PC1250-8R ShopManual PDF

SEN02048-05
HYDRAULIC PC1250 -8R

EXCAVATOR
PC1250SP -8R
PC1250- 35001
SERIAL NUMBERS and up
PC1250SP- 35001
SEN02050-05
HYDRAULIC EXCAVATOR 1SHOP MANUAL
PC1250-8R
PC1250SP-8R
Machine model Serial number

PC1250-8R 35001 and up
PC1250SP-8R 35001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
PC1250-8R 1
SEN02050-05 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN02048-05
00 Index and foreword SEN02049-05

Index SEN02050-05 q
Foreword and general information SEN02051-01
01 Specification SEN02052-02
Specification and technical data SEN02053-02
10 Structure, function and maintenance standard SEN02054-03

Engine and cooling system SEN02055-02 q
Power train SEN02056-01
Undercarriage and frame SEN02057-00
Air system SEN02058-00
Hydraulic system, Part 1 SEN02059-01 q
Hydraulic system, Part 2 SEN02060-01
Work equipment SEN02061-00
Cab and its attachments SEN02062-01
Electrical system SEN02063-02 q
20 Standard value table SEN02064-02

Standard service value table SEN02071-02 q
30 Testing and adjusting SEN02065-02

Testing and adjusting, Part 1 SEN02072-02 q
Testing and adjusting, Part 5 SEN02076-00
2 PC1250-8R
40 Troubleshooting SEN02066-02
Failure code table and fuse locations SEN02078-00
General information on troubleshooting SEN02079-02 q
Troubleshooting by failure code (Display of code), Part 1 SEN02080-00
Troubleshooting of electrical system (E-mode) SEN02085-01
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02086-01
Troubleshooting of engine (S-mode) SEN02087-01
50 Disassembly and assembly SEN02067-01

General information on disassembly and assembly SEN02785-01
Engine and cooling system (SAA6D170E-5) SEN02786-00
Engine (SAA6D170E-5) SEN02787-01
Hydraulic system SEN02790-01
Electrical system SEN02793-00
90 Diagrams and drawings SEN02068-04

Hydraulic circuit diagrams SEN02069-02 q
Electrical diagrams and drawings SEN02070-02
PC1250-8R 3
Table of contents 1
00 Index and foreword
Index SEN02050-05
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN02051-01

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN02053-02
Backhoe specification.................................................................................................................. 2
Loading shovel specification ....................................................................................................... 4
Specifications .............................................................................................................................. 6
Weight table ................................................................................................................................ 18
Table of fuel, coolant and lubricants ............................................................................................ 26
10 Structure, function and maintenance standard

Engine and cooling system SEN02055-02
PTO ............................................................................................................................................. 2
PTO lubrication system ............................................................................................................... 4
Radiator and oil cooler ................................................................................................................ 6
Power train .................................................................................................................................. 2
Swing machinery ......................................................................................................................... 4
Swing circle ................................................................................................................................. 8
Final drive.................................................................................................................................... 9
Sprocket ...................................................................................................................................... 12
Track frame, recoil spring ............................................................................................................ 2
Idler ............................................................................................................................................. 4
Carrier roller ................................................................................................................................ 6
Track roller................................................................................................................................... 7
Track shoe................................................................................................................................... 8
4 PC1250-8R
Air system SEN02058-00

Air piping drawing........................................................................................................................ 2
Air circuit diagram ....................................................................................................................... 3
Air governor................................................................................................................................. 4
Air tank ........................................................................................................................................ 5
Safety valve................................................................................................................................. 6
Horn valve ................................................................................................................................... 7
Grease pump .............................................................................................................................. 8
Hydraulic piping drawing ............................................................................................................. 2
Hydraulic tank ............................................................................................................................. 5
Hydraulic pump ........................................................................................................................... 7
Line oil filter ................................................................................................................................. 48
Pilot oil filter................................................................................................................................. 49
Return oil filter ............................................................................................................................. 50
Drain oil filter ............................................................................................................................... 51
Cooling fan pump ........................................................................................................................ 52
Cooling fan motor........................................................................................................................ 66
Aftercooler fan motor................................................................................................................... 72
Control valve ............................................................................................................................... 2
Swing motor ................................................................................................................................ 17
Center swivel joint ....................................................................................................................... 26
Travel motor ................................................................................................................................ 27
PPC control relief valve............................................................................................................... 37
Accumulator ................................................................................................................................ 38
Valve control................................................................................................................................ 39
PPC valve ................................................................................................................................... 40
Solenoid valve............................................................................................................................. 50
Hydraulic cylinder........................................................................................................................ 58
Work equipment .......................................................................................................................... 2
Dimensions of work equipment ................................................................................................... 6
Air conditioner ............................................................................................................................. 2
Engine control ............................................................................................................................. 2
Electric control system ................................................................................................................ 9
Monitor system............................................................................................................................ 45
Sensor......................................................................................................................................... 68
20 Standard value table

Standard service value table SEN02071-02
Standard value table for engine related parts.............................................................................. 2
Standard value table for chassis related parts ............................................................................ 3
PC1250-8R 5
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Measuring engine speed ............................................................................................................. 8
Measuring air supply pressure (Boost pressure)......................................................................... 9
Measuring exhaust temperature.................................................................................................. 10
Measuring exhaust color ............................................................................................................. 11
Adjustment of valve clearance .................................................................................................... 13
Measurement of compression pressure ...................................................................................... 15
Measuring blow-by pressure ....................................................................................................... 18
Measurement of engine oil pressure ........................................................................................... 19
Adjusting engine speed sensor ................................................................................................... 20
Handling fuel system parts .......................................................................................................... 21
Releasing residual pressure in fuel system................................................................................. 21
Testing fuel pressure ................................................................................................................... 22
Measurement of fuel return rate and fuel leakage....................................................................... 23
Bleeding air from fuel circuit ........................................................................................................ 26
Testing fuel system for leakage ................................................................................................... 28
Procedure for checking alternator and replacing belt.................................................................. 29
Testing swing circle bearing clearance........................................................................................ 2
Testing wear of sprocket.............................................................................................................. 3
Testing and adjusting track shoe tension .................................................................................... 4
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit...................... 5
Testing and adjusting control circuit oil pressure......................................................................... 19
Testing and adjusting piston pump control pressure ................................................................... 21
Testing servo piston stroke.......................................................................................................... 28
Measuring PPC valve output pressure and testing swing PPC shuttle valve.............................. 2
Measuring solenoid valve output pressure.................................................................................. 6
Adjusting work equipment, swing PPC valve .............................................................................. 8
Testing travel deviation................................................................................................................ 9
Testing locations causing hydraulic drift of work equipment........................................................ 10
Measuring oil leakage ................................................................................................................. 11
Measurement of fan speed.......................................................................................................... 19
Measurement of fan circuit oil pressure ...................................................................................... 20
Measuring fan pump EPC solenoid valve output pressure ......................................................... 22
Bleeding air ................................................................................................................................. 23
Releasing remaining pressure in hydraulic circuit ....................................................................... 25
Testing procedures for diode ....................................................................................................... 26
Special function of machine monitor............................................................................................ 2
Handling controller voltage circuit ............................................................................................... 42
VHMS controller initial setting procedure .................................................................................... 2
Precautions for replacing VHMS controller ................................................................................. 17
Pm-clinic service ......................................................................................................................... 2
40 Troubleshooting
Failure code table and fuse locations SEN02078-00
Failure code table........................................................................................................................ 2
Fuse locations ............................................................................................................................. 6
General information on troubleshooting SEN02079-02
Points to remember when troubleshooting .................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Checks before troubleshooting.................................................................................................... 4
6 PC1250-8R
Classification and troubleshooting steps ..................................................................................... 5

Information in troubleshooting table ............................................................................................ 9
Connection table for connector pin numbers .............................................................................. 11
T- branch box and T- branch adapter table ................................................................................. 47
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 [CA342] Calibration Code Incompatibility ............................................................... 66
Failure code [CA351] Injectors Drive Circuit Error ...................................................................... 68
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
PC1250-8R 7
Failure code [CA731] Eng Bkup Speed Sens Phase Error ......................................................... 18
Failure code [CA757] All Persistent Data Lost Error ................................................................... 19
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................. 20
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................... 22
Failure code [CA2185] Throt Sens Sup Volt High Error .............................................................. 24
Failure code [CA2186] Throt Sens Sup Volt Low Error ............................................................... 26
Failure code [CA2249] Rail Press Very Low Error ...................................................................... 27
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................. 28
Failure code [CA2556] Grid Htr Relay Volt High Error ................................................................ 30
Failure code [D110KB] Battery Relay Drive S/C ......................................................................... 32
Failure code [D163KB] Flash Light Relay S/C ............................................................................ 34
Failure code [D195KB] Step Light Relay S/C .............................................................................. 36
Failure code [DA22KK] Pump controller solenoid: Source voltage reduction ............................. 38
Failure code [DA25KP] Press. Sensor Power Abnormality ......................................................... 40
Failure code [DA2SKQ] Model selection Abnormality ................................................................. 42
Failure code [DA80MA] Auto. Lub. Abnormal ............................................................................. 44
Failure code [DA2RMC] Pump Comm. Abnormality ................................................................... 46
Failure code [DAFRMC] Monitor Comm. Abnormality................................................................. 48
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
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-LED display
from n5 to 01) ..................................................................................................................... 18
Failure code [DGT4KA] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display
from n3 to 12) ..................................................................................................................... 20
Failure code [DGT4KB] F Exhaust Temp. Sensor Failure (or change of VHMS-LED display
from n3 to 11)...................................................................................................................... 22
Failure code [DGT5KA] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display
from n3 to 22) ..................................................................................................................... 24
Failure code [DGT5KB] R Exhaust Temp. Sensor Failure (or change of VHMS-LED display
from n3 to 21) ..................................................................................................................... 26
Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of VHMS-LED display
from n3 to 32) ..................................................................................................................... 28
Failure code [DHE5KY] Blowby Pres. Sensor Failure) (or change of VHMS-LED display
from n3 to 31) ..................................................................................................................... 30
Failure code [DHPAMA] F Pump P. Sensor Abnormality............................................................. 32
Failure code [DHPAZL] F Pump Relief Pressure Abnormality .................................................... 34
Failure code [DHPBMA] R Pump P. Sensor Abnormality ............................................................ 36
Failure code [DHPBZL] R Pump Relief Pressure Abnormality.................................................... 38
Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display
from n5 to 23) ..................................................................................................................... 40
Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display
from n5 to 24) ..................................................................................................................... 42
Failure code [DV20KB] Travel Alarm S/C.................................................................................... 44
Failure code [DW41KA] Swing Priority Sol. Disc......................................................................... 46
Failure code [DW41KB] Swing Priority Sol. S/C.......................................................................... 48
Failure code [DW43KA] Travel Speed Sol. Disc. ........................................................................ 50
8 PC1250-8R
Failure code [DW43KB] Travel Speed Sol. S/C .......................................................................... 52

Failure code [DW45KA] Swing Brake Sol. Disc. ......................................................................... 54
Failure code [DW45KB] Swing Brake Sol. S/C ........................................................................... 56
Failure code [DW48KA] CO Cancel Sol. Disc............................................................................. 58
Failure code [DW48KB] CO Cancel Sol. S/C.............................................................................. 60
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
Failure code [DY2DKB] Wiper Drive (For) S/C ........................................................................... 32
Failure code [DY2EKB] Wiper Drive (Rev) S/C........................................................................... 36
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display
from n3 to 38) ..................................................................................................................... 38
Failure code [F@BYNR] High F cyl. Exhaust Temp. 2 (or change of VHMS-LED display
from n3 to 62) ..................................................................................................................... 40
Failure code [F@BYNS] High F cyl. Exhaust Temp. 1 (or change of VHMS-LED display
from n3 to 61) ..................................................................................................................... 42
Failure code [F@BZNR] High R cyl. Exhaust Temp. 2 (or change of VHMS-LED display
from n3 to 72) ..................................................................................................................... 44
Failure code [F@BZNS] High R cyl. Exhaust Temp. 1 (or change of VHMS-LED display
from n3 to 71) ..................................................................................................................... 46
Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality .................................................. 48
Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality ................................................. 50
Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display
from n5 to 11) ..................................................................................................................... 52
Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMS-LED display
from n5 to 21) ..................................................................................................................... 54
Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of VHMS-LED display
from n5 to 12) ..................................................................................................................... 56
Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMS-LED display
from n5 to 22) ..................................................................................................................... 58
Failure code [J100L6] Abnormal Cnt. gear pump press (or change of VHMS-LED display
from n5 to 71) ..................................................................................................................... 60
Failure code [j100L6] Abnormal Fan gear pump press (or change of VHMS-LED display
from n5 to 81) ..................................................................................................................... 62
Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change of VHMS-LED display
from n5 to 25) ..................................................................................................................... 64
Troubleshooting of electrical system (E-mode) SEN02085-01
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
PC1250-8R 9
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
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
E-29 Electric priming pump does not operate or does not stop automatically .............................. 54
Troubleshooting of hydraulic and mechanical system (H-mode) SEN02086-01
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
H-13 Boom shockless function cannot be turned ON or OFF ..................................................... 24
H-14 Machine deviates in one direction ...................................................................................... 24
H-15 Machine deviates largely at start ........................................................................................ 26
H-16 Machine deviates largely during compound operation ....................................................... 27
H-17 Travel speed or power is low .............................................................................................. 27
H-18 Machine does not travel (only one track)............................................................................ 28
H-19 Travel speed does not change ........................................................................................... 29
H-20 Machine does not swing ..................................................................................................... 30
H-21 Swing speed or acceleration is low .................................................................................... 31
H-22 Swing speed or power is low in compound operation of travel and bucket ........................ 32
H-23 Swing speed or power is low in compound operation of travel and boom in
swing priority mode............................................................................................................. 32
H-24 Upper structure overruns largely ........................................................................................ 33
H-25 Large shocks are made when upper structure stops swinging........................................... 34
H-26 Large abnormal sounds are made when upper structure stops swinging .......................... 35
H-27 Hydraulic drift of swing is large ........................................................................................... 36
H-28 Fan revolution is abnormal (Sound and vibration of the fan is abnormally large,
and the fan is overheated) .................................................................................................. 37
Troubleshooting of engine (S-mode) SEN02087-01
Method of using troubleshooting chart ........................................................................................ 3
S-1 Starting performance is poor................................................................................................. 6
S-2 Engine does not start............................................................................................................ 7
S-3 Engine does not pick up smoothly ........................................................................................ 10
10 PC1250-8R
S-4 Engine stops during operations ............................................................................................ 11

S-5 Engine does not rotate smoothly .......................................................................................... 12
S-6 Engine lacks output (or lacks power).................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion) ................................................................ 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................... 15
S-9 Oil becomes contaminated quickly ....................................................................................... 16
S-10 Fuel consumption is excessive........................................................................................... 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................. 18
S-12 Oil pressure drops .............................................................................................................. 19
S-13 Oil level rises (Entry of coolant or fuel) ............................................................................... 20
S-14 Coolant temperature becomes too high (overheating) ....................................................... 21
S-15 Abnormal noise is made ..................................................................................................... 22
S-16 Vibration is excessive ......................................................................................................... 23
S-17 Air cannot be bled from fuel circuit ..................................................................................... 24
50 Disassembly and assembly

General information on disassembly and assembly SEN02785-01
How to read this manual ............................................................................................................. 2
Coating materials list................................................................................................................... 4
Special tools list........................................................................................................................... 7
Sketches of special tools............................................................................................................. 13
Engine and cooling system (SAA6D170E-5) SEN02786-00
Removal and installation of engine, PTO and hydraulic pump assembly ................................... 2
Removal and installation of radiator and hydraulic oil cooler assembly ...................................... 12
Removal of air aftercooler assembly ........................................................................................... 17
Removal and installation of fuel cooler and air conditioner condenser assembly ....................... 20
Removal and installation of fan motor assembly......................................................................... 22
Removal and installation of fuel tank assembly .......................................................................... 28
Engine (SAA6D170E-5) SEN02787-01
Removal and installation of fuel supply pump assembly............................................................. 2
Removal and installation of cylinder head assembly .................................................................. 7
Removal and installation of fuel injector assembly ..................................................................... 26
Removal and installation of engine front seal ............................................................................. 31
Removal and installation of engine rear seal .............................................................................. 33
Removal and installation of PTO assembly................................................................................. 2
Disassembly and assembly of PTO assembly ............................................................................ 4
Removal and installation of swing machinery assembly ............................................................. 8
Removal and installation of swing motor and swing machinery assembly.................................. 10
Disassembly and assembly of swing machinery assembly......................................................... 13
Disassembly and assembly of swing motor and swing machinery assembly ............................. 20
Removal and installation of swing circle assembly ..................................................................... 27
Disassembly and assembly of final drive assembly .................................................................... 28
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
PC1250-8R 11
Hydraulic system SEN02790-01

Removal and installation of hydraulic tank assembly .................................................................. 2
Removal and installation of hydraulic pump assembly................................................................ 4
Removal and installation of main pump input shaft oil seal......................................................... 10
Removal and installation of 5-spool control valve assembly (No. 1) ........................................... 11
Disassembly and assembly of control valve assembly (No. 1) ................................................... 17
Removal and installation of swing motor assembly..................................................................... 28
Removal and installation of center swivel joint assembly............................................................ 32
Disassembly and assembly of center swivel joint assembly ....................................................... 33
Removal and installation of travel motor assembly ..................................................................... 35
Disassembly and assembly of work equipment PPC valve assembly ........................................ 36
Disassembly and assembly of travel PPC valve assembly ......................................................... 38
Disassembly and assembly of hydraulic cylinder assembly........................................................ 40
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
Removal and installation of bucket assembly ............................................................................. 16
Removal and installation of arm assembly .................................................................................. 20
Removal and installation of boom assembly ............................................................................... 23
Removal and installation of operator cab assembly .................................................................... 2
Removal and installation of operator’s cab glass (Stuck glass) .................................................. 5
Removal and installation of front window assembly .................................................................... 15
Removal and installation of air conditioner unit assembly........................................................... 2
Removal and installation of monitor assembly ............................................................................ 5
Removal and installation of pump controller assembly ............................................................... 6
Removal and installation of Orbcomm terminal assembly for VHMS .......................................... 7
Removal and installation of VHMS controller assembly .............................................................. 8
Removal and installation of engine controller assembly ............................................................. 9
90 Diagrams and drawings

Hydraulic circuit diagrams SEN02069-02
Hydraulic circuit diagram (1/2) Serial number 35001 – 35016 .................................................... 3
Hydraulic circuit diagram (2/2) Serial number 35001 – 35016 .................................................... 5
Hydraulic circuit diagram (1/3) Serial number 35017 and up ...................................................... 7
Hydraulic circuit diagram (2/3) Serial number 35017 and up ...................................................... 9
Hydraulic circuit diagram (3/3)..................................................................................................... 11
Electrical diagrams and drawings SEN02070-02
Electrical circuit diagram (1/7) ..................................................................................................... 3
Connector arrangement diagram ................................................................................................ 17
12 PC1250-8R
PC1250-8R 13
SEN02050-05
PC1250-8R, PC1250SP-8R Hydraulic excavator

Form No. SEN02050-05
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 11-07 (01)
14
SEN02051-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
PC1250-8R 1
Safety notice 1 (Rev. 2007/03)

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.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. gloves, apron, shielding goggles, cap and
1) Before carrying out any greasing or other clothes suited for welding work.
repairs, read all the safety plates stuck to 8) Before starting work, warm up your body
the machine. For the locations of the thoroughly to start work under good condi-
safety plates and detailed explanation of tion.
precautions, see the Operation and Main-
tenance Manual. Safety points
2) Decide a place in the repair workshop to
keep tools and removed parts. Always 1 Good arrangement
keep the tools and parts in their correct 2 Correct work clothes
places. Always keep the work area clean 3 Following work standard
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas 4 Making and checking signs
provided for smoking. Never smoke while Prohibition of operation and handling by
5
working. unlicensed workers
3) When carrying out any operation, always 6 Safety check before starting work
wear safety shoes and helmet. Do not
Wearing protective goggles
wear loose work clothes, or clothes with 7
(for cleaning or grinding work)
buttons missing.
q Always wear safety glasses when hit- Wearing shielding goggles and protectors
8
ting parts with a hammer. (for welding work)
q Always wear safety glasses when 9 Good physical condition and preparation
grinding parts with a grinder, etc. Precautions against work which you are
4) When carrying out any operation with 2 or 10
not used to or you are used to too much
more workers, always agree on the oper-
ating procedure before starting. Always
inform your fellow workers before starting 2. Preparations for work
any step of the operation. Before starting 1) Before adding oil or making any repairs,
work, hang UNDER REPAIR warning park the machine on hard and level
signs in the operator's compartment. ground, and apply the parking brake and
5) Only qualified workers must carry out work block the wheels or tracks to prevent the
and operation which require license or machine from moving.
qualification. 2) Before starting work, lower the work
6) Keep all tools in good condition, learn the equipment (blade, ripper, bucket, etc.) to
correct way to use them, and use the the ground. If this is not possible, insert
proper ones of them. Before starting work, the lock pin or use blocks to prevent the
thoroughly check the tools, machine, fork- work equipment from falling. In addition,
lift, service car, etc. be sure to lock all the control levers and
hang warning signs on them.
2 PC1250-8R
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.
PC1250-8R 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is seen well
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 PC1250-8R
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
warning lamp, and check safety. 25 55.3 5.6
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.
PC1250-8R 5
8. Precautions for disconnecting and con-

necting hoses and tubes in air conditioner
circuit
1) Disconnection
k Collect the air conditioner refriger-
ant (R134a) from the air condi-
tioner circuit in advance.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas (R134a) gets
in your eyes, you may lose your
sight. Accordingly, when collect-
ing or filling it, you must be quali-
fied for handling the refrigerant
and put on protective goggles.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
ZEXEL: ZXL100PG (equivalent to
PAG46)) to its O-rings.
a Example of O-ring (Fitted to every joint of

hoses and tubes)
a For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
6 PC1250-8R
How to read the shop manual 1
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.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The 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.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
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.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
PC1250-8R 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
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.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
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.
2 Coat Places to be coated with adhesives, etc. during 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 { }.
8 PC1250-8R
Explanation of terms for maintenance standard 1

The maintenance standard values necessary for judgment of products and parts are described by the follow-
ing terms.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
PC1250-8R 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value

q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit must be
replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value below
which the product can be used without
causing a problem is called the “allowable
value”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 PC1250-8R
Handling of electric equipment and hydraulic component 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
PC1250-8R 11
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.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 PC1250-8R
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
PC1250-8R 13
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 the 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.
14 PC1250-8R
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
PC1250-8R 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 PC1250-8R
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.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
PC1250-8R 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
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.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 PC1250-8R
5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and 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.
PC1250-8R 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 107 – 170, 12V140 engine
q 107E-1 q Various temperature sensors
q 114E-3 Example)
q 125E-5 Intake air temperature sensor in
q 140E-5 intake manifold: TIM
q 170E-5 Fuel temperature sensor: TFUEL
q 12V140E-3 Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
1. Slide lock type etc.
(FRAMATOME-3, FRAMATOME-2) Disconnect the connector by pulling lock
q 107 – 170, 12V140 engines (B) (on the wiring harness side) of connec-
q Various pressure sensors and NE tor (2) outward.
speed sensor
Examples)
Intake air pressure in intake manifold:
PIM (125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(107, 114 engines)
Ne speed sensor of flywheel housing:
NE (107 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 PC1250-8R
3. Push lock type

q 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engine

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
PC1250-8R 21
q 125 – 170, 12V140 engine 4. Turn-housing type (Round green connector)

4) While pressing lock (E) of the connector, q 140 engine
pullout connector (5) in the direction of the Example)
arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure in common rail: PFUEL etc. 1) Disconnect connector (6) according to the
(AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 PC1250-8R
How to read electric wire code 1

a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. 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.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(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)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
PC1250-8R 23
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
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
24 PC1250-8R
3. Color codes table
(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.
4. Types of circuits and color codes
(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 – – – – – – –
PC1250-8R 25
Precautions when carrying out operation 1

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 PC1250-8R
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
PC1250-8R 27
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
28 PC1250-8R
Method of disassembling and connecting push-pull type coupler 1

k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
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.
PC1250-8R 29
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
contacts contact surface (a) of the hexag-
30 PC1250-8R
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
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-
PC1250-8R 31
Standard tightening torque table 1

1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below. (When using
torque wrench)
a The following table corresponds to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5
18 27 320 – 400 33.0 – 41.0
20 30 455 – 565 46.5 – 58.0
22 32 610 – 765 62.5 – 78.0
24 36 785 – 980 80.0 – 100.0
27 41 1,150 – 1,440 118 – 147
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table corresponds to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
a Fig. A a Fig. B
32 PC1250-8R
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
PC1250-8R 33
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.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. -
No. of across Thread diame-
Thread size Number of
Range Target ter (mm) (Ref-
hose flats (mm) threads, type of
erence)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
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
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
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.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
34 PC1250-8R
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.
Thread size Tightening torque

inch Nm kgm
1/16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
PC1250-8R 35
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
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
36 PC1250-8R
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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
PC1250-8R 37
Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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
38 PC1250-8R
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
PC1250-8R 39
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.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade 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
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
40 PC1250-8R
PC1250-8R 41
SEN02051-01

© 2007 KOMATSU
All Rights Reserved
42
SEN02053-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
01 Specification 1
Specification and technical data
Backhoe specification ..................................................................................................................................... 2
Loading shovel specification ........................................................................................................................... 4
Specifications .................................................................................................................................................. 6
Weight table .................................................................................................................................................. 18
Table of fuel, coolant and lubricants.............................................................................................................. 26
PC1250-8R 1
SEN02053-02 01 Specification
Backhoe specification 1
Specification drawings
Item Unit PC1250-8R PC1250SP-8R

A Overall length mm 16,020 14,790
B Overall height mm 16,040 16,265
C Overall width mm 15,600 15,600
D Track shoe width mm 14,700 14,700
E Height of cab mm 14,120 14,120
F Tail swing radius mm 14,870 14,870
G Track overall length mm 16,425 16,425
H Length of track on ground mm 14,995 14,995
I Min. ground clearance mm 14,990 14,990
2 PC1250-8R
Working range drawing 1
Item Unit PC1250-8R PC1250SP-8R

A Max. digging reach mm 15,350 14,070
B Max. digging depth mm 19,350 17,900
C Max. digging height mm 13,400 13,000
D Max. vertical wall depth mm 17,610 15,025
E Max. dumping height mm 18,680 18,450
F Max. reach at ground level mm 15,000 13,670
PC1250-8R 3
Loading shovel specification 1

Specification drawings
Item Unit PC1250-8R (Loading shovel specification)

A Overall length mm 10,940
B Overall height mm 16,200
C Overall width mm 15,600
D Track shoe width mm 10,700
E Height of cab mm 14,120
F Tail swing radius mm 14,870
G Track overall length mm 16,425
H Length of track on ground mm 14,995
I Min. ground clearance mm 10,990
4 PC1250-8R
Working range drawing 1
Item Unit PC1250-8R (Loading shovel specification)

A Max. digging reach mm 11,400
B Max. reach at ground level mm 10,900
C Max. digging height mm 12,330
D Max. digging depth mm 13,650
E Min. reach at ground level mm 16,130
F Min. swing radius of work equipment mm 16,760
PC1250-8R 5
Specifications 1
Backhoe specification
PC1250-8R Serial number 35001 – 35016

Machine model PC1250-8R
Bucket capacity m 3
5.0
Weight of machine kg 106,500
Max. digging depth mm 9,350
Working range
Max. vertical wall depth mm 7,610

Max. digging reach mm 15,350
Max. reach at ground level mm 15,000
Max. digging height mm 13,400
Performance
Max. dumping height mm 8,680

Max. digging force kN {kg} 479 {48,800}
Swing speed rpm 5.5
Swing max. slope angle deg. 12
Travel speed km/h Lo: 2.1 Hi: 3.2
Gradeability deg. 35
Ground pressure
kPa {kg/cm2} 136 {1.39}
[standard double grouser shoe width: 700 mm]
Overall length mm 16,020
Overall width mm 5,600
Overall width of track mm 4,965
Overall height (for transport) mm 6,040
Overall height to top of machine mm 5,180
Dimensions
Ground clearance of upper structure mm 1,790

Min. ground clearance mm 990
Tail swing radius mm 4,870
Min. swing radius of work equipment mm 7,965
Height of work equipment at min. swing radius mm 11,390
Length of track on ground mm 4,995
Track gauge mm 3,900
Height of machine cab mm 4,075
6 PC1250-8R

Model SAA6D170E-5
4-cycle, water-cooled, in-line, vertical,
Type direct injection, with turbocharger and
aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 170 × 170
Piston displacement l {cc} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 502/1,800 {672/1,800}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 3,025/1,300 {308.5/1,300}

High idle rpm 2,000
Low idle rpm 900
Min. fuel consumption g/kWh {g/HPh} 217.5 {162}
Starting motor 24 V, 11 kW × 2
Alternator 24 V, 60 A
Battery 12 V, 220 Ah × 2
Radiator core type ALW-4
Carrier roller 3 on each side
carriage
Under-
Track roller 8 on each side

Assembly-type double grouser,
Track shoe
48 on each side
Variable displacement piston type:
HPV160+160
Variable displacement piston + gear type:
Type
HPV95+95+SAL014, HPV95+95+SAL008
Hydraulic
pump
Fan pump variable displacement piston +

gear type: HPV95+SAR100
Piston type: 494+494+600, 144 (Fan pump),
Delivery l/min
gear type: 158, 31, 19
Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Hydraulic Control
Type × No. 4-spool type × 2, + 5-spool type × 1

valve
Control method Hydraulic

Hydraulic system
Piston type (with brake valve, shaft brake):

Travel motor
× 2 (MSF340VP-EH)
motor
Piston type (with safety valve, shaft brake):

Swing motor
× 2 (KMF160AB-2)
*1 Boom *1, *2 Arm *1, *2 Bucket
Hydraulic cylinder
Cylinder type Double-acting piston

Inside diameter of cylinder mm 225 250 160
Outside diameter of piston rod mm 160 170 115
Stroke mm 2,390 2,435 1,825
Max. distance between pins mm 5,839 6,055 4,360
Min. distance between pins mm 3,449 3,620 2,535
Hydraulic tank Box-shaped, with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J5)
*1: Head side with cushion *2: Bottom side with cushion
PC1250-8R 7
PC1250-8R Serial number 35017 and up

Bucket capacity m 3
5.0
Working range

Performance

Swing speed rpm 5.8
Ground pressure
kPa {kg/cm2} 136 {1.39}
Dimensions

8 PC1250-8R

Model SAA6D170E-5
Performance
Engine

High idle rpm 2,000
Low idle rpm 900
carriage
Under-

Track shoe
48 on each side
HPV160+160
Type
HPV95+95+SAL014, HPV95+95+SAL008
Hydraulic
pump

Delivery l/min
gear type: 158, 31, 19
Hydraulic Control

valve

Hydraulic system

Travel motor
× 2 (MSF340VP-EH)
motor

Swing motor
× 2 (KMF230AB-5)
Hydraulic cylinder

Stroke mm 2,390 2,435 1,825
Hydraulic cooler
Air cooled (J5/J6)
(Standard spec./55°C spec.)
PC1250-8R 9
PC1250SP-8R Serial number 35001 – 35016

Machine model PC1250SP-8R
Bucket capacity m 3
6.7
Working range

Performance

Swing speed rpm 5.5
Ground pressure
kPa {kg/cm2} 141 {1.44}
Dimensions

10 PC1250-8R

Model SAA6D170E-5
Performance
Engine

High idle rpm 2,000
Low idle rpm 900
carriage
Under-

Track shoe
48 on each side
HPV160+160
Type
HPV95+95+SAL014, HPV95+95+SAL008
Hydraulic
pump

Delivery l/min
gear type: 158, 31, 19
Hydraulic Control

valve

Hydraulic system

Travel motor
× 2 (MSF340VP-EH)
motor

Swing motor
× 2 (KMF160AB-2)
Hydraulic cylinder

Stroke mm 2,390 2,435 1,950
PC1250-8R 11
PC1250SP-8R Serial number 35017 and up

Bucket capacity m 3
6.7
Working range

Performance

Swing speed rpm 5.8
Ground pressure
kPa {kg/cm2} 141 {1.44}
Dimensions

12 PC1250-8R

Model SAA6D170E-5
Performance
Engine

High idle rpm 2,000
Low idle rpm 900
carriage
Under-

Track shoe
48 on each side
HPV160+160
Type
HPV95+95+SAL014, HPV95+95+SAL008
Hydraulic
pump

Delivery l/min
gear type: 158, 31, 19
Hydraulic Control

valve

Hydraulic system

Travel motor
× 2 (MSF340VP-EH)
motor

Swing motor
× 2 (KMF230AB-5)
Hydraulic cylinder

Stroke mm 2,390 2,435 1,950
Hydraulic cooler
Air cooled (J5/J6)
PC1250-8R 13
Loading shovel specification
PC1250-8R Serial number 35001 – 35016

Machine model PC1250-8R (Loading shovel specification)
Bucket capacity m 3
6.5
Working range
Max. vertical wall depth mm —

Performance

Swing speed rpm 5.5
Ground pressure
kPa {kg/cm2} 142 {1.45}
Dimensions

14 PC1250-8R

Model SAA6D170E-5
Performance
Engine

High idle rpm 2,000
Low idle rpm 900
carriage
Under-

Track shoe
48 on each side
HPV160+160
Type
HPV95+95+SAL014, HPV95+95+SAL008
Hydraulic
pump

Delivery l/min
gear type: 158, 31, 19
Hydraulic Control

valve

Hydraulic system

Travel motor
× 2 (MSF340VP-EH)
motor

Swing motor
× 2 (KMF160AB-2)
Bottom
*1 Boom *2 Arm Bucket
dump
Hydraulic cylinder
Cylinder type Double-acting piston Double-acting piston

Inside diameter of cylinder mm 225 185 200 160
Outside diameter of piston rod mm 160 130 140 110
Stroke mm 1,960 1,765 1,700 435
Max. distance between pins mm 5,120 4,470 4,700 1,580
Min. distance between pins mm 3,160 2,705 3,000 1,145
PC1250-8R 15
PC1250-8R Serial number 35017 and up

Bucket capacity m 3
6.5
Working range
Max. vertical wall depth mm —

Performance

Swing speed rpm 5.8
Ground pressure
kPa {kg/cm2} 142 {1.45}
Dimensions

16 PC1250-8R

Model SAA6D170E-5
Performance
Engine

High idle rpm 2,000
Low idle rpm 900
carriage
Under-

Track shoe
48 on each side
HPV160+160
Type
HPV95+95+SAL014, HPV95+95+SAL008
Hydraulic
pump

Delivery l/min
gear type: 158, 31, 19
Hydraulic Control

valve

Hydraulic system

Travel motor
× 2 (MSF340VP-EH)
motor

Swing motor
× 2 (KMF230AB-5)
Bottom
*1 Boom *2 Arm Bucket
dump
Hydraulic cylinder
Cylinder type Double-acting piston Double-acting piston

Inside diameter of cylinder mm 225 185 200 160
Outside diameter of piston rod mm 160 130 140 110
Stroke mm 1,960 1,765 1,700 435
Max. distance between pins mm 5,120 4,470 4,700 1,580
Min. distance between pins mm 3,160 2,705 3,000 1,145
Hydraulic cooler
Air cooled (J5/J6)
PC1250-8R 17
Weight table 1
k This weight table is a guide for use when transporting or handling components.
PC1250-8R, PC1250SP-8R
Unit: kg
Machine model PC1250-8R PC1250SP-8R
Serial number 35001 – 35016 35001 – 35016
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
18 PC1250-8R
Unit: kg
Serial number 35001 – 35016 35001 – 35016
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
PC1250-8R 19
Unit: kg
Serial number 35017 and up 35017 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 429 × 2 429 × 2
Swing motor assembly 105 × 2 105 × 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
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
20 PC1250-8R
Unit: kg
Serial number 35017 and up 35017 and up
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
PC1250-8R 21
PC1250-8R
Unit: kg
Serial number 35001 – 35016
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
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
22 PC1250-8R
Unit: kg
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
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
PC1250-8R 23
Unit: kg
Serial number 35017 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 429 × 2
Swing motor assembly 105 × 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
Counterweight 18,000
Track frame assembly 28,374
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
Arm cylinder top pin 24.2 × 2
Bottom dump cylinder top pin 15.2 × 2
24 PC1250-8R
Unit: kg
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
PC1250-8R 25
Table of fuel, coolant and lubricants 1

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
26 PC1250-8R
Unit: l
PC1250-8R, PC1250SP-8R
Reservoir
Specified capacity Refill capacity
Serial number 35001 – 35016 35017 and up 35001 – 35016 35017 and up
Engine oil pan 97 97 86 86
PTO case 13.5 13.5 13.5 13.5
Swing machinery case (each) 24.3 20 24.3 20
Final drive case (each) 22 22 21 21
Hydraulic system 1,180 1,180 670 670
Fuel tank 1,360 1,360 — —
Cooling system 142 142 — —
PC1250-8R 27
SEN02053-02

© 2007 KOMATSU
All Rights Reserved
28
SEN02055-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
10 Structure, function and

maintenance standard 1
Engine and cooling system
PTO................................................................................................................................................................. 2
PTO lubrication system ................................................................................................................................... 4
Radiator and oil cooler .................................................................................................................................... 6
PC1250-8R 1
SEN02055-02 10 Structure, function and maintenance standard
PTO 1
2 PC1250-8R
1. Driven gear (No. of teeth: 49)

2. PTO case
3. Drive gear (No. of teeth: 56)
4. Main shaft
5. Hub
6. Connection plate
7. Driven gear (No. of teeth: 42)
8. Breather
A. Center of HPV160+160 shaft

B. Center of crankshaft (HPV95+SAR100)
C. Center of HPV95+95+SAL008 shaft
D. Center of HPV95+95+SAL014 shaft
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 shaft 0.273 – 0.374 —
(for HPV95+SAR100)
Adjust
11 0.2 – 0.74 —
and driven gear
12 and driven shaft 0.07 – 0.18 —
(for HPV95+95)
Specifications
Lubricating oil : 13.5 l
Reduction ratio : HPV95+SAR100 = 1
HPV160+160 shaft = 49/56 = 0.875
HPV95+95+SAL 008 shaft, HPV95+95+SAL 014 shaft = 42/56 = 0.750
PC1250-8R 3
PTO lubrication system 1

Hydraulic circuit diagram
Hydraulic piping diagram (Standard spec.)
4 PC1250-8R
Hydraulic piping diagram (55°C spec.)
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.
PC1250-8R 5
Radiator and oil cooler 1
6 PC1250-8R
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 spec.: 975 rpm
6. Fan 55°C spec.: 1,075 rpm
7. Radiator upper tank (At rated engine speed of
8. Oil cooler 1,800 rpm)
9. Radiator outlet tube 2. Radiator
10. Fuel cooler Core type: ALW-4
11. Radiator cap Fin pitch: 4.5 mm
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 (Standard spec./55°C spec.):
J5/J6
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
Fin pitch: 4.0 mm
PC1250-8R 7
SEN02055-02

© 2007 KOMATSU
All Rights Reserved
8
SEN02056-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Power train
Power train...................................................................................................................................................... 2
Swing machinery............................................................................................................................................. 4
Swing circle..................................................................................................................................................... 8
Final drive ....................................................................................................................................................... 9
Sprocket ........................................................................................................................................................ 12
PC1250-8R 1
Power train 1
2 PC1250-8R
1. Idler 14. Swing 4-spool control valve

2. Center swivel joint 15. Swing brake solenoid valve
3. Swing motor 16. Travel speed solenoid valve
Serial No. 35001 – 35016 (KMF160AB-2) 17. Swing machinery
Serial No. 35017 and up (KMF230AB-5) 18. Swing circle
4. L.H. 5-spool control valve 19. Cooling fan motor (LMF110)
5. R.H. 4-spool control valve 20. Fan
6. Final drive, sprocket 21. Aftercooler fan motor (LMF28)
7. Travel motor (MSF340VP) 22. Aftercooler fan
8. Engine (SAA6D170E-5)
9. PTO A. Swing 4-spool control valve
10. No. 3 pump (HPV160+160) B. Swing brake solenoid valve
11. No. 1 pump (HPV95+95+SAL014)
12. No. 2 pump (HPV95+95+SAL008)
13. Control pump
(for control and fan drive (HPV95+SAR100))
PC1250-8R 3
Swing machinery 1
4 PC1250-8R
1. Swing pinion (No. of teeth: 13)

2. Cover
3. Case
4. Coupling
5. No. 2 planetary gear (No. of teeth: 38)
6. Ring gear (No. of teeth: 97)
8. Cover
9. Swing motor
10. Dipstick
11. No. 1 sun gear (No. of teeth: 20)
12. No. 1 planetary carrier
15. Drain plug
Specification
Reduction ratio: (20 + 97)/20 × (19 + 97)/19 = 35.716
Unit: mm
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
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
21 0.17 – 0.52 1.00
22 0.21 – 0.64 1.10
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 —
PC1250-8R 5
6 PC1250-8R
1. Swing pinion (No. of teeth: 13)

2. Cover
3. Case
6. Ring gear (No. of teeth: 68)
8. Swing motor
9. Oil level gauge
13. Drain plug
Specifications
Reduction ratio: (19 + 68)/19 × (16 + 68)/16 = 24.039
Unit: mm
No. Check item Criteria Remedy
Backlash between swing Standard clearance Clearance limit
14
motor shaft and No. 1 sun gear 0.18 – 0.28 —
15 0.15 – 0.51 1.00
16 0.17 – 0.60 1.10
Backlash between No. 1 planetary
17 0.40 – 0.75 1.20
carrier and No. 2 sun gear
Backlash between No. 2 sun gear Replace
18 0.16 – 0.55 1.00
and No. 2 planetary gear
19 0.17 – 0.60 1.10
gear and ring gear
20 0.08 – 0.25 —
carrier and swing pinion
Backlash between swing pinion and
21 0 – 1.13 2.00
swing circle
Clearance between plate and No. 2
22 0.57 – 1.09 —
planetary carrier
Standard size Repair limit Repair hard
Wear of swing pinion contact sur-
23 chrome plating or
face with oil seal 150 –0 —
–0.100 replace
PC1250-8R 7
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
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)
8 PC1250-8R
Final drive 1 1. Level plug

2. Drain plug
3. Cover
9. Hub
10. Sprocket
11. Floating seal
12. Case
15. Travel motor
17. No. 1 ring gear (No. of teeth: 68)
Specifications
Reduction ratio:
–(13 + 68)/13 × (19 + 69)/19 × 63/13 = –139.852
PC1250-8R 9
10 PC1250-8R
Unit: mm
Backlash between No. 3 plane- Standard clearance Clearance limit
21
tary carrier and case 0.08 – 0.27 —
22 0.47 – 0.97 —
23 0.47 – 0.97 —
gear and No. 2 planetary carrier
24 0.25 – 0.82 —
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
28 0.07 – 0.85 —
gear and travel motor coupling
29 0.15 – 0.53 —
Backlash between No.1 ring
30 0.19 – 0.62 —
Backlash between No.2 ring
31 0.19 – 0.62 —
32 Wear of sprocket tooth shape Repair limit: 6
Standard size Repair limit Rebuild or
33 Sprocket tooth width
114 108 replace
PC1250-8R 11
Sprocket 1
Unit: mm
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)
12 PC1250-8R
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.
PC1250-8R 13
SEN02056-01

© 2007 KOMATSU
All Rights Reserved
14
SEN02057-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Undercarriage and frame
Track frame, recoil spring................................................................................................................................ 2
Idler ................................................................................................................................................................. 4
Carrier roller .................................................................................................................................................... 6
Track roller ...................................................................................................................................................... 7
Track shoe ...................................................................................................................................................... 8
PC1250-8R 1
Track frame, recoil spring 1
1. Idler q The dimensions and number of track rollers

2. Track frame may differ according to the model, but the
3. Carrier roller basic structure is the same.
4. Center frame q No. of track rollers
5. Final drive
6. Track roller Model No. of rollers (each side)
7. Track shoe PC1250-8R
8
8. Front guard PC1250SP-8R
2 PC1250-8R
Track shoe
Standard shoe
Models
PC1250-8R PC1250SP-8R
Item
Shoe width (double shoe) 700 mm 700 mm
Link pitch 280 mm 280 mm
No. of shoes (each side) 48 48
Unit: mm
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)
PC1250-8R 3
Idler 1
4 PC1250-8R
Unit: mm
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
PC1250-8R 5
Carrier roller 1
Unit: mm
1 Outside diameter of flange
220 —
2 Outside diameter of tread 205 185
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 PC1250-8R
Track roller 1
Unit: mm
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 —
7 Width of flange 35 —
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
PC1250-8R 7
Track shoe 1
a P portion shows the link of bushing press fitting end.
8 PC1250-8R
Unit: mm
1 Link pitch
280.3 283.3 Reverse or
Standard size When turned replace
2 Bushing outside diameter
98 93
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
*Dry type track link
PC1250-8R 9
Unit: mm
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
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
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
*Dry type track link
10 PC1250-8R
Double shoe
Unit: mm
1, 2 Height
50 25
Rebuild or
3 Thickness 25
replace
4 length at bottom 39
5, 6 length at top 30
PC1250-8R 11
SEN02057-00

© 2006 KOMATSU
All Rights Reserved
12
SEN02058-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Air system
Air piping drawing ........................................................................................................................................... 2
Air circuit diagram ........................................................................................................................................... 3
Air governor .................................................................................................................................................... 4
Air tank............................................................................................................................................................ 5
Safety valve .................................................................................................................................................... 6
Horn valve....................................................................................................................................................... 7
Grease pump .................................................................................................................................................. 8
PC1250-8R 1
Air piping drawing 1
1. Grease gun Outline

2. Grease reel This machine uses pressurized air to operate the
3. Grease pump air horn and automatic greasing system.
4. Air governor The pressurized air is supplied by air compressor (5)
5. Air compressor installed to the engine and is stored in air tank (7).
6. Safety valve When the pressure in the air tank reaches 0.71 MPa
7. Air tank {7.2 kg/cm2}, the air compressor is unloaded; when
8. Horn valve the tank pressure drops below 0.59 MPa {6.0 kg/cm2},
9. Air horn the air compressor again starts to supply pressurized
10. Lock valve air.
2 PC1250-8R
Air circuit diagram 1
1. Air compressor (capacity: 70 l/600 rpm)

2. Unloader valve
3. Air governor (cut-out pressure: 0.71 ± 0.03 MPa {7.2 ± 0.3 kg/cm2})
(cut-in pressure: 0.59 ± 0.03 MPa {6.0 ± 0.3 kg/cm2})
4. Check valve
5. Air tank
6. Safety valve (set pressure: 0.95 –0 –0 2
–0.05 MPa {9.7 –0.5 kg/cm })
7. Battery
8. Horn switch
9. Horn valve
10. Air horn
11. Grease pump
12. Grease reel
13. Lock valve
14. Grease gun
PC1250-8R 3
Air governor 1 Function

q Port (A) is connected to the air tank and port
(B) is connected to the unloader valve of the
air compressor. The air governor maintains the
air pressure inside the air tank within the spec-
ified range. If the pressure exceeds the speci-
fied pressure, it stops the operation of the air
compressor to prevent the air pressure from
rising any higher.
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
A. From air tank

B. From air compressor
C. Exhaust
4 PC1250-8R
Air tank 1
Specifications
q Capacity: 15 l
PC1250-8R 5
Safety valve 1 Function

q The safety valve is installed to the air tank, and
if any pressure above the set pressure is gen-
erated in the air circuit, it acts to release the
compressed air inside the air tank to the atmo-
sphere in order to maintain the safety of the air
circuit.
1. Cover
2. Sleeve
3. Spring
4. Pin
5. Cap
6. Valve
7. Nipple
–0 –0
Set pressure: 0.95 –0.05 MPa {9.7 –0.5 kg/cm2}
6 PC1250-8R
Horn valve 1
1. Spring A. From air tank

2. Magnet B. To horn
3. Wire
4. Wire
5. Coil
6. Cover
7. Piston
8. Body
PC1250-8R 7
Grease pump 1
8 PC1250-8R
1. Silencer
2. Valve
3. Cover
4. Air chamber
5. Follow plate
6. Grease chamber
7. Grease tank
A. Air inlet port

B. Grease outlet port
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).
PC1250-8R 9
SEN02058-00

© 2006 KOMATSU
All Rights Reserved
10
SEN02059-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Hydraulic system, Part 1
Hydraulic piping drawing................................................................................................................................. 2
Hydraulic tank ................................................................................................................................................. 5
Hydraulic pump ............................................................................................................................................... 7
Line oil filter................................................................................................................................................... 48
Pilot oil filter................................................................................................................................................... 49
Return oil filter............................................................................................................................................... 50
Drain oil filter ................................................................................................................................................. 51
Cooling fan pump.......................................................................................................................................... 52
Cooling fan motor.......................................................................................................................................... 66
Aftercooler fan motor .................................................................................................................................... 72
PC1250-8R 1
Hydraulic piping drawing 1
2 PC1250-8R
1. Bucket cylinder
PC1250-8R 3
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 PC1250-8R
Hydraulic tank 1
1. Hydraulic tank Specifications

2. Strainer Tank capacity: 1,146 l
3. Oil filler cap Amount of oil inside tank: 664 l (at H level)
4. Pressure valve
5. Safety valve Pressure valve
6. Return filter Relief cracking pressure: 16.7 ± 6.9 kPa
7. Drain filter {0.17 ± 0.07 kg/cm2}
8. Sight gauge Suction cracking pressure: 0 – 0.49 kPa
9. Hydraulic oil temperature sensor {0 – 0.005 kg/cm2}
10. Suction strainer
11. Drain valve
PC1250-8R 5
6 PC1250-8R
Hydraulic pump 1
1. No. 3 pump (HPV160+160) Outline

2. Control pump assembly (HPV95+SAR100) q The hydraulic pumps consist of 3 variable
2A. Pump for PPC valve control (SAR100) capacity swash plate piston pumps, 2 pumps
2B. Pump for fan drive motor (HPV95) for fan drive motor and a PTO lubrication
3. No. 2 pump (HPV95+95+SAL008) pump.
3A. No. 2 front, rear pump (HPV95+95) q The piston pumps have the valves shown in
3B. Pump for PTO lubrication (SAL008) the table below.
4. No. 1 pump (HPV95+95+SAL014)
Pump No.1 No.2 No.3
4A. No. 1 front, rear pump (HPV95+95) (type) (HPV95+95) (HPV95+95) (HPV160+160)
4B. Pump for aftercooler fan drive motor
Valve Front Rear Front Rear Front Rear
(SAL014)
TVC — Q — — — —
CO Q Q — — Q —
NC Q Q — — Q —
Servo Q Q Q Q Q Q
PC1250-8R 7
No.1 pump
Type: HPV95+95
8 PC1250-8R
P3 : No. 3 pump pressure input port

PA1 : Front pump discharge port
PA2 : Rear pump discharge port
PAG : Gear pump discharge port
PCF : CO selector pilot port
PCR : CO selector pilot port
PD : Jet sensor downstream pressure input port
PD11 : Drain port
PD12 : Drain plug
PD21 : Drain port
PD22 : Drain plug
PE : TVC output pressure pick-up port
PECN: CO + NC valve output pressure plug
PS : Pump suction port
PSG : Gear pump discharge port
PSV : Servo basic pressure input port
PT : Jet sensor upstream pressure input port
1. Front pump
2. Front servo valve
3. Front CO + NC valve
4. Rear servo valve
5. Rear CO + NC valve
6. TVC valve
7. Rear pump
8. Gear pump (Pump for aftercooler fan drive motor)
PC1250-8R 9
1. No. 1 front, rear pump
PSV1 : Servo basic pressure output port

PSV1A : Servo output port
PSV1B : Servo output port
PSV2A : Servo output port
PSV2B : Servo output port
10 PC1250-8R
1. Front shaft 11. Rear end cap

2. Front cradle 12. Valve plate
3. Front case 13. Cylinder block
4. Rocker cam 14. Piston
5. Piston 15. Rear case
6. Cylinder block 16. Rocker cam
7. Valve plate 17. Rear cradle
8. Front end cap 18. Rear shaft
9. Coupling 19. Servo piston
10. Impeller
PC1250-8R 11
2. No. 1 pump front servo assembly
PA1 :Main pump pressure input port 1. CO + NC valve

PAC :Servo actuator port 2. Servo valve
PC :CO selector pilot port
PD :Jet sensor downstream pressure input port
PDR :Servo valve drain output port
PE1 :TVC valve output pressure pick-up port
PE2 :TVC valve output pressure front, rear inter-
connection port
PECN : CO + NC valve output pressure output port
12 PC1250-8R
1) No. 1 pump front servo valve
PA2 (IN) : Main pump pressure input port

PA2 (OUT) : Main pump pressure output port
PAC : Servo actuator port
PDR : CO + NC valve drain port
PDR (OUT) : Servo valve drain output port
PSV1 : Servo basic pressure input port
PECN : CO + NC valve output pressure input
port
PC1250-8R 13
3. No. 1 pump rear servo assembly
P1 : Main pump pressure input port 1. TVC valve

P2 : Main pump pressure input port 2. CO + NC valve
PAC : Servo actuator port 3. Connector
PC : CO selector pilot port 4. Servo valve
PDR : Servo valve drain output port
PE : TVC valve output pressure front, rear inter-
connection port
14 PC1250-8R
1) No. 1 pump rear servo valve

PDR : CO + NC valve drain port
port
PC1250-8R 15
1. Locknut 10. Locknut

2. Cover 11. Control piston
3. Plug 12. Pin
4. Spring 13. Arm
5. Piston 14. Valve body
6. Sleeve 15. Spring
7. Cover 16. Plug
8. Locknut 17. Cover
9. Plug 18. Locknut
Function
q Pump delivery (Q1) and (Q2) of main pumps
(PA1) and (PA2) are controlled individually 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 PC1250-8R
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). Piston (13)
same way as control piston (8). This moves is moved to the right and closes port (a), port
piston (13) to the left. (d) and port (h), so the discharge increases by
q When piston (13) moves, port (a) and port (d) an amount that matches signal pressure
are closed and port (d) is connected to drain (PECN).
chamber (e).
PC1250-8R 17
(2) Operation in direction of decrease of pump delivery (min. angle)
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). Pis-
piston (13) to the right. ton (13) is moved to the left and closes port (a),
q When piston (13) moves, port (a) and port (h) p o r t ( d ) a nd p o r t ( h ) , s o t h e d i s c ha r g e
are closed and port (h) is connected to drain decreases by an amount that matches signal
chamber (e). pressure (PECN).
q As a result, servo piston chamber (j) is also
interconnected with chamber (e) through port
(i) and port (h).
18 PC1250-8R
4. TVC valve
PA1 : Main pump pressure input port 1. Spring

