve spring 53.6 × 31 39 —
{1.92 kg} {1.54 kg}
6.86 N 5.49 N
18 Suction valve spring 27.9 × 13 18 —
{0.7 kg} {0.56 kg}
PC1250-8 9
SEN00901-00 10 Structure, function and maintenance standard
10 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
A1 : To boom cylinder
A2 : To swing motor MB
A3 : To bucket cylinder
A4 : To arm cylinder
B1 : Plug
B2 : To swing motor MA
B3 : Plug
B4 : To arm cylinder
NCA : To NC valve at front of No. 3 main pump
NCB : To NC valve at front of No. 3 main pump
P : From No. 3 main pump
PA1 : From control pump
PA2 : From L.H. work equipment, swing PPC valve
PA3 : From R.H. work equipment, swing PPC valve
PA4 : From L.H. work equipment, swing PPC valve
PB1 : From R.H. work equipment, swing PPC valve
PB2 : From L.H. work equipment, swing PPC valve
PB3 : From R.H. work equipment, swing PPC valve
PB4 : From L.H. work equipment, swing PPC valve
PI : From pilot valve
PR : From 2-stage main relief solenoid valve
T : To hydraulic tank
PC1250-8 11
SEN00901-00 10 Structure, function and maintenance standard
Sectional view
12 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
outside Free length
13 Spool return spring length load load
diameter
431 N 345 N
69.9 × 57 63 —
{44 kg} {35.2 kg}
402 N 322 N
14 Spool return spring 75 × 37 71.5 — If damaged or
{41 kg} {32.8 kg}
deformed,
0.98 N 0.78 N replace spring
15 Throttle valve spring 31.8 × 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
16 Check valve spring 78.2 × 26.6 52 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
17 Check valve spring 65.3 × 14 46 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
18 Check valve spring 41.3 × 35.5 25.5 —
{1.92 kg} {1.54 kg}
PC1250-8 13
SEN00901-00 10 Structure, function and maintenance standard
Straight-travel valve
Outline
q The straight-travel valve is installed to the R.H.
4-spool valve. It acts to prevent any deviation
in the direction of travel if the boom, arm, or
bucket are operated when the machine is trav-
eling.
14 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
1. Orifice 5. Body
2. Check valve 6. Spool
3. Spring 7. Cover
4. Spool return spring
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
outside Free length
8 Spool return spring length load load If damaged or
diameter
deformed,
157 N 126 N replace spring
117.5 × 27.9 68 —
{16 kg} {12.8 kg}
0.98 N 0.78 N
9 Throttle valve spring 31.8 × 7.6 26.5 —
{0.1 kg} {0.08 kg}
PC1250-8 15
SEN00901-00 10 Structure, function and maintenance standard
Operation
1. When travel is operated independently
(straight-travel solenoid valve de-ener-
gized)
q The straight-travel solenoid valve is de-ener-
gized, so no pilot pressure flows, and spool (6)
remains pushed to the left.
q Because of this, port (P2) (left travel circuit)
and port (P1) (right travel circuit) are not inter-
connected, and each circuit remains indepen-
dent.
16 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Swing motor 1
KMF160AB-2
PC1250-8 17
SEN00901-00 10 Structure, function and maintenance standard
1. Swing motor
1. Housing
2. Brake spring (Belleville spring)
3. Brake piston
4. Plate
5. Disc
6. Brake case
7. Output shaft
8. Cylinder block
9. Piston
10. Valve plate
11. Center shaft
18 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
2. Safety valve
1. Safety valve
2. Housing
3. Check valve
4. Check valve spring
Specifications
Safety valve set pressure : 27 MPa {275 kg/cm2} (at 300 l/min)
Cracking pressure : Min. 19.6 MPa {200 kg/cm2} (at 5 l/min)
Check valve set pressure : 0.03 MPa {0.3 kg/cm2}
PC1250-8 19
SEN00901-00 10 Structure, function and maintenance standard
A1 : From L.H. travel control valve port B5 P2 : To L.H., R.H. travel speed selector valve
A2 : To L.H. travel motor port P1 T1 : To hydraulic tank
B1 : From L.H. travel control valve port A5 T2 : From L.H. and R.H. travel motor port DR
B2 : To L.H. travel motor port P2 1. Cover
C1 : From R.H. travel control valve port B1 2. Body
C2 : To R.H. travel motor port P2 3. Slipper seal
D1 : From R.H. travel control valve port A1 4. Oil seal
D2 : To R.H. travel motor port P1 5. Shaft
P1 : From travel speed selector solenoid valve
Unit: mm
No. Check item Criteria Remedy
Clearance between rotor Standard size Standard clearance Clearance limit
6 Replace
and shaft 110 0.056 – 0.105 0.111
20 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Travel motor 1
MSF-340VP-EH
PC1250-8 21
SEN00901-00 10 Structure, function and maintenance standard
22 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 23
SEN00901-00 10 Structure, function and maintenance standard
1-1 Motor
24 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 25
SEN00901-00 10 Structure, function and maintenance standard
q When the pilot signal is ON, pilot pressure (PI) When this happens, the main oil pressure
from the control pump acts on travel speed (M1, M2) passes through spool (1a) and
selector valve (1) and the capacity is automati- goes to the control piston chamber.
cally changed by the drive pressure of the Rocker cam (14) overcomes moment (Mx)
travel motor. with hydraulic force from propulsion force
(Fc) of control piston (10). It rotates and
Balance of force for travel speed selector valve holds the moment balance at the high
F1 [Force pushing spool (1a) to right (high- speed surface and is held in position (Mx
speed side)] = (A) (area of spool (1a) < Fc, L).
receiving pressure) × (PI) ii) When operating the steering or traveling
F2 [Force pushing spool (1a) to left (low- uphill, if the motor drive pressure is high,
speed side)] = (A) (area of spool (1a) and it goes above the set pressure, the
receiving pressure) × (PH) (motor drive condition becomes (F1) < (F2), and spool
pressure) + force of spring (1b) (1a) is pushed to the left.
When this happens, the main oil pressure
i) When traveling on level ground, if the (M1, M2) passes through spool (1a) and is
travel motor drive pressure is low, the con- drained to the motor case. This creates
dition becomes (F1) > (F2), and spool (1A) the low-speed condition in the same way
is pushed to the right. as when (PI) = 0.
26 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 27
SEN00901-00 10 Structure, function and maintenance standard
1. Shockless piston
2. Poppet
a. Poppet orifice
b. Relief housing orifice
c. Piston stroke
Function
In addition to the pressure control function, this
relief valve has a shockless function (2-stage pres-
sure increase function). This acts to reduce the
shock generated at the beginning when the speed
is reduced (when the machine is stopped).
28 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 29
SEN00901-00 10 Structure, function and maintenance standard
30 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
outside Free length
3 Check valve spring length load load Replace
diameter
6.9 N 3.9 N
56 × 21.4 37 —
{0.7 kg} {0.4 kg}
PC1250-8 31
SEN00901-00 10 Structure, function and maintenance standard
Accumulator 1 Function
q The accumulator is installed between the PPC
For PPC valve
control pump and the PPC valve. Even if the
engine is stopped with the work equipment
raised, pilot oil pressure is sent to the main
control valve by the pressure of the nitrogen
gas compressed inside the accumulator, so it
is possible to lower the work equipment under
its own weight.
Operation
q After the engine stops, when the PPC valve is at
neutral, chamber (A) inside the bladder is com-
pressed by the oil pressure in chamber (B).
q If the PPC valve is operated, the oil pressure in
chamber (B) becomes less than 2.9 MPa {30 kg/
cm2}, so the bladder expands under the pressure
of the nitrogen gas in chamber (A). The oil enter-
ing chamber (B) is sent as the pilot pressure to
actuate the main control valve.
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas : Nitrogen gas
Gas volume : 500 cc
Max. actuating pressure : 3.1 MPa {32 kg/cm2}
Min. actuating pressure : 1.2 MPa {12 kg/cm2}
32 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Valve control 1
PC1250-8 33
SEN00901-00 10 Structure, function and maintenance standard
PPC valve 1
Work equipment and swing PPC valve
34 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 35
SEN00901-00 10 Structure, function and maintenance standard
1. Spool 5. Joint
2. Piston 6. Plate
3. Disc 7. Retainer
4. Nut (for lever connection) 8. Body
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
Centering spring Outside Free length
9 length load load
(for ports P3 and P4) diameter
If damaged or
17.7 N 14.1 N
42.48 × 15.5 34.0 — deformed,
{1.80 kg} {1.44 kg}
replace spring.
Centering spring 9.8 N 7.85 N
10 38.71 × 15.5 34.0 —
(for ports P1 and P2) {1 kg} {0.8 kg}
16.6 N 13.2 N
11 Metering spring 26.7 × 8.14 24.9 —
{1.69 kg} {1.35 kg}
36 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Operation
1. When in neutral q Pressure at port (P1) also rises in proportion to
q Ports (A) and (B) of the control valve and ports the stroke of the control lever.
(P1) and (P2) of the PPC valve are connected q In this way, the control valve spool moves to a
to drain chamber (D). position where the pressure of chamber (A)
(same as pressure at port (P1)) and the force
of the return spring of the control valve spool
are balanced.
PC1250-8 37
SEN00901-00 10 Structure, function and maintenance standard
38 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 39
SEN00901-00 10 Structure, function and maintenance standard
40 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
1. Plate
2. Body
3. Piston
4. Collar
5. Valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length ×
Installed Installed Installed
Outside Free length
6 Centering spring length load load If damaged or
diameter
deformed,
108 N 86.3 N replace spring.
48.57 × 15.5 32.5 —
{11 kg} {8.8 kg}
16.6 N 13.2 N
7 Metering spring 26.7 × 8.14 24.9 —
{1.69 kg} {1.35 kg}
PC1250-8 41
SEN00901-00 10 Structure, function and maintenance standard
42 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
PC1250-8 43
SEN00901-00 10 Structure, function and maintenance standard
Solenoid valve 1
For CO cancel, straight-travel, heavy lift, machine push-up, travel speed
44 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
1. Connector 5. Spool
2. Movable core 6. Block
3. Coil 7. Spring
4. Cage
Operation
When solenoid is de-energized When solenoid is energized
q When the signal current does not flow from the q When the signal current flows from the PPC
PPC lock switch or swing lock switch, solenoid lock switch or swing lock switch to solenoid (3),
(3) is de-energized. solenoid (3) is energized.
For this reason, spool (5) is pushed fully to the For this reason, spool (5) is pushed to the right
left by spring (6). in the direction of the arrow.
As a result, the circuit between ports (P) and As a result, the pressurized oil from the control
(A) closes and the pressurized oil from the pump flows from port (P) through the inside of
control pump does not flow to the actuator. spool (5) to port (A), and then flows to the actu-
At the same time, the pressurized oil from the ator. At the same time, port (T) is closed, and
actuator flows from port (A) to port (T), and is this stops the oil from flowing to the tank.
then drained to the tank.
PC1250-8 45
SEN00901-00 10 Structure, function and maintenance standard
46 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
1. Plug 5. Connector
2. Spring 6. Solenoid
3. Spool 7. Movable iron core
4. Block
Operation
When solenoid is de-energized When solenoid is energized
q When the signal current does not flow from the q When the signal current flows from the PPC
PPC lock switch or swing lock switch, solenoid lock switch or swing lock switch to solenoid (6),
(6) is de-energized. solenoid (6) is energized.
For this reason, spool (3) is pushed fully to the For this reason, spool (3) is pushed to the right
left by spring (2). in the direction of the arrow.
As a result, the circuit between ports (P) and As a result, the pressurized oil from the control
(A) closes and the pressurized oil from the pump flows from port (P) through the inside of
control pump does not flow to the actuator. spool (3) to port (A), and then flows to the actu-
At the same time, the pressurized oil from the ator. At the same time, port (T) is closed, and
actuator flows from port (A) to port (T), and is this stops the oil from flowing to the tank.
then drained to the tank.
PC1250-8 47
SEN00901-00 10 Structure, function and maintenance standard
For swing holding brake (On right side of machine body), safety lock
48 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
1. Connector 7. Spool
2. Solenoid 8. Body
3. Variable iron core 9. Plug
4. Body 10. Spring
5. Plug 11. Spool
6. Spring
Operation
When solenoid is de-energized
q No signal current flows from the controller, so
solenoid (2) is de-energized.
q Accordingly, spool (11) is pushed up by spring
(10) and spool (7) is pushed to the left by
spring (6).
q As a result, port (P) is closed, so pressure oil
from the control pump does not flow to the
actuator.
At the same time, the oil from the actuator
flows from port (A) to port (T) and is drained to
the tank.
PC1250-8 49
SEN00901-00 10 Structure, function and maintenance standard
50 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
1. Connector
2. Variable iron core
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
Operation
When solenoid is de-energized
q No signal current flows from the controller, so
coil (3) is de-energized.
q Because of this, spool (6) is pushed fully to the
left by spring (5).
q As a result, port (P) is closed, so pressure oil
from the control pump does not flow to the
actuator.
At the same time, the oil from the actuator
flows from port (A) to port (T) and is drained to
the tank.
PC1250-8 51
SEN00901-00 10 Structure, function and maintenance standard
Hydraulic cylinder 1
Backhoe specification
Boom
Arm
Bucket
52 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Unit: mm
No. Check item Criteria Remedy
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
–0.043 +0.256 0.082 –
Clearance between Boom 160 0.662
–0.106 +0.039 0.362
1 piston rod and bush- Replace bushing
ing –0.043 +0.255 0.081 –
Arm 170 0.661
–0.106 +0.038 0.361
–0.036 +0.263 0.084 –
Bucket 115 0.653
–0.090 +0.048 0.353
–0.043 +0.025 0.043 –
Boom 140 1.0
–0.106 +0.070 0.131
Clearance between
–0.043 +0.025 0.043 –
2 piston rod support Arm 160 1.0
–0.106 +0.070 0.131
shaft and bushing
–0.036 +0.457 0.406 –
Bucket 100 1.0
–0.090 +0.370 0.547 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 140 1.0
Clearance between –0.106 +0.070 0.131
cylinder bottom sup- –0.043 +0.457 0.406 –
3 Arm 160 1.0
port shaft and bush- –0.106 +0.370 0.547
ing –0.036 +0.457 0.406 –
Bucket 100 1.0
–0.090 +0.370 0.565
PC1250-8 53
SEN00901-00 10 Structure, function and maintenance standard
Arm
Bucket
54 PC1250-8
10 Structure, function and maintenance standard SEN00901-00
Bottom dump
Unit: mm
No. Check item Criteria Remedy
Name of Standard Tolerance Standard Clearance
cylinder size Shaft Hole clearance limit
–0.043 +0.256 0.082 –
Boom 160 0.662
–0.106 +0.039 0.362
Clearance between
1 piston rod and bush- Arm –0.043 +0.256 0.082 – Replace bushing
130 0.662
ing –0.106 +0.039 0.362
–0.043 +0.256 0.082 –
Bucket 140 0.662
–0.106 +0.039 0.362
Bottom –0.036 +0.261 0.083 –
110 0.651
dump –0.090 +0.047 0.351
–0.043 +0.025 0.043 –
Boom 140 1.5
–0.106 +0.070 0.131
–0.036 –0.020 0.016 –
Clearance between Arm 115 1.5
–0.090 –0.020 0.09
2 piston rod support
shaft and bushing –0.043 +0.025 0.043 –
Bucket 130 1.5
–0.106 +0.070 0.131
Bottom –0.036 +0.457 0.406 –
100 1.5
dump –0.090 +0.370 0.547 Replace pin,
–0.043 +0.025 0.043 – bushing
Boom 140 1.5
–0.106 +0.070 0.131
Clearance between Arm –0.036 –0.020 0.016 –
115 1.5
cylinder bottom sup- –0.090 –0.020 0.09
3
port shaft and bush- –0.043 +0.025 0.043 –
ing Bucket 130 1.5
–0.106 +0.070 0.131
Bottom –0.036 +0.457 0.406 –
100 1.5
dump –0.090 +0.370 0.547
PC1250-8 55
SEN00902-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00902-00 10 Structure, function and maintenance standard
Work equipment 1
Work equipment 1
Backhoe specification
2 PC1250-8
10 Structure, function and maintenance standard SEN00902-00
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing size clearance limit
Shaft Hole
1 and mounting pin of boom and
revolving frame –0.043 +0.436 0.393 –
160 1.5
–0.106 +0.350 0.542
Clearance between bushing
–0.043 +0.172 0.128 –
2 and mounting pin of boom and 160 1.5
–0.106 +0.085 0.278
arm
Clearance between bushing
–0.043 +0.404 0.364 –
3 and mounting pin of arm and 140 1.5
–0.106 +0.321 0.510 Replace
link
Clearance between bushing
–0.043 +0.397 0.355 –
4 and mounting pin of arm and 140 1.5
–0.106 +0.312 0.503
bucket
Clearance between bushing
–0.043 +0.397 0.355 –
5 and mounting pin of link and 140 1.5
–0.106 +0.312 0.503
link
Clearance between bushing
–0.043 +0.404 0.364 –
6 and mounting pin of link and 140 1.5
–0.106 +0.321 0.510
bucket
7 Bucket clearance 0.5 – 1.0 Adjust shims
PC1250-8 3
SEN00902-00 10 Structure, function and maintenance standard
4 PC1250-8
10 Structure, function and maintenance standard SEN00902-00
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between bushing size clearance limit
Shaft Hole
1 and mounting pin of boom and
revolving frame –0.043 +0.436 0.393 –
160 1.5
–0.106 +0.350 0.542
Clearance between bushing
–0.043 +0.439 0.396 –
2 and mounting pin of boom and 160 1.5
–0.106 +0.353 0.545 Replace
arm
Clearance between bushing
–0.043 +0.439 0.396 –
3 and mounting pin of arm and 160 1.5
–0.106 +0.353 0.545
bucket
Clearance between bushing
–0.036 +0.363 0.306 –
4 and mounting pin of front 115 1.5
–0.090 +0.270 0.453
bucket and rear bucket
PC1250-8 5
SEN00902-00 10 Structure, function and maintenance standard
6 PC1250-8
10 Structure, function and maintenance standard SEN00902-00
Unit: mm
PC1250-8 7
SEN00902-00 10 Structure, function and maintenance standard
2. Bucket
8 PC1250-8
10 Structure, function and maintenance standard SEN00902-00
Unit: mm
a The figures in ( ) show the value for the long life tooth.
PC1250-8 9
SEN00903-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00903-00 10 Structure, function and maintenance standard
2 PC1250-8
10 Structure, function and maintenance standard SEN00903-00
PC1250-8 3
SEN00904-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00904-00 10 Structure, function and maintenance standard
Electrical system 1
Engine control 1
1. Battery Outline
2. Battery relay q The engine can be started and stopped simply
3. Starting switch by using starting switch (3).
4. Fuel control dial q With the dial type engine controller, the control
5. Supply pump signal from fuel control dial (4) is received by
6. Engine throttle controller engine throttle controller (6). A drive signal is
7. Starting motor sent to supply pump (5), and the rack position
is controlled to control the engine speed.
2 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 3
SEN00904-00 10 Structure, function and maintenance standard
Component
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
4 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Function
q The fuel control dial is installed at the bottom of
the machine monitor. A potentiometer is
installed under the knob, and when the knob is
turned, it rotates the potentiometer shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is sent
to the engine throttle controller.
q The hatched area in the graph below is the
abnormality detection area and the engine
speed is set at low idle.
PC1250-8 5
SEN00904-00 10 Structure, function and maintenance standard
Engine controller
6 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
28 NC (*) — 13 NC (*) —
29 Bypass valve position sensor B 14 NC (*) —
30 Fuel temperature sensor B 15 NC (*) —
31 Bypass valve (+) — 16 NC (*) —
32 NC (*) — 17 NC (*) —
33 5V electric power supply for sensor A 18 NC (*) —
34 NC (*) — 19 NC (*) —
35 NC (*) — 20 NC (*) —
36 NC (*) — 21 NC (*) —
37 5V electric power supply for sensor A 22 Fuel control dial (+5V) A
38 GND C 23 Fuel control dial (–) C
39 NC (*) — 24 NC (*) —
40 NC (*) — 25 NC (*) —
41 NC (*) — 26 NC (*) —
42 NC (*) — 27 NC (*) —
43 NC (*) — 28 NC (*) —
44 Boost pressure sensor B 29 NC (*) —
45 Injector #1 (+) D 30 NC (*) —
46 Injector #5 (+) D 31 NC (*) —
47 Sensor GND C 32 NC (*) —
48 Ne sensor (–) — 33 GND —
49 NC (*) — 34 NC (*) —
50 NC (*) — 35 NC (*) —
51 Injector #2 (–) C 36 NC (*) —
52 Injector #3 (–) C 37 CAN (shield) C
53 Injector #1 (–) C 38 NC (*) —
54 Injector #2 (+) D 39 Starting switch (ACC) B
55 Injector #3 (+) D 40 Electrical intake air heater relay drive D
56 Injector #4 (+) D 41 NC (*) D
57 Injector #6 (+) D 42 Electrical intake air heater relay return C
58 Injector #4 (–) C 43 NC (*) —
59 Injector #6 (–) C 44 NC (*) —
60 Injector #5 (–) C 45 NC (*) —
*: Never connect to NC or malfunctions or failures will 46 CAN (+) E
occur. 47 CAN (–) E
48 NC (*) —
CN-CE02 49 NC (*) —
Input/ 50 NC (*) —
Pin No. Signal name
Output *: Never connect to NC or malfunctions or failures will
1 NC (*) — occur.
2 NC (*) —
3 NC (*) — CN-CE03
4 NC (*) — Input/
Pin No. Signal name
5 NC (*) — Output
6 NC (*) — 1 GND C
7 NC (*) — 2 GND C
8 NC (*) — Electric power supply
3 A
9 Fuel control dial (+) — (+24V constantly)
10 NC (*) — Electric power supply
4 A
11 NC (*) — (+24V constantly)
12 NC (*) — *: Never connect to NC or malfunctions or failures will
*: Never connect to NC or malfunctions or failures will occur.
occur.
PC1250-8 7
SEN00904-00 10 Structure, function and maintenance standard
Rotation sensor
1. Connector
2. Sensor
3. O-ring
1. Connector
2. Sensor
3. O-ring
8 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Connector
2. Pressure import port
1. O-ring
2. Sensor
3. Connector
PC1250-8 9
SEN00904-00 10 Structure, function and maintenance standard
1. Connector
2. Sensor
3. O-ring
Coolant temperature sensor, fuel oil temperature sensor, hydraulic oil temperature sensor
1. Connector
2. Sensor
3. O-ring
10 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Core
2. O-ring
3. Sensor
4. Connector
PC1250-8 11
SEN00904-00 10 Structure, function and maintenance standard
1. Connector
2. Bracket
3. Float
4. Switch
12 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 13
SEN00904-00 10 Structure, function and maintenance standard
14 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 15
SEN00904-00 10 Structure, function and maintenance standard
16 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Operation
Control levers at neutral When control lever is operated
q If the engine is running at above the decelera- q If any control lever is operated when the
tion actuation speed (approx. 1300 rpm), and engine speed is at No. 2 deceleration, the
all the control levers are returned to neutral, engine speed will immediately rise to the
the engine speed drops immediately to approx. speed set by the fuel control dial.
100 rpm below the set speed to the No. 1
deceleration position.
q If another 4 seconds passes, the engine speed
is reduced to the No. 2 deceleration position
(approx. 1300 rpm), and is kept at that speed
until a lever is operated.
PC1250-8 17
SEN00904-00 10 Structure, function and maintenance standard
18 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 19
SEN00904-00 10 Structure, function and maintenance standard
20 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Outline
q This function increases the boom lifting power
by approx. 10%.
q It can be actuated only when the boom RAISE
is being actuated independently. If the arm IN
or bucket CURL is operated at the same time,
the heavy-lift function is automatically can-
celed.
Operation
Lever operation Heavy-lift Main relief Boom
Heavy-lift
Boom Arm IN or solenoid valve set CO valve lifting
switch
RAISE bucket CURL valve pressure force
31.4 MPa
OFF Operated — De-energized Actuated Normal
{320 kg/cm2}
34.3 MPa
Neutral Energized Canceled 10% up
{350 kg/cm2}
ON Operated If the arm IN or bucket CURL is operated during
boom RAISE operations, this function is automati-
Operated Normal
cally canceled, and the condition becomes the
same as when the switch is turned OFF.
PC1250-8 21
SEN00904-00 10 Structure, function and maintenance standard
22 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Outline
q This function switches the pushing force of the
boom. It is aimed to provide both increased
digging efficiency by reducing the digging
resistance of the boom, and increased ease of
operation by increasing the thrusting force for
excavation, digging square holes, carrying out
twist turns, or escaping from soft ground.
Operation
q This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-
spool control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2) and high pressure (33.3
MPa {340 kg/cm2}.
Machine Machine
Safety valve
Mode push-up push-up sole- Effect
set pressure
switch noid valve
By reducing the boom pushing force, it is made
Boom
easier for the boom to escape automatically in the
pushing 4.7 MPa
Energized RAISE direction and to reduce the number of
force 2
{150 kg/cm }
times that the boom is operated. At the same time
(low mode)
it also makes the digging operation smoother.
PC1250-8 23
SEN00904-00 10 Structure, function and maintenance standard
24 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Swing
See diagram
holding OFF OFF
on right
brake
PC1250-8 25
SEN00904-00 10 Structure, function and maintenance standard
26 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Cancel condition
Coolant temperature : Below 105°C
PC1250-8 27
SEN00904-00 10 Structure, function and maintenance standard
28 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Outline
q To maintain the drawbar pull when traveling,
the cut-off is canceled and the main relief pres-
sure is raised from 31.4 MPa {320 kg/cm2} to
34.3 MPa {350 kg/cm2}.
Operation
Pressure increase Main relief valve Cut-off cancel
CO valve
solenoid valve set pressure solenoid valve
When traveling Energized 34.3 MPa {350 kg/cm2} Energized Canceled
When not traveling De-energized 31.4 MPa {320 kg/cm } 2
De-energized Actuated
PC1250-8 29
SEN00904-00 10 Structure, function and maintenance standard
30 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Actuation
Boom shockless
Cancel solenoid valve Boom shockless control Remarks
switch
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF
Energized Canceled Suitable for compacting or skeleton work
(Contacts closed)
q If the boom is raised, the pilot pressure from the PPC valve is generated in line (A). When this happens,
the pressure in line (A) passes through check valve (2) and pushes the spool of the main valve in the
direction of the arrow. The pilot oil at the left end of the spool passes through line (B) and the PPC valve,
and returns to the tank. However, when this happens, check valve (4) is being pushed open by the pres-
sure in line (A), so it also allows the oil to pass in the opposite direction. For this reason, the boom can
be raised without any delay in response.
q In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the
opposite direction to the arrow and drains the oil from line (A). However, the action of check valve (2)
means that the oil must pass through orifice (1). As a result, the spool returns slowly to the neutral posi-
tion to prevent any shock.
PC1250-8 31
SEN00904-00 10 Structure, function and maintenance standard
Straight-travel function
32 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Outline
q When the travel is operated at the same time q To prevent this, the straight-travel valve is
as the boom, arm, or bucket, the pressure oil switched to interconnect the left and right
flowing to the left and right travel circuits is travel circuits. This ensures that the amount of
divided and sent to the boom, arm, or bucket oil supplied to the left and right travel motors is
circuit. equal, so the left and right travel motors both
q If the oil in one travel circuit is divided off, the rotate at the same speed, and this prevents
amount of oil supplied to the travel motor will any travel deviation.
be less than in the travel circuit which is not
divided, so the drop in the supply of oil to the
travel motor will cause the machine to deviate.
Operation
Left and right Work equipment Straight-travel
Straight-travel valve Remarks
travel levers control lever solenoid valve
Left and right travel motor
Neutral De-energize Not actuated
circuits independent
Operation
Left and right travel motor
Operated Energized Actuated
circuits actuated
PC1250-8 33
SEN00904-00 10 Structure, function and maintenance standard
34 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Operation
When swing priority mode is OFF:
Boom RAISE is driven by 3 control valves (R.H. 4-spool control valve, L.H. 5-spool control valve, and
swing 4-spool control valve).
When swing priority mode is ON:
Swing priority solenoid valve is driven and swing 4-spool control valve is locked. As a result, boom
RAISE is driven by 2 control valves (R.H. 4-spool control valve and L.H. 5-spool control valve).
(The swing and boom RAISE control valves become independent.)
PC1250-8 35
SEN00904-00 10 Structure, function and maintenance standard
Operation
q There is a throttle valve in the arm circuit of the swing 4-spool control valve, and when the swing PPC
pressure goes above 1.5 MPa {15 kg/cm2} (when the control lever is operated approx. half way), the
swing assurance selector valve is actuated and the swing drive pressure locks the pilot check valve of
the bucket throttle valve in the swing 4-spool control valve.
q When this condition occurs, the oil in the swing 4-spool control valve forms a parallel circuit, so the flow
of oil to the arm and bucket is throttled by the throttle valve and the drive pressure for the swing rises. In
this way, the drive for the swing is ensured.
36 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 37
SEN00904-00 10 Structure, function and maintenance standard
38 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Engine 8. Fan
2. Engine throttle controller 9. Servo
3. Coolant temperature sensor 10. EPC valve
4. PTO 11. Network signal
5. Cooling fan pump 12. Coolant temperature signal
6. Hydraulic pump 13. Pump controller
7. Cooling fan motor 14. Hydraulic oil temperature sensor
PC1250-8 39
SEN00904-00 10 Structure, function and maintenance standard
40 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Fan 7. Servo
2. Fan motor 8. EPC valve
3. Fan reverse valve 9. Fan pump flow control signal
4. Fan reverse EPC valve 10. Network signal
5. Fan reverse signal 11. Machine monitor
6. Pump controller
PC1250-8 41
SEN00904-00 10 Structure, function and maintenance standard
Components of system
Pump controller
42 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 43
SEN00904-00 10 Structure, function and maintenance standard
CN3 [CN-C03]
Input/
Pin No. Signal name
Output
CN3-1 PWR_IN_BATT Input
CN3-2 PWR_IN_BRY Input
CN3-3 GND_ACT —
CN3-4 Battery relay drive Output
CN3-5 NC Output
CN3-6 NC Output
CN3-7 Straight travel solenoid Output
CN3-8 Travel alarm Output
CN3-9 Bucket CURL pressure switch Input
CN3-10 Boom RAISE pressure switch Input
CN3-11 PWR_IN_BATT Input
CN3-12 PWR_IN_BRY Input
CN3-13 GND_ACT —
CN3-14 PWR_CTR_KEY Input
CN3-15 NC Output
CN3-16 TVC solenoid Output
CN3-17 2-stage relief solenoid Output
CN3-18 Flash light driver relay Output
CN3-19 Bucket DUMP pressure switch Input
CN3-20 Boom LOWER pressure switch Input
CN3-21 PWR —
CN3-22 PWR_IN_BRY Input
CN3-23 GND_ACT —
CN3-24 PWR_CTR_KEY Input
CN3-25 Fan reverse rotation solenoid Output
CN3-26 NC Output
CN3-27 Travel Hi/Lo selector solenoid Output
CN3-28 Cutoff cancel solenoid Output
CN3-29 Swing pressure switch Input
CN3-30 Arm IN pressure switch Input
CN3-31 GND_PWR —
CN3-32 GND_PWR —
CN3-33 GND_PWR —
CN3-34 NC Output
CN3-35 Fan pump EPC solenoid Output
CN3-36 NC Output
CN3-37 Swing holding brake solenoid Output
CN3-38 Swing priority solenoid Output
CN3-39 Travel hydraulic pressure switch Input
CN3-40 Arm OUT pressure switch Input
44 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Sensor
2. Connector
Function
q The engine speed sensor is installed to the ring
gear portion of the engine flywheel. It counts
electrically the number of gear teeth that pass in
front of the sensor, and sends the results to the
engine throttle and pump controller.
This detection is carried out by a magnet, and an
electric current is generated every time the gear
tooth passes in front of the magnet.
