Komatsu PC1250-8R, PC1250SP-8R 35001 & Up SEN02048-08 (Preview)
COVER
00 Index and foreword
Index
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
Specification and technical data
Backhoe specification
Loading shovel specification
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
Engine and cooling system
PTO
PTO lubrication system
Radiator and oil cooler
Power train
Power train
Swing machinery
Swing circle
Final drive
Sprocket
Undercarriage and frame
Track frame, recoil spring
Idler
Carrier roller
Track roller
Track shoe
Air system
Air piping drawing
Air circuit diagram
Air governor
Air tank
Safety valve
Horn valve
Grease pump
Hydraulic system, Part 1
Hydraulic piping drawing
Hydraulic tank
Hydraulic pump
Line oil filter
Pilot oil filter
Return oil filter
Drain oil filter
Cooling fan pump
Cooling fan motor
Aftercooler fan motor
Hydraulic system, Part 2
Control valve
Swing motor
Center swivel joint
Travel motor
PPC control relief valve
Accumulator
Valve control
PPC valve
Solenoid valve
Hydraulic cylinder
Work equipment
Work equipment
Dimensions of work equipment
Cab and its attachments
Air conditioner
Electrical system
Engine control
Electric control system
Monitor system
Sensor
20 Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts
30 Testing and adjusting
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Sketch of special tool
Measuring engine speed
Measuring air supply pressure (Boost pressure)
Measuring exhaust temperature
Measuring exhaust color
Adjustment of valve clearance
Measurement of compression pressure
Measuring blow-by pressure
Measurement of engine oil pressure
Adjusting engine speed sensor
Handling fuel system parts
Releasing residual pressure in fuel system
Testing fuel pressure
Measurement of fuel return rate and fuel leakage
Bleeding air from fuel circuit
Testing fuel system for leakage
Procedure for checking alternator and replacing belt
Testing and adjusting, Part 2
Testing swing circle bearing clearance
Testing wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit
Testing and adjusting control circuit oil pressure
Testing and adjusting piston pump control pressure
Testing servo piston stroke
Testing and adjusting, Part 3
Measuring PPC valve output pressure and testing swing PPC shuttle valve
Measuring solenoid valve output pressure
Adjusting work equipment, swing PPC valve
Testing travel deviation
Testing locations causing hydraulic drift of work equipment
Measuring oil leakage
Measurement of fan speed
Measurement of fan circuit oil pressure
Measuring fan pump EPC solenoid valve output pressure
Bleeding air
Releasing remaining pressure in hydraulic circuit
Testing procedures for diode
Testing and adjusting, Part 4
Special function of machine monitor
Handling controller voltage circuit
Testing and adjusting, Part 5
VHMS controller initial setting procedure
Precautions for replacing VHMS controller
Testing and adjusting, Part 6
Pm-clinic service
40 Troubleshooting
Failure code table and fuse locations
Failure code table
Fuse locations
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and troubleshooting steps
Information in troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code), Part 1
Failure code [A000N1] Eng. Hi Out of Std
Failure code [AA10NX] Aircleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng. Oil Press. Low
Failure code [B@BAZK] Eng. Oil Level Low
Failure code [B@BCNS] Eng. Water Overheat
Failure code [B@BCZK] Eng. Water Lvl Low
Failure code [B@CBNS] High PTO temperature
Failure code [B@HANS] Hydr. Oil Overheat
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Troubleshooting by failure code (Display of code), Part 2
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sensor Sup. 1 Volt. High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Persistent Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [D110KB] Battery Relay Drive S/C
Failure code [D163KB] Flash Light Relay S/C
Failure code [D195KB] Step Light Relay S/C
Failure code [DA22KK] Pump controller solenoid: Source voltage reduction
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA2SKQ] Model selection Abnormality
Failure code [DA80MA] Auto. Lub. Abnormal
Failure code [DA2RMC] Pump Comm. Abnormality
Failure code [DAFRMC] Monitor Comm. Abnormality
Troubleshooting by failure code (Display of code), Part 3
Failure code [DBB0KK] VHMS source voltage Error (or change of VHMSLED display from n9 to 01)
Failure code [DBB0KQ] VHMS Connector Mismatch (or change of VHMS-LED display from nf to 11)
Failure code [DBB3KK] Abnormality in VBAT voltage (or change of VHMS-LED display from n9 to 05)
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMSLED display from n9 to 04)
Failure code [DBB6KP] VHMS 24V source sys Error (or change of VHMS-LED display from n9 to 02)
Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED display from n8 to 02)
Failure code [DGE5KB] Ambi. Temp. Sensor S/C
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMSLED display from n5 to 01)
Failure code [DGT4KA] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 12)
Failure code [DGT4KB] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 11)
Failure code [DGT5KA] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 22)
Failure code [DGT5KB] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display from n3 to 21)
Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display from n3 to 32)
Failure code [DHE5KY] Blowby Pres. Sensor Failure) (or change of VHMS-LED display from n3 to 31)
Failure code [DHPAMA] F Pump P. Sensor Abnormality
Failure code [DHPAZL] F Pump Relief Pressure Abnormality
Failure code [DHPBMA] R Pump P. Sensor Abnormality
Failure code [DHPBZL] R Pump Relief Pressure Abnormality
Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 23)
Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 24)
Failure code [DV20KB] Travel Alarm S/C
Failure code [DW41KA] Swing Priority Sol. Disc.