PA2 : Main pump pressure input port 2. Spool
PA3 : Swing pump pressure input port 3. Piston
PD : TVC valve drain output port 4. Piston
PE : TVC valve output pressure output port 5. Sleeve
PSV : Servo basic pressure input port 6. Piston
7. Body
8. Solenoid
9. Sleeve
10. Piston
PC1250-8R 19
1) Operation and function of TVC valve

(1) When command current value from controller is small in P and E mode
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 PC1250-8R
(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.
PC1250-8R 21
(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 PC1250-8R
(4) When pump load is large in emergency pump drive switch “ON”
q When main pump discharge pressure (PA1) [or

(PA2)] increases, spool (2) is moved up by pis-
ton (4) or piston (6).
q As a result, the flow of oil from port (a) to port
(b) is throttled by the notch in the spool. 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.
PC1250-8R 23
5. No. 1 pump front CO + NC valve
PA1I : Main pump pressure input port

PE1 : TVC valve output pressure front, rear inter-
connection port
PC : CO selector pilot port
PDR2 : Servo valve drain output port
PE2 : TVC valve output pressure pick-up port
PECN : CO + NC valve output pressure output port
24 PC1250-8R
6. No. 1 pump rear CO + NC valve
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
PC1250-8R 25
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 PC1250-8R
1) Function and operation of CO valve

(1) When main pump discharge pressure is lower than relief pressure
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).
PC1250-8R 27
(2) When main pump discharge pressure becomes close to relief pressure
q If the load increases and main pump discharge

pressure (PA) comes close to the relief pres-
sure, main pump discharge pressure (PA)
pushes piston (5).
q At the same time, CO valve output pressure
(PEC) pushes piston (5), and spool (4) moves
up.
q As a result, the flow of oil from port (a) to port
(b) is throttled by the notch in the spool, and
the area of the opening at port (b) and port (c)
(drain port) becomes larger.
q In this way, CO valve output pressure (Pec)
goes down, and the pump discharge amount
becomes the minimum.
28 PC1250-8R
(3) When cut-off function is canceled by heavy-lift solenoid valve
q When the heavy-lift solenoid valve is energized

and is switched, pilot pressure (PC) is sent to
the port, and piston (2) is pushed down fully.
q For this reason, seat (6) contacts seat (7) and
spool (4) is locked.
q As a result, main pump discharge pressure
(PA) goes up, but even when it reaches the
relief pressure, spool (4) is not actuated, so
CO valve output pressure (PEC) remains at
the maximum.
PC1250-8R 29
2) Function and operation of NC valve

(1) When control valve is at neutral
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 PC1250-8R
(2) When control lever is operated
q When the control valve is moved, the jet sen-

sor differential pressure [(PT) – (PD)] goes
down in accordance with the movement of the
control valve. Spool (11) is pushed up, and the
area of the opening of port (c) and port (b)
becomes larger.
q In this way, NC valve output pressure (PECN)
becomes larger and the delivery from the main
pump increases. In other words, the pump
delivery increases according to the amount the
control lever is operated.
PC1250-8R 31
No. 2 pump
Type: HPV95+95
32 PC1250-8R
PA1 : Front discharge port

PA2 : Rear discharge port
PD11 : Drain plug
PD12 : Drain port
PD21 : Drain plug
PD22 : Drain port
PECN : CO + NC valve output pressure
PECN (F) : Front CO + NC valve output pressure
pick-up port
PECN (R): Rear CO + NC valve output pressure
pick-up port
PSG : Gear pump suction port
PSV : Servo basic pressure IN port
1. Front pump
3. Rear servo valve
4. Rear pump
5. Gear pump
PC1250-8R 33
1. No. 2 front, rear pump

PSV1A : Servo input port
PSV1B : Servo input port
PSV2A : Servo input port
PSV2B : Servo output pressure input port
34 PC1250-8R

5. Piston 15. Rear case
6. Cylinder block 16. Rocker cam
10. Impeller
PC1250-8R 35
2. No. 2 pump front servo
PA1 : Main pump pressure input port 1. Servo valve

PA2 : Main pump pressure input port
PECN : CO + NC valve output pressure input port
36 PC1250-8R
3. No. 2 pump rear servo
P2 : Main pump pressure input port 1. Servo valve

PECN : CO + NC valve output pressure input port
PC1250-8R 37
No. 3 pump
Type: HPV160+160
38 PC1250-8R
PA1 : Front pump discharge port

PA2 : Rear pump discharge port
PCF : CO selector pilot port
PD11 : Drain port
PD12: Drain plug
PD21: Drain port
PD22: Drain plug
PE : TVC valve output pressure input port
1. Front pump
3. Front CO + NC valve
4. Rear servo valve
5. Rear pump
PC1250-8R 39
1. No. 3 main pump
PA1 : Front pump discharge port PSV1B : Servo valve output port
PA2 : Rear pump discharge port PSV2 : Servo valve basic pressure port
PSV1 : Servo valve basic pressure port PSV2A : Servo valve output port
PSV1A : Servo valve output port PSV2B : Servo valve output port
40 PC1250-8R

5. Piston 15. Rocker cam
6. Cylinder block 16. Rear case
10. Impeller
PC1250-8R 41
2. No. 3 pump front servo assembly
PA1 :Main pump pressure input port 1. CO + NC valve

PAC :Servo actuator port 2. Servo valve
PC :CO selector pilot port
PDR :Servo valve drain output port
PD :Jet sensor downstream pressure input port
PE1 :TVC valve output pressure input port
PE2 :TVC valve output pressure front, rear inter-
connection port
PECN : CO + NC valve output pressure pick-up
port
42 PC1250-8R
(1) No. 3 pump front servo valve

PDR (IN) : CO + NC valve drain input port
port
PC1250-8R 43
3. No. 3 pump rear servo
PA1 : Main pump output pressure input port 1. Servo valve

PA2 : Main pump output pressure input port
44 PC1250-8R
4. No. 3 pump CO + NC valve
PA1I : Main pump pressure input port PE1 : TVC valve output pressure input port
PC : CO selector pilot port PE2 : TVC valve output pressure pick-up 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
PC1250-8R 45
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 PC1250-8R
1) Function and operation of CO valve for No. 3 pump:

a Structurally, the CO valve for the No. 3 pump does not function.
q Structurally, the CO valve for the No. 3 pump is

set so that it does not function. As a result,
when main pump discharge pressure (PA)
rises and reaches the relief pressure, spool (4)
is not actuated and CO valve output pressure
(PEC) always remains at the maximum.
PC1250-8R 47
Line oil filter 1
A: From hydraulic pump Outline

B: To control valve There are three line oil filters installed to the dis-
charge side of the hydraulic pump. They protect the
1. Element circuit and equipment by removing all dirt and dust
2. Case from the oil.
3. Cover
48 PC1250-8R
Pilot oil filter 1
1. Relief valve Outline

2. Case The pilot oil filter is installed to the discharge side of
3. Element the control pump and protects the PPC valve and
4. Center bolt other pilot pressure equipment.
PC1250-8R 49
Return oil filter 1
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 PC1250-8R
Drain oil filter 1
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}
PC1250-8R 51
Cooling fan pump 1

Type: HPV95+SAR100
52 PC1250-8R
Outline
q This pump consists of 1 variable capacity
swash plate piston pump, PC valve, EPC valve
and gear pump.
IM : PC mode selector current

PA : Pump discharge port
PC : Pump discharge pressure detection port
PD1 : Case drain port
PD2 : Drain plug
PEN : Control pressure detection port
PEPB : EPC basic pressure detection port
PEPC : EPC basic pressure port
PM : EPC output pressure detection port
PSG : Gear pump suction port
1. Piston pump
2. Gear pump
3. EPC valve
4. PC valve
PC1250-8R 53
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 PC1250-8R
Function q Piston (6) carries out relative movement in the

q The pump converts the engine rotation trans- axial direction inside each cylinder chamber of
mitted to its shaft to oil pressure and delivers cylinder block (7).
pressurized oil corresponding to the load. q Cylinder block (7) seals the pressurized oil to
q It is possible to change the delivery by chang- valve plate (8) and carries out relative rotation.
ing the swash plate angle. q This surface is designed so that the oil pres-
sure balance is maintained at a suitable level.
Structure q The oil inside the respective cylinder chambers
q Cylinder block (7) is supported to shaft (1) by of cylinder block (7) is suctioned and dis-
spline (12). charged through valve plate (8).
q Shaft (1) is supported by front and rear bear-
ings (13).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) constitute the spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
the cylinder surface (B) with cradle (2), which
is secured to the case, and forms a static pres-
sure bearing when it slides.
PC1250-8R 55
Operation of pump q As center line (X) of rocker cam (4) matches

q Cylinder block (7) rotates together with shaft the axial direction of cylinder block (7) (swash
(1), and shoe (5) slides on flat surface (A). plate angle (a) = 0), the difference between
q When this happens, rocker cam (4) moves volumes (E) and (F) inside cylinder block (7)
along cylindrical surface (B), so angle (a) becomes 0.
between center line (X) of rocker cam (4) and q Suction and discharge of pressurized oil is not
the ax ial di rec tio n of cy li nder b loc k (7) carried out in this state. Namely pumping
changes. action is not performed (Actually, however, the
q (a) is named the swash plate angle. swash plate angle is not set to 0).
q With center line (X) of rocker cam (4) at a

swash plate angle (a) in relation to the axial
direction of cylinder block (7), flat surface (A)
acts as a cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) suctions and discharges the
oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
56 PC1250-8R
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).
PC1250-8R 57
2. PC valve
PA : Pump port 1. Plug

PDP : Drain port 2. Servo piston assembly
PM : EPC pressure input port 3. Pin
PPL : Control pressure output port (to servo piston 4. Spool
large diameter end) 5. Retainer
6. Sheet
7. Cover
8. Wiring
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 PC1250-8R
1) Action of PC-EPC valve solenoid (1)
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).
PC1250-8R 59
2) When PC mode selector current decreases (When EPC output pressure lowers)
Operation q As a result, the pressure on port (C) rises and

q Port (C) of the PC valve is connected to the the pressure on the large diameter end of the
large diameter end of servo piston (9). piston also rises. Thus, the leftward move of
q Pump pressure (PA) is applied to the diameter servo piston (9) is stopped.
end of servo piston (9) and port (B). q The stop position of servo piston (9) (= pump
q When EPC output pressure (PM) is low, spool delivery) is determined by the position where
(3) moves to the left. the pressing force generated by the EPC valve
q Port (C) is connected to port (D) and the pres- output pressure is balanced with the force of
sure applied to the large diameter end of the spring (4).
piston becomes drain pressure (PT) and servo q When the stop position of servo piston (9)
piston (9) moves to the left. (=pump delivery) is at the middle position
q The pump delivery will be set to the increasing between the maximum and minimum pump
trend. delivery positions, the pressure on the large
q Accompanied with move of servo piston (9), di ame ter end of th e pis to n is th e lat ter
spring (4) will be expanded and the spring becomes drain pressure (PT).
force becomes weaker.
q As the spring force is weakened, spool (3)
moves to the right, the connecting between
port (C) and port (D) is shut off and the pump
discharge pressure ports (B) and (C) are con-
nected.
60 PC1250-8R
3) When PC mode selector current increases (When EPC output pressure rises)
Operation q When the stop position of servo piston (9) (=

q When EPC output pressure (PM) is large, pump delivery) is at the middle position
spool (3) moves to the right. between the maximum and minimum pump
q If port (C) is connected to port (B), the pres- delivery positions, the pressure on the large
sure on the large diameter end of the piston diameter end of the piston is about a half of
rises and servo piston (9) moves to the right. pump discharge pressure (PA). When the
q The pump delivery decreases. former is at the minimum pump delivery posi-
q As servo piston (9) moves, spring (4) is com- tion, the latter becomes pump discharge pres-
pressed and its force is increased. sure (PA).
q If the spring force is increased, spool (3)
moves to the left, port (C) is disconnected from
port (B), and draining port (D) is connected to
port (C).
q If the pressure in port (C) lowers, the pressure
on the large diameter end of the piston lowers
and consequently servo piston (9) stops mov-
ing to the right.
q The stop position of servo piston (9) (= pump
delivery) is determined by the position where
the pressing force generated by the EPC valve
output pressure is balanced with the force of
spring (4).
PC1250-8R 61
q The relationship between PC mode selector

current (IM) and pump delivery (Q) becomes
as shown below.
62 PC1250-8R
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
PC1250-8R 63
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 PC1250-8R
2) When signal current is very small 3) When signal current is maximum

(coil is energized) (coil is energized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressure on port (C) increases and the force to q Spool (5) is pushed toward right side by rod
act on spool (5) surface and the spring load on (6).
spring (4) become larger than the propulsion q The maximum volume of pressurized oil is
force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and PC
shut off from port (C). valve to the maximum level.
q Port (C) and port (T) are connected. q Since port (T) is closed, pressurized oil does
q Spool (5) moves up and down so that the pro- not flow to the tank.
pulsion force of plunger (7) may be balanced
with pressure of port (C) + spring load of spring
(4).
q The circuit pressure between the EPC valve
and the PC valve is controlled in proportion to
the size of the signal current.
PC1250-8R 65
Cooling fan motor 1

Type: LMF110
P : From fan pump Specifications

T : From cooler to tank Type : LMF110
TC : To tank Capacity : 110.7 cm3/rev
Rated speed : 1,050 rpm
Rated flow : 116.2 l/mm
Check valve crack pressure: 78.5 kPa {0.8 kg/cm2}
Safety valve crack pressure: 24.5 MPa {250 kg/cm2}
66 PC1250-8R
1. Output shaft 8. End cover

2. Case 9. Center spring
3. Thrust plate 10. Suction valve
4. Shoe 11. Pilot valve
5. Piston 12. Reversible valve spool
6. Cylinder block 13. Safety valve
7. Valve plate
Unit: mm
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}
PC1250-8R 67
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 PC1250-8R
2. Suction valve 2) When the pump is stopped

q If the engine is stopped and the input revolu-
Function tion of the fan pump lowers to 0 rpm, the pres-
q If the fan pump stops, the pressurized oil does surized oil from the pump is not supplied to
not flow into the motor. Since the motor contin- port (P) any more. As the pressurized oil is not
ues revolution because of the force of inertia, supplied to the (MA) side of the motor, the
however, the pressure on the outlet side of the motor speed lowers gradually to stop.
motor rises. q If the motor shaft is revolved by the force of
q When the oil stops flowing in from inlet port (P), inertia while the oil flow in the port (P) is reduc-
suction valve (1) sucks in the oil on the outlet ing, the oil in port (T) on the outlet side is sent
side and supplies it to port (MA) where there is by the suction valve (1) to the (MA) side to pre-
not sufficient oil to prevent cavitation. vent cavitation.
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.
PC1250-8R 69
3. Operation of reversible valve 2) When the ON-OFF solenoid is energized.

q If ON-OFF solenoid (1) is “energized”, ON-
1) When the ON-OFF solenoid is de-energized. OFF selector valve (2) changes to let the pres-
q If ON-OFF solenoid (1) is “de-energized”, the surized oil from the pump flow through port (C)
pressurized oil from the pump is blocked by into spool chamber (D).
ON-OFF selector valve (2), and port (C) opens q The pressurized oil in chamber (D) pushes
for the tank circuit. valve spool (3) to the left against spring (4).
q Spool (3) is pushed to the right by spring (4). q Motor port (MB) opens and pressurized oil
q Motor port (MA) opens and pressurized oil flows in to revolve the motor in reverse (coun-
flows in to revolve the motor in forward (clock- terclockwise).
wise).
70 PC1250-8R
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.
PC1250-8R 71
Aftercooler fan motor 1

Type: LMF28
P : From fan pump Specifications

T : From cooler to tank Type : LMF28
TC : To tank Capacity : 28.0 cm3/rev
Rated flow : 33 l/min
Check valve
cracking pressure: 0.044 MPa {0.45 kg/cm2}
72 PC1250-8R
1. Output shaft 7. Valve plate

2. Case 8. End cover
3. Thrust plate 9. Center spring
4. Shoe 10. Suction valve
5. Piston 11. Safety valve
6. Cylinder block
Unit: mm
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}
PC1250-8R 73
Hydraulic motor unit
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 PC1250-8R
Suction valve When stopping

q If the engine is stopped and the input revolu-
Function tion of the gear pump lowers to 0 rpm, the
q If the gear pump stops, the pressurized oil pressurized oil from the pump is not supplied
does not flow into the motor. Since the motor to port (P) any more. As the pressurized oil is
continues revolution because of the force of not supplied to (MA) side of the motor, the
inertia, however, the pressure on the outlet motor speed lowers gradually to stop.
side of the motor rises. q If the motor shaft is revolved by the force of
q When the oil stops flowing in from inlet port (P), inertia while the oil flow in port (P) is reducing,
the suction valve (1) sucks in the oil on the out- the oil in port (T) on the outlet side is sent by
let side and supplies it to port (MA) where suction valve (1) to (MA) side to prevent cavita-
there is not sufficient oil to prevent cavitation. tion.
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.
PC1250-8R 75
Safety valve Function

q When the engine is started, the pressure in
port (P) of the 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.
76 PC1250-8R
PC1250-8R 77
SEN02059-01

© 2007 KOMATSU
All Rights Reserved
78
SEN02060-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Hydraulic system, Part 2
Control valve ................................................................................................................................................... 2
Swing motor .................................................................................................................................................. 17
Center swivel joint......................................................................................................................................... 26
Travel motor .................................................................................................................................................. 27
PPC control relief valve................................................................................................................................. 37
Accumulator .................................................................................................................................................. 38
Valve control ................................................................................................................................................. 39
PPC valve ..................................................................................................................................................... 40
Solenoid valve............................................................................................................................................... 50
Hydraulic cylinder.......................................................................................................................................... 58
PC1250-8R 1
Control valve 1
L.H. 5-spool valve
General view
2 PC1250-8R
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
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
PB5 : From L.H. travel PPC valve
PP : From 2-stage main relief solenoid valve
T : To hydraulic tank
PC1250-8R 3
Sectional view
4 PC1250-8R
1. Main relief valve 8. Jet sensor relief valve

2. Spool (Bottom) 9. Valve body
3. Spool (Boom Hi) 10. Throttle valve
4. Spool (Arm Lo) 11. Orifice-check valve
5. Spool (Bucket Hi) 12. Suction-safety valve
6. Spool (L.H. travel) 13. Suction valve
7. Jet sensor orifice
Unit: mm
Free length ×
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,
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}
PC1250-8R 5
R.H. 4-spool valve

General view
6 PC1250-8R
A1 : To R.H. travel motor port (P1)

B1 : To R.H. travel motor port (P2)
B2 : To boom cylinder
B3 : To bucket cylinder
NCA : To NC valve at front of No. 1 main pump
NCB : To NC valve at front of No. 1 main pump
P : From No. 1, No. 2 main pump
P1 : From No. 1, No. 2 main pump
P2 : To L.H. 5-spool control valve port (P1)
PA1 : From R.H. travel PPC valve
PB1 : From R.H. travel PPC valve
PP : From control pump
PR : From 2-stage main relief solenoid valve
PS : From 2-stage safety solenoid valve
PT : To hydraulic tank
PC1250-8R 7
Sectional view
8 PC1250-8R
1. Main relief valve 8. Valve body

2. Spool (R.H. travel) 9. Check valve
3. Spool (Boom Lo) 10. Straight-travel valve
4. Spool (Bucket Lo) 11. Suction valve
5. Spool (Arm Hi) 12. 2-stage suction-safety valve
6. Jet sensor orifice 13. Suction-safety valve
7. Jet sensor relief valve
Unit: mm
Free length ×
outside Free length
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
{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}
PC1250-8R 9
Swing 4-spool control valve

General view
10 PC1250-8R
A2 : To swing motor MB
B1 : Plug
B2 : To swing motor MA
B3 : Plug
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
PI : From pilot valve
PR : From 2-stage main relief solenoid valve
PC1250-8R 11
Sectional view
12 PC1250-8R
1. Main relief valve 7. Jet sensor relief valve

2. Spool (Boom plus) 8. Valve body
3. Spool (Swing) 9. Orifice-check valve
4. Spool (Bucket plus) 10. Piston
5. Spool (Arm plus) 11. Check valve
6. Jet sensor orifice 12. Suction-safety valve
Unit: mm
Free length ×
outside Free length
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
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
{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}
PC1250-8R 13
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.
P : From pump at front of No. 1 main pump

P1 : From pump at rear of No. 1 main pump
P2 : To L.H. travel spool of L.H. 5-spool valve
P3 : To bucket, boom spool
P4 : To arm spool
PP: From control pump
PT : To hydraulic tank
14 PC1250-8R
1. Orifice 5. Body
2. Check valve 6. Spool
3. Spring 7. Cover
4. Spool return spring
Unit: mm
Free length ×
outside Free length
8 Spool return spring length load load If damaged or
diameter
deformed,
117.5 × 27.9 68 —
{16 kg} {12.8 kg}
0.98 N 0.78 N
{0.1 kg} {0.08 kg}
PC1250-8R 15
Function 2. When travel and work equipment are oper-

q When the travel is operated at the same time ated at same time (straight-travel solenoid
as the boom, arm, or bucket, the pressure oil valve energized)
flowing to the left and right travel circuits is q The straight-travel solenoid valve is energized,
divided and sent to the boom, arm, or bucket so the pilot pressure flows and spool (6) is
circuit. pushed to the right.
q If the oil in one travel circuit is divided off, the q Because of this, port (P2) and port (P1) are
amount of oil supplied to the travel motor will interconnected, so the amount of oil supplied
be less than in the travel circuit which is not to the left and right travel motors is the same.
divided, so the drop in the supply of oil to the As a result, the left and right travel motors both
travel motor will cause the machine to deviate. rotate at the same speed, so there is no travel
q To prevent this, the straight-travel valve is deviation.
switched to interconnect the left and right
travel circuits. This ensures that the amount of
oil supplied to the left and right travel motors is
equal, so the left and right travel motors both
rotate at the same speed, and this prevents
any travel deviation.
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 PC1250-8R
Swing motor 1
KMF160AB-2
1. Swing motor Specifications

2. Swing holding brake Model : KMF160AB-2
Theoretical discharge : 160.7 cc/rev
B : From swing holding brake solenoid valve Brake release pressure : 1.8 ± 0.4 MPa
S : From tank {18.4 ± 4 kg/cm2}
T1 : To tank
T2 : From cooling piping port S
MA : From swing control valve port B1
MB : From swing control valve port A1
PC1250-8R 17
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 PC1250-8R
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}
PC1250-8R 19
20 PC1250-8R
Serial unmber 35017 and up

Type: KMF230AB-5
B : From swing brake solenoid valve Specifications

MA : From control valve Type : KMF230AB-5
MB : From control valve Theoretical delivery : 229.4 cm3/rev
S : From control valve Safety valve set pressure : 27.5 MPa {280 kg/cm2}
T : To tank Rated speed : 1,282 rpm
Brake release pressure : 1.9 MPa {19 kg/cm2}
1. Plate
2. Safety valve
PC1250-8R 21
22 PC1250-8R
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10. Cylinder block
11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Unit: mm
Free length
× outside Free length
16 Check valve spring length load load If damaged or
diameter
deformed,
6.96 N 5.59 N replace spring
66.5 × 25.6 45.0 —
{0.71 kg} {0.57 kg}
7.45 N 5.98 N
17 Shuttle valve spring 24.5 × 11.6 14.5 —
{0.76 kg} {0.61 kg}
PC1250-8R 23
Swing holding brake
1. When solenoid valve is de-energized 2. When solenoid valve is energized
Operation Operation
q As the swing brake solenoid valve is de-ener- q As the swing brake solenoid valve is ener-
gized, the pressurized oil from the pump is gized, the valve is switched.
shut off. q The pressurized oil from the pump is con-
q Port (B) is connected to tank circuit (T). ducted brake chamber (a) through port (B).
q Brake piston (7) is pushed down by brake q After entering chamber (a), the pressurized oil
spring (1). compresses brake spring (1) and pushes
q Disc (5) and plate (6) are pushed together, and brake piston (7) up.
the brake is applied. q Disc (5) is separated from plate (6), releasing
the brake.
24 PC1250-8R
Relief valve
Outline 2. When swing is stopped

q The relief valve consists of check valves (2) q When the swing control lever is returned to
and (3), shuttle valves (4) and (5), and relief neutral, the supply of pressurized oil from the
valve (1). pump to port (MA) is stopped.
q The pressurized oil from the motor outlet can't
Function return to the tank since the returning circuit to
q When the machine is in the swing holding the tank is closed from control valve (6). Thus,
mode, control valve (6) closes the motor outlet pressure on port (MB) increases.
circuit, but the motor rotation is continued by q Rotation resistance is generated on the motor
inertial force. and hence the brake starts working.
q The motor output, therefore, is abnormally q The pressure on port (MB) pushes shuttle
increased, resulting in damaging the motor. valve (4) as it goes higher than that on port
q In order to prevent the motor damages, the (MA).
relief valve relieves the abnormally high pres- q The pressure on chamber (C) is increased to
sure to port (S) from the motor outlet side the set pres sure of relief valve (1) and
(high-pressure side) of the motor. becomes the same as that of port (MB).
q A high braking torque works on the motor,
Operation thereby stopping the motor.
q When relief valve (1) is being actuated, the
1. When starting swing relieved pressurized oil and the pressurized oil
q When the swing control lever is operated to the
from port (S) are fed to port (MA) through
right-swing, the pressurized oil from the pump is
check valve (3).
supplied to port (MA) through control valve (6).
q Above prevents cavitation on port (MA).
q The pressure on port (MA) rises, the starting
torque is generated in the motor, and the motor
starts to rotate.
q The pressurized oil from the outlet port of the
motor passes from port (MB) through control
valve (6) and returns to the tank.
PC1250-8R 25
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
C1 : From R.H. travel control valve port B1 1. Cover
C2 : To R.H. travel motor port P2 2. Body
D1 : From R.H. travel control valve port A1 3. Slipper seal
D2 : To R.H. travel motor port P1 4. Oil seal
P1 : From travel speed selector solenoid valve 5. Shaft
Unit: mm
Clearance between rotor Standard size Standard clearance Clearance limit
6 Replace
and shaft 110 0.056 – 0.105 0.111
26 PC1250-8R
Travel motor 1
MSF-340VP-EH
P1 : From control valve Specifications

P2 : From control valve Model : MSF-340VP-EH
P1 : From travel speed solenoid valve Theoretical delivery : 1st 337.2 cc/rev
T : To hydraulic tank : 2nd 228.6 cc/rev
Rated pressure : 34.3 MPa {350 kg/cm2}
1. Travel selector valve Rated speed : 1st 1,465 rpm
2. Motor (at 494 l/min.)
3. Travel brake valve : 2nd 2,161 rpm
(at 494 l/min.)
Brake release pressure : 1.8 MPa {18.4 kg/cm2}
PC1250-8R 27
1. Travel motor, travel speed selector valve, relief valve
1. Travel speed selector valve

1a. Spool
1b. Spring
2. Relief valve
2a. Shockless piston
2b. Poppet
28 PC1250-8R
3. Rear cover 12. Shaft

4. Collar 13. Bearing collar
5. Valve plate 14. Rocker cam
6. Cylinder block assembly 15. Preload spring
7. Piston assembly 16. Disc
8. Holder 17. Plate
9. Retainer 18. Brake piston
10. Piston assembly 19. Spring
11. Case
PC1250-8R 29
1-1 Motor
q There are 9 pistons (7) assembled in cylinder

block (6). The end face of the cylinder block
has a spherical surface and is in contact with
valve plate (5), which has two half-moon
shaped ports (divider valve for high/low speed
selector).
q The fixed surface (contact surface with the

motor case) forming the non-sliding surface of
rocker cam (13) has two faces. The high/low
speed volume selection for this motor is car-
ried out by fixing each face to provide large
capacity (low speed) or small capacity (high
speed).
The angling operation of rocker cam (14) is
carried out by actuating control piston (10) with
the self-pressure through the speed selector
valve when the motor is being driven, and this
angles the rocker cam.
There are two control pistons each for the high/
low pressure divider ports of valve plate (5),
and they provide propulsion force to the rocker
cam.
30 PC1250-8R
1-2 Speed selector valve

Operation
1) At low speed (pilot pressure PI = 0)
q When pilot pressure (PI) from the control pump

is 0, spool (1a) of travel speed selector valve
(1) is not switched.
In this condition, the oil from the chamber of
control piston (10) passes through spool (1a)
and is drained into the motor case. There is no
angle propulsion force acting on rocker cam
(14), so the low-speed surface is kept in a
static condition.
PC1250-8R 31
2) At high speed (automatic 2nd)
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.
32 PC1250-8R
1-3 Parking brake

The parking brake is a hydraulic release, wet When parking brake is OFF
type, multiple disc negative brake. The release When the travel lever is operated, the pressur-
pressure employs a self-pressure release ized oil from the pump actuates the counterbal-
method using the travel motor drive pressure ance valve spool, opens the circuit to the
through the oil passage in the counterbalance parking brake, and flows into chamber (e) of
valve spool of the travel brake valve. brake piston (18). It overcomes the force of
spring (19), and pushes brake piston (18) to
When the machine is traveling, the drive pres- the right.
sure is sent to port (P) of the parking brake cir- When this happens, the force pushing plate
cuit, acts on the piston in the brake cylinder (17) and disc (16) together is lost, so the plate
chamber, overcomes the force of the spring and disc separate and the brake is released.
and releases the brake.
When the machine is parked or stopped, the
counterbalance valve spool returns to neutral,
and the oil in the cylinder chamber is released
to the tank through the counterbalance valve
spool, so the brake is applied by the force of
the spring to mechanically lock the motor shaft
and hold the machine in position.
When parking brake is ON

When the travel lever is placed in neutral, the
counterbalance valve spool returns to the neu-
tral position and parking brake circuit (P) is
closed.
The pressurized oil in chamber (e) of the brake
piston passes through the counterbalance
valve spool, and is drained to the tank, and
brake piston (18) is pushed fully to the left by
force (FS) of spring (19), and the brake is
applied.
PC1250-8R 33
1-4 Relief valve
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).
34 PC1250-8R
1-5 Travel brake valve
Function 1. Cap assembly

q The brake valve consists of counterbalance 2. Return spring
valve (3) and check valve (4). 3. Counterbalance valve
q The counterbalance valve acts to prevent the 4. Check valve
piston motor from stopping or overrunning. 5. Check valve spring
q When traveling downhill, the weight of the
machine makes it try to travel at a speed faster Specification
than the rotation of the motor. Safety valve set pressure: 34 MPa {350 kg/cm2}
For this reason, if the machine is traveling with Counterbalance switching pressure:
the engine running at low speed, the motor will 1.0 ± 0.1 MPa {10 ± 1 kg/cm2}
rotate under no load or may run away, which is Check valve switching pressure:
extremely dangerous. 0.02 ± 0.01 MPa {0.2 ± 0.1 kg/cm2}
To prevent this, this valve controls the amount
of oil on the return side in order to keep the
valve pressure constant, and makes it possible
to carry out travel operations which match the
oil delivery from the motor.
PC1250-8R 35
Operation when oil is supplied Operation of brake when traveling downhill

q When the travel lever is operated, the pressur- q If the machine tries to run away when traveling
ized oil from the control valve is supplied to downhill, the motor will turn under no load, so
port (P1). It pushes open check valve (5a) and the pressure at the motor inlet port will drop,
flows from motor inlet port (M1) to motor outlet and the pressure in chamber (A) through ori-
port (M2). fice (a) will also drop.
However, the motor outlet port is closed by When the pressure in chamber (A) drops
check valve (5b) and spool (3), so the pressure below the spool switching pressure, spool (3)
at the supply side rises. is returned to the right by spring (2), and outlet
port (M2) is throttled.
As a result, the pressure at the outlet port side
rises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, spool (3) moves to a position
where the pressure at outlet port (M2) bal-
ances the pressure at the inlet port and the
force generated by the weight of the machine.
It throttles the outlet port circuit and controls
the travel speed according to the amount of oil
discharged from the pump.
q The pressurized oil at the supply side flows

from orifice (a) in spool (3) to chamber (A).
When the pressure in chamber (A) goes above
the spool switching pressure, spool (3) is
pushed to the left.
As a result, port (M2) and port (P2) are con-
nected, the outlet port side of the motor is
opened, and the motor starts to rotate.
36 PC1250-8R
PPC control relief valve 1
A : From PPC valve 1. Relief valve

B : From solenoid valve 2. Valve body
C : From pilot valve 3. Check valve spring
D : To PPC valve 4. Check valve
E : To accumulator
F : To solenoid valve Specifications
P : From control pump Set pressure: 3.1 +0.3 +3 2
+0.3 MPa {32 +0 kg/cm }
T : To tank (at 182 l/min)
Unit: mm
Free length ×
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}
PC1250-8R 37
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}
38 PC1250-8R
Valve control 1
1. R.H. 4-spool control valve Lever positions

2. L.H. 5-spool control valve (1) HOLD
3. Accumulator (2) Boom RAISE
4. Swing 4-spool control valve (3) Boom LOWER
5. PPC lock solenoid valve (4) Bucket DUMP
6. Lock lever (5) Bucket CURL
7. Left PPC valve (6) HOLD
8. Left work equipment lever (7) Arm IN
9. Travel PPC valve (8) Arm OUT
10. L.H. travel lever (9) Swing RIGHT
11. R.H. travel lever (10) Swing LEFT
12. Right PPC valve (11) NEUTRAL
13. Right work equipment lever (12) Travel REVERSE
(13) Travel FORWARD
(14) LOCK
(15) FREE
PC1250-8R 39
PPC valve 1
Work equipment and swing PPC valve
P: From control pump

P1: L.H. PPC: Swing right / R.H. PPC: Bucket
dump
P2: L.H. PPC: Swing left / R.H. PPC: Bucket curl
P3: L.H. PPC: Arm out / R.H. PPC: Boom lower
P4: L.H. PPC: Arm in / R.H. PPC: Boom raise
T: To tank
40 PC1250-8R
PC1250-8R 41
1. Spool 5. Joint
2. Piston 6. Plate
3. Disc 7. Retainer
4. Nut (for lever connection) 8. Body
Unit: mm
Free length ×
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}
42 PC1250-8R
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.
2. During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When port (P1) is shut off from drain chamber
(D), it is almost simultaneously interconnected
to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and port (P1)
is shut off from pump pressure chamber (PP).
At almost the same time, it is connected to
drain chamber (D) to release the pressure at
port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
q The relationship between the position of spool
(1) and body (10) does not change until
retainer (9) contacts spool (1).
q Metering spring (2) contracts in proportion to
the stroke of the control lever.
PC1250-8R 43
3. During fine control 4. At full stroke

(When control lever is returned) q Disc (5) pushes down piston (4), and retainer
q When disc (5) starts to be returned, spool (1) is (9) pushes down spool (1).
pushed up by the force of centering spring (3) q Port (P1) is shut off from drain chamber (D),
and the pressure at port (P1). and is interconnected to pump pressure cham-
q Because of this, port (P1) is connected to drain ber (PP).
chamber (D), and the pressurized oil at port q Therefore, the pilot pressure oil from the con-
(P1) is released. trol pump passes through port (P1) and flows
q If the pressure of port (P1) is lowered exces- to chamber (A) from port (P1) to push the con-
sively, spool (1) is pushed down by metering trol valve spool.
spring (2). q The oil returning from chamber (B) passes
q Port (P1) is shut off from drain chamber (D), from port (P2) through port (P1) and flows to
and it is almost simultaneously interconnected drain chamber (D).
to pump pressure chamber (PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from port
(P1) in the valve on the side that is not work-
ing. The oil passes through port (P2) and
enters chamber (B) to replenish the chamber
with pressurized oil.
44 PC1250-8R
Travel PPC valve
P: From control pump

P1: L.H. reverse
P2: L.H. forward
P3: R.H. reverse
P4: R.H. forward
T: To tank
PC1250-8R 45
46 PC1250-8R
1. Plate
2. Body
3. Piston
4. Collar
5. Valve
Unit: mm
Free length ×
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}
PC1250-8R 47
Operation q Metering spring (2) contracts in proportion to

1. When in neutral the stroke of the control lever.
q Ports (A) and (B) of the control valve and ports q Pressure at port (P1) also rises in proportion to
(P1) and (P2) of the PPC valve are connected the stroke of the control lever.
to drain chamber (D) through fine control hole q In this way, the control valve spool moves to a
(f) in spool (1). 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.
2. During fine control

(Neutral o fine control)
q When piston (4) is pushed by disc (5), retainer
(9) is pushed, spool (1) is also pushed by
metering spring (2), and moves down.
q When fine control hole (f) is shut off from drain
chamber (D), it is almost simultaneously inter-
connected to pump pressure chamber (PP).
q Pilot pressurized oil of the control pump is led
to port (A) from port (P1) through fine control
hole (f).
q When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine con-
trol hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q As a result, spool (1) moves up and down until
the force of metering spool (2) is balanced with
the pressure at port (P1).
q The relationship between the position of spool
(1) and body (10) [fine control hole (f) is in the
middle between drain chamber (D) and pump
pressure chamber (PP)] does not change until
retainer (9) contacts spool (1).
48 PC1250-8R
3. During fine control 4. At full stroke

(When control lever is returned) q Lever (5) pushes down piston (4), and retainer
q When lever (5) starts to be returned, spool (1) (9) pushes down spool (1).
is pushed up by the force of centering spring q Fine control hole (f) is shut off from drain
(3) and pressure at port (P1). chamber (D), and is interconnected to pump
q Because of this, fine control hole (f) is con- pressure chamber (PP).
nected to drain chamber (D), and the pressur- q Therefore, the pilot pressure oil from the con-
ized oil at port (P1) is released. trol pump passes through fine control hole (f)
q If the pressure of port (P1) is lowered exces- and flows to chamber (A) from port (P1) to
sively, spool (1) is pushed down by metering push the control valve spool.
spring (2). q The oil returning from chamber (B) passes
q Fine control hole (f) is shut off from drain from port (P2) through fine control hole (f') and
chamber (D), and it is almost simultaneously flows to drain chamber (D).
interconnected to pump pressure chamber
(PP).
q Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q When the spool of the control valve returns,
the oil in drain chamber (D) flows in from fine
control hole (f') in the valve on the side that is
not working. The oil passes through port (P2)
and enters chamber (B) to replenish the cham-
ber with pressurized oil.
PC1250-8R 49
Solenoid valve 1
For CO cancel, straight-travel, heavy lift, machine push-up, travel speed
A1 : To No. 1 pump (CO valve) 1. CO cancel solenoid valve

A2 : To straight-travel valve 2. Straight-travel solenoid valve
A3 : To main valve (Relief valve) 3. Heavy lift solenoid valve
A4 : To boom LOWER 2-stage safety valve 4. Machine push-up solenoid valve
A5 : To left and right travel motor 5. Travel speed solenoid valve
ACC : Blind
P1 : From control pump
PPC : Blind
T : To tank
50 PC1250-8R
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 control-
controller, solenoid (3) is de-energized. ler to solenoid (3), 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.
PC1250-8R 51
For swing priority (On left side of machine body)
1. Swing priority solenoid valve
A : To swing 4-spool control valve

P : From control pump
T : To tank
52 PC1250-8R
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 control-
controller, solenoid (6) is de-energized. ler to solenoid (6), 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.
PC1250-8R 53
For swing holding brake (On left side of machine body), safety lock
A : To front and rear swing motors (For swing holding brake)

To PPC valve (To safety lock)
T : To tank
54 PC1250-8R
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.
When solenoid is energized

q When the signal current flows from the control-
ler to solenoid (2), solenoid (2) is energized.
q Accordingly, spool (11) is pushed down and the
pressure oil from the control pump flows
through port (P) to port (A) and spool (7) is
pushed to the right.
q As a result, pressure oil from the control pump
flows from port (P) to port (A), and then flows
to the actuator.
At the same time, port (T) is closed, so the oil
does not flow to the tank.
PC1250-8R 55
For bottom dump OPEN/CLOSE change over
A1 : See table 1. Outline

A2 : See table 1. The solenoid valves control the following hydraulic
A3 : See table 1. devices respectively.
T : To hydraulic tank Table 1
Connected
1. Bottom dump OPEN solenoid valve port
2. — A1 A2 A3
3. Bottom dump CLOSE solenoid valve Solenoid
valve
Rear of Left 5-spool Left 5-spool

—
hydraulic tank control valve control valve
56 PC1250-8R
When solenoid is energized

q When the signal current flows from the control-
ler to coil (3), coil (3) is energized.
q Because of this, spool (6) is pushed to the right
by push pin (4).
q As a result, pressure oil from the control pump
flows from port (P) to port (A), and then flows
to the actuator.
At the same time, port (T) is closed, so the oil
does not flow to the tank.
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.
PC1250-8R 57
Hydraulic cylinder 1
Boom
Arm
Bucket
58 PC1250-8R
Unit: mm
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
PC1250-8R 59

Boom
Arm
Bucket
60 PC1250-8R
Bottom dump
Unit: mm
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
PC1250-8R 61
SEN02060-01

© 2007 KOMATSU
All Rights Reserved
62
SEN02061-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Work equipment
Work equipment .............................................................................................................................................. 2
Dimensions of work equipment....................................................................................................................... 6
PC1250-8R 1
Work equipment 1
2 PC1250-8R
Unit: mm
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
–0.043 +0.404 0.364 –
3 and mounting pin of arm and 140 1.5
–0.106 +0.321 0.510 Replace
link
–0.043 +0.397 0.355 –
–0.106 +0.312 0.503
bucket
–0.043 +0.397 0.355 –
5 and mounting pin of link and 140 1.5
–0.106 +0.312 0.503
link
–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
PC1250-8R 3
4 PC1250-8R
Unit: mm
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
–0.043 +0.439 0.396 –
2 and mounting pin of boom and 160 1.5
–0.106 +0.353 0.545 Replace
arm
–0.043 +0.439 0.396 –
–0.106 +0.353 0.545
bucket
–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
PC1250-8R 5
Dimensions of work equipment 1

1. Arm
6 PC1250-8R
Unit: mm
Model PC1250-8R PC1250SP-8R
with 3.4 m heavy-duty arm with 4.5 m heavy-duty arm with 3.4 m heavy-duty arm
No.
1 160 160 160
2 120 120 120
3 636 636 636
4 160 160 160
5 489 550 496
6 635 635 635
7 1,348 1,326 1,348
8 3,340 4,455 3,340
9 4,108 4,087 4,274
10 610 610 590
11 1,223 1,223 1,290
12 977 977 1,028
13 840 840 950
14 2,653 2,600 2,690
15 140 140 140
16 636 636 636
17 140 140 140
Arm as individual part 637 637 637
18
When press-fitting bushing 653 653 653
Min. 2,535 2,535 2,660
19
Max. 4,360 4,360 4,610
20 20 0 20
PC1250-8R 7
2. Bucket
8 PC1250-8R
Unit: mm
Model PC1250-8R PC1250SP-8R
3.4 m3 bucket 4.0 m3 bucket 5.0 m3 bucket 5.2 m3 bucket 6.7 m3 bucket
No.
1 837 837 837 837 945
2 76 76 76 76 100
3 95° 95° 95° 95° 95°
4 840 840 840 840 950
5 2,576 (2,618) 2,576 (2,618) 2,576 (2,618) 2,648 2,686
6 353 (404) 353 (404) 353 (404) 412 397
a Ø170 Ø170 Ø170 Ø170 Ø170
7
b Ø170 Ø170 Ø170 Ø170 Ø170
8 637.5 637.5 637.5 637.5 637.5
9 100 100 100 100 100
10 100 100 100 100 100
11 Ø280 Ø280 Ø280 Ø280 Ø280
12 Ø310 Ø310 Ø310 Ø310 Ø310
13 210.6 210.6 210.6 203 218
14 241 241 241 241 222
15 174 174 174 174 174
16 160 160 160 160 160
17 679.5 679.5 679.5 679.5 679.5
18 83 83 83 83 83
a The figures in ( ) show the value for the long life tooth.
PC1250-8R 9
SEN02061-00

© 2006 KOMATSU
All Rights Reserved
10
SEN02062-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Cab and its attachments
Air conditioner ................................................................................................................................................. 2
PC1250-8R 1
Air conditioner 1
Air conditioner piping
Standard cab specification/55°C cab specification
Large capacity air conditioner
1. Duct A : Fresh air

2. Condenser B : Recirculated air
3. Air conditioner compressor C : Hot air/cold air
4. Hot water return piping
5. Hot water pickup piping
6. Refrigerant piping
7. Receiver tank
8. Air conditioner unit
9. Blower (large capacity air conditioner only)
2 PC1250-8R
PC1250-8R 3
SEN02062-01

© 2007 KOMATSU
All Rights Reserved
4
SEN02063-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Electrical system
Engine control ................................................................................................................................................. 2
Electric control system .................................................................................................................................... 9
Monitor system.............................................................................................................................................. 45
Sensor........................................................................................................................................................... 68
PC1250-8R 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 controller engine controller (6) to control the engine
7. Starting motor speed.
2 PC1250-8R
Operation of system Stopping engine

Starting engine q When detecting that the starting switch is set to
q When the starting switch is turned to the the "STOP" position, the engine controller cuts
"START" position, the starting signal flows to the fuel injection to stop the engine.
the starting motor. Then, the starting motor
turns to start the engine.
When it happens, the engine controller checks

the signal voltage from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
Engine speed control

q The fuel control dial sends a signal voltage cor-
responding to the rotation angle to the engine
controller.
q The pump controller receives the fuel dial posi-
tion information from the engine controller
through the network.
q The pump controller calculates the engine
speed in accordance with the working mode,
the deceleration, and the like, and sends an
instruction to the engine controller.
q The engine controller determines the fuel injec-
tion quantity based on the instruction received
from the pump controller.
PC1250-8R 3
Component
Fuel control dial
1. Knob 4. Ball
2. Dial 5. Potentiometer
3. Spring 6. Connector
4 PC1250-8R
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.
PC1250-8R 5
Engine controller
q Meanings of signal classes in the terminal CN-CE01

table shown below are as follows. Input/
A: Power supply Pin No. Signal name
Output
B: Input 11 NC (*) —
C: Ground/Shield/Return 12 NC (*) —
D: Output 13 Engine oil pressure sensor B
E: Communication 14 NC (*) —
CN-CE01 15 Engine coolant temperature sensor B
Input/ 16 5V electric power supply for sensor A
Pin No. Signal name
Output 17 Engine oil temperature sensor B
1 NC (*) — 18 NC (*) —
2 NC (*) — 19 NC (*) —
3 Atmosphere sensor B 20 NC (*) —
4 Fuel supply pump #1 (+) D 21 NC (*) —
5 Fuel supply pump #1 (–) C 22 NC (*) —
6 CAN (–) E 23 Boost temperature sensor B
7 NC (*) — 24 NC (*) —
8 CAN (+) E 25 Common rail pressure sensor B
9 Fuel supply pump #2 (+) D 26 G sensor (+) B
10 Fuel supply pump #2 (–) C 27 NE sensor (+) B
*: Never connect to NC as malfunctions or failures will *: Never connect to NC as malfunctions or failures will
occur. occur.
6 PC1250-8R
CN-CE01 CN-CE02
Input/ Input/
Pin No. Signal name Pin No. Signal name
Output Output
28 NC (*) — 13 NC (*) —
29 NC (*) — 14 NC (*) —
30 Fuel temperature sensor B 15 NC (*) —
31 NC (*) — 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 G sensor (–) C 32 NC (*) —
48 Ne sensor (–) C 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 as 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 as 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 NC (*) —
8 NC (*) — Electric power supply
3 A
9 Fuel control dial (+) — (+24V constantly)
10 NC (*) — 4 NC (*) —
11 NC (*) — *: Never connect to NC as malfunctions or failures will
12 NC (*) — occur.
*: Never connect to NC as malfunctions or failures will
occur.
PC1250-8R 7
8 PC1250-8R
Electric control system 1

Control function
PC1250-8R 9
Machine control system diagram
10 PC1250-8R
PC1250-8R 11
Auto deceleration function
1. Machine monitor Function

2. Fuel control dial q If all the control levers are at neutral when
3. Engine waiting for work or waiting for a dump truck,
4. Control pump the engine speed is automatically reduced to a
5. Right work equipment lever midrange speed to reduce fuel consumption
6. Hydraulic switch and noise.
7. Left work equipment lever q If any lever is operated, the engine speed
8. Hydraulic switch returns immediately to the set speed.
9. Travel lever
10. Hydraulic switch
11. Engine controller
12. Pump controller
12 PC1250-8R
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.
PC1250-8R 13
Electronic OLSS function

Pump control system
q Interconnected control of all pumps is carried

out by one TVC valve.
q P mode:Total horsepower control by sensing
engine speed
q E mode:Total horsepower control by sensing
engine speed
q Emergency pump drive circuit: Constant deliv-
ery control
14 PC1250-8R
1. Control method in each mode

P, E mode
q Matching point in P, E mode: Rated output 2. Cut-off function

point q If the load during operation increases and the
pump discharge pressure rises to near the
Model
PC1250-8R relief pressure, the main pump cut-off valve is
Mode actuated to reduce the relief loss.
P 485 kW/1,800 rpm {651 HP/1,800 rpm}
E 402 kW/1,710 rpm {539 HP/1,710 rpm}
q When the load on the pump rises and the

pressure rises, the engine speed goes
down.
When this happens, the pump discharge
amount is reduced, and the engine speed
is controlled so that it becomes close to
the rated speed.
If the reverse happens and the pressure
goes down, the system is controlled so
th at th e p u mp d is c h a r ge a mo u nt is
increased until the engine speed reaches
close to the rated speed.
By repeating this control, the engine can
always be used at near the rated output
point.
q Compared with the P mode, which pro-
vides the maximum output, the E mode
lowers the engine output to provide
matching at a point which gives better fuel
consumption efficiency than the P mode.
PC1250-8R 15
Heavy lift function
16 PC1250-8R
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.
a Heavy-lift solenoid valve

For details of the structure and function, see “Solenoid valve”.
a CO valve
For details of the structure and function, see “No. 1 pump”.
a
a Main relief valve
For details of the structure and function, see “L.H. 5-spool valve”.
PC1250-8R 17
2-stage boom pushing force selector function
18 PC1250-8R
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.
Boom By increasing the thrust force for boom LOWER,

pushing 33.3 MPa the ease of operation is improved for excavation,
De-energized
force {340 kg/cm2} digging square holes, carrying out twist turns, or
(high mode) escaping from soft ground.
a Machine push-up solenoid valve

For details of the structure and function, see “Solenoid valve”.
a Boom safety valve
For details of the structure and function, see “R.H. 4-spool valve”.
PC1250-8R 19
Swing control function

1. Swing speed sensor Function

2. Swing motor q The system is provided with a swing lock and
3. PPC valve for arm control and swing control swing holding brake function.
5. Hydraulic switch
6. Control pump
7. Machine monitor
8. Swing holding brake release switch
9. Swing lock switch
10. Fuse
11. Battery
12. Battery relay
13. Pump controller
20 PC1250-8R
1) Swing lock, swing holding brake function

q The swing lock (manual) can be locked at any a Swing brake solenoid valve
desired position, and the swing lock and swing For details of the structure and function,
holding brake (automatic) are interconnected see “Solenoid valve”.
with the swing, so they prevent any hydraulic a Swing motor
drift after the swing is stopped. For details of the structure and function,
see “Swing motor”.
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch lamp solenoid valve
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 11 sec; when
any swing or work equipment lever is operated, brake is
canceled and swing can be operated freely
Swing
See diagram
holding OFF OFF
on right
brake
Swing lock is actuated and swing is held in position. Even

Swing
ON ON De-energized when swing lever is operated, swing lock is not canceled
brake
and swing does not move.
2) Operation of swing holding brake release switch

q If any abnormality should occur in the control- a When the swing brake is canceled, the swing
ler, and the swing holding brake is not actuated has only a hydraulic brake operated by the
normally and the swing cannot be operated, safety valve, so if the swing is stopped on a
the swing holding brake release switch (2) can slope, there may be hydraulic drift.
be operated to cancel the swing lock and allow
the swing to be operated.
Swing
holding
A: FREE B: NORMAL
brake
(when controller is (when controller is
release
abnormal) normal)
switch
(2)
Swing
lock
ON OFF ON OFF
switch
(1)
Swing
Swing Swing lock Swing lock Swing lock holding
brake applied canceled applied brake
applied
a Even when the swing holding brake release

switch (2) is turned ON, the swing lock switch
(1) stays ON and the swing brake is not can-
celed.
PC1250-8R 21
1. Swing motor Function

2. PPC valve for arm control and swing control q The system is provided with a swing lock and
3. Swing holding brake solenoid valve swing holding brake function.
4. Hydraulic switch
5. Control pump
6. Machine monitor
7. Swing holding brake release switch
8. Swing lock switch
9. Fuse
10. Battery
11. Battery relay
12. Pump controller
22 PC1250-8R
1) Swing lock, swing holding brake function

q The swing lock (manual) can be locked at any a Swing brake solenoid valve
desired position, and the swing lock and swing For details of the structure and function,
holding brake (automatic) are interconnected see “Solenoid valve”.
with the swing, so they prevent any hydraulic a Swing motor
drift after the swing is stopped. For details of the structure and function,
see “Swing motor”.
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch lamp solenoid valve
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 11 sec; when
any swing or work equipment lever is operated, brake is
canceled and swing can be operated freely
Swing
See diagram
holding OFF OFF
on right
brake
Swing lock is actuated and swing is held in position. Even

Swing
ON ON De-energized when swing lever is operated, swing lock is not canceled
brake
and swing does not move.
2) Operation of swing holding brake release switch

q If any abnormality should occur in the control- a When the swing brake is canceled, the swing
ler, and the swing holding brake is not actuated has only a hydraulic brake operated by the
normally and the swing cannot be operated, safety valve, so if the swing is stopped on a
the swing holding brake release switch (2) can slope, there may be hydraulic drift.
be operated to cancel the swing lock and allow
the swing to be operated.
Swing
holding
A: FREE B: NORMAL
brake
(when controller is (when controller is
release
abnormal) normal)
switch
(2)
Swing
lock
ON OFF ON OFF
switch
(1)
Swing
Swing Swing lock Swing lock Swing lock holding
brake applied canceled applied brake
applied
a Even when the swing holding brake release

switch (2) is turned ON, the swing lock switch
(1) stays ON and the swing brake is not can-
celed.
PC1250-8R 23
Engine automatic warming-up, overheat prevention function, turbo protect function
1. Machine monitor Function