PC1250-8 45
SEN00904-00 10 Structure, function and maintenance standard
1. Plug
2. Switch
3. Connector
Specifications
Composition of points: N.O. points
Actuation (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Reset (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
q There are 8 switches installed to the PPC shut-
tle valve. The operating condition of each actu-
ator is detected from the PPC pressure, and
this is sent to the engine throttle and pump
controller.
46 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Resistor
2. Connector
Specification
Resistance: 20 z
Function
q This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC prolix
switch is ON.
q No current flows when the TVC prolix switch is
OFF.
Monitor panel
a See “Machine monitor”.
TVC valve
a See “Hydraulic pump”.
PC1250-8 47
SEN00904-00 10 Structure, function and maintenance standard
Monitor system 1
48 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Machine monitor
Outline
q The machine monitor has the functions to dis-
play various items and the functions to select
modes and electrical parts.
The machine monitor has a CPU (Central Pro-
cessing Unit) in it to process, display, and out-
put the information.
The monitor display unit consists of LCD (Liq-
uid Crystal Display). The switches are flat
sheet switches.
PC1250-8 49
SEN00904-00 10 Structure, function and maintenance standard
50 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 51
SEN00904-00 10 Structure, function and maintenance standard
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
52 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 53
SEN00904-00 10 Structure, function and maintenance standard
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the
hydraulic oil temperature gauge and the hydraulic oil temperature monitor are stopped, and the fol-
lowing cautions are displayed.
When abnormal,
Engine oil pressure ● — lights up and buzzer
sounds
Lights up when
Battery charge ● —
abnormal
When abnormal,
Radiator coolant Lights up when
● lights up and buzzer
level abnormal
sounds
Lights up when
Engine oil level ● —
abnormal
Lights up when
Air cleaner clogging ● —
abnormal
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is dis-
played.
54 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
ON INT OFF
Displays set
Wiper
condition
Displays set
Working mode
mode
Monitor
Displays set
Travel speed
speed
Auto-decelera- Displays
ON ⇔ OFF
tion actuation status
Lights up when
Service meter
Service meter When service meter is working service meter is
indicator
working
PC1250-8 55
SEN00904-00 10 Structure, function and maintenance standard
Switches
56 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 57
SEN00904-00 10 Structure, function and maintenance standard
58 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Maintenance operation
1. After completing the selection, press input con-
firmation switch (3).
The screen will change to the maintenance
reset screen.
PC1250-8 59
SEN00904-00 10 Structure, function and maintenance standard
60 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
q If the return switch is pressed, the previous q If input confirmation switch (4) is pressed, the
screen appears again. following screen appears and the fan rotation
a While the rotation direction is being changed, is changed to the normal.
the engine speed is set to low idle automati-
cally for 15 seconds.
a While the fan is rotating in reverse, the swash
plate angle of the main pump is minimized.
a If the engine is stopped while the fan is rotating
in reverse and then started again, the fan rota-
tion is returned to the normal direction.
PC1250-8 61
SEN00904-00 10 Structure, function and maintenance standard
E mode adjustment
q With this menu, the balance of the fuel con-
sumption and production in unit time can be
changed by changing the engine speed and
pump absorption torque in the E mode.
q Select the target value with operation switch
(3). If input confirmation switch (4) is pressed,
the target value is confirmed and the normal
screen appears.
q The target value can be selected from 4 levels
of “E0” – “E3”. As the number is increased, the
fuel consumption is reduced and the produc-
tion in unit time is also reduced.
a The initial target value is “E0”.
62 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
Adjustment method
a Operate as follows when on the operator
screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment screen.
01 Contrast
02 Brightness
PC1250-8 63
SEN00904-00 10 Structure, function and maintenance standard
64 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
User code display function q If there is more than one service code or failure
q If there is any problem in operating the code, the display switches every 2 seconds
machine, the user code is displayed on the and displays all the service codes/failure codes
monitor to advise the operator of the steps to that caused the user code to be displayed.
take. Even if service codes/failure codes have
This code display appears on the operator occurred, if they did not cause the user code to
screen. be displayed, this function does not display
q On the operator screen, the user code is dis- them.
played on the portion for the hydraulic oil tem-
perature gauge.
PC1250-8 65
SEN00904-00 10 Structure, function and maintenance standard
VHMS controller
66 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 67
SEN00904-00 10 Structure, function and maintenance standard
68 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 69
SEN00904-00 10 Structure, function and maintenance standard
70 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 71
SEN00904-00 10 Structure, function and maintenance standard
Sensor 1
q The signals from the sensors are input to the
panel directly. Either side of a sensor of con-
tact type is always connected to the chassis
ground.
Sensor name Type of sensor When normal When abnormal
Engine oil level Contact ON (Closed) OFF (Open)
Hydraulic oil temperature Resistance — —
Fuel level Resistance — —
Air cleaner clogging Contact OFF (Closed) ON (Open)
1. Connector 3. Float
2. Bracket 4. Switch
72 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Float
2. Connector
3. Cover
4. Variable resistor
PC1250-8 73
SEN00904-00 10 Structure, function and maintenance standard
74 PC1250-8
10 Structure, function and maintenance standard SEN00904-00
PC1250-8 75
SEN00904-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 04-06 (01)
76
SEN01631-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01631-00 20 Standard value table
a When measuring the low idle speed after reducing speed suddenly from high speed, wait for several
seconds for the speed to stabilize before measuring.
2 PC1250-8
20 Standard value table SEN01631-00
Right travel
Right 4-spool
control valve
mm
Boom Lo
16 ± 0.5 16 ± 0.5 16 ± 0.5 16 ± 0.5
Bucket Lo
Arm Hi
Boom Plus
Swing 4-spool
control valve
Swing
16 ± 0.5 16 ± 0.5 16 ± 0.5 16 ± 0.5
Bucket Plus
Arm Plus
• Engine No
Boom control lever 85 ± 10 85 ± 10
stopped RAISE • LOWER
• Center of lever No
Arm control lever knob 85 ± 10 85 ± 10
IN • OUT
Control lever stroke
• Read max.
value to end of No
Bucket control lever 85 ± 10 85 ± 10
travel CURL • DUMP
mm
N o Left •
Swing control lever 85 ± 10 85 ± 10
Right swing
N o Forward •
Travel control lever 112 ± 15 115 ± 15
Reverse (both sides)
Control lever play Work equipment •
Max. 10 Max. 10
amount swing, travel
PC1250-8 3
SEN01631-00 20 Standard value table
PC1250-8, PC1250LC-8,
Applicable model
PC1250SP-8
Cate- Standard value Service limit
Item Measurement conditions Unit
gory for new machine value
• Engine stopped 15.7 ± 4.9 15.7 ± 4.9
Operating effort of control levers
+1.0 +1.0
Machine 31.4 –1.5 31.4 –2.5
push-up ON {320
+10
} {320
+10
}
–15 –25
+1.0 +1.0
31.4 –1.5 31.4 –2.5
Arm +10 +10
{320 –15 } {320 –25 }
Hydraulic pressure
+1.0 +1.0
31.4 –1.5 31.4 –2.5
Bucket +10 +10
MPa {320 –15 } {320 –25 }
{kg/cm2} +1.0 +1.0
34.3 –1.5 34.3 –2.5
Travel +10 +10
{350 –15 } {350 –25 }
+1.0 +1.0
31.4 –1.5 31.4 –2.5
Swing +10 +10
{320 –15 } {320 –25 }
• Engine at full throttle +0.5 +0.5
3.1 0 3.1 0
Control pump • Oil temperature: 45 – 55°C +5.0 +5.0
• All control levers at neutral {32 0 } {32 0 }
• Engine at full throttle All control levers at 2.3 ± 0.3 Min. 1.8
• Oil temperature: neutral {23 ± 3} {18}
45 – 55°C Heavy lift 1.13 ± 0.2 1.08 ± 0.2
Boom RAISE
4 PC1250-8
20 Standard value table SEN01631-00
PC1250-8, PC1250LC-8,
Applicable Model
PC1250SP-8
Cate- Standard value Service limit
Item Measuring Conditions Unit
gory for new machine value
• Engine at full All control levers at
Max. 0.25 {2.6} Max. 0.4 {4.1}
No.1 pump throttle neutral
No.2 pump • Oil temperature: Travel under no
CO • NC 45 – 55°C Min. 1.7 {17} Min. 1.7 {17}
load
valve output • In P-mode
pressure All control levers at
Max. 0.25 {2.6} Max. 0.4 {4.1}
neutral
No.3 pump
Swing under no
Min. 1.7 {17} Min. 1.7 {17}
load
Left 5-spool • Engine at full All control levers at
Min. 1.76 {18} Min. 1.5 {15}
control valve throttle neutral
Jet sensor Right 4-spool • Oil temperature: Travel under no
Hydraulic pressure
PC1250-8 5
SEN01631-00 20 Standard value table
PC1250-8, PC1250LC-8,
Applicable Model
PC1250SP-8
Cate- Standard value Service limit
Item Measuring Conditions Unit
gory for new machine value
Work equipment posture
• In P-mode
• Bucket: No load
• Swing one turn, then measure time taken to
swing next 5 turns
Work equipment posture
6 PC1250-8
20 Standard value table SEN01631-00
PC1250-8, PC1250LC-8,
Applicable Model
PC1250SP-8
Cate- Standard value Service limit
Item Measuring Conditions Unit
gory for new machine value
Work equipment posture
Low speed
105 ± 11 105 ± 11
(120 ± 12) (120 ± 12)
High speed
• Hydraulic oil temperature: 45 – 55°C
73 ± 8 73 ± 8
• In P-mode
(84 ± 9) (84 ± 9)
• Raise track on one side at a time,
rotate one turn, then measure time
taken for next 5 turns with no load.
Work equipment posture
Low speed
27 – 37 27 – 37
20m
10m BKP00107
( ): PC1250LC-8
PC1250-8 7
SEN01631-00 20 Standard value table
PC1250-8, PC1250LC-8,
Applicable Model
PC1250SP-8
Cate- Standard value Service limit
Item Measuring Conditions Unit
gory for new machine value
Work equipment posture
Hydraulic drift of
mm 0 0
travel • Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Stop machine on 12° slope with sprocket at
uphill end of machine.
• Do not place the work equipment on the
ground.
Travel
Leakage of travel
l/min Max. 20 Max. 40
motor
8 PC1250-8
20 Standard value table SEN01631-00
Boom cylin-
der (amount Max. 115 Max. 175
Hydraulic drift of work equipment
of retraction • Place in above posture and measure (Max. 55) (Max. 85)
of cylinder) extension or retraction of each cylinder
and downward movement at tip of bucket
teeth.
• Engine stopped
• Hydraulic oil temperature: 45 – 55°C mm
Arm cylinder • Horizontal, flat ground
(amount of • All control levers at neutral Max. 160 Max. 240
extension of • Bucket: Rated load or full load of soil (Max. 70) (Max. 105)
cylinder) STD, LC specification: 75.9 kN {7,740 kg}
Work equipment
Bucket teeth
in cotact
6.0 ± 0.6 6.4 ± 0.7 Max. 7.4 Max. 7.8
with
ground sec
PC1250-8 9
SEN01631-00 20 Standard value table
IN
Cylinder fully
retracted
5.0 ± 0.5 5.0 ± 0.5 Max. 6.0 Max. 6.0
Fully sec
extended
OUT
Work equipment speed
• Engine at full throttle 4.0 ± 0.4 4.0 ± 0.4 Max. 4.8 Max. 4.8
• Hydraulic oil temperature: 45 – 55°C
• In P-mode
• Bucket: No load
Work equipment posture
Bucket
CURL
Cylinder fully 3.3 ± 0.4 3.5 ± 0.4 Max. 4.1 Max. 4.3
retracted
Work equipment
Fully sec
extended
DUMP
• Engine at full throttle 2.9 ± 0.4 3.1 ± 0.4 Max. 3.9 Max. 4.1
• Hydraulic oil temperature: 45 – 55°C
• In P-mode
• Bucket: No load
Work equipment posture
Time lag
10 PC1250-8
20 Standard value table SEN01631-00
PC1250-8 11
SEN01631-00 20 Standard value table
12 PC1250-8
20 Standard value table SEN01631-00
• Engine stopped a b a b
Bottom dump
Left 5-spool control valve
Boom raise Hi
Arm Lo
16 ± 0.5 16 ± 0.5 16 ± 0.5 16 ± 0.5
Bucket Hi
Left travel
Spool stroke
Right travel
mm
Right 4-spool
control valve
Boom Lo
16 ± 0.5 16 ± 0.5 16 ± 0.5 16 ± 0.5
Bucket Lo
Arm Hi
Boom Plus
Swing 4-spool
control valve
Swing
16 ± 0.5 16 ± 0.5 16 ± 0.5 16 ± 0.5
Bucket Plus
Arm Plus
• Engine No
Boom control lever 79 ± 10 79 ± 10
stopped RAISE • LOWER
• Center of No
Arm control lever lever knob 79 ± 10 79 ± 10
Control lever stroke
IN • OUT
• Read max.
No
Bucket control lever value to end 79 ± 10 79 ± 10
CURL • DUMP
of travel mm
N o Left •
Swing control lever 79 ± 10 79 ± 10
Right swing
N o Forward •
Travel control lever 115 ± 15 115 ± 15
Reverse (both sides)
Control lever play Work equipment •
Max. 10 Max. 10
amount swing, travel
PC1250-8 13
SEN01631-00 20 Standard value table
OFF
+1.0 +1.0
Machine 31.4 –1.5 31.4 –2.5
push-up ON {320
+10
} {320
+10
}
–15 –25
+1.0 +1.0
31.4 –1.5 31.4 –2.5
Arm +10 +10
{320 –15 } {320 –25 }
+1.0 +1.0
31.4 –1.5 31.4 –2.5
Bucket +10 +10
{320 –15 } {320 –25 }
Hydraulic pressure
+0.5 +0.5
28.9 +0 28.9 –1.0
Open MPa +5 +5
{295 +0 } {295 –10 }
Bottom dump {kg/cm2}
+1.0 +1.0
31.4 –1.5 31.5 –2.5
Close +10 +10
{320 –15 } {320 –25 }
+1.0 +1.0
34.3 –1.5 34.3 –2.5
Travel +10 +10
{350 –15 } {350 –25 }
+1.0 +1.0
31.4 –1.5 31.4 –2.5
Swing +10 +10
{320 –15 } {320 –25 }
• Engine at full throttle +0.4 +0.4
3.1 0 3.1 0
Control pump • Oil temperature: 45 – 55°C +3.5 +3.5
• All control levers at neutral {32 0 } {32 0 }
• Engine at full throttle All control levers at 2.3 ± 0.3 Min. 1.8
• Oil temperature: neutral {23 ± 3} {18}
45 – 55°C Heavy lift 1.13 ± 0.2 1.08 ± 0.2
Boom RAISE
14 PC1250-8
20 Standard value table SEN01631-00
PC1250-8 15
SEN01631-00 20 Standard value table
16 PC1250-8
20 Standard value table SEN01631-00
Low speed
95 – 117 95 – 117
High speed
• Hydraulic oil temperature: 45 – 55°C
• In P-mode 63 – 77 63 – 77
• Raise track on one side at a time,
rotate one turn, then measure time
taken for next 5 turns with no load.
Low speed
30 – 40 30 – 40
20 – 25 20 – 25
• Run up for at least 10 m, and mea-
sure time taken to travel next 20 m
on flat ground.
Work equipment posture
10m BKP00107
PC1250-8 17
SEN01631-00 20 Standard value table
Hydraulic drift of
mm 0 0
travel • Engine stopped
• Hydraulic oil temperature: 45 – 55°C
• Stop machine on 12° slope with sprocket at
uphill end of machine.
• Do not place the work equipment on the
ground.
Travel
Leakage of travel
l/min Max. 20 Max. 40
motor
18 PC1250-8
20 Standard value table SEN01631-00
Bucket
cylinder
(amount of
retraction of
cylinder)
Boom
RAISE
Bucket teeth
in cotact
with ground
sec
Cylinder fully
extended
LOWER
PC1250-8 19
SEN01631-00 20 Standard value table
IN
Cylinder fully
retracted
Fully sec
extended
OUT
• Engine at full throttle 3.1 ± 0.4 Max. 3.9
• Hydraulic oil temperature: 45 – 55°C
• In P-mode
• Bucket: No load
Cylinder fully
Work equipment
retracted
Fully sec
extended
DUMP
Fully sec
extended
CLOSE
20 PC1250-8
20 Standard value table SEN01631-00
Time lag
sec
PC1250-8 21
SEN01631-00 20 Standard value table
Bottom
Max. 3 Max. 5
dump
• Engine at low idle
• Hydraulic oil temperature: 45 – 55°C
• Extend boom and arm cylinders fully,
retract bucket cylinder fully, then close bot-
tom in full open state and measure time
taken for bottom to start moving again after
Work equipment
stopping once.
• Engine at full throttle
Internal oil leakage
22 PC1250-8
20 Standard value table SEN01631-00
PC1250-8 23
SEN01632-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01632-00 30 Testing and adjusting
2 PC1250-8
30 Testing and adjusting SEN01632-00
Quantity
symbol
Testing and adjusting item Part No. Part name Remarks
Measuring engine oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
G
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
799-101-5230 Nipple 1 14 mm, P=1.5 mm
3
07002-11423 O-ring 1
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing fuel pressure H
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
1 6167-11-6640 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint diameter: 10 mm
Testing fuel return rate 3 Purchased Hose 1 Size x Length: Ø 5 mm x (2 to 3 m)
J
and leakage 4 Purchased Hose 1 Size x Length: Ø 15 mm x (2 to 3 m)
5 Purchased Measuring cylinder 1 Capacity: 1 l
6 Purchased Stopwatch 1
Measuring clearance of
N Purchased Dial gauge 1 With magnet
swing circle bearing
Testing and adjusting work Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
equipment, swing, and {25, 60, 400, 600 kg/cm2}
K
travel circuit oil
pressures 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
Testing and adjusting 799-101-5002 Hydraulic tester 1
L {25, 60, 400, 600 kg/cm2}
control circuit oil pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
PC1250-8 3
SEN01632-00 30 Testing and adjusting
Quantity
symbol
Testing and adjusting item Part No. Part name Remarks
4 PC1250-8
30 Testing and adjusting SEN01632-00
Quantity
symbol
Testing and adjusting item Part No. Part name Remarks
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the
machine monitor, controllers, sensors, actuators, and wiring harnesses, see Troubleshooting, “T-adapt-
ers and T-boxes table”.
PC1250-8 5
SEN01632-00 30 Testing and adjusting
6 PC1250-8
30 Testing and adjusting SEN01632-00
Measuring air supply pressure 4. Run the engine at high idle under the following
(Boost pressure) 1 condition and measure the intake air pressure
(boost pressure).
q Working mode switch: P-mode
a Tools for measuring air supply pressure (boost q Heavy lift switch: ON
pressure) q Work equipment, swing, travel:
Symbol Part No. Part name Relieve circuit by raising boom.
A 799-201-2202 Boost gauge kit
PC1250-8 7
SEN01632-00 30 Testing and adjusting
8 PC1250-8
30 Testing and adjusting SEN01632-00
1. Measuring with Handy Smoke Checker C1 2) Connect the air hose and the socket of the
1) Install filter paper to Handy Smoke Checker prove hose and accelerator switch to
C1. Smoke Meter C2.
2) Insert the exhaust gas suction port into the a Keep the pressure of the air supply
exhaust pipe. below 1.5 MPa {15 kg/cm2}.
3) Start the engine. 3) Connect the power cord to the AC100V
4) Accelerate the engine suddenly or run at socket.
high idle, and operate the handle of Handy a Before connecting the cord, check
Smoke Checker C1 at the same time to that the power switch of the Smoke
collect the exhaust gas on the filter paper. Meter is OFF.
4) Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter C2
ON.
PC1250-8 9
SEN01632-00 30 Testing and adjusting
10 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 11
SEN01632-00 30 Testing and adjusting
a Valve clearance
q Intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
12 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 13
SEN01632-00 30 Testing and adjusting
14 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 15
SEN01632-00 30 Testing and adjusting
16 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 17
SEN01632-00 30 Testing and adjusting
Adjusting engine speed sensor 1 5. After completing the adjustment, switch the
machine monitor to the monitoring display, and
check that the engine speed is displayed nor-
a If the engine speed sensor has been removed mally.
a n d i n s ta l l e d o r t h e f l y w he e l h a s b e e n a For details of the method of operation, see
removed or installed, adjust as follows. “Special function of machine monitor”.
q Monitoring code: 01006 Engine speed
1. Remove engine speed sensor (1).
a Before adjusting, remove the engine speed
sensor, check that the tip of the sensor is not
scratched and that there are no iron parti-
cles sticking to it, then install it again.
18 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 19
SEN01632-00 30 Testing and adjusting
Testing fuel pressure 1 2. Install nipple [1] of hydraulic tester H1 and con-
nect it to gauge H2 with hose [2].
a Testing tools for fuel pressure
Symbol Part No. Part name 3. Run the engine at high idle and measure the
fuel pressure.
799-101-5002 Hydraulic tester
1 a If the fuel pressure is in the following
H 790-261-1204 Digital hydraulic tester range, it is normal.
2 799-401-2320 Gauge
Engine speed Fuel pressure
a Test only the fuel pressure in the low-pressure High idle
Min. 0.15 MPa
circuit from the feed pump through the engine {Min. 1.5 kg/cm2}
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
20 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 21
SEN01632-00 30 Testing and adjusting
3) Insert joint J2 on common rail (1) side and a If the leakage from the pressure lim-
tighten the removed joint bolt again. iter is in the following standard range,
a Be sure to fit the gaskets to both ends it is normal.
of the joint.
Measurement
4) Connect test hose J3 to the end of joint Leakage (cc/min)
condition
J2.
a Bind the connecting part of the test Relief Max. 10
hose with a wire etc. to prevent it from
coming off.
a The above is the preparation work for
measurement of the leakage from the
pressure limiter.
22 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 23
SEN01632-00 30 Testing and adjusting
Bleeding air from fuel circuit 1 a This switch has a timer in it to start and
stop the electric priming pump automati-
cally (See the figure).
a Bleed air from the fuel circuit in the following a The electric priming pump stops while the
cases according to this procedure. lamp is blinking. This phenomenon is not
q When the fuel filter is replaced abnormal, however.
q When fuel is used up a If the switch is turned to the “OFF” position
q When the engine is started for the first while the lamp is blinking, the lamp goes
time after the fuel piping or supply pump is off and the electric priming pump stops.
k
replaced While the electric priming pump is in
a If the fuel filter was replaced, do not fill the operation, pressure is applied to the
main filter and prefilter with the fuel. fuel circuit. Do not loosen the air bleed-
ing plug at this time, since the fuel may
1. Turn the starting switch to the “OFF” position. spout out.
2. Open the left side door of the engine.
24 PC1250-8
30 Testing and adjusting SEN01632-00
PC1250-8 25
SEN01632-00 30 Testing and adjusting
Testing fuel system for leakage 1 9. Inspect the fuel piping and devices for fuel
leakage.
k Very high pressure is generated in the high- a Check mainly around the high-pressure
pressure circuit of the fuel system. If fuel circuit parts coated with the color checker
leaks while the engine is running, it is dan- for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
its parts, test it for fuel leakage according a If no fuel leakage is detected, check is
to the following procedure. completed.
a Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
26 PC1250-8
30 Testing and adjusting SEN01632-00
1. Check of alternator
1) Remove the alternator belt.
a See 2 below.
2) Turn the alternator pulley with the hand to
check that it rotates smoothly.
3) Install the alternator belt.
a See 2 below.
PC1250-8 27
SEN01633-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01633-00 30 Testing and adjusting
2 PC1250-8
30 Testing and adjusting SEN01633-00
PC1250-8 3
SEN01633-00 30 Testing and adjusting
4 PC1250-8
30 Testing and adjusting SEN01633-00
PC1250-8 5
SEN01633-00 30 Testing and adjusting
q (1): Quick coupler for No. 1 F pump q (4): Quick coupler for No. 2 R pump
q (2): Quick coupler for No. 2 F pump q (5): Quick coupler for No. 3 F pump
q (3): Quick coupler for No. 1 R pump q (6): Quick coupler for No. 3 R pump
6 PC1250-8
30 Testing and adjusting SEN01633-00
2. Measuring hydraulic pressure in work a Since the set pressure of the safety-
equipment circuit suction valve on the boom head side of
1) Measuring normal relief pressure the R.H. 4-spool valve rises higher than
i) Start the engine and set the working the set pressure of the main relief
mode switch in the P-mode position. valve, the main relief valve relieves on
ii) Run the engine at high idle, relieve the low-pressure setting side.
each cylinder singly at its stroke end,
and measure the hydraulic pressure.
a The main relief valve of each control
valve relieves on the low-pressure
setting side.
a If the boom cylinder is relieved at the
LOWER stroke end, the safety-suction
valve on the boom head side of the
R.H. 4-spool valve relieves on the low-
pressure setting side. (The set pres-
sure of the safety-suction valve is lower
than that of the main relief valve.)
2) Measuring relief pressure during heavy lift
operation
i) Start the engine and set the working
mode switch in the P-mode position. 3. Measuring hydraulic pressure in swing cir-
ii) Turn the heavy lift switch ON. cuit
iii) Run the engine at high idle, relieve 1) Start the engine and set the working mode
the boom cylinder singly at the RAISE switch in the P-mode position.
stroke end, and measure the hydrau- 2) Turn the swing lock switch ON.
lic pressure. 3) Run the engine at high idle, relieve the
a The heavy lift function operates only swing motor, and measure the hydraulic
when the boom RAISE operation is pressure.
operated singly. a The safety valves of the front and rear
a The main relief valve of each control swing motors relieve. (The set pressure
valve relieves on the high-pressure of the safety valves is lower than that of
setting side. the main relief valve.)
3) Measuring relief pressure during machine
push-up operation
i) Start the engine and set the working
mode switch in the P-mode position.
ii) Turn the machine push-up switch ON.
iii) Run the engine at high idle, relieve
the boom cylinder singly at the
LOWER stroke end, and measure the
hydraulic pressure.
PC1250-8 7
SEN01633-00 30 Testing and adjusting
8 PC1250-8
30 Testing and adjusting SEN01633-00
PC1250-8 9
SEN01633-00 30 Testing and adjusting
5) Fix union (14) and tighten locknut (15). 4. Adjusting main relief valve (low-pressure
3 Locknut: setting) of L.H. 5-spool control valve
78 – 93 Nm {8.0 – 9.5 kgm} a If the work equipment hydraulic pressure
in the rear pump circuit (during normal
relief operation) is abnormal or the high
pressure setting side was adjusted, adjust
the low pressure setting side of main relief
valve (16) of the L.H. 5-spool control valve
according to the following procedure.
a Adjust the L.H. 5-spool control valve simi-
larly to the R.H. 4-spool control valve.
10 PC1250-8
30 Testing and adjusting SEN01633-00
7. Adjusting swing motor safety valve 3) Fix adjustment screw (20) and tighten
a If the swing hydraulic oil pressure is locknut (21).
abnormal, adjust safety valves (18) and 3 Locknut:
(19) of the swing motor according to the 147 – 196 Nm {15 – 20 kgm}
following procedure.
q (18): Safety valve of front swing motor
PC1250-8 11
SEN01633-00 30 Testing and adjusting
Testing and adjusting control 2. Run the engine at high idle, set the work equip-
circuit oil pressure 1 ment/swing lever and travel lever in neutral,
and measure the oil pressure.
Measuring
a Measure the control circuit oil pressure under
the following condition.
q Hydraulic oil temperature: 45 – 55°C
k Lower the work equipment to the ground and
stop the engine. Operate the control levers
several times to release the residual pressure Adjusting
in the piping, and then loosen the oil filler cap a If the control circuit oil pressure is abnormal,
of the hydraulic tank slowly to release the adjust control relief valve (5) according to the
internal pressure of the hydraulic tank. following procedure.
12 PC1250-8
30 Testing and adjusting SEN01633-00
PC1250-8 13
SEN01633-00 30 Testing and adjusting
Testing and adjusting piston 2) Install nipple M3 and connect oil pressure
pump control pressure 1 gauge [1] of hydraulic tester M1 with hose
[2].
a Use the oil pressure gauges of 5.9 MPa
a Tools for testing and adjusting piston pump {60 kg/cm2}.
control pressure
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
2 799-401-2701 Differential pressure gauge
799-101-5220 Nipple (10 × 1.25 mm)
3
M 07002-11023 O-ring
799-101-5230 Nipple (14 × 1.5 mm)
4
07002-11423 O-ring
799-401-3200 Adapter (Size: 03)
5
02896-11009 O-ring
14 PC1250-8
30 Testing and adjusting SEN01633-00
2. Measuring CO-NC valve output pressure of 5) When the track is rotating under no load,
No. 1 and No. 2 pumps measure the CO-NC valve output pres-
1) Remove oil pressure pickup plugs (2) and sure under the following condition.
(3) of the No. 2 pump. i) Raise the track shoe to be measured
q (2): For front pump circuit by using the boom and arm.
q (3): For rear pump circuit ii) Run the engine at high idle, rotate
track under no load, and measure the
output pressure.
3) Start the engine and set the working mode 3. Measuring CO-NC valve output pressure of
switch in the P-mode position. No. 3 pump
4) Set all the control levers in neutral and 1) Remove oil pressure pickup plug (4) of the
measure the CO-NC valve output pres- No. 3 pump.
sure under the following condition.
i) Set all the control levers in neutral.
ii) Run the engine at high idle and mea-
sure the output pressure.
PC1250-8 15
SEN01633-00 30 Testing and adjusting
2) Install nipple M4 and connect oil pressure 4. Measuring jet sensor output differential
gauge [1] of hydraulic tester M1 with hose pressure of R.H. 4-spool control valve and
[2]. L.H. 5-spool control valve
a Use the oil pressure gauges of 5.9 MPa 1) Disconnect hose (5) on the high pressure
{60 kg/cm2}. (Pt) side at the lower part of the control
valve and hose (6) on the low pressure
side (Pd). Install adapter M5 and connect
the hoses again.
2) Install nipple [3] of hydraulic tester M1 and
connect it to differential pressure gauge
M2 or oil pressure gauge [1] with hose [2].
a When using differential pressure gauge:
Connect the high pressure (Pt) to the
high pressure side (back side) and
connect the low pressure (Pd) to the
low pressure side (lower side). Since
the differential pressure gauge needs
DC 12 V, connect 1 battery to it.
a When using pressure gauge:
Connect a pressure gauge of 5.9
3) Start the engine and set the working mode MPa {60 kg/cm2} to the high pressure
switch in the P-mode position. (Pt) side and connect a pressure
4) Set all the control levers in neutral and gauge of 2.5 MPa {25 kg/cm2} to the
measure the CO-NC valve output pres- low pressure (Pd) side.
sure under the following condition. q The following figure shows the R.H.
i) Set all the control levers in neutral. 4-spool control valve.
ii) Run the engine at high idle and mea-
sure the output pressure.
5) When the swing is rotating under no load
and measure the CO-NC valve output
pressure under the following condition.
i) Turn the swing lock switch OFF.
ii) Run the engine at high idle, when the
swing is rotating under no load, and
measure the output pressure.
16 PC1250-8
30 Testing and adjusting SEN01633-00
3) Start the engine and set the working mode 5. Measuring jet sensor output differential
switch in the P-mode position. pressure of swing 4-spool control valve
4) Set all the control levers in neutral and 1) Remove oil pressure pickup plug (7) on
measure the jet sensor output differential the high pressure (Pt) side of the No. 3
pressure under the following condition. pump and oil pressure pickup plug (8) on
i) Set all the control levers in neutral. the low pressure (Pd) side.
ii) Run the engine at high idle and mea-
sure the output differential pressure.
a Jet sensor output differential pressure =
High pressure (Pt) – Low pressure (Pd)
5) When the track is rotating under no load,
measure the jet sensor output differential
pressure under the following condition.
i) Raise the track shoe to be measured
by using the boom and arm.
ii) Run the engine at high idle, rotate
track under no load, and measure the
output differential pressure.
a Jet sensor output differential pressure =
High pressure (Pt) – Low pressure (Pd)
PC1250-8 17
SEN01633-00 30 Testing and adjusting
4) Set all the control levers in neutral and 1) Fix adjustment screw (10) and loosen
measure the jet sensor output differential locknut (11).
pressure under the following condition. 2) Turn adjustment screw (10) to adjust the
i) Set all the control levers in neutral. pressure.
ii) Run the engine at high idle and mea- a If the adjustment screw is
sure the output differential pressure. q turned to the right, the pressure
a Jet sensor output differential pressure = rises.