Failure code [DW41KB] Swing Priority Sol. S/C
Failure code [DW43KA] Travel Speed Sol. Disc.
Failure code [DW43KB] Travel Speed Sol. S/C
Failure code [DW45KA] Swing Brake Sol. Disc.
Failure code [DW45KB] Swing Brake Sol. S/C
Failure code [DW48KA] CO Cancel Sol. Disc.
Failure code [DW48KB] CO Cancel Sol. S/C
Troubleshooting by failure code (Display of code), Part 4
Failure code [DW7BKA] Fan Reverse Sol. Disc.
Failure code [DW7BKB] Fan Reverse Sol. S/C
Failure code [DW91KA] Travel Junction Sol. Disc.
Failure code [DW91KB] Travel Junction Sol. S/C
Failure code [DWK0KA] 2-stage Relief Sol. Disc.
Failure code [DWK0KB] 2-stage Relief Sol. S/C
Failure code [DX16KA] Fan Pump EPC Sol. Disc.
Failure code [DX16KB] Fan Pump EPC Sol. S/C
Failure code [DXA0KA] TVC Sol. Disc.
Failure code [DXA0KB] TVC Sol. S/C
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)
Failure code [F@BYNR] High F cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 62)
Failure code [F@BYNS] High F cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 61)
Failure code [F@BZNR] High R cyl. Exhaust Temp. 2 (or change of VHMS-LED display from n3 to 72)
Failure code [F@BZNS] High R cyl. Exhaust Temp. 1 (or change of VHMS-LED display from n3 to 71)
Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality
Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality
Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 11)
Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMSLED display from n5 to 21)
Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display from n5 to 12)
Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMSLED display from n5 to 22)
Failure code [J100L6] Abnormal Cnt. gear pump press (or change of VHMS-LED display from n5 to 71)
Failure code [j100L6] Abnormal Fan gear pump press (or change of VHMS-LED display from n5 to 81)
Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change of VHMS-LED display from n5 to 25)
Troubleshooting of electrical system (E-mode)
Before carrying out troubleshooting of electrical system
Information contained in troubleshooting table
E-1 Engine does not start (Engine does not rotate)
E-2 Auto-decelerator does not work
E-3 Auto engine warm-up device does not work
E-4 Preheater does not work
E-5 All work equipment, swing and travel do not move
E-6 Machine push-up circuit does not work
E-7 Boom shockless circuit cannot be reset
E-8 No display in machine monitor at all
E-9 Part of display on machine monitor is missing
E-10 Machine monitor displays contents irrelevant to the model
E-11 Fuel level monitor red lamp lights up while engine is running
E-12 Hydraulic oil temperature gauge does not display correctly
E-13 Fuel gauge does not display correctly
E-14 Swing lock monitor does not display correctly
E-15 When the monitor switch is operated, no display appears
E-16 Windshield wiper does not work
E-17 “Boom RAISE” is not correctly displayed in monitor function
E-18 “Boom LOWER” is not correctly displayed in monitor function
E-19 “Arm DIGGING” is not correctly displayed in monitor function
E-20 “Arm DUMPING” is not correctly displayed in monitor function
E-21 “Bucket CURL” is not correctly displayed in monitor function
E-22 “Bucket DUMPING” is not correctly displayed in monitor function
E-23 “SWING” is not correctly displayed in monitor function
E-24 “TRAVEL” is not correctly displayed in monitor function
E-25 Air conditioner does not work
E-26 Travel alarm does not sound
E-27 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up
E-28 Step light does not light up or go off
E-29 Electric priming pump does not operate or does not stop automatically
Troubleshooting of hydraulic and mechanical system (H-mode)
Before troubleshooting for hydraulic and mechanical systems
H-1 Speed or power of all work equipment, travel, and swing is low
H-2 Engine speed lowers remarkably or engine stalls
H-3 All work equipment, travel, and swing systems do not work
H-4 Abnormal sound is heard from around pump
H-5 Speed or power of boom is low