2. Engine q If the coolant temperature is low, it automati-
3. Engine coolant temperature sensor cally raises the engine speed to warm up the
4. Engine speed sensor engine after it is started. In addition, if the cool-
5. Fuel control dial ant temperature rises too high during opera-
6. Throttle signal tions, it automatically lowers engine speed to
7. Engine coolant temperature signal low idle, and reduces the load of the pump to
8. Drive signal prevent overheating.
9. Speed sensor signal q To protect the turbocharger bearing during cold
10. Network signal weather, the engine speed is kept below the
11. Engine controller fixed speed when the engine is started.
12. Network signal
13. Network signal
14. Speed signal
15. Pump controller
24 PC1250-8R
1. Engine automatic warming-up function

q After the engine is started, if the engine coolant temperature is low, the engine speed is automatically
raised to warm up the engine.
Conditions for actuation (both are necessary) Actuation
Coolant temperature: Less than 30°C

Engine speed: 1200 rpm
Engine speed: Less than 1200 rpm
Conditions for cancellation (any one) Actuation

Coolant temperature: 30°C or more
Automatic
Automatic warming-up time: 10 minutes or more
Engine speed: As desired
Fuel control dial: Held at more than 70% of full throt-
Manual
tle for more than 3 seconds
2. Engine overheat prevention function

q This function protects the engine by lowering the pump load and engine speed to prevent overheating
when the engine coolant temperature has risen too high.
q This system is actuated at 105°C and above.
Actuation condition Actuation, remedy
Coolant temperature: Working mode : In any mode
105°C and above Engine speed : Low idle
(Coolant temperature gauge: Red range) Monitor warning lamp : Lights up
Alarm buzzer : Sounds
Cancel condition
Coolant temperature : Below 105°C
3. Turbo protect function

Function to protect turbocharger bearing dur- Engine speed: 1000 rpm
ing cold weather by keeping engine speed
below fixed speed when engine is started. Even if the fuel control dial is operated during
the above time, the engine speed will not
Actuation condition change. After the set time passes, the opera-
tion moves to the automatic warming up func-
Engine coolant Turbo protect time
tion in Step 1.
temperature (sec)
More than +10°C 0
Gradually changes
+10°C to –10°C
between 0 and 20
Less than –10°C 20
PC1250-8R 25
Travel speed selector function

1. Travel pressure rise function
26 PC1250-8R
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
PC1250-8R 27
2. Travel speed selector function
1. Control valve 5. Pump controller

2. Hydraulic pump 6. Machine monitor
3. Control pump 7. Travel speed change switch
4. Travel speed solenoid valve
The travel pressure (self pressure) changes the

swash plate angle of the travel motor and automati-
cally shifts the speed range.
q When traveling at high speed with the travel
speed switch at Hi, if the travel pressure goes
above 28.4 MPa {290 kg/cm2}, such as when
starting to travel uphill, the self pressure shifts
to low speed travel. If the machine continues to
travel at low speed and then comes again to a
flat area, when the travel pressure drops below
28.4 MPa {290 kg/cm2}, the speed is switched
back to high speed travel.
Travel speed Travel speed Travel motor swash

Travel speed Remarks
switch solenoid valve plate angle
Suitable for traveling on rough
Lo De-energized Max. Low speed (max. 2.1 km/h)
ground or traveling downhill
Max.
Low speed (2.1 km/h) Suitable for moving
Hi Energized
high speed (3.2 km/h) long distances
Min
28 PC1250-8R
Boom shockless control function

This function improves safety by preventing spillage of the load from the bucket and by reducing the shock
when the boom is stopped, thereby reducing operator fatigue.
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.
PC1250-8R 29
Straight-travel function
30 PC1250-8R
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
PC1250-8R 31
Swing priority function

q There is swing priority mode switch (1) on the
machine monitor. By turning this switch ON/
OFF, it is possible to change the matching of
the boom RAISE and swing. This divides the
flow to provide a swing speed which matches
the swing angle, thereby enabling the operator
to carry out compound operations easily.
Swing priority mode OFF:

90° swing and load dump truck
Swing priority mode ON:
180° swing and load dump truck
Swing priority Number of boom raise

Solenoid
selector valve control valve
Swing priority mode OFF
OFF (de-energized) OFF 3
(standard)
Swing priority mode ON
ON (energized) ON 2
(swing priority)
32 PC1250-8R
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.)
PC1250-8R 33
Swing compensation function

q If the swing is operated at the same time as the arm or bucket, the throttle valve in the arm or bucket cir-
cuit acts to ensure the flow of oil to the swing to ensure good performance during combined operations.
1. Hydraulic pump 10. Shuttle valve

2. Swing 4-spool valve 11. Swing PPC valve
3. Pilot check valve 12. No. 3 pump (HPV 160+160)
4. Swing 13. No. 1 pump (HPV 95+95)
5. Throttle valve 14. No. 2 pump (HPV 95+95)
6. Bucket 15. Control pump
7. Throttle valve 16. To L.H. 5-spool valve
8. Arm 17. To R.H. 4-spool valve
9. Swing compensation selector valve
changeover pressure: 1.5 MPa {15 kg/cm2}
Operation
q There is a constant actuated arm throttle valve in the arm circuit of the swing 4-spool control valve.
When the swing PPC pressure goes above 1.5 MPa {15 kg/cm2} (when the control lever is operated
approx. halfway), the swing compensation 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.
34 PC1250-8R
PC1250-8R 35
Hydraulic fan control function

1. Fan speed control
q The fan speed is controlled according to the
engine speed, hydraulic oil temperature, and
coolant temperature. When the temperature is
low, the fan speed is lowered to reduce the
noise and the horsepower consumed by the
fan unnecessarily.
36 PC1250-8R
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
2. Engine output control

q The fan speed is controlled according to the
temperature (hydraulic oil temperature and
coolant temperature). When the fan speed is
low, the pump controller calculates the horse-
power consumed by the fan and controls the
fan speed to reduce unnecessary horsepower
and fuel consumption.
A: Work and travel consumption horsepower zone

B: Fan and consumption horsepower zone
C: Engine output curve is controlled according to
fan speed
D: Work and travel consumption horsepower zone
is kept constant regardless of temperature, thus
production is kept constant
PC1250-8R 37
Fan reverse function

q The fan reverse function is installed for the
ease of cleaning the cooling system.
Enter the fan reverse mode with adjustment
switch (1) of the machine monitor.
38 PC1250-8R
q Upon receiving the signal from the machine

monitor, the pump controller outputs the fan
reverse signal, which drives the fan reverse
solenoid valve of the fan motor to change the
fan reverse valve and reverse the fan rotation
direction.
Note) Since the fan reverse function is for
cleaning the cooling devices, the fan
speed in reverse direction is not con-
trolled by the temperature (hydraulic oil
temperature and coolant temperature)
but controlled by only the engine speed.
1. Cooling fan 7. Servo

2. Fan motor 8. EPC valve
3. Fan reverse valve 9. Fan pump flow control signal
4. Fan reverse solenoid valve 10. Network signal
5. Fan reverse signal 11. Machine monitor
6. Pump controller
PC1250-8R 39
Components of system
Pump controller
40 PC1250-8R
q Meanings of signal classes in the terminal

table shown below are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
Input and output signals

CN1 [CN-C01] CN2 [CN-C02]
Input/ Input/
Output Output
CN1-1 NC (*) B CN2-1 NC (*) D
CN1-2 R pump pressure sensor B CN2-2 Swing lock override switch B
CN1-3 NC (*) B CN2-3 NC (*) B
CN1-4 GND_SIG_D C CN2-4 NC (*) E
CN1-5 Auto grease-up error B CN2-5 NC (*) B
CN1-6 NC (*) B CN2-6 NC (*) B
CN1-7 NC (*) B CN2-7 Model selection 4 (unused) B
CN1-8 F pump pressure sensor B CN2-8 NC (*) D
CN1-9 Ambient temperature sensor B CN2-9 NC (*) D
CN1-10 GND_SIG_D C CN2-10 NC (*) B
CN1-11 NC (*) B CN2-11 NC (*) D
CN1-12 NC (*) B CN2-12 CAN shield C
CN1-13 NC (*) B CN2-13 Model selection 5 (unused) B
CN1-14 NC (*) B CN2-14 NC (*) E
CN1-15 NC (*) B CN2-15 NC (*) B
CN1-16 NC (*) A CN2-16 Left travel pressure switch B
CN1-17 Starting switch (Terminal C) B CN2-17 Model selection 3 (unused) B
CN1-18 NC (*) B CN2-18 Step light driver relay (unused) D
CN1-19 Swing pump pressure sensor B CN2-19 NC (*) D
CN1-20 NC (*) B CN2-20 NC (*) B
CN1-21 GND_SIG_A C CN2-21 NC (*) E
CN1-22 PWR_CUT_5 V_O A CN2-22 COMM_CAN_L_O E
CN1-23 Starting switch (Terminal Acc) B CN2-23 NC (*) E
CN1-24 Step light switch B CN2-24 PWR_CTN_EXT B
*:Never connect to NC as malfunctions or failures will CN2-25 Horn switch B
occur. CN2-26 NC B
CN2-27 Model selection 2 (unused) B
CN2-28 NC (*) B
CN2-29 NC (*) C
CN2-30 NC (*) B
CN2-31 NC (*) C
CN2-32 COMM_CAN_H_O E
CN2-33 NC (*) E
CN2-34 NC (*) C
CN2-35 Service valve pressure switch B
CN2-36 NC (*) B
CN2-37 Model selection 1 (unused) B
CN2-38 Swing lock switch B
CN2-39 Pulse GND C
CN2-40 Engine speed sensor B
*:Never connect to NC as malfunctions or failures will
occur.
PC1250-8R 41
CN3 [CN-C03]
Input/
Pin No. Signal name
Output
CN3-1 PWR_IN_BATT A
CN3-2 PWR_IN_BRY A
CN3-3 GND_ACT C
CN3-4 Battery relay drive D
CN3-5 NC (*) D
CN3-6 NC (*) D
CN3-7 Straight travel solenoid D
CN3-8 Travel alarm D
CN3-9 Bucket CURL pressure switch B
CN3-10 Boom RAISE pressure switch B
CN3-11 PWR_IN_BATT A
CN3-12 PWR_IN_BRY A
CN3-13 GND_ACT C
CN3-14 PWR_CTR_KEY B
CN3-15 NC (*) D
CN3-16 TVC solenoid D
CN3-17 2-stage relief solenoid D
CN3-18 Flash light driver relay D
CN3-19 Bucket DUMP pressure switch B
CN3-20 Boom LOWER pressure switch B
CN3-21 PWR C
CN3-22 PWR_IN_BRY A
CN3-23 GND_ACT C
CN3-25 Fan reverse rotation solenoid D
CN3-26 NC (*) D
CN3-27 Travel Hi/Lo selector solenoid D
CN3-28 Cutoff cancel solenoid D
CN3-29 Swing pressure switch B
CN3-30 Arm IN pressure switch B
CN3-31 GND_PWR C
CN3-32 GND_PWR C
CN3-33 GND_PWR C
CN3-34 NC (*) A
CN3-35 Fan pump EPC solenoid D
CN3-36 NC (*) D
CN3-37 Swing holding brake solenoid D
CN3-38 Swing priority solenoid D
CN3-39 Travel hydraulic pressure switch B
CN3-40 Arm OUT pressure switch B
occur.
42 PC1250-8R
PPC hydraulic pressure switch
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 controller and pump
controller.
PC1250-8R 43
TVC prolix resistor
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.
Fuel control dial

a See “Engine control”.
Monitor panel
a See “Machine monitor”.
TVC valve
a See “Hydraulic pump”.
44 PC1250-8R
Monitor system 1
1. Sensors q The monitor system monitors the condition of

2. Hydraulic oil temperature, fuel level signals the machine with sensors installed on various
3. Machine monitor parts of the machine. It processes and immedi-
4. Antenna ately displays the obtained information on the
5. ORBCCOMM controller (If equipped) panel notifying the operator of the condition of
6. Network signal the machine.
7. VHMS controller The panel is roughly divided as follows.
8. Switch signal 1. Monitor section to output alarms when the
9. Engine and pump controller machine has troubles
10. Caution signal 2. Gauge section to display the condition
11. Power source constantly (Coolant temperature, hydrau-
12. Battery lic oil temperature, fuel level, etc.)
13. Sensor signal q The machine monitor also has various mode
selector switches and functions to operate the
machine control system.
PC1250-8R 45
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.
46 PC1250-8R

A: Power supply
B: Input
D: Output
E: Communication

CN-1 CN-3
Input/ Input/
Output Output
1 Starting switch (Battery) B 1 NC (*) —
2 Starting switch (Battery) B 2 NC (*) —
3 Washer motor output D 3 NC (*) —
4 Starting signal (Terminal C) B 4 NC (*) —
5 Wiper contact W B 5 NC (*) —
6 GND C 6 NC (*) —
7 GND C 7 NC (*) —
8 VB + (24 V) A 8 NC (*) —
9 Wiper motor (+) D 9 NC (*) —
10 Wiper motor (–) D 10 NC (*) —
11 NC (*) — 11 NC (*) —
12 Wiper contact P B 12 NC (*) —
*:Never connect to NC as malfunctions or failures will 13 NC (*) —
occur. 14 CAN (Shield) E
15 CAN H E
CN-2 16 CAN L E
Input/ *:Never connect to NC as malfunctions or failures will
Pin No. Signal name
Output occur.
1 NC (*) —
2 Fuel level B
3 Radiator coolant level B
4 NC (*) —
5 Air cleaner clogging sensor B
6 NC (*) —
7 NC (*) —
8 Engine oil level sensor B
9 NC (*) —
10 NC (*) —
11 Charge level B
12 Hydraulic oil temperature (Analog) B
13 GND (For analog signal) C
14 NC (*) —
15 Window limit switch B
16 NC (*) —
17 Swing lock B
18 Preheating B
19 Light switch B
20 NC (*) —
occur.
PC1250-8R 47
Monitor control and display portion

Monitor portion
1. Wiper monitor 12. Hydraulic oil temperature monitor

2. Preheating monitor 13. Auto-deceleration monitor
3. Swing lock monitor 14. Radiator coolant level caution
4. Engine coolant temperature monitor 15. Battery charge caution
5. Hydraulic oil temperature gauge 16. Engine oil pressure caution
6. Engine coolant temperature gauge 17. Engine oil level caution
7. Working mode monitor 18. Air cleaner clogging
8. Service monitor 19. Maintenance time warning caution
9. Travel speed monitor
10. Fuel gauge A. Checks before starting (caution lamps all light up)
11. Fuel level monitor B. When maintenance interval is exceeded
48 PC1250-8R
Monitor items and display
Symbol Display item Display method
Swing holding brake

Swing lock switch Swing lock monitor
release switch
OFF OFF OFF
Swing lock
ON OFF ON
OFF ON Flashes
ON ON ON
Continuous set time Preheating monitor status

Up to 30 sec. ON
Preheating
From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
PC1250-8R 49
Gauge Range Temperature, volume Indicator Buzzer sound

A1 105 Red Q
A2 102 Red
Engine coolant A3 100 Green
temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red Q
B2 102 Red
Hydraulic oil B3 100 Green
temperature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 289 Green
C2 244.5 Green
C3 200 Green
Fuel level (l)
C4 100 Green
C5 60 Green
C6 41 Red
50 PC1250-8R
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.
Check before When engine is When engine is

Symbol Display item
starting item stopped running
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
Lights up when there is a warning. Lights up

Maintenance for only 30 sec. after key is turned ON, then
goes out.
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.
Condition of hydraulic oil Color of symbol

Low temperature
Black on white background
(below B6 or equivalent)
Normal (B6 – B2) No display
High temperature
White on red background
(above B2)
PC1250-8R 51
Display category Symbol Display item Display range Display method
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
52 PC1250-8R
Switches
1. Working mode selector switch 7. Input confirmation switch

2. Select switch 8. Window washer switch
3. Buzzer cancel switch 9. Wiper switch
4. Display brightness, contrast adjustment switch 10. Maintenance switch
5. Return switch 11. Travel speed selector switch
6. Control switch 12. Auto-deceleration switch
PC1250-8R 53
q Working mode selector switch q Wiper switch

The condition of the machine changes according Each time the wiper switch is pressed, the
to the switch that is pressed (Shown in the figure wiper setting changes OFF o INT o ON o
below). It is possible to check the condition on OFF o ……
the working mode monitor display. The relation- Use the wiper monitor display to check the
ship between each working mode and the moni- present condition.
tor display is shown in the table below. The relationship between the wiper setting and
the monitor display is as shown in the table
Switch that Working mode status
Display below.
is pressed after setting
[P] P P mode (default) Wiper actuation
Display Setting
status
[E] E E mode
Stowing stopped
None OFF
or now stowing
Heavy-lift mode Intermittent
Wiper symbol + INT INT
actuation
Continuous
Wiper symbol + ON ON
Swing priority mode actuation
q Window washer switch

q Maintenance switch While the switch is being pressed, window
Check the condition of the maintenance items. washer liquid is sprayed out. There is a time
(For details, see “Maintenance function”.) delay before the wiper starts.
q Auto-deceleration switch q Control switch

Each time the auto-deceleration switch is This is used for control when using the mainte-
pressed, the auto-deceleration function is nance function or select function.
switched ON/OFF. (For details, see each function.)
Use the auto-deceleration monitor display to
check the present condition. q Display brightness, contrast adjustment
When the working mode switch is operated to switch
switch the working mode, it is automatically set Use this switch when adjusting the display
to ON. brightness and contrast.
(For details, see each function.)
q Travel speed selector switch
Each time the travel speed selector switch is q Selector switch
pressed, the travel speed changes. This is used when making detailed settings in
Lo o Hi o Lo …… each working mode. For details, See “Select
Use the travel speed monitor display to check mode function”.
the present condition.
The relationship between the set speed and q Buzzer cancel switch
the monitor display is as shown in the table Pressing this switch when the alarm buzzer is
below. making sound stops the alarm buzzer.
If a new abnormality is detected, the alarm
Display Setting buzzer sounds.
Crawler symbol + Lo Low speed (default) Depending on the alarm buzzer type, it does
Crawler symbol + Hi High speed not stop even if you press the buzzer cancel
switch.
54 PC1250-8R
Maintenance function Method of checking status maintenance items

When the maintenance time for replacement, a Operate as follows when on the operator
inspection, or filling has approached for the 11 screen.
maintenance items, press maintenance switch (1) 1) Press maintenance switch (1) and switch
and the caution display (yellow or red) appears on to the maintenance list display screen.
the monitor display for 30 seconds after the key is a The maintenance items are displayed
turned ON to remind the operator to carry out lubri- as symbols on the screen.
cation maintenance.
2) Press control switch (2), or use the 10-key

a Maintenance items pad to input the number (01 – 10) of the
Replacement interval maintenance item to select the item.
No. Item a The cursor moves and the item is
(Hours)
01 Engine oil 500 highlighted.
a The display method is the same as
02 Engine oil filter 500
described above (relationship
03 Fuel main filter 500 between remaining time and caution
41 Fuel pre-filter 500 display). If the remaining time is less
04 Hydraulic filter 1,000 than 30 hours, the item is displayed in
05 Hydraulic tank breather 1,000 yellow, and if it is less than 0 hours, it
06 Corrosion resistor 1,000 is displayed in red.
07 PTO case oil 1,000
08 Final case oil 2,000
09 Machinery case oil 1,000
10 Hydraulic oil 5,000
*: Option, so not set
a The above replacement intervals are set for

each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the ramaining time. The relation-
ship is as shown in the table below.
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for mainte-
background)
nance
There is one or more items
Warning display (white
with less than 0 hours
symbol displayed on red
remaining time for mainte-
background)
nance
PC1250-8R 55
Maintenance operation
1. After completing the selection, press input con-
firmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check

the content, and if there is no problem, press
input confirmation switch (3) to move to the
check screen.
If the wrong item is selected, press return
switch (4) to return to the maintenance list
screen.
3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To
check the remaining time, or if the wrong item
is selected, press return switch (4) to return to
the maintenance list screen.
a The check screen shows the symbol for
the maintenance item and the set time in
large letters.
a The background color of the symbol for
the item where the maintenance item was
reset is the same as the background of the
screen, so it is possible to check that it
has been reset.
56 PC1250-8R
User mode function Setting fan rotation direction

q In the user mode, the fan rotation direction can q With this menu, the fan rotation direction can
be reversed and the set values in the E mode be reversed. The cooling devices can be
can be changed. cleaned easily by rotating the fan in reverse.
q Press selector switch (1) while the normal
screen is displayed, and the user mode menu
is displayed.
q From this menu, you can select the fan speed
setting screen or E mode adjustment screen.
q Move the reversed display part with operation
switch (3) or input “00” – “02” with the numeral
keys to select an item and press input confir-
m ati on sw it ch (4 ) , an d th e ne xt s c r ee n
appears.
q If return switch (2) is pressed, the normal
screen appears again.
q If “01” is selected, the reverse confirmation
screen appears.
q If “02” is selected, the E mode adjustment a If any of the following conditions is established,
screen appears. the following reverse prohibition screen
appears and the fan does not rotate in reverse.
Coolant temperature > 90°C
Hydraulic oil temperature < 15°C
Hydraulic oil temperature > 95°C
q If return switch (2) is pressed, the user mode

menu appears again.
q If input confirmation switch (4) is pressed, the
fan rotates in reverse.
PC1250-8R 57
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.
q If the return switch is pressed, the previous

screen appears.
a While the rotation direction is being changed,
the engine speed is set to low idle automati-
cally for 15 seconds.
a If an error occurs while the fan is rotating in

reverse, the caution mark is displayed.
a If select switch (1) is pressed while the fan is

rotating in reverse, the following reverse rota-
tion confirmation screen appears.
58 PC1250-8R
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”.
PC1250-8R 59
Brightness, contrast adjustment

function 1 3. Press control switch (2) and adjust the bright-
This function is used to adjust the brightness and ness and contrast as desired.
contrast of the display.
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.
Control switch Actuation
Flow level bar graph

extends to the right
Flow level bar graph

retracts to the left
a Relationship between menu symbol and content
No. Symbol Content
00 Return mark Return
01 Contrast
02 Brightness
2. Press control switch (2), or use the 10-key pad

to input the number (00 – 02) to select either
contrast or brightness.
After completing the selection, press input con-
firmation switch (3) and return to the adjust-
ment screen.
Then press return switch (4) or use the 10-key
pad to set to [00] and press input confirmation
switch (3) to return to the normal screen.
60 PC1250-8R
Service meter check function 1

q When the starting switch is at the OFF posi-
tion, keep return switch (1) and control switch
(2) of the monitor pressed at the same time,
and the service meter is shown on the display.
q This display is shown only while the two
s w i t c h e s a r e b e i n g p r e s s e d . W he n t h e
switches are released, the display goes out.
Note that it takes 3 – 5 seconds after the
switches are pressed for the service meter dis-
play to appear.
Display LCD check function

q On the password input screen or on the normal
screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the
whole screen will become white, so the display
can be checked.
q If any part of the display is black, the LCD is
broken.
PC1250-8R 61
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.
q If the telephone number has been set by using

the telephone number input on the service
q If more than one user code is generated at the menu, it is possible to switch on the service
same time, the user codes are displayed in code/failure code and display the telephone
turn for 2 seconds each to display all the user symbol and telephone number.
codes. For details of inputting and setting the tele-
phone number, see “Special functions of moni-
tor panel” in the Testing and adjusting section.
q While the user code is being displayed, if the

input confirmation switch is pressed, the ser-
vice code and failure code can be displayed.
62 PC1250-8R
VHMS controller
PC1250-8R 63

A: Power supply
B: Input
D: Output
E: Communication

CN-1 [CN1] CN-2 [CN2 A, B]
Pin No. Signal name Input/Output Pin No. Signal name Input/Output
CN1-1 NC (*) — CN2-A1 NC (*) —
CN1-2 Sensor power source (24 V) A CN2-A2 PTO oil temperature B
CN1-3 NC (*) — CN2-A3 Engine oil temperature B
CN1-4 NC (*) — CN2-A4 NC (*) —
CN1-5 Sensor power source (5 V) A CN2-A5 Exhaust temperature R B
CN1-6 Power source (Constant) A CN2-A6 Gear pump pressure 1 B
CN1-7 Power source (Constant) A CN2-A7 Exhaust temperature F B
CN1-8 BR power source A CN2-A8 NC (*) —
CN1-9 BR power source A CN2-A9 CONNECTOR SEL0 B
CN1-10 NC (*) — CN2-A10 NC (*) —
CN1-11 GND C CN2-A11 NC (*) —
CN1-12 GND C CN2-A12 Sensor GND C
CN1-13 NC (*) — CN2-A13 GND C
CN1-14 NC (*) — CN2-A14 NC (*) —
CN1-15 NC (*) — CN2-A15 NC (*) —
CN1-16 NC (*) — CN2-A16 Gear pump pressure 2 B
CN1-17 NC (*) — CN2-A17 WAKE UP (L) B
CN1-18 NC (*) — CN2-A18 Blow-by pressure B
CN1-19 GND C CN2-B1 NC (*) —
CN1-20 GND C CN2-B2 NC (*) —
*:Never connect to NC as malfunctions or failures will CN2-B3 NC (*) —
occur. CN2-B4 NC (*) —
CN2-B5 NC (*) —
CN2-B6 NC (*) —
CN2-B7 NC (*) —
CN2-B8 NC (*) —
CN2-B9 GND C
CN2-B10 NC (*) —
CN2-B11 NC (*) —
CN2-B12 CONNECTOR SEL1 B
occur.
64 PC1250-8R
CN-3 [CN3 A, B] CN-4 [CN4 A, B]

CN3-A1 NC (*) — CN4-A1 NC (*) —
CN3-A2 NC (*) — CN4-A2 NC (*) —
CN3-A3 NC (*) — CN4-A3 RS232C GND C
CN3-A4 NC (*) — CN4-A4 CAN1+ E
CN3-A5 Model selection B CN4-A5 NC (*) —
CN3-A6 NC (*) — CN4-A6 NC (*) —
CN3-A7 NC (*) — CN4-A7 NC (*) —
CN3-A8 NC (*) — CN4-A8 NC (*) —
CN3-A9 NC (*) — CN4-A9 GND C
CN3-A10 NC (*) — CN4-A10 RS232C RX0 (PC Tool) E
CN3-A11 NC (*) — CN4-A11 RS232C TX0 (PC Tool) E
CN3-A12 NC (*) — CN4-A12 CAN1– E
CN3-A13 GND C CN4-A13 CAN Shield 1 C
CN3-A14 NC (*) — CN4-A14 NC (*) —
CN3-A15 NC (*) — CN4-B1 NC (*) —
CN3-A16 NC (*) — CN4-B2 NC (*) —
CN3-A17 GND C CN4-B3 GND C
CN3-A18 NC (*) — CN4-B4 RS232C TX1 (Orbcomm) E
CN3-B1 NC (*) — CN4-B5 NC (*) —
CN3-B2 NC (*) — CN4-B6 NC (*) —
CN3-B3 NC (*) — CN4-B7 NC (*) —
CN3-B4 NC (*) — CN4-B8 NC (*) —
CN3-B5 NC (*) — CN4-B9 GND C
CN3-B6 NC (*) — CN4-B10 RS232C RX1 (Orbcomm) E
CN3-B7 NC (*) — *:Never connect to NC as malfunctions or failures will
CN3-B8 NC (*) — occur.
CN3-B9 GND C CN-5 [CN5]

CN3-B10 NC (*) —
Pin No. Signal name Input/Output
CN3-B11 NC (*) —
CN5-1 NC (*) —
CN3-B12 NC (*) —
CN5-2 NC (*) —
CN5-3 NC (*) —
occur.
CN5-4 NC (*) —
CN5-5 NC (*) —
CN5-6 NC (*) —
CN5-7 NC (*) —
CN5-8 NC (*) —
CN5-9 NC (*) —
CN5-10 NC (*) —
CN5-11 NC (*) —
CN5-12 NC (*) —
occur.
PC1250-8R 65
ORBCOMM controller (If equipped)
66 PC1250-8R

A: Power supply
B: Input
D: Output
E: Communication

CN-1 [CN1]
CN1-1 NC (*) — CN1-38 GND_PWR C
CN1-2 NC (*) — CN1-39 PWR_IN_BATT A
CN1-3 NC (*) — CN1-40 PWR_IN_BATT A
CN1-4 COMM_232C_RXD E CN2: Communications satellite connector BNC

CN1-5 COMM_232C_TXD E occur.
CN1-6 NC (*) —
CN1-7 NC (*) —
CN1-8 NC (*) —
CN1-9 NC (*) —
CN1-10 NC (*) —
CN1-11 GND_R232C C
CN1-12 NC (*) —
CN1-13 NC (*) —
CN1-14 NC (*) —
CN1-15 NC (*) —
CN1-16 NC (*) —
CN1-17 NC (*) —
CN1-18 NC (*) —
CN1-19 PWP_CTR_EXT D
CN1-20 NC (*) —
CN1-21 NC (*) —
CN1-22 NC (*) —
CN1-23 NC (*) —
CN1-24 NC (*) —
CN1-25 NC (*) —
CN1-26 NC (*) —
CN1-27 NC (*) —
CN1-28 NC (*) —
CN1-29 DOUT (GND) C
CN1-30 NC (*) —
CN1-31 NC (*) —
CN1-32 NC (*) —
CN1-33 NC (*) —
CN1-34 NC (*) —
CN1-35 NC (*) —
CN1-37 GND_PWR C
PC1250-8R 67
Sensor 1
Rotation sensor
1. Connector
2. Sensor
3. O-ring
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.
68 PC1250-8R
Oil pressure sensor
1. Connector
2. Sensor
3. O-ring
Ambient pressure sensor
1. Connector
2. Pressure import port
PC1250-8R 69
Boost pressure sensor
1. O-ring 3. Connector
2. Sensor
Boost temperature sensor
1. Connector 3. O-ring
2. Sensor
Coolant temperature sensor, fuel oil temperature sensor, hydraulic oil temperature sensor
1. Connector 3. O-ring
2. Sensor
70 PC1250-8R
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
PC1250-8R 71
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
Air cleaner clogging sensor
72 PC1250-8R
PC1250-8R 73
SEN02063-02

© 2007 KOMATSU
All Rights Reserved
74
SEN02071-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
20 Standard value table 1

Standard service value table
Standard value table for engine related parts ................................................................................................. 2
Standard value table for chassis related parts ................................................................................................ 3
PC1250-8R 1
SEN02071-02 20 Standard value table
Standard value table for engine related parts 1

Engine unit
Engine SAA6D170E-5
Standard value for
Item Measurement condition Unit Service limit value
new machine
High idle 2,000 ± 50 2,000 ± 50
Engine speed Low idle rpm 900 ± 50 900 ± 50
Rated speed 1,800 1,800
Air supply kPa Min. 133 120
At rated output
(boost pressure) {mmHg} {Min. 1,000} {900}
Whole speed range
Exhaust temperature °C Max. 650 700
(ambient temperature: 20°C)
At sudden acceleration Bosch Max. 3.5 4.5
Exhaust gas color
At high idle index Max. 1.0 2.0
Valve clearance Intake valve Max. 0.32 Max. 0.32
mm
(normal temperature) Exhaust valve Max. 0.62 Max. 0.62
Oil temperature:40 – 60°C MPa Min. 2.9 2.1
Compression pressure {kg/cm2} {Min. 30} {21}
(engine speed) (rpm) (200 – 250) (200 – 250)
Coolant temperature: Within operating range kPa Max. 3.43 12.94
Blow-by pressure
At rated output {mmH2O} {Max. 350} {1,320}
Coolant temperature: Within operating range
Min. 0.34 0.21
At high idle MPa
Oil pressure {Min. 3.5} {2.1}
{kg/cm2}
Min. 0.10 0.08
At low idle
{Min. 1.0} {0.8}
Oil temperature Whole speed range (inside oil pan) °C 90 – 110 120
Fuel temperature Ambient temperature: 50°C °C Max. 71 Max. 71
Deflection when pressed with finger force
Alternator belt tension mm Auto tension Auto tension
of approx. 58.8 N {6 kg}
Air conditioner Deflection when pressed with finger force
mm Auto tension Auto tension
compressor belt tension of approx. 98 N {10 kg}
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 PC1250-8R
Standard value table for chassis related parts 1

Applicable model PC1250-8R, PC1250SP-8R
Cate- Standard value for
Item Measurement conditions Unit Service limit value
gory new machine
All pumps at relief • Engine at full throttle Min. 1,700 Min. 1,700
• Hydraulic oil temperature: 45 – 55°C
• Engine oil pressure:
All pumps at relief Within operating range
Engine speed
+ • Engine coolant temperature: Min. 1,700 Min. 1,700

heavy lift ON Within operating range rpm
• In P-mode
• Boom RAISE relief
Engine speed when
Engine at full throttle
auto-deceleration is 1,300 ± 50 —
All control levers at neutral
actuated
• Engine stopped a b a b
Left 5-spool control valve
Boom lower Hi
12 ± 0.5 12 ± 0.5 12 ± 0.5 12 ± 0.5
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
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
PC1250-8R 3

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
Boom control lever

• Oil temperature: 45 – 55°C {1.6 ± 0.5} {1.6 ± 0.5}
• Fit push-pull scale to center of control 15.7 ± 4.9 15.7 ± 4.9
Arm control lever lever knob {1.6 ± 0.5} {1.6 ± 0.5}
• Measure max. value to end of travel
12.7 ± 3.9 12.7 ± 3.9
Bucket control lever N {kg} {1.3 ± 0.4} {1.3 ± 0.4}
12.7 ± 3.9 12.7 ± 3.9
Swing control lever
{1.3 ± 0.4} {1.3 ± 0.4}
21.5 ± 5.9 21.5 ± 5.9
Travel control lever
{2.2 ± 0.6} {2.2 ± 0.6}
• Engine at full throttle Heavy lift 31.4
+1.0
31.4
+1.0
–1.5 –2.5
• Oil temperature: OFF +10 +10
{320 } {320 }
RAISE
45 – 55°C –15 –25
• In P-mode +1.0 +1.0

33.3 –1.5 33.3 –2.5
• Relieve only circuit Heavy lift ON +10 +10
Boom being measured {340 –15 } {340 –25 }
Machine 18.6 ± 1.9 18.6 ± 1.9
push-up OFF {190 ± 20} {190 ± 20}
LOWER
+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
30.4 –1.5 30.4 –2.5
Swing +10 +10
{310 –15 } {310 –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
TVC valve output • In P-mode OFF {11.5 ± 2} {11 ± 2}

pressure
relief
Heavy lift 1.03 ± 0.2 0.98 ± 0.2

ON {10.5 ± 2} {10 ± 2}
4 PC1250-8R
Applicable Model PC1250-8R, PC1250SP-8R

Item Measuring Conditions Unit
• 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. 1.5 {15} Min. 1.5 {15}
control valve throttle neutral
Jet sensor Right 4-spool • Oil temperature: Travel under no
Hydraulic pressure
45 – 55°C Max. 0.2 {2} Max. 0.2 {2}

differential control valve load
output pres- • In P-mode
All control levers at MPa
sure Swing Min. 1.5 {15} Min. 1.5 {15}
neutral {kg/cm2}
4-spool
control valve Swing under no
Max. 0.2 {2} Max. 0.2 {2}
load
2.9 –0.2 2.9 –0.2
PPC valve output pressure • Hydraulic oil temperature: 45 – 55°C +5.5 +5.5
• Control lever full stroke {30 –1.5 } {30 –1.5 }
• Engine at full throttle
Solenoid valve output • Hydraulic oil temperature: 45 – 55°C 2.9 ± 0.6 2.9 ± 0.6
pressure • Operate only solenoid being mea- {30 ± 5.5} {30 ± 5.5}
sured
• Difference between relief pressure
Drop in hydraulic pressure Max. 2.0 {20} Max. 2.9 {30}
with engine at full throttle and relief
pressure with engine at low idle
Work equipment posture
Swing
Overrun when stopping deg. Max. 85 Max. 105

swing (mm) (Max. 1,805) (Max. 2,230)
• In P-mode
• Bucket: No load
• Stop after swinging one turn and
measure distance that swing circle
moves
• Value in ( ) shows distance at out-
side circumference of swing circle
PC1250-8R 5

90° 4.7 ± 0.5 Max. 5.7
Time taken to start

swing • Engine at full throttle
• Hydraulic oil temperature:
45 – 55°C
• In P-mode 180° 7.2 ± 0.7 Max. 8.8
• Bucket: No load
• Time taken to swing 90° and 180°
from starting position sec
Time taken to swing 52 ± 5.2 Max. 59

Swing
• In P-mode
• Bucket: No load
• Swing one turn, then measure time taken to
swing next 5 turns
Hydraulic drift of deg. 0 0

• Engine stopped
swing (mm) (0) (0)
• Bucket: No load
• Set machine on 15° slope, and set upper
structure at 90° to the side.
• Make match marks on swing circle outer
race and track frame.
• Measure distance that match marks move
apart after 5 minutes.
Leakage from swing • Hydraulic oil temperature: 45 – 55°C
l/min Max. 14 Max. 28
motor • Swing lock switch: ON
• Relieve swing circuit.
6 PC1250-8R

Low speed
105 ± 11 105 ± 11
Travel speed (1) sec
High speed
• In P-mode 73 ± 8 73 ± 8
• Raise track on one side at a time,
rotate one turn, then measure time
taken for next 5 turns with no load.
Low speed
27 – 37 27 – 37

High speed

• In P-mode 20 – 25 20 – 25
Travel
• Run up for at least 10 m, and mea-

sure time taken to travel next 20 m
on flat ground.

• In P-mode
Travel deviation • Use a hard horizontal surface. mm Max. 200 Max. 220
• Run up for at least 10 m, and measure
deviation (χ) when traveling next 20 m on
flat ground.
20m
10m BKP00107
PC1250-8R 7

Hydraulic drift of
mm 0 0
travel • Engine stopped
• Stop machine on 12° slope with sprocket at
uphill end of machine.
• Do not place the work equipment on the
ground.
Travel
• Measure the distance the machine moves

in 5 minutes.
Leakage of travel
motor

• Lock shoes and relieve travel circuit.
8 PC1250-8R

gory new machine
Total work Work equipment posture
equipment
Max. 1,200 Max. 1,800
(hydraulic
(Max. 650) (Max. 1,000)
drift at tip of
bucket teeth)
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 specification: 75.9 kN {7,740 kg}
Work equipment
• SP specification: 100.6 kN {10,260 kg}

• Start measuring immediately after setting.
• Measure hydraulic drift every 5 minutes,
and judge from results for 15 minutes.
Bucket cylin- • Figures in ( ) are value when bucket is not
der loaded.
Max. 95 Max. 145
(amount of
(Max. 45) (Max. 70)
retraction of
cylinder)
Work equipment posture STD SP STD SP

specifi- specifi- specifi- specifi-
Boom cation cation cation cation
RAISE
Work equipment speed
Bucket teeth
in contact
6.0 ± 0.6 6.4 ± 0.7 Max. 7.4 Max. 7.8
with
ground sec
Cylinder • Engine at full throttle

LOWER
fully • Hydraulic oil temperature: 45 – 55°C

• In P-mode 4.0 ± 0.4 4.4 ± 0.4 Max. 4.8 Max. 5.2
extended
• Bucket: No load
PC1250-8R 9

Cate- Standard value
gory for new machine
Work equipment posture STD SP STD SP
specifi- specifi- specifi- specifi-
Arm cation cation cation cation
IN
Cylinder fully
retracted
5.0 ± 0.5 5.0 ± 0.5 Max. 6.0 Max. 6.0
Fully sec
extended
OUT
• Engine at full throttle 4.0 ± 0.4 4.0 ± 0.4 Max. 4.8 Max. 4.8
• In P-mode
• Bucket: No load
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
• In P-mode
• Bucket: No load
Time lag
Boom sec Max. 5 Max. 7

• Engine at low idle
• Retract arm and bucket cylinder fully, then
lower boom from max. RAISE point and
measure time taken from point where
bucket contacts ground to point where
chassis rises from ground.
10 PC1250-8R

gory new machine
Arm Max. 2 Max. 4

• Set top surface of boom horizontal, retract
bucket cylinder fully, then extend arm cylin-
der and measure time taken for arm to start
Time lag
moving again after stopping at bottom.

sec
Work equipment
Bucket Max. 2 Max. 4

arm cylinder fully, then extend bucket cylin-
der and measure time taken for bucket to
start moving again after stopping at bottom.
Internal oil leakage
Cylinders • Hydraulic oil temperature: 45 – 55°C Max. 7 Max. 28

• Relieve only circuit being measured.
cc/min
Center
Max. 10 Max. 100
swivel joint

45 – 55°C Standard
975 ± 50 975 ± 50
• Engine: High idle specification
(Operate the work equip- r/min
Fan speed
ment lever slightly not to {rpm}
move the work equipment) 55°C
1,075 ± 50/0 1,075 ± 50/0
Cooling fan
• Fan 100% speed mode specification

Fan
• Hydraulic oil temperature: 16.2 ± 4.4 16.2 ± 4.4

{165 ± 45} {165 ± 45}
Cooling fan (Reference value) (Reference value)
(Operate the work equip- MPa
circuit oil
ment lever slightly not to {kg/cm2} 19.6 ± 4.4 19.6 ± 4.4
pressure
{200 ± 45} {200 ± 45}
(Reference value) (Reference value)
PC1250-8R 11

gory new machine
45 – 55°C Standard 1.62 ± 0.49 1.62 ± 0.49
• Engine speed: High idle specification {16.5 ± 5.0} {16.5 ± 5.0}
• Operate work equipment MPa
control lever to degree that {kg/cm2}
work equipment does not 55°C 1.47 ± 0.49 1.47 ± 0.49
Cooling fan
Fan pump move. specification {15.0 ± 5.0} {15.0 ± 5.0}

EPC sole- • Fan 100% speed mode
noid valve
pressure Standard 1.42 ± 0.49 1.42 ± 0.49
45 – 55°C
down MPa
• Set all control levers in neu- {kg/cm2}
tral. 55°C 1.27 ± 0.49 1.27 ± 0.49
• Fan 100% speed mode specification {13.0 ± 5.0} {13.0 ± 5.0}
Fan

• Engine: High idle 1,288 ± 150 1,288 ± 150
• Operate the work equipment lever slightly (Reference value) (Reference value)
not to move the work equipment
Fan speed rpm
• Engine: High idle down 1,127 ± 150 1,127 ± 150
Aftercooler fan
• All levers in neutral (Reference value) (Reference value)

11.3 ± 2.9 11.3 ± 2.9
• Engine: High idle
{115 ± 30} {115 ± 30}
• Operate the work equipment lever slightly
Fan hydrau- not to move the work equipment MPa (Reference value) (Reference value)
lic circuit {kg/cm2}
• Hydraulic oil temperature: 45 – 55°C 8.5 ± 2.5 8.5 ± 2.5
• Engine: High idle down {87 ± 25} {87 ± 25}
12 PC1250-8R

Applicable model PC1250-8R (Loading shovel spec.)
gory new machine
All pumps at relief Min. 1,700 Min. 1,700
• Engine oil pressure:
Within operating range
Engine speed
• Engine coolant temperature:

All pumps at relief
Within operating range
+ rpm Min. 1,700 Min. 1,700
• In P-mode
heavy lift ON
• Boom RAISE relief
Engine speed when

auto-deceleration is 1,300 ± 50 —
• All control levers at neutral
actuated
• Engine stopped a b a b
Bottom dump
Left 5-spool control valve
12 ± 0.5 12 ± 0.5 12 ± 0.5 12 ± 0.5

Boom lower Hi
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
PC1250-8R 13

• Engine stopped 16.7 ± 4.9 16.7 ± 4.9
Operating effort of control levers
Boom control lever

• Oil temperature: 45 – 55°C {1.7 ± 0.5} {1.7 ± 0.5}
• Fit push-pull scale to center of control 16.7 ± 4.9 16.7 ± 4.9
Arm control lever lever knob {1.7 ± 0.5} {1.7 ± 0.5}
• Measure max. value to end of travel
13.7 ± 3.9 13.7 ± 3.9
Bucket control lever N {kg} {1.4 ± 0.4} {1.4 ± 0.4}
13.7 ± 3.9 13.7 ± 3.9
Swing control lever
{1.4 ± 0.4} {1.4 ± 0.4}
24.5 ± 5.9 24.5 ± 5.9
Travel control lever
{2.5 ± 0.6} {2.5 ± 0.6}
• Engine at full throttle Heavy lift 31.4
+1.0
31.4
+1.0
–1.5 –2.5
• Oil temperature: OFF +10 +10
{320 } {320 }
RAISE
45 – 55°C –15 –25
• In P-mode +1.0 +1.0

33.3 –1.5 33.3 –2.5
• Relieve only circuit Heavy lift ON +10 +10
being measured {340 –15 } {340 –25 }
Boom
Machine
18.6 ± 1.9 18.6 ± 1.9
push-up
{190 ± 20} {190 ± 20}
LOWER
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
30.4 –1.5 30.4 –2.5
Swing +10 +10
{310 –15 } {310 –25 }
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
TVC valve output • In P-mode OFF {11.5 ± 2} {11 ± 2}

pressure
relief
Heavy lift 1.03 ± 0.2 0.98 ± 0.2

ON {10.5 ± 2} {10 ± 2}
14 PC1250-8R
Applicable Model PC1250-8R (Loading shovel spec.)

• Engine at full All control levers
Max. 0.25 {2.6} Max. 0.4 {4.1}
No.1 pump throttle at 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
Max. 0.25 {2.6} Max. 0.4 {4.1}
at 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
Min. 1.5 {15} Min. 1.5 {15}
control valve throttle at neutral
Right 4-spool • Oil temperature: Travel under no
Hydraulic pressure
Jet sensor Max. 0.2 {2} Max. 0.2 {2}

control valve 45 – 55°C load
differential
• In P-mode
output pres- All control levers MPa
sure Swing Min. 1.5 {15} Min. 1.5 {15}
at neutral {kg/cm2}
4-spool
control valve Swing under no
Max. 0.2 {2} Max. 0.2 {2}
load
2.9 –0.2 2.9 –0.2
PPC valve output pressure • Hydraulic oil temperature: 45 – 55°C +5.5 +5.5
• Control lever full stroke {30 –1.5 } {30 –1.5 }
Solenoid valve output • Hydraulic oil temperature: 45 – 55°C 2.9 ± 0.6 2.9 ± 0.6
pressure • Operate only solenoid being mea- {30 ± 5.5} {30 ± 5.5}
sured
• Difference between relief pressure
Drop in hydraulic pressure Max. 2.0 {20} Max. 2.9 {30}
with engine at full throttle and relief
pressure with engine at low idle
Swing
Overrun when stopping deg. Max. 85 Max. 105

swing (mm) (Max. 1,805) (Max. 2,230)
• In P-mode
• Bucket: No load
• Stop after swinging one turn and
measure distance that swing circle
moves
• Value in ( ) shows distance at out-
side circumference of swing circle
PC1250-8R 15

90° 4.7 ± 0.5 Max. 5.7
Time taken to start

swing • Engine at full throttle
45 – 55°C
• In P-mode
• Bucket: No load 180° 7.2 ± 0.7 Max. 8.8
• Time taken to swing 90° and 180°
from starting position
sec
Time taken to swing 52 ± 5.2 Max. 59

Swing

• In P-mode
• Bucket: No load
• Swing one turn, then measure time taken
to swing next 5 turns
Hydraulic drift of deg. 0 0

• Engine stopped
swing (mm) (0) (0)
• Bucket: No load
• Set machine on 15° slope, and set upper
structure at 90° to the side.
• Make match marks on swing circle outer
race and track frame.
• Measure distance that match marks move
apart after 5 minutes.
Leakage from • Hydraulic oil temperature: 45 – 55°C
swing motor • Swing lock switch: ON
• Relieve swing circuit.
16 PC1250-8R

Low speed
105 ± 11 105 ± 11

High speed
• In P-mode 73 ± 8 73 ± 8
• Raise track on one side at a time,
rotate one turn, then measure time
taken for next 5 turns with no load.
Low speed
27 – 37 27 – 37

High speed

• In P-mode
Travel
20 – 25 20 – 25
• Run up for at least 10 m, and mea-
sure time taken to travel next 20 m
on flat ground.

• In P-mode
Travel deviation • Use a hard horizontal surface. mm Max. 200 Max. 220
• Run up for at least 10 m, and measure
deviation (χ) when traveling next 20 m on
flat ground.
20m
10m BKP00107
PC1250-8R 17

Hydraulic drift of
mm 0 0
travel • Engine stopped
• Stop machine on 12° slope with sprocket at
uphill end of machine.
• Do not place the work equipment on the
ground.
Travel
• Measure the distance the machine moves

in 5 minutes.
Leakage of travel
motor

• Lock shoes and relieve travel circuit.
18 PC1250-8R

gory new machine
Total work Work equipment posture
equipment
Max. 1,400 Max. 2,100
(hydraulic
(Max. 760) (Max. 1,200)
drift at tip of
bucket teeth)
Boom cylinder • Place in above posture and measure exten-

(amount of sion or retraction of each cylinder and Max. 115 Max. 175
Hydraulic drift of work equipment
retraction of downward movement at tip of bucket teeth.

cylinder) • Engine stopped
• Horizontal, flat ground
• All control levers at neutral
• Bucket: Rated load or full load of soil mm
Arm cylinder Loading shovel specification:
(amount of 114.7 kN {11,700 kg}
Max. 80 Max. 120
extension of • Start measuring immediately after setting.
cylinder) • Measure hydraulic drift every 5 minutes,
Work equipment
and judge from results for 15 minutes.