High pressure (Pt) – Low pressure (Pd) q turned to the left, the pressure
5) When the swing is rotating under no load, lowers.
measure the jet sensor output differential a Pressure changed by 1 turn of adjust-
pressure under the following condition. ment screw: 0.4 MPa {4.1 kg/cm2}
i) Turn the swing lock switch OFF. 3) Fix adjustment screw (10) and tighten
ii) Run the engine at high idle, when the locknut (11).
swing is rotating under no load, mea- 3 Locknut:
sure the output differential pressure. 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
a Jet sensor output differential pressure =
High pressure (Pt) – Low pressure (Pd)
18 PC1250-8
30 Testing and adjusting SEN01633-00
PC1250-8 19
SEN01633-00 30 Testing and adjusting
q (21): NC valve of No. 3 pump 1) Fix adjustment screw (24) and loosen
locknut (25).
2) Turn adjustment screw (24) to adjust the
pressure.
a If the adjustment screw is
q turned to the right, the pressure
rises.
q turned to the left, the pressure
lowers.
a Pressure changed by 1 turn of adjust-
ment screw: 0.29 MPa {2.96 kg/cm2}
3) Fix adjustment screw (24) and tighten
locknut (25).
3 Locknut: 59 – 78 Nm {6 – 8 kgm}
20 PC1250-8
30 Testing and adjusting SEN01633-00
Testing servo piston stroke 1 4) Run engine at full throttle and drive the track
shoe on either side or swing under no load.
a Move the control lever to the stroke
a Tools for testing servo piston stroke end.
Symbol Part No. Part name a When measuring, press the rod with
the hand and check that it moves
Cap
708-25-14140 smoothly according to the stroke of
(No. 1 & No. 2 Pump)
1 the control lever.
O-ring
07000-B2065 a After checking that the rod moves
O (No. 1 & No. 2 Pump)
smoothly, keep the rod at the position
708-27-14150 Cap (No. 3 Pump) of the maximum projection.
2
07000-B2075 O-ring (No. 3 Pump) 5) Stop the engine and measure projection
3 566-98-41120 Disc gauge (a2) of the rod.
6) Calculate stroke (b) of the servo piston
from the measured projections.
a If the NC valve output pressure is normal and a Servo piston stroke (b) = (a2) – (a1)
the pump performance seems to defective, test a Standard stroke (b)
the servo valve piston according to the follow- q No. 1 & No. 2 pumps: 9.37 mm
ing procedure. q No. 3 (swing) pump: 12.2 mm
1. Preparation of tools
Make a through hole of R 1/4 at the center of
cap O1 or O2 and screw disc gauge O3 in that
hole.
a Use the cap on the spring side of the
hydraulic pump servo piston.
PC1250-8 21
SEN01634-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01634-00 30 Testing and adjusting
2 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 3
SEN01634-00 30 Testing and adjusting
4 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 5
SEN01634-00 30 Testing and adjusting
Measuring solenoid valve output q (6): Swing holding brake solenoid valve
pressure 1
6 PC1250-8
30 Testing and adjusting SEN01634-00
Table
Condition Oil pressure
No. Solenoid Measurement conditions Operating condition
of solenoid (MPa {kg/cm2})
When travel lever is in neutral
OFF 0 Pump CO function actuated
and heavy-lift switch is OFF
1 CO cancel
When travel lever is operated 2.9 ± 0.6
ON Pump CO function canceled
or heavy-lift switch is ON {30 ± 5.5}
Flow from front pump circuit and
All levers at neutral OFF 0
rear pump circuit divided
2 Straight travel When work equipment and
2.9 ± 0.6 Flow from front pump circuit and
both travel levers are operated ON
{30 ± 5.5} rear pump circuit merged
simultaneously
Main relief valve at low-pressure
When heavy-lift switch is OFF OFF 0
setting
2-stage
3 When heavy-lift switch is ON
main relief 2.9 ± 0.6 Main relief valve at high-pressure
and boom is raised singly or ON
{30 ± 5.5} setting
when travel lever is operated
When machine push-up switch Boom LOWER safety valve at
OFF 0
Machine is at high-pressure setting high-pressure setting
4
push-up When machine push-up switch 2.9 ± 0.6 Boom LOWER safety valve at low-
ON
is at low-pressure setting {30 ± 5.5} pressure setting
Travel motor swash plate angle at
Travel speed switch at Lo OFF 0
MAX
5 Travel speed
Travel speed switch at Hi and 2.9 ± 0.6 Travel motor swash plate angle at
ON
travel lever operated {30 ± 5.5} MIN
11 sec after all work equipment
and swing levers are returned OFF 0 Swing holding brake applied
Swing holding to neutral
6
brake
Swing or work equipment lever 2.9 ± 0.6
ON Swing holding brake canceled
operated {30 ± 5.5}
Swing priority switch is OFF OFF 0 Boom Plus spool actuated
PC1250-8 7
SEN01634-00 30 Testing and adjusting
8 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 9
SEN01634-00 30 Testing and adjusting
10 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 11
SEN01634-00 30 Testing and adjusting
12 PC1250-8
30 Testing and adjusting SEN01634-00
4. Measuring center swivel joint 3) Run the engine at full throttle, and mea-
Table (inspection port and measurement port) sure as follows.
i) Ports (A), (B), (C), (D)
Swivel joint Direction of rota- Swivel joint
Relieve the travel motor slowly in the
inspection tion of travel measurement
port motor port direction of rotation for the port to be
inspected.
k If the lever is operated mistak-
A L.H. FORWARD T and B
B L.H. REVERSE A and P enly, it may lead to serious
C R.H. FORWARD P and D injury or damage, so be sure to
D R.H. REVERSE T and C conf irm signals and signs
carefully.
P Speed selection B and C
ii) Port (P)
Set the travel speed switch to Hi.
4) Continue for 30 seconds, then measure
1) Put block [1] between the sprocket and
the oil leakage for the next one minute.
frame to lock the rotation of the travel
motor where the port is to be inspected,
and stop the engine.
PC1250-8 13
SEN01634-00 30 Testing and adjusting
14 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 15
SEN01634-00 30 Testing and adjusting
16 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 17
SEN01634-00 30 Testing and adjusting
18 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 19
SEN01634-00 30 Testing and adjusting
3. Bleeding air from swing motor 4) Run the engine at high idle, operate the
a When the swing motor has been removed cylinder slowly (take at least 10 seconds)
or installed again, or when the related pip- from a point approx. 100 mm before the
ing has been disconnected or connected, end of the stroke, extend the cylinder to
do as follows to bleed the air from the the end of its stroke to relieve the circuit,
swing motor. and hold in the relief position for 1 minute.
1) Run the engine at low idle, then start and
stop the swing several times.
a This operation will bleed the air inside
the swing motor automatically.
20 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 21
SEN01634-00 30 Testing and adjusting
22 PC1250-8
30 Testing and adjusting SEN01634-00
PC1250-8 23
SEN01635-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01635-00 30 Testing and adjusting
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [E] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [R] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
2 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 3
SEN01635-00 30 Testing and adjusting
4 PC1250-8
30 Testing and adjusting SEN01635-00
6. Function for confirming working mode and 8. Function for adjusting display luminance
travel speed and contrast
After the display of machine inspection before Luminance as well as contrast of the display
day's work, amplified symbol marks for working can be adjusted by operating the display
mode and travel speed are shown for 2 seconds adjusting switch.
to urge an operator to confirm the setting.
PC1250-8 5
SEN01635-00 30 Testing and adjusting
10. Function for showing service meter reading 12. Function for showing occurrence of caution
Only the service meter reading can be shown item
by the following switching operation, when the If any of the caution items occurs, the magni-
engine starting switch is turned OFF. fied corresponding symbol mark is shown for 2
q Switching operation: [ ] + [E] (synchro- seconds and thereafter stays on the display as
nized switching operation) a small symbol mark until it is dissolved.
6 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 7
SEN01635-00 30 Testing and adjusting
14. Function for showing failure code No. a The telephone symbol mark and telephone No.
If the following switching operation is made are shown only when they are registered in the
while the action code No. is shown, a phone machine monitor.
symbol (if registered), phone numbers (if regis- For registration, correction and deletion of tele-
tered), failure code No. are shown in turn. phone No., use Service Menu.
q Switching operation: [ ] a For detailed information of failure code, see
a The following display is repeated in order the failure codes table.
according to the operation of the switch.
(1) Telephone symbol mark
8 PC1250-8
30 Testing and adjusting SEN01635-00
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E15 CA135 Eng Oil Press Sensor High Error ENG Electrical system
E15 CA141 Eng Oil Press Sensor Low Error ENG Electrical system
E15 CA144 Coolant Temp Sens High Error ENG Electrical system
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E15 CA221 Ambient Press Sens High Error ENG Electrical system
E15 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
E03 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E15 CA263 Fuel Temp Sensor High Error ENG Electrical system
E15 CA265 Fuel Temp Sensor Low Error ENG Electrical system
PC1250-8 9
SEN01635-00 30 Testing and adjusting
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E11 CA449 Rail Press Very High Error ENG Electrical system
E11 CA451 Rail Press Sensor High Error ENG Electrical system
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E11 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E11 CA1626 BP Valve Sol Current High Error ENG Electrical system
E11 CA1627 BP Valve Sol Current Low Error ENG Electrical system
E11 CA1631 BP Valve Pos Sens High Error ENG Electrical system
E11 CA1632 BP Valve Pos Sens Low Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E11 CA2271 EGR Valve Pos Sens High Error ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error ENG Electrical system
E15 CA2555 Grid Htr relay Volt Low Error ENG Electrical system
E15 CA2556 Grid Htr relay Volt High Error ENG Electrical system
10 PC1250-8
30 Testing and adjusting SEN01635-00
— DBB3KK [n9 o 05] Abnormality in VBAT voltage (VHMS VBAT < 10V) VHMS —
PC1250-8 11
SEN01635-00 30 Testing and adjusting
E11 DX16KA Fan Pump EPC Sol. Disc. PUMP Electrical system
E11 DX16KB Fan Pump EPC Sol. S/C PUMP Electrical system
a This table lists the failed sections in the order of the failure code.
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
a The VHMS system is a special failure code for the VHMS specification, however. The failures in the
VHMS system are saved only in the VHMS controller, they are not recorded in the failure history. Each
4-digit code in ( ) after the VHMS system is an error code displayed (2-digits) on the 7-segment LED
panel of the VHMS controller.
a E of at beginning the action code indicates the following state.
q With E: The failure still remains without being resolved.
q Without E: The failure is already resolved.
12 PC1250-8
30 Testing and adjusting SEN01635-00
15. Function of reversing fan rotation and a When not reversing the fan rota-
adjusting economy mode value tion, press the return switch [ ],
1) Reversing fan rotation and the previous screen appears.
1] Press switch [5] of the monitor, and
the following screen appears.
q “01”: Fan rotation reversing menu
q “02”: Economy mode value adjust-
ing menu
PC1250-8 13
SEN01635-00 30 Testing and adjusting
5] If the fan rotation is reversed, the fol- 2] The following screen appears. When
lowing screen appears automatically returning the fan rotation to the nor-
and is maintained as long as the fan mal direction, press the [ ] switch.
rotation is in reverse. a If the [ ] switch is pressed, the
a The fan mark is yellow. previous screen appears.
14 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 15
SEN01635-00 30 Testing and adjusting
E1 Economy adjustment 1
E2 Economy adjustment 2
E3 Economy adjustment 3
Good Little
16 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 17
SEN01635-00 30 Testing and adjusting
3) Monitoring operation
Call the monitoring information display
and confirm the monitored information,
while operating the machine.
18 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 19
SEN01635-00 30 Testing and adjusting
20 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 21
SEN01635-00 30 Testing and adjusting
a As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be
selected.
a The unit of display can be changed with “Uni” in the “AAAA/ Default” function of the Service Menu.
a “CA” of the unit of display denotes the crankshaft angle.
Note 1: The momentary Fuel Consumption Ratio shown above is the theoretical fuel consumption ratio
(Since it is a theoretical value, it is a little different from the actual fuel consumption ratio).
Note 2: The Fuel Consumption is the theoretical fuel consumption amount after the engine is started until
the engine is stopped (Since it is a theoretical value, it is a little different from the actual fuel con-
sumption amount).
22 PC1250-8
30 Testing and adjusting SEN01635-00
17. Function for Abnormality Record [02] 3) Information shown in display of Abnormal-
The machine monitor records failures that ity Record in the electrical system
occurred on the machines in the past after [1]: The numerator expresses sequence of
classifying them into failures in the electric sys- failure occurrence, counting from the
tem and those in the mechanical system. Infor- latest one.The denominator expresses
mation on them can be displayed through the the total number of a specific failure
following operation. recorded.
[2]: “E” is displayed as long as the failure
1) Selection of menu is not repaired.
Select 02 Abnormality Record in the initial [3]: Abnormality Code No. (section in 4
display of Service Menu and depress [ ] digits and phenomenon in 2 digits)
switch. [4]: Time elapsed since the occurrence of
the first failure
[5]: Contents of failure
a See the operator menu “Failure codes
table”.
2) Selection of Submenu
Select an appropriate item from Submenu
in the Abnormality Record display and
depress [ ] switch.
4) Information shown in display of Failure
History in the mechanical systems
[1]: Record No.
[2]: Contents of Abnormality
[3]: Abnormality Code No. (section in 4
digits and phenomenon in 2 digits)
[4]: Total number of occurrence
[5]: Service meter reading at the initial
occurrence
a See the operator menu “Failure codes
table”.
PC1250-8 23
SEN01635-00 30 Testing and adjusting
24 PC1250-8
30 Testing and adjusting SEN01635-00
18. Function for maintenance history [03] 19. Function for maintenance mode change [04]
The machine monitor records information on Conditions set for controlling maintenance dis-
the maintenance of filters and oils. The stored play function can be changed in the following
information can be displayed through the fol- manner.
lowing switch operation. q Turn the function effectual or ineffectual.
q Change the set interval for replacement.
1) Selection of menu
Select 03 Maintenance Record in Service 1) Selection of menu
Menu and depress [ ] switch. Select 04 Maintenance Mode Change in
the initial display of Service Menu, and
depress [ ] switch.
2) Information to be displayed
[1]: Name of oils and filters
[2]: Times of replacement to date 2) Selection of item to be changed
[3]: Service meter reading at the latest Select an item to be changed in the dis-
replacement p l a y o f M ai nt e n an c e M o d e Ch a n g e
Selecting Menu.
PC1250-8 25
SEN01635-00 30 Testing and adjusting
26 PC1250-8
30 Testing and adjusting SEN01635-00
20. Function for recording phone No. [05] a Numbers can be entered up to the
In the display of action code, a telephone num- max. 12 digits, but omit unnecessary
ber and failure code are shown alternately. digits.
Phone number can be inputted or modified in a When entering a wrong number,
the following manner. depress [Swing priority] switch, then the
a If there is no Phone number registered, the cursor goes back by one digit.
display for Phone numbers does not appear. a When input is finished, the display
changes to Entry display shown above.
1) Selection of menu If the inputted Phone number is shown
Select 05 Phone Number Entry menu in in this display, the input is normal.
the display of Service Menu, and depress
[ ] switch.
1) Selection of menu
Select 06 “AAAA/Default menu” in the
initial display of Service Menu, and
depress [ ] switch.
PC1250-8 27
SEN01635-00 30 Testing and adjusting
28 PC1250-8
30 Testing and adjusting SEN01635-00
1) Selection of menu
Select “07 Adjustment” on the service
menu and press the [ ] switch.
PC1250-8 29
SEN01635-00 30 Testing and adjusting
30 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 31
SEN01635-00 30 Testing and adjusting
24. Function of no injection cranking [09] 3) As the checkup is over, following screen
No injection cranking of the engine is available appears.
from the machine monitor.
No injection cranking denotes stopping injec-
tion of fuel from the injector even if the engine
is run from the starting motor. This mode is
used, for instance, for measurement of com-
pressive pressure.
a This setting must be done after stopping
the engine.
1) Selecting menu
Select “09 No Injection Cranking” from the
service menu initial screen and press [ ]
switch.
32 PC1250-8
30 Testing and adjusting SEN01635-00
6) From this state, crank the engine using 8) Press “Return” when ending the no injection
the starting motor. cranking.
a Limit the cranking time to 20 seconds a If the no injection cranking function is
to protect the starting motor. inadvertently selected while the
engine is running, “Engine Running”
will appear as No Injection in step 4)
is selected. This “Engine Running”
display remains on the screen even
after the engine is stopped. Restoring
the service menu screen alone
deletes the display.
PC1250-8 33
SEN01635-00 30 Testing and adjusting
1) Selecting menu
Select “10 Snap shot” menu on the initial
screen of the service menu and press the
“ ” switch.
2) Preparing snap shot operation
Check that the snap shot operation is pre-
pared and start the engine.
3) Starting snap shot operation
Press the “ ” switch to start the snap shot
operation.
34 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 35
SEN01635-00 30 Testing and adjusting
36 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 37
SEN01635-00 30 Testing and adjusting
38 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 39
SEN01635-00 30 Testing and adjusting
40 PC1250-8
30 Testing and adjusting SEN01635-00
PC1250-8 41
SEN01636-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01636-00 30 Testing and adjusting
2 PC1250-8
30 Testing and adjusting SEN01636-00
PC1250-8 3
SEN01636-00 30 Testing and adjusting
4. Starting the VHMS initial setting tool 5. Initial setting of VHMS controller (Ver. 3. 5. 2. 1
a This work is done inside the cab (from PC). or older version)
1) Turn on the PC power and start the OS. a This work is done inside the cab (from
2) Operating [VHMS initial setting tool] icon on PC).
the PC, start up the VHMS initial setting tool. a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
Important [Machine Information]
a Appearance of the setup screen of 1) Open [Machine Information] tab.
the VHMS setting tool depends its a [Data clear and Set up] menu displays
tool. [Machine Information] tab first.
a When using Ver.3.5.2.1 or older ver- 2) Check every data for correctness.
sion (CD-ROM), the setting proce-
dure shall conform to that described
in Section 5.
a When using an update version
(Ver.3.5.2.1 or after), the procedure in
Section 6 shall be used.
a It is recommended to download the
latest VHMS version from WebCARE
to update the currently used version.
(Related material: PARTS & SER-
VICE OPERAT ION TIPS SEK N-
5052)
3) Enter the 10-digit service ID to [Service ID].
a Service ID: 7826143000
4) Select [Data clear and Set up] from
[Select Function] item.
5) Click [OK] button to proceed to the setup
screen. 3) When [Date/Time] information is not appro-
priate, correct it in the following manner.
1] Press [Edit] button in the lower right
side of [Date/Time] box to display the
correction screen.
2] After correcting it to the correct infor-
mation, press [OK] button.
4 PC1250-8
30 Testing and adjusting SEN01636-00
PC1250-8 5
SEN01636-00 30 Testing and adjusting
9) When modifying the setting of [SHORT 11) As every data in [Communication Setting]
TREND ANALYSIS], employ the following has been checked and corrected, press
procedure. [Apply] button to settle the setting.
1] Select [SHORT TREND ANALYSIS] a As [Apply] button is pressed, a mes-
from the screen and then press [Edit] sage confirming above setting will
button in the lower left side of [File appear on the screen. Check the set-
Transfer Setting] block to display the ting again and, if the setting is correct,
setup screen. press [OK] button.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, enter [20h] to
[SMR] and then set the function to
ON.
10) When modifying the setting of [Satellite 12) As every data in [Machine Information]
Setting], employ the following procedure. and [Communication Setting] has been
1] Press [Edit] button in the [Satellite checked and corrected, press [Exit] button
Setting] block to display the correc- to end [VHMS initial setting tool].
tion screen.
2] Set the GCC code to the region
applied and, as setting is completed,
press [OK] button.
6 PC1250-8
30 Testing and adjusting SEN01636-00
6. Initial setting of VHMS controller (Ver. 3. 5. 2. 1 3) Confirm the machine information and, if
or later version) they are correct, press [Next] button.
a This work is done inside the cab (from PC).
a It is prohibited in the initial setting to mod-
ify the data of service meter [SMR].
1) Select [VHMS Setting] and then press
[Next] button.
PC1250-8 7
SEN01636-00 30 Testing and adjusting
8 PC1250-8
30 Testing and adjusting SEN01636-00
PC1250-8 9
SEN01636-00 30 Testing and adjusting
10 PC1250-8
30 Testing and adjusting SEN01636-00
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
PC1250-8 11
SEN01636-00 30 Testing and adjusting
12 PC1250-8
30 Testing and adjusting SEN01636-00
E-mail: webcare@komatsu.co.jp
PC1250-8 13
SEN01636-00 30 Testing and adjusting
Model name
Confirmation of machine body and Serial No.
1
component nameplates Engine serial No.
VHMS controller serial No.
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
Is "Data Clear and Set up" selected for the setting tool
4 Starting of VHMS initial setting tool yes no
mode?
Initial setting of VHMS controller Is model name identical with machine body? yes no
Is machine body serial No. correctly entered? yes no
(Setting of machine body informa- Is engine serial No. correctly entered? yes no
5 tion)
In this step, basic machine body Is today's date entered? yes no
information are set on VHMS con- Is current time entered? yes no
troller
Is SMR correctly entered? yes no
14 PC1250-8
30 Testing and adjusting SEN01636-00
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
VHMS controller serial No.
ORBCOMM terminal serial No.
Is it operating normally?
VHMS controller check for normal
3 (Displays counting in ascending-order succeeding to yes no
operation
rotation)
4 Starting of VHMS initial setting tool Is "Set up" selected for the setting tool mode? yes no
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
PC1250-8 15
SEN01636-00 30 Testing and adjusting
16 PC1250-8
30 Testing and adjusting SEN01636-00
PC1250-8 17
SEN01636-00 30 Testing and adjusting
18 PC1250-8
30 Testing and adjusting SEN01636-00
4) Currently saved information will be dis- 7) After adjusting time, press [OK] button.
played. Press [OK] button.
PC1250-8 19
SEN01636-00 30 Testing and adjusting
9) The confirmation screen will ask whether 3. Confirmation, saving and loading of VHMS
or not the data before the above setup is controller setting information (Ver. 3. 5. 2. 1
to be saved. Press [NO] button. or later version)
a It is not necessary to save the data before a This work is done inside the cab (from PC).
the setting. a Setting information is saved from the VHMS
controller to be replaced to the PC and the
saved information is loaded to the new
VHMS controller after the replacement.
3-1. Confirmation of VHMS controller setting infor-
mation prior to replacement
1) Connect the PC and start the VHMS initial
setting tool.
a See the “VHMS controller initial set-
ting procedure” for this operation.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
20 PC1250-8
30 Testing and adjusting SEN01636-00
4) Confirm every information before the 3) Select [Use previous setting after replace-
replacement and then press [Save] but- ment of VHMS controller] and press [Next]
ton. button.
5) Select [Exit] from [File] of the menu to end 4) Currently saved information will be dis-
the VHMS initial setting tool. played. Press [Next] button.
6) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
7) Turns the PC power off.
8) Proceed to replacement of VHMS control-
lers.
PC1250-8 21
SEN01636-00 30 Testing and adjusting
6) The confirmation screen will ask whether [Operations needed after replacement of VHMS
or not the data before the above setup is controller]
to be saved. Press [NO] button. a Execute the quick Pm referring “7. Executing
a It is not necessary to save the data quick Pm” in “VHMS controller initial setting
before the setting. procedure”.
a Download the data referring “8. Download of
setting data” in “VHMS controller initial setting
procedure”.
a After the replacement, send VHMS/WebCARE
setting report sheet to VHMS/WebCARE Sup-
port Center in Komatsu Headquarters.
a Also send two sets of data, the downloaded
before and after the VHMS replacement, via
Notes (LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
E-mail: webcare@komatsu.co.jp
22 PC1250-8
30 Testing and adjusting SEN01636-00
PC1250-8 23
SEN01674-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01674-00 30 Testing and adjusting
2 PC1250-8
30 Testing and adjusting SEN01674-00
Procedure for measuring with machine 3. Checking engine coolant temperature and
monitor and measuring instruments hydraulic oil temperature
Check the engine coolant thermometer and
1. Preparation of measuring instruments hydraulic oil thermometer.
Connect the instruments for measuring the Pm a If the engine coolant temperature and the
clinic to the engine, PTO, fan, and hydraulic hydraulic oil temperature are low, warm up
equipment. the machine until they are in the operating
a Referring to “Installation positions of mea- range.
suring instruments”, connect the measur-
ing instruments shown in the following
table (excluding the items measured with
the machine monitor).
a The measuring instruments are installed
to the male side of connectors (V16, V17)
of the exhaust temperature sensor to
measure the machine of the VHMS speci-
fication. If the engine is started with the
female side disconnected, however, dis-
connection of a wiring harness (VHMS
system) is detected. To prevent this,
install the same exhaust temperature sen-
sor (6215-11-8280) or an equivalent
dummy resistor to the connector on the
female side. 4. Setting machine monitor
1) Set the machine monitor to display the
No. Measurement item Measuring instrument service menu and select the “Monitoring”
1 Blow-by pressure Blow-by checker menu.
2 Boost pressure Pressure gauges group a For the operating method, see “Spe-
cial function of machine monitor”.
Digital thermometer + adapter
3 Exhaust temperature 2) Select and display the following monitor-
connector
ing items.
PTO temperature q 01002 Engine speed
4 Thermo-label
(Oil temperature) q 37200 Engine oil pressure
Control pump
5 Pressure gauges group (60K)
pressure
6 TVC pressure Pressure gauges group (60K)
No. 1 & 2F CO-NC
7 Pressure gauges group (60K)
pressure
No. 1 & 2R CO-NC
8 Pressure gauges group (60K)
pressure
No. 3 CO-NC
9 Pressure gauges group (60K)
pressure
10 Fan speed Multitachometer
11 Fan pump pressure Pressure gauges group (60K)
2. Starting engine
1) Turn the starting switch ON and check that 5. Measuring and testing items related to
the machine monitor does not indicate any engine, PTO, and work equipment speed
abnormality. Measure and test the items related to the
2) Check the safety around the machine, engine, PTO, and work equipment speed
sound the horn, and then start the engine. (Items 1 - 3 on check sheet).
k Since the operator must operate the
work equipment, swing the boom, and
drive the machine actually for mea-
surement, take extreme care of safety
around the machine during the work.
PC1250-8 3
SEN01674-00 30 Testing and adjusting
8. Stopping engine
Set the work equipment in the position for
measuring the hydraulic drift and stop the
engine.
4 PC1250-8
30 Testing and adjusting SEN01674-00
PC1250-8 5
SEN01674-00 30 Testing and adjusting
6 PC1250-8
30 Testing and adjusting SEN01674-00
2. Starting engine
1) Turn the starting switch ON and check that
the machine monitor does not indicate any
abnormality.
2) Check the safety around the machine,
sound the horn, and then start the engine.
PC1250-8 7
SEN01674-00 30 Testing and adjusting
a If the snap shot operation is inter- 7) If the following screen appears 7 minutes
rupted, the data collected up to now 30 seconds after the snap shot is started,
are not recorded. In this case, repeat the snap shot is finished.
the operation from the first. a The initial screen of the service menu
appears automatically 5 seconds after
the snap shot operation is finished.
8 PC1250-8
30 Testing and adjusting SEN01674-00
2) Connect personal computer W2 and 3) Turn the starting switch to the ON position.
download connector VH13 by wiring har- 4) Operate the [VHMS Analysis Tool] icon on
ness [1] of service kit W1. the personal computer to start the VHMS
a Connect the personal computer to the Analysis Tool.
RS232C terminal. a Input the [User Name] and [Password].
a For the operating method, see the
instruction manual for the VHMS analy-
sis tool.
PC1250-8 9
SEN01674-00 30 Testing and adjusting
10 PC1250-8
30 Testing and adjusting SEN01674-00
Note: To turn off the decelerator and set the engine speed to high idle, move one of both work equipment control
levers and both travel levers to a degree that the work equipment does not move or the machine does not
swing or travel. (If the PPC oil pressure switch is turned ON, the auto-decelerator is turned OFF.)
PC1250-8 11
12 PC1250-8
PC1250-8 13
14 PC1250-8
PC1250-8 15
SEN01637-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
General information on troubleshooting
General information on troubleshooting.......................................................................................................... 2
Points to remember when troubleshooting........................................................................................... 2
Sequence of events in troubleshooting ................................................................................................ 3
Checks before troubleshooting ............................................................................................................ 4
Classification and troubleshooting steps .............................................................................................. 5
Information in troubleshooting table ..................................................................................................... 9
Wiring table for connector pin numbers ..............................................................................................11
T-adapter box and T-adapter table ..................................................................................................... 35
PC1250-8 1
SEN01637-00 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to
understand the structure and function. However, a short cut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
2 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 3
SEN01637-00 40 Troubleshooting
Hydraulic,
1. Check for abnormal noise and smell — Repair
Mechanical 2. Check of oil leakage — Repair
equipment
3. Bleeding air — Bleed air
1. Check of battery voltage (with engine stopped) 20 – 30 V Replace
2. Check of electrolyte level — Add or replace
3. Check of wires for discoloration, burn, and removal of
— Replace
cover
4. Check for released wire clamp and drooping wire — Repair
Electric, 5. Check of wires for wetness (Check connectors and Disconnect the
electrical —
terminals for wetness, in particular) connectors and dry
equipment
6. Check of fuse for disconnection and corrosion — Replace
7. Check of alternator voltage (while engine speed is at After operating for
middle or higher) several minutes: Replace
27.5 – 29.5 V
8. Check of battery relay for operating sound (When
— Replace
starting switch is turned ON or OFF)
4 PC1250-8
40 Troubleshooting SEN01637-00
Troubleshooting steps
If a problem that appears to be a failure occurs on the machine, identify the relevant troubleshooting No. by
performing the following steps and proceed to the main body of troubleshooting.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
When action code is displayed on machine monitor, press [3] switch at panel switch section to display
failure code.
Code for the electrical system, carry out the troubleshooting for the corresponding [Display of code]
according to the displayed failure code.
2. Troubleshooting steps when the electrical system failure code or mechanical system failure
code is recorded in the failure history:
If not calling action code in the machine monitor, check the electrical system failure code or mechanical
system failure code, using the failure history function of the monitor panel.
If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes and reproduce them, and then
see if the trouble is still detected.
a An error code of the mechanical system cannot be deleted.