H-6 Speed or power of arm is low
H-7 Speed or power of bucket is low
H-8 Boom does not move
H-9 Arm does not move
H-10 Bucket does not move
H-11 Hydraulic drift of work equipment is large
H-12 Time lag of work equipment is large
H-13 Boom shockless function cannot be turned ON or OFF
H-14 Machine deviates in one direction
H-15 Machine deviates largely at start
H-16 Machine deviates largely during compound operation
H-17 Travel speed or power is low
H-18 Machine does not travel (only one track)
H-19 Travel speed does not change
H-20 Machine does not swing
H-21 Swing speed or acceleration is low
H-22 Swing speed or power is low in compound operation of travel and bucket
H-23 Swing speed or power is low in compound operation of travel and boom in swing priority mode
H-24 Upper structure overruns largely
H-25 Large shocks are made when upper structure stops swinging
H-26 Large abnormal sounds are made when upper structure stops swinging
H-27 Hydraulic drift of swing is large
H-28 Fan revolution is abnormal (Sound and vibration of the fan is abnormally large, and the fan is overheated)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
S-17 Air cannot be bled from fuel circuit
50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system (SAA6D170E-5)
Removal and installation of engine, PTO and hydraulic pump assembly
Removal and installation of radiator and hydraulic oil cooler assembly
Removal of air aftercooler assembly
Removal and installation of fuel cooler and air conditioner condenser assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Engine (SAA6D170E-5)
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Power train
Removal and installation of PTO assembly
Disassembly and assembly of PTO assembly
Removal and installation of swing machinery assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track shoe assembly
Disassembly and assembly of one link in field
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler adjustment cylinder assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of hydraulic pump assembly
Removal and installation of main pump input shaft oil seal
Removal and installation of 5-spool control valve assembly (No. 1)
Removal and installation of 4-spool control valve assembly (No. 2)
Removal and installation of 4-spool control valve assembly (No. 3)
Disassembly and assembly of control valve assembly (No. 1)
Disassembly and assembly of control valve assembly (No. 2)
Disassembly and assembly of control valve assembly (No. 3)
Removal and installation of swing motor assembly
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of travel motor assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of bucket cylinder assembly
Removal and installation of bottom dump cylinder assembly
Removal and installation of arm cylinder assembly
Removal and installation of boom cylinder assembly
Removal and installation of bucket assembly
Removal and installation of arm assembly
Removal and installation of boom assembly
Cab and its attachments
Removal and installation of operator cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of front window assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of Orbcomm terminal assembly for VHMS
Removal and installation of VHMS controller assembly
Removal and installation of engine controller assembly
90 Diagrams and drawings
Hydraulic circuit diagrams
Hydraulic circuit diagram (1/2) Serial number 35001 – 35016
Hydraulic circuit diagram (2/2) Serial number 35001 – 35016
Hydraulic circuit diagram (1/3) Serial number 35017 and up
Hydraulic circuit diagram (2/3) Serial number 35017 and up
Hydraulic circuit diagram (3/3)
Electrical diagrams and drawings
Electrical circuit diagram (1/7)
Electrical circuit diagram (2/7)
Electrical circuit diagram (3/7)
Electrical circuit diagram (4/7)
Electrical circuit diagram (5/7)
Electrical circuit diagram (6/7)
Electrical circuit diagram (7/7)
Connector arrangement diagram
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