• Figures in ( ) are value when bucket is not
loaded.
Bucket
cylinder
(amount of Max. 65 Max. 100
retraction of
cylinder)
Boom
RAISE
6.9 ± 0.7 Max. 8.3

Bucket teeth
in contact
with ground
sec
Cylinder fully
extended
LOWER
• Engine at full throttle 4.8 ± 0.5 Max. 5.8

• In P-mode
• Bucket: No load
PC1250-8R 19

Arm 4.0 ± 0.5 Max. 5.0
IN
Cylinder fully
retracted
Fully sec
extended
OUT
• In P-mode
• Bucket: No load
CURL
Bucket 3.9 ± 0.4 Max. 4.7
Cylinder fully
Work equipment
retracted
Fully sec
extended
DUMP

• In P-mode
• Bucket: No load

OPEN
Bottom dump 2.3 ± 0.3 Max. 2.9

Cylinder fully
retracted
Fully sec
extended
CLOSE

• In P-mode
• Bucket: No load
20 PC1250-8R

Boom Max. 5 Max. 7
• Engine at low idling

• Retract arm and bucket cylinder fully, then
lower boom from max. RAISE point and
measure time taken from point where
bucket contacts ground to point where
chassis rises from ground.
Work equipment
Time lag
sec
Arm Max. 2 Max. 4

bucket cylinder fully, then retract arm cylin-
der and measure time taken for arm to start
moving again after stopping at bottom.
Bucket Max. 2 Max. 4

arm cylinder fully, then retract bucket cylin-
der and measure time taken for bucket to
start moving again after stopping at bottom.
PC1250-8R 21

Time lag
Bottom
Max. 3 Max. 5
dump
Work equipment

• Extend boom and arm cylinders fully,
retract bucket cylinder fully, then close
bottom in full open state and measure
time taken for bottom to start moving
again after stopping once.
Internal oil leakage
Cylinders • Hydraulic oil temperature: 45 – 55°C Max. 7 Max. 28

• Relieve only circuit being measured.
cc/min
Center
Max. 10 Max. 100
swivel joint

975 ± 50 975 ± 50
(Operate the work equip- r/min
Fan speed
ment lever slightly not to {rpm}
1,075 ± 50/0 1,075 ± 50/0
• Hydraulic oil temperature: 16.2 ± 4.4 16.2 ± 4.4

{165 ± 45} {165 ± 45}
specification
Cooling fan • Engine: High idle (Reference value) (Reference value)
(Operate the work equip- MPa
circuit oil
ment lever slightly not to {kg/cm2} 19.6 ± 4.4 19.6 ± 4.4
pressure
{200 ± 45} {200 ± 45}
specification
Cooling fan
• Fan 100% speed mode (Reference value) (Reference value)

Fan

45 – 55°C Standard 1.62 ± 0.49 1.62 ± 0.49
• Operate work equipment MPa
control lever to degree that {kg/cm2}
work equipment does not 55°C 1.47 ± 0.49 1.47 ± 0.49
Fan pump move. specification {15.0 ± 5.0} {15.0 ± 5.0}
EPC sole- • Fan 100% speed mode
noid valve
pressure Standard 1.42 ± 0.49 1.42 ± 0.49
45 – 55°C
down MPa
• Set all control levers in {kg/cm2}
neutral. 55°C 1.27 ± 0.49 1.27 ± 0.49
• Fan 100% speed mode specification {13.0 ± 5.0} {13.0 ± 5.0}
22 PC1250-8R

• Engine: High idle 1,288 ± 150 1,288 ± 150
• Operate the work equipment lever (Reference value) (Reference value)
slightly not to move the work equipment
Fan speed rpm
• Engine: High idle down 1,127 ± 150 1,127 ± 150
Aftercooler fan

Fan

11.3 ± 2.9 11.3 ± 2.9
• Engine: High idle
{115 ± 30} {115 ± 30}
• Operate the work equipment lever
Fan (Reference value) (Reference value)
slightly not to move the work equipment MPa
hydraulic
• Hydraulic oil temperature: 45 – 55°C {kg/cm2}
circuit 8.5 ± 2.5 8.5 ± 2.5
• Engine: High idle down {87 ± 25} {87 ± 25}
PC1250-8R 23
SEN02071-02

© 2007 KOMATSU
All Rights Reserved
24
SEN02072-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
30 Testing and adjusting 1

Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Measuring engine speed................................................................................................................................. 8
Measuring air supply pressure (Boost pressure) ............................................................................................ 9
Measuring exhaust temperature ................................................................................................................... 10
Measuring exhaust color................................................................................................................................11
Adjustment of valve clearance ...................................................................................................................... 13
Measurement of compression pressure........................................................................................................ 15
Measuring blow-by pressure......................................................................................................................... 18
Measurement of engine oil pressure............................................................................................................. 19
Adjusting engine speed sensor..................................................................................................................... 20
Handling fuel system parts............................................................................................................................ 21
Releasing residual pressure in fuel system .................................................................................................. 21
Testing fuel pressure..................................................................................................................................... 22
Measurement of fuel return rate and fuel leakage ........................................................................................ 23
Bleeding air from fuel circuit.......................................................................................................................... 26
Testing fuel system for leakage..................................................................................................................... 28
PC1250-8R 1
SEN02072-02 30 Testing and adjusting
Procedure for checking alternator and replacing belt.................................................................................... 29
2 PC1250-8R
Tools for testing, adjusting, and troubleshooting 1
Quantity
symbol
Testing and adjusting item Part No. Part name Remarks
Measuring intake air

A 799-201-2202 Boost gauge kit 1 –101 to 200 kPa {–760 to 1,500 mmHg}
pressure (boost pressure)
Measuring exhaust 1 799-101-1502 Digital thermometer 1 –99.9 to 1,299 ºC
B
temperature 2 799-201-1150 Adapter connector 1 *For machine equipped with sensor
Measuring exhaust gas 1 799-201-9001 Handy smoke checker 1 Bosch index: 0 to 9 (With standard color)
C
color 2 Purchased Smoke meter 1
Adjusting valve clearance D Purchased Feeler gauge 1 (Intake: 0.32 mm, Exhaust: 0.62 mm)
1 795-502-1590 Compression gauge 1 0 to 7 MPa {0 to 70 kg/cm2}
795-611-1220 Adapter 1 For 170E-5 engine
Measuring compression 2
E 6261-71-6150 Gasket 1 For 170E-5 engine
pressure
795-799-5410 Adapter 1
3
795-799-5420 Remover 1
Measuring blow-by
F 799-201-1504 Blow-by checker 1
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
G
pressure 2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5230 Nipple 1 14 mm, P=1.5 mm
3
6215-81-9720 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing fuel pressure H
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
952-471-1450 Adapter 1
3
07005-00812 Gasket 1
1 6167-11-6640 Spacer 1 Inside diameter: 10 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 16 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, 6, 40, 60 MPa
equipment, swing, and {25, 60, 400, 600 kg/cm2}
K
travel circuit oil
pressures 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}

Testing and adjusting 799-101-5002 Hydraulic tester 1
L {25, 60, 400, 600 kg/cm2}
control circuit oil pressure
PC1250-8R 3
Quantity
symbol

1 {25, 60, 400, 600 kg/cm2}
Differential pressure
2 799-401-2701 1
gauge
Testing and adjusting
control oil pressure of M 3 799-101-5220 Nipple 2 Size: 10 × 1.25 mm
piston pump 07002-11023 O-ring 2
799-101-5230 Nipple 1 14 mm, P=1.5 mm
4
07000-11423 O-ring 1
799-401-3200 Adapter 2 Size: 03
5
02896-11009 O-ring 2
708-25-14140 Cap 1 For No. 1 and No. 2 pump
1
07000-B2065 O-ring 1 For No. 1 and No. 2 pump
Testing servo piston stroke O 708-27-14150 Cap 1 For No. 3 pump
2
07000-B2075 O-ring 1 For No. 3 pump
3 566-98-41120 Disc gauge 1
1 {25, 60, 400, 600 kg/cm2}
Measuring PPC valve 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
P
output pressure
799-401-3200 Adapter 1 Size: 03
2
02896-11009 O-ring 2
1 {25, 60, 400, 600 kg/cm2}
Measuring outlet pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Q
of solenoid valve
799-401-3200 Adapter 1 Size: 03
2
02896-11009 O-ring 1
Measuring fan speed R 799-205-1100 Multiple tachometer 1 L: 60 – 2000 rpm, H: 60 – 19999 rpm
1 {25, 60, 400, 600 kg/cm2}
Measuring fan circuit oil 799-401-3300 Adapter 1 Size: 04
S
pressure 2
02896-11012 O-ring 1
799-101-5220 Nipple 1 10 mm, P=1.25 mm
3
07002-11023 O-ring 1
1 Purchased Measuring cylinder 1
07378-11000 Sleeve head 1 Size: 10
2
Measuring oil leakage T 07000-13032 O-ring 1
07378-11200 Sleeve head 1 Size: 12
3
07000-13038 O-ring 1
1 {25, 60, 400, 600 kg/cm2}
Measuring fan pump EPC 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
U
solenoid output pressure
799-101-5220 Nipple Size: 10 × 1.5 mm
2
07002-11023 O-ring
Measuring wear of
V 796-627-1110 Wear gauge 1
sprocket
4 PC1250-8R
Quantity
symbol
799-601-4101
or T-adapter assembly
799-601-4201
For DR60, ECONO (Max. 60P)
799-601-4350 • T-box 1 (Dose not include in assembly No. 799-
601-4201)
For engine (CRI-T3) coolant tempera-
ture sensor (PACKARD 2P)
For engine (CRI-T3) fuel temperature
795-799-5530 • Socket 1
sensor (PACKARD 2P)
For engine (CRI-T3) oil temperature
sensor (PACKARD 2P)
For engine (CRI-T3) boost temperature
795-799-5540 • Socket 1
sensor (PACKARD 2P)
For engine (CRI-T3) ambient pressure
799-601-4240 • Socket 1
sensor (AMP 3P)
For engine (CRI-T3) boost pressure
799-601-4250 • Socket 1
sensor (SUMITOMO 3P)
For engine (CRI-T3) G (Bkup) sensor
799-601-4330 • Socket 1
(SUMITOMO 3P)
Engine related controller, For engine (CRI-T3) supply pump
sensor and actuator — 799-601-9430 • Socket 1 PCV1, supply pump PCV sensor
diagnosis (SUMITOMO 3P)
For engine (CRI-T3) NE sensor
799-601-4130 • T-adapter 1
(FRAMATOME 3P)
For engine (CRI-T3) oil pressure sen-
799-601-4150 • T-adapter 1
sor (FRAMATOME 3P)
For engine (CRI-T3) common rail pres-
799-601-9420 • T-adapter 1
sure sensor (AMP 3P)
For engine controller (DRC26-50P)
799-601-4211 • T-adapter 1 (Does not include in assembly No. 799-
601-4201)
For engine controller (DRC26-60P)
799-601-4220 • T-adapter 1 (Does not include in assembly No. 799-
601-4201)
For engine controller (DTP-4P) (Include
799-601-4260 • T-adapter 1 in assembly No. 799-601-9000 and
799-601-9100, too)
For DT 4P (Include in assembly No.
799-601-9040 • T-adapter 1
799-601-9000 and 799-601-9200, too)
799-601-9020 • T-adapter 1
799-601-9000 and 799-601-9200, too)
799-601-9000
or
799-601-9100 • T-adapter assembly
Machine related controller or
and sensors/wiring — 799-601-9300
harnesses diagnosis 799-601-9320 • T-box 1 For ECONO*1 (Max. 24P)
799-601-4101 T-adapter assembly
799-601-4350 • T-box 1 For DRC60, ECONO*2 (Max. 60P)
PC1250-8R 5
Quantity
symbol
799-601-7000
or
799-601-7100
799-601-7400
or
799-601-8000
For ECONO (Max. 21P) (Does not
799-601-2600 • T-box 1
include in assembly No. 799-601-7000)
799-601-7210 • T-adapter 1 For AMP040 16P
For M 1P (Does not include in assem-
799-601-7080 • T-adapter 1 bly No. 799-601-7000 and 799-601-
7100)
799-601-7090 • T-adapter 1 For M 2P
799-601-7110 • T-adapter 1 For M 3P
799-601-7120 • T-adapter 1 For M 4P
799-601-7130 • T-adapter 1 For M 6P
799-601-7340 • T-adapter 1 For M 8P (No assembly No.)
799-601-7140 • T-adapter 1 For S 8P
799-601-7350 • T-adapter 1 For S 12P (White) (No assembly No.)
799-601-7170 • T-adapter 1 For S 16P (Blue)
799-601-7330 • T-adapter 1 For S 16P (White) (No assembly No.)
For SWP 8P (Does not include in
Machine related controller 799-601-7060 • T-adapter 1
assembly No. 799-601-8000)
and sensors/wiring —
harnesses diagnosis 799-601-7320 • T-adapter 1 For SWP 16P (No assembly No.)
799-601-7020 • T-adapter 1 For X 2P
799-601-7030 • T-adapter 1 For X 3P
799-601-7040 • T-adapter 1 For X 4P
799-601-9000
799-601-9200
799-601-9040 • T-adapter 1
799-601-4101 and 799-601-4201, too)
799-601-9020 • T-adapter 1 For DT 2P
799-601-9030 • T-adapter 1 For DT 3P
799-601-9050 • T-adapter 1 For DT 6P
799-601-9060 • T-adapter 1 For DT 8P
799-601-9070 • T-adapter 1 For DT 8P
799-601-9110 • T-adapter 1 For DT 12P (Gray)
799-601-9120 • T-adapter 1 For DT 12P (Black)
799-601-9130 • T-adapter 1 For DT 12P (Green)
6 PC1250-8R
Quantity
symbol
799-601-9140 • T-adapter 1 For DT 12P (Brown)

For HD36 24-21P
(Does not include in assembly No. 799-
Machine related controller 799-601-9270 • T-adapter 1 601-9200)
(Include in assembly No. 799-601-
and sensors/wiring —
harnesses diagnosis 9100, too)
799-601-9360 • T-adapter 1 For pump controller (DRC26-24P)
799-601-9350 • T-adapter 1 For pump controller (DRC26-40P)
Measuring coolant tem-
perature and oil tempera- — 799-101-1502 Digital thermometer 1 –99.9 to 1,299ºC
ture
Measuring operating effort 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
—
and pressing force 79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
Measuring stroke and
— Purchased Scale 1
hydraulic drift
Measuring work equipment
— Purchased Stopwatch 1
speed
Measuring voltage and
— Purchased Multimeter 1
resistance
PC1250-8R 7
Measuring engine speed 1 4. Measuring all-pump relief speed

1) Start the engine and set the fuel control
dial in the high idle position (MAX).
a Measure the engine speed under the following 2) Set the working mode switch in the P-mode
condition. position.
q Engine coolant temperature: Within oper- 3) Turn the heavy lift switch OFF.
ating range 4) Relieve the boom circuit by raising the
q Hydraulic oil temperature: 45 – 55°C boom and measure the engine speed.
1. Preparation work 5. Measuring heavy-lift ON + all-pump relief

Turn the starting switch ON and set the speed
machine monitor to “Monitoring”. 1) Start the engine and set the fuel control
a For the operating method, see “Special dial in the high idle position (MAX).
functions of machine monitor”. 2) Set the working mode switch in the P-
a Monitoring code: 01002 Engine speed mode position.
01006 Engine speed 3) Turn the heavy lift switch ON.
a Code 01002 is information of the engine 4) Relieve the boom circuit by raising the
controller and code 01006 is information of boom and measure the engine speed.
the pump controller. The engine speed can
be measured with either of those codes. 6. Measuring auto-deceleration ON speed
a The engine speed is displayed in rpm. 1) Start the engine and set the fuel control
2) Turn the auto-deceleration switch ON.
3) Set the work equipment control, swing
control, and travel control levers in neutral.
When the auto-decelerator operates,
measure the engine speed.
a The engine speed lowers to a certain
level about 6 seconds after all the
levers are set in neutral. This level is
the auto-deceleration speed.
2. Measuring low idle speed

dial in the low idle position (MIN).
2) Set the work equipment control, swing con-
trol, and travel levers in neutral and measure
the engine speed.
3. Measuring high idle speed

2) Set the working mode switch to the P-mode
position.
3) Turn the auto-decelerator switch OFF.
4) Measure the engine speed at the same
time.
8 PC1250-8R
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
k Be careful not to touch any hot parts when

removing or installing the measuring tools.
a Measure the air supply pressure (boost pres-
sure) under the following conditions.
q Coolant temperature: Within operating
range
q Hydraulic oil temperature: 45 – 55°C
1. Remove air supply pressure measurement plug

(1) and install nipple [1] of boost gauge kit A.
2. Connect gauge A with hose [2].

5. After completing the measurement, remove the
measuring equipment and set to the original
condition.
3. Run the engine at a mid-range speed or above

to bleed the oil from the hose.
a Insert the connection of the hose and
pressure gauge about half way, repeat the
action to open the self-seal portion at the
hose end, and bleed the oil.
a If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
used.
a If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
PC1250-8R 9
Measuring exhaust temperature 1 3. Procedure for measuring maximum value by

troubleshooting
Measure the maximum exhaust temperature
a Tools for measuring exhaust temperature during actual work.
Symbol Part No. Part name a Use the PEAK mode of the digital ther-
mometer.
B 799-101-1502 Digital temperature gauge
4. Procedure for measuring exhaust temperature

a Instruments for measuring exhaust tempera- periodically for preventive maintenance service
ture (Model with exhaust temperature sensor) (Pm clinic), etc.
If the machine is equipped with an exhaust 1) Run the engine and set the working mode
temperature sensor, prepare an adapter con- switch to the P-mode position.
nector to connect the exhaust temperature 2) Turn the heavy lift switch ON.
sensor and a digital temperature gauge. (The 3) Run the engine at high idle, relieve the
sensor installed to the digital thermometer is boom circuit by raising the boom, and
equivalent to the one installed to the engine.) measure the exhaust temperature.
a Measure the exhaust temperature after
Symbol Part No. Part name it is stabilized.
1 799-101-1502 Digital temperature gauge
B
2 799-201-1150 Adapter connector
k Wait for the manifold temperature to go

down before removing or installing the
measuring equipment.
a Measure the exhaust temperature under the
following conditions.
q Coolant temperature: Within operating
range
1. Connect adapter connector B2 to the connec-

tor of exhaust temperature measurement sen-
sor [1].
a Since the exhaust manifold of the No. 1 –
No. 3 cylinders and that of the No. 4 – No.
6 cylinders are independent from each
other, measure the exhaust temperature
at both plugs.
2. Fit digital temperature gauge B1.

a Clamp the wiring harness of the digital tem-
perature gauge to prevent it from touching
any hot part during measurement.
10 PC1250-8R
Measuring exhaust color 1 2. Measuring with Smoke Meter C2

1) Insert probe [1] of Smoke Meter C2 into
the outlet port of the exhaust pipe, and
a Tools for measuring exhaust color tighten the clip to secure it to the exhaust
Symbol Part No. Part name pipe.
1 799-201-9000 Handy Smoke Checker
C Commercially
2 Smoke Meter
available
k Be careful not to touch any hot parts when

removing or installing the measuring tools.
a When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker C1; when recording formal data, use
Smoke Meter C2.
a Measure the exhaust color under the following
conditions.
q Coolant temperature: Within operating range
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.
5) Remove the filter paper and compare it with

the scale supplied to judge the condition.
6) After completing the measurement, remove
the measuring equipment and set to the
original condition.
PC1250-8R 11
6) Start the engine.

7) Accelerate the engine suddenly or run at
high idle, and depress the accelerator
pedal of Smoke Meter C2 at the same
time to collect the exhaust gas color on
the filter.
8) Place the filter paper used to catch the
exhaust gas color on top of at least 10
sheets of unused filter paper inside the fil-
ter paper holder, and read the value
shown.
9) After completing the measurement, remove
the measuring equipment and set to the
original condition.
12 PC1250-8R
Adjustment of valve clearance 1 2. Rotate the crankshaft forward to set notch (b)
of the supply pump drive gear to the center of
inspection hole (a) on the left side of the fly-
a Adjustment tool for valve clearance wheel housing.
Symbol Part No. Part name a Rotate the crankshaft with the cranking
device at the left rear of the engine.
Commercially
D
available
Thickness gauge a The left side of the right upper figure
shows the compression top dead center of
the No. 1 cylinder and the right side shows
1. Remove covers (1) and (2), bracket (3) and 6 that of the No. 6 cylinder.
cylinder head covers (4). For details, see Dis- a When the No. 1 cylinder is at the compres-
assembly and assembly volume, “Removal sion top dead center, the rocker arm of the
and installation of cylinder head assembly”. No. 1 cylinder can be moved by the valve
clearance with the hand. If the rocker arm
cannot be moved, the No. 1 cylinder is not
at the compression top dead center. In this
case, rotate the crankshaft one more turn.
PC1250-8R 13
3. While the No. 1 cylinder is at the compression 6. After finishing adjustment, return the removed
top dead center, adjust the valve clearances parts.
marked with q in the valve arrangement draw- 3 Cylinder head cover mounting bolt:
ing. [No. 1, 3, 4, 5 and 6 cylinders]
a Loosen locknut (8) of adjustment screw 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
(7) and insert thickness gauge D between [No. 2 cylinder]
crosshead (6) and rocker arm (5) and set 58.8 – 73.5 Nm {6 – 7.5 kgm}
adjustment screw (7) to a degree that you
can move the thickness gauge lightly.
4. Rotate the crankshaft forward by 1 turn and

adjust the valve clearances marked with Q in
the valve arrangement drawing.
a Perform the same adjusting procedure
described above.
a Valve clearance
q Intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
5. While fixing adjustment screw (7), tighten lock-

nut (8).
3 Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}
a After tightening the locknut, check the
valve clearance again.
14 PC1250-8R
Measurement of compression 4. Remove holder (7) and then remove adapter

pressure 1 (9) and injector (8) together.
a Measuring instruments for compression pressure

Symbol Part No. Part name
1 795-502-1590 Compression gauge
795-611-1220 Adapter
2
E 6261-71-6150 Gasket
795-799-5410 Adapter
3
795-799-5420 Remover
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part. a Insert the pin (indicated with the arrow) at
a Measure the compression pressure after the the end of tool E3 in hole (a) of adapter (9)
engine is warmed up (Engine oil temperature: and move the weight of tool E3 up and
40 – 60°C). down to pull out the injector.
1. Remove covers (1) and (2), bracket (3) and
cylinder head cover (4) of the cylinder to mea-
sure the compression pressure. For details,
see Disassembly and assembly volume,
“Removal and installation of cylinder head
assembly”.
2. Adjust the valve clearance of the cylinder to be

checked. For details, see “Adjustment of valve
clearance”.
3. Disconnect fuel high-pressure tube (5) and

injector wiring harness (6).
a Remove the terminal of the injector wiring
harness on the injector side and the
mounting bolt on the rocker housing side
and remove the injector wiring harness
from the injector.
a Loosen the 2 terminal nuts alternately.
PC1250-8R 15
5. Install adapter E2 to the mounting hole of the

injector and connect compression gauge E1.
a Fit the gasket to the injector end without
fail.
a Fix the adapter with the injector holder
and adapter.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}
a Apply a little amount of engine oil to the
connecting parts of the adapter and gauge
so that air will not leak easily.
3) Install holder (7) and tighten bolt (13) and

washer (14) temporarily.
2 Spherical part of washer: Engine oil
4) Install the fuel high-pressure tube and
tighten sleeve nut (5) temporarily.
5) Tighten bolt (13) permanently.
3 Bolt: 58.8 – 73.5 Nm {6 – 7.5 kgm}
6) Tighten sleeve nut (5) permanently.
3 Sleeve nut:
39.2 – 44.1 Nm {4 – 4.5 kgm}
6. Referring to “Special functions of machine

monitor”, set the engine in the no-injection
cranking mode.
k If the engine is not set in the no-injec-
tion cranking mode, it will start and will
be dangerous. Accordingly, be sure to
set the engine in this mode.
7. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the pressure gauge pointer when it
is stabilized.
8. After finishing measurement, remove the mea-

suring instruments and return the removed parts. a Install the injector wiring harness accord-
a Install the injector and fuel high-pressure ing to the following procedure.
tube according to the following procedure. 1) Install injector wiring harness (6) from
1) Fit gasket (10) and O-rings (11) and (12). inside of the rocker arm housing and fix
a Take care not to fit O-ring (11) to the connector end with plate (15).
groove (b).
2) While setting adapter (9) to injector (8),
push them into the cylinder head.
2 O-ring: Engine oil
16 PC1250-8R
2)Set spacer (16) and fix it with bolt (17).

3)Tighten nuts (18) on the injector side alter-
nately.
3 Nut: 2 ± 0.2 Nm {0.2 ± 0.02 kgm}
3 Cylinder head cover mounting bolt:

[No. 1, 3, 4, 5 and 6 cylinders]
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
[No. 2 cylinder]
58.8 – 73.5 Nm {6 – 7.5 kgm}
PC1250-8R 17
Measuring blow-by pressure 1 3. After completing the measurement, remove

the measuring equipment and set to the origi-
nal condition.
a Tools for measuring blow-by pressure
F 799-201-1504 Blow-by checker
a Measure the blow-by pressure under the fol-

lowing conditions.
q Coolant temperature: Within operating range
1. Install nozzle [1] of blow-by checker F to blow-by

hose (1), then connect gauge [2] with hose [3].
2. Run the engine at high idle under the following

condition and measure the blow-by pressure.
q Work equipment, swing, travel: Relieve
circuit by digging with arm.
a Read the gauge when its pointer is stabi-
lized.
a Blow-by varies greatly according to the
condition of the engine. Therefore, if the
blow-by value is considered abnormal,
check for problems connected with defec-
tive blow-by, such as excessive oil con-
sumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
18 PC1250-8R
Measurement of engine oil 1. Open the right side cover.

pressure 1
2. Remove negative pressure pickup plug (1) (14
× 1.5 mm) of the engine oil filter bracket.
a Measuring instruments for engine oil pressure
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
G 2 799-401-2320 Hydraulic tester
799-101-5230 Nipple (14 × 1.5 mm)
3
6215-81-9720 O-ring
a Measure the engine oil pressure under the fol-

lowing condition.
q Engine coolant temperature: Within oper-
ating range
a The engine oil pressure can be checked with 3. Install nipple G3 (14 × 1.5 mm) and connect
the monitoring function of the monitor panel, hydraulic tester G2 (1 MPa {10 kg/cm 2 } by
too (For the operating method, see “Special hose [2].
functions of machine monitor”).
q Monitoring code: 37200 (Engine oil pres-
sure)
q The engine oil pressure is displayed by 1
MPa {1 kg/cm2, 1 PSI}
4. Start the engine and increase the coolant tem-

perature to the operating range.
5. While running the engine at low idle and high

idle, measure the oil pressure.

suring instruments and return the removed
parts.
3 Oil pressure pickup plug:
45 – 49 Nm {4.6 – 5 kgm}
PC1250-8R 19
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.
2. Screw in sensor (1) until the tip of the sensor

contacts the tip of the tooth of flywheel ring
gear (2).
2 Thread: Loctite hydraulic sealant
(No. 21028)
3. Return sensor (1) by the specified angle from

that position.
a Angle to return: 1/2 – 3/4 turns
a Adjust clearance (a) between the tip of the
sensor and the tip of the gear tooth so that
it is 0.75 – 1.25 mm.
4. Secure sensor (1) in position, then tighten

locknut (3).
3 Locknut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}
20 PC1250-8R
Handling fuel system parts 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-
The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacing fuel filter cartridge stopped.
Be sure to use the Komatsu genuine fuel filter a Before the fuel circuit is tested and its parts are
cartridge. removed, the residual pressure in the fuel cir-
Since the common rail fuel injection system cuit must be released completely. Accordingly,
(CRI) consists of more precise parts than the observe the following.
conventional fuel injection pump and nozzle, it k Before testing the fuel system or removing
employs a high-efficiency special filter to pre- its parts, wait at least 30 seconds after stop-
vent foreign matter from entering it. If a filter ping the engine until the residual pressure
other than the genuine one is used, the fuel in the fuel circuit is released. (Do not start
system may have a trouble. Accordingly, never the work just after stopping the engine
use such a filter. since there is residual pressure.)
PC1250-8R 21
Testing fuel pressure 1 2. Install adapter H3 of hydraulic tester H1 and

connect 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.
1 a If the fuel pressure is in the following
790-261-1204 Digital hydraulic tester range, it is normal.
H 2 799-401-2320 Gauge
Engine speed Fuel pressure
952-471-1450 Adapter
3 Min. 0.15 MPa
07005-00812 Gasket High idle
{Min. 1.5 kg/cm2}
a Test only the fuel pressure in the low-pressure

circuit from the feed pump through the engine
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.
1. Remove plug (1).
4. After finishing testing, remove the testing tools

and return the removed parts.
22 PC1250-8R
Measurement of fuel return rate and fuel leakage 1
a Testing tools for fuel pressure 1. Preparation work

1) Remove tube (3) between common rail (1)
and block (2).
1 6167-11-6640 Spacer 2) Insert spacer J1 on block (2) side and
2 6206-71-1770 Joint tighten the removed joint bolt again.
Commercially a Connect the return pipe to the fuel tank
3 Hose again, too.
available
a Be sure to fit the gaskets to both ends of
J Commercially
4 Hose the spacer.
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the measurement.
PC1250-8R 23
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.
5) After finishing measurement, stop the

engine.
3. Measurement of return rate from injector

2. Measurement of leakage from pressure lim-
iter
1) Lay test hose J3 so that it will not slacken
and put its end in the oil pan.
2) Referring to “Special functions of machine
monitor”, prepare for measurement of the
engine speed with the real-time monitor-
ing function.
3) Start the engine and keep its speed to
1,600 rpm with no load.
4) After the engine speed is stabilized, mea-
sure the leakage in 1 minute with measur-
ing cylinder J5.
a You may measure for 20 seconds and
judge by multiplying the result by 3.
1) Disconnect the hose of spill outlet (4),
connect test hose J4 and put its end in the
oil pan.
2) Referring to “Special functions of machine
monitor”, prepare for measurement of the
engine speed with the real-time monitor-
ing function.
3) Run the engine at the rated output.
4) After the engine speed is stabilized, mea-
sure the return rate in 1 minute with mea-
suring cylinder J5.
a You may measure for 20 seconds and
judge by multiplying the result by 3.
24 PC1250-8R
a If the supply pump is not supplying

fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the measurement.
a If the return rate (spill) from the injec-
tor is in the following standard range,
it is normal.
Rated output Limit of return rate
speed (rpm) (spill) (cc/min)
1,600 1,960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
5) After finishing measurement, stop the

engine.
4. Work after finishing measurement

After finishing all measurement, remove the
measuring instruments and return the removed
parts.
PC1250-8R 25
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.
3. Open air bleeding valve (1) at the top of the

prefilter head.
a Set the valve lever in the horizontal position.
5. After the specified time (approx. 6 minutes 30

seconds), lamp (3) goes off and the electric
priming pump stops automatically.
a If only the fuel filter was replaced, the air
bleeding work is completed now.
4. Turn electric priming pump switch (2) installed in 6. If the fuel was used up or the fuel piping or
the engine compartment to the “ON” position. supply pump was replaced and there is not fuel
a Lamp (3) blinks and the electric priming in the fuel circuit, turn switch (2) to the “ON”
pump operates. position after the electric priming pump stops
automatically.
7. When lamp (3) goes off, the air bleeding work

is completed.
8. Close air bleeding valve (1) at the top of the

prefilter head.
a Set the valve lever in the vertical position.
26 PC1250-8R
9. Start the engine with the starting motor.

a The air in the high-pressure circuit is bled
automatically when the engine is rotated.
a If the engine does not start, the air in the
low-pressure circuit may have not been
bled. In this case, start the engine accord-
ing to the following procedure.
1. Turn the electric priming pump switch
to the “ON” position.
2. While the electric priming pump is
operating, start the engine.
3. After the engine starts, keep it run-
ning for at least 5 minutes to bleed all
air from the fuel circuit.
PC1250-8R 27
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.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If any fuel leakage is detected, repair it
and inspect again from step 1.
4. Run the engine at low idle.

leakage.
for fuel leakage.
6. Run the engine at high idle.

leakage.
for fuel leakage.
8. Run the engine at high idle and load it.

a When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.
28 PC1250-8R
Procedure for checking alternator

and replacing belt 1
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.
2. Replacement of alternator belt

1) Loosen locknut (2) of push bolt (1).
Tighten the push bolt fully to loosen the
tension pulley.
2) Replace the belt.
3) Loosen push bolt (2) until its threaded part
comes out about 90 mm and tighten lock-
nut (2).
PC1250-8R 29
SEN02072-02

© 2007 KOMATSU
All Rights Reserved
30
SEN02073-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Testing swing circle bearing clearance ........................................................................................................... 2
Testing wear of sprocket ................................................................................................................................. 3
Testing and adjusting track shoe tension ........................................................................................................ 4
Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ......................................... 5
Testing and adjusting control circuit oil pressure .......................................................................................... 19
Testing and adjusting piston pump control pressure..................................................................................... 21
Testing servo piston stroke ........................................................................................................................... 28
PC1250-8R 1
Testing swing circle bearing 3. Set the dial gauge N to the zero point.
clearance 1
4. Arrange the arm almost at right angles to the
ground and lower the boom until the front leg
a Testing device of swing circle bearing clearance of the machine body rises.
Symbol Part No. Part name a At the time, the front of the upper structure
rises and its rear lowers.
N Purchased Dial gauge (with magnet)
a When measuring swing circle bearing clear-

ance on a machine, follow the procedures
below:
a For the standard values, see Structure, func-
tion and maintenance standard, “Swing circle”.
1. Fix the dial gauge N to the track frame (center

frame) and bring the stylus to the outer race
end face.
a Set the dial gauge to the front or to the rear.
5. At the time, read the value on the dial gauge N.

This value on the dial gauge indicates the
swing circle bearing clearance.
k During the measurement, never place
hands and legs below the undercar-
riage.
6. Return the work equipment to the state in

Paragraph 2 and make sure that the dial gauge
N has returned to the zero point. If not, repeat
Steps 2 to 5.
2. Set the work equipment to the maximum reach

and set the bucket tip to the height of the
revolving frame lower face.
a At the time, the front of the upper structure
lowers and its rear rises.
2 PC1250-8R
Testing wear of sprocket 1
a Tools for testing wear of sprocket

V 796-827-1120 Wear gauge
1. Align wear gauge V with the portion of the

sprocket not meshed with the track shoe.
a Align with the datum line (a), then align the
wave shape of the sprocket with the wave
shape of the wear gauge.
2. Judge the wear of the sprocket.

a If the sprocket wave pattern is above the
wear limit line (b), it is possible to use the
sprocket as it is.
a If the sprocket wave pattern has reached
the wear limit line (b), replace the sprocket
with a new part.
PC1250-8R 3
Testing and adjusting track shoe Adjusting

tension 1 a If the track shoe tension is not proper, adjust it
in the following manner.
Testing
1. Travel the machine forward by the length of 1. When the tension is too strong
track on ground, keeping the engine at low Discharge grease by loosening valve (1).
idle, and stop the machine slowly. k Do not loosen valve (1) by more than
one turn, because grease will spurt due
2. Place wood bar [1] on the track shoe between to its internal high pressure.
second carrier roller (1) and third carrier roller
(2). 2. When the tension is too weak
a V beam is recommended for bar [1], Add grease through grease fitting (2).
because of its deflection-free nature. a If the normal track shoe tension is not
restored even after greasing, move the
3. Measure max. clearance (a) between bar [1] machine slowly back and forth.
and the track shoe.
q Max. standard clearance (a): 10 – 30 mm
4 PC1250-8R
Testing and adjusting hydraulic

pressure in work equipment,
swing, travel circuit 1
a Tools for testing and adjusting hydraulic pressure
in work equipment, swing, and travel circuits
K
a Circuit configuration of hydraulic pump and

control valve 1. Preparation work
k Lower the work equipment to the ground
and stop the engine. Operate the control
levers several times to release the resid-
ual pressure in the piping, and then
loosen the oil filler cap of the hydraulic
tank slowly to release the internal pres-
sure of the hydraulic tank.
1) Connect oil pressure gauges [1] of hydraulic
tester K to quick couplers (1) – (6) installed
to each pump outlet of the circuit to be mea-
sured with hose [2].
a To measure the hydraulic pressure in
the front pump circuit (No. 1 F + No. 2
F), connect the pressure gauge to
either of quick couplers (1) and (2).
Measuring a To measure the hydraulic pressure of
the rear pump circuit (No. 1 R + No. 2
<Measurement conditions>
R), connect the pressure gauge to
a Measure the hydraulic pressure in the work either of quick couplers (3) and (4).
equipment, swing, and travel circuits under the a To measure the hydraulic pressure of
following condition. the No. 3 pump pressure (No. 3 F +
q Hydraulic oil temperature: 45 – 55°C No. 3 R), connect the pressure gauge
a The hydraulic pressure in the work equipment, to either of quick couplers (5) and (6).
swing, and travel circuits can be checked with a The relief pressure in the boom
the monitoring function of the machine monitor LOWER circuit can be measured only
(For the operating method, see “Special func- in the front pump circuit.
tion of machine monitor”). a The relief pressure in the bucket
q Monitoring code: 01100 F pump pressure DUMP circuit cannot be measured in
q Monitoring code: 01101 R pump pressure the No. 3 pump circuit.
q Monitoring code: 09000 Swing pump pres- a Use the oil pressure gauges of 60
sure MPa {600 kg/cm2}.
q The pump pressure is displayed in 0.1 MPa
{1 kg/cm2, 1 PSI}
PC1250-8R 5
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 PC1250-8R
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
mode switch in the P-mode position.
ii) Turn the machine push-up switch ON.
iii) Run the engine at high idle, relieve
t h e b o o m c y li n d e r s i n gl y a t t h e
LOWER stroke end, and measure the
hydraulic pressure.
PC1250-8R 7
4. Measuring high pressure in travel circuit

1) Start the engine and put pin [4] between
the sprocket and track frame to lock the
travel mechanism.
2) Run the engine at high idle, relieve the

travel motor, and measure the hydraulic
pressure.
a The main relief valves of the L.H. 5-spool
control valve and R.H. 4-spool control valve
relieve on the high pressure setting side.
8 PC1250-8R
Adjusting a If the high pressure setting side is

a Do not adjust any safety valve other than the adjusted, the low pressure setting
swing motor safety valve. side changes. Accordingly, adjust the
low pressure setting side, too.
1. Adjusting main relief valve (high-pressure
setting) of R.H. 4-spool control valve
a If the work equipment hydraulic pressure in
the front pump circuit (during Heavy lift oper-
ation) and the right travel are abnormal,
adjust the high pressure setting side of main
relief valve (7) of the R.H. 4-spool control
valve according to the following procedure.
6) Fix elbow (10) and tighten locknut (9).

7) Connect hose (8).
8) After finishing adjustment, check the
hydraulic pressure again according to the
above described measurement procedure.
2. Adjusting main relief valve (low-pressure

a The high pressure setting is the state in a If the work equipment hydraulic pressure
which the 2-stage relief solenoid valve is in the front pump circuit (during normal
turned ON and the pilot pr essure is relief operation) is abnormal or the high
applied to the changeover port. pressure setting side was adjusted, adjust
1) Disconnect hose (8). the low pressure setting side of main relief
2) Loosen locknut (9) and set elbow (10) free. valve (7) of the R.H. 4-spool control valve
3) Fix holder (11) and loosen locknut (12). according to the following procedure.
4) Turn holder (11) to adjust the pressure. a The low pressure setting is the state in
a If the holder is which the 2-stage relief solenoid valve is
q turned to the right, the pressure turned OFF and the pilot pressure is not
rises. applied to the changeover port.
q turned to the left, the pressure 1) Disconnect hose (8).
lowers. 2) Loosen locknut (9) and set elbow (10) free.
a Pressure changed by 1 turn of holder: 3) Fix union (14) and loosen locknut (15).
21.8 MPa {222 kg/cm2} 4) Turn union (14) to adjust the pressure.
5) Fix holder (11) and tighten locknut (12). a If the union is
3 Locknut: q turned to the right, the pressure
93 – 123 Nm {9.5 – 12.5 kgm} rises.
q turned to the left, the pressure
lowers.
a Pressure changed by 1 turn of union:
21.8 MPa {222 kg/cm2}
PC1250-8R 9
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.

setting) of swing 4-spool control valve
the No. 3 pump circuit (during Heavy lift
operation) is abnormal, adjust the high pres-
sure setting side of main relief valve (17) of
6) Fix elbow (10) and tighten locknut (9). the swing 4-spool control valve according to
7) Connect hose (8). the following procedure.

setting) of L.H. 5-spool control valve
the rear pump circuit (during Heavy lift oper-
ation) and the left travel are abnormal,
relief valve (16) of the L.H. 5-spool control
a Adjust the swing 4-spool control valve

similarly to the R.H. 4-spool control valve.

the No. 3 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
(17) of the swing 4-spool control valve
a Adjust the L.H. 5-spool control valve simi- a Adjust the swing 4-spool control valve
larly to the R.H. 4-spool control valve. similarly to the right 4-spool control valve.
10 PC1250-8R
7. Adjusting swing motor safety valve a Pressure adjusted by one turn of the
a If the swing hydraulic oil pressure is adjustment screw :
abnormal, adjust safety valves (18) and Approx. 4.7 MPa {47.9 kg/cm2}
(19) of the swing motor according to the 3 Locknut :
following procedure. 147 – 196 Nm {15 – 20 kgm}
q (18): Safety valve of front swing motor 3) Start the engine, relieve the swing lock,
and measure the relief oil pressure.
4) Rise of the oil pressure shows lowering of
the valve set pressure. Adjust the pres-
sure according to the criteria.
5) If the oil pressure is not changed, return
the valves to the original positions in
accordance with the match marks.
6) Adjust the relief valves on the other side in
the same steps 2) – 4) above.
q (19): Safety valve of rear swing motor

a The front and rear swing motors are

divided from one spool. Adjust the valves
in the following procedures.
a If swing starting power is not powerful, or if
swing speed is not fast:
1) Put match marks on the body and on
adjustment screw (16) for safety valves
(14) and (15) of each motor.
a The match marks are for returning the
screw and body to the original posi-
tions after no fault is found.
2) Loosen locknut (17) of safety valve on one
side and tighten adjustment screw (16).
q Turn the adjustment screw to the
right, and the pressure will rise.
q Turn the adjustment screw to the left,
and the pressure will lower.
PC1250-8R 11
Serial number 35017 and up 1. Preparation work

a Tools for testing and adjusting hydraulic pressure and stop the engine. Operate the control
in work equipment, swing, and travel circuits levers several times to release the resid-
Symbol Part No. Part name ual pressure in the piping, and then
loosen the oil filler cap of the hydraulic
K tank slowly to release the internal pres-
790-261-1203 Digital hydraulic tester sure of the hydraulic tank.
1) Connect oil pressure gauges [1] of hydraulic
tester K to quick couplers (1) – (6) installed
a Circuit configuration of hydraulic pump and to each pump outlet of the circuit to be mea-
control valve sured with hose [2].
a To measure the hydraulic pressure in
the front pump circuit (No. 1 F + No. 2
F), connect the pressure gauge to
a To measure the hydraulic pressure of
the rear pump circuit (No. 1 R + No. 2
R), connect the pressure gauge to
a To measure the hydraulic pressure of
the No. 3 pump pressure (No. 3 F +
No. 3 R), connect the pressure gauge
to either of quick couplers (5) and (6).
a The relief pressure in the boom
LOWER circuit can be measured only
in the front pump circuit.
Measuring a The relief pressure in the bucket
<Measurement conditions> DUMP circuit cannot be measured in
a Measure the hydraulic pressure in the work the No. 3 pump circuit.
equipment, swing, and travel circuits under the a Use the oil pressure gauges of 60
following condition. MPa {600 kg/cm2}.
a The hydraulic pressure in the work equipment, q (1): Quick coupler for No. 1 F pump
swing, and travel circuits can be checked with
the monitoring function of the machine monitor
(For the operating method, see “Special func-
tion of machine monitor”).
q Monitoring code: 01100 F pump pressure
q Monitoring code: 01101 R pump pressure
q Monitoring code: 09000 Swing pump pres-
sure
q The pump pressure is displayed in 0.1 MPa
{1 kg/cm2, 1 PSI}
12 PC1250-8R
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
q (4): Quick coupler for No. 2 R pump
PC1250-8R 13
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
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
mode switch in the P-mode position.
ii) Turn the machine push-up switch ON.
iii) Run the engine at high idle, relieve
t h e b o o m c y li n d e r s i n gl y a t t h e
LOWER stroke end, and measure the
hydraulic pressure.
14 PC1250-8R
4. Measuring high pressure in travel circuit

1) Start the engine and put pin [4] between
the sprocket and track frame to lock the
travel mechanism.
2) Run the engine at high idle, relieve the

travel motor, and measure the hydraulic
pressure.
a The main relief valves of the L.H. 5-spool
control valve and R.H. 4-spool control valve
relieve on the high pressure setting side.
PC1250-8R 15
Adjusting a If the high pressure setting side is

a Do not adjust any safety valve other than the adjusted, the low pressure setting
swing motor safety valve. side changes. Accordingly, adjust the
low pressure setting side, too.
the front pump circuit (during Heavy lift oper-
ation) and the right travel are abnormal,
relief valve (7) of the R.H. 4-spool control
6) Fix elbow (10) and tighten locknut (9).

7) Connect hose (8).

a The high pressure setting is the state in a If the work equipment hydraulic pressure
which the 2-stage relief solenoid valve is in the front pump circuit (during normal
turned ON and the pilot pr essure is relief operation) is abnormal or the high
applied to the changeover port. pressure setting side was adjusted, adjust
1) Disconnect hose (8). the low pressure setting side of main relief
2) Loosen locknut (9) and set elbow (10) free. valve (7) of the R.H. 4-spool control valve
3) Fix holder (11) and loosen locknut (12). according to the following procedure.
4) Turn holder (11) to adjust the pressure. a The low pressure setting is the state in
a If the holder is which the 2-stage relief solenoid valve is
q turned to the right, the pressure turned OFF and the pilot pressure is not
rises. applied to the changeover port.
q turned to the left, the pressure 1) Disconnect hose (8).
lowers. 2) Loosen locknut (9) and set elbow (10) free.
a Pressure changed by 1 turn of holder: 3) Fix union (14) and loosen locknut (15).
21.8 MPa {222 kg/cm2} 4) Turn union (14) to adjust the pressure.
5) Fix holder (11) and tighten locknut (12). a If the union is
3 Locknut: q turned to the right, the pressure
93 – 123 Nm {9.5 – 12.5 kgm} rises.
lowers.
a Pressure changed by 1 turn of union:
21.8 MPa {222 kg/cm2}
16 PC1250-8R
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
a Adjust the L.H. 5-spool control valve simi-
larly to the R.H. 4-spool control valve.

the No. 3 pump circuit (during Heavy lift
operation) is abnormal, adjust the high pres-
sure setting side of main relief valve (17) of
6) Fix elbow (10) and tighten locknut (9). the swing 4-spool control valve according to
7) Connect hose (8). the following procedure.

setting) of L.H. 5-spool control valve
the rear pump circuit (during Heavy lift oper-
ation) and the left travel are abnormal,
relief valve (16) of the L.H. 5-spool control
a Adjust the swing 4-spool control valve

similarly to the R.H. 4-spool control valve.

the No. 3 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
(17) of the swing 4-spool control valve
a Adjust the L.H. 5-spool control valve simi- a Adjust the swing 4-spool control valve
larly to the R.H. 4-spool control valve. similarly to the right 4-spool control valve.
PC1250-8R 17
7. Adjusting swing motor safety valve a Pressure adjusted by one turn of the
a If the swing hydraulic oil pressure is adjustment screw :
abnormal, adjust safety valves (18) and Approx. 4.7 MPa {47.9 kg/cm2}
(19) of the swing motor according to the 3 Locknut :
following procedure. 147 – 196 Nm {15 – 20 kgm}
q (18): Safety valve of front swing motor 3) Start the engine, relieve the swing lock,
and measure the relief oil pressure.
4) Rise of the oil pressure shows lowering of
the valve set pressure. Adjust the pres-
sure according to the criteria.
5) If the oil pressure is not changed, return
the valves to the original positions in
accordance with the match marks.
6) Adjust the relief valves on the other side in
the same steps 2) – 4) above.
q (19): Safety valve of rear swing motor

a The front and rear swing motors are

divided from one spool. Adjust the valves
in the following procedures.
a If swing starting power is not powerful, or if
swing speed is not fast:
1) Put match marks on the body and on
adjustment screw (16) for safety valves
(14) and (15) of each motor.
a The match marks are for returning the
screw and body to the original posi-
tions after no fault is found.
2) Loosen locknut (17) of safety valve on one
side and tighten adjustment screw (16).
q Turn the adjustment screw to the
right, and the pressure will rise.
q Turn the adjustment screw to the left,
and the pressure will lower.
18 PC1250-8R
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.
a Tools for testing and adjusting control circuit oil

pressure
L
Measuring
a Measure the control circuit oil pressure under
the following condition.
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.
1. Connect oil pressure gauge [1] of hydraulic

tester L to quick coupler (1) installed to the out-
let of the control pump with hose [2].
a Use the oil pressure gauge of 6 MPa {60
kg/cm2}
1. Remove cap (2).
2. Fix adjustment screw (4) and loosen locknut (3).
3. Turn adjustment screw (4) 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 adjustment
screw: 4.4 MPa {45 kg/cm2}
PC1250-8R 19
4. Fix adjustment screw (4) and tighten locknut (3).

3 Locknut: 9.8 Nm {1 kgm}
5. After finishing adjustment, check the oil pres-

sure again according to the above described
measurement procedure.
20 PC1250-8R
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 6 MPa
a Tools for testing and adjusting piston pump {60 kg/cm2}.
control pressure
1
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
3) Start the engine and set the working mode

Measuring switch in the P-mode position.
a Measure the piston pump control pressure 4) Set all the control levers in neutral and
under the following condition. measure the TVC valve output pressure
q Hydraulic oil temperature: 45 – 55°C under the following condition.
k Lower the work equipment to the ground and i) Set all the control levers in neutral.
stop the engine. Operate the control levers ii) Run the engine at high idle and mea-
several times to release the residual pressure sure the output pressure.
in the piping, and then loosen the oil filler cap 5) Turn the heavy lift switch OFF, relieve the
of the hydraulic tank slowly to release the boom circuit by raising the boom, and
internal pressure of the hydraulic tank. measure the TVC valve output pressure
under the following condition.
1. Measuring TVC valve output pressure i) Turn the heavy lift switch OFF.
a Since the TVC valve output pressure var- ii) Run the engine at high idle, relieve
ies with the discharge pressure of each the boom circuit by raising the boom,
pump, check that the oil pressure in the and measure the output pressure.
work equipment, swing, and travel circuits 6) Turn the heavy lift switch ON, relieve the
is normal before starting measurement. boom circuit by raising the boom, and
a Since the basic pressure of the TVC valve measure the TVC valve output pressure
output pressure is the control circuit pres- under the following condition.
sure, check that the control circuit pressure i) Turn the heavy lift switch ON.
is normal before starting measurement. ii) Run the engine at high idle, relieve
1) Remove oil pressure pickup plug (1) of the the boom circuit by raising the boom,
No. 3 front pump. and measure the output pressure.
7) After finishing measurement, remove the
measuring instruments and return the
removed parts.
PC1250-8R 21
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.
2) Install nipple M3 and connect oil pressure

gauge [1] of hydraulic tester M1 with hose
[2].
a Use the oil pressure gauges of 6 MPa
{60 kg/cm2}.

removed parts.
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.
22 PC1250-8R
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 6 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 6 MPa
3) Start the engine and set the working mode {60 kg/cm2} to the high pressure (Pt)
switch in the P-mode position. side and connect a pressure gauge of
4) Set all the control levers in neutral and 2.5 MPa {25 kg/cm2} to the low pres-
measure the CO-NC valve output 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.
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.
q The following figure shows the L.H. 5-

spool control valve.

removed parts.
PC1250-8R 23
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.
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.
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) of the
differential pressure gauge and con-
nect 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 6 MPa
{60 kg/cm2} to the high pressure (Pt)
side and connect a pressure gauge of
2.5 MPa {25 kg/cm2} to the low pres-
sure (Pd) side.

removed parts.
3) Start the engine and set the working mode

switch in the P-mode position.
24 PC1250-8R
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}
4) After finishing adjustment, check the oil

pressure again according to the above
6) After finishing measurement, remove the described measurement procedure.
removed parts. 2. Adjusting CO-NC valves of No. 1 and No. 2
pumps
Adjusting a If the CO-NC valve output pressure of the
1. Adjusting TVC valve No. 1 or No. 2 pump is abnormal, adjust
a If the TVC valve output pressure is abnor- CO valves (12) and (13) and NC valves
mal, adjust TVC valve (9) of the No. 1 pump (14) and (15) of the No. 1 pump according
according to the following procedure. to the following procedure.
q (12): Front CO valve of No. 1 pump
q (13): Rear CO valve of No. 1 pump
PC1250-8R 25
q (14): Front NC valve of No. 1 pump 2) Adjusting NC valve side

q (15): Rear NC valve of No. 1 pump i) Fix adjustment screw (18) and loosen
locknut (19).
ii) Turn adjustment screw (18) to adjust
the pressure.
q turned to the right, the pres-
sure rises.
q turned to the left, the pres-
sure lowers.
a Pressure changed by 1 turn of
adjustment screw: 0.42 MPa {4.3
kg/cm2}
iii) Fix adjustment screw (18) and tighten
locknut (19).
3 Locknut:
5.9 – 9.8 Nm {0.6 – 1.0 kgm}
1) Adjusting CO valve side
i) Fix adjustment screw (16) and loosen
locknut (17).
ii) Turn adjustment screw (16) to adjust
the pressure.
q turned to the right, the pres-
sure rises.
q turned to the left, the pres-
sure lowers.
a Pressure changed by 1 turn of
adjustment screw:
2.20 MPa {22.4 kg/cm2}
iii) Fix adjustment screw (16) and tighten
locknut (17).
3 Locknut: iv) After finishing adjustment, check the oil
5.9 – 9.8 Nm {0.6 – 1.0 kgm} pressure again according to the above
described measurement procedure.
3. Adjusting CO-NC valves of No. 3 pump

a If the CO-NC valve output pressure of the
No. 3 pump is abnormal, adjust CO valve
(20) and NC valve (21) of the No. 3 pump
q (20): CO valve of No. 3 pump
iv) After finishing adjustment, check the oil

26 PC1250-8R
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.
q turned to the right, the pressure
rises.
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}
a Adjust the CO-NC valves of the No. 3 simi-

larly to those of the No. 1 and No. 2 pumps.
4. Adjusting jet sensors of R.H. 4-spool con-

trol valve and L.H. 5-spool control valve
a If the jet sensor output differential pres-
sure of the R.H. 4-spool control valve or
L.H. 5-spool control valve is abnormal,
adjust jet sensor relief valves (22) and
(23) according to the following procedure.
q (22): Jet sensor relief valve of R.H. 4-spool
control valve.
4) After finishing adjustment, check the oil

5. Adjusting jet sensor of swing 4-spool con-

trol valve
a If the jet sensor output differential pres-
sure of the swing 4-spool control valve is
abnormal, adjust jet sensor relief valve
(26) according to the following procedure.
q (23): Jet sensor relief valve of L.H. 5-spool

control valve
a Adjust the jet sensor of the swing 4-spool

control valve similarly to those of the right-
hand 4-spool control valve and left-hand
5-spool control valve.
PC1250-8R 27
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 11.5 mm at the center
of cap O1 or O2 and then make a female
screw of R 1/4 on the outside of the cap and
screw in disc gauge O3.
a Use the cap on the spring side of the
hydraulic pump servo piston.
7) After finishing testing, remove the testing

tools and return the removed parts.
3. Judgment of servo valve

a If the servo piston stroke is abnormal,
remove the servo valve, servo piston cap,
and spring, and check that you can move
the servo piston smoothly before judging
2. Measuring stroke the condition of the servo valve.
1) Remove the cap and shim of the servo 1) When servo piston stroke is normal:
valve on the side of the servo piston to be Servo valve is normal.
measured. 2) When servo piston stroke is abnormal:
a Since the cap is pressed by the q Servo piston moves smoothly:
spring, remove it slowly with a long Servo valve is abnormal.
bolt (01016-31070, etc.) and a nut so q Servo piston does not move smoothly:
that it will not fly out. Servo valve is normal.
2) Fit the removed shim and install measur-
ing tool O to the servo piston.
a Take care that the shim will not be
hitched on the threads of the bolt.
3) Push in the rod of measuring tool O fully
and measure projection (a1).
28 PC1250-8R
PC1250-8R 29
SEN02073-02

© 2007 KOMATSU
All Rights Reserved
30
SEN02074-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Measuring PPC valve output pressure and testing swing PPC shuttle valve ................................................. 2
Measuring solenoid valve output pressure ..................................................................................................... 6
Adjusting work equipment, swing PPC valve.................................................................................................. 8
Testing travel deviation ................................................................................................................................... 9
Testing locations causing hydraulic drift of work equipment ......................................................................... 10
Measuring oil leakage ....................................................................................................................................11
Measurement of fan speed ........................................................................................................................... 19
Measurement of fan circuit oil pressure ........................................................................................................ 20
Measuring fan pump EPC solenoid valve output pressure ........................................................................... 22
Bleeding air ................................................................................................................................................... 23
Releasing remaining pressure in hydraulic circuit......................................................................................... 25
Testing procedures for diode......................................................................................................................... 26
PC1250-8R 1
Measuring PPC valve output 2) Install nipple [1] of hydraulic tester P1 and
pressure and testing swing PPC connect it to oil pressure gauge [2].
a Use a pressure gauge of 6 MPa {60
shuttle valve 1 kg/cm2}
a Tools for measuring PPC valve output pres-

sure and testing swing PPC shuttle valve
1
P
799-401-3200 Adapter (Size: 03)
2
02896-11009 O-ring
a Measure the PPC valve output pressure and

test the swing PPC shuttle valve under the fol-
lowing condition.
q Hydraulic oil temperature: Within operat-
3) Run the engine at high idle, operate the
ing range
k
control lever of the PPC circuit to be mea-
Lower the work equipment to the ground and
sured, and measure the oil pressure.
a Move the control lever to the stroke
several times to release the residual pressure
end.
in the piping, and then loosen the oil filler cap
a Condition of actuator to be measured
of the hydraulic tank slowly to release the
q When measuring the pressure
internal pressure of the hydraulic tank.
for the work equipment, move
each cylinder to the stroke end.
1. Measuring PPC valve output pressure
1) Disconnect hose (1) of the PPC circuit to
for swing, turn the swing lock
be measured. Install adapter P2 and con-
switch ON.
nect the hose again.
a For the hose to be disconnected, see
for travel, put pin [4] between the
the connection diagram of PPC cir-
sprocket and track frame to lock
cuit.
the track shoe.
2 PC1250-8R
3) Run the engine at high idle, swing the

machine to the right and left, and measure
the oil pressure.
a If oil pressure rises when the machine
swings to each direction, the shuttle
valve is normal.
a If oil pressure does not rise when the
machine swings in either direction,
the shuttle valve may have a trouble
such as fixing of the ball, etc.

removed parts.
2. Testing swing PPC shuttle valve

1) Disconnect hose (2) of the swing PPC
shuttle valve. Install adapter P2 and con-
nect the hose again.

removed parts.
2) Install nipple [3] of hydraulic tester P1 and

connect it to oil pressure gauge [1] with
hose [2].
a Use a pressure gauge of 6 MPa {60
kg/cm2}
PC1250-8R 3
Connection diagram of PPC circuit
4 PC1250-8R
PC1250-8R 5
Measuring solenoid valve output q (6): Swing holding brake solenoid valve
pressure 1
a Tools for measuring solenoid valve output

pressure
1
Q
799-401-3200 Adapter (Size: 03)
2
02896-11009 O-ring
a Measure the solenoid valve output pressure

under the following condition.
q Hydraulic oil temperature: 45 – 55°C q (7): Swing priority solenoid valve
k Lower the work equipment to the ground and
several times to release the residual pressure
in the piping, and then loosen the oil filler cap
of the hydraulic tank slowly to release the
internal pressure of the hydraulic tank.
1. Disconnect the outlet hoses of solenoid valves

to be measured (1) – (8). Install adapters Q2
and connect the hoses again.
q (1): CO cancel solenoid valve
q (2): Straight-travel solenoid valve
q (3): 2-stage relief solenoid valve
q (4): Machine push-up solenoid valve
q (5): Travel speed solenoid valve
q (8): PPC lock solenoid valve
6 PC1250-8R
2. Install nipple [3] of hydraulic tester Q1 and con-

nect it to oil pressure gauge [1] with hose [2].
a Use a pressure gauge of 6 MPa {60 kg/
cm2}
3. Run the engine at high idle, set the condition or
operate the control levers as shown in the
table, and measure the output pressure.
a When operating the work equipment, swing,
or travel control lever, operate it finely to a
degree that the PPC oil pressure switch is
turned ON.
suring instruments and return the removed
parts.
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
7 Swing priority When swing priority switch is

2.9 ± 0.6
ON and swing lever is oper- ON Boom Plus spool stopped
{30 ± 5.5}
ated
When lock lever is at LOCK
OFF 0 Circuit to PPC valve closed
(upper) position
8 PPC lock
When lock lever is at FREE 2.9 ± 0.6
ON Circuit to PPC valve opened
(lower) position {30 ± 5.5}
PC1250-8R 7
Adjusting work equipment, swing

PPC valve 1
a If there is excessive play at the tip of the work

equipment or swing lever, adjust at the PPC
valve end as follows.
q Standard lever play (a): 0.5 – 3 mm at point
200 mm from rotating center of lever (forward
and reverse, and left and right)
1. Remove boot (1).
2. Loosen locknut (2), then turn disc (3) to adjust

the play of the lever.
a When doing this, do not move the piston.
3. Secure disc (3) in position, then tighten locknut

(2) to the specified torque.
3 Locknut:
98.07 – 127.49 Nm {10 – 13 kgm}
4. Install boot (1).
8 PC1250-8R
Testing travel deviation 1
a When traveling on level ground.