3. Procedure for troubleshooting to be taken when action code is not displayed and no failure code
is recorded in abnormality record:
If an action code is not displayed on the machine monitor and no failure code is recorded in the abnor-
mality record, a trouble that the machine cannot find out by itself may have occurred in the electrical
system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.”, and then carry out trouble-
shooting corresponding to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
PC1250-8 5
SEN01637-00 40 Troubleshooting
Troubleshooting
No. Failure-looking phenomenon Code
E-mode H-mode S-mode
display
Action to be taken concerning action code and failure code
1 Display user code in machine monitor Accord-
2 Display failure code in electrical system after checking failure history ing to dis-
Display failure code in mechanical system after checking failure his- played
3 code
tory
Engine-related failure
Engine does not start up easily. (It always takes some time to start up
4 S-1
the engine)
5 Engine does not rotate E-1 S-2 1)
6 Engine rotates, but there is no exhaust gas S-2 2)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 3)
start
8 Engine pickup is poor. (Engine does not follow acceleration) S-3
9 Engine stops while in operation S-4
10 Engine rotation is irregular. (There is hunting) S-5
11 Engine is short of output, or lacks power S-6
12 Color of exhaust gas is too dark. (Incomplete combustion) S-7
13 Excessive engine oil consumption, or color of exhaust gas is blue S-8
14 Premature engine oil contamination S-9
15 Excessive fuel consumption S-10
16 Engine coolant is mixed with engine oil, spurts out or decreases S-11
17 Engine oil amount increases. (Coolant or fuel gets in) S-13
18 Abnormal noises are heard S-15
19 Excessive vibrations are caused S-16
20 Engine does not stop
21 Auto-decelerator does not work E-2
22 Engine auto warming-up device does not work E-3
23 Engine preheater does not work E-4
Failure related to work equipment, swing and travel
24 Speed or power of all work equipment, travel, and swing is low H-1 S-6
25 Engine speed lowers remarkably or engine stalls H-2 S-4
26 All work equipment, travel, and swing systems do not work E-5 H-3
27 Abnormal sound is heard from around pump H-4
6 PC1250-8
40 Troubleshooting SEN01637-00
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Work equipment-related failure
28 Speed or power of boom is low H-5
29 Speed or power of arm is low H-6
30 Speed or power of bucket is low H-7
31 Boom does not move H-8
32 Arm does not move H-9
33 Bucket does not move H-10
34 Hydraulic drift of work equipment is large H-11
35 Time lag of work equipment is large H-12
36 Machine push-up circuit does not work E-6
37 Boom shockless function cannot be turned ON or OFF E-7 H-13
Travel-related failure
38 Machine deviates in one direction H-14
39 Machine deviates largely at start H-15
40 Machine deviates largely during compound operation H-16
41 Travel speed or power is low H-17
42 Machine does not travel (only one track) H-18
43 Travel speed does not change H-19
Swing-related failure
44 Machine does not swing H-20
45 Swing speed or acceleration is low H-21
Swing speed or power is low in compound operation of travel and
46 H-22
bucket
Swing speed or power is low in compound operation of travel and
47 H-23
boom in swing priority mode
48 Upper structure overruns largely H-24
49 Large shocks are made when upper structure stops swinging H-25
Large abnormal sounds are made when upper structure stops swing-
50 H-26
ing
51 Hydraulic drift of swing is large H-27
Machine monitor-related failure (Operator's Menu: ordinary display)
52 No display appears in machine monitor at all E-8
53 Part of display is missing in machine monitor E-9
54 Descriptions on machine monitor do not apply to the machine model E-10
55 In startup inspection, radiator coolant level monitor lamp lights up red B@BCZK
56 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
PC1250-8 7
SEN01637-00 40 Troubleshooting
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
60 In startup inspection, maintenance hour monitor lamp lights up red Refer to Operation and Maintenance Manual
While engine is running, battery charging level monitor lamp lights up
61 AB00KE
red
62 While engine is running, fuel level monitor lamp lights up red E-11
63 While engine is running, air cleaner clogging monitor lamp lights up red AA10NX
While engine is running, engine coolant temperature monitor lamp
64 B@BCNS
lights up red
While engine is running, hydraulic oil temperature monitor lamp lights
65 B@HANS
up red
66 Engine coolant temperature gauge does not display correctly
67 Hydraulic oil temperature gauge does not display correctly E-12
68 Fuel gauge does not display correctly E-13
69 Swing lock monitor does not display correctly E-14
70 When operating monitor switch, no display appears E-15
71 Windshield wiper does not work E-16
Monitor panel-related failure (Service Menu: Special Function Display)
72 In monitoring function, “Boom RAISE” cannot be displayed correctly E-17
73 In monitoring function, “Boom LOWER” cannot be displayed correctly E-18
74 In monitoring function, “Arm DIGGING” cannot be displayed correctly E-19
75 In monitoring function, “Arm DUMPING” cannot be displayed correctly E-20
In monitoring function, “Bucket DIGGING” cannot be displayed cor-
76 E-21
rectly
In monitoring function, “Bucket DUMPING” cannot be displayed cor-
77 E-22
rectly
78 In monitoring function, “Swing” cannot be displayed correctly E-23
79 In monitoring function, “Travel” cannot be displayed correctly E-24
Other failure
80 Air conditioner does not work E-25
81 Travel alarm does not sound E-26
Any of panel lamp, head lamp, working lamp (Including additional
82 E-27
lamp) does not light up
83 Step light does not light up or light off E-28
Radiator fan rotation is abnormal (Fan noise or vibration is excessively
84 H-28
large or overheats)
8 PC1250-8
40 Troubleshooting SEN01637-00
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Action code Failure code
Display on Display on Trouble Title of failure phenomenon shown in failure history
machine machine
monitor monitor
Contents of
Contents of trouble detected by machine monitor or controller
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine con-
controller troller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
PC1250-8 9
SEN01637-00 40 Troubleshooting
10 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 11
SEN01637-00 40 Troubleshooting
12 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 13
SEN01637-00 40 Troubleshooting
14 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 15
SEN01637-00 40 Troubleshooting
16 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 17
SEN01637-00 40 Troubleshooting
18 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 19
SEN01637-00 40 Troubleshooting
20 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 21
SEN01637-00 40 Troubleshooting
22 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 23
SEN01637-00 40 Troubleshooting
24 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 25
SEN01637-00 40 Troubleshooting
26 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 27
SEN01637-00 40 Troubleshooting
28 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 29
SEN01637-00 40 Troubleshooting
30 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 31
SEN01637-00 40 Troubleshooting
32 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 33
SEN01637-00 40 Troubleshooting
34 PC1250-8
40 Troubleshooting SEN01637-00
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
PC1250-8 35
SEN01637-00 40 Troubleshooting
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
36 PC1250-8
40 Troubleshooting SEN01637-00
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
DT12G
799-601-9110 Adapter for DT (gray) 12 q q
R
799-601-9120 Adapter for DT (black) 12 DT12B q q
799-601-9130 Adapter for DT (green) 12 DT12G q q
799-601-9140 Adapter for DT 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9220 Adapter for HD30-18 14 D18-14 q q
799-601-9230 Adapter for HD30-18 20 D18-20 q q
799-601-9240 Adapter for HD30-18 21 D18-21 q q
799-601-9250 Adapter for HD30-24 9 D24-9 q q
799-601-9260 Adapter for HD30-24 16 D24-16 q q
799-601-9270 Adapter for HD30-24 21 D24-21 q q
799-601-9280 Adapter for HD30-24 23 D24-23 q q
799-601-9290 Adapter for HD30-24 31 D24-31 q q
799-601-9310 Plate for HD30 (24 pins) q q q
T-adapter box
799-601-9320 12 q q q
(for DT and HD)
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410 Adapter for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 3 A3 q
Adapter for engine (CRI-T3)
Adapter for engine (CRI-T2)
799-601-9430 2 P q
Adapter for engine (CRI-T3)
799-601-9440 Adapter for engine (CRI-T2) 3 1,2,3 q
795-799-5520 Adapter for engine (HPI-T2) 2 S q
Adapter for engine (HPI-T2)
795-799-5530 2 C q
Adapter for engine (CRI-T3)
Adapter for engine (HPI-T2)
795-799-5540 2 A q
Adapter for engine (CRI-T3)
795-799-5460 Cable for engine (HPI-T2) 3 q
795-799-5470 Cable for engine (HPI-T2) 3 q
795-799-5480 Cable for engine (HPI-T2) 3 q
799-601-4160 Adapter for engine (CRI-T3) 2 OIL q
799-601-4340 Adapter for engine (CRI-T3) 2 1,2,3 q
799-601-4130 Adapter for engine (CRI-T3) 3 FCIN q
799-601-4140 Adapter for engine (CRI-T3) 3 FCIG q
799-601-4150 Adapter for engine (CRI-T3) 3 FCIB q
799-601-4180 Adapter for engine (CRI-T3) 3 FCIP3 q
799-601-4190 Adapter for engine (CRI-T3) 3 1,2,3 q
799-601-4240 Adapter for engine (CRI-T3) 3 1,2,3 q
799-601-4250 Adapter for engine (CRI-T3) 3 1,2,3 q
799-601-4330 Adapter for engine (CRI-T3) 3 1,2,3 q
799-601-4230 Adapter for engine (CRI-T3) 4 1,2,3,4 q
PC1250-8 37
SEN01637-00 40 Troubleshooting
T-adapter kit
Identification
No. of pins
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
out of kit
code
Part No. Part name
38 PC1250-8
40 Troubleshooting SEN01637-00
PC1250-8 39
SEN01638-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table and fuse locations
Failure code table................................................................................................................................. 2
Fuse locations ...................................................................................................................................... 7
PC1250-8 1
SEN01638-00 40 Troubleshooting
E10 CA115 Eng Ne and Bkup Speed Sens Error ENG Electrical system
E11 CA122 Chg Air Press Sensor High Error ENG Electrical system
E11 CA123 Chg Air Press Sensor Low Error ENG Electrical system
E15 CA135 Eng Oil Press Sensor High Error ENG Electrical system
E15 CA141 Eng Oil Press Sensor Low Error ENG Electrical system Troubleshooting by
E15 CA144 Coolant Temp Sens High Error ENG Electrical system failure code, Part 1
SEN01639-00
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor Low Error ENG Electrical system
E15 CA187 Sens Supply 2 Volt Low Error ENG Electrical system
E15 CA221 Ambient Press Sens High Error ENG Electrical system
E15 CA222 Ambient Press Sens Low Error ENG Electrical system
E15 CA227 Sens Supply 2 Volt High Error ENG Electrical system
E03 CA238 Ne Speed Sens Supply Volt Error ENG Electrical system
E15 CA263 Fuel Temp Sensor High Error ENG Electrical system
E15 CA265 Fuel Temp Sensor Low Error ENG Electrical system
2 PC1250-8
40 Troubleshooting SEN01638-00
E11 CA331 Inj #2(L#2) Open/Short Error ENG Electrical system Troubleshooting by
failure code, Part 1
E11 CA332 Inj #4(L#4) Open/Short Error ENG Electrical system SEN01639-00
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E15 CA352 Sens Supply 1 Volt Low Error ENG Electrical system
E15 CA386 Sens Supply 1 Volt High Error ENG Electrical system
E11 CA449 Rail Press Very High Error ENG Electrical system
E11 CA451 Rail Press Sensor High Error ENG Electrical system
E11 CA452 Rail Press Sensor Low Error ENG Electrical system
E11 CA731 Eng Bkup Speed Sens Phase Error ENG Electrical system
E10 CA757 All Persistent Data Lost Error ENG Electrical system
E11 CA778 Eng Bkup Speed Sensor Error ENG Electrical system
E11 CA1631 BP Valve Pos Sens High Error ENG Electrical system
E11 CA1632 BP Valve Pos Sens Low Error ENG Electrical system
E14 CA2185 Throt Sens Sup Volt High Error ENG Electrical system
E14 CA2186 Throt Sens Sup Volt Low Error ENG Electrical system
E11 CA2249 Rail Press Very Low Error ENG Electrical system
E11 CA2271 EGR Valve Pos Sens High Error ENG Electrical system
E11 CA2272 EGR Valve Pos Sens Low Error ENG Electrical system
E11 CA2351 EGR Valve Sol Current High Error ENG Electrical system
E11 CA2352 EGR Valve Sol Current Low Error ENG Electrical system
E15 CA2555 Grid Htr relay Volt Low Error ENG Electrical system
E15 CA2556 Grid Htr relay Volt High Error ENG Electrical system
PC1250-8 3
SEN01638-00 40 Troubleshooting
4 PC1250-8
40 Troubleshooting SEN01638-00
E11 DX16KA Fan Pump EPC Sol. Disc. PUMP Electrical system
E11 DX16KB Fan Pump EPC Sol. S/C PUMP Electrical system
PC1250-8 5
SEN01638-00 40 Troubleshooting
a This table lists the failed sections in the order of the failure code.
a Those failure codes to which the corresponding number is not indicated in the action code space are not
displayed on the ordinary screen if a failure is found. They are just recorded in the abnormality record
(electrical system and mechanical system) of the service menu.
a The category of record is used for indicating to which of the electrical and mechanical system of the ser-
vice menu's abnormality record a given failure is classified.
a The VHMS system is a special failure code for the VHMS specification, however. The failures in the
VHMS system are saved only in the VHMS controller, they are not recorded in the failure history. Each
4-digit code in ( ) after the VHMS system is an error code displayed (2-digits) on the 7-segment LED
panel of the VHMS controller.
a E of at beginning the action code indicates the following state.
q With E: The failure still remains without being resolved.
q Without E: The failure is already resolved.
6 PC1250-8
40 Troubleshooting SEN01638-00
Fuse locations 1
Connection table of circuit breakers
a This connection table shows the devices to which each power supply of the circuit breakers supplies
power (A switch power supply is a device which supplies power while the starting switch is at the ON
position and a constant power supply is a device which supplies power while the starting switch is at the
OFF position).
a When carrying out troubleshooting for a displayed code, you should check the circuit breakers to see if
the power is supplied normally.
PC1250-8 7
SEN01638-00 40 Troubleshooting
Type of power
Fuse No. Fuse capacity Destination of power
supply
Machine push-up solenoid
1 10 A
Boom shockless solenoid
EPC solenoid (for emergency pump drive)
2 10 A
Swing holding brake solenoid (for swing brake release)
Switch power supply PPC lock solenoid
3 10 A
(Circuit breaker 1) Starting motor cut-out relay
Cigarette lighter
4 20 A
Windshield washer motor
Horn
5 10 A
Flash light
6 10 A Automatic greasing
7 10 A Rotary lamp
Switch power supply 8 10 A (Spare)
(Circuit breaker 1) 9 10 A Radio
Intake air heater
10 20 A
Buzzer
11 25 A Air conditioner unit
12 20 A VHMS controller
Optional power source (2)
Switch power supply 13 20 A Travel alarm
(Circuit breaker 1) 12V power source
14 10 A Optional power source (1)
15
5A Starting switch ACC circuit (engine controller)
(ACC circuit)
16 10 A Radio backup
Constant power 17 10 A Network bus
supply 18 10 A VHMS controller (backup)
(Circuit breaker 9) 19 10 A Room lamp
20 10 A Step light
8 PC1250-8
40 Troubleshooting SEN01638-00
PC1250-8 9
SEN01639-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
Troubleshooting by failure code (Display of code), Part 1 .............................................................................. 3
Failure code [A000N1] Eng. Hi Out of Std............................................................................................ 3
Failure code [AA10NX] Aircleaner Clogging ........................................................................................ 4
Failure code [AB00KE] Charge Voltage Low ....................................................................................... 6
Failure code [B@BAZG] Eng. Oil Press. Low ...................................................................................... 8
Failure code [B@BAZK] Eng. Oil Level Low ...................................................................................... 10
Failure code [B@BCNS] Eng. Water Overheat.................................................................................. 12
Failure code [B@BCZK] Eng. Water Lvl Low..................................................................................... 14
Failure code [B@CBNS] High PTO temperature ............................................................................... 16
Failure code [B@HANS] Hydr. Oil Overheat...................................................................................... 18
Failure code [CA111] ECM Critical Internal Failure ............................................................................ 19
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................... 21
Failure code [CA122] Chg Air Press Sensor High Error .................................................................... 22
Failure code [CA123] Chg Air Press Sensor Low Error ..................................................................... 24
PC1250-8 1
SEN01639-00 40 Troubleshooting
2 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 3
SEN01639-00 40 Troubleshooting
4 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 5
SEN01639-00 40 Troubleshooting
6 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 7
SEN01639-00 40 Troubleshooting
8 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 9
SEN01639-00 40 Troubleshooting
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Machine monitor P02 Engine oil pressure Voltage
4
defective When in normal
Between (8) and Max. 1 V
condition
grounding
When lowered 20 – 30 V
10 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 11
SEN01639-00 40 Troubleshooting
12 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 13
SEN01639-00 40 Troubleshooting
14 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 15
SEN01639-00 40 Troubleshooting
Grounding fault of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness (Contact the OFF position during the troubleshooting.
4
with grounding (GND) Between wiring harness between VC2A (female) Resistance
circuit) Min. 1 Mz
(2) and VH09 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
VC2A (female) Oil temperature Resistance value
VHMS controller
5 Between (2) and (12), 25°C 46 – 59 kz
defective
(13) 100°C 3.6 – 4.0 kz
Between (2) and
— Min. 1 Mz
grounding
16 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 17
SEN01639-00 40 Troubleshooting
18 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 19
SEN01639-00 40 Troubleshooting
20 PC1250-8
40 Troubleshooting SEN01639-00
Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
E10 CA115 (Engine controller system)
Contents of
• Failure occurred simultaneously in engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
• None in particular.
controller
Problem that
• Engine cannot be started. (Engine is stopped.)
appears on
• Engine stops (during operations).
machine
Related
information
PC1250-8 21
SEN01639-00 40 Troubleshooting
22 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 23
SEN01639-00 40 Troubleshooting
Action code Failure code Chg Air Press Sensor Low Error
Trouble
E11 CA123 (Engine controller system)
Contents of
• Low pressure error occurred in charge air pressure sensor circuit.
trouble
Action of
• Fixes charge pressure at 400 kPa {4.1 kg/cm2} and continues operation.
controller
Problem that
appears on • Engine does not accelerate easily.
machine
Related
information
24 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 25
SEN01639-00 40 Troubleshooting
26 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 27
SEN01639-00 40 Troubleshooting
Action code Failure code Eng Oil Press Sensor High Error
Trouble
E15 CA135 (Engine controller system)
Contents of
• High pressure error occurred in engine oil pressure sensor circuit.
trouble
Action of
• Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
controller
Problem that
appears on • Starting performance of the engine lowers during low temperature.
machine
Related • Signal voltage of the oil pressure sensor can be checked by monitoring function
information (Code No. 37201: oil pressure sensor voltage).
28 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 29
SEN01639-00 40 Troubleshooting
Action code Failure code Eng Oil Press Sensor Low Error
Trouble
E15 CA141 (Engine controller system)
Contents of
• Low pressure error occurred in engine oil pressure sensor circuit.
trouble
Action of
• Sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
controller
Problem that
appears on • Starting performance of the engine lowers during low temperature.
machine
Related • Signal voltage of the oil pressure sensor can be checked by monitoring function
information (Code No. 37201: oil pressure sensor voltage).
30 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 31
SEN01639-00 40 Troubleshooting
32 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 33
SEN01639-00 40 Troubleshooting
Action code Failure code Chg Air Temp Sensor High Error
Trouble
E15 CA153 (Engine controller system)
Contents of
• High temperature error occurred in charge air temperature sensor circuit.
trouble
Action of
• Fixes charge air temperature (air intake temperature) at 70°C and continues operation.
controller
Problem that
appears on • Starting performance of the engine lowers during low temperature.
machine
Related • Signal voltage of charge air temperature sensor can be checked by monitoring function
information (Code No. 18501: Boost temperature sensor voltage).
34 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 35
SEN01639-00 40 Troubleshooting
Action code Failure code Chg Air Temp Sensor Low Error
Trouble
E15 CA154 (Engine controller system)
Contents of
• Low temperature error occurred in charge air temperature sensor circuit.
trouble
Action of
• Fixes charge air temperature (air intake temperature) at 70°C and continues operation.
controller
Problem that
appears on • Starting performance of the engine lowers during low temperature.
machine
Related • Signal voltage of charge air temperature sensor can be checked by monitoring function
information (Code No. 18501: Boost temperature sensor voltage).
36 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 37
SEN01639-00 40 Troubleshooting
38 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 39
SEN01639-00 40 Troubleshooting
40 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 41
SEN01639-00 40 Troubleshooting
42 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 43
SEN01639-00 40 Troubleshooting
44 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 45
SEN01639-00 40 Troubleshooting
46 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 47
SEN01639-00 40 Troubleshooting
48 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 49
SEN01639-00 40 Troubleshooting
50 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 51
SEN01639-00 40 Troubleshooting
52 PC1250-8
40 Troubleshooting SEN01639-00
Defective supply pump a Prepare with starting switch OFF, then carry out troubleshooting without
PCV2 turning starting switch ON.
1
(Internal disconnec- PCV2 (male) Resistance
tion) Between (1) – (2) 2.3 – 5.3 z
a Prepare with starting switch OFF, then carry out troubleshooting without
Disconnection in wir- turning starting switch ON.
ing harness
Wiring harness between ENG (female) (9) –
2 (Disconnection in wir- Resistance Max. 1 z
PCV2 (female) (1)
ing or defective con-
tact in connector) Wiring harness between ENG (female) (10) –
Possible Resistance Max. 1 z
PCV2 (female) (2)
causes and
standard value a Prepare with starting switch OFF, then carry out troubleshooting without
in normal state Ground fault in wiring turning starting switch ON.
harness Wiring harness between ENG (female) (9) –
3 Resistance Min. 1 Mz
(Short circuit with GND PCV2 (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (10) –
Resistance Min. 1 Mz
PCV2 (female) (2) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective engine con- ENG (female) Resistance
4
troller Between (9) – (10) 2.3 – 5.3 z
Between (9), (10) –
Min. 1 Mz
chassis ground
PC1250-8 53
SEN01639-00 40 Troubleshooting
54 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 55
SEN01639-00 40 Troubleshooting
56 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 57
SEN01639-00 40 Troubleshooting
58 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 59
SEN01639-00 40 Troubleshooting
60 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 61
SEN01639-00 40 Troubleshooting
62 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 63
SEN01639-00 40 Troubleshooting
64 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 65
SEN01639-00 40 Troubleshooting
66 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 67
SEN01639-00 40 Troubleshooting
68 PC1250-8
40 Troubleshooting SEN01639-00
PC1250-8 69
SEN01640-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 2
Troubleshooting by failure code (Display of code), Part 2 .............................................................................. 3
Failure code [CA352] Sens Supply 1 Volt Low Error............................................................................ 3
Failure code [CA386] Sensor Sup. 1 Volt. High Error .......................................................................... 4
Failure code [CA441] Battery Voltage Low Error ................................................................................. 6
Failure code [CA442] Battery Voltage High Error................................................................................. 6
Failure code [CA449] Rail Press Very High Error ................................................................................ 7
Failure code [CA451] Rail Press Sensor High Error ............................................................................ 8
Failure code [CA452] Rail Press Sensor Low Error ........................................................................... 10
Failure code [CA553] Rail Press High Error....................................................................................... 10
Failure code [CA554] Rail Press Sensor In Range Error ....................................................................11
Failure code [CA559] Rail Press Low Error ....................................................................................... 12
Failure code [CA689] Eng Ne Speed Sensor Error............................................................................ 16
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................................ 18
Failure code [CA757] All Persistent Data Lost Error .......................................................................... 19
PC1250-8 1
SEN01640-00 40 Troubleshooting
2 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 3
SEN01640-00 40 Troubleshooting
a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring Wiring harness between ENG (female) (33) –
harness Resistance Max. 1 z
PAMB.SBP (female) (1)
3 (Disconnection in wir-
Possible ing or defective contact Wiring harness between ENG (female) (16) – NE
Resistance Max. 1 z
causes and in connector) (female) (1)
standard value Wiring harness between ENG (female) (38) –
Resistance Max. 1 z
in normal state each sensor (female)
a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Ground fault in wiring Wiring harness between ENG (female) (33) –
Resistance Min. 1 Mz
harness PAMB.SBP (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (16) – NE
circuit) Resistance Max. 1 z
(female) (1) and chassis ground
Wiring harness between ENG (female) (38) –
Resistance Min. 1 Mz
each sensor (female) and chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Short circuit in wiring Wiring harness between ENG (female) (33) –
harness PAMB.SBP (female) (1) and wiring harness
5 Resistance Min. 1 Mz
(With another wiring between ENG (female) (38) – each sensor
harness) (female)
Wiring harness between ENG (female) (16) – NE
Resistance Min. 1 Mz
(female) (1)
4 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 5
SEN01640-00 40 Troubleshooting
6 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 7
SEN01640-00 40 Troubleshooting
8 PC1250-8
40 Troubleshooting SEN01640-00
Possible a Prepare with starting switch OFF, then turn starting switch ON or start
causes and engine and carry out troubleshooting.
standard value Defective engine ENG Voltage
6
in normal state controller
Between (37) – (47) 4.75 – 5.25 V
Between (25) – (47) 0.25 – 4.6 V
PC1250-8 9
SEN01640-00 40 Troubleshooting
10 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 11
SEN01640-00 40 Troubleshooting
12 PC1250-8
40 Troubleshooting SEN01640-00
Note 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Defective operation of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Follow the procedure below to check, clean, and replace filter and strainer.
1) Gauze filter: Disassemble this filter for checking. If clogged, clean it
2) Gauze filter upstream strainer: Clean upstream strainer if gauze filter is clogged
3) Fuel filter: If failure is not remedied after steps 1) and 2) above were executed, replace fuel filter
PC1250-8 13
SEN01640-00 40 Troubleshooting
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error/failure code / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle rpm 825 ± 25
*1 Engine Speed High idle rpm 1,980 ± 50
Rating or equivalent rpm 1,800
Low idle % 0
*2 Throttle speed
High idle % 100
*3 Injection rate command Rating or equivalent mm3 — — —
4
Common rail pressure
*4 Rating or equivalent MPa
command
*5 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
*6 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
*7 Boost Pressure Rating or equivalent kPa — — —
*8 Engine coolant temperature Low idle °C — — —
*9 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Func- Standard value Measured
Cut-out cylinder Check conditions Unit Good Bad
tion (Reference value) value
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder 3 Low idle rpm — — —
*10
Cylinder 4 Low idle rpm — — —
Cylinder 5 Low idle rpm — — —
Cylinder 6 Low idle rpm — — —
14 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 15
SEN01640-00 40 Troubleshooting
16 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 17
SEN01640-00 40 Troubleshooting
Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
E11 CA731 (Engine controller system)
Contents of
• There is phase error in engine Bkup speed sensor circuit.
trouble
Action of
• Controls the engine with signal from engine Ne speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Ne speed sensor is also defective)
machine
Related
information
18 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 19
SEN01640-00 40 Troubleshooting
20 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 21
SEN01640-00 40 Troubleshooting
Possible If engine oil pressure is not normal, carry out troubleshooting for mechani-
causes and cal system. (S-12 Oil pressure lowers.)
standard value Defective EGR valve Oil pump or relief valve for EGR valve circuit may be defective. Check it
3
in normal state oil pump directly.
Defective EGR valve
Oil pressure supply piping for EGR valve circuit may be defective. Check it
4 oil pressure supply pip-
directly.
ing
Defective EGR valve
Oil pressure return piping for EGR valve circuit may be defective. Check it
5 oil pressure return pip-
directly.
ing
6 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
Defective engine con- If causes 1 – 6 are not detected, engine controller may be defective.
7
troller (Since trouble is in system, troubleshooting cannot be carried out.)
22 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 23
SEN01640-00 40 Troubleshooting
24 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 25
SEN01640-00 40 Troubleshooting
26 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 27
SEN01640-00 40 Troubleshooting
28 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 29
SEN01640-00 40 Troubleshooting
30 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 31
SEN01640-00 40 Troubleshooting
32 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 33
SEN01640-00 40 Troubleshooting
Action code Failure code Throt Sens Sup Volt High Error
Trouble
E14 CA2185 (Engine controller system)
Contents of
• High voltage error occurred in throttle sensor power supply (5V) circuit.
trouble
• If the error is detected while the starting switch is ON, the controller indicates 100%.
Action of
• If the error is detected while the engine is operating, the controller keeps the signal of the fuel con-
controller
trol dial which has been output just before the error detection.
Problem that
appears on • Engine speed can not be controlled.
machine
Related • Signal voltage of the fuel control dial can be checked by monitoring function
information (Code No. 03000: voltage of fuel control dial).
34 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 35
SEN01640-00 40 Troubleshooting
Action code Failure code Throt Sens Sup Volt Low Error
Trouble
E14 CA2186 (Engine controller system)
Contents of
• Low voltage error occurred in throttle sensor power supply (5V) circuit.
trouble
• If the error is detected while the starting switch is ON, the controller indicates 100%.
Action of
• If the error is detected while the engine is operating, the controller keeps the signal of the fuel con-
controller
trol dial which has been output just before the error detection.
Problem that
appears on • Engine speed can not be controlled.
machine
Related • Signal voltage of the fuel control dial can be checked by monitoring function
information (Code No. 03000: voltage of fuel control dial).
36 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 37
SEN01640-00 40 Troubleshooting
Action code Failure code EGR Valve Pos Sens High Error
Trouble
E11 CA2271 (Engine controller system)
Contents of
• High error occurred in EGR valve lift sensor circuit.
trouble
Action of • Limits output and continues operation.
controller • Close EGR and bypass valves.
Problem that
appears on • Engine output lowers.
machine
Related • Signal voltage of EGR valve position sensor can be checked by monitoring function
information (Code No. 18101: Voltage of EGR valve position sensor).
38 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 39
SEN01640-00 40 Troubleshooting
Action code Failure code EGR Valve Pos Sens Low Error
Trouble
E11 CA2272 (Engine controller system)
Contents of
• Low error occurred in EGR valve lift sensor circuit.
trouble
Action of • Limits output and continues operation.
controller • Close EGR and bypass valves.
Problem that
appears on • Engine output lowers.
machine
Related • Signal voltage of EGR valve position sensor can be checked by monitoring function
information (Code No. 18101: Voltage of EGR valve position sensor).
40 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 41
SEN01640-00 40 Troubleshooting
Action code Failure code EGR Valve Sol Current High Error
Trouble
E11 CA2351 (Engine controller system)
Contents of
• High current error occurred in drive circuit of EGR valve solenoid.
trouble
Action of • Limits output and continues operation.
controller • Closes EGR and bypass valves.
Problem that
appears on • Engine output lowers.
machine
Related
information
42 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 43
SEN01640-00 40 Troubleshooting
Action code Failure code EGR Valve Sol Current Low Error
Trouble
E11 CA2352 (Engine controller system)
Contents of
• Low current error occurred in drive circuit of EGR valve solenoid.
trouble
Action of • Limits output and continues operation.
controller • Close EGR and bypass valves.
Problem that
appears on • Engine output lowers.
machine
Related
information
44 PC1250-8
40 Troubleshooting SEN01640-00
Action code Failure code Grid Htr Relay Volt Low Error
Trouble
E15 CA2555 (Engine controller system)
Contents of
• Voltage low error was detected in grid heater relay circuit.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
information
PC1250-8 45
SEN01640-00 40 Troubleshooting
Action code Failure code Grid Htr Relay Volt High Error
Trouble
E15 CA2556 (Engine controller system)
Contents of
• Open error was detected in intake air heater relay circuit
trouble
Action of
• Stops driving auto-preheater relay R18.
controller
Problem that
• Auto-preheater does not work (Manual preheater works).
appears on
• Engine does not start easily at low temperature.
machine
Related
information
46 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 47
SEN01640-00 40 Troubleshooting
48 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 49
SEN01640-00 40 Troubleshooting
Flash light relay defec- a Turn the engine starting switch OFF for the preparations, and hold it in
tive the OFF position during the troubleshooting.
1
(Internal short-circuit- R21 (male) Resistance value
ing) Between (1) and (2) 250 – 350 z
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
Possible the OFF position during the troubleshooting.
ing harness
causes and 2
(Contact with 24V cir- Between wiring harness between C03 (female) Resistance
standard value Max. 1 Mz
cuit) (18) and R21 (female) (1) and grounding value
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller C03 Horn switch Voltage
3
defective 20 – 30 V⇔Max. 1 V
Between (18) and ON
(at constant cycle)
grounding
OFF Max. 1 V
50 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 51
SEN01640-00 40 Troubleshooting
52 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 53
SEN01640-00 40 Troubleshooting
Action code Failure code Pump controller solenoid: Source voltage reduction
Trouble
E0E DA22KK (Pump controller system)
Contents of
• Pump controller solenoid valve is below 20 V.
trouble
Action of
• Limits engine speed to upper limit of 1,400 rpm.
controller
• If solenoid source voltage lowers extremely, work equipment, swing system and travel system do
Problem that
not move.
appears on
• Engine speed does not rise above 1,400 rpm.
machine
• Hydraulic fan cannot be reversed.
Related
• If D110KB is displayed, carry out troubleshooting for it first.
information
Disconnection in wiring Wiring harness between J07 (female) (1) – B26 Resistance Max. 1 z
harness Wiring harness between circuit breaker B16 –
Resistance Max. 1 z
2 (Disconnection in wir- B22
ing or defective contact Wiring harness between battery relay terminal M
in connector) Resistance Max. 1 z
– B12
Possible Wiring harness between starting switch terminal
Resistance Max. 1 z
causes and BR – battery relay terminal BR
standard value Wiring harness between C03 (female) (21), (32),
in normal state Resistance Min. 1 Mz
(33) – J05 – ground
a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Wiring harness between C03 (female) (2), (12),
Resistance Min. 1 Mz
Ground fault in wiring (22) – J07 (female) (5), (7), (9)
3 harness (Contact with Wiring harness between J07 (female) (1) – B26 Resistance Min. 1 Mz
GND circuit) Wiring harness between circuit breaker B16 –
Resistance Min. 1 Mz
B22
Wiring harness between battery relay terminal M
Resistance Min. 1 Mz
– B12
a Prepare with starting switch OFF, then turn starting switch ON and carry
Defective pump con- out troubleshooting.
4
troller
Between C03 (2), (12), (22) – (21), (32), (33) Voltage 20 – 30 V
54 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 55
SEN01640-00 40 Troubleshooting
56 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 57
SEN01640-00 40 Troubleshooting
58 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 59
SEN01640-00 40 Troubleshooting
60 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 61
SEN01640-00 40 Troubleshooting
62 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 63
SEN01640-00 40 Troubleshooting
64 PC1250-8
40 Troubleshooting SEN01640-00
PC1250-8 65
SEN01641-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
Troubleshooting by failure code (Display of code), Part 3 .............................................................................. 4
Failure code [DBB0KK] VHMS source voltage Error
(or change of VHMS-LED display from n9 to 01)................................................................................. 4
Failure code [DBB0KQ] VHMS Connector Mismatch
(or change of VHMS-LED display from nf to 11) .................................................................................. 6
Failure code [DBB3KK] Abnormality in VBAT voltage
(or change of VHMS-LED display from n9 to 05)................................................................................. 8
Failure code [DBB5KP] VHMS 5V source sys Error
(or change of VHMS-LED display from n9 to 04)............................................................................... 10
Failure code [DBB6KP] VHMS 24V source sys Error
(or change of VHMS-LED display from n9 to 02)............................................................................... 12
Failure code [DBBQKR] KOM-NET/c error (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
PC1250-8 1
SEN01641-00 40 Troubleshooting
2 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 3
SEN01641-00 40 Troubleshooting
4 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 5
SEN01641-00 40 Troubleshooting
Defective model selec- a Prepare with starting switch OFF, then carry out troubleshooting without
tion connector (Internal turning starting switch ON.
1
disconnection or short Between C09 (female) (8) – (7) Resistance Max. 1 z
circuit) Between C09 (female) (1), (2), (3), (4) – (7), (8) Resistance Min. 1 Mz
Possible a Prepare with starting switch OFF, then carry out troubleshooting without
causes and turning starting switch ON.
standard value Wiring harness between C02 (female) (7) – C09
in normal state (male) (4), between C02 (female) (17) – C09
Ground fault in wiring
(male) (3), between C02 (female) (27) – C09 Resistance Min. 1 Mz
2 harness (Contact with
(male) (2), or between C02 (female) (37) – C09
GND circuit)
(male) (1)
Wiring harness between C02 (female) (7), (17),
(27), (37) – C09 (male) (4), (3), (2), (1) or Resistance Min. 1 Mz
between C09 (male) (7) (8) – ground
6 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 7
SEN01641-00 40 Troubleshooting
8 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 9
SEN01641-00 40 Troubleshooting
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-
LED display from n9 to 04) 1
10 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 11
SEN01641-00 40 Troubleshooting
Failure code [DBB6KP] VHMS 24V source sys Error (or change of
VHMS-LED display from n9 to 02) 1
12 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 13
SEN01641-00 40 Troubleshooting
14 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 15
SEN01641-00 40 Troubleshooting
16 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 17
SEN01641-00 40 Troubleshooting
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-
LED display from n5 to 01) 1
18 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 19
SEN01641-00 40 Troubleshooting
20 PC1250-8
40 Troubleshooting SEN01641-00
Possible a Turn the engine starting switch OFF for the preparations, and hold it in
causes and the ON position or run the engine during the troubleshooting.
standard value VHMS controller VC2A Exhaust temperature Voltage
6
in normal state defective
Between (7) and (12), At 20°C Approx. 0.9 – 1.2 V
(13) At 500°C Approx. 2.6 – 3.5 V
PC1250-8 21
SEN01641-00 40 Troubleshooting
22 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 23
SEN01641-00 40 Troubleshooting
24 PC1250-8
40 Troubleshooting SEN01641-00
Possible a Turn the engine starting switch OFF for the preparations, and hold it in
causes and the ON position or run the engine during the troubleshooting.
standard value VHMS controller VC2A Exhaust temperature Voltage
6
in normal state defective
Between (5) and (12), At 20°C Approx. 0.9 – 1.2 V
(13) At 500°C Approx. 2.6 – 3.5 V
PC1250-8 25
SEN01641-00 40 Troubleshooting
26 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 27
SEN01641-00 40 Troubleshooting
28 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 29
SEN01641-00 40 Troubleshooting
30 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 31
SEN01641-00 40 Troubleshooting
32 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 33
SEN01641-00 40 Troubleshooting
34 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 35
SEN01641-00 40 Troubleshooting
36 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 37
SEN01641-00 40 Troubleshooting
38 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 39
SEN01641-00 40 Troubleshooting
Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of
VHMS-LED display from n5 to 23) 1
40 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 41
SEN01641-00 40 Troubleshooting
Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of
VHMS-LED display from n5 to 24) 1
42 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 43
SEN01641-00 40 Troubleshooting
44 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 45
SEN01641-00 40 Troubleshooting
Swing priority solenoid a Turn the engine starting switch OFF for the preparations, and hold it in
defective the OFF position during the troubleshooting.
1
(Internal disconnec- V01 (male) Resistance value
tion) Between (2) and (1) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness from C03 (female) (38) to J07 to Resistance
2 (Disconnection or Max. 1 z
Possible V01 (female) (2) value
defective contact with
causes and connector) Wiring harness between V01 (female) (1) and Resistance
standard value Max. 1 z
grounding value
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
Hot short circuit in wir- the ON position during the troubleshooting.
ing harness
3
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) (38), J07, and V01 (female) (2) or between D04 Voltage Max. 1 V
(female) (3) and J07 (male) (11) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
Pump controller the OFF position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (38) and grounding 20 – 60 z
46 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 47
SEN01641-00 40 Troubleshooting
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D04 defective the OFF position during the troubleshooting.
2
(Internal short-circuit- D04 (male) Resistance value
Possible ing)
causes and Between (3) and (7) Min. 1 Mz
standard value a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state Grounding fault of wir- the OFF position during the troubleshooting.
ing harness
3
(Contact with ground- Between wiring harness between C03 (female) Resistance
ing circuit) (38), J07, and V01 (female) (2) or between D04 Min. 1 Mz
value
(female) (3) and J07 (male) (11) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it
running during the troubleshooting.
Pump controller Swing priority mode
4 C03 Voltage
defective switch
Between (38) and OFF Max. 1 V
grounding ON + Swing operation 20 – 30 V
48 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 49
SEN01641-00 40 Troubleshooting
Travel speed solenoid a Turn the engine starting switch OFF for the preparations, and hold it in
defective the OFF position during the troubleshooting.
1
(Internal disconnec- V06 (male) Resistance value
tion) Between (2) and (1) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness from C03 (female) (27) to J06 to Resistance
2 (Disconnection or Max. 1 z
Possible V06 (female) (2) value
defective contact with
causes and connector) Wiring harness between V06 (female) (1) and Resistance
standard value Max. 1 z
grounding value
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
Hot short circuit in wir- the ON position during the troubleshooting.
ing harness
3
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) (27), J06, and V06 (female) (2) or between D04 Voltage Max. 1 V
(female) (2) and J06 (male) (19) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
Pump controller the OFF position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (27) and grounding 20 – 60 z
50 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 51
SEN01641-00 40 Troubleshooting
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D04 defective the OFF position during the troubleshooting.
2
Possible (Internal short-circuit- D04 (male) Resistance value
causes and ing) Between (2) and (6) Min. 1 Mz
standard value
a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state Grounding fault of wir- the OFF position during the troubleshooting.
ing harness
3
(Contact with ground- Between wiring harness between C03 (female) Resistance
ing circuit) (27), J06, and V06 (female) (2) or between D04 Min. 1 Mz
value
(female) (2) and J06 (male) (19) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it
running during the troubleshooting.
Pump controller C03 Travel lever Voltage
4
defective
Between (27) and Lo Max. 1 V
grounding Hi + Travel operation 20 – 30 V
52 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 53
SEN01641-00 40 Troubleshooting
Swing holding brake a Turn the engine starting switch OFF for the preparations, and hold it in
solenoid defective the OFF position during the troubleshooting.
1
(Internal disconnec- V04 (male) Resistance value
tion) Between (2) and (1) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Swing lock switch the OFF position during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Max. 1 z
Between (3) and (4)
LOCK Min. 1 Mz
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D01 defective the OFF position during the troubleshooting.
Possible 3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
causes and tion) Between (7) and (3) Diode mode Continued
standard value
in normal state a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Wiring harness between C03 (female) (37) and Resistance
Disconnection of Max. 1 z
D01 (female) (7) value
wiring harness
Wiring harness from D01 (female) (3) to J02 to Resistance
4 (Disconnection or Max. 1 z
X05 (male) (3) value
defective contact with
connector) Wiring harness from X05 (male) (4) to J06 to V04 Resistance
Max. 1 z
(female) (2) value
Wiring harness between V04 (female) (1) and Resistance
Max. 1 z
grounding value
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
5
(Contact with 24V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(37) and D01 (female) (7) and grounding
54 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 55
SEN01641-00 40 Troubleshooting
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D03 defective the OFF position during the troubleshooting.
2
(Internal short-circuit- D03 (male) Resistance value
Possible ing)
causes and Between (4) and (8) Min. 1 Mz
standard value a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state Grounding fault of wir- the OFF position during the troubleshooting.
ing harness Between wiring harness between C03 (female)
3
(Contact with ground- (37), D01, J02, X05, J06, and V04 (female) (2) or Resistance
ing circuit) Min. 1 Mz
between D03 (female) (4) and J06 (male) (13) value
and grounding
a Turn the engine starting switch OFF for the preparations, and hold it
running during the troubleshooting.
Pump controller C03 Swing control lever Voltage
4
defective
Between (37) and NEUTRAL Max. 1 V
grounding Swing 20 – 30 V
56 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 57
SEN01641-00 40 Troubleshooting
CO cancel a Turn the engine starting switch OFF for the preparations, and hold it in
solenoid defective the OFF position during the troubleshooting.
1
(Internal disconnec- V07 (male) Resistance value
tion) Between (2) and (1) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness from C03 (female) (28) to J06 to Resistance
2 (Disconnection or Max. 1 z
Possible V07 (female) (2) value
defective contact with
causes and connector) Wiring harness between V07 (female) (1) and Resistance
standard value Max. 1 z
grounding value
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
Hot short circuit in wir- the ON position during the troubleshooting.
ing harness
3
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) (28), J06, and V07 (female) (2) or between D03 Voltage Max. 1 V
(female) (1) and J06 (male) (3) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
Pump controller the OFF position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (28) and grounding 20 – 60 z
58 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 59
SEN01641-00 40 Troubleshooting
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D03 defective the OFF position during the troubleshooting.
2
Possible (Internal short-circuit- D03 (male) Resistance value
causes and ing) Between (1) and (5) Min. 1 Mz
standard value
a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state Grounding fault of wir- the OFF position during the troubleshooting.
ing harness
3
(Contact with ground- Between wiring harness between C03 (female) Resistance
ing circuit) (28), J06, and V07 (female) (2) or between D03 Min. 1 Mz
value
(female) (1) and J06 (male) (3) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it
running during the troubleshooting.
Pump controller C03 Heavy lift switch Voltage
4
defective
Between (28) and OFF Max. 1 V
grounding ON 20 – 30 V
60 PC1250-8
40 Troubleshooting SEN01641-00
PC1250-8 61
SEN01642-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 4
Troubleshooting by failure code (Display of code), Part 4 .............................................................................. 4
Failure code [DW7BKA] Fan Reverse Sol. Disc. ................................................................................. 4
Failure code [DW7BKB] Fan Reverse Sol. S/C ................................................................................... 6
Failure code [DW91KA] Travel Junction Sol. Disc. .............................................................................. 8
Failure code [DW91KB] Travel Junction Sol. S/C .............................................................................. 10
Failure code [DWK0KA] 2-stage Relief Sol. Disc. .............................................................................. 12
Failure code [DWK0KB] 2-stage Relief Sol. S/C ................................................................................ 14
Failure code [DX16KA] Fan Pump EPC Sol. Disc. ............................................................................ 16
Failure code [DX16KB] Fan Pump EPC Sol. S/C .............................................................................. 18
Failure code [DXA0KA] TVC Sol. Disc............................................................................................... 20
Failure code [DXA0KB] TVC Sol. S/C................................................................................................ 22
Failure code [DY20KA] Wiper Working Abnormality .......................................................................... 24
Failure code [DY20MA] Wiper Parking Abnormality .......................................................................... 26
Failure code [DY2CKB] Washer Drive S/C ........................................................................................ 30
PC1250-8 1
SEN01642-00 40 Troubleshooting
2 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 3
SEN01642-00 40 Troubleshooting
4 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 5
SEN01642-00 40 Troubleshooting
6 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 7
SEN01642-00 40 Troubleshooting
Straight travel a Turn the engine starting switch OFF for the preparations, and hold it in
solenoid defective the OFF position during the troubleshooting.
1
(Internal disconnec- V03 (male) Resistance value
tion) Between (2) and (1) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness from C03 (female) (7) to J06 to Resistance
2 (Disconnection or Max. 1 z
Possible V03 (female) (2) value
defective contact with
causes and connector) Wiring harness between V03 (female) (1) and Resistance
standard value Max. 1 z
grounding value
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
Hot short circuit in wir- the ON position during the troubleshooting.
ing harness
3 Between wiring harness between C03 (female)
(Contact with 24 V cir-
cuit) (7), J06, and V03 (female) (2) or between D03 Voltage Max. 1 V
(female) (3) and J06 (male) (9) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
Pump controller the OFF position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (7) and grounding 20 – 60 z
8 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 9
SEN01642-00 40 Troubleshooting
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D03 defective the OFF position during the troubleshooting.
2
(Internal short-circuit- D03 (male) Resistance value
Possible ing) Between (3) and (7) Min. 1 Mz
causes and
a Turn the engine starting switch OFF for the preparations, and hold it in
standard value Grounding fault of wir- the OFF position during the troubleshooting.
in normal state ing harness
3
(Contact with ground- Between wiring harness between C03 (female) Resistance
ing circuit) (7), J06, and V03 (female) (2) or between D03 Min. 1 Mz
value
(female) (3) and J06 (male) (9) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it
running during the troubleshooting.
C03 Travel control lever Voltage
Pump controller
4 NEUTRAL Max. 1 V
defective
Between (7) and Both tracks operation +
grounding Work equipment opera- 20 – 30 V
tion
10 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 11
SEN01642-00 40 Troubleshooting
2-stage relief solenoid a Turn the engine starting switch OFF for the preparations, and hold it in
defective the OFF position during the troubleshooting.
1
(Internal disconnec- V02 (male) Resistance value
tion) Between (2) and (1) 20 – 60 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness from C03 (female) (17) to J06 to Resistance
2 (Disconnection or Max. 1 z
Possible V02 (female) (2) value
defective contact with
causes and connector) Wiring harness between V02 (female) (1) and Resistance
standard value Max. 1 z
grounding value
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
Hot short circuit in wir- the ON position during the troubleshooting.
ing harness
3
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) (17), J06, and V02 (female) (2) or between D03 Voltage Max. 1 V
(female) (2) and J06 (male) (6) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
Pump controller the OFF position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (17) and grounding 20 – 60 z
12 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 13
SEN01642-00 40 Troubleshooting
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
D03 defective the OFF position during the troubleshooting.
2
(Internal short-circuit- D03 (male) Resistance value
Possible ing)
causes and Between (2) and (6) Min. 1 Mz
standard value a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state Grounding fault of wir- the OFF position during the troubleshooting.
ing harness
3
(Contact with ground- Between wiring harness between C03 (female) Resistance
ing circuit) (17), J06, and V02 (female) (2) or between D03 Min. 1 Mz
value
(female) (2) and J06 (male) (6) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller C03 Working mode Voltage
4
defective Heavy lift mode Max. 1 V
Between (17) and
grounding Boom is raised singly in
20 – 30 V
heavy lift mode
14 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 15
SEN01642-00 40 Troubleshooting
16 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 17
SEN01642-00 40 Troubleshooting
18 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 19
SEN01642-00 40 Troubleshooting
20 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 21
SEN01642-00 40 Troubleshooting
22 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 23
SEN01642-00 40 Troubleshooting
24 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 25
SEN01642-00 40 Troubleshooting
26 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 27
SEN01642-00 40 Troubleshooting
Single-wiper specification
Action code Failure code Wiper Parking Abnormality
Trouble
— DY20MA (Machine monitor system)
Contents of
• P signal in the retraction range is not inputted, when the wiper is retracted.
trouble
Response
• Power supply to the windshield wiper motor is switched OFF, when the wiper is
from Monitor
retracted.
Panel
Problem that
appears on • The windshield wiper cannot be retracted completely.
machine
Related • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction opera-
information tion range is inputted or not. (Code No. 04502: Monitor Input 3)
28 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 29
SEN01642-00 40 Troubleshooting
Window washer drive a Turn the engine starting switch OFF for the preparations, and hold it in
motor defective the OFF position for the troubleshooting.
1
(Internal short-circuit- M95 (male), M28 (male) Resistance value
ing) Between (1) and (2) 5 – 20 z
a Turn the engine starting switch OFF for the preparations, and hold it in
Possible Short-circuiting of wir- the ON position for the troubleshooting.
causes and ing harness Between wiring harness between P01 (female)
2
standard value (Contact with 24 V (3) and M28 (female) (2), P01 (female) (3) and
in normal state circuit) Voltage Max. 1 V
M96 (female) (2), P01 (female) (3) to D05
(female) (7) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position for the troubleshooting.
Machine monitor P01 Window washer switch Voltage
3
defective
Between (3) and OFF 20 – 30 V
grounding ON Max. 1 V
30 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 31
SEN01642-00 40 Troubleshooting
32 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 33
SEN01642-00 40 Troubleshooting
Single-wiper specification
Action code Failure code Wiper Drive (For) S/C
Trouble
— DY2DKB (Machine monitor system)
Contents of • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is pro-
trouble vided.
Response
from • Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Problem that
appears on • The windshield wiper stops moving.
machine
34 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 35
SEN01642-00 40 Troubleshooting
36 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 37
SEN01642-00 40 Troubleshooting
38 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 39
SEN01642-00 40 Troubleshooting
40 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 41
SEN01642-00 40 Troubleshooting
42 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 43
SEN01642-00 40 Troubleshooting
44 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 45
SEN01642-00 40 Troubleshooting
46 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 47
SEN01642-00 40 Troubleshooting
48 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 49
SEN01642-00 40 Troubleshooting
50 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 51
SEN01642-00 40 Troubleshooting
Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of
VHMS-LED display from n5 to 11) 1
52 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 53
SEN01642-00 40 Troubleshooting
Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMS-
LED display from n5 to 21) 1
54 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 55
SEN01642-00 40 Troubleshooting
Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of
VHMS-LED display from n5 to 12) 1
56 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 57
SEN01642-00 40 Troubleshooting
Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMS-
LED display from n5 to 22) 1
58 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 59
SEN01642-00 40 Troubleshooting
Failure code [J100L6] Abnormal Cnt. gear pump press (or change of
VHMS-LED display from n5 to 71) 1
Control pump pres- If failure code [J100KA] is displayed, perform troubleshooting for it first.
Possible 2 sure sensor system If failure code [J100KB] is displayed, perform troubleshooting for it first.
causes and defective If failure code [DBB6KP] is displayed, perform troubleshooting for it first.
standard value
in normal state a Turn the engine starting switch OFF for the preparations, and run the
engine during the troubleshooting.
VC2A Control pump pressure Voltage
VHMS controller
3 2.84 MPa
defective Approx. 3.32 V
Between (6) and (12), {29 kg/cm2}
(13) 3.73 MPa
Approx. 4.04 V
{38 kg/cm2}
60 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 61
SEN01642-00 40 Troubleshooting
Failure code [j100L6] Abnormal Fan gear pump press (or change of
VHMS-LED display from n5 to 81) 1
Radiator fan pump If failure code [j100KA] is displayed, perform troubleshooting for it first.
Possible 2 pressure sensor sys- If failure code [j100KB] is displayed, perform troubleshooting for it first.
causes and tem defective If failure code [DBB5KP] is displayed, perform troubleshooting for it first.
standard value
in normal state a Turn the engine starting switch OFF for the preparations, and run the
engine during the troubleshooting.
VC2A Fan pump pressure Voltage
VHMS controller
3 4.91 MPa
defective Approx. 0.89 V
Between (15) and (12), {50 kg/cm2}
(13) 22.6 MPa
Approx. 2.31 V
{230 kg/cm2}
62 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 63
SEN01642-00 40 Troubleshooting
Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change
of VHMS-LED display from n5 to 25) 1
64 PC1250-8
40 Troubleshooting SEN01642-00
PC1250-8 65
SEN01643-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Troubleshooting of electrical system (E-mode)............................................................................................... 3
Before carrying out troubleshooting of electrical system...................................................................... 3
Information contained in troubleshooting table..................................................................................... 5
E-1 Engine does not start (Engine does not rotate) ............................................................................. 6
E-2 Auto-decelerator does not work................................................................................................... 10
E-3 Auto engine warm-up device does not work................................................................................ 12
E-4 Preheater does not work ............................................................................................................. 14
E-5 All work equipment, swing and travel do not move ..................................................................... 16
E-6 Machine push-up circuit does not work ....................................................................................... 18
E-7 Boom shockless circuit cannot be reset ...................................................................................... 20
E-8 No display in machine monitor at all............................................................................................ 22
E-9 Part of display on machine monitor is missing ............................................................................ 24
E-10 Machine monitor displays contents irrelevant to the model ....................................................... 24
E-11 Fuel level monitor red lamp lights up while engine is running.................................................... 25
PC1250-8 1
SEN01643-00 40 Troubleshooting
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 ........................................................ 30
E-16 Windshield wiper does not work ................................................................................................ 32
E-17 “Boom RAISE” is not correctly displayed in monitor function .................................................... 34
E-18 “Boom LOWER” is not correctly displayed in monitor function .................................................. 35
E-19 “Arm DIGGING” is not correctly displayed in monitor function .................................................. 36
E-20 “Arm DUMPING” is not correctly displayed in monitor function ................................................. 37
E-21 “Bucket CURL” is not correctly displayed in monitor function.................................................... 38
E-22 “Bucket DUMPING” is not correctly displayed in monitor function............................................. 39
E-23 “SWING” is not correctly displayed in monitor function ............................................................. 40
E-24 “TRAVEL” is not correctly displayed in monitor function ............................................................ 42
E-25 Air conditioner does not work .................................................................................................... 44
E-26 Travel alarm does not sound ..................................................................................................... 46
E-27 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up...... 47
E-28 Step light does not light up or go off .......................................................................................... 51
2 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 3
SEN01643-00 40 Troubleshooting
Type of power
Fuse No. Fuse capacity Destination of power
supply
Machine push-up solenoid
1 10 A
Boom shockless solenoid
EPC solenoid (for emergency pump drive)
2 10 A
Swing holding brake solenoid (for swing brake release)
Switch power supply PPC lock solenoid
3 10 A
(Circuit breaker 1) Starting motor cut relay
Cigarette lighter
4 20 A
Windshield washer motor
Horn
5 10 A
Flash light
6 10 A Self-greasing equipment
7 10 A Rotary lamp
Switch power supply 8 10 A (Spare)
(Circuit breaker 1) 9 10A Radio
Intake air heater
10 20 A
Buzzer
11 25 A Air conditioner unit
12 20 A VHMS controller
Power supply (2) (if equipped)
Switch power supply 13 10 A Travel alarm
(Circuit breaker 1) 12V power supply
14 10 A Power supply (1) (if equipped)
5A
15 Starting switch ACC circuit (Engine controller)
(ACC circuit)
16 10 A Radio backup
Constant power 17 10 A Network bus
supply 18 10 A VHMS controller (Backup)
(Circuit breaker 9) 19 10 A Room lamp
20 10 A Step light
4 PC1250-8
40 Troubleshooting SEN01643-00
a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure
Phenomenon occurring on machine
information
Related
Information on the failure occurred as well as the troubleshooting
information
This is part of the electrical circuit diagram which shows the portion
where the failure occurred.
• Connector No.: Indicates (Type – numbers of a pin) (color)
• Arrow : Roughly indicates the location in the machine where it is
installed.
PC1250-8 5
SEN01643-00 40 Troubleshooting
Failure
• The engine does not start (the engine does not rotate).
information
Related
• The following two engine start locking mechanisms are provided in the engine starting circuit.
information
6 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 7
SEN01643-00 40 Troubleshooting
8 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 9
SEN01643-00 40 Troubleshooting
Failure
• The auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level,
Related
the auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.
10 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 11
SEN01643-00 40 Troubleshooting
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C,
and raise the engine rotation up to 1,200 rpm.
Related
• The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for
information
more than 3 seconds, when the engine starting switch is in the ON position or after the engine is
started.
12 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 13
SEN01643-00 40 Troubleshooting
Failure • Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does
information (1) not light up.
Related • Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.
information (Code No. 04500: Monitor input 1)
Failure • Even if the preheater switch is turned to the PREHEAT position, the preheater does not become
information (2) warm.
• In low coolant temperature (lower than 30°C), the pump controller drives the heater relay for 100
Related
seconds after the engine is started and automatically warms up the engine.
information
If failure code [CA2556] is displayed, perform troubleshooting for it first.
a Turn the engine starting switch OFF for the preparations, and hold it in
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness from H15 (female) (3) to J02 to Resistance
4 (Disconnection or Max. 1 z
heater relay terminal (S) value
defective contact with
connector) Wiring harness between battery relay M terminal Resistance
Max. 1 z
and heater relay terminal B value
14 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 15
SEN01643-00 40 Troubleshooting
Failure
• All the work equipment, swing and travel do not move.
information
Related
—
information
Assembled-type diode a Turn the engine starting switch OFF for the preparations, and hold it in
Possible D01 fault the OFF position during the troubleshooting.
4
causes and (Internal short-circuit- D01 (male) Resistance value
standard value ing) Between (4) and (8) Min. 1 Mz
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Disconnection of wiring Wiring harness between FB1-3 outlet and S14 Resistance
harness Max. 1 z
(male) (1) value
5 (Disconnection or
defective contact with Wiring harness from S14 (male) (2) to J02 to V08 Resistance
Max. 1 z
connector) (female) (2) value
Wiring harness between V08 (female) (1) and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Grounding fault of wir-
Between wiring harness between FB1-3 outlet Resistance
ing harness Min. 1 Mz
and S14 (male) (1) and grounding value
6 (Contact with ground-
ing (GND) Wiring harness from S14 (male) (2) to J02 to V02
circuit) (female) (2), or between wiring harness between Resistance
Min. 1 Mz
D01 (female) (4) and J02 (male) (18) and value
grounding
16 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 17
SEN01643-00 40 Troubleshooting
Failure
• Machine push-up circuit does not work
information
Related
—
information
Collected diode D04 a Turn the engine starting switch OFF for the preparations, and hold it in
Possible the OFF position during the troubleshooting.
defective
causes and 4
(Internal short-circuit- D04 (male) Resistance value
standard value
ing) Between (1) and (5) Min. 1 Mz
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Wiring harness discon- Wiring harness between FB1-2 outlet and M38 Resistance
nected Max. 1 z
(male) (1) value
5 (Disconnection or
defective contact of Wiring harness between M38 (male) (2), J06, Resistance
Max. 1 z
connector) and V05 (female) (2) value
Wiring harness between V05 (female) (2) and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in
Grounding fault of wir- the OFF position during the troubleshooting.
ing harness Between wiring harness between FB1-2 outlet Resistance
Max. 1 z
5 (Contact with ground- and M38 (male) (1) and grounding value
ing (GND) Between wiring harness between M38 (male) (2),
circuit) Resistance
J06, V05 (female) (2), or D04 (female) (1), J06 Max. 1 z
value
(male) (16) and grounding
18 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 19
SEN01643-00 40 Troubleshooting
Failure
• Boom shockless circuit cannot be reset
information
Related
—
information
Collected diode D05 a Turn the engine starting switch OFF for the preparations, and hold it in
Possible defective the OFF position during the troubleshooting.
4
causes and (Internal short-circuit- D05 (male) Resistance value
standard value ing) Between (1) and (5) Min. 1 Mz
in normal state
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Wiring harness discon- Wiring harness between FB1-2 outlet and M39 Resistance
nected Max. 1 z
(male) (2) value
5 (Disconnection or
defective contact of Wiring harness between M39 (male) (3), J01, Resistance
Max. 1 z
connector) J11, and V09, V10 (female) (2) value
Wiring harness between V09, V10 (female) (1) Resistance
Max. 1 z
and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in
Grounding fault of wir- the OFF position during the troubleshooting.
ing harness Between wiring harness between FB1-2 outlet Resistance
Max. 1 z
5 (Contact with ground- and M39 (male) (2) and grounding value
ing (GND) Between wiring harness between M39 (male) (3),
circuit) Resistance
J01, J11, V09, V10 (female) (2), or D05 (female) Max. 1 z
value
(1), and J01 (male) (19) and grounding
20 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 21
SEN01643-00 40 Troubleshooting
Failure • When the engine starting switch is turned ON, there appears no display at all in the machine moni-
information tor.
Related
—
information
22 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 23
SEN01643-00 40 Troubleshooting
Failure
• Part of the display in the machine monitor is missing.
information
Related
—
information
Failure • The machine monitor displays contents that have nothing to do with the model on which it is
information installed.
Related
—
information
24 PC1250-8
40 Troubleshooting SEN01643-00
E-11 Fuel level monitor red lamp lights up while engine is running 1
Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
• If the fuel gauge shows in a red range on the machine monitor, the fuel level monitor lamp lights up
Related red.
information • (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No. 04200: Fuel level sensor)
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Pump controller defec- P02 (female) Fuel level Resistance value
4
tive
Between (2) and FULL (Upper limit) Approx. 12 z
grounding EMPTY (Lower limit) 85 – 110 z
PC1250-8 25
SEN01643-00 40 Troubleshooting
Failure • Hydraulic oil temperature rises normally, but the display does not exceed the white range (C).
information • Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Related • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 04401: Hydraulic oil temperature)
Short-circuiting of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between P02 (female)
cuit) Voltage Max. 1 V
(12) and P10 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Engine coolant
Machine monitor P02 Resistance value
5 temperature
defective
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100 °C
Min. 1 Mz
grounding
26 PC1250-8
40 Troubleshooting SEN01643-00
Failure • Though fuel was refilled, the display does not exceed the red range (E).
information • Though the remaining fuel level is low, the display does not drop below the green range (F).
Related • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 04200: Fuel sensor voltage)
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between P02 (female)
cuit) Voltage Max. 1 V
(2) and P06 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Machine monitor P02 Fuel level Resistance value
5
defective
Between (2) and FULL (Upper limit) Approx. 12 z
grounding EMPTY (Lower limit) 85 – 110 z
PC1250-8 27
SEN01643-00 40 Troubleshooting
Failure • Though the swing lock switch was turned ON, the swing lock monitor does not light up.
information • Though the swing lock switch was turned OFF, the swing lock monitor lights up.