1. Set the machine in the travel posture.
a For the travel posture, extend the bucket
and arm cylinder rods fully, and hold the
boom angle at 45°.
2. Operate with the engine at full throttle, run up

for 10 m, then measure the deviation (A) over
the next 20 m.
a Install the oil pressure gauge and measure
the pump discharge pressure at the same
time.
PC1250-8R 9
Testing locations causing q Posture for measuring the arm.

hydraulic drift of work equipment1
a If there is any hydraulic drift in the work equip-

ment (cylinders), check as follows to determine
if the cause is in the cylinder packing or in the
control valve.
1. Checking boom and bucket cylinders

1) Set in the same posture as when measur-
ing hydraulic drift, and stop the engine.
2) Operate the boom control lever to RAISE
or the bucket control lever to CURL.
q If the lowering speed increases, the
packing is defective.
q If there is no change, the boom lock [Reference] If the cause of the hydraulic drift is in
valve (boom) or the control valve the packing, and the above operation
(bucket) is defective. is carried out, the downward move-
a If the pressure in the accumulator has ment becomes faster for the following
dropped, run the engine for approx. reasons.
10 seconds to charge the accumula- 1) If the work equipment is set to the above
tor again before operating. posture (holding pressure applied to the
q Posture for measuring the boom and bottom end), the oil at the bottom end
bucket. leaks to the head end. However, the vol-
ume at the head end is smaller than the
volume at the bottom end by the volume of
the rod, so the internal pressure at the
head end increases because of the oil
flowing in from the bottom end.
2) When the internal pressure at the head
end increases, the pressure at the bottom
end also rises in proportion to this. The
balance is maintained at a certain pres-
sure (this differs according to the amount
of leakage) by repeating this procedure.
3) When the pressure is balanced, the down-
ward movement becomes slower. If the
lever is then operated according to the
procedure given above, the circuit at the
2. Checking arm cylinder head end is opened to the drain circuit
1) Stop the arm cylinder at a point approx. (the bottom end is closed by the check
100 mm before the end of the IN stroke, valve), so the oil at the head end flows to
then stop the engine. the drain circuit and the downward move-
2) Operate the control lever to arm IN. ment becomes faster.
q If the lowering speed increases, the
packing is defective.
q If there is no change, the control
valve is defective.
a If the pressure in the accumulator has
dropped, run the engine for approx.
10 seconds to charge the accumula-
tor again before operating.
10 PC1250-8R
Measuring oil leakage 1 q Boom cylinder q Arm cylinder

Serial number: 35001 – 35016
Tools for measuring oil leakage

1 Purchased part Measuring cylinder
07378-11000 Sleeve head
2
T 07000-13032 O-ring
3
07000-13038 O-ring
a Measure the amount of oil leakage under the

following condition.
q Hydraulic oil temperature: 45 – 55°C q Bucket cylinder
1. Measuring work equipment cylinder

1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
q a: Measurement posture of boom cyl-
inder
q b: Measurement posture of arm and
bucket cylinder
3) Start the engine and apply the relief pres-

sure to the bottom end of the cylinder with
the engine at full throttle.
q Boom cylinder: RAISE
q Arm cylinder: IN
q Bucket cylinder: CURL
k A mistake in operation of the levers
can cause an accident. Accordingly,
2) Disconnect hose (1) at the head end, then make signs and check the opera-
block the hose at the machine end with a tions securely.
sleeve head. 4) Continue this condition for 30 seconds,
k Be careful not to disconnect the then measure the oil leakage for the next
piping at the bottom end. one minute.
removed parts.
PC1250-8R 11
2. Measuring swing motor 3. Measuring travel motor

k Loosen the hydraulic tank oil filler cap k Loosen the hydraulic tank oil filler cap
slowly to release the pressure inside slowly to release the pressure inside
the tank. the tank.
1) Disconnect drain hoses (2), (3) from the 1) Disconnect drain hose (4) from the travel
swing motor to be measured, then block motor to be measured, then block the
the hose of the machine side with a plug. hose of the machine side with a plug.
2) Fit block [1] between the sprocket and

frame to lock the track.
2) Turn the swing lock switch LOCK.

3) Start the engine and operate the swing
relief with the engine at full throttle.
4) Continue this condition for 30 seconds, 3) Start the engine and operate the travel
then measure the oil leakage for the next relief with the engine at full throttle.
one minute. k When measuring the oil leakage
a After measuring, swing 180° and measure from the travel motor, mistaken
again. operation of the control lever may
q Hoses (2) and (3) are for the front lead to a serious acciden t, so
motor and rear motor respectively. alw ays use signals and check
carefully when carrying out this
operation.
4) Continue this condition for 30 seconds,
then measure the oil leakage for the next
one minute.
a When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and between the piston
and cylinder), and measure several times.
12 PC1250-8R
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 co nf irm sig nals an d sig n s
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.
k Loosen the hydraulic tank oil filler

cap slowly to release the pressure
inside the tank.
2) Disconnect the hoses at the bottom of the
swivel joint for the measurement port at
both sides of the port to be inspected, and
fit blind plugs in the hoses.
a When measuring at port (T), discon-
nect and block the hoses at the top of
the swivel joint to prevent the oil from
the other circuits from flowing in. At
the bottom, disconnect the hoses,
and do not block them. Catch the oil
in an oil pan.
PC1250-8R 13
14 PC1250-8R
Serial number: 35017 and up q Boom cylinder q Arm cylinder
Tools for measuring oil leakage

1 Purchased part Measuring cylinder
2
T 07000-13032 O-ring
3
07000-13038 O-ring
a Measure the amount of oil leakage under the

following condition.
q Bucket cylinder
1. Measuring work equipment cylinder
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
q a: Measurement posture of boom cyl-
inder
q b: Measurement posture of arm and
bucket cylinder
3) Start the engine and apply the relief pres-

sure to the bottom end of the cylinder with
the engine at full throttle.
q Boom cylinder: RAISE
q Arm cylinder: IN
q Bucket cylinder: CURL
k A mistake in operation of the levers
2) Disconnect hose (1) at the head end, then can cause an accident. Accordingly,
block the hose at the machine end with a make signs and check the opera-
sleeve head. tions securely.
k Be careful not to disconnect the 4) Continue this condition for 30 seconds,
piping at the bottom end. then measure the oil leakage for the next
one minute.
removed parts.
PC1250-8R 15
2. Measuring swing motor 3. Measuring travel motor

k Loosen the hydraulic tank oil filler cap k Loosen the hydraulic tank oil filler cap
slowly to release the pressure inside slowly to release the pressure inside
the tank. the tank.
1) Disconnect drain hoses (2), (3) from the 1) Disconnect drain hose (4) from the travel
swing motor to be measured, then block motor to be measured, then block the
the hose of the machine side with a plug. hose of the machine side with a plug.
2) Fit block [1] between the sprocket and

frame to lock the track.
2) Turn the swing lock switch LOCK.

3) Start the engine and operate the swing
relief with the engine at full throttle.
4) Continue this condition for 30 seconds, 3) Start the engine and operate the travel
then measure the oil leakage for the next relief with the engine at full throttle.
one minute. k When measuring the oil leakage
a After measuring, swing 180° and measure from the travel motor, mistaken
again. operation of the control lever may
q Hoses (2) and (3) are for the front lead to a serious acciden t, so
motor and rear motor respectively. alw ays use signals and check
carefully when carrying out this
operation.
4) Continue this condition for 30 seconds,
then measure the oil leakage for the next
one minute.
a When measuring, move the motor slightly
(to change the position between the valve
plate and cylinder, and between the piston
and cylinder), and measure several times.
16 PC1250-8R
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 co nf irm sig nals an d sig n s
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,
k Loosen the hydraulic tank oil filler

cap slowly to release the pressure
inside the tank.
2) Disconnect the hoses at the bottom of the
swivel joint for the measurement port at
both sides of the port to be inspected, and
fit blind plugs in the hoses.
a When measuring at port (T), discon-
nect and block the hoses at the top of
the swivel joint to prevent the oil from
the other circuits from flowing in. At
the bottom, disconnect the hoses,
and do not block them. Catch the oil
in an oil pan.
PC1250-8R 17
18 PC1250-8R
Measurement of fan speed 1 a Adjust the probe so that the meter

reading will be stabilized.
a Measuring instrument for fan speed a If the meter reading is stabilized, the
fan speed is measured accurately.
Symbol Part No. Part name 6) After finishing measurement, remove the
R 799-205-1100 Multitachometer measuring instruments and return the
removed parts.
a Measure the fan speed under the following 2. Measurement of aftercooler fan speed
condition. 1) Stick reflection tape (a) to a place of the
q Hydraulic oil temperature: 45 – 55°C fan.
a Use an oblong tape.
1. Measurement of cooling fan speed 2) Set probe [1] of multitachometer R with
1) Open the left side cover of the engine. stand [2] to the reflection tape from out of
2) Stick reflection tape (a) to a place of the the fan guard and connect it to meter [3].
fan. a Set the probe at 100 – 200 mm from
a Use an oblong tape. the fan, matching it to the clearance
3) Set probe [1] of multitachometer R with of the fan guard.
stand [2] to the reflection tape from out of
the fan guard and connect it to meter [3].
a Set the probe at 100 – 200 mm from
the fan, matching it to the clearance
of the fan guard.
3) Start the engine and measure the fan

speed at high idle and high idle down.
a Adjust the probe so that the meter
reading will be stabilized.
a If the meter reading is stabilized, the
4) Start the engine and set the fan in the fan
fan speed is measured accurately.
speed 100% mode.
5) While running the engine at high idle,
operate the work equipment control lever
removed parts.
to the degree that the work equipment
does not move and measure the fan
speed.
PC1250-8R 19
Measurement of fan circuit oil

pressure 1
a Measuring instruments for fan circuit oil pressure

1
799-401-3300 Adapter (Size: 04)
S 2
02896-11012 O-ring
799-101-5220 Nipple (10 × 1.25 mm)
3
07002-11023 O-ring
3) Start the engine and set the fan in the fan

a Measure the fan circuit oil pressure under the speed 100% mode.
following condition. 4) While running the engine at high idle,
q Hydraulic oil temperature: 45 – 55°C operate the work equipment control lever
k Lower the work equipment to the ground, to the degree that the work equipment
stop the engine, operate the control lever does not move and measure the oil pres-
several times to release the residual pressure.
sure in the piping, and then loosen the 5) After finishing measurement, remove the
hydraulic tank cap gradually to release the measuring instruments and return the
residual pressure in the tank. removed parts.
1. Measurement of cooling fan circuit oil pres-

sure
1) Remove pressure pickup plug (1) on the
side of the cooling fan pump.
2) Install nipple S3 and connect oil pressure
gauge [1] of hydraulic tester S1 by hose [2].
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
20 PC1250-8R
2. Measurement of aftercooler fan circuit oil

pressure
1) Disconnect fan pump outlet hose (1),
install adapter S2 and connect the discon-
nected hose again.
2) Install nipple S3 and connect it to oil pres-
sure gauge [1] of hydraulic tester S1 by
hose [2].
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
3) Start the engine and measure the oil pres-

sure at high idle and high idle down.
removed parts.
PC1250-8R 21
Measuring fan pump EPC

solenoid valve output pressure 1
a Measuring instruments for fan pump EPC sole-

noid valve output pressure
1
U
799-101-5220 Nipple (M10 x 1.25 mm)
2
07002-11023 O-ring
a Measure the fan pump EPC solenoid valve

output pressure
a Since the basic pressure of the EPC solenoid

valve output pressure is the control circuit
pressure, check that the control circuit pres-
sure is normal before measuring the EPC sole-
noid valve output pressure.
and stop the engine. Then, operate the
control levers several times to release the
residual pressure in the piping and loosen
the hydraulic tank cap gradually to release
the internal pressure of the hydraulic tank.
1) Remove oil pressure pickup plug (1) from
the top of the fan pump.
2) Install nipple U2 and connect it to oil pres-

sure gauge [1] of hydraulic tester U1.
q Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
3) Run the engine at high idle or high idle
down and measure the EPC valve output
pressure in the fan 100% speed mode.
removed parts.
22 PC1250-8R
Bleeding air 1 2. Bleeding air from travel motor

a If the travel motor, center swivel joint, or
related piping has been removed and
1. Bleeding air from hydraulic pumps installed again, bleed the air from the
a If the hydraulic pump or related piping has hydraulic pumps as follows.
been removed and installed again, bleed the 1) Loosen air bleed plug (5).
air from the hydraulic pumps as follows. 2) Start the engine and use the boom and
1) Loosen air bleed plugs (1), (2), and (3) 4 arm to jack up the track shoe from the
turns. ground on the side where the air is to be
bled.
3) Run the engine at low idle and rotate the
track under no load.
4) When oil comes out from air bleed plug
(5), tighten air bleed plug (5).
2) Loosen the oil filler cap of the hydraulic

tank and leave for approx. 10 minutes.
a The time needed differs according to
the amount of oil remaining inside the
pump case.
3) When oil comes out of air bleed plugs (1)
and (2), tighten air bleed plugs (1) and (2).
4) Start the engine and run at low idle.
a Set the lock lever to the LOCK posi-
tion to prevent the work equipment
from moving.
5) When no more cloudy white oil comes out
from air bleed plug (3), tighten air bleed
plug (3).
PC1250-8R 23
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.
4. Bleeding air from hydraulic cylinders

a When the hydraulic cylinders have been
removed or installed again, or when the
related piping has been disconnected or
connected, do as follows to bleed the air
from the hydraulic cylinders.
1) Start the engine and run at idle for approx.
5 minutes.
2) Run the engine at low idle, then raise and
lower the boom 4 – 5 times in succession.
a Operate the piston rod to a point
approx. 100 mm before the end of its
stroke. Do not relieve the circuit under
any circumstances.
3) Keep the engine running at low idle, oper-
ate the cylinder slowly (take at least 10
seconds) from a point approx. 100 mm
before the end of the stroke, extend the
cylinder to the end of its stroke to relieve
the circuit, and hold in the relief position
for 3 minutes.
24 PC1250-8R
Releasing remaining pressure in

hydraulic circuit 1
a If the piping between the hydraulic cylinder and

the control valve, or the swing motor is to be
disconnected, release the remaining pressure
from the circuit as follows.
a The travel motor circuit is an open circuit, so
there is no remaining pressure. It is enough to
remove the oil filler cap.
1. Lower the work equipment and loosen the oil

filler cap slowly to release the pressure inside
the tank.
2. Operate the right and left control levers back

and forth, rightward and leftward.
a When the levers are operated 2 – 3 times,
the pressure stored in the accumulator is
removed.
3. Start the engine, run at low idle for approx. 10

seconds then store pressure in the accumulator.
a Repeat the above operation 2 – 3 times to
release all the remaining pressure.
PC1250-8R 25
Testing procedures for diode 1 3) Determine if a specific diode is good or no

good with the indicated value.
q No change in the indicated value: No
a Check an assembled-type diode (8 pins) and continuity (defective).
single diode (2 pins) in the following manner. q Change in the indicated value: Conti-
a The continuity direction of an assembled-type nuity established (normal) (Note)
diode is as shown in the diagram below. Note: A silicon diode shows a value between
a The continuity direction of a single diode is 400 and 600.
shown on the diode surface.
2. When using analog type circuit tester

1) Switch the testing mode to resistance range.
2) Check the needle swing in case of the fol-
lowing connections.
i) Put the red probe (+) of the test lead
to the anode (P) and the black probe
(–) to the cathode (N) of diode.
ii) Put the red probe (+) of the test lead
to the cathode (N) and the black
probe (–) to the anode of diode.
3) Determine if a specific diode is good or no
good by the way the needle swings.
q If the needle does not swing in Case i),
but swings in Case ii): Normal (but the
breadth of swing (i.e. resistance value)
1. When using digital type circuit tester will differ depending on a circuit tester
1) Switch the testing mode to diode range type or a selected measurement range)
and confirm the indicated value. q If the needle swings in either case of i)
a Voltage of the battery inside is dis- and ii): Defective (short-circuited inter-
played with conventional circuit testers. nally)
2) Put the red probe (+) of the test lead to the q If the needle does not swing in any
anode (P) and the black probe (–) to the case of i) and ii): Defective (short-cir-
cathode (N) of diode, and confirm the dis- cuited internally)
played value.
26 PC1250-8R
PC1250-8R 27
SEN02074-02

© 2007 KOMATSU
All Rights Reserved
28
SEN02075-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Special function of machine monitor ............................................................................................................... 2
Handling controller voltage circuit ................................................................................................................. 42
PC1250-8R 1
Special function of machine monitor 1
[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 PC1250-8R
Machine monitor functions – conventional and special

The machine monitor is provided with conventional and special functions, and various kind of information are
shown in the display. Display items consists of automatic display items that are preset in the machine moni-
tor and others that are shown by switch operations.
1. Conventional function: Operator's Menu

This is a function by which an operator can set or show displays by switch operations. The display con-
tents are those which are normally shown.
2. Special function: Service Menu

This is a function by which a service mechanic can set or show displays by special switch operations.
The display contents are those which are not normally shown. It is mainly used for inspection, adjust-
ment, troubleshooting or special setting of machines.
Operator's Menu Service Menu

1 Password input and setting function 16 Function for monitoring [01]
2 Function for showing KOMATSU logo Function for failure Electrical system
17
3 Function for check before starting history [02] Mechanical system
4 Function for showing machine maintenance 18 Function for maintenance history [03]
5 Function for showing caution items 19 Function for maintenance mode change [04]
Function for confirming working mode and travel 20 Function for recording phone No. [05]
6
speed Mode with key on
7 Function for display of ordinary items Language
Function for default set-
Function for adjusting display luminance and con- 21
8 ting [06] Unit
trast
Wiper select
9 Function for confirming maintenance information
22 Function for adjustment [07]
10 Function for showing service meter reading
23 Function for reduced cylinder mode operation [08]
11 Function for checking display LCD
24 Function of no injection cranking [09]
12 Function for showing occurrence of caution item
25 Function of snap shot [10] (VHMS specification)
13 Function for showing action code No.
14 Function for showing failure code No.
Function of reversing fan rotation and adjusting
15
economy mode value
PC1250-8R 3
Operation of operator's menu and display

(outline)
a This section introduces only the outline of the

operator's menu. For details on the contents and
operation steps of each menu, refer to the opera-
tion and maintenance manual or the chapter of
“Structure and function” in this shop manual.
1. Password input and setting function

Displays the password input screen as the
starting switch is turned ON.
a Above display is available only when the
password function is selected.
4. Function for showing machine maintenance
Following the display of machine inspection
before starting day's work, the maintenance
mark appears for 30 seconds, if there is an oil
filter whose maintenance time is approaching
or has just passed.
a This display appears only when the main-
tenance function is set.
2. Function for showing KOMATSU logo

When the engine starting switch is turned ON,
KOMATSU logo is shown for 2 seconds.
5. Function for showing caution items

If there is any item of machine inspection
before starting day's work that indicates some
abnormality, a corresponding symbol mark is
shown after the display of machine inspection
before starting day's work.
3. Function for check before starting

Following the KOMATSU logo, the display of
machine inspection before starting day's work
is shown for 2 seconds.
4 PC1250-8R
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.
9. Function for confirming maintenance infor-

7. Function for display of ordinary items mation
The display of confirming working mode and Detailed information on maintenance items
travel speed is switched to this display of ordi- (set time and elapse of time) can be confirmed
nary items. and resetting after the confirmation is feasible
a If the working mode setting or travel speed by operating the maintenance switch.
setting is changed, or auto-deceleration or a Use Service Menu for setting or releasing
windshield wiper setting is activated while maintenance items and setting mainte-
this is in display, an amplified correspond- nance time.
ing symbol mark is shown for 2 seconds.
a In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
PC1250-8R 5
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.
11. Function for checking display LCD

Display of the Display LCD can be confirmed
by the following switching operation in the dis-
play of ordinary items
q Switching operation: [ ] + [A] (synchro-
nized switching operation)
a All the LCD light up, turning the entire
screen white. If there is no showing in
black, the display is normal.
a This display returns to the immediately
preceding one, if making any other switch-
ing operation.
6 PC1250-8R
13. Function for showing action code No.

When a trouble occurs on the machine, the
user's code is automatically displayed depend-
ing on the magnitude of the trouble to call
attention of the operator for a proper action.
a Operating any switch while an action code
is on the screen, switch the failure code
display screen (See Item 14).
a Action codes and instructions given to operator

Action
Failure mode Instructions given to operator
code
If the drive switch of the emergency pump is turned on, the
E02 Error in pump control system machine can operate normally.
Have it inspected immediately, however.
E03 Error in swing brake system Have the machine inspected immediately.
Error in engine controller power supply system
E10 Abnormality in engine controller drive system Have the machine inspected immediately.
circuit (engine stop)
Error in engine controller system Set the machine in a safe position and have the machine
E11
(Engine protection output down) inspected immediately.
Set the machine in a safe position and have the machine
E14 Error is throttle system
inspected immediately.
Error in engine sensor (coolant temperature, Ordinary operation is possible. Have the machine inspected
E15
fuel temperature and oil pressure) immediately, however.
Set the machine in a safe position and have the machine
E0E Error in network
inspected immediately.
PC1250-8R 7
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
(2) Telephone No.
(3) Failure code No.
8 PC1250-8R
Failure code table
Action Failure Component in

Trouble (Displayed on screen) Category of record
code code charge
— A000N1 Eng. Hi Out of Std MON Mechanical system
— AA10NX Aircleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng. Oil Press. Low MON Mechanical system
— B@BAZK Eng. Oil Level Low MON Mechanical system
— B@BCNS Eng. Water Overheat MON Mechanical system
— B@BCZK Eng. Water Lvl Low MON Mechanical system
— B@CBNS [n5 o 61] High PTO temperature VHMS —
— B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 ECM Critical Internal Failure ENG Electrical system
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
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle 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
— CA234 Eng Overspeed ENG Mechanical 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
E11 CA271 IMV/PCV1 Short Error ENG Electrical system
E11 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA273 PCV2 Short Error ENG Electrical system
E11 CA274 PCV2 Open Error ENG Electrical system
E11 CA322 Inj #1(L#1) Open/Short Error ENG Electrical system
PC1250-8R 9

code code charge
E10 CA342 Calibration Code Incompatibility ENG Electrical system
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E10 CA441 Battery Voltage low error ENG Electrical system
E10 CA442 Battery Voltage high error ENG Mechanical 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
E15 CA553 Rail Press High Error ENG Electrical system
— CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error 1 ENG Electrical system
E11 CA689 Eng Ne Speed Sensor 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
E0E CA1633 KOMNET Datalink Timeout 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 2 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
— D110KB Battery Relay Drive S/C PUMP Electrical system
— D163KB Flash Light Relay S/C PUMP Electrical system
— D195KB Step Light Relay S/C PUMP Electrical system
— DA22KK Pump controller PUMP Electrical system
— DA25KP Press. Sensor Power Abnormality PUMP Electrical system
— DA2SKQ Model selection Abnormality PUMP Electrical system
— DA80MA Auto. Lub. Abnormal PUMP Mechanical system
E0E DA2RMC Pump Comm. Abnormality PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality PUMP Electrical system
— DBB0KK [n9 o 01] VHMS source voltage Error VHMS —
— DBB0KQ [nf o 11] VHMS Connector Mismatch VHMS —
— DBB3KK [n9 o 05] Abnormality in VBAT voltage (VHMS VBAT < 10V) VHMS —
— DBB5KP [n9 o 04] VHMS 5V source sys Error VHMS —
— DBB6KP [n9 o 02] VHMS 24V source sys Error VHMS —
— DBBQKR [n8 o 02] KOM-NET/c error VHMS —
10 PC1250-8R

code code charge
— DGE5KB Ambi. Temp. Sensor S/C PUMP Electrical system
— DGH2KB Hydr. Oil Temp. Sensor S/C PUMP Electrical system
— DGT3KZ [n5 o 01] PTO Temp Sensor Failure VHMS —
— DGT4KA [n3 o 12] F Exhaust Temp. Sensor Failure VHMS —
— DGT4KB [n3 o 11] F Exhaust Temp. Sensor Failure VHMS —
— DGT5KA [n3 o 22] R Exhaust Temp. Sensor Failure VHMS —
— DGT5KB [n3 o 21] R Exhaust Temp. Sensor Failure VHMS —
— DHE5KB [n3 o 22] Blowby Pres. Sensor Failure VHMS —
— DHE5KY [n3 o 31] Blowby Pres. Sensor Failure VHMS —
— DHPAMA F Pump P.Sensor Abnormality PUMP Electrical system
— DHPAZL F Pump Relief Pressure Abnormality PUMP Electrical system
— DHPBMA R Pump P.Sensor Abnormality PUMP Electrical system
— DHPBZL R Pump Relief Pressure Abnormality PUMP Electrical system
— DHPTKA [n5 o 23] Fan Pump Pre. Sens Failure VHMS —
— DHPTKB [n5 o 24] Fan Pump Pre. Sens Failure VHMS —
— DV20KB Travel Alarm S/C PUMP Electrical system
— DW41KA Swing Priority Sol. Disc. PUMP Electrical system
— DW41KB Swing Priority Sol. S/C PUMP Electrical system
— DW43KA Travel Speed Sol. Disc. PUMP Electrical system
— DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C PUMP Electrical system
— DW48KA CO Cancel Sol. Disc. PUMP Electrical system
— DW48KB CO Cancel Sol. S/C PUMP Electrical system
— DW7BKA Fan Reverse Sol. Disc. PUMP Electrical system
— DW7BKB Fan Reverse Sol. S/C PUMP Electrical system
— DW91KA Straight Travel Sol. Disc. PUMP Electrical system
— DW91KB Straight Travel Sol. S/C PUMP Electrical system
— DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system
— DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E11 DX16KA Fan Pump EPC Sol. Disc. PUMP Electrical system
E11 DX16KB Fan Pump EPC Sol. S/C PUMP Electrical system
E02 DXA0KA TVC Sol. Disc. PUMP Electrical system
E02 DXA0KB TVC Sol. S/C PUMP Electrical system
— DY20KA Wiper Working Abnormality PUMP Electrical system
— DY20MA Wiper Parking Abnormality PUMP Electrical system
— DY2CKB Washer Drive S/C PUMP Electrical system
— DY2DKB Wiper Drive (For) S/C PUMP Electrical system
— DY2EKB Wiper Drive (Rev) S/C PUMP Electrical system
PC1250-8R 11

code code charge
— F@BBZL [n3 o 38] High Blowby Pressure VHMS —
— F@BYNR [n3 o 62] High F cyl. Exhaust Temp. 2 VHMS —
— F@BYNS [n3 o 61] High F cyl. Exhaust Temp. 1 VHMS —
— F@BZNR [n3 o 72] High R cyl. Exhaust Temp. 2 VHMS —
— F@BZNS [n3 o 71] High R cyl. Exhaust Temp. 1 VHMS —
— F@HCMA Swing Pump Pres. Sen. Abnormality PUMP Electrical system
— F@HCZL Swing Pump Relief Pres. Abnormality PUMP Electrical system
— J100KA [n5 o 11] Cnt. Pump Pre. Sens Failure VHMS —
— j100KA [n5 o 21] Fan Pump Pre. Sens Failure VHMS —
— J100KB [n5 o 12] Cnt. Pump Pre. Sens Failure VHMS —
— j100KB [n5 o 22] Fan Pump Pre. Sens Failure VHMS —
— J100L6 [n5 o 71] Abnomal Cnt. gear pump press VHMS —
— j100L6 [n5 o 81] Abnomal Fan gear pump press VHMS —
— LA10ZL [n5 o 25] Fan Pump Relief Press Abnormality VHMS —
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 PC1250-8R
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
4] If the [ ] switch is pressed, the screen

to wait for change of the fan rotation
direction appears and the engine speed
is lowered to low idle automatically.
After about 15 seconds, the fan rotation
is reversed. After 4 seconds, the engine
speed returns to the level before the
[ ] switch was pressed.
2] Select “1” Fan rotation reversing and

press the [ ] switch, and the follow-
ing screen appears.
a The fan mark is green.
3] When reversing the fan rotation, a The fan speed is in proportion to
press the [ ] switch. the engine speed. If the engine
speed is low idle, the fan speed
is MIN.
To i n c r e a s e t h e f a n s p e e d ,
increase the engine speed with
the fuel control dial.
a When reversing the fan rotation
while the engine is stopped, turn
the starting switch to the START
position after the above screen
appears. (This screen does not
change until the engine is
started. When stopping reversing
the fan rotation, turn the starting
switch to the OFF position.)
PC1250-8R 13
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.
3] If the [ ] switch is pressed, the

6] If any trouble occurs while the fan is screen to wait for change of the fan
rotating in reverse, the following rotation direction appears and the
warning monitor is displayed. In this engine speed is lowered to low idle
case, see the page of explanation of automatically. After about 15 sec-
the monitoring items and take neces- onds, the fan rotation is returned to
sary remedy. the normal direction. After 4 seconds,
the engine speed returns to the level
before the [ ] switch was pressed.
2) Returning fan rotation to normal direction

1] Press switch [5] of the panel.
14 PC1250-8R
4] If the fan rotation is returned to the

normal direction, the initial screen
appears automatically.
3) Adjusting economy mode value

1] In the screen of 2)-1], select “2” E
mode and press the [ ] switch, and
Remarks the following screen appears.
1) The screen in 2)-1] may not change to the
screen in 2)-2] but the following screen
may appear and the fan rotation may not
be reversed.
a The fan mark is blue.
a The economy mode can be set to 4

levels of E0, E1, E2, and E3 as
shown above.
(It is set to E0 when delivered.)
2] While watching the economy mode
2) This state shows that reversing of the fan adjusting menu, press the [E] or [R]
rotation is prohibited to protect the compo- switch of the panel to select E0 – E3
nents under some conditions of coolant tem- and press the [ ] switch.
perature and hydraulic oil temperature.
a To reverse the fan rotation in this
state, press the [ ] switch to return
the screen to the normal screen and
lower the engine speed to low idle or
stop the engine to warm up (cool
down) the engine.
If the coolant temperature and
hydraulic oil temperature gauges are
in the range shown below, the fan
rotation can be reversed.
Perform the procedure from 2)-1].
q (a): Coolant temperature
q (b): Hydraulic oil temperature
PC1250-8R 15
3] The relationship between the value

and production is as follows.
Fuel
Production
consumption
E0 Initial value
E1 Economy adjustment 1
Good Little
a As the value is increased to [E3

side], the fuel consumption is
reduced and the production is
also reduced.
16 PC1250-8R
Operation and display of service menu 3) Showing Service Menu display

The display is changed to the initial dis-
Way of switching to Service Menu play of Service Menu program. Select an
a When using Service Menu, change the display appropriate item from among the menu.
to Service Menu display through the following a You may enter a 2-digit code with the
special operation. numeral input switches to select the
1) Confirmation of display record of that code and confirm it with
Confirm that the display of ordinary items [ ].
is shown.
a Changing to Service Menu cannot be
made from displays other than this.
No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
2) Switch operation 02 Abnormality Record
Operate the switch as instructed below. 03 Maintenance Record
q Switch operation: [E] + [1] o [2] o [3]
04 Maintenance Mode Change
(Enter a figure, depressing [E])
05 Phone Number Entry
06 Default
07 Adjustment
08 Cylinder cut out
09 No injection cranking
10 Function of snap shot (VHMS specification)
4) Termination of Service Menu function

When terminating the initial display or any
subsequent display of Service Menu, do
that through any one of the following
methods.
[1] Depress [ ] switch. (This method may
be used for terminating any display)
[2] If “Return” switch is shown, depress it.
[3] If “Return” menu is shown, call that
menu and depress [ ] switch.
PC1250-8R 17
16. Function for monitoring [01] a A monitoring item can be set in any num-
The machine monitor monitors signals from an ber between the min. one to the max. four.
assortment of switches, sensors and actuators (Depending upon the selected item, the
installed in various parts of the machine. Moni- max. number is less than four)
tored information can be put in display or con- a In case of monitoring 1 to 3 items, move to
firmed on a real time basis through the the monitored information display through
following operations. any of the following switch operations,
after the registration work has been com-
1) Selection of menu pleted.
Select “01 Monitoring” in the initial display q Keep [ ] switch depressed. (For
of Service Menu and depress [ ] switch. about 3 seconds)
q Select Menu 99999 and depress [ ]
switch.
a The display automatically moves to the
display of monitored information, when all
of the registrable items have been duly
registered.
a Monitored information are transmitted via
communication circuits. Thus the number
of selected items can impact the commu-
nication speed. If truly real time monitoring
is required, reduce the selected items to
the minimum.
a For details on the monitoring items, dis-
play unit, etc., refer to the Table for Moni-
toring Items.
2) Setting of monitoring item
i] Select or register an item to be moni- 3) Monitoring operation
tored through the following switch Call the monitoring information display
operation. and confirm the monitored information,
q [E] switch: Selection while operating the machine.
q [R] switch: Selection
q [ ] switch: Registration
ii] Selection with numeral keys:
Input a 5-digit code to select the item
of that code directly and depress [ ]
switch.
18 PC1250-8R
4) Monitored information holding function

If [E] switch is depressed while monitor-
ing, all the monitored information are put
on hold. If [R] switch is depressed in this
condition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change set-
tings of working mode, travel speed and
auto-decel while monitoring, depress the
corresponding switch, then the mode con-
firmation display is shown.
a When a specific setting is confirmed,

depress [ ] switch, then the display
returns to that of monitoring.
a In case a specific setting has been
changed while monitoring, the new
setting is still maintained when return-
ing from Service Menu to Operator's
Menu after the monitoring is finished.
PC1250-8R 19
Monitoring items list

Code Unit (Default: ISO)
Monitoring item Remarks
No. ISO meter inch
00000 Return (Not displayed) Ending menu
99999 To Display Screen (Not displayed) Display execution menu
00200 Controller Model Select Numeral
00201 Machine ID Numeral
01002 Engine Speed r/min rpm rpm
01601 2nd Eng Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm 2
Psi
01101 R Pump Pressure MPa kg/cm 2
Psi
09000 Swing Pump Pressure MPa kg/cm 2
Psi
04107 Coolant Temperature °C °C °F
14200 Fuel Temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
37502 Ambient Temperature °C °C °F
01300 TVC Sol. Curr mA mA mA
31623 Fan Pump EPC Sol. Curr mA mA mA
03200 Battery Voltage V V V
03203 Battery Power Supply V V V
04300 Battery Charge Vol. V V V
01006 Engine Speed r/min rpm rpm
37200 Engine Oil Pressure kPa kg/cm 2
Psi
36400 Rail Pressure MPa kg/cm 2
Psi
37400 Ambient Pressure kPa kg/cm 2
Psi
18400 Intake Temperature °C °C °F
18500 Charge Temperature °C °C °F
36500 Boost Pressure kPa kg/cm2 Psi
36700 Engine Torque Ratio % % %
18700 Engine Output Torque Nm Nm kgfm
01112 F Pump Pres. Sensor Vol. V V V
01113 R Pump Pres. Sensor Vol. V V V
09005 Swing Pump Pressure Sensor Voltage V V V
03000 Fuel Dial Pos Sens Volt V V V
04200 Fuel Level Sensor Vol. V V V
04105 Coolant Temp Sens Volt V V V
14201 Fuel Temp. Sensor Vol. V V V
04402 Hydr. Temp. Sensor Vol. V V V
37503 Ambi. Temp. Sensor Vol. V V V
37201 Eng Oil Press Sens Volt V V V
37401 Ambient Press Sens Volt V V V
18401 Intake Temp Sens Volt V V V
18501 Charge Temp Sens Volt V V V
36501 Charge Press Sens Volt V V V
36401 Rail Pressure Sens Volt V V V
17201 PCV Close Timing CA CA CA
20 PC1250-8R

No. ISO meter inch
17500 Engine Power Mode — — —
31701 Throttle Position % % %
31706 Final Throttle Position % % %
18600 Inject Fueling Command mg/st mg/st mg/st
36200 Rail Press Command MPa kg/cm 2
PSi
36300 Injection Timing Command CA CA CA
37300 Fuel Rate (Note 1) L/h L/h L/h
01602 2nd Eng. Speed Command % % %
13113 Main Pump Absorb Torque Nm kgm Ibft
13114 Fan Pump Absorb Torque Nm kgm Ibft
13112 Total Pump Absorb Torque Nm kgm Ibft
Swing Display of ON/OFF
Travel Display of ON/OFF
Boom Lower Display of ON/OFF
01900 Pressure Switch 1
Boom Raise Display of ON/OFF
Arm Curl Display of ON/OFF
Arm Dump Display of ON/OFF
Bucket Curl Display of ON/OFF
Bucket Dump Display of ON/OFF
01901 Pressure Switch 2
Service Display of ON/OFF
Left Travel Display of ON/OFF
02301 Hydraulic Drive Fan Reverse Display of ON/OFF
Straight Travel Display of ON/OFF
Swing Brake Display of ON/OFF
Swing Priority Display of ON/OFF
02300 Solenoid 1
2-Stage Relief Display of ON/OFF
Travel Speed Display of ON/OFF
CO Cancel Display of ON/OFF
Lever SW Display of ON/OFF
02200 Switch Input 1 Swing Release SW Display of ON/OFF
Swing Brake S Display of ON/OFF
Model Select 1 Display of ON/OFF
02201 Switch Input 2 Model Select 4 Display of ON/OFF
Low Viscosity Fuel Display of ON/OFF
Overload Alarm Effective Display of ON/OFF
02202 Switch Input 3 Key Switch (AAC) Display of ON/OFF
Step Light SW Display of ON/OFF
02203 Switch Input 4
Horn SW Display of ON/OFF
Over Load Sensor Display of ON/OFF
05500 Sensor Input 1
Auto Greasing Display of ON/OFF
03700 Controller Output 1 Batt. Relay Dr. Display of ON/OFF
PC1250-8R 21

No. ISO meter inch
Step L. Relay Display of ON/OFF
03701 Controller Output 2 Flush L. Relay Display of ON/OFF
Travel Alarm Display of ON/OFF
Key Switch Display of ON/OFF
Start Display of ON/OFF
04500 Monitor Input 1 Preheat Display of ON/OFF
Light Display of ON/OFF
Rad. Level Display of ON/OFF
Aircleaner Display of ON/OFF
04501 Monitor Input 2 Eng. Oil Level Display of ON/OFF
Battery Charge Display of ON/OFF
Swing Brake SW. Display of ON/OFF
Bzzr Cancel SW. Display of ON/OFF
Window Limit SW. Display of ON/OFF
04502 Monitor Input 3
W Limit SW. Display of ON/OFF
Upper P Limit SW. Display of ON/OFF
Lower P Limit SW. Display of ON/OFF
20216 ECM Build Version — — —
20217 ECM CAL Data Ver. — — —
18900 ECM Internal Temp °C °C °F
20400 ECM Serial No. — — —
20227 Assembly No. (Monitor) — — —
20403 Serial No. (Monitor) — — —
20200 Monitor Prog. Version — — —
20229 Assembly No. (Pump controller) — — —
20403 Serial No. (Pump controller) — — —
20230 Program No. (Pump controller) — — —
20212 Pump Con. Prog. Version — — —
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 “Unit” in the “Default” function of the Service Menu.
a “CA” of the unit of display denotes the crankshaft angle.
Note 1: The momentary fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio
(Since it is a theoretical value, it is a little different from the actual fuel consumption ratio).
22 PC1250-8R
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.
a You may enter a 2-digit code with the 4) Information shown in display of Failure
numeral input switches to select the History in the mechanical systems
record of that code and confirm it with [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”.
No. Abnormality Record Submenu

Return
00
(termination of Abnormality Record)
01 Electrical Systems
02 Mechanical Systems
PC1250-8R 23
5) Resetting Electrical Systems ii) Operate the switch, following the

a Resetting Electrical Systems (dele- instructions shown in the resetting
tion) is possible only with the electri- display.
cal system. The failure history in the a When resetting specific informa-
mechanical system cannot be reset. tion only, call the display of that
a For resetting any specific or all infor- specific information and reset it
mation in the Electrical Systems, fol- with either [E] switch or [R]
low the operation explained below. switch.
a When resetting all the informa-
tion, a display of any information
will do.
i) Through the following switch opera-

tion, call the resetting display in the
display of Electrical Systems.
q Switch operation: [E] + [1] o [2]
o [3]
a This is the same switch operation

in changing the display to Service
Menu.
24 PC1250-8R
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 play of Maintenance Mode Change
Selecting Menu.
3) You may enter a 2-digit code with the
numeral input switches to select the
record of that code and confirm it with [ ].
PC1250-8R 25
5) Set contents of individual items

No. Maintenance mode change item
[1]: Default: The maintenance time set in
Return (Termination of maintenance the monitor (recommended by the
00
mode change) manufacturer and cannot be changed).
01 Maintenance Mode On/Off [2]: Set: Maintenance time that can be
02 Engine Oil Exch. Int. freely set. The maintenance mode
program functions based on this
03 Engine Oil Filter Exch. Int.
maintenance time. (The maintenance
04 Fuel Main Filter Exch. Int. time can be increased or decreased
41 Fuel Pre Filter Change Int. by 50 hours with [E] or [R] switch)
05 Hydr. Oil Filter Exch. Int. [3]: On: Maintenance display function with
this instruction becomes effectual.
06 H/Tank Breather Exch. Int.
[4]: Off: Maintenance display with this
07 Corro. Resis. Exch. Int. instruction becomes ineffectual.
08 PTO Oil Service Int. a The lowest maintenance time is 50 h.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Pilot Filter Exch. Int.
13 Drain Filter Exch. Int.
14 Use Default Values
a 01 and 14 menus are provided for setting

the whole maintenance mode, while those
from 02 through 13 are for setting individ-
ual items.
4) Contents of Maintenance Mode On/Off
q Use: The maintenance display function
6) Set contents of “Use Default Values”
of all oil and filter-related items are
When selecting this menu and depressing
turned effectual. (Irrespective of
the switch [ ], all individual time settings
whether “On” or “Off” set for individual
are reduced to the initial settings.
items, this setting prevails)
q Do not use: The maintenance display
function of all oil and filter-related items
are turned ineffectual. (Irrespective of
whether “On” or “Off” set for individual
items, this setting prevails)
26 PC1250-8R
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.
21. Function for default setting [06]

It is possible to change the following settings for
2) Changing the display the machine monitor as well as the machine.
Select Entry next to change the display to Make a change as is required.
the Phone Number Entry display. q Working mode when the engine starting
a Even if a Phone number is already switch is in the ON position.
inputted, it is deleted, upon switching q Display language in Service Menu
to the Phone Number Entry display. q Display unit in the monitoring function
q Setting of double wiper or single wiper
Select 06 “Default menu” in the initial dis-
play of Service Menu, and depress [ ]
switch.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone Num-
ber Entry display. (Entry automatically
begins with a cursor at the left end)
i) Enter a number into a cursor at the
left end with a ten-key.
ii) Depress [ ] switch when all the num-
bers have been entered.
PC1250-8R 27
2) Selection of submenu q Default Value: If this mode is set, the

Select an item to change from the sub- machine ramps up with the default
menu, and depress [ ] switch. mode (P mode) that was originally set
3) You may enter a 2-digit code with the at the time of delivery from the factory.
numeral input switches to select the 5) Function for AA/Language
record of that code and confirm it with [ ]. In Service Menu, the language in use can
be changed between Japanese and
English.
a English is used as the language for
default setting in the machine monitor.
a If the machine monitor for spare parts
is to be used in a Japanese-speaking
region or organization, change the
language from English to Japanese,
using this function.
No. Default submenu

00 Return
01 Key-on Mode
02 Language
03 Unit
04 Wiper Select
05 All Default Value
4) Function for Key-on Mode 6) Function for unit selection

When the engine starting switch is turned As the unit to be used in the monitoring
ON, a working mode can be set that is function display of Service Menu, three
shown in the machine monitor. kinds of unit are provided.
a Unit used for default setting in the
machine monitor is SI, i.e. Interna-
tional System of Units.
q P Mode, E Mode, Swing Priority Mode

OFF/ON: If any of them is set, the
machine always ramps up with that
working mode, when turning the engine
starting switch ON.
q Mode at Previous Key-off: If this mode
is set, the machine ramps up with the
working mode that was last used in the
previous machine operation.
28 PC1250-8R
7) Function for selection of wiper specification 2) Selection of sub menu

The wiper specification can be set. Select the sub menu to check the setting
q One wiper: Machine with standard cab and press the [ ] switch.
or fixed-front window cab 3) You may enter a 2-digit code with the
(Only upper wiper) numeral input switches to select the
q Two wipers:Machine with fixed-front record of that code and confirm it with [ ].
window cab (if equipped)
(Upper wiper and lower wiper)
a If this setting is not matched to the
specification of the actually installed
wiper, the wiper may not operate nor-
mally or an error is detected.
No. Sub menu of adjustment

00 Return (Finish adjustment)
01 Pump Absorption Torque
4) Function of pump absorption torque

22. Function for adjustment [07] The pump absorption torque can be
(Serial number: 35001 – 35016) adjusted in the following ranges.
The machine can be adjusted with the a Basically, this setting does not need
machine monitor. to be changed.
Select “07 Adjustment” on the service
menu and press the [ ] switch.
Adjustment value Pump absorption torque

220 +98.1 Nm {+10.0 kgm}
221 +73.5 Nm {+7.5 kgm}
222 +49.0 Nm {+5.0 kgm}
223 +24.5 Nm {+2.5 kgm}
224 0.0 Nm {0.0 kgm}
225 –24.5 Nm {–2.5 kgm}
226 –49.0 Nm {–5.0 kgm}
227 –73.5 Nm {–7.5 kgm}
228 –98.1 Nm {–10.0 kgm}
PC1250-8R 29
22. Function for adjustment [07] 4) Function of pump absorption torque

(Serial number: 35017 and up) The pump absorption torque can be
The machine can be adjusted with the adjusted in the following ranges.
machine monitor. a Basically, this setting does not need
to be changed.
Select “07 Adjustment” on the service
menu and press the [ ] switch.
Adjustment
Pump absorption torque
value
220 +98.1 Nm {+10.0 kgm}
2) Selection of sub menu
221 +73.5 Nm {+7.5 kgm}
Select the sub menu to check the setting
and press the [ ] switch. 222 +49.0 Nm {+5.0 kgm}
3) You may enter a 2-digit code with the 223 +24.5 Nm {+2.5 kgm}
numeral input switches to select the 224 0.0 Nm {0.0 kgm}
record of that code and confirm it with [ ].
225 –24.5 Nm {–2.5 kgm}
226 –49.0 Nm {–5.0 kgm}
227 –73.5 Nm {–7.5 kgm}
228 –98.1 Nm {–10.0 kgm}
No. Sub menu of adjustment

00 Return (Finish adjustment)
01 Pump Absorption Torque
02 Fan Speed Mode Select
03 Fan 100% Speed Adjust
04 Fan 70% Speed Adjust
30 PC1250-8R
5) Fan speed mode selection function 6) Fan 100% speed adjustment function
i] The fan speed mode during the nor- After “100% speed” is set in 4) above, the
mal operation is “550”. When adjust- fan speed can be adjusted within the fol-
ing the fan 100% speed mode, lowing range.
however, select fan 100% speed a Standard specification: 975 ± 50 rpm
mode “552” and then carry out the (at hydraulic oil temperature 50°C)
operation of 5). a 55°C specification: 1,075 + 50/0 rpm
ii] Fan 70% speed mode “551” is used (at hydraulic oil temperature 50°C)
for only the inspection for regulation a For measurement procedure of the
in the factory. When adjusting the fan fan speed, see “Testing and adjust-
70% speed mode, select “551” and ing, Part 3, Measuring fan speed”.
then carry out the operation of 6).
Adjustment
Fan 100% Speed
No. Fan speed mode selection value
Normal mode: For normal oper- 560 + 105 rpm
550
ation 561 + 90 rpm
70% speed mode: For check of 562 + 75 rpm
551
meeting of regulations
563 + 60 rpm
100% speed mode: For fan
552 564 + 45 rpm
speed adjustment
565 + 30 rpm
a If the starting switch is turned OFF,
the fan speed mode returns to “550: 566 + 15 rpm
Normal mode”. 567 0
Keep the starting switch ON while 568 – 15 rpm
adjusting the fan speed.
569 – 30 rpm
56A – 45 rpm
56B – 60 rpm
56C – 75 rpm
56D – 90 rpm
56E – 105 rpm
a The set value is kept even after the
starting switch is turned OFF.
a After finishing adjustment of the fan
speed, return the fan speed mode of
4) to normal mode “550” or turn the
starting switch OFF.
PC1250-8R 31
7) Fan 70% speed adjustment function 23. Function of reduced cylinder mode operation
After “70% speed” is set in 4) above, the [08]
fan speed can be adjusted within the fol- The reduced cylinder mode can be controlled
lowing range. with the machine monitor.
Reduced cylinder mode operation means to
run the engine with 1 or more fuel injectors dis-
abled electrically to reduce the number of
effective cylinders. This operation is used to
find out a cylinder which does not output power
normally (or, combustion in it is abnormal).
Select “08 Cylinder cut out” on the initial
screen of the service menu and press the
[ ] switch.
Adjustment
Fan 70% Speed
value
570 + 105 rpm
571 + 90 rpm
572 + 75 rpm
573 + 60 rpm
574 + 45 rpm
575 + 30 rpm
576 + 15 rpm
577 0 2) Setting of cylinders to be disabled
578 – 15 rpm
Press switches [1] – [6] on the machine
monitor corresponding to the cylinder Nos.
579 – 30 rpm to be disabled.
57A – 45 rpm a After a switch is pressed, if the cylin-
57B – 60 rpm der No. corresponding to it on the
57C – 75 rpm
machine monitor is displayed white in
a white frame, the cylinder is disabled
57D – 90 rpm (If setting is wrong, press the same
57E – 105 rpm switch again).
a The set value is kept even after the a Only one or more cylinders can be
starting switch is turned OFF (only disabled for the reduced cylinder
when the fan is set in the 70% speed mode operation.
mode).
a After finishing adjustment of the fan
speed, return the fan speed mode of
4) to normal mode “550” or turn the
starting switch OFF.
32 PC1250-8R
4) Function of holding engine speed

If the [E] switch is pressed while the
reduced cylinder mode operation screen
is used, the engine speed is held and dis-
played on the lower line.
If the [R] switch is pressed while the
engine speed is held, holding of the
engine speed is cancelled and the engine
speed displayed on the lower line goes off.
a If the holding function is used, the
held engine speed is displayed in ( )
on the lower line and the current
engine speed is displayed on the
upper line.
a The holding function can be used both
3) Cancellation of disabled cylinders in and out of the reduced cylinder
Press switches [1] – [6] on the machine mode.
monitor corresponding to the disabled cyl-
inder Nos. to cancel disabling of those cyl-
inders.
a After a switch is pressed, if the cylin-
der No. corresponding to it on the
machine monitor is displayed black in
a black frame, disabling of the cylin-
der is cancelled.
PC1250-8R 33
[Reference]: How to use holding function 24. Function of no injection cranking [09]
effectively No injection cranking of the engine is available
The engine speed displayed by the hold- from the machine monitor.
ing function is held on the screen until the No injection cranking denotes stopping injec-
holding function is cancelled, regardless tion of fuel from the injector even if the engine
of setting and cancellation of the reduced is run from the starting motor. This mode is
cylinder mode. Accordingly, a defective used, for instance, for measurement of com-
cylinder can be found out effectively pressive pressure.
according to the following procedure. a This setting must be done after stopping
(1) Run the engine normally (without dis- the engine.
abling any cylinder) and hold the
engine speed. 1) Selecting menu
(2) Disable a cylinder to be checked. Select “09 No Injection Cranking” from the
(3) Run the engine under the same con- service menu initial screen and press [ ]
dition as the normal operation in step switch.
(1) and compare the engine speed at
this time with the held engine speed.
(4) If there is not a difference between
the current engine speed and the held
engine speed in step (3), cancel the
reduced cylinder mode.
(5) Repeat steps (2) – (4) to check the
other cylinders.
2) The initial screen for the no injection

cranking will appear.
a “Check Communication” will be dis-
played in red.
34 PC1250-8R
3) As the checkup is over, following screen 6) From this state, crank the engine using
appears. the starting motor.
a Limit the cranking time to 20 seconds
to protect the starting motor.
4) Select “No Injection” and press [ ] switch.