Related • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
information (Code No. 04502: Monitor input 3)
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness from P02 (female) (17)
cuit) Voltage Max. 1 V
to J02 to X05 (male) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Machine monitor P02 Swing lock switch Voltage
5
defective
Between (17) and OFF 20 – 30 V
grounding ON Max. 1 V
28 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 29
SEN01643-00 40 Troubleshooting
Failure
• When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Related
—
information
Failure
• When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
information (2)
Related
a If the auto-decelerator itself does not work, either, carry out No. E-2 Troubleshooting.
information
Failure
• When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Related a If the travel speed does not actually change, carry out failure code [DW43KA], [DW43KB] Trouble-
information shooting.
Failure
• When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Related
a If the windshield wiper itself does not work, either, carry out No. E-16 Troubleshooting.
information
• When operating the select switch, the adjustment display does not appear.
Failure
• When operating the LCD monitor adjusting switch, the adjustment display does not appear.
information (5)
• When operating the maintenance switch, the item display does not appear.
Related
—
information
30 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 31
SEN01643-00 40 Troubleshooting
Failure
• The windshield wiper does not work.
information
Related
information
32 PC1250-8
40 Troubleshooting SEN01643-00
Electrical diagram related to wiper motor (Cab with front window fixed) (When 2 wipers are set)
PC1250-8 33
SEN01643-00 40 Troubleshooting
Failure
• “Boom RAISE” is not correctly displayed in the monitor function on the machine monitor.
information
Related
—
information
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(10) and S02 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller defec- C03 Boom control lever Voltage
5
tive
Between (10) and NEUTRAL 20 – 30 V
grounding RAISE Max. 1 V
34 PC1250-8
40 Troubleshooting SEN01643-00
Failure
• “Boom LOWER” is not correctly displayed in the monitor function on the machine monitor.
information
Related
—
information
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(20) and S04 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller defec- C03 Boom control lever Voltage
5
tive
Between (20) and NEUTRAL 20 – 30 V
grounding LOWER Max. 1 V
PC1250-8 35
SEN01643-00 40 Troubleshooting
Failure • “Arm DIGGING” is not correctly displayed in the monitor function (special function) on the machine
information monitor.
Related
—
information
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(30) and S05 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller defec- C03 Arm control lever Voltage
5
tive
Between (30) and NEUTRAL 20 – 30 V
grounding DIGGING Max. 1 V
36 PC1250-8
40 Troubleshooting SEN01643-00
Failure • “Arm DUMPING” is not correctly displayed in the monitor function (special function) on the machine
information monitor.
Related
—
information
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(40) and S03 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller defec- C03 Arm control lever Voltage
5
tive
Between (40) and NEUTRAL 20 – 30 V
grounding DUMPING Max. 1 V
PC1250-8 37
SEN01643-00 40 Troubleshooting
Failure • “Bucket CURL” is not correctly displayed in the monitor function (special function) on the machine
information monitor.
Related
—
information
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(9) and S06 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller defec- C03 Bucket control lever Voltage
5
tive
Between (9) and NEUTRAL 20 – 30 V
grounding CURL Max. 1 V
38 PC1250-8
40 Troubleshooting SEN01643-00
Failure • “Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the
information machine monitor.
Related
—
information
Hot short circuit in wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the ON position during the troubleshooting.
4
(Contact with 24 V cir- Between wiring harness between C03 (female)
cuit) Voltage Max. 1 V
(19) and S07 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting.
Pump controller defec- C03 Bucket control lever Voltage
5
tive
Between (19) and NEUTRAL 20 – 30 V
grounding DUMPING Max. 1 V
PC1250-8 39
SEN01643-00 40 Troubleshooting
Failure • “SWING” is not correctly displayed in the monitor function (special function) on the machine moni-
information tor.
Related
—
information
40 PC1250-8
40 Troubleshooting SEN01643-00
Electrical diagram related to right and left swing PPC hydraulic switches
PC1250-8 41
SEN01643-00 40 Troubleshooting
Failure • “TRAVEL” is not correctly displayed in the monitor function (special function) on the machine mon-
information itor.
Related
—
information
42 PC1250-8
40 Troubleshooting SEN01643-00
Electrical diagram related to travel PPC pressure switch and travel alarm
PC1250-8 43
SEN01643-00 40 Troubleshooting
Failure
• The air conditioner does not work.
information
Related • For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE
information AND FUNCTION - Air Conditioner in this manual.
a Turn the engine starting switch OFF for the preparations, and hold it in
the ON position during the troubleshooting. (If the result is as follows,
Air conditioner unit the air conditioner unit is detective inside)
4
defective
M26 Voltage
Between (4) (5) and (8) 20 – 30 V
44 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 45
SEN01643-00 40 Troubleshooting
Failure • The travel alarm does not sound while the machine is traveling.
information • The alarm begins to sound when the machine is at a standstill.
Related
—
information
46 PC1250-8
40 Troubleshooting SEN01643-00
E-27 Any of panel lamp, head lamp, working lamp (including additional
lamp) does not light up 1
Failure
• Any of panel lamp, head lamp, and working lamp (including additional lamp) does not light up
information (1)
Related
—
information
PC1250-8 47
SEN01643-00 40 Troubleshooting
Failure
• Head lamp and working lamp do not light up.
information (2)
Related
• Machine monitor and additional lamp light up.
information
Failure
• Panel lamp does not light up.
information (3)
Related
• Head lamp and working lamp light up.
information
48 PC1250-8
40 Troubleshooting SEN01643-00
Failure
• Additional lamp does not light up.
information (4)
Related
• Head lamp and working lamp light up.
information
PC1250-8 49
SEN01643-00 40 Troubleshooting
Electrical diagram related to panel lamp, head lamp and working lamp
50 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 51
SEN01643-00 40 Troubleshooting
Failure (2) While the switch is not pressed, the light lights
• Step light does not light up or go off.
phenomenon up.
Related
information
52 PC1250-8
40 Troubleshooting SEN01643-00
PC1250-8 53
SEN01644-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................... 3
Before troubleshooting for hydraulic and mechanical systems ............................................................ 3
H-1 Speed or power of all work equipment, travel, and swing is 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 is low ................................................................................................... 15
H-6 Speed or power of arm is low ...................................................................................................... 17
H-7 Speed or power of bucket is low.................................................................................................. 18
H-8 Boom does not move .................................................................................................................. 19
H-9 Arm does not move ..................................................................................................................... 20
H-10 Bucket does not move............................................................................................................... 21
H-11 Hydraulic drift of work equipment is large.................................................................................. 22
H-12 Time lag of work equipment is large.......................................................................................... 23
PC1250-8 1
SEN01644-00 40 Troubleshooting
2 PC1250-8
40 Troubleshooting SEN01644-00
PC1250-8 3
SEN01644-00 40 Troubleshooting
4 PC1250-8
40 Troubleshooting SEN01644-00
PC1250-8 5
SEN01644-00 40 Troubleshooting
Causes
5. Troubleshooting chart for judgement when
work equipment is slow and there is travel a b c d e f g h i j k l m n
deviation to the left L.H. 5- R.H. 4-
spool spool
No. 1 pump No. 2 pump
control control
a Use this troubleshooting chart to judge if the valve valve
location of the problem is in the No. 1 pump sys-
Front Rear
tem or in the No. 2 pump system. Front pump Rear pump
pump pump
a Start troubleshooting from the top, and judge
that the item with the most ● marks is the cause
of the failure.
1. To judge if the servo valve is defective or not,
remove the servo valve and carry out a test on
the individual part, or measure the servo piston
stroke.
a Carry out the individual test on the servo
Defective CO • NC valve
2. If there is a big drop in speed and it seems that
Defective servo valve
Defective pump
Defective pump
Defective pump
Defective pump
line filter also.
3. If there is only a small drop in speed and the
problem is not corrected by adjusting the equip-
ment, check the line filter also.
Remedy
A A A A A A
No.
X X X X X X X X X X X X X X
Diagnosis
There is travel deviation to left, and work equipment speed
1 ● ● ● ● ● ● ●
is slow
2 Travel relief pressure of rear pump is low ●
Machine deviates to left (no
3 ● ●
Item 2 is normal, and when change)
Travel deviates to left
6 PC1250-8
40 Troubleshooting SEN01644-00
Interchange method of No. 2 pump outlet hoses between front and rear
PC1250-8 7
SEN01644-00 40 Troubleshooting
a Tables and related circuit diagrams concerning troubleshooting contains the following information.
Please understand the contents sufficiently before carrying out troubleshooting.
Failure
Phenomena on machine
information
Related
Information concerning to failure or troubleshooting.
information
2
Possible Possible causes of fail-
causes and ure
<Contents>
standard value (The sequence num-
• Standard values for judgement of possible causes.
in normal state ber is only for refer-
• Remarks for judgement
ence and does not
state priority.)
3
8 PC1250-8
40 Troubleshooting SEN01644-00
H-1 Speed or power of all work equipment, travel, and swing is low 1
Failure
• Speed or power of all work equipment, travel, and swing is low
information
• Measure the speed of the work equipment, travel, and swing speed and check that all of them are
slow (or their power is low).
• Check that abnormal sound is not heard from around the pump.
Related
(If abnormal sound is heard, carry out the related troubleshooting.)
information
• Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.
PC1250-8 9
SEN01644-00 40 Troubleshooting
10 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Engine speed lowers remarkably or engine stalls
information
Related
• Carry out all the troubleshooting in working mode P.
information
PC1250-8 11
SEN01644-00 40 Troubleshooting
H-3 All work equipment, travel, and swing systems do not work 1
Failure
• All work equipment, travel, and swing systems do not work
information
Related
• Carry out all the troubleshooting in working mode P.
information
12 PC1250-8
40 Troubleshooting SEN01644-00
PC1250-8 13
SEN01644-00 40 Troubleshooting
Failure
• Abnormal sound is heard from around pump
information
Related
information
14 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Speed or power of boom is low in normal mode
information (1)
• The ordinary mode means the condition that the heavy lift switch, swing priority mode switch, and
machine pushup switch are turned OFF.
• Check that the speeds of the other work equipment, travel, and swing are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.
PC1250-8 15
SEN01644-00 40 Troubleshooting
Failure
• Rising speed or power of boom is low in heavy lift mode
information (2)
• The heavy lift mode means the condition that the heavy lift switch is turned ON.
• Check that the speeds of the other work equipment, travel, and swing are normal.
Related (If they are abnormal, carry out the related troubleshooting.)
information • Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.
Failure
• Lowering speed or power of boom is low in machine pushup mode
information (3)
• The machine pushup mode means the condition that the machine pushup switch is turned ON.
• Check that the speeds of the other work equipment, travel, and swing are normal.
Related (If they are abnormal, carry out the related troubleshooting.)
information • Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.
16 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Speed or power of arm is low
information
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
• Check that the machine does not deviate.
information
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.
PC1250-8 17
SEN01644-00 40 Troubleshooting
Failure
• Speed or power of bucket is low
information
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
• Check that the machine does not deviate.
information
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode P.
18 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Boom does not move
information
• Check that operations of the other work equipment, travel, and swing are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
PC1250-8 19
SEN01644-00 40 Troubleshooting
Failure
• Arm does not move
information
• Check that operations of the other work equipment, travel, and swing are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
20 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Bucket does not move
information
• Check that operations of the other work equipment, travel, and swing are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
PC1250-8 21
SEN01644-00 40 Troubleshooting
Failure
• Hydraulic drift of boom is large
information (1)
Related
information
Failure
• Hydraulic drift of arm is large
information (2)
Related
information
Failure
• Hydraulic drift of bucket is large
information (3)
Related
information
22 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Time lag of boom is large
information (1)
Related
information
Possible Since the safety & suction valve (head side) of the boom control valve (Lo)
causes and may have a malfunction, check it directly. (When checking by replacing the
Malfunction of boom
standard value safety & suction valve with one of another work equipment circuit, stop the
1 control valve (safety &
in normal state oil in the machine pushup solenoid hose securely. After checking, be sure
suction valve)
to return the safety & suction valve since its set pressure and structure are
different from the others.)
Failure
• Time lag of arm is large
information (2)
Related
information
Failure
• Time lag of bucket is large
information (3)
Related
information
PC1250-8 23
SEN01644-00 40 Troubleshooting
Failure
• Boom shockless function cannot be turned ON or OFF
information
Related
information
Failure
• Machine deviates in the same direction, regardless of its travel direction
information (1)
Related • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
information • Carry out all the troubleshooting in working mode P.
24 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Machine deviates in different directions, depending on its travel direction
information (2)
Related • Check that the travel speed is normal. (If it is abnormal, carry out the related troubleshooting.)
information • Carry out all the troubleshooting in working mode P.
Figure 2: Defective seals in center swivel joint and travel deviation directions
PC1250-8 25
SEN01644-00 40 Troubleshooting
Failure
• Machine deviates only when started with travel lever at full stroke
information (1)
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
Failure
• Machine deviates when started, regardless of travel lever stroke
information (2)
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
26 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Machine deviates largely during compound operation
information
• Check that the machine does not deviate when the work equipment is not operated.
Related
(If the machine deviates under that condition, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
Failure
• Travel speed or power is low
information
• Check that the machine does not deviate.
Related
(If the machine deviates, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
PC1250-8 27
SEN01644-00 40 Troubleshooting
Failure
• Machine does not travel in either direction.
information (1)
Related
• Carry out all the troubleshooting in working mode P.
information
Failure
• Machine does not travel forward or in reverse
information (2)
Related
• Carry out all the troubleshooting in working mode P.
information
28 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Travel speed does not change
information
• Check that the Lo and Hi travel speeds are normal.
(If they are abnormal, carry out the related troubleshooting.)
• The travel speed selection system has the automatic speed change function. The travel speed
Related
does not change from Lo to Hi even if Hi is selected under the following condition.
information
1) Engine speed is below 1,400 rpm.
2) Travel hydraulic pressure is above 28.4 MPa {290 kg/cm2}.
• Carry out all the troubleshooting in working mode P.
PC1250-8 29
SEN01644-00 40 Troubleshooting
Failure
• Machine does not swing in either direction
information (1)
• Check that the work equipment and travel are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
Failure
• Machine does not swing in one direction
information (2)
• Check that the work equipment and travel are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting in working mode P.
30 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Swing speed or acceleration is low in both directions
information (1)
• Check that the work equipment and travel are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting with the swing lock switch turned OFF in working mode P.
Failure
• Swing speed or acceleration is low in one direction
information (2)
• Check that the work equipment and travel are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
information
• Carry out all the troubleshooting with the swing lock switch turned OFF in working mode P.
PC1250-8 31
SEN01644-00 40 Troubleshooting
Failure
• Swing speed or power is low in compound operation of travel and bucket
information
Related
• Carry out all the troubleshooting with the swing lock switch turned OFF in working mode P.
information
Failure
• Swing speed or power is low in compound operation in swing priority mode
information
Related
• Swing priority mode means the condition that the swing priority mode switch is turned ON.
information
32 PC1250-8
40 Troubleshooting SEN01644-00
Failure
• Upper structure overruns largely in both directions
information (1)
Related
information
a Prepare with the engine stopped, then carry out troubleshooting with
the engine at high idle.
Possible
causes and
standard value Leakage in swing
1 Left control lever (swing) Solenoid valve outlet pressure
in normal state motor
Failure
• Upper structure overruns largely in one direction
information (2)
Related
information
PC1250-8 33
SEN01644-00 40 Troubleshooting
H-25 Large shocks are made when upper structure stops swinging 1
Failure
• Large shocks are made when upper structure stops swinging in both directions
information (1)
Related
• Carry out all the troubleshooting with the swing lock switch turned OFF in working mode P.
information
Failure
• Large shocks are made when upper structure stops swinging in one direction
information (2)
Related
• Carry out all the troubleshooting with the swing lock switch turned OFF in working mode P.
information
34 PC1250-8
40 Troubleshooting SEN01644-00
H-26 Large abnormal sounds are made when upper structure stops
swinging 1
Failure
• Large abnormal sounds are made when upper structure stops swinging in both directions
information (1)
Related
information
Malfunction of back
Since the back pressure compensation valve may have a malfunction,
1 pressure compensa-
Possible check it directly.
tion valve
causes and
standard value
in normal state
Since the swing machinery may have a defect in it, check it directly. (The
Internal defect of swing
2 defect can be judged by abnormal sound, abnormal heat, metal chips in
machinery
drained oil, etc.)
Failure
• Large abnormal sounds are made when upper structure stops swinging in one direction
information (2)
Related
information
PC1250-8 35
SEN01644-00 40 Troubleshooting
Failure
• Hydraulic drift of swing is large
information
Related
information
36 PC1250-8
40 Troubleshooting SEN01644-00
Failure • Fan revolution is abnormal (Sound and vibration of the fan is abnormally large, and the fan is over-
information (1) heated)
Related • Measure the speed of fan revolution to see if it is in a normal range or not.
information • Carry out troubleshooting in P-mode of all working mode and in fan 100 percent speed mode.
PC1250-8 37
SEN01645-00
PC1250-8
PC1250SP-8
PC1250LC-8
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode)............................................................................................................... 3
Method of using troubleshooting chart ................................................................................................. 3
S-1 Starting performance is poor ......................................................................................................... 6
S-2 Engine does not start..................................................................................................................... 8
S-3 Engine does not pick up smoothly............................................................................................... 12
S-4 Engine stops during operations ................................................................................................... 13
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 .............................................................................................. 18
S-10 Fuel consumption is excessive.................................................................................................. 19
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ........................................ 20
S-12 Oil pressure drops ..................................................................................................................... 21
S-13 Oil level rises (Entry of coolant or fuel)...................................................................................... 22
S-14 Coolant temperature becomes too high (overheating) .............................................................. 24
PC1250-8 1
SEN01645-00 40 Troubleshooting
2 PC1250-8
40 Troubleshooting SEN01645-00
Questions:
Items to be drawn from the user or operator. They
correspond to A and B in the chart on the right.
The items in A are basic ones. The items in B can
be drawn from the user or operator, depending on
their level.
Check items:
Simple check items used by the serviceman to nar-
row the causes. They correspond to C in the chart
on the right.
Causes:
Items to be narrowed from the questions and check
items.
The serviceman narrows down the probable
causes from A, B, and C.
Troubleshooting:
Items used to find out the true cause by verifying
the narrowed causes finally in order from the most
probable one by applying troubleshooting tools or
direct inspection.
Items listed in the [Questions] and [Check items]
and related to the [Causes] are marked with E, Q,
and w.
PC1250-8 3
SEN01645-00 40 Troubleshooting
4 PC1250-8
40 Troubleshooting SEN01645-00
There is a causal relationship between 3 items in the [Questions] and [Check items] sections and 6 items in
the [Causes] sections.
The method of pinpointing the [cause] from the causal relationship and approaching the [troubleshooting] is
explained according to Step 1 — Step 3 shown below.
PC1250-8 5
SEN01645-00 40 Troubleshooting
Defective injector
ingly, even if the starting operation is carried out,
the engine may not start until the crankshaft
revolves 2 turns at maximum. This phenomenon
does not indicate a trouble, however.
Confirm recent repair history
Degree of use of
Operated for long period E E E E E
machine
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow out w w
cranked with start- If spill hose from injector is disconnected,
ing motor, w
little fuel spills
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
6 PC1250-8
40 Troubleshooting SEN01645-00
Loosen 4 mounting bolts (1) on the EGR cooler inlet gas piping and confirm for coolant flowage.
A slight amount of flocculated water generated when exhaust gas is cooled may flow out; there is no
problem if it is clear and colorless.
PC1250-8 7
SEN01645-00 40 Troubleshooting
When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out (*1). q
Inspect flywheel ring gear directly q
When specific gravity of electrolyte and voltage of battery are measured, they are low q Carry out troubleshooting
Troubleshooting
Turn starting switch When terminal B and terminal C of starting switch are connected, q
OFF, connect cord, engine starts
and carry out trouble- When terminal B and terminal C at safety relay outlet are connected,
shooting at ON q
engine starts
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
—
8 PC1250-8
40 Troubleshooting SEN01645-00
PC1250-8 9
SEN01645-00 40 Troubleshooting
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow
out Q Q w Q
cranked with
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add
10 PC1250-8
40 Troubleshooting SEN01645-00
wiring harness
q Insufficient intake of air
q Improper selection of fuel
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow out Q w w
cranked with starting
motor, If spill hose from injector is disconnected, little fuel spills w
When exhaust manifold is touched immediately after starting engine, temperature of
some cylinders is low w
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
PC1250-8 11
SEN01645-00 40 Troubleshooting
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
12 PC1250-8
40 Troubleshooting SEN01645-00
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
PC1250-8 13
SEN01645-00 40 Troubleshooting
or replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
Clean
Add
14 PC1250-8
40 Troubleshooting SEN01645-00
(air leakage)
error in electrical system)
Suddenly Q Q Q Q
Questions
Replacement of filters has not been carried out according to Operation and Maintenance w
Manual
Black w w
Exhaust smoke color
Blue under light load w
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low
High idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” in E-mode q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not q q
change
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
PC1250-8 15
SEN01645-00 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy
16 PC1250-8
40 Troubleshooting SEN01645-00
Turbocharger
When EGR valve is removed, exhaust port is found to be dirty with oil q
Inspect breather and breather hose directly q
When compression pressure is measured, it is found to be low q q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC1250-8 17
SEN01645-00 40 Troubleshooting
Replace
Replace
Clean
Clean
Clean
Remedy
—
18 PC1250-8
40 Troubleshooting SEN01645-00
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
PC1250-8 19
SEN01645-00 40 Troubleshooting
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
Remedy
20 PC1250-8
40 Troubleshooting SEN01645-00
machine
Oil pressure monitor indicates low oil pressure Q w
Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Mainte- w
nance Manual
Indicates pressure drop at low idle w Q Q
Valve and spring of oil pump relief valve are fatigued, damaged q
Inspect oil filter directly q
Relief valve of EGR oil pump is damage, oil leaks from it q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting according to “Abnormality in oil pressure sensor (*1)” q
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Clean
Clean
Clean
Remedy
—
Add
PC1250-8 21
SEN01645-00 40 Troubleshooting
When EGR cooler inlet gas piping is removed, coolant containing antifreeze flows out (*1). q
When compression pressure is measured, it is found to be low q
Remove and inspect head cover directly q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
22 PC1250-8
40 Troubleshooting SEN01645-00
PC1250-8 23
SEN01645-00 40 Troubleshooting
When light bulb is held behind radiator core, no light passes through w
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
When operation of thermostat is carried out, it does not open at cracking temperature q
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Check
Remedy
—
Add
24 PC1250-8
40 Troubleshooting SEN01645-00
Gradually occurred Q Q Q
Abnormal noise
Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Oil must be added more frequently w
Metal particles are found when oil filter is drained Q w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
When engine is cranked, abnormal sound is generated around EGR gas piping w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low w Q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
PC1250-8 25
SEN01645-00 40 Troubleshooting
Remedy
26 PC1250-8
40 Troubleshooting SEN01645-00
PC1250-8 27
SEN01195-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01195-00 50 Disassembly and assembly
2 PC1250-8
50 Disassembly and assembly SEN01195-00
PC1250-8 3
SEN01195-00 50 Disassembly and assembly
Cate- Komatsu
Part number Q'ty Container Main features and applications
gory code
• Used to prevent rubber gaskets, rubber cush-
LT-1A 790-129-9030 150 g Tube
ions, and cork plugs from coming out.
• Used for plastic (except polyethylene,
polypropylene, tetrafluoroethylene and vinyl
20 g Polyethylene
LT-1B 790-129-9050 chloride), rubber, metal, and non-metal parts
(2 pcs.) container
which require immediate and strong adhe-
sion.
Polyethylene • Features: Resistance to heat and chemicals.
LT-2 09940-00030 50 g
container • Used to fix and seal bolts and plugs.
790-129-9060
Adhesive: 1 kg • Used to stick and seal metal, glass, and plas-
LT-3 (Set of adhesive Can
Hardener: 500 g tics.
and hardener)
Adhesive
Polyethylene
LT-4 790-129-9040 250 g • Used to seal plugs.
container
Holtz MH 705 790-129-9120 75 g Tube • Heat-resistant seal used to repair engines.
• Quick-setting adhesive.
ThreeBond Polyethylene • Setting time: Within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly to stick metals, rubbers, plastics,
and woods.
• Quick-setting adhesive.
• Quick-setting type.
Aron-alpha Polyethylene
790-129-9130 2g (max. strength is obtained after 30 minutes)
201 container
• Used mainly to stick rubbers, plastics, and
metals.
• Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc • Used for fitted portions used at high tempera-
648-50 container
tures.
• Used to stick or seal gaskets and packings of
LG-1 790-129-9010 200 g Tube
power train case, etc.
• Used to seal various threaded portions, pipe
Polyethylene joints, and flanges.
LG-5 790-129-9080 1 kg
container • Used to seal tapered plugs, elbows, and nip-
ples of hydraulic piping.
• Features: Silicon-based heat and cold-resis-
tant sealant.
Gasket sealant
LG-6 790-129-9020 200 g Tube • Used to seal flange surfaces and threaded
portions.
• Used to seal oil pan, final drive case, etc.
• Features: Silicon-based quick-setting sealant.
LG-7 790-129-9070 1 kg Tube • Used to seal flywheel housing, intake mani-
fold, oil pan, thermostat housing, etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
• Features: Silicon-based, heat and cold-resis-
ThreeBond tant, vibration-resistant, impact-resistant seal-
419-15-18131 100 g Tube
1207B ant.
• Used to seal transfer case, etc.
4 PC1250-8
50 Disassembly and assembly SEN01195-00
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used to lubricate sliding portions.
disulfide lubricant
SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PC1250-8 5
SEN01195-00 50 Disassembly and assembly
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • “S” is used for high-temperature season
PENGUINE and “W” for low-temperature season as
Polyethylene
SEAL 580 417-926-3910 320 ml adhesive for glass.
container
SUPER “S” or (Using limit: 4 months after date of manu-
“W” facture)
Adhesive
6 PC1250-8
50 Disassembly and assembly SEN01195-00
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
PC1250-8 7
SEN01195-00 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
8 PC1250-8
50 Disassembly and assembly SEN01195-00
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
791-685-8501 Compressor t 1
791-635-3160 Extention t 1
796T-830-1110 Plate t 1 Q
Recoil spring 796T-830-1120 Spacer t 1 Q Disassembly and assembly of
M 1
assembly 01010-61640 Bolt t 2 recoil spring assembly
Cylinder
790-101-1600 t 1
(686.47 kN {70 ton})
790-101-1102 Hydraulic pump t 1
796-832-1100 Remover & installer t 1
• 791-685-9510 • Frame 1
• 791-685-9520 • Frame 1
• 791-685-9530 • Rod 1
• 791-685-9540 • Rod 1
• 791-685-9550 • Nut 3
• 791-685-9560 • Bolt 4
• 791-126-0150 • Adapter 1
• 791-680-5520 • Guide 1
• 791-632-1150 • Pusher 1
• 791-632-1140 • Adapter 1
• 791-832-1110 • Adapter 1
Track shoe Separation and installation of
R 1 • 790-434-1610 • Grip 1
assembly track shoe assembly
• 01010-51440 • Bolt 2
• 791-685-9620 • Extension 1
• 791-632-1160 • Guide 1
• 791-680-5543 • Adapter 1
• 791-680-5551 • Guide 1
• 796-832-1120 • Adapter 1
• 791-632-1170 • Guide 1
• 791-680-9630 • Adapter 1
• Cylinder
• 790-101-4300 t 1
(1,471 kN {150 ton})
Puller
790-101-4200 t 1
(294.2 kN {30 ton})
790-101-1102 Hydraulic pump t 1
Hydraulic pump
S 796-770-1301 Oil stopper t 1 Stopping oil leak
assembly
Disassembly and assembly of
1 790-502-1003 Repair stand q 1
hydraulic cylinder
PC1250-8 9
SEN01195-00 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part number Part name Nature of work, remarks
07281-02709 Clamp t 1
3 796-702-1720 Ring t 1 Installation of piston ring
07281-02429 Clamp t 1
790-863-1110 Push tool t 1
Hydraulic cylinder 4 • 790-101-5421 • Grip t 1 Press-fitting of bushing
U
assembly • 01010-51240 • Bolt t 1
790-201-1500 Push tool kit t 1
• 790-201-1670 • Plate 1
5 Press-fitting of dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-445-4120 Sleeve t 1
790-445-4140 Sleeve t 1
02215-11622 Nut t 1 Removal and installation of
Boom cylinder
V 2 01643-32780 Washer t 1 boom cylinder assembly
assembly
(backhoe specification)
Puller
790-101-4200 t 1
(294.2 kN {30 ton})
790-101-1102 Hydraulic pump t 1
796T-870-1150 Sleeve t 1 Q
790-438-1110 Screw t 1
796-775-1110 Adapter t 1
Removal and installation of arm
Arm cylinder 791-112-1180 Nut t 1
V 4 cylinder assembly (backhoe
assembly 790-101-2540 Washer t 1 specification)
Puller
790-101-2102 t 1
(490.3 kN {50 ton})
790-101-1102 Hydraulic pump t 1
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100 V) t 1
Air conditioner Charging air conditioner
X 1 799-703-1111 Vacuum pump (220 V) t 1
assembly refrigerant gas
799-703-1121 Vacuum pump (240 V) t 1
799-703-1401 Gas leak detector t 1
Operator’s cab 1 793-498-1210 Lifter (Suction cup) t 2 Removal of window glass
Y
glass (Stuck glass) 2 20Y-54-13180 Adapter t 2 Fixing of window glass
10 PC1250-8
50 Disassembly and assembly SEN01195-00
A2 Socket
PC1250-8 11
SEN01195-00 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
A5 Push tool
F2 Plate
12 PC1250-8
50 Disassembly and assembly SEN01195-00
Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
F3 Push tool
F4 Push tool
PC1250-8 13
SEN01195-00 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
J2 Spacer
J7 Push tool
14 PC1250-8
50 Disassembly and assembly SEN01195-00
Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
L2 Push tool
L3 Adapter
PC1250-8 15
SEN01195-00 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
M1 Plate
M1 Spacer
16 PC1250-8
50 Disassembly and assembly SEN01195-00
Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
V4 Sleeve
PC1250-8 17
SEN01196-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01196-00 50 Disassembly and assembly
2 PC1250-8
50 Disassembly and assembly SEN01196-00
11. Disconnect connector P11 (8) from the top of 17. Lift and remove frame and cover assembly
air cleaner (A). (14).
PC1250-8 3
SEN01196-00 50 Disassembly and assembly
4 PC1250-8
50 Disassembly and assembly SEN01196-00
28. Disconnect clamps (31) to (33). 32. Disconnect hoses (39), (42) and (43).
PC1250-8 5
SEN01196-00 50 Disassembly and assembly
35. Disconnect hoses (51) and (52) from the fan 40. Disconnect clamp (58) from the bottom of
and pilot pumps F and P. PTO.
6 PC1250-8
50 Disassembly and assembly SEN01196-00
PC1250-8 7
SEN01196-00 50 Disassembly and assembly
[*4]
q Air hose
a Use brand new article for MIKALOR clamp.
1) Align the hose to the original position
(marked position). (Air hose insertion
depth: 80 mm)
a Reference: Clamping position
q Air hose (18) (Top side)
8 PC1250-8
50 Disassembly and assembly SEN01196-00
[*5]
q Suction hoses (E) – (H)
a Use brand new article for MIKALOR clamp.
2 Entire perimeter of hose (E) on the tube side:
Adhesive (ThreeBond No.4314)
a Apply the adhesive uniformly along the entire
perimeter
PC1250-8 9
SEN01196-00 50 Disassembly and assembly
2)Place the bridge (BR) under the clamping q Refilling with oil (Hydraulic tank)
bolt and adjust the overlapping (b) Add oil through oil filler to the specified level.
between the bridge (BR) and band to Min. Run the engine to circulate the oil through the
5 mm. system. Then check the oil level again.
5
(b) dimension: Min. 5 mm
2 Threaded portion (BC) of clamping bolt:
Hydraulic tank (Hydraulic tank refill oil capacity):
Approx. 670 l
Lubricant (PANDO 18B from Three-
Bond)
q Refilling with coolant
a Impact wrench is not applicable to use. Add coolant through the coolant filler to the
specified level. Run the engine to increase
q When the current hose is reused coolant temperature and then confirm the cool-
3) Align the clamp position to the trace of the ant level again.
clamp left on the hose. 5 Coolant: 142 l
3 Clamp tightening bolt:
Min. 6 Nm {0.6 kgm}
q Bleed air from the main pump, referring to
“Bleeding air from each part” in Testing and
q When a new hose is used
adjusting.
4) Tighten the bolt until (a) dimension
becomes 7 – 10 mm. (Common to hoses
(E) to (H))
[*6]
2 Flanged surface: Gasket sealant (LG-1)
[*7]
3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*8]
3 Air cleaner band:
12.8 – 17.7 Nm {1.3 – 1.8 kgm}
[*9]
3 Engine mounting bolt:
824 – 1,030 Nm (84 – 105 kgm)
Target: 927 Nm (94.5 kgm)
10 PC1250-8
50 Disassembly and assembly SEN01196-00
PC1250-8 11
SEN01196-00 50 Disassembly and assembly
13. Open ducts (13) and (14). 17. Disconnect the hose clamp and disconnect air
conditioner condenser (17).
12 PC1250-8
50 Disassembly and assembly SEN01196-00
22. Disconnect hoses (23) and (24). 25. Lift radiator and hydraulic oil cooler assembly
a Disconnect the hose clamp. (32) temporarily.
PC1250-8 13
SEN01196-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Hose clamp of Komaclone tube assembly:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*2]
3 Radiator hose (20) clamp:
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
[*3]
3 Radiator hose clamp:
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
[*4]
3 Radiator hose clamp:
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
14 PC1250-8
50 Disassembly and assembly SEN01196-00
Removal of air aftercooler 7. Lift and remove frame, duct and cover assem-
assembly 1 bly (8).
PC1250-8 15
SEN01196-00 50 Disassembly and assembly
16 PC1250-8
50 Disassembly and assembly SEN01196-00
Removal and installation of fuel 3. Disconnect fuel cooler hoses (3) and (4). [*1]
cooler and air conditioner a Use the double spanner (its reactive force)
when removing the fuel hose. (To prevent
condenser assembly 1 damaging weld on the fuel cooler.)
a Also use the double spanner (its reactive
Special tools
force) when removing the elbow at the fuel
cooler inlet and outlet. (To prevent damag-
Necessity
Symbol
Sketch
ing weld on the fuel cooler.)
Q’ty
N/R
Part number Part name
4. Remove fuel cooler assembly (5).
799-703-1200 Service tool kit t 1
799-703-1100 Vacuum pump (100 V) t 1
X 1 799-703-1111 Vacuum pump (220 V) t 1
799-703-1121 Vacuum pump (240 V) t 1
799-703-1401 Gas leak detector t 1
Removal
k Disconnect the negative terminal (–) of the
battery before starting with the work.
k Collect air conditioner gas (R134a) before
disconnecting the hose.
k If the air conditioner gas (R134a) gets 5. Disconnect clamp (6).
inside one's eyes, it may cause blindness.
Therefore, make sure to wear protective 6. Disconnect hose (7) from the air conditioner
glasses when collecting or filling the gas. compressor. [*2]
Collecting and filling work must be con-
ducted by a qualified person. 7. Disconnect hose (8) to the receiver tank. [*1]
k Close the fuel tank valve in advance.
8. Remove 4 mounting bolts (9) and remove air
1. Open radiator duct (1). conditioner condenser assembly (10).
2. Remove net (2).
PC1250-8 17
SEN01196-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
[*1]
a Use the double spanner (its reactive force)
when tightening the elbow and hose at the fuel
cooler inlet and outlet. (To prevent damaging
weld on the fuel cooler.)
3 Elbow: 34.3 – 63.7 Nm {3.5 – 6.5 kgm}
[*2]
a Care must be exercised in the installation so
that dusts, dirt or water may not enter the hose
of the air conditioner circuit.
a When connecting the air conditioner hose,
apply the O-ring with the compressor oil for
R134a (Denso: ND-OIL8 or Zexel: ZXL100PG
(PAG46 or equivalent)).
a Check the O-ring for scratches or degradation.
18 PC1250-8
50 Disassembly and assembly SEN01196-00
PC1250-8 19
SEN01196-00 50 Disassembly and assembly
13. Lift and remove bracket (12-1). 16. Disconnect hoses (16) to (19). [*3]
20 PC1250-8
50 Disassembly and assembly SEN01196-00
20. Remove the portion of the cover indicated as 25. Disconnect fan motor hoses (28) to (30).
(C).
26. Disconnect connector V17 (31) from the bot-
21. Remove bracket (23). tom of cover (B).
PC1250-8 21
SEN01196-00 50 Disassembly and assembly
[*1]
3 Hose clamp of Komaclone tube assembly:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*2]
3 Radiator hose clamp:
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
[*3]
3 Radiator hose (16) clamp:
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
3 Radiator hose (18) clamp:
31. Remove tubes (36) to (38) from fan motor
assembly (39). 11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
[*4] – [*6]
q Air hoses clamps (A) to (D) for tubes (24) and
(27)
22 PC1250-8
50 Disassembly and assembly SEN01196-00
[*8]
When aligning the bolt hole of the lock plate, turn
the nut in the retightening direction.
PC1250-8 23
SEN01196-00 50 Disassembly and assembly
24 PC1250-8
50 Disassembly and assembly SEN01196-00
PC1250-8 25
SEN01197-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01197-00 50 Disassembly and assembly
2 PC1250-8
50 Disassembly and assembly SEN01197-00
PC1250-8 3
SEN01197-00 50 Disassembly and assembly
4 PC1250-8
50 Disassembly and assembly SEN01197-00
PC1250-8 5
SEN01197-00 50 Disassembly and assembly
[*1]
3 Tube (21)
Joint bolt (Overflow valve):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Sleeve nut (Fuel block side):
54 – 93 Nm {5.5 – 9.5 kgm}
[*2]
3 Tube (23)
Joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (23) sleeve nut:
84 – 132 Nm {8.5 – 13.5 kgm}
[*3]
3 Tube (26)
Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*4]
3 Tube (27)
Joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (27) sleeve nut:
84 – 132 Nm {8.5 – 13.5 kgm}
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
6 PC1250-8
50 Disassembly and assembly SEN01197-00
Necessity
Symbol
Q’ty
N/R
Part number Part name
9. Remove air cleaner bracket (6).
795-799-5410 Adapter t 1 N
1 10. Disconnect muffler drain tube (7).
795-799-5420 Remover t 1 N
A
2 795T-675-1110 Socket q 1 N 11. Lift and remove muffler (8).
4
6 790-331-1120 Wrench (Angle) q 1 Muffler assembly: 100 kg
Removal
k Stop the machine on level ground and set
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
2. Remove counterweight assembly (1), referring 12. Disconnect fuel hose (13).
to “Removal of counterweight assembly”.
13. Disconnect tubes (14) and (15). [*4]
3. Remove the engine hood and covers, referring
to “Removal and installation of engine, PTO 14. Remove filter assembly (16).
and hydraulic pump assembly”.
PC1250-8 7
SEN01197-00 50 Disassembly and assembly
15. Remove fuel tube clamps (17). 20. Lift and remove filter assembly (23).
8 PC1250-8
50 Disassembly and assembly SEN01197-00
PC1250-8 9
SEN01197-00 50 Disassembly and assembly
32. Disconnect connector PFUEL (36). 40. Disconnect high-pressure piping clamps (49)
and (50).
33. Remove high-pressure piping cover (37).
41. Remove fuel tube (51). [*10]
10 PC1250-8
50 Disassembly and assembly SEN01197-00
47. Disconnect wiring harness clamp (59) from the 53. Disconnect clamp (67).
rear side of the fuel supply pump.
54. Disconnect tubes (68). [*12]
48. Disconnect the connector from the bottom of
clamp (59).
49. Disconnect connectors PCV1 (60) and PCV2 56. Remove high-pressure pipings (70).
(61).
PC1250-8 11
SEN01197-00 50 Disassembly and assembly
12 PC1250-8
50 Disassembly and assembly SEN01197-00
65. Remove diffuser (76). 70. Pull out pin (A) and then push in bolt (B).
a Take care a convexed tube bites into the
inner face of the diffuser (indicated as A). 71. Deburr using bolt (B) and then align 1.6TOP.
(Confirm the result after removing bolt (BB).)
a For above operation, see “Testing and
adjusting valve clearance” in Testing and
adjusting.
PC1250-8 13
SEN01197-00 50 Disassembly and assembly
73. Disconnect terminal mounting nuts (82). 81. Using tool A1, remove fuel injector assembly
(92).
74. Remove wiring harness assembly mounting a Remove the assembly by hitching tip of
bolts (83) and spacer (84). tool A1 to hole (H) of the fuel injector
adapter.
75. Loosen locknut (85) and then loosen adjust- a Do not grip the solenoid valve at the top of
ment screw (86). the injector to pull off the injector.
78. Remove crosshead assembly (89). 83. Remove the cylinder head gasket.
14 PC1250-8
50 Disassembly and assembly SEN01197-00
Installation
PC1250-8 15
SEN01197-00 50 Disassembly and assembly
3. Assemble gasket (94) and O-rings (95) and 6. Install push rod (88).
(96) to fuel injector (92). a Check that the push rod end is securely
a Take care not to install O-ring (95) in placed in the cam follower socket.
groove (A) at the center.
7. Apply gasket sealant and then install rocker
4. Insert fuel injector (92) to adapter (97) and housing (90).
injector holder (91). 2 Rocker housing: Gasket sealant (LG-7)
a Diameter of the gasket sealant line shall
5. Attach spherical washer (100) to bolt (99) and be 2 to 3 mm and it should be applied
then tighten injector holder (91) temporarily. along the housing groove as shown below.
2 Ball washer: Engine oil (EO30) 3 Rocker housing mounting bolt:
78.4 – 93.2 Nm {8.0 – 9.5 kgm}
16 PC1250-8
50 Disassembly and assembly SEN01197-00
9. Adjust the crosshead in the following proce- a After tightening the locknut, check the
dure. valve clearance again.
1) Loosen locknut (102) and then loosen
adjustment screw (103) to a position
where it does not touch valve stem (104).
2) Maintain the contact with valve stem (105)
on the push rod side by pressing the con-
tact face against the rocker arm using a
finger.
3) Tighten adjustment screw (103) to confirm
the position where adjustment screw (103)
is contacted against valve stem (104).
4) Drive in adjustment screw (103) further by
20 – 30° from the contacting position
against valve stem (104).
5) Tighten locknut (102) while suppressing
move of adjustment screw (103).
3 Locknut: Injector wiring harness
53.0 – 64.7 Nm {5.4 – 6.6 kgm} 11. Install spacer (84).
a When installing the spacer, direct its pro-
jection (B) toward the outside.
PC1250-8 17
SEN01197-00 50 Disassembly and assembly
High-pressure piping
k When handing the high-pressure pip-
ing and clamp, pay attention to the fol-
lowing.
q It is strictly prohibited to bend the
high-pressure piping to use it again or
using it in other locations.
q Install the specified clamp securely in
the specified position with the speci-
fied torque.
q Don't apply lubricant and the like to
the high-pressure piping sleeve nut
and the threaded portion of the mat-
ing side.
a Axial force in the tightening can be
excessive, potentially damaging
the high-pressure piping.
18 PC1250-8
50 Disassembly and assembly SEN01197-00
15. Install O-ring (106) to high-pressure piping 20. Install cylinder head cover (81).
sleeve (101). a A different tightening torque is employed
2 O-ring: Engine oil (EO30) for No. 2 cylinder mounting bolt alone.
3 Cylinder head cover mounting bolt:
16. Tighten sleeve nut (75) temporarily aligning it No.1, 3, 4, 5 and 6 cylinders:
connector (98) of the injector. 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a When it is difficult to hitch sleeve nut to the No. 2 cylinder:
threaded portion, turn the spanner while 58.8 – 73.5 Nm {6 – 7.5 kgm}
pushing sleeve nut (75) end toward the
injector by use of a short bar and the like.
21. Install air vent tube (80).
3 Air bleeding tube joint bolt (Cylinder
17. Tighten the common rail side sleeve nut (69)
head side):
temporarily, too.
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
18. Tighten injector holder (91) permanently.
3 Injector holder mounting bolt:
22. Install turbocharger coolant tube (79) and lubri-
58.9 – 73.5 Nm {6.0 – 7.5 kgm} cating oil tube (78).
PC1250-8 19
SEN01197-00 50 Disassembly and assembly
20 PC1250-8
50 Disassembly and assembly SEN01197-00
[*6]
3 Air hose clamp (Turbocharger side):
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
q Air hose (Aftercooler side)
a Use brand new article for MIKALOR clamp.
1) Align the hose to the original position
(marked position). (Air hose insertion
depth: 80 mm)
a Reference: Clamping position
q Air hose (25-1)
PC1250-8 21
SEN01197-00 50 Disassembly and assembly
[*7]
3 Coolant tube assembly (26) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
22 PC1250-8
50 Disassembly and assembly SEN01197-00
[*9]
3 Oil tube (44) joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tubes (45) and (46) sleeve nut:
54 – 93 Nm {5.5 – 9.5 kgm}
3 Tube (46) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*10]
3 Tube (51) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*11]
3 Oil tube (63) joint bolt (Supply pump side):
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
3 Oil tube (63) joint bolt (Block side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Tube (65)
joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tubes (64) (bottom) and (65) sleeve nut:
84 – 132 Nm {8.5 – 13.5 kgm}
[*12]
3 Tube (68) joint bolt (Corrosion resistor side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
PC1250-8 23
SEN01197-00 50 Disassembly and assembly
Necessity
5. Remove bracket (6).
Symbol
Sketch
Q’ty
N/R
Part number Part name
795-799-5410 Adapter t 1 N
1
A 795-799-5420 Remover t 1 N
2 795T-675-1110 Socket q 1 N Q
Removal
k Stop the machine on level ground and set
the frame lock bar.
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels. 6. Disconnect high-pressure piping clamps (7)
k Disconnect the negative terminal (–) of the and (8).
battery before starting with the work. a A clamp is provided on the fuel supply
pump side.
1. Remove the engine hood and covers, referring
to “Removal and installation of engine, PTO
and hydraulic pump assembly”.
24 PC1250-8
50 Disassembly and assembly SEN01197-00
9. Disconnect 6 sleeves (11) and (12). 12. Disconnect terminal mounting nuts (15).
a Loosen the nuts alternately.
10. Remove high-pressure piping (13).
13. Remove wiring harness assembly mounting
11. Remove cylinder head cover (14). bolts (16) and spacer (17).
PC1250-8 25
SEN01197-00 50 Disassembly and assembly
26 PC1250-8
50 Disassembly and assembly SEN01197-00
and clamp, pay attention to the following. 58.9 – 73.5 Nm {6.0 – 7.5 kgm}
q It is strictly prohibited to bend the high-
pressure piping to use it again or using it 25. Tighten high-pressure piping sleeve nuts (11)
in other locations. and (12) permanently using the spanner type
q Install the specified clamp securely in the torque wrench.
specified position with the specified 3 Sleeve nut:
torque. 39.2 – 44.1 Nm {4 – 4.5 kgm}
q Don't apply lubricant and the like to the a After finishing the work, check that O-
high-pressure piping sleeve nut and the ring (32) is not projected from the end
threaded portion of the mating side. of the sleeve nut (12).
a Axial force in the tightening can be
excessive, potentially damaging the 26. Install cylinder head cover (14).
high-pressure piping. a A different tightening torque is employed
k Before installing the high-pressure piping, for No. 2 cylinder mounting bolt alone.
check it for the following defects. If there is 3 Cylinder head cover mounting bolt:
any of these defects, it can cause fuel leak- No.1, 3, 4, 5 and 6 cylinders:
age. Accordingly, replace the high-pressure 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
piping. No. 2 cylinder:
q Check the taper seal of the connecting
58.8 – 73.5 Nm {6 – 7.5 kgm}
part (Part (a): Part of 2 mm from the end)
for visible lengthwise slit (b) and dent (c).
q Check part (d) (end of the taper seal: Part
at 2 mm from the end) for stepped-type
wear (fatigue) which your nail can feel.
PC1250-8 27
SEN01197-00 50 Disassembly and assembly
28 PC1250-8
50 Disassembly and assembly SEN01197-00
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
Removal
k Stop the machine on level ground and set 1) Replace the tip of tool A3 with the hook
the frame lock bar. type one.
k Lower the work equipment to the ground 2) Hitch the hook to the hoop of front seal
completely and stop the engine. Apply the (8).
parking brake and put the blocks under the 3) Remove front seal with impact of slide
wheels. hammer (SH).
a CS: Crankshaft
PC1250-8 29
SEN01197-00 50 Disassembly and assembly
[*1]
3 Pulley and damper mounting bolt:
1st time: 53.9 – 93.1 Nm {5.5 – 9.5 kgm}
2nd time: 225.4 – 264.6Nm {23 – 27 kgm}
3rd time: 617.4 – 656.6 Nm {63 – 67 kgm}
30 PC1250-8
50 Disassembly and assembly SEN01197-00
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name once to free it from fixation.
a When rear seal (2) is fixed too hard to the
flywheel housing (FWH), remove the fol-
3 795-931-1100 Seal puller assembly t 1
lowing procedure.
A 795T-621-1160 Push tool t 1 N Q 1) Replace the tip of tool A3 with the
5
• 01050-32235 • Bolt t 5 hook type one.
2) Hitch the hook to the hoop of seal (2).
3) Remove front seal with impact of slide
hammer (SH).
Removal a When the sleeve is attached, cut sleeve
k Stop the machine on level ground and set (5) using a gad and hammer to remove it.
the frame lock bar. a Take care not to damage crankshaft (4).
k Lower the work equipment to the ground
completely and stop the engine. Apply the
parking brake and put the blocks under the
wheels.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
q Tool A3
PC1250-8 31
SEN01197-00 50 Disassembly and assembly
32 PC1250-8
50 Disassembly and assembly SEN01197-00
[*1]
Flywheel assembly
a Check the punch mark on the mounting bolt
head. If 5 marks are punched, replace it with a
new one without using it.
a In order to prevent the flywheel from rotating,
fix the space between the flywheel and fly-
wheel housing using the bolt hole.
a Tighten the mounting bolts in the following
order.
2 Flywheel assembly mounting bolt:
Engine oil (EO30)
3 Flywheel assembly mounting bolt:
1st time: 196.1 ± 19.6 Nm {20 ± 2 kgm}
2nd time: 460.9 ± 19.6 Nm {47 ± 2 kgm}
3rd time: 90 – 120° retightening
a After tightening the bolt, make a punch mark
(a) on its head. (When a new bolt is used, do
not make a punch mark on its head.)
PC1250-8 33
SEN01197-00 50 Disassembly and assembly
34 PC1250-8
50 Disassembly and assembly SEN01197-00
PC1250-8 35
SEN01198-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01198-00 50 Disassembly and assembly
Power train 1
Removal and installation of PTO
assembly 1
Removal
1. Remove the counterweight assembly, referring
to “Removal of counterweight assembly”.
5. Drain oil in the PTO case (lubricating oil). 14. Install eyebolt in the position indicated as (C).
6 Amount of lubricating oil: 13.5 l
15. Remove mount bolts (10) and (11). [*3]
6. Disconnect hose (2) between flywheel housing 16. Lift PTO assembly (9) temporarily.
and PTO.
8. Disconnect air hose (4). [*1] 18. Place the block between the rear frame (RF)
and oil pan (BL).
9. Remove air cleaner (5). [*2]
2 PC1250-8
50 Disassembly and assembly SEN01198-00
[*3]
3 Engine mount bolt:
824 – 1030 Nm {84 – 105 kgm}
Target: 927 Nm {94.5 kgm}
[*4]
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
[*5]
3 Mounting bolt: 245 – 309 Nm {25 – 31.5 kgm}
[*6]
3 Mounting bolt: 98 – 123 Nm {10 – 12.5 kgm}
21. Remove shaft (14).
q Oil filling (PTO case)
22. Remove bolt (15) and then remove hub (16). Fill oil up to the specified level from the oil filler
[*5] port.
0°C or above : TO30
23. Remove bolt (17) and then remove plate (18). 10°C or below : TO10
5
[*6] PTO case: Approx. 13.5 l
PC1250-8 3
SEN01198-00 50 Disassembly and assembly
1. Front Cover
1) Remove oil gauge and bracket assembly
(13).
2) Remove mounting bolts (1), then remove
front cover (2) using forcing screws at (A)
area.
a Use a bar to adjust in the up-down
direction to reduce the load on the
forcing screw, and when a clearance
is made, insert wooden sheets.
3. Removal of bearing
Using puller [2], remove bearing from each
gear.
4 PC1250-8
50 Disassembly and assembly SEN01198-00
PC1250-8 5
SEN01198-00 50 Disassembly and assembly
4. Front cover
1) After coating front cover (2) and bearing
(4) with grease press fit, then install snap
ring (3).
2 Bearing: Lubrication oil (G2-LI)
6 PC1250-8
50 Disassembly and assembly SEN01198-00
PC1250-8 7
SEN01198-00 50 Disassembly and assembly
8 PC1250-8
50 Disassembly and assembly SEN01198-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt:
927 ± 103 Nm {94.5 ± 10.5 kgm}
PC1250-8 9
SEN01198-00 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
Disassembly
1. Draining oil
Loosen drain plug and drain oil from swing
machinery case.
6 Swing machinery case: Approx. 21.5 l
2. Cover
Remove mounting bolts, then lift off cover (1).
10 PC1250-8
50 Disassembly and assembly SEN01198-00
PC1250-8 11
SEN01198-00 50 Disassembly and assembly
12 PC1250-8
50 Disassembly and assembly SEN01198-00
Assembly
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with
engine oil before installing.
1. Bearing
Using push tool F2, press fit bearing (31) to
case (35).
3. Case assembly
1) Set case assembly (35) to shaft (32), then
using push tool [2], press fit bearing inner
race portion.
a When setting the case assembly to
the shaft, be extremely careful not to
damage the oil seal.
2. Cover assembly
1) Using push tool F1, press fit oil seal (33)
to cover (27).
2 Outside circumference of oil seal:
Gasket sealant (LG-6)
a Be careful not to let the gasket seal-
ant (LG-6) get on the oil seal lip when
press fitting.
2) Bearing
Using tool F3, press fit bearing (34).
a Push the bearing inner race and outer
race at the same time when press fit-
ting. Do not push only the inner race
when press fitting.
a After press fitting the bearing, check
that the case rotates smoothly.
PC1250-8 13
SEN01198-00 50 Disassembly and assembly
14 PC1250-8
50 Disassembly and assembly SEN01198-00
PC1250-8 15
SEN01198-00 50 Disassembly and assembly
11. Cover
Install cover (1).
2 Cover mounting surface:
Gasket sealant (LG-6)
3 Mounting bolt:
1st pass: 98 Nm {10 kgm}
2nd pass: 120 ± 5°
16 PC1250-8
50 Disassembly and assembly SEN01198-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
[*2]
4. Pass a round bar through revolving frame 2 Mounting surface of swing circle:
mounting bolt holes, then fit wire and lift off Gasket sealant (LG-6)
swing circle assembly (3). [*2] a Amount of grease (G2-LI) to fill oil bath:
Approx. 75 l
4 Swing circle assembly: 2,169 kg
a Coat the inner teeth with grease (G2-LI).
a Set the soft zone (S) mark on the inner
race facing the left side of the machine,
then install.
PC1250-8 17
SEN01198-00 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
Wrench assem-
1 796-627-1200 t 1
bly
796T-827-1130 Spacer t 1 Q
2 01017-52450 Bolt t 1
01580-12419 Nut t 1
3 790-201-2820 Spacer q 1
790-101-5401 Push tool kit (C) q 1
790-101-5491 Push tool 1 4. No. 3 carrier assembly
4
790-101-5421 Grip 1 1) Remove thrust washer (50).
01010-51240 Bolt 1 2) Using eyebolts [2], remove No. 3 carrier
assembly (2).
J 6 796-627-1030 Push tool t 1
790-101-2300 Push puller t 1
790-101-2310 Block 1
790-101-2350 Leg 2
790-101-2360 Plate 2
7 02215-11622 Nut 2
791-181-1010 Adapter t 2
796T-627-1340 Push tool t 1 Q
790-101-2102 Puller (30 tons) t 1
790-101-1102 Hydraulic pump t 1
8 796-627-1050 Installer t 1
18 PC1250-8
50 Disassembly and assembly SEN01198-00
iii) Turn over carrier assembly (2) and 5. No. 3 sun gear
set to press, then using tool J3, pull 1) Remove thrust washer (11) from No 3. sun
out pin (5) and remove gear assembly gear (10).
(6). 2) Remove No. 3 sun gear (10).
iv) Remove bearing (7) and spacer (8) 6. No. 3 ring gear
from gear assembly (6). 1) Using eyebolts [3], remove No. 3 ring gear
a If the parts are to be used again, (12).
make counter marks to prevent
any change in the combination
with the outer race.
v) Remove outer race (9) from gear
assembly (6).
7. Hub assembly
1) Remove lock plate (13).
2) Using tool J4, remove nut (14).
PC1250-8 19
SEN01198-00 50 Disassembly and assembly
8. Spacer
1) Remove spacer (19) from shaft (41).
12. Spacer
9. No. 2 carrier assembly 1) Remove spacer (31).
1) Using eyebolts [5], remove No. 2 carrier
assembly (20).
2) Disassemble No. 2 carrier assembly as
follows.
i) Knock pin (21) into shaft (22).
ii) Push shaft (22) from pin side to
remove.
a Remove the pin from the shaft.
20 PC1250-8
50 Disassembly and assembly SEN01198-00
PC1250-8 21
SEN01198-00 50 Disassembly and assembly
22 PC1250-8
50 Disassembly and assembly SEN01198-00
PC1250-8 23
SEN01198-00 50 Disassembly and assembly
9. Spacer
Align protruding portion with protruding portion
of shaft (41), and install spacer (19).
a Set the spacer with the shallow protruding
part facing the motor.
24 PC1250-8
50 Disassembly and assembly SEN01198-00
6) Outside bearing
Install bearing (16).
3) Outer race at hub end
Expand fit outer race (18) to hub (49), or
use tool J6 to install.
a When using tool J6, see the drawing
below.
PC1250-8 25
SEN01198-00 50 Disassembly and assembly
iv) Measure dimension (a) in the condi- 11. No. 3 ring gear
tion below. 1) Install O-ring to shaft end.
2) Using eyebolts [3], install No. 3 ring gear
(12).
a Align the bolt holes.
a Install the ring gear with the machined
outside circumference facing up (out-
side).
26 PC1250-8
50 Disassembly and assembly SEN01198-00
iii)Expand fit shaft (5) or press fit with a a Align the bolt holes also.
press.
a Do not move the gear until the tip
of shaft (5) enters the carrier. Be
pa r ti c u la r l y c a r ef ul wi t h th e
spacer.
a When press fitting the shaft, be
careful of the angle of the shaft,
and press fit so that there is no
clearance between the pin and
end face (m) of the bearing.
a After press fitting the pin, check
that the gear rotates smoothly.
iv) Assemble holder (4) to shaft (5).
14. Cover
Using eyebolts [1], install cover (1).
2 Mounting surface:
Gasket sealant (LG-6)
2 Bolt: Thread tightener (LT-2)
3 Bolt: 982 – 1,030 Nm {90 – 105 kgm}
PC1250-8 27
SEN01199-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01199-00 50 Disassembly and assembly
New/Remodel
roller. The track shoe is opened to the
Necessity
Symbol
Q'ty
Part number Part name
space to lay it out.
R 1 790-434-1610 Grip 1
01010-51440 Bolt 2
791-685-9620 Extension 1
791-632-1160 Guide 1
791-680-5543 Adapter 1
3. Using tool R1, pull out master pin.
791-680-5551 Guide 1
796-832-1120 Adapter 1
791-632-1170 Guide 1
791-680-9630 Adapter 1
Cylinder
790-101-4300 t 1
(1,471 kN {150 tons})
Puller
790-101-4200 t 1
(294.2 kN {30 tons}
790-101-1102 Hydraulic pump t 1
2 PC1250-8
50 Disassembly and assembly SEN01199-00
[*1]
a Adjust the track shoe tension.
For details, see Testing and adjusting, “Testing
and adjusting track shoe tension”.
3 Lubricator:
73.5 ± 14.7 Nm {7.5 ± 1.5 kgm}
[*2]
a Assemble spacer (4) and washer (5) to the
link, connect to the bottom link, then install the
guide pin.
PC1250-8 3
SEN01199-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
4 PC1250-8
50 Disassembly and assembly SEN01199-00
Necessity
Symbol
Q'ty
Part number Part name
Disassembly
1. Remove plug and drain oil.
5 Idler: Approx. 750 – 830 cc
PC1250-8 5
SEN01199-00 50 Disassembly and assembly
6 PC1250-8
50 Disassembly and assembly SEN01199-00
4. Install shaft (13) to idler assembly (1). 11. Assemble support (9) to shaft (13).
a Assemble the shaft so that the UP mark at a Align the dowel pin with the hole at the
the end face of the shaft is at the top. support end.
a Assemble so that the oil filler plug is facing
the right side of the machine 12. Install bolt and nut (8), and secure support (9).
5. Assemble plate (5) to idler (1). 13. Turn over idler, and assemble support (3) to
shaft (13).
6. Install dowel pin (6) to plate (5). a Align the dowel pin with the hole at the
support end.
7. Fit O-ring (4) to shaft (13).
14. Install bolt and nut (2), and secure support (3).
PC1250-8 7
SEN01199-00 50 Disassembly and assembly
8 PC1250-8
50 Disassembly and assembly SEN01199-00
PC1250-8 9
SEN01199-00 50 Disassembly and assembly
10 PC1250-8
50 Disassembly and assembly SEN01199-00
New/Remodel
tension of spring, then remove recoil spring
Necessity
assembly (1) from tool M1.
Symbol
Sketch
Q'ty
Part number Part name
791-685-8501 Compressor t 1
791-635-3160 Extension t 1
796T-830-1110 Plate t 1 Q
796T-830-1120 Spacer t 1 Q
M 1
01010-61640 Bolt t 2
Cylinder
790-101-1600 t 1
(70 tons)
790-101-1102 Hydraulic pump t 1
Disassembly 4. Remove rear pilot (4) and rod (5) from spring
(3).
1. Set recoil spring assembly (1) to tool M1.
k The recoil spring is under a large
installed load, so be sure to set the tool
properly. Failure to do this is dangerous.
a Installed load of spring:
578 kN {58,957 kg}
PC1250-8 11
SEN01199-00 50 Disassembly and assembly
Installation
12 PC1250-8
50 Disassembly and assembly SEN01199-00
Removal and installation of track 4. Using tool L7, remove track roller assembly
roller assembly 1 (2). [*1]
4 Track roller assembly (S flange): 140 kg
Special tools
Necessity
Symbol
Q'ty
Part number Part name
Removal
PC1250-8 13
SEN01199-00 50 Disassembly and assembly
Disassembly and assembly of 4. Pull out roller (4) from shaft (5).
track roller assembly 1 a It is filled with 800 – 850 cc. of oil, so drain
the oil at this point or lay a cloth to prevent
Special tools the area from becoming dirty.
Necessity
Symbol
Q'ty
Part number Part name
6 790-434-1620 Installer t 1
791-601-1000 Oil pump t 1
L
10 791-646-8002 Oil lubricator t 1
790-701-3000 Seal checker t 1
Disassembly
14 PC1250-8
50 Disassembly and assembly SEN01199-00
PC1250-8 15
SEN01199-00 50 Disassembly and assembly
16 PC1250-8
50 Disassembly and assembly SEN01199-00
PC1250-8 17
SEN01199-00 50 Disassembly and assembly
Disassembly and assembly of 6. Remove floating seal (5) from support (2).
carrier roller assembly 1
7. Remove bearing (6) from support (2).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
4. Remove shaft (3) and bearing (6) as one unit 10. Remove bearing outer race (7) from support
from support (2). (2).