“Under Preparation” will be displayed on
the screen. 7) After the no injection cranking is over,
a The letters “Under Preparation” are press [ ] switch from the previous screen
displayed in red. and the letters “End” will be displayed for 3
seconds.
a The letters “End” are displayed in
green.
5) As the preparation for no injection crank-

ing is completed, display of “Under Prepa-
ration” is replaced with “After No
Injection”.
a The letters “After No Injection” are
displayed in green.
PC1250-8R 35
8) Press “Return” when ending the no injection 25. Snap shot function [10] (VHMS specification)
cranking. The VHMS specification has the manual snap
a If the no injection cranking function is shot function and automatic snap shot function.
inadvertently selected while the While the manual snap shot function is turned
engine is running, “Engine Running” ON, various data in 7 minutes 30 seconds for
will appear as No Injection in step 4) the Pm clinic, testing, and adjusting can be
is selected. This “Engine Running” saved in the VHMS controller by operating the
display remains on the screen even machine monitor.
after the engine is stopped. Restoring While the automatic snap shot function is
the service menu screen alone turned ON, if an item which the VHMS control-
deletes the display. ler monitors constantly becomes abnormal (if
the corresponding failure code is displayed),
the snap shot data of that item in 7 minutes 30
seconds are saved in the VHMS controller.
Manual snap shot function

a To collect data periodically for the Pm
clinic, the machine must be operated as
specified by the Quick Pm. When data are
required and collected for testing, adjust-
ing, etc., however, the operations of the
machine are not limited.
a To use the data saved with the manual
snap shot function, a personal computer
must be connected. For the procedure for
connecting the personal computer, see
“Pm Clinic”. (The personal computer may
be connected either before or after the
snap shot operation.)
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.
36 PC1250-8R
a When collecting data for the Pm 4) Finishing snap shot operation

clinic, operate the machine according If the screen shown at right appears 7
to the procedure of Quick Pm (See minutes 30 seconds after the snap shot is
“Pm Clinic”). started, the snap shot is finished.
a When collecting data for testing and a The initial screen of the service menu
adjusting, perform necessary opera- appears automatically 5 seconds after
tions of the machine (See “Corre- the snap shot operation is finished.
sponding testing and adjusting”).
a The data of 36 items are recorded
and saved for 7 minutes 30 seconds
after the “ ” switch is pressed.
a The data are recorded at the intervals
of 10 seconds for the first 5 minutes
and at the intervals of 1 second for 2
minutes 30 seconds after the 5 min-
utes.
a To interrupt the snap shot operation,
press the “ ” switch.
a If the snap shot operation is inter-
rupted, the data collected up to now
are not recorded. Take care.
PC1250-8R 37
5) Data items of manual snap shot function

No. Item Contents Unit
1 Time Elapsed time sec
2 Eng Speed Engine speed rpm
3 Fuel Inject Engine fuel injection rate mm3/st
4 Blowby Press Engine blow-by pressure mmAq
5 Boost Press Engine boost pressure mmHg
6 Eng Oil Temp Engine oil temperature degC
7 Eng Oil Press Engine oil pressure kg/cm2
8 F Exh Temp Engine exhaust temperature (Front) degC
9 R Exh Temp Engine exhaust temperature (Rear) degC
10 Eng Cool Temp Engine coolant temperature degC
11 Rail Press Engine fuel rail pressure kg/cm2
12 Ambient Temp Ambient temperature degC
13 F Pump Press Front pump pressure kg/cm2
14 R Pump Press Rear pump pressure kg/cm2
15 Swing Pump Pres Swig pump pressure kg/cm2
16 G1 Pump Press [kg/cm2] Gear pump pressure for driving A/A fan kg/cm2
17 G2 Pump Press [kg/cm2] Gear pump pressure for pilot kg/cm2
18 Fan Pump Press Fan pump pressure kg/cm2
19 Hydr Oil Temp Hydraulic oil temperature degC
20 TVC Amp TVC current mA
21 Throt Position [%] Fuel dial (Full: 100%) %
22 PTO Temp PTO oil temperature degC
23 PPC Boom Raise ON Boom RAISE oil pressure switch on-off
24 PPC Boom Lower ON Boom LOWER oil pressure switch on-off
25 PPC Arm IN ON Arm IN oil pressure switch on-off
26 PPC Arm OUT ON Arm OUT oil pressure switch on-off
27 PPC Bucket Curl ON Bucket CURL oil pressure switch on-off
28 PPC Bucket Dump ON Bucket DUMP oil pressure switch on-off
29 PPC RH Travel ON Right travel oil pressure switch on-off
30 PPC LH Travel ON Left travel oil pressure switch on-off
31 PPC Swing ON Swing oil pressure switch on-off
32 Straight Travel Valv Straight travel solenoid valve on-off
33 Main Relief Valve 2-stage relief solenoid valve on-off
34 CO Cancel Valve CO cancel solenoid valve on-off
35 Swing Brake Valve Swing holding brake solenoid valve on-off
36 Swing Priority Valve Swing priority solenoid valve on-off
38 PC1250-8R
6) Example of snap shot data

The following figure shows an example of engine speed data displayed on a personal computer.
a The starting point of the snap shot on the personal computer is always –330 sec (in both man-
ual and automatic modes).
Automatic snap shot function

1) Operation of snap shot function
Since the VHMS controller automatically
performs the automatic snap shot function
according to the monitoring item data, the
operator does not need to operate the
monitor.
2) How to collect snap shot data
If the value of a monitoring item data
becomes abnormal, that data is recorded
and saved for 7 minutes 30 seconds from
5 minutes 30 seconds ago.
and at the intervals of 1 second for
the 2 minutes 30 seconds after the 5
minutes.
PC1250-8R 39
Auto snap shot monitoring items

Monitoring item Failure code Service limit
A000N1 Above 2,625 rpm
Engine overspeed
CA234
Below straight line connecting following points
• Engine speed of 600 rpm and oil pressure of 50 kPa {0.5 kg/cm2}
• Engine speed of 1,000 rpm and oil pressure of 90 kPa {0.9 kg/cm2}
Low engine oil pressure BABAZG • Engine speed of 1,500 rpm and oil pressure of 150 kPa {1.53 kg/cm2}
Common rail pressure is kept above 190 MPa {1,940 kg/cm2} for 1 sec-
CA449
ond
High common rail pressure
Common rail pressure is kept 10 MPa {102 kg/cm2} above specified
CA553
pressure for 10 seconds
Common rail pressure is kept 10 MPa {102 kg/cm2} below specified
CA559
Low supply pump pressure
Common rail pressure is kept 10 MPa {102 kg/cm2} below specified
CA2249
DHPAZL
High pump relief pressure DHPBZL Kept above 37.3 MPa {380 kg/cm2} for 5 seconds
F@HCZL
High PTO temperature B@CBNS Kept above 125°C for 1 second
When engine speed is above 1,750 rpm and hydraulic oil temperature
is above 50°C,
Abnormal gear pump pressure • Gear pump pressure is kept below 2.8 MPa {29 kg/cm2} for 5 sec-
J100L6
(for pilot) onds
• Gear pump pressure is kept above 3.7 MPa {38 kg/cm2} for 5 sec-
onds
When engine speed is above 1,750 rpm and hydraulic oil temperature
is above 50°C,
Abnormal gear pump pressure • Gear pump pressure is kept below 4.9 MPa {50 kg/cm2} for 5 sec-
j100L6
(for A/A fan drive) onds
• Gear pump pressure is kept above 22.5 MPa {230 kg/cm2} for 5 sec-
onds
When engine speed is below 1,400 rpm, temperature is kept above
F@BYNS
750°C for 20 seconds
Kept above straight line connecting following 2 points for 20 seconds
• Engine speed of 1,400 rpm and temperature of 750°C
F@BZNS • Engine speed of 1,800 rpm and temperature of 700°C
When engine speed is above 1,800 rpm, temperature is kept above
High exhaust temperature
When engine speed is below 1,400 rpm, temperature is kept above
F@BYNR
Kept above straight line connecting following 2 points for 10 seconds
• Engine speed of 1,400 rpm and temperature of 800°C
F@BZNR • Engine speed of 1,800 rpm and temperature of 750°C
When engine speed is above 1,800 rpm, temperature is kept above
High blow-by pressure F@BBZL Above 12.9 kPa {1320 mmAq}
High engine coolant temperature F@BCNS Kept above 105°C for 3 seconds
40 PC1250-8R
3) Example of snap shot data

The following figure shows an example of engine speed data displayed on a personal computer.
a The starting point of the snap shot on the personal computer is always –330 sec (in both manual
and automatic modes).
PC1250-8R 41
Handling controller voltage circuit 1

1. When disconnecting or connecting a connector
between the engine controller and engine, be
sure to turn the starting switch OFF.
2. If a T-adapter is inserted in or connected to a

connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
42 PC1250-8R
PC1250-8R 43
SEN02075-02

© 2007 KOMATSU
All Rights Reserved
44
SEN02076-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

VHMS controller initial setting procedure........................................................................................................ 2
Precautions for replacing VHMS controller ................................................................................................... 17
PC1250-8R 1
VHMS controller initial setting 1. Confirmation of machine information,

procedure 1 engine information, transmission controller
information and controller information
a Equipment used for VHMS controller initial set- a This confirmation procedure is targeted at
ting the entire machine.
Confirm and record the machine informa-
Symbol Part No. Part name tion, engine information, VHMS controller
799-608-3211 Diskette information and ORBCOMM terminal
1 information.
799-608-3220 Wiring harness
ZB Note type PC
Commercially No. Information to be confirmed
2 (Windows 98/2000/Me/XP),
available 1 Model name
with RS232C terminal
2 Machine serial No.
a Initial setting of VHMS controller shall be done 3 Current service meter hour
according to the following procedure. This
4 Engine serial No.
operation is needed prior to a full-scale opera-
tion of a machine being delivered and assem- 5 VHMS controller serial No.
bled in the field, or prior to resumption of its ORBCOM terminal serial No.
6
operation after a long time of storage. [Only for machines equipped with ORBCOMM]
a Machine data collected with VHMS controller
are stored and managed on WebCARE data- a VHMS controller (1) and ORBCOMM ter-
base. In order to endure smooth data process- minal (2) are installed in the rear under the
ing on WebCARE , consistency must be operator seat.
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. The ini-
tial setting, therefore, is a must.
a For the installation procedure of the VHMS ini-
tial setting program to a PC, refer to the opera-
tion and maintenance manual being bundled
with the service kit ZB1.
a In the procedure, service menus of the
machine monitor are used. Thus, it is advis-
able to reference the information contained in
the “Special functions of machine monitor” to
understand their procedure beforehand.
a The initial setting procedure is described in the
ORBCOMM installation specification and the
ORBCOMM-less specification. When using the
ORBCOMM installation specification, imple-
ment the procedures needed for VHMS alone,
bypassing those prepared only for ORBCOMM
installation specification.
a Check each step of the setting work referenc-
ing the VHMS initial setting work check sheet.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
2 PC1250-8R
2. Connecting a PC 3. Confirming VHMS controller operation and

a This work is done inside the cab. confirming satellite capturing state
1) Make sure the starting switch is at OFF a This work is done inside the cab.
position. a Confirmation of capturing of the satellite is
k Before connecting or disconnect- done for [ORBCOMM installation specifi-
ing a PC, be sure to turn off the cation].
starting switch. 1) Turn the starting switch ON.
2) Using harness [1] of service kit ZB1, con- 2) Check the controller for normal operation
nect the PC ZB2 and download connector referencing 7-segment LED of VHMS con-
VH13. troller.
a Then connect the PC to RS232C ter- a VHMS controller is fed with switch
minal. power supply. Thus, its operation is
judged normal if its 7-segment LED
starts flashing while rotating as the
starting switch is turned on and then if
the controller starts counting in the
ascending order.
a Download connector VH13 is

installed in the front side of the right
stand of operator seat.
3) Among the 7-segment LED situated in the

right side of VHMS controller, refer to the
one that represents the decimal point to
check whether or not ORBCOMM control-
ler has captured the communication satel-
lite. [ORBCOMM installation specification]
a Check whether or not ORBCOMM
controller is capturing the communi-
cation satellite from VHMS controller.
a It is successfully capturing the satel-
lite when the LED representing the
decimal point in the right side 7-seg-
ment LED is flashing.
PC1250-8R 3
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-
V IC E O PE RAT IO N T IP S S EK 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 PC1250-8R
4) When [Machine Information] information is [Communication Setting] [ORBCOMM installation

not appropriate, correct it in the following specification only]
manner. a This setting shall be implemented after the
1] Press [Edit] button in the lower right request for station opening has been made
side of [Machine Information] dialog and station of ORBCOMM has been opened.
box to display the correction screen. 6) Open [Communication Setting] tab.
2] After correcting it to the correct infor- 7) Check every data for correctness.
mation, press [OK] button.
5) As every data in [Machine Information]

has been checked and corrected, press
[Apply] button to settle the setting.
a As [Apply] button is pressed, a mes-
sage confirming above setting will
appear on the screen. Check the set- 8) When modifying the setting of [SHORT
ting again and, if the setting is correct, FAULT HISTORY], employ the following
press [OK] button. procedure.
a ORBCOMM installation specification 1] Select [SHORT FAULT HISTORY] from
requires the settlement operation after the screen and then press [Edit] button
[Communication Setting] is completed. in the lower left side of [File Transfer
Setting] block to display the setup
screen.
2] Correct the setting and, as it is com-
pleted, press [OK] button.
a In the initial setting, select [Occur-
rence] from [Timing] item and then
set the function to ON.
PC1250-8R 5
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.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
6 PC1250-8R
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.
a When VHMS has been installed later,

it is required to enter the information
such as [Serial No.].
2) Select [Set up & All clear] and press [Next]

button.
PC1250-8R 7
4) Select the time zone. 8) If there is no problem in the setting dis-

5) Enter the local time. played last, press [Apply] button.
6) When DST (Daylight Saving Time) (or
summer time) is currently used, press
[Next] button.
a Selecting DST advances the clock by
an hour. Thus, correction of the time
is needed again.
9) A screen message will confirm whether or

not the data before the setting is to be
saved. If the data is not necessary, select
[NO].
7) Set the GCC code to the target region of

application and, as setting is completed,
press [Next] button.
GCC codes and applicable regions

Code Applicable region Code Applicable region
1 America 122 Korea
120 Italy 123 Brazil
121 Malaysia 130 Japan
10) As correction of the first setting is com-

pleted, press [OK] button to end the pro-
gram.
8 PC1250-8R
7. Performing Quick Pm a If the snap shot operation is inter-

a Perform the following procedure in the cab. rupted, the data collected up to now
a The Quick Pm means the Pm clinic per- are not recorded. In this case, repeat
formed by using the snap shot (manual) the operation from the first.
function of the machine monitor.
1) Run the engine at low idle and set the
machine in the following position.
q Swing the boom 90° to right
(with the idler on the front side).
q Set the arm vertically.
q Lower the bucket bottom to the ground
and set it horizontally.
2) Set the switches and lever in the following
positions.
q Heavy lift switch: ON
q Auto-decelerator switch: ON
q Swing lock switch: OFF
q PCC lock lever: Free 6) Operate the fuel dial, swing lock switch,
3) Set the machine monitor to display the both work equipment control levers, and
service menu. both travel levers according to the “Oper-
a For the operating method, see “Spe- a t i n g p r oc e d u r e f or Q u i c k P m ” a n d
cial function of machine monitor”. elapsed time.
4) On the initial screen of the service menu, a The elapsed time is displayed on the
select “10 Snap shot” menu. machine monitor.
k Since the operator must operate
the work equipment, swing the
boom, and drive the machine actu-
ally for the Quick Pm, take extreme
care of safety around the machine
during the work.
5) Press the [ ] switch to start the snap shot

operation.
a Before starting the snap shot opera-
tion, understand the operating proce-
dure for the Quick Pm by referring to
“Operating procedure for Quick Pm”.
after the “ ” switch on the machine
monitor is pressed.
and at the intervals of 1 second for
the 2 minutes 20 seconds after the 5
minutes.
PC1250-8R 9
7) If the following screen appears 7 minutes

30 seconds after the snap shot is started,
the snap shot is finished.
a The initial screen of the service menu
appears automatically 5 seconds after
the snap shot operation is finished.
10 PC1250-8R
Operating procedure for Quick Pm

Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
• Engine speed (Low idle)
• Engine oil pressure (Low idle)
Start 0:00 –330.00
MIN • Engine coolant temperature
1 O O O OFF Set all levers in neutral.
(Low) • Hydraulic oil temperature
Finish 0:30 –300.00
• Outside temperature
• Control pump pressure (Low idle)
Start 0:30 –300.00
MAX Set all levers in neutral • Engine speed
2 O O O OFF
(High) (Turn decelerator on). (2nd deceleration speed)
Finish 1:00 –270.00
• Engine speed (High idle)
Start 1:00 –270.00 • Engine oil pressure (High idle)
MAX Move levers finely [Note]
3 O O O OFF • Control pump pressure (High idle)
(High) (Turn decelerator off).
Finish 1:30 –240.00 • Fan pump pressure
(Cooling fan, aftercooler fan)
Start 1:30 –240.00 Raise right-hand track
MAX • Front pump oil pressure
4 O O O OFF shoe and drive it idle
(High) (Hydraulic pressure)
Finish 2:30 –180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 –180.00
MAX Raise left-hand track shoe • Rear pump oil pressure
5 O O O OFF
(High) and drive it idle (Set lever (Hydraulic pressure)
Finish 3:30 –120.00
to stroke end).
Start 3:30 –120.00
MAX • Swing pump oil pressure
6 O O O ON R.H. swing relief.
(High) (Relief pressure)
Finish 4:00 0–90.00
Start 4:00 0–90.00
7 O O O ON L.H. swing relief.
Finish 4:30 0–60.00
Start 4:30 0–60.00
MAX • Front, rear, swing pump oil pressure
8 O O O ON Arm OUT relief.
(High) (Low relief pressure)
Finish 5:00 0–30.00
Start 5:00 0–30.00
MAX • Front, rear pump oil pressure
9 O O O ON Bucket DUMP relief.
Finish 5:30 0–00.00
Start 5:30 0–00.00
10 O O O ON Bucket CURL relief.
Finish 6:00 0–30.00
Start 6:00 0–30.00
11 O O O ON Arm IN relief.
Finish 6:30 0–60.00
• Front, rear, swing pump oil pressure
Start 6:30 0–60.00 (High relief pressure)
MAX
12 O O O ON Boom RAISE relief. • Engine speed
(High)
Finish 7:00 0–90.00 • Blow-by pressure, exhaust
temperature, PTO oil temperature
Start 7:00 0–90.00 Set all levers in neutral
MAX • Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 –120.00 deceleration)
MIN
14 — 7:30 –120.00 ON Finish
(Low)
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.)
PC1250-8R 11
8. Download of setting data a Enter [User Name] and [Password].

1) Using harness [1] of service kit ZB1, con- a For the operating procedure, see the
nect PC ZB2 to download connector DLF VHMS analysis tool operation and
in the cab or download connector VDL on maintenance manual.
the ground.
3) Using [Download] function, download the

data currently recorded on VHMS to PC.
a For the operating procedure, see the
a Download connector VH13 in the cab VHMS analysis tool operation and
is installed in the front side of the right maintenance manual.
stand of operator seat. a After making sure the download is
complete, proceed to the next step.
9. Confirmation of download data

1) Check the setting data using [View] function.
a For the operating procedure, see the
2) Operating [VHMS analysis tool] on PC, VHMS analysis tool operation and
start up the VHMS analysis tool. maintenance manual.
a Make sure that [MFA0] code, which
was used in the quick snapshot, is
indicated in [Fault History].
a Make sure the snap shot data are
recorded.
2) As check of the setting data is finished,

end [VHMS analysis tool].
12 PC1250-8R
10. Disconnecting the PC 11. Report to Komatsu

1) Make sure the starting switch is at OFF As steps 1 – 9 are completed, send VHMS/
position. WebCARE setting report to VHMS/WebCARE
k Before connecting or disconnect- Support Center in Komatsu Headquarters.
ing a PC, be sure to turn off the a This report is a must since setting on the
starting switch. receiving end in the satellite communica-
2) End the OS of PC ZB2 and then turn off tion must be done by Komatsu.
the PC power. a In this case, send VHMS data via Notes
(LAN) or E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
3) When the data was download into the cab,

disconnect harness [1] of service kit ZB1
from download connector VH13.
PC1250-8R 13
[For storage] Date of setting:

DB/branch
VHMS initial setting work check sheet office name
Data entered by:
Setup step Check item Result
Model name
Confirmation of machine body and Serial No.
1
component nameplates Engine serial No.
VHMS controller serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
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?
Is model name identical with machine body? yes no

Initial setting of VHMS controller
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
6 Saving of settings Is LED (7-segment) turned off? yes no
7 Confirmation of VHMS function Is LED operation normal? yes no
Is service mode "SNAPSHOT" turned on and is the

8 Execution of quick Pm yes no
switch hit?
9 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
10 Download Is LED operation normal? yes no
Are all files downloaded? yes no

Hour,
The time downloaded (Reference wrist watch)
minute:
[Confirmation of data]
11 Confirmation of download data
Is [MFA0] error present in Fault History? yes no
Are SMR and time in Fault History consistent with set-
yes no
tings?
Is any data missing in Snap Shot0? yes no
12 Data storing operation on VHMS Is LED (7-segment) turned off? yes no
14 PC1250-8R
[For storage] Date of setting:

DB/branch
ORBCOMM station opening work office name
check sheet Data entered by:
Setup step Check item Result
Model name
Serial No.
Confirmation of machine body and
1 Engine serial No.
component nameplates
VHMS controller serial No.
ORBCOMM terminal serial No.
Connection between PC and VHMS

2 Is the connection secure? yes no
controller
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
Entry of setting to S.Fault History

Initial setting of VHMS controller Presence/absence of communication On Off
1. Setting of communication
(Setting of machine body infor- Number of cases (Default is 8 cases)
mation and PLM are completed) Entry of setting of S.Trend Analysis setting
Presence/absence of communication On Off
Interval (Default is 20H)
5
Entry of setting of S.Payload data
Presence/absence of communication On Off
Tabulation start time
Interval of tabulation (in days) day
2. Setting for start of communica-
Is GCC code set? (130 for Japan) yes no
tion
6 Saving of settings Is LED (7-segment) turned off after data was stored? yes no
How is decimal point display in VHMS monitor

ORBCOMM controller performance
7 (7-segment)? yes no
check
(OFF, ON, long/short flashing)
PC1250-8R 15
16 PC1250-8R
Precautions for replacing VHMS 2. Confirmation, saving and loading of VHMS

controller 1 controller setting information (Ver. 3. 5. 2. 1
or older version)
a Care should be paid to the following equipment a This work is done inside the cab (from PC).
when replacing VHMS controller a Setting information is saved from the
VHMS controller to be replaced to the PC
Symbol Part No. Part name and the saved information is loaded to the
799-608-3211 Diskette new VHMS controller after the replace-
1 ment.
2-1. Confirmation and saving of VHMS controller
ZB Note type PC
Commercially setting information prior to replacement
2 (Windows 98/2000/Me/XP), 1) Connect the PC and start the VHMS initial
available
with RS232C terminal setting tool.
a See the “VHMS controller initial set-
a When it is required to replace a VHMS control- ting procedure” for this operation.
ler, setup of the replacing VHMS controller 2) Select [Save/Load] and press [OK] button.
shall be conducted before and after the
replacement according to the following proce-
dure.
a Machine data collected with VHMS controller
are stored and managed on WebCARE data-
base. In order to endure smooth data process-
ing on WebCARE , consistency must be
provided among the settings done on VHMS
controller. Inconsistencies in the settings
obstruct loading of data to WebCARE, ham-
pering appropriate use of VHMS data. Setting
work after replacement, therefore, is a must.
a Check each step of the setting work referenc-
ing the “VHMS initial setting work check
sheet”.
a Information such as models shown in the fig-
ures may not be identical with actual ones.
[Operations needed prior to replacement of

VHMS controller]
1. Download of the remaining data
a This work is done inside the cab (from PC).
a Using [Download] function, download the 3) Confirm every information before the
currently recorded and remained data on replacement.
VHMS to PC. 4) Select [Save] from [File] of the menu.
a For the operating procedure, refer to “8.
Download of setting data” in “VHMS con-
troller initial setting procedure”.
PC1250-8R 17
2-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
ting procedure” for this operation.
2) Select [Save/Load] and press [OK] button.
5) Reconfirm the information and then press

[OK] button to save the information.
3) Select [Load] from [File] of the menu.
6) Select [Exit] from [File] of the menu to end

the VHMS setting tool.
7) Disconnect the PC.
a Refer to “10. Disconnecting the PC” in
“VHMS controller initial setting proce-
dure”.
8) Turns the PC power off.
9) Proceed to replacement of VHMS control-
lers.
18 PC1250-8R
4) Currently saved information will be dis- 7) After adjusting time, press [OK] button.
played. Press [OK] button.
8) Press [Apply] button to display contents of

the setting. Check the setting again and, if
it is acceptable, press [OK] button.
5) Display the saved information on another

screen.
6) Press [Edit] button and adjust the time.
PC1250-8R 19
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.
2) Select [When VHMS needs to be replaced]
and then press [Next] button.
10) The setup result is displayed. Confirm the

contents and press [Close] button.
3) Select [Save current setting before

replacement of VHMS controller] and
press [Next] button.
11) Select [Exit] from [File] of the menu to end

the VHMS initial setting tool.
20 PC1250-8R
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.
3-2. Loading the setting information to the replacing

VHMS controller
1) Connect the PC again and start the VHMS
initial setting tool.
2) Select [When VHMS needs to be
replaced] and then press [Next] button.
5) Adjust the time and press [Apply] button.
PC1250-8R 21
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
2-3-6, Akasaka Minato-Ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

FAX: 03-5561-4766 (Domestic user)
E-mail: webcare@komatsu.co.jp
7) The above completes modification of the

setting. Press [OK] button to end the
VHMS initial setting tool.
22 PC1250-8R
SEN02076-00

© 2006 KOMATSU
All Rights Reserved
24
SEN02077-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Pm-clinic service ............................................................................................................................................. 2
PC1250-8R 1
Pm-clinic service 1
Inspection sheet for PC1250 (SP)-8R
PC1250-8R PC1250SP-8R
2 PC1250-8R
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
pressure
No. 1 & 2R CO-NC
pressure
No. 3 CO-NC
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.
PC1250-8R 3
6. Setting machine monitor

1) Set the machine monitor to select the
“Monitoring” items again.
2) Select and display the following monitor-
ing items.
q 01100 F pump pressure
q 01101 R pump pressure
q 09000 Swing pump pressure
7. Measuring items related to hydraulic equip-

ment and fan
Measure the items related to the hydraulic
equipment and fan (Items 4 and 5 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.
8. Stopping engine
Set the work equipment in the position for
measuring the hydraulic drift and stop the
engine.
9. Measuring and testing hydraulic drift of work

equipment and hydraulic oil return strainer
Measure and test the hydraulic drift of the work
equipment and hydraulic oil return strainer
(Items 6 and 7 on check sheet).
4 PC1250-8R
Installation positions of measuring instruments 1
PC1250-8R 5
Installation positions of measuring instruments 2
6 PC1250-8R
Procedure for measuring by Quick Pm 4. Measuring with snap shot function

1) Run the engine at low idle and set the
1. Preparation of measuring instruments machine in the following position.
Connect the instruments for measuring the Pm q Swing the boom 90° to right
clinic to the fan and hydraulic equipment. (with the idler on the front side).
a Referring to “Installation positions of mea- q Set the arm vertically.
suring instruments”, connect the measuring q Lower the bucket bottom to the ground
instruments shown in the following table. and set it horizontally.
a Record the measurement items other than 2) Set the switches and lever in the following
the following table in the VHMS controller positions.
with the snap shot function of the machine q Working mode switch: P-mode
monitor. q Heavy lift switch: ON
q Auto-decelerator switch: ON
No. Measurement item Measuring instrument q Swing lock switch: OFF
1 TVC pressure Pressure gauges group (60K) q Lock lever: Free
No. 1 & 2F CO-NC 3) Set the machine monitor to display the
2 Pressure gauges group (60K) service menu.
pressure
No. 1 & 2R CO-NC a For the operating method, see “Spe-
3 Pressure gauges group (60K) cial functions of machine monitor”.
pressure
4) On the initial screen of the service menu,
No. 3 CO-NC
4 Pressure gauges group (60K) select “10 Snap shot” menu.
pressure
5 Fan speed Multitachometer
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.
3. Checking engine coolant temperature and

hydraulic oil temperature
Check the engine coolant thermometer and
hydraulic oil thermometer.
a If the engine coolant temperature and the 5) Press the [ ] switch to start the snap shot
hydraulic oil temperature are low, warm up operation.
the machine until they are in the operating a Before starting the snap shot opera-
range. tion, understand the operating proce-
dure for the Quick Pm by referring to
“Operating procedure for Quick Pm”.
after the “ ” switch on the machine
monitor is pressed.
and at the intervals of 1 second for the
2 minutes 20 seconds after the 5 min-
utes.
PC1250-8R 7
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.
6) Operate the fuel dial, swing lock switch, both

work equipment control levers, and both
travel levers according to the “Operating 5. Measuring and testing items other than
procedure for Quick Pm” and elapsed time. snap shot items
a The elapsed time is displayed on the Measure and test the items that cannot be
machine monitor. measured and tested with the snap shot func-
k Since the operator must operate the tion according to the check sheet.
work equipment, swing the boom, 2-1: Visual inspection of strainer
and drive the machine actually for 3: Work equipment speed
the Quick Pm, take extreme care of 4-5: TVC pressure
safety around the machine during 4-6: Front CO-NC pressure
the work. 4-7: Rear CO-NC pressure
4-8: Swing CO-NC pressure
5-1: Fan speed
6: Hydraulic drift of work equipment
7: Hydraulic oil return strainer
6. Downloading snap shot data

a The following devices are necessary for
downloading and using the snap shot data.
799-608-3211 Diskette
1
W
Notebook personal computer
2 Purchased Part
(OS : Windows98/2000/Me/XP)
1) Check that the starting switch is in the OFF

position.
k When connecting and disconnect-
ing the personal computer, be sure
to turn the starting switch to the
OFF position.
8 PC1250-8R
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.
a Download connector VH13 is installed

to the back side of the right-hand con-
sole box.
5) Using the [Download] function, download

the snap shot data recorded in the VHMS
controller to the personal computer.
instruction manual for the VHMS
analysis tool.
a Before starting the next step, check
that downloading is completed.
6) Using the [Download] function, check the

downloaded snap shot data and enter the
necessary data in the check sheet.
instruction manual for the VHMS
analysis tool.
7) Check that the starting switch is in the
OFF position.
k When connecting and disconnect-
ing the personal computer, be sure
to turn the starting switch to the
OFF position.
8) Finish the operating system of personal
computer W2 and turn the personal com-
puter OFF.
PC1250-8R 9
Installation positions of measuring instruments
10 PC1250-8R
Operating procedure for Quick Pm

Time on Fuel Swing lock Data read in Pm clinic after data
No. Elapsed time Operation of lever
snap data dial switch are downloaded
• Engine speed (Low idle)
• Engine oil pressure (Low idle)
Start 0:00 –330.00
MIN • Engine coolant temperature
1 O O O OFF Set all levers in neutral.
(Low) • Hydraulic oil temperature
Finish 0:30 –300.00
• Outside temperature
• Control pump pressure (Low idle)
Start 0:30 –300.00
MAX Set all levers in neutral • Engine speed
2 O O O OFF
(High) (Turn decelerator on). (2nd deceleration speed)
Finish 1:00 –270.00
• Engine speed (High idle)
Start 1:00 –270.00 • Engine oil pressure (High idle)
MAX Move levers finely [Note]
3 O O O OFF • Control pump pressure (High idle)
(High) (Turn decelerator off).
Finish 1:30 –240.00 • Fan pump pressure
(Radiator fan, aftercooler fan)
Start 1:30 –240.00 Raise right-hand track
MAX • Front pump oil pressure
4 O O O OFF shoe and drive it idle
(High) (Hydraulic pressure)
Finish 2:30 –180.00 (Set lever to stroke end).
Swing 180°.
Start 2:30 –180.00
MAX Raise left-hand track shoe • Rear pump oil pressure
5 O O O OFF
(High) and drive it idle (Set lever (Hydraulic pressure)
Finish 3:30 –120.00
to stroke end).
Start 3:30 –120.00
6 O O O ON R.H. swing relief.
Finish 4:00 0–90.00
Start 4:00 0–90.00
7 O O O ON L.H. swing relief.
Finish 4:30 0–60.00
Start 4:30 0–60.00
8 O O O ON Arm OUT relief.
Finish 5:00 0–30.00
Start 5:00 0–30.00
MAX • Front, rear pump oil pressure
9 O O O ON Bucket DUMP relief.
Finish 5:30 0–00.00
Start 5:30 0–00.00
10 O O O ON Bucket CURL relief.
Finish 6:00 0–30.00
Start 6:00 0–30.00
11 O O O ON Arm IN relief.
Finish 6:30 0–60.00
• Front, rear, swing pump oil pressure
Start 6:30 0–60.00 (High relief pressure)
MAX
12 O O O ON Boom RAISE relief. • Engine speed
(High)
Finish 7:00 0–90.00 • Blow-by pressure, exhaust
temperature, PTO oil temperature
Start 7:00 0–90.00 Set all levers in neutral
MAX • Engine speed
13 O O O ON (1st deceleration o 2nd
(High) (1st deceleration speed)
Finish 7:30 –120.00 deceleration)
MIN
14 — 7:30 –120.00 ON Finish
(Low)
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.)
PC1250-8R 11
12 PC1250-8R
Measurement items
Auto- Standard value Service limit
Working Fuel Heavy Machine Swing 1. 2. 3. 4. 5. 6. 7. 8.
Inspection order and part to be inspected decele- Operation of levers for new machine value
mode dial lift pushup lock Front pump Rear pump Swing pump Control TVC Front CO-NC Rear CO-NC Swing CO-NC
ration MPa {kg/cm2} MPa {kg/cm2}
pressure pressure pressure pressure pressure pressure pressure pressure
PC1250-8R
MIN (Reference) (Reference)
1 P OFF OFF OFF OFF Set levers in neutral. 7.8-15.7 7.8-15.7
(Low) {80-160} {80-160}
Pilot relief valve
2 P (Full) OFF OFF OFF OFF Set levers in neutral. 32.9-35.3 31.8-35.3
{335-360} {325-360}
Pilot relief valve
3 E (Full) OFF OFF OFF OFF Set levers in neutral. 29.9-32.4 28.9-32.4
TVC valve {305-330} {295-330}
R.H. travel under no load.
4 Front CO-NC valve P (Full) OFF OFF OFF OFF 31.8-34.3 30.8-34.3
(Move lever to stroke end) {325-350} {315-350}
L.H. travel under no load. (Reference) (Reference)
5 Rear CO-NC valve P (Full) OFF OFF OFF OFF Min. 2.3 Min. 2.1
(Move lever to stroke end) {Min. 26} {Min. 21}
Main relief valve of R.H. 4-spool valve R.H. travel relief.

6 P (Full) OFF OFF OFF OFF 3.1-3.5 3.1-3.5
(High pressure relief) (Forward) {32.0-35.5} {32.0-35.5}
CO cancel solenoid R.H. travel relief.
7 PPC valve P (Full) OFF OFF OFF OFF 2.0-2.6 Min. 1.8
(Reverse) {20-26} {Min. 18}
L.H. travel relief. (Reference) (Reference)
8 Main relief valve of L.H. 5-spool valve P (Full) OFF OFF OFF OFF 1.6-2.2 Min. 1.4
(High pressure relief) (Forward) {16-22} {Min. 14}
CO cancel solenoid L.H. travel relief. (Reference) (Reference)
9 PPC valve P (Full) OFF OFF OFF OFF Max. 0.25 Max. 0.4
(Reverse) {Max. 2.6} {Max. 4.1}
Swing under no load.
10 Swing CO-NC valve P (Full) OFF OFF OFF OFF Min. 1.7 Min. 1.7
(Move lever to stroke end) {Min. 17} {Min. 17}
4. Hydraulic equipment
(Reference) (Reference)
11 P (Full) OFF OFF OFF ON R.H. swing relief. Max. 1.33 Max. 1.37
Swing motor safety valve {Max. 13.5} {Max. 14}
PPC valve (Reference) (Reference)
12 P (Full) OFF OFF OFF ON L.H. swing relief. 0.83-1.23 0.78-1.27
{8.5-12.5} {8.0-13.0}
13 P (Full) OFF OFF OFF OFF Arm OUT relief.
14 P (Full) OFF OFF OFF OFF Bucket DUMP relief.
Main relief valve (Low-pressure relief)

15 P (Full) OFF OFF OFF OFF Bucket CURL relief.
PPC valve
16 P (Full) OFF OFF OFF OFF Arm IN relief.
17 P (Full) OFF OFF OFF OFF Boom RAISE relief.
Main relief valve (High-pressure relief)

18 P (Full) OFF ON OFF OFF Boom RAISE relief.
PPC valve
13
14
Measurement items Condition Unit Standard value for new machine Service limit value Measurement result Good Bad
High idle (Operate the work equipment lever to the extent that the work equipment does r/min
1. Aftercooler fan speed {rpm} 1,138 – 1,438 (Reference value) 1,138 – 1,438 (Reference value)
not move).
High idle (Operate the work equipment lever to the extent that the work equipment does MPa 8.4 – 14.2 {85 – 145} 8.4 – 14.2 {85 – 145}
2. Aftercooler fan circuit oil pressure {kg/cm2}
not move). (Reference value) (Reference value)
High idle Standard specification 925 – 1,025 925 – 1,025
3. Cooling fan speed (Operate the work equipment lever to the extent that the work r/min
{rpm}
5. Fan
equipment does not move) (Fan 100% speed mode). 55˚C specification 1,075 – 1,125 1,075 – 1,125
High idle 11.8 – 20.6 {120 – 210} 11.8 – 20.6 {120 – 210}
Standard specification (Reference value) (Reference value)
4. Cooling fan circuit oil pressure (Operate the work equipment lever to the extent that the work MPa
{kg/cm2} 15.2 – 24.0 {155 – 245} 15.2 – 24.0 {155 – 245}
equipment does not move) (Fan 100% speed mode). 55˚C specification (Reference value) (Reference value)
6. Hydraulic drift of work equipment Whole work equipment, with no load mm Max. 650 Max. 1000
7. Hydraulic oil return strainer Visually check hydraulic oil return strainer. — — —
PC1250-8R
PC1250-8R 15
16 PC1250-8R
PC1250-8R 17
SEN02077-01

© 2007 KOMATSU
All Rights Reserved
18
SEN02078-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations................................................................................................................................................. 6
PC1250-8R 1
SEN02078-00 40 Troubleshooting
Failure code table 1

Action Failure Component in Reference
code code charge document No.
— A000N1 Eng. Hi Out of Std MON Mechanical system
— AA10NX Aircleaner Clogging MON Mechanical system
— AB00KE Charge Voltage Low MON Mechanical system
— B@BAZG Eng. Oil Press. Low MON Mechanical system
— B@BAZK Eng. Oil Level Low MON Mechanical system
— B@BCNS Eng. Water Overheat MON Mechanical system
— B@BCZK Eng. Water Lvl Low MON Mechanical system

B@CBNS
— High PTO temperature VHMS —
[n5 o 61]
— B@HANS Hydr. Oil Overheat MON Mechanical system
E10 CA111 ECM Critical Internal Failure ENG Electrical system
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
E14 CA131 Throttle Sensor High Error ENG Electrical system
E14 CA132 Throttle 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 Troubleshooting by
E15 CA145 Coolant Temp Sens Low Error ENG Electrical system failure code, Part 1
SEN02080-00
E15 CA153 Chg Air Temp Sensor High Error ENG Electrical system
E15 CA154 Chg Air Temp Sensor 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
— CA234 Eng Overspeed ENG Mechanical 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
E11 CA271 IMV/PCV1 Short Error ENG Electrical system
E11 CA272 IMV/PCV1 Open Error ENG Electrical system
E11 CA273 PCV2 Short Error ENG Electrical system
E11 CA274 PCV2 Open Error ENG Electrical system
2 PC1250-8R

E11 CA332 Inj #4(L#4) Open/Short Error ENG Electrical system Troubleshooting by
failure code, Part 1
E10 CA342 Calibration Code Incompatibility ENG Electrical system SEN02080-00
E10 CA351 Injectors Drive Circuit Error ENG Electrical system
E10 CA441 Battery Voltage low error ENG Electrical system
E10 CA442 Battery Voltage high error ENG Mechanical 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
E15 CA553 Rail Press High Error 1 ENG Electrical system
— CA554 Rail Press Sensor In Range Error ENG Electrical system
E15 CA559 Rail Press Low Error ENG Electrical system
E11 CA689 Eng Ne Speed Sensor 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
Troubleshooting by
E0E CA1633 KOMNET Datalink Timeout Error ENG Electrical system failure code, Part 2
SEN02081-00
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 2 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
— D110KB Battery Relay Drive S/C PUMP Electrical system
— D163KB Flash Light Relay S/C PUMP Electrical system
— D195KB Step Light Relay S/C PUMP Electrical system
— DA22KK Pump controller PUMP Electrical system
— DA25KP Press. Sensor Power Abnormality PUMP Electrical system
— DA2SKQ Model selection Abnormality PUMP Electrical system
— DA80MA Auto. Lub. Abnormal PUMP Mechanical system
E0E DA2RMC Pump Comm. Abnormality PUMP Electrical system
E0E DAFRMC Monitor Comm. Abnormality PUMP Electrical system

DBB0KK
— VHMS source voltage Error VHMS —
[n9 o 01]
DBB0KQ Troubleshooting by
— VHMS Connector Mismatch VHMS —
[nf o 11] failure code, Part 3
DBB3KK Abnormality in VBAT voltage SEN02082-00
— VHMS —
[n9 o 05] (VHMS VBAT < 10V)
DBB5KP
— VHMS 5V source sys Error VHMS —
[n9 o 04]
PC1250-8R 3

DBB6KP
— VHMS 24V source sys Error VHMS —
[n9 o 02]
DBBQKR
— KOM-NET/c error VHMS —
[n8 o 02]
— DGE5KB Ambi. Temp. Sensor S/C PUMP Electrical system
— DGH2KB Hydr. Oil Temp. Sensor S/C PUMP Electrical system

DGT3KZ
— PTO Temp Sensor Failure VHMS —
[n5 o 01]
DGT4KA
— F Exhaust Temp. Sensor Failure VHMS —
[n3 o 12]
DGT4KB
— F Exhaust Temp. Sensor Failure VHMS —
[n3 o 11]
DGT5KA
— R Exhaust Temp. Sensor Failure VHMS —
[n3 o 22]
DGT5KB
— R Exhaust Temp. Sensor Failure VHMS —
[n3 o 21]
DHE5KB
— Blowby Pres. Sensor Failure VHMS —
[n3 o 22]
DHE5KY
— Blowby Pres. Sensor Failure VHMS —
[n3 o 31]
Troubleshooting by
— DHPAMA F Pump P.Sensor Abnormality PUMP Electrical system failure code, Part 3
— DHPAZL F Pump Relief Pressure Abnormality PUMP Electrical system SEN02082-00
— DHPBMA R Pump P.Sensor Abnormality PUMP Electrical system
— DHPBZL R Pump Relief Pressure Abnormality PUMP Electrical system

DHPTKA
— Fan Pump Pre. Sens Failure VHMS —
[n5 o 23]
DHPTKB
[n5 o 24]
— DV20KB Travel Alarm S/C PUMP Electrical system
— DW41KA Swing Priority Sol. Disc. PUMP Electrical system
— DW41KB Swing Priority Sol. S/C PUMP Electrical system
— DW43KA Travel Speed Sol. Disc. PUMP Electrical system
— DW43KB Travel Speed Sol. S/C PUMP Electrical system
E03 DW45KA Swing Brake Sol. Disc. PUMP Electrical system
E03 DW45KB Swing Brake Sol. S/C PUMP Electrical system
— DW48KA CO Cancel Sol. Disc. PUMP Electrical system
— DW48KB CO Cancel Sol. S/C PUMP Electrical system
— DW7BKA Fan Reverse Sol. Disc. PUMP Electrical system
— DW7BKB Fan Reverse Sol. S/C PUMP Electrical system
— DW91KA Straight Travel Sol. Disc. PUMP Electrical system
— DW91KB Straight Travel Sol. S/C PUMP Electrical system Troubleshooting by

failure code, Part 4
— DWK0KA 2-stage Relief Sol. Disc. PUMP Electrical system SEN02083-00
— DWK0KB 2-stage Relief Sol. S/C PUMP Electrical system
E11 DX16KA Fan Pump EPC Sol. Disc. PUMP Electrical system
E11 DX16KB Fan Pump EPC Sol. S/C PUMP Electrical system
4 PC1250-8R

E02 DXA0KA TVC Sol. Disc. PUMP Electrical system
E02 DXA0KB TVC Sol. S/C PUMP Electrical system
— DY20KA Wiper Working Abnormality PUMP Electrical system
— DY20MA Wiper Parking Abnormality PUMP Electrical system
— DY2CKB Washer Drive S/C PUMP Electrical system
— DY2DKB Wiper Drive (For) S/C PUMP Electrical system
— DY2EKB Wiper Drive (Rev) S/C PUMP Electrical system

F@BBZL
— High Blowby Pressure VHMS —
[n3 o 38]
F@BYNR
— High F cyl. Exhaust Temp. 2 VHMS —
[n3 o 62]
F@BYNS
— High F cyl. Exhaust Temp. 1 VHMS —
[n3 o 61]
F@BZNR
— High R cyl. Exhaust Temp. 2 VHMS —
[n3 o 72] Troubleshooting by
F@BZNS failure code, Part 4
— High R cyl. Exhaust Temp. 1 VHMS — SEN02083-00
[n3 o 71]
— F@HCMA Swing Pump Pres. Sen. Abnormality PUMP Electrical system
— F@HCZL Swing Pump Relief Pres. Abnormality PUMP Electrical system

J100KA
— Cnt. Pump Pre. Sens Failure VHMS —
[n5 o 11]
j100KA
[n5 o 21]
J100KB
— Cnt. Pump Pre. Sens Failure VHMS —
[n5 o 12]
j100KB
[n5 o 22]
J100L6
— Abnomal Cnt. gear pump press VHMS —
[n5 o 71]
j100L6
— Abnomal Fan gear pump press VHMS —
[n5 o 81]
LA10ZL
— Fan Pump Relief Press Abnormality VHMS —
[n5 o 25]
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.
PC1250-8R 5
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.
Type of power Circuit breaker Circuit breaker

Destination of power
supply No. capacity
1 40A Fuse box (Fuses No. 1 – 14)
2 40A
Switch power supply 3 40A
(Battery relay 4 20A Machine monitor
terminal M) 5 20A Lamp switch
6 20A Pump controller (Solenoid power source)
7 20A Lamp relay
8 20A Pump controller and starting switch
Constant power 9 20A Engine controller
supply
10 20A Machine monitor
(Battery relay
terminal B) 11 20A Fuse box (Fuses No. 16 – 20)
12 20A Priming pump
6 PC1250-8R
Connection table of fuse boxes

a This connection table shows the devices to which each power supply of the fuse boxes 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 fuse boxes to see if the
power is supplied normally.
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 10 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
PC1250-8R 7
SEN02078-00

© 2006 KOMATSU
All Rights Reserved
8
SEN02079-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
General information on troubleshooting
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
Connection table for connector pin numbers .................................................................................................11
T- branch box and T- branch adapter table ................................................................................................... 47
PC1250-8R 1
Points to remember when troubleshooting 1

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
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.
1. When carrying out troubleshooting, do not 3. Check before troubleshooting

hurry to disassemble the components. 1) Is there any sign of irregularities of the
If components are disassembled immediately machine?
any failure occurs: 2) Make checks before starting day's work.
q Parts that have no connection with the fail- 3) Make checks of other items.
ure or other unnecessary parts will be dis- 4) Other maintenance items can be checked
assembled. externally, so check any item that is con-
q It will become impossible to find the cause sidered to be necessary.
of the failure. 4. Confirming failure
It will also cause a waste of manhours, parts, Confirm the extent of the failure yourself, and
or oil or grease, and at the same time, will also judge whether to handle it as a real failure or
lose the confidence of the user or operator. For as a problem with the method of operation, etc.
this reason, when carrying out troubleshooting, a When operating the machine to reenact
it is necessary to carry out thorough prior the troubleshooting symptoms, do not
investigation and to carry out troubleshooting carry out any investigation or measure-
in accordance with the fixed procedure. ment that may make the problem worse.
2. Points to ask user or operator 5. Troubleshooting

1) Have any other problems occurred apart Use the results of the investigation and inspec-
from the problem that has been reported? tion in Items 2 – 4 to narrow down the causes
2) Was there anything strange about the of failure, then use the troubleshooting table or
machine before the failure occurred? troubleshooting flowchart to locate the position
3) Did the failure occur suddenly, or were of the failure exactly.
there problems with the machine condition a The basic procedure for troubleshooting is
before this? as follows.
4) Under what conditions did the failure 1] Start from the simple points.
occur? 2] Start from the most likely points.
5) Had any repairs been carried out before 3] Investigate other related parts or
the failure? information.
When were these repairs carried out?
6) Has the same kind of failure occurred 6. Measures to remove root cause of failure
before? Even if the failure is repaired, if the root cause
of the failure is not repaired, the same failure
will occur again.To prevent this, always investi-
gate why the problem occurred. Then, remove
the root cause.
2 PC1250-8R
Sequence of events in troubleshooting 1
PC1250-8R 3
Checks before troubleshooting 1

Item Criterion Remedy
1. Check of level and type of fuel — Add fuel
2. Check of fuel for foreign matter — Clean and drain
3. Check of fuel filter — Replace
4. Check of hydraulic oil level — Add oil
Lubricating 5. Check of hydraulic oil strainer — Clean and drain

oil, Coolant 6. Check of swing machinery oil level — Add oil
7. Check of level and type of engine oil (in oil pan) — Add oil
8. Check of coolant level — Add coolant
9. Check of dust indicator for clogging — Clean or replace
10. Check of hydraulic oil filter — Replace
1. Check of battery terminals and wiring for looseness
— Retighten or replace
and corrosion
Electrical 2. Check of alternator terminals and wiring for looseness
equipment and corrosion
3. Check of starting motor terminals and wiring for loose-
ness and corrosion
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 PC1250-8R
Classification and troubleshooting steps 1

Classification of troubleshooting
Mode Contents
Display of code Troubleshooting by failure code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
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”.
PC1250-8R 5
Failure-looking Phenomenon and Troubleshooting No.
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 PC1250-8R
Troubleshooting
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
PC1250-8R 7
Troubleshooting
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 PC1250-8R
Information in troubleshooting table 1
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
Cause Standard value in normal state/Remarks on troubleshooting

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>

• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Ground fault
2 Wiring harness which is not connected to chassis ground circuit is in
contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24 V) circuit
Possible Possible causes of trou- is in contact with power source (24 V) circuit.
causes and ble
standard value (Given numbers are
3
in normal state reference numbers, <Precautions for troubleshooting>
which do not indicate (1) Method of indicating connector No. and handling of T-adapter
priority) Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
• If connector No. has no marks of “male” and “female”, disconnect
connector and insert T-adapters in both male side and female side.
4 • If connector No. has marks of “male” and “female”, disconnect
connector and connect T-adapter to only male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as explained
below for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or wiring harness entered on front
5 side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
PC1250-8R 9
Related circuit diagram
This drawing is a part of the electric circuit diagram related to troubleshooting.

• Connector No.: Indicates (Model – Number of pins) and (Color).
• (Arrow): Roughly shows the location on the machine.
10 PC1250-8R
Connection table for connector pin numbers (Rev. 2007.10)
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
PC1250-8R 11
12 PC1250-8R
PC1250-8R 13
14 PC1250-8R
PC1250-8R 15
16 PC1250-8R
PC1250-8R 17
18 PC1250-8R
PC1250-8R 19
20 PC1250-8R
PC1250-8R 21
22 PC1250-8R
PC1250-8R 23
24 PC1250-8R
PC1250-8R 25
26 PC1250-8R
PC1250-8R 27
28 PC1250-8R
PC1250-8R 29
30 PC1250-8R
PC1250-8R 31
32 PC1250-8R
PC1250-8R 33
34 PC1250-8R
PC1250-8R 35
36 PC1250-8R
PC1250-8R 37
38 PC1250-8R
PC1250-8R 39
40 PC1250-8R
PC1250-8R 41
42 PC1250-8R
PC1250-8R 43
44 PC1250-8R
PC1250-8R 45
46 PC1250-8R
T- branch box and T- branch adapter table 1

(Rev. 2007.8)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 • Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3510 Adapter for BENDIX (MS) 5 MS-5S q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
PC1250-8R 47
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
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
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
48 PC1250-8R
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
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
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
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* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280 Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
“*” Shows not T-adapter but socket.
PC1250-8R 49
SEN02079-02

© 2007 KOMATSU
All Rights Reserved
50
SEN02080-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
Troubleshooting by failure code
(Display of code), Part 1
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
PC1250-8R 1
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 [CA342] Calibration Code Incompatibility ................................................................................. 66
Failure code [CA351] Injectors Drive Circuit Error ........................................................................................ 68
2 PC1250-8R
Failure code [A000N1] Eng. Hi Out of Std 1
Action code Failure code Eng. Hi Out of Std

Trouble
— A000N1 (in VHMS controller system)
Contents of
• While the engine was running, engine speed of 2,625 rpm or higher was detected.
trouble
Action of
• The machine is controlled as the default model.
controller
Problem that
appears on • If the machine is used as it is, the engine may be broken.
machine
• The failure codes of the VHMS system are not recorded in the failure history of the machine moni-
Related tor.
information • The 7-segment LED of the VHMS controller displays n2 o 01 (displays the code 2 characters by 2).
• The engine speed can be checked in the monitoring function (Code 01002: Engine speed).

Overrun of engine
Check for external and internal factors that can make the engine overrun,
1 (While system is nor-
then perform troubleshooting for the mechanical system.
mal)
Possible
causes and Engine speed sensor
2 Perform troubleshooting for failure code [C115KZ] or [C121LC].
standard value defective
in normal state a Turn the engine starting switch ON (monitoring) for the preparations,
VHMS controller and run the engine during the troubleshooting.
3
defective Monitoring code Engine Engine speed
01002 High idle 2,000 ± 40 rpm
PC1250-8R 3
Failure code [AA10NX] Aircleaner Clogging 1
Action code Failure code Aircleaner Clogging

Trouble
— AA10NX (mechanical system)
Contents of • While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e.
trouble disconnected from grounding circuit).
Action of
• None in particular
controller
Problem that
appears on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• If the red air cleaner clogging monitor of the machine monitor lights up while the engine is running,
Related this failure code is recorded.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the machine monitor.
(Code No. 04501: Monitor input 2)

Air cleaner clogged
Check the air cleaner for clogging. If it is clogged, clean or replace it with
1 (when the system is in
new one.
normal condition)
a Turn the engine starting switch OFF for the preparations, and keep the
engine running during the troubleshooting.
Air cleaner clogging
switch defective P11 (male) Air cleaner Resistance value
2
(Internal disconnec- When in normal
tion) Max. 1 z
Between (1) and (2) condition
Possible When clogged Min. 1 Mz

causes and a Turn the engine starting switch OFF for the preparations, and hold it
standard value Disconnection of wiring running during the troubleshooting.
in normal state harness
Wiring harness between P02 (female) (5) and Resistance
3 (Disconnection or Max. 1 z
P11 (female) (1) value
defective contact with
connector) Between wiring harness P11 (female) (2), J15 Resistance
Max. 1 z
and grounding value
Machine monitor P02 Air cleaner Voltage
4
defective When in normal
Between (5) and Max. 1 V
condition
grounding
When clogged 20 – 30 V
4 PC1250-8R
Electrical circuit for air cleaner clogging switch
PC1250-8R 5
Failure code [AB00KE] Charge Voltage Low 1
Action code Failure code Charge Voltage Low

Trouble
— AB00KE (in mechanical system)
Contents of
• Generation signal from the alternator is not inputted, while the engine is running.
trouble
Action of
controller
Problem that
• There is a possibility that the battery may not be charged, if charging is continued without correc-
appears on
tive action.
machine
• If the red charge level monitor of the machine monitor lights up while the engine is running, this fail-
Related ure code is recorded.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 04300: Charging voltage)

a Turn the engine starting switch OFF for the preparations, and hold it
Alternator defective running during the troubleshooting.
1 (short generating out- Alternator Engine rotation Voltage
put) Between terminal R and
Min. medium speed 27.5 – 29.5 V
grounding
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in
harness the OFF position during the troubleshooting.
2 (Disconnection or
Possible defective contact with Wiring harness from P02 (female) (11) to J02 to Resistance Max. 1 z
causes and connector) J21 to E08 alternator terminal R value
standard value
in normal state 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
3
(Contact with ground- Between wiring harness between P02 (female) Resistance
ing circuit) (11), J02, J21, E08 and alternator terminal R, Min. 1 Mz
value
other related circuits and grounding
Machine monitor
4 P02 Engine rotation Voltage
defective
Between (11) and
Min. medium speed 27.5 – 29.5 V
grounding
6 PC1250-8R
Electrical diagram related to charging voltage
PC1250-8R 7
Failure code [B@BAZG] Eng. Oil Press. Low 1
Action code Failure code

Trouble Eng. Oil Press. Low
— B@BAZG
Contents of • While engine was running, signal circuit of engine oil pressure switch detected low engine oil pres-
trouble sure (opening of sensor contact).
Action of • Displays engine oil pressure monitor of machine monitor.
controller • Sets oil pressure to default value (250 kPa {2.5 kg/cm2} and continues operation.
Problem that
appears on If machine is operated as it is, engine may be damaged.
machine
• Input (Voltage) from oil pressure sensor can be checked with monitoring function (Code: 37201).
Related • Signals of engine oil pressure switch are input to engine controller and then transmitted to machine
information monitor through communication system.
• Method of reproducing failure code: Start engine.

Defective sensor If code [CA187] or [CA227] is indicated, carry out troubleshooting for it
1
power supply system first.
a Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting.
Defective oil pressure POIL Voltage
2 sensor Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal trouble)
Sensor voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for another
cause of trouble, and then judge.
a Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Disconnection in wiring Wiring harness between ENG (female) (37) –
Possible Resistance Max. 1 z
harness POIL (female) (1)
causes and
3 (Disconnection in wir-
standard value Wiring harness between ENG (female) (47) –
ing or defective contact Resistance Max. 1 z
in normal state POIL (female) (2)
in connector)
Wiring harness between ENG (female) (13) –
Resistance Max. 1 z
POIL (female) (3)
Ground fault in wiring turning starting switch ON.
harness Wiring harness between ENG (female) (37) –
4 Resistance Min. 1 Mz
(Short circuit with GND POIL (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (13) –
Resistance Min. 1 Mz
POIL (female) (3) and chassis ground
Defective engine con- engine and carry out troubleshooting.
5
troller ENG Voltage
Between (37) – (47) Power supply 4.75 – 5.25 V
8 PC1250-8R
Circuit diagram related to engine oil pressure sensor
PC1250-8R 9
Failure code [B@BAZK] Eng. Oil Level Low 1
Action code Failure code Eng. Oil Level Low

Trouble
— B@BAZK (in mechanical system)
Contents of • The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding),
trouble when the engine is stopped (with the starting switch in the ON position).
Action of
controller
Problem that
appears on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• If the red engine oil level monitor of the machine monitor lights up while the engine is stopped (and
Related the starting switch is in the ON position), this failure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code
No. 04501: Monitor input 2)

Engine oil level low-
ered Check the engine oil level, and refill oil.
1
(System in normal con- (If the phenomenon occurs frequently, check the cause)
dition)
a Turn the engine starting switch OFF for the preparations, and hold it in
the OFF position during the troubleshooting.
Engine oil level switch
defective OLV (male) Engine oil level Resistance value
2
tion) Between (1) and Max. 1 z
Possible condition
grounding
causes and When lowered Min. 1 Mz
standard value Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state harness the OFF position during the troubleshooting.
3 (Disconnection or
defective contact with Wiring harness between P02 (female) (8) and Resistance
Max. 1 z
connector) OLV (female) (1) value
the ON position during the troubleshooting.
Machine monitor P02 Engine oil pressure Voltage
4
defective When in normal
condition
grounding
When lowered 20 – 30 V
Electrical diagram related to engine oil level switch
10 PC1250-8R
Failure code [B@BCNS] Eng. Water Overheat 1
Action code Failure code Eng. Water Overheat

Trouble
— B@BCNS (Engine controller system)
Contents of
• The signal circuit of the engine coolant temperature sensor detected temperature above 105°C
trouble
Action of
machine • Fixes coolant temperature (90°C) and continues operation.
monitor
Problem that
appears on • If machine is operated as it is, engine may be damaged.
machine
• Input from the engine coolant temperature sensor (temperature) can be checked with monitoring func-
tion
Related
(Code: 04107)
information
• Engine coolant temperature sensor signal is input to engine controller and then transmitted to
machine monitor.

Defective coolant tem- turning starting switch ON.
1 perature sensor (Inter- Coolant
TWTR (male) Resistance
nal trouble) temperature
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
Disconnection in wiring turning starting switch ON.
harness (Disconnec-
2 tion in wiring or defec- Resistance Max. 1 z
Possible TWTR (female) (A)
tive contact in
causes and connector) Wiring harness between ENG (female) (38) –
standard value Resistance Max. 1 z
TWTR (female) (B)
in normal state
Ground fault in wiring a Prepare with starting switch OFF, then carry out troubleshooting without
harness turning starting switch ON.
3
(Short circuit with GND Between wiring harness of ENG (female) (15) –
circuit) Resistance Min. 1 Mz
TWTR (female) (A) and chassis ground
Defective engine con- Engine coolant
4 ENG (female) Resistance
troller temperature
Between (15) – (38)
10 – 100°C 0.6 – 20 kz
chassis ground
12 PC1250-8R
Circuit diagram related to coolant temperature sensor
PC1250-8R 13
Failure code [B@BCZK] Eng. Water Lvl Low 1
Action code Failure code Eng. Water Lvl Low

Trouble
— B@BCZK (in mechanical system)
Contents of • The signal circuit in the radiator coolant level switch was opened (i.e. disconnected from ground-
trouble ing).
Action of
controller
Problem that
appears on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• If the red radiator coolant level monitor of the machine monitor lights up while the engine is running,
Related this failure code is recorded.
information • Input from the radiator coolant level switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 04500: Monitor input 1)

Radiator coolant level
lowered Check the coolant level and refill coolant.
1
(System in normal con- (If this phenomenon occurs frequently, check the cause)
dition)
Radiator coolant level
switch defective P08 (male), P20 (male) Engine coolant level Resistance value
2
tion) Max. 1 z
Between (1) and (2) condition
When lowered Min. 1 Mz
Possible a Turn the engine starting switch OFF for the preparations, and hold it in
causes and the OFF position during the troubleshooting.
standard value Disconnection of wiring Wiring harness between P02 (female) (3) and Resistance
in normal state harness Max. 1 z
3 (Disconnection or
Max. 1 z
connector) P08 (female) (1) value
Max. 1 z
grounding value
Engine coolant
Machine monitor P02 Voltage
4 temperature
defective
When in normal
condition
grounding
When lowered 20 – 30 V
14 PC1250-8R
Electrical diagram related to radiator coolant level switch
PC1250-8R 15
Failure code [B@CBNS] High PTO temperature 1
Action code Failure code High PTO temperature

Trouble
— B@CBNS (in VHMS controller system)
Contents of
• The signal circuit of the PTO oil temperature sensor detected temperature of 125°C or higher.
trouble
Action of
• None in particular.
controller
Problem that
appears on • If the machine is used as it is, the PTO may be broken.
machine
tor.
Related
• The 7-segment LED of the VHMS controller displays n5 o 61 (displays the code 2 characters by 2).
information
• The PTO oil temperature can be checked by performing the snap shot operation and downloading
the data to a personal computer.

Overheating of PTO oil
temperature
1 Check the PTO lubrication system, then repair it if abnormal.
(While system is nor-
mal)
PTO oil temperature VH09 (male) Oil temperature Resistance value

2 sensor system defec- 25°C 46 – 59 kz
tive Between (1) and (2)
100°C 3.6 – 4.0 kz
Between (1) and
— Min. 1 Mz
grounding
Possible Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in
causes and harness the OFF position during the troubleshooting.
standard value 3 (Disconnection or
in normal state defective contact in Wiring harness between VC2A (female) (2) and Resistance
Max. 1 z
connector) VH09 (male) (1) value
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
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 PC1250-8R
Electric diagram related to PTO oil temperature sensor
PC1250-8R 17
Failure code [B@HANS] Hydr. Oil Overheat 1
Action code Failure code Hydr. Oil Overheat

Trouble
— B@HANS (in mechanical system)
Contents of
• The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
trouble
Action of
controller
Problem that
appears on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• If the red hydraulic oil temperature monitor of the machine monitor lights up while the engine is run-
Related ning, this failure code is recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor func-
tion. (Code No. 04401: Hydraulic oil temperature)

Hydraulic oil overheat-
ing
1 Check the cause and damage to the hydraulic equipment, and repair it.
(System in normal con-
dition)
Hydraulic oil tempera- Hydraulic oil tempera-
ture sensor defective P10 (male) Resistance value
2 ture
(Internal short-circuit-
ing) Between (1) and (2) 90 – 3.5 kz
Possible Between (2) and 10 – 100°C
causes and Min. 1 Mz
grounding
standard value
in normal state Grounding fault of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness the OFF position during the troubleshooting.
3
ing circuit) Min. 1 Mz
(12) and P10 (female) (1) and grounding value
Engine coolant temper-
Machine monitor P02 (female) Resistance value
4 ature
defective
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Min. 1 Mz
grounding
Electrical diagram related to hydraulic oil temperature sensor
18 PC1250-8R
Failure code [CA111] ECM Critical Internal Failure 1
Action code Failure code ECM Critical Internal Failure

Trouble
E10 CA111 (Engine controller system)
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
information

Defective circuit
Circuit breaker may be defective. Check it directly.
1 breaker No.3 and
(If circuit breaker is turned OFF, circuit probably has ground fault.)
No.9.
harness
Wiring harness between CE03 (female) (3) – bat-
2 (Disconnection in wir- Resistance Max. 1 z
tery (+)
ing or defective contact
Possible in connector) Wiring harness between CE03 (female) (1) –
Resistance Max. 1 z
causes and chassis ground
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 CE03 (female) (3) – bat-
(Short circuit with GND tery (+) and chassis ground
circuit) Wiring harness between CE03 (female) (1) –
chassis ground
a Prepare with starting switch OFF, then turn starting switch ON and carry
Defective engine con- out troubleshooting.
4
troller CE03 Voltage
Between (3) – (1) 20 – 30 V
PC1250-8R 19
Electrical diagram related to controller power supply
20 PC1250-8R
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 1
Action code Failure code Eng Ne and Bkup Speed Sens Error
Trouble
Contents of
• Failure occurred simultaneously in engine Ne speed sensor and engine Bkup speed sensor.
trouble
Action of
controller
Problem that
• Engine cannot be started. (Engine is stopped.)
appears on
• Engine stops (during operations).
machine
Related
information

Defective Ne speed
1 Carry out troubleshooting for failure code [CA689].
sensor system
Defective Bkup speed
2 Carry out troubleshooting for failure code [CA778].
sensor system
Possible Defective installation of Ne speed sensor may be installed defectively. Check it directly. (Defective
3
causes and Ne speed sensor installation of sensor itself, internal defect of flywheel, etc.)
standard value Defective installation of Bkup speed sensor may be installed defectively. Check it directly. (Defec-
in normal state 4
Bkup speed sensor tive installation of sensor itself, internal defect of supply pump, etc.)
Defective connection
Ne speed sensor and Bkup speed sensor may be connected defectively
5 of sensor connector
(or connected to wrong parts). Check them directly.
(Wrong connection)
Defective engine con- If causes 1 – 5 are not detected, engine controller may be defective. (Since
6
troller trouble is in system, troubleshooting cannot be carried out.)
PC1250-8R 21
Failure code [CA122] Chg Air Press Sensor High Error 1

Action code Failure code Chg Air Press Sensor High Error
Trouble
Contents of
• High 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
• Engine does not accelerate easily.
appears on
• Black smoke increases during acceleration.
machine
Related
information

Defective sensor If failure code [CA187] or [CA227] is displayed, carry out troubleshooting
1
power supply system for it first.
Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting in each case.
Defective charge air PIM Voltage
2 pressure sensor Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal defect)
Disconnection in wiring Wiring harness between ENG (female) (37) – PIM
harness Resistance Max. 1 z
(female) (1)
3 (Disconnection in wiring
or defective contact in Wiring harness between ENG (female) (47) – PIM
Resistance Max. 1 z
connector) (female) (2)
Wiring harness between ENG (female) (44) – PIM
Resistance Max. 1 z
(female) (3)
Possible turning starting switch ON.
causes and Ground fault in wiring Between wiring harness of ENG (female) (37) –
standard value Resistance Min. 1 Mz
harness PIM (female) (1) and chassis ground
in normal state 4
PIM (female) (2) and chassis ground
Between wiring harness of ENG (female) (44) –
PIM (female) (3) and chassis ground
(female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (47) – PIM (female) (3)
harness
5 Wiring harness between ENG (female) (37) – PIM
(with another wiring
harness) (female) (1) and between ENG Resistance Min. 1 Mz
(female) (44) – PIM (female) (2)
(female) (3) and between ENG Resistance Min. 1 Mz
(female) (44) – PIM (female) (2)
Defective engine con- ENG Voltage
6
troller
Between (44) – (47) Signal 0.3 – 4.7 V
22 PC1250-8R
Circuit diagram related to charge pressure sensor
PC1250-8R 23
Failure code [CA123] Chg Air Press Sensor Low Error 1
Action code Failure code Chg Air Press Sensor Low Error
Trouble
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
• Engine does not accelerate easily.
appears on
• Black smoke increases during acceleration.
machine
Related
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

causes and
standard value Carry out troubleshooting for failure code [CA122].
in normal state
24 PC1250-8R
Failure code [CA131] Throttle Sensor High Error 1
Action code Failure code Throttle Sensor High Error

Trouble
Contents of
• High error occurred in throttle sensor 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).

Defective sensor If failure code [CA2185] or [CA2186] is displayed, carry out troubleshoot-
1
power supply system ing for it first.
Defective fuel control P20 (male) Resistance
2 dial
Between (1) – (3) 4.0 – 6.0 kz
(Internal defect)
Between (2) – (1) 0.25 – 5.0 kz
Between (2) – (3) 0.25 – 5.0 kz
Disconnection in wiring Wiring harness between CE02 (female) (22) –
P20 (female) (1)
Possible or defective contact in Wiring harness between CE02 (female) (9) –
Resistance Max. 1 z
causes and connector) P20 (female) (2)
standard value Wiring harness between CE02 (female) (23) –
in normal state Resistance Max. 1 z
P20 (female) (3)
Ground fault in wiring Wiring harness between CE02 (female) (22) –
harness P20 (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between CE02 (female) (9) –
P20 (female) (2) and chassis ground
Wiring harness between CE02 (female) (23) –
out troubleshooting.
Defective engine con- CE02 Voltage
5
troller
Between (22) – (23) Voltage 4.75 – 5.25 V
Between (9) – (23) Signal 0.5 – 4.5 V
PC1250-8R 25
Circuit diagram related to fuel control dial
26 PC1250-8R
Failure code [CA132] Throttle Sensor Low Error 1
Action code Failure code Throttle Sensor Low Error

Trouble
Contents of
• Low error occurred in throttle sensor circuit.
trouble
Action of
controller
Problem that
machine

causes and
in normal state
PC1250-8R 27
Failure code [CA135] Eng Oil Press Sensor High Error 1
Action code Failure code Eng Oil Press Sensor High Error
Trouble
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).

1
Prepare with starting switch OFF, then turn starting switch ON or start
engine and carry out troubleshooting in each case.
Defective oil pressure POIL Voltage
2 sensor Between (1) – (2) Power supply 4.75 – 5.25 V
(Internal defect) Sensor voltage is measured with wiring harness connected. Accordingly, if
POIL (female) (1)
or defective contact in Wiring harness between ENG (female) (47) –
Resistance Max. 1 z
connector) POIL (female) (2)
Resistance Max. 1 z
POIL (female) (3)
Possible
causes and
standard value Ground fault in wiring Between wiring harness of ENG (female) (37) –
in normal state harness POIL (female) (1) and chassis ground
4
POIL (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (47) – POIL (female) (2)
harness
5 Wiring harness between ENG (female) (37) –
harness) POIL (female) (1) and between ENG Resistance Min. 1 Mz
(female) (13) – POIL (female) (3)
POIL (female) (2) and between ENG Resistance Min. 1 Mz
(female) (13) – POIL (female) (3)
Defective engine con- engine and carry out troubleshooting.
6
troller ENG Voltage
28 PC1250-8R
Circuit diagram related to oil pressure sensor
PC1250-8R 29
Failure code [CA141] Eng Oil Press Sensor Low Error 1
Action code Failure code Eng Oil Press Sensor Low Error
Trouble
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
machine
Related • Signal voltage of the oil pressure sensor can be checked by monitoring function
information (Code No. 37201: oil pressure sensor voltage).

causes and
in normal state
30 PC1250-8R
Failure code [CA144] Coolant Temp Sens High Error 1
Action code Failure code Coolant Temp Sens High Error

Trouble
Contents of
• High temperature error occurred in coolant temperature sensor circuit.
trouble
Action of
• Fixes coolant temperature value (90°C) and continues operation.
controller
Problem that
machine
Related • Signal voltage of coolant temperature sensor can be checked by monitoring function
information (Code No. 04105: voltage of coolant temperature sensor).

Defective coolant tem- turning starting switch ON.
1 perature sensor
TWTR (male) Coolant temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
harness
Possible 2 (Disconnection in wiring Resistance Max. 1 z
TWTR (female) (A)
causes and or defective contact in
standard value connector) Wiring harness between ENG (female) (38) –
Resistance Max. 1 z
in normal state TWTR (female) (B)
3
TWTR (female) (A) and chassis ground
Defective engine con- turning starting switch ON.
4
troller ENG (female) Coolant temperature Resistance
Between (15) – (38) 10 – 100°C 0.6 – 20 kz
PC1250-8R 31
Circuit diagram related to coolant temperature sensor
32 PC1250-8R
Failure code [CA145] Coolant Temp Sens Low Error 1
Action code Failure code Coolant Temp Sens Low Error

Trouble
Contents of
• Low temperature error occurred in coolant temperature sensor circuit.
trouble
Action of
• Fixes coolant temperature value (90°C) and continues operation.
controller
Problem that
machine
Related • Signal voltage of coolant temperature sensor can be checked by monitoring function
information (Code No. 04105: voltage of coolant temperature sensor).

causes and
in normal state
PC1250-8R 33
Failure code [CA153] Chg Air Temp Sensor High Error 1
Action code Failure code Chg Air Temp Sensor High Error
Trouble
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
machine
Related • Signal voltage of charge air temperature sensor can be checked by monitoring function
information (Code No. 18501: Boost temperature sensor voltage).

Defective charge air TIM (male) Air intake temperature Resistance
1 temperature sensor
(Internal defect) Between (A) – (B) 10 – 100°C 0.5 – 20 kz
Between (A) –
Whole area Min. 1 Mz
chassis ground
Possible harness
causes and 2 (Disconnection in wiring Resistance Max. 1 z
TIM (female) (A)
standard value or defective contact in
in normal state connector) Wiring harness between ENG (female) (47) –
Resistance Max. 1 z
TIM (female) (B)
3
TIM (female) (A) and chassis ground
Defective engine con- turning starting switch ON.
4
troller ENG (female) Air intake temperature Resistance
Between (23) – (47) 10 – 100°C 0.5 – 20 kz
34 PC1250-8R
Circuit diagram related to charge temperature sensor
PC1250-8R 35
Failure code [CA154] Chg Air Temp Sensor Low Error 1
Action code Failure code Chg Air Temp Sensor Low Error
Trouble
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
machine
Related • Signal voltage of charge air temperature sensor can be checked by monitoring function
information (Code No. 18501: Boost temperature sensor voltage).

causes and
in normal state
Failure code [CA187] Sens Supply 2 Volt Low Error 1
Action code Failure code Sens Supply 2 Volt Low Error

Trouble
Contents of
• Low voltage error occurred in sensor power supply 2 (5V) circuit.
trouble
• Engine Bkup speed sensor operates with signal from engine Ne speed sensor.
• Oil pressure sensor sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Action of
• EGR valve lift sensor limits output, and closes EGR and bypass valves.
controller
• Common rail pressure sensor limits output and continues operation (With common rail pressure lim-
ited).
Problem that
appears on • Engine output lowers.
machine
Related
information

causes and
in normal state
36 PC1250-8R
Failure code [CA221] Ambient Press Sens High Error 1
Action code Failure code Ambient Press Sens High Error

Trouble
Contents of
• High pressure error occurred in ambient pressure sensor circuit.
trouble
Action of
• Sets ambient pressure to default (52.44 kPa {0.52 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • Signal voltage of ambient pressure sensor can be checked by monitoring function
information (Code No. 37401: Voltage of ambient pressure sensor).

1
PAMB Voltage
Defective ambient
Between (1) – (2) Voltage 4.75 – 5.25 V
2 pressure sensor
(Internal defect) Between (3) – (2) Signal 0.3 – 4.7 V
PAMB (female) (1)
or defective contact in Resistance Max. 1 z
connector) PAMB (female) (2)
Resistance Max. 1 z
PAMB (female) (3)
Possible
causes and
standard value Ground fault in wiring Between wiring harness of ENG (female) (33) –
in normal state harness PAMB (female) (1) and chassis ground
4
PAMB (female) (2) and chassis ground
PAMB (female) (3) and chassis ground
PAMB (female) (1) and between ENG (female) Resistance Min. 1 Mz
Short circuit in wiring (38) – PAMB (female) (2)
harness
PAMB (female) (1) and between ENG (female) (3) Resistance Min. 1 Mz
harness)
– PAMB (female) (3)
PAMB (female) (2) and between ENG (female) Resistance Min. 1 Mz
(3) – PAMB (female) (3)
Defective engine con- ENG Voltage
6
troller
Between (33) – (38) 4.75 – 5.25 V
Between (3) – (38) 0.3 – 4.7 V
PC1250-8R 37
Circuit diagram related to ambient pressure sensor
38 PC1250-8R
Failure code [CA222] Ambient Press Sens Low Error 1
Action code Failure code Ambient Press Sens Low Error

Trouble
Contents of
• Low pressure error occurred in engine ambient pressure sensor circuit.
trouble
Action of
• Sets ambient pressure to default (52.44 kPa {0.51 kg/cm2}) and continues operation.
controller
Problem that
machine
Related • Signal voltage of ambient pressure sensor can be checked by monitoring function
information (Code No. 37401: Voltage of ambient pressure sensor).

causes and
in normal state
PC1250-8R 39
Failure code [CA227] Sens Supply 2 Volt High Error 1
Action code Failure code Sens Supply 2 Volt High Error

Trouble
Contents of
• High voltage error occurred in sensor power supply 2 (5V) circuit.
trouble
• Engine Bkup speed sensor operates with signal from engine Ne speed sensor.
• Oil pressure sensor sets oil pressure to default (250 kPa {2.5 kg/cm2}) and continues operation.
Action of • Common rail pressure sensor limits output and continues operation (With common rail pressure lim-
controller ited).
• Charge air pressure sensor (boost pressure sensor) sets charge pressure to default (400 kPa {4.1
kg/cm2} and continues operation.
Problem that
machine
Related
information

Defect in related sys-
1 If another failure code is displayed, carry out troubleshooting for it.
tem
Bkup Speed Sensor G connector
Oil pressure sensor POIL connector
Defective sensor Disconnect sensors at
2 Common rail oil pres-
(Internal defect) right in order. If no error PFUEL connector
sure sensor
code is displayed, that
sensor is defective. Charge air pressure
PIM connector
sensor
Resistor RES connector
harness
Possible 3 (Disconnection in wir- Resistance Max. 1 z
each sensor (female)
causes and ing or defective contact
standard value in connector) Wiring harness between ENG (female) (47) –
Resistance Max. 1 z
in normal state each sensor (female)
(Short circuit with GND each sensor (female) and chassis ground
each sensor (female) and chassis ground
Short circuit in wiring turning starting switch ON.
harness
harness) each sensor (female) and between ENG Resistance Min. 1 Mz
(female) (47) – each sensor (female)
6
troller ENG Voltage
Between (37) – (47) 4.75 – 5.25 V
40 PC1250-8R
Circuit diagram related to sensor power supply 2 (5 V)
PC1250-8R 41
Failure code [CA234] Eng Overspeed 1
Action code Failure code Eng Overspeed

Trouble
— CA234 (Engine controller system)
Contents of
• Engine speed exceeded operating range.
trouble
Action of
• Limits fuel injection rate until it lowers in operating range.
controller
Problem that
appears on • Engine speed fluctuates.
machine
Related
information

Possible Defect in related sys-
causes and tem
standard value 2 Improper use Machine may be used improperly. Teach operator proper using method.
in normal state
Defective engine con- If causes 1 and 2 are not detected, engine controller may be defective.
3
troller (Since trouble is in system, troubleshooting cannot be carried out.)
42 PC1250-8R
Failure code [CA238] Ne Speed Sens Supply Volt Error 1
Action code Failure code Ne Speed Sens Supply Volt Error

Trouble
Contents of
• High voltage error in engine Ne speed sensor power supply (5V) circuit.
trouble
Action of • Controls the engine with signal from engine Bkup speed sensor.
controller • Operates limiting output.
Problem that • Output lowers.
appears on • Engine stops during operations. (when engine Bkup speed sensor is also defective)
machine • Engine cannot be started during operations. (when engine Bkup speed sensor is also defective)
Related
information

Defective Ne speed
1 sensor Disconnect sensors at
(Internal defect) right in order. If no error
Ne speed sensor NE connector
sensor is defective.
harness
Wiring harness between ENG (female) (16) – NE
(female) (A)
in connector) Wiring harness between ENG (female) (48) – NE
Resistance Max. 1 z
(female) (B)
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting without
standard value Ground fault in wiring turning starting switch ON.
in normal state harness Wiring harness between ENG (female) (16) – NE
(Short circuit with GND (female) (A) and chassis ground
circuit) Wiring harness between ENG (female) (48) – NE
(female) (B) and chassis ground
harness
4 Wiring harness between ENG (female) (16) – NE
harness) (female) (A) and between ENG Resistance Min. 1 Mz
(female) (48) – NE (female) (B)
5
troller ENG Voltage
Between (16) – (48) 4.75 – 5.25 V
44 PC1250-8R
Circuit diagram related to Ne speed sensor power supply
PC1250-8R 45
Failure code [CA263] Fuel Temp Sensor High Error 1
Action code Failure code Fuel Temp Sensor High Error

Trouble
Contents of
• High temperature error occurred in fuel temperature sensor circuit.
trouble
• Usually fuel injection rate is corrected by fuel temperature signal, but fuel injection rate for substitute
Action of
water temperature sensor signal. (If fuel temperature sensor and water temperature sensor are mal-
controller
function condition, fix the water temperature signal (95°C) and to continue engine operation.)
Problem that
appears on
machine
Related • Signal voltage of fuel temperature sensor can be checked by monitoring function
information (Code No. 14201: Voltage of fuel temperature sensor).

Defective fuel temper- turning starting switch ON.
1 ature sensor
TFUEL (male) Fuel temperature Resistance
(Internal defect)
Between (A) – (B) 10 – 100°C 0.6 – 20 kz
harness
Possible 2 (Disconnection in wir- Resistance Max. 1 z
TFUEL (female) (A)
causes and ing or defective contact
standard value in connector) Wiring harness between ENG (female) (47) –
Resistance Max. 1 z
in normal state TFUEL (female) (B)
(Short circuit with GND TFUEL (female) (A) and chassis ground
circuit) a Prepare with starting switch OFF, then carry out troubleshooting without
Defective engine con- ENG (female) Fuel temperature Resistance
4
troller Between (30) – (47) 10 – 100°C 0.6 – 20 kz
46 PC1250-8R
Circuit diagram related to fuel temperature sensor
PC1250-8R 47
Failure code [CA265] Fuel Temp Sensor Low Error 1
Action code Failure code Fuel Temp Sensor Low Error

Trouble
Contents of
• Low temperature error occurred in fuel temperature sensor circuit.
trouble
• Usually fuel injection rate is corrected by fuel temperature signal, but fuel injection rate for substitute
Action of
water temperature sensor signal. (If fuel temperature sensor and water temperature sensor are mal-
controller
function condition, fix the water temperature signal (95°C) and to continue engine operation.)
Problem that
appears on
machine
Related • Signal voltage of fuel temperature sensor can be checked by monitoring function
information (Code No. 14201: Voltage of fuel temperature sensor).

causes and
in normal state
48 PC1250-8R
Failure code [CA271] IMV/PCV1 Short Error 1
Action code Failure code IMV/PCV1 Short Error

Trouble
Contents of
• Short circuit was detected in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
Related a As approximate 70 V pulse is applied to terminal (1) of PCV1 during engine running (when it is nor-
information mal), the measurement cannot be taken with a tester.

Defective supply pump PCV1 (male) Resistance
1 PCV1
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
(Short circuit with GND PCV1 (female) (1) and chassis ground
Possible circuit) Wiring harness between ENG (female) (5) –
causes and Resistance Min. 1 Mz
PCV1 (female) (2) and chassis ground
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON and carry
Hot short in wiring har-
3 ness (Short circuit with Voltage Max. 1 V
24V circuit)
Voltage Max. 1 V
Defective engine con- ENG (female) Resistance
4
troller Between (4) – (5) 2.3 – 5.3 z
Between (4), (5) –
Min. 1 Mz
chassis ground
Circuit diagram related to supply pump PCV1
PC1250-8R 49
Failure code [CA272] IMV/PCV1 Open Error 1
Action code Failure code IMV/PCV1 Open Error

Trouble
Contents of
• Open error was detected in PCV1 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine

Defective supply pump
PCV1 PCV1 (male) Resistance
1
(Internal disconnec- Between (1) – (2) 2.3 – 5.3 z
tion)
Between (1), (2) –
Min. 1 Mz
chassis ground
harness
PCV1 (female) (1)
in connector) Wiring harness between ENG (female) (5) –
PCV1 (female) (2)
causes and
in normal state turning starting switch ON.
Ground fault in wiring Between wiring harness of ENG (female) (4) –
harness PCV1 (female) (1) and chassis ground and chas- Resistance Max. 1 Mz
3
(Short circuit with GND sis ground
circuit) Between wiring harness of ENG (female) (5) –
PCV1 (female) (2) and chassis ground and chas- Resistance Max. 1 Mz
sis ground
4
Between (4), (5) –
Min. 1 Mz
chassis ground
50 PC1250-8R
PC1250-8R 51
Failure code [CA273] PCV2 Short Error 1
Action code Failure code PCV2 Short Error

Trouble
Contents of
• Short circuit was detected in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine

Defective supply pump PCV2 (male) Resistance
1 PCV2
(Internal short circuit) Between (1) – (2) 2.3 – 5.3 z
Between (1), (2) –
Min. 1 Mz
chassis ground
Possible circuit) Wiring harness between ENG (female) (10) –
standard value
Hot short in wiring har-
3 ness (Short circuit with Voltage Max. 1 V
24V circuit)
Voltage Max. 1 V
4
Between (9), (10) –
Min. 1 Mz
chassis ground
52 PC1250-8R
Failure code [CA274] PCV2 Open Error 1
Action code Failure code PCV2 Open Error

Trouble
Contents of
• Open error was detected in PCV2 circuit of supply pump.
trouble
Action of
controller
Problem that
appears on
machine
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
Disconnection in wir- turning starting switch ON.
ing harness
PCV2 (female) (1)
ing or defective con-
tact in connector) Wiring harness between ENG (female) (10) –
PCV2 (female) (2)
causes and
in normal state Ground fault in wiring turning starting switch ON.
4
Between (9), (10) –
Min. 1 Mz
chassis ground
PC1250-8R 53
Failure code [CA322] Inj #1 (L#1) Open/Short Error 1
Action code Failure code Inj #1 (L#1) Open/Short Error

Trouble
Contents of
• Opening or short circuit was detected in injector #1 circuit.
trouble
Action of
controller
Problem that
• Engine output lowers.
appears on
• Speed is unstable.
machine
Related a As approximate 70 V pulse is applied to the injector terminal during engine running (when it is nor-

Defective injector #1 INJ (male) Resistance
1
(Internal defect) Between (1) – (12) 0.4 – 1.1 z
Between (1), (12) –
Min. 1 Mz
chassis ground
harness
Wiring harness between ENG (female) (45) – INJ
(female) (1)
in connector) Wiring harness between ENG (female) (53) – INJ
Resistance Max. 1 z
Possible (female) (12)
standard value turning starting switch ON.
Ground fault in wiring
in normal state
harness Wiring harness between ENG (female) (45) – INJ
(Short circuit with GND (female) (1) and chassis ground
circuit) Wiring harness between ENG (female) (53) – INJ
(female) (12) and chassis ground
Defective another cyl-
If failure codes are displayed for multiple injectors, carry out troubleshoot-
4 inder injector or wiring
ing for them, too.
harness
5
Between (45), (53) –
Min. 1 Mz
chassis ground
54 PC1250-8R
Circuit diagram related to injector #1
PC1250-8R 55

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

1
Between (5), (8) –
Min. 1 Mz
chassis ground
harness
(female) (5)
in connector) Wiring harness between ENG (female) (60) – INJ
Resistance Max. 1 z
in normal state
ing for them, too.
harness
5
Between (46), (60) –
Min. 1 Mz
chassis ground
56 PC1250-8R
PC1250-8R 57

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

1
Between (3), (10) –
Min. 1 Mz
chassis ground
harness
2 (Disconnection in wiring Resistance Max. 1 z
(female) (3)
or defective contact in
connector) Wiring harness between ENG (female) (52) – INJ
Resistance Max. 1 z
in normal state
ing for them, too.
harness
5
Between (55), (52) –
Min. 1 Mz
chassis ground
58 PC1250-8R
PC1250-8R 59

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

1
Between (6), (7) –
Min. 1 Mz
chassis ground
harness
(female) (6)
Resistance Max. 1 z
in normal state
ing for them, too.
harness
5
Between (57), (59) –
Min. 1 Mz
chassis ground
60 PC1250-8R
PC1250-8R 61

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

1
Between (2), (11) –
Min. 1 Mz
chassis ground
harness
(female) (2)
Resistance Max. 1 z
in normal state
ing for them, too.
harness
5
Between (54), (51) –
Min. 1 Mz
chassis ground
62 PC1250-8R
PC1250-8R 63

Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine

1
Between (4), (9) –
Min. 1 Mz
chassis ground
harness
(female) (4)
Resistance Max. 1 z
in normal state
ing for them, too.
harness
5
Between (56), (58) –
Min. 1 Mz
chassis ground
64 PC1250-8R
PC1250-8R 65
Failure code [CA342] Calibration Code Incompatibility 1
Action code Failure code Calibration Code Incompatibility

Trouble
Contents of
• Incompatibility of data occurred in engine controller.
trouble
Action of
controller
Problem that
machine
Related
information

causes and
in normal state
66 PC1250-8R
Failure code [CA351] Injectors Drive Circuit Error 1
Action code Failure code Injectors Drive Circuit Error

Trouble
Contents of
• There is error in injector drive circuit.
trouble
Action of
• Limits output and continues operation (limits common rail pressure).
controller
Problem that
machine
Related
information

Defect in related sys- Check the code (injector system error code) that is displayed simulta-
1
tem neously. If another code is displayed, carry out troubleshooting for it.
Defective circuit Check circuit breaker directly for defect.
2
breaker No.3 and No.9 (If circuit breaker is shut down, circuit probably has ground fault.)
harness
Wiring harness between CE03 (female) (3) – bat-
tery (+)
Possible Wiring harness between CE03 (female) (1) –
connector) Resistance Max. 1 z
causes and chassis ground
standard value
in normal state a Prepare with starting switch OFF, then carry out troubleshooting without
harness Wiring harness between CE03 (female) (3) – bat-
(Short circuit with GND tery (+) and chassis ground
chassis ground
5
Between (3) – (1) 20 – 30 V
68 PC1250-8R
Circuit diagram related to controller power supply
PC1250-8R 69
SEN02080-00

© 2006 KOMATSU
All Rights Reserved
70
SEN02081-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
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
Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 20
PC1250-8R 1
Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 22

Failure code [CA2185] Throt Sens Sup Volt High Error ................................................................................ 24
Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 26
Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 27
Failure code [CA2555] Grid Htr Relay Volt Low Error ................................................................................... 28
Failure code [CA2556] Grid Htr Relay Volt High Error .................................................................................. 30
Failure code [D110KB] Battery Relay Drive S/C ........................................................................................... 32
Failure code [D163KB] Flash Light Relay S/C .............................................................................................. 34
Failure code [D195KB] Step Light Relay S/C................................................................................................ 36
Failure code [DA22KK] Pump controller solenoid: Source voltage reduction ............................................... 38
Failure code [DA25KP] Press. Sensor Power Abnormality........................................................................... 40
Failure code [DA2SKQ] Model selection Abnormality................................................................................... 42
Failure code [DA80MA] Auto. Lub. Abnormal ............................................................................................... 44
Failure code [DA2RMC] Pump Comm. Abnormality ..................................................................................... 46
Failure code [DAFRMC] Monitor Comm. Abnormality .................................................................................. 48
2 PC1250-8R
Failure code [CA352] Sens Supply 1 Volt Low Error 1
Action code Failure code Sens Supply 1 Volt Low Error

Trouble
Contents of
• Low voltage error occurred in sensor power supply 1 (5V) circuit.
trouble
• Operates the Ne speed sensor with signal from the Bkup speed sensor.
Action of • Limits output of the bypass valve lift sensor and closes the EGR valve.
controller • Fixes the pressure of the ambient pressure sensor at 50.99 kPa {0.52 kg/cm2} and continues the
operation.
Problem that
machine
Related
information

causes and
in normal state
PC1250-8R 3
Failure code [CA386] Sensor Sup. 1 Volt. High Error 1
Error code Failure code Sensor Sup. 1 Volt. High Error

Trouble
E15 CA386 (Engine controller)
Contents of
• Signal voltage in sensor power supply 1 (5 V) circuit is abnormally high.
trouble
• Operates the Ne speed sensor with signal from the Bkup speed sensor.
Action of • Limits output of the bypass valve lift sensor and closes the EGR valve.
controller • Fixes the pressure of the ambient pressure sensor at 50.99 kPa {0.52 kg/cm2} and continues the
operation.
Problem that
appears on • Output drops.
machine
Related
information
Causes Standard value in normal state/Remarks on troubleshooting

Defective related sys-
1 If another failure code is indicated, carry out troubleshooting for it.
tem
Disconnect devices at
Defective sensor right in order. If error
2
(Internal trouble) code disappears when Atmospheric pressure
PAMB connector
a device is discon- sensor
nected, that device has
a defect in it.
PAMB (female) (1)
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)
Ground fault in wiring Wiring harness between ENG (female) (33) –
harness PAMB (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (16) – NE
circuit) Resistance Max. 1 z
each sensor (female) and chassis ground
Short circuit in wiring
harness
5 PAMB (female) (1) and wiring harness between Resistance Min. 1 Mz
(With another wiring
ENG (female) (38) – each sensor (female)
harness)
(female) (1)
4 PC1250-8R
Causes Standard value in normal state/Remarks on troubleshooting

Possible a Prepare with starting switch OFF, then turn starting switch ON and carry
causes and out troubleshooting.
standard value Defective engine con-
6 ENG Voltage
in normal state troller
Between (16) – (48) and
4.75 – 5.25 V
(33) – (38)
Circuit diagram related to sensor power supply 1 (5 V)
PC1250-8R 5
Failure code [CA441] Battery Voltage Low Error 1
Action code Failure code Battery Voltage Low Error

Trouble
Contents of
• Low voltage error occurred in power supply circuit.
trouble
Action of
controller
Problem that
machine
Related • Power supply voltage can be checked with monitoring function
information (Code No. 03200: Power supply voltage).

causes and
in normal state
Failure code [CA442] Battery Voltage High Error 1
Action code Failure code Battery Voltage High Error

Trouble
Contents of
• High voltage error occurred in power supply circuit.
trouble
Action of
controller
Problem that
machine
Related
information

causes and
in normal state
6 PC1250-8R
Failure code [CA449] Rail Press Very High Error 1
Action code Failure code Rail Press Very High Error

Trouble
Contents of
• There is high pressure error (level 2) in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related • Common rail pressure can be checked with monitoring function
information (Code No. 36400: Common rail pressure).

causes and
in normal state
PC1250-8R 7
Failure code [CA451] Rail Press Sensor High Error 1
Action code Failure code Rail Press Sensor High Error

Trouble
Contents of
• High pressure error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related • Signal voltage of common rail pressure sensor can be checked by monitoring function
information (Code No. 36401: Voltage of common rail pressure).

1
PFUEL Voltage
Defective common rail
2 pressure sensor
(Internal defect) Between (3) – (2) Signal 0.25 – 4.6 V
PFUEL (female) (1)
ing or defective contact Wiring harness between ENG (female) (25) –
Resistance Max. 1 z
in connector) PFUEL (female) (3)
Possible Wiring harness between ENG (female) (47) –
causes and Resistance Max. 1 z
PFUEL (female) (2)
standard value
Ground fault in wiring Wiring harness between ENG (female) (37) –
harness PFUEL (female) (1) and chassis ground
4
(Short circuit with GND Wiring harness between ENG (female) (25) –
PFUEL (female) (3) and chassis ground
PFUEL (female) (2) and chassis ground
PFUEL (female) (1) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (25) – PFUEL (female) (3)
harness
harness) PFUEL (female) (1) and between ENG Resistance Min. 1 Mz
(female) (47) – PFUEL (female) (2)
PFUEL (female) (3) and between ENG Resistance Min. 1 Mz
(female) (47) – PFUEL (female) (2)
8 PC1250-8R
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
Circuit diagram related to common rail pressure sensor
PC1250-8R 9
Failure code [CA452] Rail Press Sensor Low Error 1
Action code Failure code Rail Press Sensor Low Error

Trouble
Contents of
• Low pressure error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine

causes and
in normal state
Failure code [CA553] Rail Press High Error 1
Action code Failure code Rail Press High Error

Trouble
Contents of • Excessively high pressure is detected in the common rail pressure sensor circuit (Excessively high
trouble pressure, which is far beyond the specified pressure, is indicated for over 10 sec).
Action of
controller
Problem that
machine
Related • Common rail pressure can be checked with monitoring function
information (Code No. 36400: Common rail pressure).

tem
Fuel used may be improper. Check it directly.
2 Use of improper fuel
(Viscosity is high)
Defective electrical
Electrical system of common rail pressure sensor may be defective. Carry
3 system of common rail
Possible out troubleshooting for failure code [CA451].
pressure sensor
causes and
standard value Defective mechanical
Mechanical system of common rail pressure sensor may be defective.
in normal state 4 system of common rail
Check it directly.
pressure sensor
Defective overflow Spring damage, seat wear, or ball fixing of overflow valve is suspected.
5
valve Check it directly.
Clogged overflow pip-
6 Overflow piping may be clogged. Check it directly.
ing
Defective pressure lim-
7 Pressure limiter may be damaged mechanically. Check it directly.
iter
10 PC1250-8R
Failure code [CA554] Rail Press Sensor In Range Error 1
Action code Failure code Rail Press Sensor In Range Error

Trouble
Contents of
• In range error occurred in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
machine
Related
information

causes and
in normal state
PC1250-8R 11
Failure code [CA559] Rail Press Low Error 1
Action code Failure code Rail Press Low Error

Trouble
Contents of
• There is rail press very low error (level 1).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine

tem
2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check of pres-
sure in fuel low pressure circuit, see Testing and adjusting, Checking
Defect in low pressure fuel pressure.
3
circuit parts
Pressure in fuel low-pressure Min. 0.15 MPa
circuit {Min. 1.5 kg/cm2}
Clogged fuel filter,
4 a For more information on troubleshooting, see Note 2.
strainer
Defective electrical
Electrical system of supply pump PCV may be defective. Carry out trou-
5 system of supply pump
bleshooting for failure code [CA271], [CA272], [CA273], or [CA274].
Possible PCV
causes and Defective common rail Mechanical system of common rail pressure sensor may be defective.
6
standard value pressure sensor Check whether wiring harness is damaged.
in normal state a For check of leakage through pressure limiter, see Testing and adjust-
Defective pressure lim- ing, Checking fuel return rate and leakage.
7
iter
Leakage through pressure limiter Max. 10 cc/min (at 1,600 rpm)
a For check of limit return rate (spill) from injector, see Testing and adjust-
ing, Checking fuel return rate and leakage.
Limited return (spill) rate from injec-
Speed in rated operation
tor
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
9 Defective supply pump If causes 1 – 8 are not detected, supply pump may be defective.
<How to use check sheet>

Carry out the above troubleshooting and take a record of the contents of the attached “Check sheet for no-
pressure feed”.
12 PC1250-8R
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
PC1250-8R 13
Check sheet for no-pressure feed

Machine model Working No.
Model serial No. # Checked on / /
Engine Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
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 900 ± 25
*1 Engine Speed High idle rpm 2,000 ± 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 160 {1,200} — —
*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 — — —
*10

C. Checking fuel circuit pressure Check conditions Unit Good Bad
Pressure in fuel low-pressure High idle or equivalent to MPa Min. 0.15
6
circuit rated load (Pump relief) {kg/cm2} {Min. 1.5}
D. Checking strainer and filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No-load, 1600 rpm cc/min Max. 10
Rating or equivalent 1,600 rpm cc/min 960 Speed:
Rating or equivalent 1,700 rpm cc/min 1,020
12 Return rate from injector Rating or equivalent 1,800 rpm cc/min 1,080 Return
rate:
*1 – *10: Check with the monitoring function of the machine monitor.
14 PC1250-8R
Failure code [CA689] Eng Ne Speed Sensor Error 1
Action code Failure code Eng Ne Speed Sensor Error

Trouble
Contents of
• There is error in engine Ne speed sensor circuit.
trouble
Action of
• Operates the engine with signal from engine Bkup speed sensor.
controller
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
machine
Related
information

Defective sensor
1 If failure code [CA238] is displayed, carry out troubleshooting for it first.
power supply system
Disconnection in wiring Wiring harness between ENGINE (female) (16) –
NE (female) (A)
ing or defective contact Wiring harness between ENGINE (female) (48) –
Resistance Max. 1 z
in connector) NE (female) (B)
Wiring harness between ENGINE (female) (27) –
Resistance Max. 1 z
NE (female) (C)
Ground fault in wiring Wiring harness between ENG (female) (16) – NE
harness (female) (A) and chassis ground
3
(Short circuit with GND Wiring harness between ENG (female) (48) – NE
Possible Wiring harness between ENG (female) (27) – NE
(female) (C) and chassis ground
standard value
(female) (A) and between ENG Resistance Min. 1 Mz
Short circuit in wiring (female) (48) – NE (female) (B)
harness
4 Wiring harness between ENG (female) (16) – NE
harness) (female) (A) and between ENG Resistance Min. 1 Mz
(female) (27) – NE (female) (C)
(female) (B) and between ENG Resistance Min. 1 Mz
(female) (27) – NE (female) (C)
Defective sensor
installation or defec- Ne speed sensor may be installed defectively (improper clearance), or
5
tive rotation sensor rotation sensor parts (flywheel) may be defective. Check them directly.
parts
Defective engine Ne If causes 1 – 5 are not detected, engine Ne speed sensor may be defec-
6
speed sensor tive. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective engine con- If causes 1 – 6 are not detected, engine controller may be defective.
7
16 PC1250-8R
Circuit diagram related to engine Ne speed sensor
PC1250-8R 17
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1
Action code Failure code Eng Bkup Speed Sens Phase Error
Trouble
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 • Bkup speed sensor is changed together with the fuel supply pump (For details, see "Removal and
information installation of fuel supply pump" in Disassembly and assembly).

Possible
Defective engine Ne Engine Ne speed sensor may be defective. Carry out troubleshooting for
causes and 1
speed sensor system failure code [CA689].
standard value
in normal state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out troubleshooting
2
speed sensor system for failure code [CA778].
18 PC1250-8R
Failure code [CA757] All Persistent Data Lost Error 1
Action code Failure code All Persistent Data Lost Error

Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
machine
Related infor-
mation

causes and
in normal state
PC1250-8R 19
Failure code [CA778] Eng Bkup Speed Sensor Error 1
Action code Failure code Engine Bkup speed sensor error

Trouble
Contents of
• There is error in engine Bkup speed sensor circuit.
trouble
Action of
• Operates 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 • Bkup speed sensor is changed together with the fuel supply pump (For details, see "Removal and
information installation of fuel supply pump" in Disassembly and assembly).

1
Disconnection in wiring Wiring harness between ENG (female) (37) – G
(female) (A)
or defective contact in Wiring harness between ENG (female) (47) – G
Resistance Max. 1 z
connector) (female) (B)
Wiring harness between ENG (female) (26) – G
Resistance Max. 1 z
(female) (C)
Ground fault in wiring Wiring harness between ENG (female) (37) – G
harness (female) (A) and chassis ground
3
(Short circuit with GND Wiring harness between ENG (female) (47) – G
Possible Wiring harness between ENG (female) (26) – G
(female) (C) and chassis ground
standard value
(female) (A) and between ENG (female) (47) – G Resistance Min. 1 Mz
Short circuit in wiring (female) (B)
harness
4
(with another wiring har- Wiring harness between ENG (female) (37) – G
ness) (female) (A) and between ENG (female) (26) – G Resistance Min. 1 Mz
(female) (C)
(female) (B) and between ENG (female) (26) – G Resistance Min. 1 Mz
(female) (C)
Defective sensor
Bkup speed sensor may be installed defectively (improper clearance), or
installation or defec-
5 rotation sensor parts (in supply pump) may be defective. Check them
tive rotation sensor
directly.
parts
Defective engine Bkup If causes 1 – 5 are not detected, engine Bkup speed sensor may be defec-
6
speed sensor tive. (Since trouble is in system, troubleshooting cannot be carried out.)
Defective engine con- If causes 1 – 6 are not detected, engine controller may be defective.
7
20 PC1250-8R
Circuit diagram related to engine Bkup speed sensor
PC1250-8R 21
Failure code [CA1633] KOMNET Datalink Timeout Error 1
Action code Failure code KOMNET Datalink Timeout Error

Trouble
E0E CA1633 (Engine controller system)
Contents of
• There is error in KOMNET communication circuit with machine monitor, or pump controller.
trouble
Action of
• Operates in default mode or holds the state set when error occurred.
controller
Problem that
appears on
machine
Related
information

harness
Wiring harness between P03 (female) (16) –
CE02 (female) (47), – C02 (female) (22)
in connector) Wiring harness between P03 (female) (15) –
Resistance Max. 1 z
Ground fault in wiring Wiring harness between P03 (female) (16) –
harness CE02 (female) (47), – C02 (female) (22), – other Resistance Min. 1 Mz
2
(Short circuit with GND related circuit and chassis ground
circuit) Wiring harness between P03 (female) (15) –
CE02 (female) (46), – C02 (female) (32), – other Resistance Min. 1 Mz
Possible related circuit and chassis ground
causes and
standard value a Prepare with starting switch OFF, then turn starting switch ON and carry
in normal state out troubleshooting.
Hot short (Short circuit
CE02 (female) (47), – C02 (female) (22), – other Voltage Max. 1 V
3 with 24V circuit) in wir-
related circuit and chassis ground
ing harness
Defective CAN termi- turning starting switch ON.
4
nal resistance K02(male), K31 (male) Resistance
Between (A) – (B) 120 ± 12 z
Defective machine
If causes 1 – 4 are not detected, machine monitor, engine controller, or
monitor, engine con-
5 pump controller may be defective. (Since trouble is in system, trouble-
troller, or pump control-
shooting cannot be carried out.)
ler
22 PC1250-8R
Circuit diagram related to CAN communication of pump controller
PC1250-8R 23
Failure code [CA2185] Throt Sens Sup Volt High Error 1
Action code Failure code Throt Sens Sup Volt High Error
Trouble
Contents of
• High voltage error occurred in throttle sensor power supply (5V) circuit.
trouble
Action of
controller
Problem that
machine

Defective fuel control
1 dial Disconnect sensors at
(Internal defect) right in order. If no error
Fuel control dial P20 connector
sensor is defective.
harness
P20 (female) (1)
in connector) Wiring harness between CE02 (female) (23) –
Resistance Max. 1 z
P20 (female) (3)
Possible
standard value Ground fault in wiring turning starting switch ON.
in normal state harness Wiring harness between CE02 (female) (22) –
(Short circuit with GND P20 (female) (1) and chassis ground
harness
4 Wiring harness between CE02 (female) (22) –
harness) P20 (female) (1) and between CE02 Resistance Min. 1 Mz
(female) (23) – P20 (female) (3)
5
Between (22) – (23) 4.75 – 5.25 V
24 PC1250-8R
Circuit diagram related to fuel control dial throttle sensor
PC1250-8R 25
Failure code [CA2186] Throt Sens Sup Volt Low Error 1
Action code Failure code Throt Sens Sup Volt Low Error
Trouble
Contents of
• Low voltage error occurred in throttle sensor power supply (5V) circuit.
trouble
Action of
controller
Problem that
machine

causes and
in normal state
26 PC1250-8R
Failure code [CA2249] Rail Press Very Low Error 1
Action code Failure code Rail Press Very Low Error

Trouble
Contents of
• There is rail press very low error (level 2).
trouble
Action of
• Limits common rail pressure.
controller
Problem that
machine
Related
information

causes and
in normal state
PC1250-8R 27
Failure code [CA2555] Grid Htr Relay Volt Low Error 1
Action code Failure code Grid Htr Relay Volt Low Error
Trouble
Contents of
• Voltage low error was detected in grid heater relay circuit.
trouble
Action of
controller
Problem that
appears on • Engine does not start easily at low temperature.
machine
Related
information

causes and
in normal state
28 PC1250-8R
Failure code [CA2556] Grid Htr Relay Volt High Error 1
Action code Failure code Grid Htr Relay Volt High Error
Trouble
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

Defective grid heater turning starting switch ON.
1 relay
R18 (male) Resistance
(Internal defect)
Between (1) – (2) 200 – 400 z
harness
R18 (female) (1)
Possible in connector) Wiring harness between CE02 (female) (42) –
Resistance Max. 1 z
causes and R18 (female) (2)
in normal state turning starting switch ON.
harness Wiring harness between CE02 (female) (40) –
(Short circuit with GND R18 (female) (1) and chassis ground
R18 (female) (2) and chassis ground
Defective engine con- CE02 Heater relay Voltage
4
troller
Operating condition Max. 1 V
Between (40) – (42)
Stop condition 20 – 30 V
30 PC1250-8R
Circuit diagram related to intake air heater relay (Case of PC1250-8)
PC1250-8R 31
Failure code [D110KB] Battery Relay Drive S/C 1
Action code Failure code Battery Relay Drive S/C

Trouble
— D110KB (in pump controller system)
Contents of
• When a signal is output to the battery relay drive circuit, abnormal current flowed.
trouble
Action of • The controller turns OFF the output to the battery relay drive circuit.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Problem that
• When this fault occurs, if the starting switch is turned to the OFF position with the Hi idle switch and
appears on
auto-deceleration switch ON, the engine speed rises for a while and then stops.
machine
Related • Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
information (Code No. 03700: Controller output 1)

Battery relay defec- Battery relay Continuity/Resistance value
1
tive (Internal fault) Between terminals BR and E There is continuity
Between terminal BR
Min. 1 Mz
and grounding
Possible
causes and a Turn the engine starting switch OFF for the preparations, and hold it in
standard value ing harness
in normal state 2
(Contact with ground- Between wiring harness between C03 (female) Resis-
ing circuit) (4), D01, J01, J20, and battery relay terminal tance Min. 1 Mz
BR and grounding value
Pump controller
3 C03 (female) Starting switch Voltage
defective
Between (4) and 20 – 30 V
ON → OFF
grounding (For 0.5 sec)
32 PC1250-8R
Circuit diagram related to battery relay drive
PC1250-8R 33
Failure code [D163KB] Flash Light Relay S/C 1
Action code Failure code Flash Light Relay S/C

Trouble
Contents of • Abnormal current flowed when the power for the flash light drive relay (the primary circuit of the
trouble relay) is turned ON.
• The controller turns OFF the output to the coil circuit of the flash light relay.
Action of
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Problem that
appears on • The flash light does not flash.
machine
• Operation (ON/OFF) of the flash light drive relay circuit (the primary side of the relay) can be
Related
checked in the monitoring function (Code 03701: Controller output 2).
information
• The pump controller cannot detect abnormality in the secondary circuit of the relay.
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
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
34 PC1250-8R
Electrical diagram related to horn & flash light
PC1250-8R 35
Failure code [D195KB] Step Light Relay S/C 1
Action code Failure code Step Light Relay S/C

Trouble
Contents of • When a signal is output to the step light power source drive relay circuit (the primary circuit of the
trouble relay), abnormal current flowed.
• The controller turns OFF the output to the step light drive relay circuit.
Action of
controller
Problem that
appears on • The step light does not light up.
machine
• Operation of the step light drive relay circuit (the primary circuit of the relay) (ON or OFF) can be
Related
checked in the monitoring function. (Code No. 03701: Controller output 2)
information
• The pump controller cannot detect abnormality in the secondary circuit of the relay.