18 PC1250-8
50 Disassembly and assembly SEN01199-00
PC1250-8 19
SEN01199-00 50 Disassembly and assembly
Removal and installation of 9. Leave 4 mounting bolts (8) at front and rear,
revolving frame assembly 1 and remove remaining mounting bolts. [*1]
Removal
Installation
q Carry out installation in the reverse order to
removal.
a Remove the mounting bolts of the swing motor,
raise the swing gear enough for it to be free,
8. Disconnect stopper link (7).
then set on a block.
[*1]
2 Mounting bolt: Thread tightener (LT-2)
3 Mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
20 PC1250-8
50 Disassembly and assembly SEN01199-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Counterweight mounting bolt:
3,822 ± 392 Nm {390 ± 40 kgm}
PC1250-8 21
SEN01200-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01200-00 50 Disassembly and assembly
2 PC1250-8
50 Disassembly and assembly SEN01200-00
Hydraulic system 1
Removal and installation of
hydraulic tank assembly 1
Removal
k Disconnect the negative (–) terminal of the
battery beforehand.
k Lower the work equipment completely to
the ground, stop the engine and then
relieve internal pressure of the hydraulic
tank.
PC1250-8 3
SEN01200-00 50 Disassembly and assembly
14. Disconnect hoses (14) and (15). 20. Lift and remove hydraulic tank (21).
4 Hydraulic tank assembly: 780 kg
15. Remove the clamps, disconnect hose (16).
Installation
q Carry out installation in reverse order of
17. Disconnect washer tanks (18).
removal.
[*1]
2 Mounting bolt: Adhesive (LT-2)
3 Hydraulic tank mounting bolt:
549 ± 59 Nm {56 ± 6 kgm}
q Bleeding air
18. Disconnect tube (19). Bleed air from the parts, refer to “Bleeding air
from various system” in Testing and adjusting.
19. Remove 12 mounting bolts (20). [*1]
4 PC1250-8
50 Disassembly and assembly SEN01200-00
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
Removal
k Lower the work equipment completely to
Pump name
the ground, stop the engine and then
q No. 1 pump
loosen the oil filler cap gradually to release
q No. 2 pump
the internal pressure of the hydraulic tank.
k
q No. 3 pump
Disconnect the negative (–) terminal of the
q Fan and pilot pump (F, P)
battery beforehand.
PC1250-8 5
SEN01200-00 50 Disassembly and assembly
6 PC1250-8
50 Disassembly and assembly SEN01200-00
9. No. 1 pump
2) Disconnect connector (29). 1) Remove the No. 3 pump.
3) Disconnect clamp (30). 2) Disconnect hoses (37) to (40).
PC1250-8 7
SEN01200-00 50 Disassembly and assembly
8 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 9
SEN01200-00 50 Disassembly and assembly
q Bleeding air
Bleed air from the parts, referring to “Bleeding
air from various system” in Testing and adjust-
ing.
10 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 11
SEN01200-00 50 Disassembly and assembly
Removal and installation of 5-spool 5. Disconnect R.H. PPC hoses (7) (L.H. travel),
control valve assembly (No. 1) 1 (8) (bucket Hi), (9) (arm Lo), and (10) (boom
Hi).
Removal
k Lower the work equipment completely to 6. Disconnect hoses (11) going to 4-spool main
the ground and stop the engine. Then relief valve and hose between 2-stage main
loosen the oil filler cap slowly to release the relief solenoid valve and main relief valve.
pressure inside the hydraulic tank.
k Release the remaining pressure inside the
hydraulic circuit.
For details, see Testing and adjusting,
“ R el ea s in g r em ai n i n g p r e s su re f r o m
hydraulic circuit”.
a After disconnecting the PPC hoses, make
counter marks to distinguish the mounting
positions.
a After disconnecting the hoses and tubes, fit
blind plugs.
12 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 13
SEN01200-00 50 Disassembly and assembly
Removal and installation of 4-spool 6. Disconnect hose (10) from solenoid valve of 2-
control valve assembly (No. 2) 1 stage safety valve.
Removal
k Lower the work equipment completely to
the ground and stop the engine. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
k Release the remaining pressure inside the
hydraulic circuit.
For details, see Testing and adjusting,
“Releasing remaining pressure in hydraulic
circuit”.
a After disconnecting the PPC hoses, make
counter marks to distinguish the mounting
positions.
a After disconnecting the hoses and tubes, fit
blind plugs. 7. Disconnect hose (12) from straight travel valve
solenoid.
1. Disconnect tube (1) coming from main pump.
8. Disconnect L.H. PPC hoses (13) (R.H. travel),
2. Disconnect branch hoses (2) and (3). (14) (boom Lo), (15) (bucket Lo), and (16) (arm
Hi).
4. Disconnect drain hose (straight. travel valve) 10. Disconnect tube (18) going to 5-spool control
(5). valve (L.H. travel).
5. Disconnect R.H. PPC hoses (6) (R.H. travel), 11. Disconnect tube (19) for R.H. travel (FOR-
(7) (boom Lo), (8) (bucket Lo), and (9) (arm WARD) control.
Hi).
12. Disconnect tube (20) for R.H. travel (REVERSE)
control.
14 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 15
SEN01200-00 50 Disassembly and assembly
Removal and installation of 4-spool 8. Remove tube (8) going to control valves No. 1
control valve assembly (No. 3) 1 and No. 2.
Removal
k Lower the work equipment completely to
the ground and stop the engine. Then
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
k Release the remaining pressure inside the
hydraulic circuit.
For details, see Testing and adjusting,
“Releasing remaining pressure in hydraulic
circuit”.
a Before disconnecting the PPC hoses, make
counter marks to distinguish the mounting
positions.
a After disconnecting the hoses and tubes, fit
blind plugs. 9. Disconnect hoses (9) coming from the pilot
valve.
1. Remove control valve cover (1).
10. Disconnect swing control tube (10).
16 PC1250-8
50 Disassembly and assembly SEN01200-00
13. Remove pilot hoses (17), (18), (19), and (20), Installation
and then disconnect main relief valve (21). q Carry out installation in the reverse order to
removal.
14. Disconnect pilot valve hose (22).
q Refilling with oil (hydraulic tank)
15. Disconnect PPC hose (23). Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
16. Remove 4-spool control valve assembly (No. 3) through the system. Then check the oil level
(24). again.
4 4-spool control valve assembly: 240 kg
q Bleeding air
Bleed the air from the circuit between the valve
and hydraulic pressure cylinder.
For details, see Testing and adjusting, “Bleed-
ing air”.
PC1250-8 17
SEN01200-00 50 Disassembly and assembly
4. Remove tube (7) and retainer (9) from boom Hi 15. Remove plug (24), then remove backup ring
control valve mount. and O-ring (24A) from plug.
18 PC1250-8
50 Disassembly and assembly SEN01200-00
Assembly 11. Fit O-ring, backup ring, and O-ring (19) to plug
(18), then assemble to valve body (1).
1. Fit backup ring (37) and O-ring (38) to sleeve
(36), then assemble to valve body. 12. Assemble main relief valve (17) to valve body
2 Sleeve: Thread tightener (Seal end 242) (1).
3 Sleeve: 177 – 216 Nm {18 – 22 kgm} 3 Main relief valve:
275 – 368 Nm {28 – 37.5 kgm}
2. Assemble nut (35) to sleeve (36).
3 Nut: 177 – 216 Nm {18 – 22 kgm} 13. Assemble suction-safety valve (16) to valve
body (1).
3. Assemble check valve (34) and spring (33) to 3 Suction-safety valve:
sleeve (36). 216 – 235 Nm {22 – 24 kgm}
4. Fit backup ring (31) and O-ring (32) to plug 14. Assemble suction valve (15) to valve body (1).
(30), then assemble to sleeve (36). 3 Suction valve:
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm} 294 – 314 Nm {30 – 32 kgm}
PC1250-8 19
SEN01200-00 50 Disassembly and assembly
20 PC1250-8
50 Disassembly and assembly SEN01200-00
4. Remove seat (9), spring (10), and check valve 15. Remove backup ring and O-ring (30) from plug
(11) from valve body (1). (29).
PC1250-8 21
SEN01200-00 50 Disassembly and assembly
22 PC1250-8
50 Disassembly and assembly SEN01200-00
2. Fit O-ring to plug (31) and install. 9. Insert spools (18) (R.H. travel), (19) (boom Lo),
3 Plug: 58.8 – 78.5 Nm {6 – 8 kgm} (20) (bucket Lo), and (21) (arm Hi) in valve
body (1).
3. Fit backup ring and O-ring (30) to plug (29) and a Coat the spool with engine oil, then insert.
install. a Be careful not to mistake the location and
3 Plug: 118 – 162 Nm {12 – 16.5 kgm} direction of the spool.
4. Install main relief valve (28). 10. Assemble retainer (17) and springs (15) and
3 Main relief valve: (16).
275 – 368 Nm {28 – 37.5 kgm}
11. Fit O-ring (14) to case (13) and tighten with
5. Install jet sensor relief valve (27). bolt (12).
3 Jet sensor relief valve:
177 – 196 Nm {18 – 20 kgm}
PC1250-8 23
SEN01200-00 50 Disassembly and assembly
24 PC1250-8
50 Disassembly and assembly SEN01200-00
Disassembly and assembly of 6. Remove mounting bolts (14) from each control
control valve assembly (No. 3) 1 valve mount on left side (main relief valve
mount side), then remove case (15).
Disassembly
7. Remove O-ring (16) from each case (15).
1. Remove mounting bolts (2) and (3) from valve
body (1), then remove swing priority valve (4). 8. Remove bolt (14) from each control valve
mount (Boom Plus), then remove case (15),
2. Remove O-rings (5) and (6) from swing priority tube (20), and retainer (19).
valve (4). 9. Pull out spool (22) for Boom Plus.
3. Remove spring (7) and check valve (8) from 16. Remove O-ring (16) from each case.
each port of valve body (1).
PC1250-8 25
SEN01200-00 50 Disassembly and assembly
24. Remove backup ring and O-ring (34) from plug Assembly
(33). 1. Assembly of swing priority valve
1) Fit washer to bolt (49), then install O-ring
25. Remove plug (35). (51) and flange (50) to valve body (4).
2) Fit backup ring and O-ring (48) to sleeve
(43), and assemble to valve body.
2 Sleeve:
Liquid sealant {Seal end 242}
3 Sleeve:
177 – 216 Nm {18 – 22 kgm}
3) Tighten nut (42) to sleeve (43).
3 Nut: 177 – 216 Nm {18 – 22 kgm}
4) Fit backup ring and O-ring (47) to plug
(44).
5) Insert check valve (46) and spring (45) in
sleeve (43), then assemble plug (44).
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm}
6) Fit backup ring and O-ring (40) and O-ring
(41) to plug (39), then insert in valve body
26. Disassembly of swing priority valve assembly (4).
1) Remove mounting bolts (36), then remove 7) Fit O-ring, then set cover (37) together
cover (37). with bolt (36) to valve body (4).
2) Remove O-ring (38) from cover (37).
3) Remove plug (39).
4) Remove backup ring, O-ring (40), and O-
ring (41) from plug (39).
5) Loosen nut (42), and remove sleeve (43).
6) Remove plug (44), spring (45), and check
valve (46) from sleeve (43).
7) Remove backup ring and O-rings (47) and
(48) from plug (44) and sleeve (43).
8) Remove mounting bolts (49), then remove
flange (50) and O-ring (51).
26 PC1250-8
50 Disassembly and assembly SEN01200-00
20. Fit spring (9) to check valve (11) and seat (10),
then set to valve body (1).
9. Insert spools (22) (Boom Plus), (23) (swing),
(24) (Bucket Plus), and (25) (Arm Plus) in 21. Set check valve (13) and spring (12) to valve
valve body (1). body.
a Coat the spool with engine oil, then insert.
a Be careful not to mistake the location and
direction of the spool.
14. Assemble retainer (19) and tube (21). 22. Fit O-rings (5) and (6) to swing priority valve
assembly (4), then set to valve body assembly
15. Fit O-ring to case (15) and tighten with bolt (1).
(14).
PC1250-8 27
SEN01200-00 50 Disassembly and assembly
28 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 29
SEN01200-00 50 Disassembly and assembly
Installation
q Carry out installation in the reverse order to
removal.
30 PC1250-8
50 Disassembly and assembly SEN01200-00
Removal and installation of center 10. Remove the pin of stopper link (14).
swivel joint assembly 1
Removal
k Lower the work equipment to the ground
and stop the engine. Then loosen the oil
filler cap slowly to release the pressure
inside the hydraulic tank.
4. Disconnect tubes (3) and (4) between swivel 12. Disconnect inside and outside swing motor
joint bottom and L.H. travel motor. drain hoses (16) and (17).
a Remove the clamps.
13. Lift off center swivel joint assembly (18).
5. Disconnect tubes (5) and (6) between swivel
4 Center swivel joint assembly: 70 kg
joint bottom and R.H. travel motor.
a Disconnect the clamps.
PC1250-8 31
SEN01200-00 50 Disassembly and assembly
1. Remove cover (1). 2. Set swivel shaft (5) on block, and using push
tool [2], tap swivel rotor (4) with a plastic ham-
2. Remove snap ring (2). mer, and install.
2 Contact surface of rotor, slipper seal:
3. Using puller [1], pull out swivel rotor (4) and Grease (G2-Ll)
ring (3) from swivel shaft (5). a When installing the rotor, be extremely
careful not to damage the lips of the slip-
per seal and the O-ring.
32 PC1250-8
50 Disassembly and assembly SEN01200-00
New/Remodel
and use forcing screws to pull out the
Necessity
motor assembly.
Symbol
Sketch
Q'ty
Part number Part name
4 Travel motor assembly: 60 kg
Removal
k Swing the work equipment 90º, then lower
in completely to the ground and stop the
engine.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
Installation
q Carry out installation in the reverse order to
removal.
a Be sure to install the thrust rings and O-rings.
PC1250-8 33
SEN01200-00 50 Disassembly and assembly
34 PC1250-8
50 Disassembly and assembly SEN01200-00
Assembly
PC1250-8 35
SEN01200-00 50 Disassembly and assembly
36 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 37
SEN01200-00 50 Disassembly and assembly
New/Remodel
Necessity
Bolt width across flats Unit mm
Symbol
Q'ty
Part number Part name Cylinder Boom Arm Bucket
PC1250 46 50 30
38 PC1250-8
50 Disassembly and assembly SEN01200-00
2. Piston assembly and head assembly 7) Remove ring (18) from collar (17).
q Boom cylinder
1) Fix the head side of piston rod assembly
(3) with tool U1 or a press.
2) Remove bolts (7), piston assembly (9),
and spacer (8).
3) Remove the O-ring and backup ring (10).
4) Remove plunger (11).
PC1250-8 39
SEN01200-00 50 Disassembly and assembly
40 PC1250-8
50 Disassembly and assembly SEN01200-00
q Bucket cylinder
1) Fix the head side of piston rod assembly
(3) with tool U1 or a press.
2) Remove bolts (7), piston assembly (9),
and spacer (8).
3) Remove screw (4), 12 balls (5), and
plunger (6).
4) Remove the O-ring and backup ring (10).
5) Remove plunger (11).
PC1250-8 41
SEN01200-00 50 Disassembly and assembly
42 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 43
SEN01200-00 50 Disassembly and assembly
44 PC1250-8
50 Disassembly and assembly SEN01200-00
PC1250-8 45
SEN01201-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01201-00 50 Disassembly and assembly
Work equipment 1
Removal and installation of
bucket cylinder assembly 1
Backhoe specification
Removal
k Set mounting pin (1) and link (2) at the
bucket cylinder rod end to a position where
there is no interference, then set the back
face of the bucket on a block.
k Stop the engine, then operate the bucket
control lever to release the remaining pres-
sure in the hydraulic circuit.
2 PC1250-8
50 Disassembly and assembly SEN01201-00
[*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust with shims so that clearance (b)
between the end face and the bottom of cylin-
der (8) and bracket (9) is 2 – 3 mm.
q Shim thickness: 0.8 mm (STD)
1.0 mm (SP)
PC1250-8 3
SEN01201-00 50 Disassembly and assembly
Removal and installation of 5. Remove lock plate (5) and pull out bottom pin
bucket cylinder assembly 1 (6). [*2]
a Pull out the pin to a position where the cyl-
Loading shovel inder bottom can be disconnected.
4 Pin: 50 kg
Removal
k Extend the arm cylinder fully, set the bot-
tom of the bucket horizontal, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remain-
ing pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Plug the hose to stop oil flow-out.
4 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1] [*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
q Bleeding air
a For details, see Testing and adjusting,
“Bleeding air from each part”.
PC1250-8 5
SEN01201-00 50 Disassembly and assembly
Removal
k Set the bottom of the bucket horizontal, and
retract the rod to a position where the rod
connecting pin of the bottom dump cylin-
der can be removed. Then fit a block under
the bucket, lower the work equipment com-
pletely to the ground and stop the engine.
6 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
k When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
[*2]
k When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
PC1250-8 7
SEN01201-00 50 Disassembly and assembly
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
796T-870-1150 Sleeve t 1 Q
790-438-1110 Screw t 1
790-775-1110 Adapter t 1
791-112-1180 Nut t 1 5. Disconnect bottom grease hose (5).
V 4
790-101-2540 Washer t 1
6. Remove lock plate, then remove pin (6). [*2]
Puller
790-101-2102 t 1
(490 kN {50 tons})
790-101-1102 Hydraulic pump t 1
Removal
k Retract the arm cylinder fully and set block
[1] under the tip of the arm.
k Stop the engine and operate the control
levers to release the remaining pressure in
each cylinder.
8 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
[*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust with shims (9) so that clearance (a)
between the end face of the bottom of cylinder
(7) and bracket (8) is 2 – 3 mm.
q Shim thickness: 0.8 mm
q Bleeding air
a Bleed the air.
For details, see Testing and adjusting,
“Bleeding air”.
PC1250-8 9
SEN01201-00 50 Disassembly and assembly
Removal and installation of arm 3. Start engine and retract piston rod fully.
k Tie the rod with wire to prevent it from
cylinder assembly 1
coming out.
Loading shovel k After stopping the engine, release the
pressure inside the piping.
Removal For details, see Testing and adjusting,
k Retract boom cylinder fully, and extend arm “Releasing pressure in PPC circuit”.
cylinder, then set the bottom of the bucket
horizontal, lower the work equipment com- 4. Disconnect 4 arm cylinder hoses (3).
pletely to the ground and stop the engine.
Operate the control levers several times to 5. Sling piston rod end and bottom end, and
release the remaining pressure in the remove plate, then using forcing screws
hydraulic piping. (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
k Loosen the oil filler cap slowly to release pin (4). [*2]
the pressure inside the hydraulic tank. a Pull out the pin to a position where the cyl-
a Plug the hose to stop oil flow-out. inder bottom can be disconnected.
4 Pin: 24.2 kg
1. Disconnect grease tube (1) at piston rod end.
10 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
k When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
[*2]
k When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
a Adjust with shims so that the clearance at the
cylinder bottom end is less than 1 mm.
PC1250-8 11
SEN01201-00 50 Disassembly and assembly
Removal and installation of boom 4. Lower boom cylinder slowly, and insert wedge
cylinder assembly 1 [1] between cylinder bottom and revolving
frame.
Backhoe specification a Insert so that the cylinder is horizontal.
Necessity
6. Disconnect bottom hose (5).
Symbol
Q'ty
Part number Part name
790-445-4120 Sleeve t 1
790-445-4140 Sleeve t 1
02215-11622 Nut t 1
V 2 01643-32780 Washer t 1
Puller
790-101-4200 t 1
(294 kN {30 tons})
790-101-1102 Hydraulic pump t 1
Removal
k Extend the arm and bucket cylinder rods
fully; lower the work equipment completely 7. Sling boom cylinder assembly (7) and remove
to the ground, and put the lock lever in the lock plate, then remove pin (6). [*2]
LOCK position. a Use forcing screws when removing.
k Stop the engine and operate the control
levers to release the remaining pressure in 8. Lift off boom cylinder assembly (7).
4
the hydraulic circuit. Boom cylinder assembly: 1,049 kg
1. Disconnect grease hose (1).
12 PC1250-8
50 Disassembly and assembly SEN01201-00
[*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust with shims (9) so that clearance (a)
between the end face of the bottom of boom
cylinder (7) and bracket (8) is less than 1 mm.
q Shim thickness: 1.0, 1.5 mm
PC1250-8 13
SEN01201-00 50 Disassembly and assembly
Removal and installation of boom 5. Lower boom cylinder assembly onto stand,
cylinder assembly 1 then disconnect hoses (4).
Loading shovel
Removal
k Extend the arm and bucket fully, lower the
work equipment completely to the ground
and stop the engine. Operate the control
levers several times to release the remain-
ing pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Plug the hose to stop oil flow-out.
14 PC1250-8
50 Disassembly and assembly SEN01201-00
[*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
a Adjust with shims (7) so that clearance (a)
between bracket (6) and the bottom end face
of boom cylinder (5) is less than 1 mm.
q Shim thickness: 1.0, 1.5 mm
PC1250-8 15
SEN01201-00 50 Disassembly and assembly
Removal
k Set the back face of the bucket facing
down, lower the work equipment com-
pletely to the ground, and set the lock lever
to the LOCK position.
16 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
[*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Insert the O-ring at the end face of the bucket
boss securely.
a Adjustment of bucket clearance
1) Measure clearance (a) between arm (14)
and bushing (12).
a Put the edge of the arm boss and the
edge of the bucket boss in contact,
and measure clearance (a).
2) After removing the shims (11), take out
shims equal to clearance (a), and fit the
remaining shims.
a Shim thickness: 0.5, 1.0 mm
a If clearance (a) is smaller than the
thickness of one shim, do not carry
out any adjustment.
3) Tighten bolt (8) and bolt (6).
PC1250-8 17
SEN01201-00 50 Disassembly and assembly
Removal and installation of 4. Sling bucket assembly, and remove plate (5),
bucket assembly 1 then pull out arm-bucket connecting pin (6).
[*2]
Loading shovel a Remove the pin on the other side in the
same way.
Removal 4 Pin: 67.9 kg
k Set the bottom of the bucket horizontal,
lower the work equipment completely to the
ground and stop the engine. Operate the
control levers several times to release the
remaining pressure in the hydraulic piping.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
a Plug the hose to stop oil flow-out.
18 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1] [*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
q Bleeding air
a Bleed the air.
For details, see Testing and adjusting,
“Bleeding air from each part”.
PC1250-8 19
SEN01201-00 50 Disassembly and assembly
For details, see “Removal of bucket assembly”. k When aligning the position of the pin hole,
a Secure the bucket link to the arm. never insert your fingers in the pin hole.
4. Sling arm cylinder assembly (3) and remove never insert your fingers in the pin hole.
pin (4). [*1] a Adjust with shims so that clearance (a)
a Set block [1] between the arm cylinder between the end face of the bottom of arm (6)
and the boom. and boom (7) is less than 1 mm.
q Shim thickness: 1.0 mm
6. Lift off arm assembly (6). q Refilling with oil (hydraulic tank)
a Add oil through the oil filler to the specified
4 Arm assembly: 4,000 kg level. Run the engine to circulate the oil
through the system. Then check the oil
level again.
20 PC1250-8
50 Disassembly and assembly SEN01201-00
Removal
PC1250-8 21
SEN01201-00 50 Disassembly and assembly
Removal and installation of boom 5. Disconnect wiring connector M10 (4) for work-
assembly 1 ing lamp.
22 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
[*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the pin hole.
a Adjust with shims (9) so that clearance (a)
between the end face of the foot of boom (7)
and bracket (8) is less than 1 mm.
q Shim thickness: 1.0, 1.5 mm
q Bleeding air
a Bleed the air.
For details, see Testing and adjusting,
“Bleeding air”.
PC1250-8 23
SEN01201-00 50 Disassembly and assembly
24 PC1250-8
50 Disassembly and assembly SEN01201-00
Installation
q Carry out installation in the reverse order to
removal.
[*1] [*2]
2 Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
2 Grease after assembling pin: Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
a Adjust with shims (15) so that clearance (a)
between bracket (14) and the end face of the
foot of boom (13) is less than 1 mm.
q Shim thickness : 1.0, 1.5 mm
q Bleeding air
For details, see Testing and adjusting, “Bleed-
ing air from each part”.
PC1250-8 25
SEN01202-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01202-00 50 Disassembly and assembly
2 PC1250-8
50 Disassembly and assembly SEN01202-00
14. Pull outside air filter cover open-close lever (18). 19. Disconnect 2 antenna wires (25) and connec-
tor (26).
15. Remove outside air filter (19).
20. Disconnect 2 cab wiring intermediate connec-
tors (27).
q H09: Top side
q H08: Bottom side
PC1250-8 3
SEN01202-00 50 Disassembly and assembly
4 PC1250-8
50 Disassembly and assembly SEN01202-00
a Among the panes of window glass on the 4 (1) : Right side window glass
sides of the operator's cab, 4 panes (1) – (4) (2) : Left side rear window glass
are stuck. (3) : Door lower window glass
In this section, the procedure for replacing the (4) : Front window glass
stuck glass is explained. (5) : Front window assembly
When replacing front window glass (4), remove (Front window glass + Front frame)
front window assembly (5). (It is impossible to *For the front window pull-up specification only
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the oper- (16) : Center trim seal
ator's cab.)
For the procedure for replacing the front win-
dow assembly, see “Removal and installation
of front window assembly”.
PC1250-8 5
SEN01202-00 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part number Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
Removal
a Remove the window glass to be replaced
according to the following procedure.
6 PC1250-8
50 Disassembly and assembly SEN01202-00
PC1250-8 7
SEN01202-00 50 Disassembly and assembly
8 PC1250-8
50 Disassembly and assembly SEN01202-00
a Parts to be coated with primer: Apply the 1) Stick both-sided adhesive tape (6) for right
primer to the sticking surfaces of window side window glass (1) as shown in the fig-
glass (9) and all over dimension (d) which ure.
will be on both-sided adhesive tape (6)
and operator's cab (8).
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
PC1250-8 9
SEN01202-00 50 Disassembly and assembly
3) Stick both-sided adhesive tape (6) for door a Stick both-sided adhesive tape (6c) of
lower window glass (3) as shown in the the lower side of the front window
figure. glass along the outside edge of the
lower line, differently from other both-
sided adhesive tapes (6). (If it is stuck
along the inside, it will be seen
through the transparent part of the
glass.)
10 PC1250-8
50 Disassembly and assembly SEN01202-00
6. Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer): 3) Set adhesive cartridge (12) to caulking
SUNSTAR PENGUINE gun [7].
SEAL 580 SUPER "S" a An electric caulking gun is more effi-
2 Adhesive (Winter): cient.
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25°C.
a Never heat the adhesive higher than
30°C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
PC1250-8 11
SEN01202-00 50 Disassembly and assembly
12 PC1250-8
50 Disassembly and assembly SEN01202-00
PC1250-8 13
SEN01202-00 50 Disassembly and assembly
14 PC1250-8
50 Disassembly and assembly SEN01202-00
Removal and installation of front 7. Remove rollers (8) and (9) under the both
window assembly 1 sides of the front window.
Removal
PC1250-8 15
SEN01202-00 50 Disassembly and assembly
16 PC1250-8
50 Disassembly and assembly SEN01202-00
Installation 4. Install right corner block (3) and fix right corner
q Carry out installation in the reverse order to block bracket (7) with right striker bolt (5).
removal. a Tighten the striker bolt securely after
adjusting it in step 6.
[*1] [*2] a Install the right corner block so that there
q Adjust opening and closing of the front window will be no level difference at part (a).
assembly according to the following proce- a Install the right corner block so that level
dure. difference (b) between the rail and right
corner block (3) at part (PF) will be 0 – 1.0
1. Open and close the front window to check that mm. Check that the right corner block is
it does not interfere with the rails and the roll- not projected from the rail at the rolling
ers are not hitch. surface of the roller.
a Secure roller clearance (c) at part (PJ).
2. If there is any problem in opening or closing of
the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
3 Mounting bolt: 9.8 Nm {1.0 kgm}
PC1250-8 17
SEN01202-00 50 Disassembly and assembly
5. Install left corner blocks (1) and (2) and secure 6. Adjust the striker bolts according to the follow-
left corner bracket (6) with left striker bolt (4). ing procedure (Adjust the “CLOSE” positions of
a Tighten the striker bolt securely after the front window assembly locks).
adjusting it in step 6. 1) Tighten left striker bolt (4) and right striker
a Install the left corner blocks so that there bolt (5) at roughly right positions so that
will be no level difference at 2 parts (d). front window glass (18) will be fitted to
a Secure roller clearance (e). cab-side trim seal (19).
18 PC1250-8
50 Disassembly and assembly SEN01202-00
PC1250-8 19
SEN01202-00 50 Disassembly and assembly
[*3]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
20 PC1250-8
50 Disassembly and assembly SEN01202-00
PC1250-8 21
SEN01203-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN01203-00 50 Disassembly and assembly
Electrical system 1
Removal and installation of air
conditioner unit assembly 1
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
2 PC1250-8
50 Disassembly and assembly SEN01203-00
10. Pull ambient air filter cover open-close lever 18. Remove the mounting clamp and disconnect
(11). air conditioner wiring connector (27).
11. Remove outside air filter (12). 19. Remove 4 mounting bolts and remove pump
control assembly (28).
a Put aside the governor pump control
assembly.
PC1250-8 3
SEN01203-00 50 Disassembly and assembly
Installation
q Installation is done in the reverse order of
removal.
[*1]
a When installing the air conditioner circuit
hoses, use care so that dirt, water, may not
enter.
a Make sure before the installation that there is
O-ring at the piping connector of the air condi-
tioner hose.
a Check that there is no defect or deterioration
on the O-ring.
a When connecting the piping for refrigerant,
apply the compressor oil for the new refriger-
ant to the O-ring (Denso: ND-OIL8 or ZEXEL:
ZXL100PG (PAG46 or equivalent)).
4 PC1250-8
50 Disassembly and assembly SEN01203-00
Installation
q Installation is done in the reverse order of
removal.
PC1250-8 5
SEN01203-00 50 Disassembly and assembly
Installation
q Installation is done in the reverse order of
removal.
6 PC1250-8
50 Disassembly and assembly SEN01203-00
Installation
q Carry out installation in the reverse order to
removal.
PC1250-8 7
SEN01203-00 50 Disassembly and assembly
8 PC1250-8
50 Disassembly and assembly SEN01203-00
PC1250-8 9
SEN00910-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00910-00 90 Diagrams and drawings
2 PC1250-8
Hydraulic circuit diagram (1/2)
Hydraulic diagrams and drawings PC1250-8
1
Hydraulic circuit diagram (1/2) 1
SEN00910-00
PC1250-8 3
Hydraulic circuit diagram (2/2)
PC1250-8
Hydraulic circuit diagram (2/2) 1
SEN00910-00
PC1250-8 5
90 Diagrams and drawings SEN00910-00
PC1250-8 7
SEN00911-00
PC1250-8
PC1250SP-8
PC1250LC-8
PC1250-8 1
SEN00911-00 90 Diagrams and drawings
2 PC1250-8
Electrical circuit diagram (1/7)
Electrical diagrams and drawings PC1250-8
1
Electrical circuit diagram (1/7) 1
SEN00911-00
PC1250-8 3
Electrical circuit diagram (2/7)
PC1250-8
Electrical circuit diagram (2/7) 1
SEN00911-00
PC1250-8 5
Electrical circuit diagram (3/7)
PC1250-8
Electrical circuit diagram (3/7) 1
SEN00911-00
PC1250-8 7
Electrical circuit diagram (4/7)
PC1250-8
Electrical circuit diagram (4/7) 1
SEN00911-00
PC1250-8 9
Electrical circuit diagram (5/7)
PC1250-8
Electrical circuit diagram (5/7) 1
SEN00911-00
PC1250-8 11
Electrical circuit diagram (6/7)
PC1250-8
Electrical circuit diagram (6/7) 1
SEN00911-00
PC1250-8 13
Electrical circuit diagram (7/7)
PC1250-8
Electrical circuit diagram (7/7) 1
SEN00911-00
PC1250-8 15
90 Diagrams and drawings SEN00911-00
PC1250-8 17