Step light drive relay the OFF position during the troubleshooting.
1 defective (Internal
R15 (female) Resistance value
short-circuiting)
Between (1) and (2) 250 – 300 z
ing harness
causes and 2
(Contact with ground- Between wiring harness between C02 (female) Resistance
standard value Min. 1 Mz
ing circuit) (18) and R15 (female) (2) and grounding value
in normal state
Pump controller C02 Step light switch Voltage
3
defective 20 – 30 V
Between (18) and ON
(For 60 seconds)
grounding
OFF Max. 1 V
36 PC1250-8R
Electric diagram related to step light
PC1250-8R 37
Failure code [DA22KK] Pump controller solenoid: Source voltage

reduction 1
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

Defective circuit a If circuit breaker No. 2 or No. 6 is turned OFF, circuit probably has
1
breaker No. 2 or No. 6 ground fault etc. (See Cause 3.)
Wiring harness between C03 (female) (2), (12),
Resistance Max. 1 z
(22) – J07 (female) (5), (7), (9)
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
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 –
B22
Wiring harness between battery relay terminal M
– B12
Defective pump con- out troubleshooting.
4
troller
Between C03 (2), (12), (22) – (21), (32), (33) Voltage 20 – 30 V
38 PC1250-8R
Electric diagram related to pump controller power supply
PC1250-8R 39
Failure code [DA25KP] Press. Sensor Power Abnormality 1
Action code Failure code Press. Sensor Power Abnormality

Trouble
— DA25KP (in pump controller system)
Contents of
• Abnormal current flowed in the power supply (5-V) circuit of the pressure sensor.
trouble
• The output to the power supply (5-V) circuit is turned OFF.
Action of
• Even if the cause of the failure disappears, the system does not reset itself until the starting switch
controller
is turned OFF.
Problem that
• The signal of the pressure sensor is not input normally.
appears on
• The failure code of a pressure sensor trouble is displayed, too.
machine
Related
information

Pressure sensor Disconnect parts shown F pump pressure sen- VH02 connector
defective at right in order. If fail- sor
1
(Internal short-circuit- ure code disappears R pump pressure sen-
ing) VH03 connector
when a part is discon- sor
nected, that part has Swing pump pressure
internal defect. VH04 connector
sensor
Possible Between wiring harness between C01 (female)

causes and (22), JC22, and VH02 (female) (C) and ground- Resistance
Min. 1 Mz
standard value ing value
in normal state Grounding fault of wir- [F pump pressure sensor system]
ing harness Between wiring harness between C01 (female)
2
(Contact with ground- (22), JC22, and VH03 (female) (C) and ground- Resistance
ing (GND) circuit) Min. 1 Mz
ing value
[R pump pressure sensor system]
Between wiring harness between C01 (female)
(22), JC22, and VH04 (female) (C) and ground- Resistance
Min. 1 Mz
ing value
[Swing pump pressure sensor system]
Pump controller the ON position during the troubleshooting.
3
defective C01 Voltage
Between (22) and (21) 4.5 – 5.5 V
40 PC1250-8R
Electric diagram related to pressure sensor
PC1250-8R 41
Failure code [DA2SKQ] Model selection Abnormality 1
Action code Failure code Model selection Abnormality

Trouble
— DA2SKQ (in pump controller system)
Contents of • A model code signal was inputted which indicates another model that is not registered in the con-
trouble troller.
• The controller treats it as a default-set model (PC1250).
Action of
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
Problem that
appears on • None in particular with PC1250 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the moni-
Related toring function. (Code No. 10201: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 02201:Switch Input 2)

Model selecting con- the OFF position during the troubleshooting.
nector defective C09 (female) Resistance value
1
(Internal disconnec-
tion or short-circuiting) Between (7) and (8) Max. 1 z
Between (1), (2), (3), (4) and (7), (8) Min. 1 Mz
Possible Between wiring harness between C02 (female)
causes and Grounding fault of wir- Resistance
(7) (17) (27) (37) and C09 (male) (4) (3) (2) (1) Min. 1 Mz
standard value ing harness value
2 and grounding
in normal state (Contact with ground-
ing circuit) Between wiring harness between C02 (female)
(7) (17) (27) (37) and C09 (male) (4) (3) (2) (1) Resistance
Min. 1 Mz
Between wiring harness between C09 (male) (7) value
(9) and grounding
Pump controller C02 Voltage
3
defective
Between (17), (27) and grounding 20 – 30 V
Between (7), (37) and grounding Max. 1 V
42 PC1250-8R
Electric circuit diagram related to model selection connector
PC1250-8R 43
Failure code [DA80MA] Auto. Lub. Abnormal 1

a This failure code is displayed only when automatic lubrication equipment is installed.
44 PC1250-8R
Failure code [DA2RMC] Pump Comm. Abnormality 1
Action code Failure code Pump Comm. Abnormality

Trouble
E0E DA2RMC (Pump controller system)
Contents of • Pump controller detected communication error in CAN communication circuit between machine
trouble monitor and engine controller.
Action of • Fixes engine output to E-mode, and limits pump absorption torque to about 80%.
controller • If cause of failure disappears, system resets itself.
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information

harness
in connector) Wiring harness between P03 (female) (15) –
Resistance Max. 1 z
2
causes and
ing harness
4
nal resistance K02 (male), K31 (male) Resistance
Between (A) – (B) 120 ± 12 z
Defective machine
5 pump controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
ler
46 PC1250-8R
PC1250-8R 47
Failure code [DAFRMC] Monitor Comm. Abnormality 1
Action code Failure code Monitor Comm. Abnormality

Trouble
E0E DAFRMC (Machine monitor system)
Contents of • Machine monitor detected communication error in CAN communication circuit between pump con-
trouble troller and engine controller.
Action of
• Fix engine output to E-mode, and limit pump absorption torque to about 80%.
machine moni-
• If cause of failure disappears, system resets itself.
tor
Problem that
• Output lowers. (Pump absorption torque decreases.)
appears on
• As the working load increases, engine may stall.
machine
Related
information

harness
connector) Wiring harnesses between P03 (female) (15) –
Resistance Max. 1 z
CE02 (male) (46) and – C02 (females) (32)
2
causes and
ing harness
4
nal resistance K02(male), K31 (male) Resistance
Between (A) – (B) 120 ± 12 z
Defective machine
5 pump controller may be defective. (Since trouble is in system, trouble-
shooting cannot be carried out.)
ler
48 PC1250-8R
PC1250-8R 49
SEN02081-00

© 2006 KOMATSU
All Rights Reserved
50
SEN02082-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
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
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
PC1250-8R 1
Failure code [DGT3KZ] PTO Temp Sensor Failure

Failure code [DGT4KA] F Exhaust Temp. Sensor Failure
Failure code [DGT4KB] F Exhaust Temp. Sensor Failure
(or change of VHMS-LED display from n3 to 11) ...................................................................................... 22
Failure code [DGT5KA] R Exhaust Temp. Sensor Failure
Failure code [DGT5KB] R Exhaust Temp. Sensor Failure
Failure code [DHE5KB] Blowby Pres. Sensor Failure
Failure code [DHE5KY] Blowby Pres. Sensor Failure)
Failure code [DHPAMA] F Pump P. Sensor Abnormality .............................................................................. 32
Failure code [DHPAZL] F Pump Relief Pressure Abnormality ...................................................................... 34
Failure code [DHPBMA] R Pump P. Sensor Abnormality.............................................................................. 36
Failure code [DHPBZL] R Pump Relief Pressure Abnormality...................................................................... 38
Failure code [DHPTKA] Fan Pump Pre. Sens Failure
Failure code [DHPTKB] Fan Pump Pre. Sens Failure
Failure code [DV20KB] Travel Alarm S/C ..................................................................................................... 44
Failure code [DW41KA] Swing Priority Sol. Disc. ......................................................................................... 46
Failure code [DW41KB] Swing Priority Sol. S/C ........................................................................................... 48
Failure code [DW43KA] Travel Speed Sol. Disc. .......................................................................................... 50
Failure code [DW43KB] Travel Speed Sol. S/C ............................................................................................ 52
Failure code [DW45KA] Swing Brake Sol. Disc. ........................................................................................... 54
Failure code [DW45KB] Swing Brake Sol. S/C ............................................................................................. 56
Failure code [DW48KA] CO Cancel Sol. Disc............................................................................................... 58
Failure code [DW48KB] CO Cancel Sol. S/C................................................................................................ 60
2 PC1250-8R
Failure code [DBB0KK] VHMS source voltage Error (or change of VHMS-
LED display from n9 to 01) 1
Action code Failure code VHMS source voltage Error

Trouble
— DBB0KK (VHMS controller)
Contents of
• The switch source voltage of the VHMS controller lowered to below 19.5 V.
trouble
Action of
controller
Problem that
appears on • The system may not operate normally.
machine
Related
tor.
information

If fuse No. 12 is broken, the circuit may have grounding fault, etc. (See
1 Fuse No. 12 defective
cause 4.)
Circuit breaker No. 1 If circuit breaker No. 1 is turned OFF, the circuit may have grounding fault,
2
defective etc. (See cause 4.)
Wiring harness between VC1 (female) (8), (9), Resistance
Max. 1 z
Disconnection of wiring J25, and FB1-12 value
harness (Disconnec- Resistance
3 Wiring harness between FB1 inlet and B21 Max. 1 z
tion or defective con- value
tact with connector) Wiring harness between B11 and battery relay Resistance
Possible Max. 1 z
terminal M value
causes and
Wiring harness between VC1 (female) (19), (20), Resistance
standard value Max. 1 z
J25, and J05 value
in normal state
Grounding fault of wir- Between wiring harness between VC1 (female) Resistance
Min. 1 Mz
ing harness (Contact (8), (9), J25, and FB1-12 and grounding value
4
with grounding (GND) Between wiring harness between FB1 inlet and Resistance
circuit) Min. 1 Mz
B21 and grounding value
Between wiring harness between B11 and bat- Resistance
Min. 1 Mz
tery relay terminal M and grounding value
VHMS controller the ON position during the troubleshooting.
5
defective VC1 Voltage
Between (8), (9) and (19), (20) 20 – 30 V
4 PC1250-8R
Electrical diagram related to VHMS controller power supply
PC1250-8R 5
Failure code [DBB0KQ] VHMS Connector Mismatch (or change of

VHMS-LED display from nf to 11) 1
Action code Failure code VHMS Connector Mismatch

Trouble
— DBB0KQ (VHMS controller system)
Contents of • Model selection signal obtained directly by pump controller is different from that obtained through
trouble communication.
Action of
machine moni- • Assumes model to be default model and continues control.
tor
Problem that
appears on • System may not operate normally.
machine
Related • Failure code of VHMS system is not recorded in failure history of machine monitor.
information • 7-segment LED display of VHMS controller: nf o 11 (Code is displayed 2 letters by 2.)
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
(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)
(27), (37) – C09 (male) (4), (3), (2), (1) or Resistance Min. 1 Mz
between C09 (male) (7) (8) – ground
6 PC1250-8R
Circuit diagram related to model selection connector
PC1250-8R 7
Failure code [DBB3KK] Abnormality in VBAT voltage (or change of

VHMS-LED display from n9 to 05) 1
Action code Failure code Abnormality in VBAT voltage

Trouble
— DBB3KK (VHMS controller system)
Contents of
• Battery direction voltage (24 V) is out of normal range (below 10 V).
trouble
Action of
machine moni- • None in particular.
tor
Problem that
appears on • System may not operate normally.
machine
information • 7-segment LED display of VHMS controller: n9 o 05 (Code is displayed 2 letters by 2.)

1 Defective fuse No. 18 If fuse No. 18 is broken, circuit probably has ground fault. (See Cause 4.)
Defective circuit If circuit breaker No. 11 is turned OFF, circuit probably has ground fault.
2
breaker No. 11 (See Cause 4.)
harness (Disconnec- Wiring harness between VC1 (female) (6), (7) –
3 tion in wiring or defec- J24 – FB1 – B02 – B28 – A10 – B23 – battery Resistance Max. 1 z
Possible tive contact in relay terminal (B)
causes and connector) Wiring harness between VC1 (female) (11), (12)
standard value Resistance Max. 1 z
– J25 – J05 – chassis ground
in normal state
Wiring harness between VC1 (female) (6), (7) –
Ground fault in wiring J24 – FB1 – B02 – B28 – A10 – B23 – battery
4 harness (Contact with relay terminal (B) and wiring harnesses related to
GND circuit) it
Wiring harness between VC1 (female) (6), (7) –
J24 – FB1 – B02 – B28 – A10 – B23 – battery Resistance Min. 1 Mz
relay terminal (B)
8 PC1250-8R
Circuit diagram related to VHMS controller
PC1250-8R 9
Failure code [DBB5KP] VHMS 5V source sys Error (or change of VHMS-
Action code Failure code VHMS 5V source sys Error

Trouble
— DBB5KP (VHMS controller system)
Contents of
• Sensor source voltage is out of normal range (4.5 – 5.5 V).
trouble
Action of
tor
Problem that
appears on • Sensor value may not be displayed normally.
machine

harness (Disconnection Wiring harness between VC1 (female) (5) – A16
1
in wiring or defective – P34 (female) (C), between VC1 (female) (5) –
contact in connector) Resistance Max. 1 z
A12 (6) – VH08 (female) (B), or between VC1
(female) (5) – A13 (6) – VH12 (female) (B)
Possible
causes and
standard value Ground fault in wiring
in normal state 2 harness (Contact with Wiring harness between VC1 (female) (5) – A12
GND circuit) (2) – P34 (female) (B), between VC1 (female) (5)
– A12 (6) – VH08 (female) (B), or between VC1
(female) (5) – A13 (6) – VH12 (female) (B)
3 Defective controller
Between VC1 (female) (5) – VC2A (female) (12),
Voltage 4.5 – 5.5 V
(13)
10 PC1250-8R
Electrical diagram related to 5V sensor power supply
PC1250-8R 11
Failure code [DBB6KP] VHMS 24V source sys Error (or change of
Action code Failure code VHMS 24V source sys Error

Trouble
— DBB6KP (VHMS controller system)
Contents of
• Sensor source voltage output is out of normal range (20 – 30 V).
trouble
Action of
tor
Problem that
appears on • Sensor value may not be displayed normally.
machine

harness (Disconnection Wiring harness between VC1 (female) (2) – A13
1
in wiring or defective (2) – VH11 (female) (B), between VC1 (female)
contact in connector) Resistance Max. 1 z
(2) – VH06 (female) (A), or between VC1
(female) (2) – VH07 (female) (A)
Possible
causes and
standard value Ground fault in wiring
in normal state 2 harness (Contact with Wiring harness between VC1 (female) (2) – A13
GND circuit) (2) – VH11 (female) (B), between VC1 (female)
(2) – VH06 (female) (A), or between VC1
(female) (2) – VH07 (female) (A)
Defective VHMS con- out troubleshooting.
3
troller Between VC1 (female) (2) – VC2A (female) (12),
Voltage 20 – 30 V
(13)
12 PC1250-8R
Electrical diagram related to 24V sensor power supply
PC1250-8R 13
Failure code [DBBQKR] KOM-NET/c error (or change of VHMS-LED

display from n8 to 02) 1
Action code Failure code KOM-NET/c error

Trouble
— DBBQKR (VHMS controller system)
Contents of • Communication (CAN_NET) information cannot be obtained from engine controller, pump controller
trouble and machine monitor.
Action of
machine moni- • Keeps condition at time when trouble occurs.
tor
Problem that
appears on • VHMS function of collecting information from each controller does not operate.
machine
• If failure code CA1633, DA2RMC or DAFRMC is displayed, carry out troubleshooting for it first.
Related
• Failure code of VHMS system is not recorded in failure history of machine monitor.
information
• 7-segment LED display of VHMS controller: n8 o 02 (Code is displayed 2 letters by 2.)

Disconnection in wiring
harness (Disconnection Wiring harness between C02 (female) (32) (from
1 branch point) – VC4A (female) (4) – M45
in wiring or defective
contact in connector) (female) (10) or between C02 (female) (22) (from Resistance Max. 1 z
branch point) – VC4A (female) (12) – M45
(female) (10)
Ground fault in wiring Wiring harness between C02 (female) (32) (from
2 harness (Contact with branch point) – VC4A (female) (4) – M45
GND circuit) (female) (10) or between C02 (female) (22) (from Resistance Min. 1 Mz
Possible branch point) – VC4A (female) (12) – M45
causes and (female) (10) and chassis ground
standard value
Hot short (Contact with Wiring harness between C02 (female) (32) (from
3 24V circuit) in wiring branch point) – VC4A (female) (4) – M45
harness (female) (10) or between C02 (female) (22) (from Voltage Max. 1 V
branch point) – VC4A (female) (12) – M45
1) Turn starting switch OFF.
2) Replace VHMS controller.
3) Turn starting switch ON.
Defective VHMS con-
4 VHMS controller is
troller Yes
Is communication defective.
normal? VHMS controller is
No
normal.
14 PC1250-8R
Circuit diagram related to CAN communication of VHMS controller
PC1250-8R 15
Failure code [DGE5KB] Ambi. Temp. Sensor S/C 1
Action code Failure code Ambi. Temp. Sensor S/C

Trouble
— DGE5KB (Pump controller system)
Contents of
• Abnormal current flowed in ambient temperature sensor circuit.
trouble
Action of
machine moni-
• If failure disappears, system resets itself.
tor
Problem that
appears on • Fan speed may rise (depending on operating condition).
machine
Related • Input (Temperature) from ambient temperature sensor can be checked with monitoring function.
information (Code: 37502)

Defective ambient tem- turning starting switch ON.
1
perature sensor P29 (male) Ambient temperature Resistance
Between (1) – (2) 20°C 4–6z
harness (Disconnec-
Wiring harness between C01 (female) (9) – P29
Possible 2 tion in wiring or defec- Resistance Max. 1 z
(female) (1)
causes and tive contact in
standard value connector) Wiring harness between C01 (female) (21) – P29
Resistance Max. 1 z
in normal state (female) (2)
Hot short (Short circuit out troubleshooting.
ing harness Wiring harness between C01 (female) (9) – P29
Voltage Max. 1 V
Defective pump con- turning starting switch ON.
4
troller C01 (male) Ambient temperature Resistance
Between (9) – (21) 20°C 4–6z
Circuit diagram related to ambient temperature sensor
16 PC1250-8R
Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C 1
Action code Failure code Hydr. Oil Temp. Sensor S/C

Trouble
— DGH2KB (Mechanical system)
Contents of
• The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
trouble
Action of
tor
Problem that
appears on • If the machine is used as it is, the hydraulic equipment may be damaged.
machine
• If the hydraulic oil temperature monitor on the machine monitor lights up in red while the engine is
Related running, this failure code is recorded.
information • Input from the hydraulic oil temperature sensor can be checked in the monitoring function. (Code
No. 04401: Hydraulic oil temperature, 04402: Hydraulic oil temperature sensor voltage

Hydraulic oil over-
Check the hydraulic oil for overheating. If it has been overheated, find out
1 heated (While system
the cause and check the hydraulic equipment for damage, then repair.
is normal)
Hydraulic oil tempera- Hydraulic oil tempera-
ture sensor defective P10 (male) Resistance
2 ture
ing) Between (1) – (2) 90 – 3.5 kz
Possible Between (1) – chassis 10 – 100°C
Min. 1 Mz
causes and ground
standard value Grounding fault of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state ing harness the OFF position during the troubleshooting.
3
(Contact with ground- Between wiring harness between P02 (female)
ing circuit) Resistance Min. 1 Mz
(12) – P10 (female) (1) and chassis ground
Hydraulic oil tempera-
Machine monitor P02 (female) Resistance
4 ture
defective
Between (12) – (13) 90 – 3.5 kz
Between (12) – 10 – 100°C
Min. 1 Mz
chassis ground
Circuit diagram related to hydraulic oil temperature sensor
PC1250-8R 17
Failure code [DGT3KZ] PTO Temp Sensor Failure (or change of VHMS-
Action code Failure code PTO Temp Sensor Failure

Trouble
— DGT3KZ (VHMS controller system)
Contents of
• The signal voltage of the PTO oil temperature sensor is below 0.3 V.
trouble
Action of
controller
Problem that
appears on • The snap shot data downloaded to a personal computer are not displayed normally.
machine
• The error codes of the VHMS system are not recorded in the failure history of the machine monitor.
Related • The 7-segment LED of the VHMS controller displays n5 o 01 (displays the code 2 characters by 2).
information • The PTO oil temperature can be checked by downloading the data to a personal computer after
performing the snap shot operation.

PTO oil temperature
sensor defective VH09 (male) Oil temperature Resistance value
1 (Internal disconnec- 25°C 46 – 59 kz
tion or short-circuit- Between (1) and (2)
100°C 3.6 – 4.0 kz
ing)
Between (1) and
— Min. 1 Mz
grounding
Disconnection of wir-
Resis-
ing harness (Discon- Wiring harness between VC2A (female) (2) and
tance Max. 1 z
2 nection or defective VH09 (female) (1)
Possible value
contact with connec-
causes and tor) Resis-
standard value Wiring harness between VC2A (female) (12),
tance Max. 1 z
in normal state (13) – J23 – J24 – J23 and VH09 (female) (2)
value
ing harness (Contact
3 Between wiring harness between VC2A Resis-
with grounding (GND)
circuit) (female) (2) and VH09 (female) (1) and ground- tance Min. 1 Mz
ing value
VC2A (female) Oil temperature Resistance value
VHMS controller
4 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
18 PC1250-8R
Electrical diagram related to PTO oil temperature sensor
PC1250-8R 19
Failure code [DGT4KA] F Exhaust Temp. Sensor Failure (or change of

Action code Failure code F Exhaust Temp. Sensor Failure

Trouble
— DGT4KA (VHMS controller system)
Contents of
• The signal voltage of the front exhaust temperature sensor is below 0.3 V.
trouble
Action of
controller
Problem that
machine
information • The exhaust temperature can be checked by downloading the data to a personal computer after

Sensor 24-V power
1 If error code [DBB6KP] is displayed, perform troubleshooting for it first.
supply defective
a Turn the engine starting switch OFF for the preparations, and run the
Front exhaust temper- engine during the troubleshooting.
ature sensor defective
2 When the connectors of the front and rear VH16 connector
tion) exhaust temperature sensors are exchanged, if
the error code disappears, the sensor is normal. VH17 connector
the ON position or run the engine during the troubleshooting.
VH06 Exhaust temperature Voltage
Front exhaust temper- Between (A) and (C) All temperature range 20 – 30 V
ature sensor amplifier
3 At 20°C Approx. 0.9 – 1.2 V
defective Between (B) and (C)
Possible (Internal defect) At 500°C Approx. 2.6 – 3.5 V
causes and The voltage of the amplifier is measured with the wiring harness con-
standard value nected. Accordingly, if the voltage is abnormal, check the wiring harness
in normal state and controller for another cause of the trouble, and then judge.
Wiring harness between VH14 (male) (1) and Resistance
Max. 1 z
Disconnection of wiring VH16 (female) (1) value
harness (Disconnec- Wiring harness between VH14 (male) (2) and Resistance
4 Max. 1 z
tion or defective con- VH16 (female) (2) value
tact with connector) Wiring harness between VC1 (female) (2) – J24 Resistance
Max. 1 z
and VH06 (female) (A) value
Wiring harness between VC2A (female) (7) and Resistance
Max. 1 z
VH06 (female) (B) value
5
with grounding (GND) Between wiring harness between VH14 (male) Resistance
circuit) Min. 1 Mz
20 PC1250-8R
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
Electrical diagram related to exhaust temperature sensor
PC1250-8R 21
Failure code [DGT4KB] F Exhaust Temp. Sensor Failure (or change of

Action code Failure code F Exhaust Temp. Sensor Failure

Trouble
— DGT4KB (VHMS controller system)
Contents of
• The signal voltage of the front exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine

Sensor 24-V power
supply defective
Front exhaust temper- engine during the troubleshooting.
ature sensor defective
Front exhaust temper- Between (A) and (C) All temperature range 20 – 30 V
ature sensor amplifier
3 At 20°C Approx. 0.9 – 1.2 V
4
circuit) Min. 1 Mz
Short-circuiting of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
ing harness with power the ON position during the troubleshooting.
5
source (Contact with Between wiring harness between VC2A (female)
24-V circuit) Voltage Max. 1 V
(7) and VH06 (female) (B) and grounding
VHMS controller VC2A Exhaust temperature Voltage
6
defective
(13) At 500°C Approx. 2.6 – 3.5 V
22 PC1250-8R
PC1250-8R 23
Failure code [DGT5KA] R Exhaust Temp. Sensor Failure (or change of

Action code Failure code R Exhaust Temp. Sensor Failure

Trouble
— DGT5KA (VHMS controller system)
Contents of
• The signal voltage of the rear exhaust temperature sensor is below 0.3 V.
trouble
Action of
controller
Problem that
machine

Sensor 24-V power
supply defective
Rear exhaust tempera- engine during the troubleshooting.
ture sensor defective
Rear exhaust tempera- Between (A) and (C) All temperature range 20 – 30 V
ture sensor amplifier
3 At 20°C Approx. 0.9 – 1.2 V
Wiring harness between VH15 (male) (1) and Resistance
Max. 1 z
Disconnection of wiring VH17 (female) (1) value
harness (Disconnec- Wiring harness between VH15 (male) (2) and Resistance
4 Max. 1 z
tion or defective con- VH17 (female) (2) value
tact with connector) Wiring harness between VC1 (female) (2) – J24 Resistance
Max. 1 z
and VH07 (female) (A) value
Wiring harness between VC2A (female) (5) and Resistance
Max. 1 z
5
with grounding (GND) Between wiring harness between VC2A (female)
circuit) Voltage Min. 1 Mz
24 PC1250-8R
causes and the ON position or run the engine during the troubleshooting.
standard value VHMS controller VC2A Exhaust temperature Voltage
6
(13) At 500°C Approx. 2.6 – 3.5 V
PC1250-8R 25
Failure code [DGT5KB] R Exhaust Temp. Sensor Failure (or change of

Action code Failure code R Exhaust Temp. Sensor Failure

Trouble
— DGT5KB (VHMS controller system)
Contents of
• The signal voltage of the rear exhaust temperature sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine

Sensor 24-V power
supply defective
Rear exhaust tempera- engine during the troubleshooting.
ture sensor defective
Rear exhaust tempera- Between (A) and (C) All temperature range 20 – 30 V
ture sensor amplifier
3 At 20°C Approx. 0.9 – 1.2 V
4
circuit) Min. 1 Mz
Hot short circuit in wir- the ON position during the troubleshooting.
5 ing harness (Contact
with 24-V circuit) Between wiring harness between VC2A (female)
Voltage Max. 1 V
6
defective
(13) At 500°C Approx. 2.6 – 3.5 V
26 PC1250-8R
PC1250-8R 27
Failure code [DHE5KB] Blowby Pres. Sensor Failure (or change of

Action code Failure code Blowby Pres. Sensor Failure

Trouble
— DHE5KB (VHMS controller system)
Contents of
• The signal voltage of the blow-by pressure sensor is below 0.1 V.
trouble
Action of
controller
Problem that
machine
information • The blow-by pressure can be checked by downloading the data to a personal computer after per-
forming the snap shot operation.

Sensor 5-V power
supply defective
VH08 Voltage
Blow-by pressure sen-
Between (B) and (A) 4.5 – 5.5 V
2 sor defective (Internal
defect) Between (C) and (A) 0.3 – 0.7 V
The voltage of the pressure sensor is measured with the wiring harness
connected. Accordingly, if the voltage is abnormal, check the wiring har-
ness and controller for another cause of the trouble, and then judge.
Blow-by pressure
Referring to TESTING AND ADJUSTING, check the sensor for sticking oil,
3 sensor defective
dust, water, etc. and clean it.
(External defect)
Possible
Blow-by pressure
causes and Referring to TESTING AND ADJUSTING, check the sensor for defective
4 sensor defective
standard value installation and repair it.
(Installation defective)
in normal state
Disconnection of wiring the OFF position during the troubleshooting.
harness
Wiring harness between VC1 (female) (5) and Resistance
connector) Wiring harness between VC2A (female) (18) and Resistance
Max. 1 z
VH08 (female) (C) value
6
(Contact with ground- Between wiring harness between VC2A (female) Resistance
(18) and VH08 (female) (C) value
7
defective VC2A Voltage
Between (18) and (12), (13) 0.3 – 0.7 V
28 PC1250-8R
Electrical diagram related to blow-by pressure sensor
PC1250-8R 29
Failure code [DHE5KY] Blowby Pres. Sensor Failure) (or change of

Action code Failure code Blowby Pres. Sensor Failure

Trouble
— DHE5KY (VHMS controller system)
Contents of
• The signal voltage of the blow-by pressure sensor is above 4.7 V.
trouble
Action of
controller
Problem that
machine
information • The blow-by pressure can be checked by downloading the data to a personal computer after per-

Sensor 5-V power sup-
ply defective
VH08 Voltage
Between (B) and (A) 4.5 – 5.5 V
2 sor defective
(Internal defect) Between (C) and (A) 0.3 – 0.7 V
Possible
causes and Blow-by pressure sen-
Referring to TESTING AND ADJUSTING, check the sensor for sticking oil,
standard value 3 sor defective (External
dust, water, etc. and clean it.
in normal state defect)
Referring to TESTING AND ADJUSTING, check the sensor for defective
4 sor defective (Installa-
installation and repair it.
tion defective)
Voltage Max. 1 V
(18) and VH08 (female) (C) and grounding
6
Between (18) and (12), (13) 0.3 – 0.7 V
30 PC1250-8R
PC1250-8R 31
Failure code [DHPAMA] F Pump P. Sensor Abnormality 1
Action code Failure code F Pump P. Sensor Abnormality

Trouble
— DHPAMA (Pump controller system)
Contents of
• The signal voltage from the F pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • The F pump pressure is set to 0 MPa {0 kg/cm2} (This does not affect the control of the machine).
controller • If the cause of the failure disappears, the system resets itself.
Problem that
appears on • The F pump pressure cannot be monitored (Special function of machine monitor).
machine
a If the 5-V circuit (B) and grounding (GND) circuit (A) of the pressure sensor are connected
Related inversely, the pressure sensor will be broken. Take extreme care when checking.
information • Input (pressure) from the F pump pressure sensor can be checked in the monitoring function
(Code 01100: F pump pressure).

Sensor power supply
1 a If error code [DA25KP] is displayed, perform troubleshooting for it first.
system defective
VH02 Voltage
F pump pressure sen-
Between (C) and (A) Power supply 4.5 – 5.5 V
2 sor defective
(Internal defect) Between (B) and (A) Signal 0.5 – 4.5 V
Disconnection of wiring Wiring harness between C01 (female) (22), Resistance
Max. 1 z
harness (Disconnec- JC22, and VH02 (female) (C) value
3
tion or defective con- Wiring harness between C01 (female) (21), Resistance
Possible tact with connector) Max. 1 z
JC22, and VH02 (female) (A) value
causes and
standard value Wiring harness between C01 (female) (8) and Resistance
Max. 1 z
in normal state VH02 (female) (B) value
4
with grounding (GND) Between wiring harness between C01 (female) Resistance
circuit) Min. 1 Mz
(8) and VH02 (female) (B) and grounding value
Hot short circuit in wir- Between wiring harness between C01 (female)
5 ing harness (Contact (22), JC22, and VH02 (female) (C) and ground- Voltage Max. 1 V
with 24-V circuit) ing
Voltage Max. 1 V
Pump controller defec- C01 Voltage
6
tive
Between (22) and (21) 4.5 – 5.5 V
Between (8) and (21) 0.5 – 4.5 V
32 PC1250-8R
Electrical diagram related to F pump pressure sensor
PC1250-8R 33
Failure code [DHPAZL] F Pump Relief Pressure Abnormality 1
Action code Failure code F Pump Relief Pressure Abnormality

Trouble
— DHPAZL (Pump controller system)
Contents of • The signal circuit of the F pump pressure sensor detected pressure of 37.3 MPa or higher {380 kg/
trouble cm2 or higher}.
Action of
controller
Problem that
appears on • If the machine is used as it is, the hydraulic equipment may be broken.
machine
Related • Input (pressure) from the F pump pressure sensor can be checked in the monitoring function
information (Code 01100: F pump pressure).

Abnormal rise of F
1 pump pressure (While Check the relief pressure of the F pump and repair it if abnormal.
system is normal)
Possible F pump pressure sen- If failure error code [DHPAMA] is displayed, perform troubleshooting for it
causes and 2
sor defective first.
standard value
in normal state a Turn the engine starting switch OFF for the preparations, and run the
engine during the troubleshooting.
Pump controller defec-
3 C01 F pump pressure Voltage
tive
37.3 MPa
Between (8) and (21) 3.42 – 3.54 V
{380 kg/cm2}
34 PC1250-8R
Electrical diagram related to F pump pressure sensor
PC1250-8R 35
Failure code [DHPBMA] R Pump P. Sensor Abnormality 1
Action code Failure code R Pump P. Sensor Abnormality

Trouble
— DHPBMA (Pump controller system)
Contents of
• The signal voltage from the R pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
Action of • The R pump pressure is set to 0 MPa {0 kg/cm2} (This does not affect the control of the machine).
controller • If the cause of the failure disappears, the system resets itself.
Problem that
appears on • The R pump pressure cannot be monitored (Special function of machine monitor).
machine
information • Input (pressure) from the R pump pressure sensor can be checked in the monitoring function
(Code 01101: R pump pressure).

Sensor power supply
1 a If error code [DA25KP] is displayed, perform troubleshooting for it first.
system defective
VH03 Voltage
R pump pressure sen-
Between (C) and (A) Power supply 4.5 – 5.5 V
2 sor defective
(Internal defect) Between (B) and (A) Signal 0.5 – 4.5 V
Max. 1 z
3
causes and
Max. 1 z
4
circuit) Min. 1 Mz
Voltage Max. 1 V
6
tive
Between (22) and (21) 4.5 – 5.5 V
Between (2) and (21) 0.5 – 4.5 V
36 PC1250-8R
Electrical diagram related to R pump pressure sensor
PC1250-8R 37
Failure code [DHPBZL] R Pump Relief Pressure Abnormality 1
Action code Failure code R Pump Relief Pressure Abnormality

Trouble
— DHPBZL (Pump controller system)
Contents of • The signal circuit of the R pump pressure sensor detected pressure of 37.3 MPa or higher {380 kg/
trouble cm2 or higher}.
Action of
controller
Problem that
machine
Related • Input (pressure) from the R pump pressure sensor can be checked in the monitoring function
information (Code 01101: R pump pressure).

Abnormal rise of R
1 pump pressure (While Check the relief pressure of the R pump and repair it if abnormal.
system is normal)
Possible R pump pressure sen-
causes and 2 If error code [DHPBMA] is displayed, perform troubleshooting for it.
sor defective
standard value
3 C01 R pump pressure Voltage
tive
37.3 MPa
Between (2) and (21) 3.42 – 3.54 V
{380 kg/cm2}
Electrical diagram related to R pump pressure sensor
38 PC1250-8R
Failure code [DHPTKA] Fan Pump Pre. Sens Failure (or change of
Action code Failure code Fan Pump Pre. Sens Failure

Trouble
— DHPTKA (VHMS controller system)
Contents of
• Sensor output voltage is out of normal range (0.5 – 4.5 V) and below 0.3 V.
trouble
Action of
tor
Problem that
appears on • Pressure may not be displayed normally.
machine
Related • 7-segment LED display of VHMS controller: n5 o 23 (Code is displayed 2 letters by 2.)
information • Fan pump pressure can be checked by downloading data to personal computer after snap shot
operation.

Defective pressure out troubleshooting.
1
sensor 0.46 –
Between P34 (A) – (B) Voltage
0.54 V
harness (Disconnec-
Possible 2 tion in wiring or defec- Wiring harness between VC1 (female) (5) – P34
tive contact in (female) (C), between VC2A (female) (15) – P34
connector) (female) (B) or between VC2A (female) (12), (13)
standard value
– P34 (female) (A)
in normal state
3 harness (Contact with Wiring harness between VC1 (female) (5) – P34
GND circuit) (female) (C) or between VC2A (female) (15) – Resistance Min. 1 Mz
P34 (female) (B) and chassis ground
4
troller
Between VC2A (15) – (12), (13) Voltage 4.5 – 5.5 V
40 PC1250-8R
Electrical diagram related to cooling fan pressure sensor
PC1250-8R 41
Failure code [DHPTKB] Fan Pump Pre. Sens Failure (or change of

Trouble
— DHPTKB (VHMS controller system)
Contents of
• Sensor output voltage is out of normal range (0.5 – 4.5 V) and above 4.7 V.
trouble
Action of
tor
Problem that
appears on • Pressure may not be displayed normally.
machine
operation.

Defective pressure out troubleshooting.
1
sensor 0.46 –
Between P34 (A) – (C) Voltage
0.54 V
Possible a Prepare with starting switch OFF, then carry out troubleshooting without
causes and Ground fault in wiring turning starting switch ON.
standard value 2 harness (Contact with Wiring harness between VC1 (female) (5) – P34
in normal state GND circuit) (female) (C) or between VC2A (female) (15) – Resistance Min. 1 Mz
P34 (female) (B)
3
troller Between P34 (A) – (B) or between VC2A (15) –
(12), (13)
42 PC1250-8R
PC1250-8R 43
Failure code [DV20KB] Travel Alarm S/C 1
Action code Failure code Travel Alarm S/C

Trouble
— DV20KB (Pump controller system)
Contents of
• Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
trouble
Action of • Power to the travel alarm circuit is switched OFF.
machine moni- • Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
tor unless the engine starting switch is once turned OFF.
Problem that
appears on • The travel alarm does not sound.
machine
Related • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
information (Code No. 03701: Controller output 2)

F01 (female) Travel lever Voltage
Travel alarm defective
1 Neutral Max. 1 V
(Internal defect) Between (2) – (1)
Operated 20 – 30 V
If the above voltage is normal but the travel alarm does not operate, the
Possible travel alarm is defective.
causes and
2
(Contact with ground- Between wiring harness between C03 (female)
(8) – F01 (female) (1) and grounding
Pump controller defec- C03 Travel lever Voltage
3
tive
Between (8) – chassis Neutral Max. 1 V
ground Operated 20 – 30 V
44 PC1250-8R
Circuit diagram related to travel alarm
PC1250-8R 45
Failure code [DW41KA] Swing Priority Sol. Disc. 1
Action code Failure code Swing Priority Sol. Disc.

Trouble
— DW41KA (Pump controller system)
Contents of
• No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.
trouble
Action of • None in particular (The solenoid does not function as there is no current flowing to it)
Problem that
appears on • When the boom is raised and swung in the swing priority mode, the swing speed is low.
machine
• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Related
a Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn
information
the solenoid output ON when checking the solenoid again after repairing it. (For how to turn power
ON or OFF, refer to the troubleshooting under failure code [DW41KB].)
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
harness
Wiring harness from C03 (female) (38) to J07 to Resistance
Possible V01 (female) (2) value
causes and connector) Wiring harness between V01 (female) (1) and Resistance
grounding value
in normal state
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
Pump controller the OFF position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (38) and grounding 20 – 60 z
46 PC1250-8R
Electrical diagram related to swing priority solenoid
PC1250-8R 47
Failure code [DW41KB] Swing Priority Sol. S/C 1
Action code Failure code Swing Priority Sol. S/C

Trouble
— DW41KB (Pump controller system)
Contents of
• Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.
trouble
• Power supply to the swing priority solenoid circuit is switched OFF.
Action of
controller
Problem that
appears on • When the boom is raised and swung in the swing priority mode, the swing speed is low.
machine
Related • Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)

Swing priority solenoid the OFF position during the troubleshooting.
defective V01 (male) Resistance value
1
ing or grounding fault) Between (2) and (1) 20 – 60 z
Between (2) and grounding Min. 1 Mz
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
ing circuit) (38), J07, and V01 (female) (2) or between D04 Min. 1 Mz
value
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 PC1250-8R
Electrical diagram related to swing priority solenoid
PC1250-8R 49
Failure code [DW43KA] Travel Speed Sol. Disc. 1
Action code Failure code Travel Speed Sol. Disc.

Trouble
Contents of
• No current flows to the travel speed solenoid circuit, when power is supplied to the circuit.
trouble
Problem that
• The travel speed does not shift to Hi.
appears on
(The display changes normally in the machine monitor)
machine
• Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function.
Related
information
Travel speed solenoid a Turn the engine starting switch OFF for the preparations, and hold it in
1
harness
grounding value
in normal state
ing harness
3
4
50 PC1250-8R
Electrical diagram related to travel speed solenoid
PC1250-8R 51
Failure code [DW43KB] Travel Speed Sol. S/C 1
Action code Failure code Travel Speed Sol. S/C

Trouble
Contents of
• Abnormal current flew to the travel speed solenoid, when power was supplied to the circuit.
trouble
• Power supply to the travel speed solenoid circuit is switched OFF.
Action of
controller
Problem that
• The travel speed does not turn to Hi.
appears on
(The display in the machine monitor changes correctly)
machine
Related • Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function.

Travel speed solenoid the OFF position during the troubleshooting.
1
2
Possible (Internal short-circuit- D04 (male) Resistance value
causes and ing) Between (2) and (6) Min. 1 Mz
standard value
ing harness
3
value
Pump controller C03 Travel lever Voltage
4
defective
Between (27) and Lo Max. 1 V
grounding Hi + Travel operation 20 – 30 V
52 PC1250-8R
Electrical diagram related to travel speed solenoid
PC1250-8R 53
Failure code [DW45KA] Swing Brake Sol. Disc. 1
Action code Failure code Swing Brake Sol. Disc.

Trouble
E03 DW45KA (Pump controller system)
Contents of
• No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
trouble
• Flashes user code and turns on caution buzzer.
Action of
• None in particular (The solenoid does not function as there is no current flowing to it)
controller
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Problem that
appears on • The machine cannot swing.
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring func-
tion. (Code No. 02300: Solenoid 1)
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
brake release switch to the RELEASE position (The swing brake does not operate when the
Related machine stops swinging, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the
RELEASE position during troubleshooting.
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn
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
Swing lock switch the OFF position during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
tion) OFF Max. 1 z
Between (3) and (4)
LOCK Min. 1 Mz
Possible 3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
causes and tion) Between (7) and (3) Diode mode Continued
standard value
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
X05 (male) (3) value
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
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 PC1250-8R

standard value Pump controller
6 C03 (female) Disconnect D01 and Resistance value
Between (37) and connect pins (3) and (7)
of the female side. 20 – 60 z
grounding
Electrical diagram related to swing holding brake
PC1250-8R 55
Failure code [DW45KB] Swing Brake Sol. S/C 1
Action code Failure code Swing Brake Sol. S/C

Trouble
E03 DW45KB (Pump controller system)
Contents of • Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the
trouble circuit.
• Flashes user code and turns on caution buzzer.
Action of • Power supply to the swing holding brake solenoid circuit is switched OFF.
controller • Even after the failure cause disappears of itself, the swing and steering brake does not return to
normalcy, unless the engine starting switch is once turned OFF.
Problem that
appears on • The machine cannot swing.
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring func-
tion. (Code No. 02300: Solenoid 1)
Related
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turn-
information
ing the emergency swing brake releasing switch to the FREE position.
(In this case, however, the holding brake does not work, when stopping the machine)

Swing holding brake the OFF position during the troubleshooting.
solenoid defective V04 (male) Resistance value
1
2
Possible ing)
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
Pump controller C03 Swing control lever Voltage
4
defective
Between (37) and NEUTRAL Max. 1 V
grounding Swing 20 – 30 V
56 PC1250-8R
Electrical diagram related to swing holding brake
PC1250-8R 57
Failure code [DW48KA] CO Cancel Sol. Disc. 1
Action code Failure code CO Cancel Sol. Disc.

Trouble
Contents of
• No current flows to the CO cancel solenoid circuit, when power is supplied to the circuit.
trouble
Action of • None in particular (The solenoid does not function as there is current flowing to it)
Problem that
appears on • When the machine travels or the boom is raised, power is insufficient.
machine
• Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
Related
information
CO cancel a Turn the engine starting switch OFF for the preparations, and hold it in
1
harness
grounding value
in normal state
ing harness
3
4
58 PC1250-8R
Electrical diagram related to CO cancel solenoid
PC1250-8R 59
Failure code [DW48KB] CO Cancel Sol. S/C 1
Action code Failure code CO Cancel Sol. S/C

Trouble
Contents of
• Abnormal current flew to the CO cancel circuit, when power was supplied to the circuit.
trouble
• Power supply to the CO cancel circuit is switched OFF.
Action of
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy,
controller
Problem that
appears on • When the machine travels or the boom is raised, power is insufficient.
machine
Related • Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid)

CO cancel solenoid the OFF position during the troubleshooting.
1
2
Possible (Internal short-circuit- D03 (male) Resistance value
causes and ing) Between (1) and (5) Min. 1 Mz
standard value
ing harness
3
value
Pump controller C03 Heavy lift switch Voltage
4
defective
grounding ON 20 – 30 V
60 PC1250-8R
Electrical diagram related to CO cancel solenoid
PC1250-8R 61
SEN02082-00

© 2006 KOMATSU
All Rights Reserved
62
SEN02083-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
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
Failure code [DY2DKB] Wiper Drive (For) S/C ............................................................................................. 32
PC1250-8R 1
Failure code [DY2EKB] Wiper Drive (Rev) S/C............................................................................................. 36

Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED display from n3 to 38)............... 38
Failure code [F@BYNR] High F cyl. Exhaust Temp. 2
Failure code [F@BYNS] High F cyl. Exhaust Temp. 1
Failure code [F@BZNR] High R cyl. Exhaust Temp. 2
Failure code [F@BZNS] High R cyl. Exhaust Temp. 1
Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality .................................................................... 48
Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality ................................................................... 50
Failure code [J100KA] Cnt. Pump Pre. Sens Failure
(or change of VHMS-LED display from n5 to 11) ...................................................................................... 52
Failure code [j100KA] Fan Pump Pre. Sens Failure
Failure code [J100KB] Cnt. Pump Pre. Sens Failure
Failure code [j100KB] Fan Pump Pre. Sens Failure
Failure code [J100L6] Abnormal Cnt. gear pump press
Failure code [j100L6] Abnormal Fan gear pump press
Failure code [LA10ZL] Fan Pump Relief Press Abnormality
2 PC1250-8R
Failure code [DW7BKA] Fan Reverse Sol. Disc. 1
Action code Failure code Fan Reverse Sol. Disc.

Trouble
— DW7BKA (Pump controller system)
Contents of
• When signal is output to hydraulic fan reverse solenoid circuit, no current flows.
trouble
Problem that
appears on • Fan does not rotate in reverse.
machine
• Operating condition (ON/OFF) of fan reverse solenoid can be checked with monitoring function.
Related (Code 02301: Solenoid 1)
information • Since disconnection of solenoid is detected while output is turned ON, be sure to turn output ON
(rotate fan in reverse) when checking reproduction of failure after repair.

Defective hydraulic fan the OFF position during the troubleshooting.
1 reverse solenoid (Inter-
V17 (male) Resistance
nal disconnection)
Between (1) – (2) 20 – 60 z
harness (Disconnec- Wiring harness between C03 (female) (25) – V17
Possible 2 Resistance Max. 1 z
tion of defective con- (female) (1)
causes and tact with connector)
standard value Wiring harness between V17 (female) (2) – C03
Resistance Max. 1 z
in normal state (female) (3)
Short-circuiting of wir- the ON position during the troubleshooting.
with 24 V circuit) Between wiring harness between C03 (female)
Voltage Max. 1 V
(25) – V17 (female) (1) and grounding
Pump controller engine running during the troubleshooting.
4
defective C03 (female) Resistance
4 PC1250-8R
Circuit diagram related to hydraulic fan
PC1250-8R 5
Failure code [DW7BKB] Fan Reverse Sol. S/C 1
Action code Failure code Fan Reverse Sol. S/C

Trouble
— DW7BKB (Pump controller system)
Contents of
• When signal was output to hydraulic fan reverse solenoid circuit, abnormal current flowed.
trouble
Action of • Turns signal to hydraulic fan reverse solenoid circuit OFF.
Problem that
appears on • Fan does not rotate in reverse.
machine
Related • Operating condition (ON/OFF) of fan reverse solenoid can be checked with monitoring function.
information (Code 02300: Solenoid 1)

Defective hydraulic fan
1 reverse solenoid (Inter- V17 (male) Resistance
nal disconnection) Between (1) – (2) 20 – 60 z
Possible Between (2) and grounding Min. 1 Mz
causes and Grounding fault of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
standard value ing harness the OFF position during the troubleshooting.
in normal state 2
(Contact with ground- Between wiring harness between C03 (female)
(25), – V17 (female) (1) and grounding
Pump controller engine running during the troubleshooting.
3
defective C03 Resistance
6 PC1250-8R
PC1250-8R 7
Failure code [DW91KA] Travel Junction Sol. Disc. 1
Action code Failure code Travel Junction Sol. Disc.

Trouble
Contents of
• No current flows to the straight travel solenoid circuit, when power is supplied to the circuit.
trouble
Action of • None in particular (The solenoid does not function as there is current flowing to it)
Problem that
appears on • When both tracks and work equipment are operated simultaneously, the machine deviates.
machine
• Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function.
Related
information
Straight travel a Turn the engine starting switch OFF for the preparations, and hold it in
1
harness
grounding value
in normal state
ing harness
3 Between wiring harness between C03 (female)
(Contact with 24 V cir-
4
8 PC1250-8R
Electrical diagram related to straight travel solenoid
PC1250-8R 9
Failure code [DW91KB] Travel Junction Sol. S/C 1
Action code Failure code Travel Junction Sol. S/C

Trouble
Contents of
• Abnormal current flew to the straight travel circuit, when power was supplied to the circuit.
trouble
• Power supply to the straight travel circuit is switched OFF.
Action of
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Problem that
appears on • When both tracks and work equipment are operated simultaneously, the machine deviates.
machine
Related • Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid)

Straight travel sole- the OFF position during the troubleshooting.
noid defective V03 (male) Resistance value
1
2
Possible ing) Between (3) and (7) Min. 1 Mz
causes and
standard value Grounding fault of wir- the OFF position during the troubleshooting.
in normal state ing harness
3
value
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 PC1250-8R
Electrical diagram related to travel junction solenoid
PC1250-8R 11
Failure code [DWK0KA] 2-stage Relief Sol. Disc. 1
Action code Failure code 2-stage Relief Sol. Disc.

Trouble
— DWK0KA (Pump controller system)
Contents of
• No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
trouble
Problem that
appears on • The heavy-lift function does not work.
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
Related
information
ON or OFF, refer to the troubleshooting under failure code [DWK0KB].)
2-stage relief solenoid a Turn the engine starting switch OFF for the preparations, and hold it in
1
harness
grounding value
in normal state
ing harness
3
4
12 PC1250-8R
Electrical diagram related to 2-stage relief solenoid
PC1250-8R 13
Failure code [DWK0KB] 2-stage Relief Sol. S/C 1
Action code Failure code 2-stage Relief Sol. S/C

Trouble
— DWK0KB (Pump controller system)
Contents of
• Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
trouble
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Action of
controller
Problem that
appears on • The heavy-lift function does not work.
machine
Related • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.

2-stage relief solenoid the OFF position during the troubleshooting.
1
2
Possible ing)
ing harness
3
value
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 PC1250-8R
Electrical diagram related to 2-stage relief solenoid
PC1250-8R 15
Failure code [DX16KA] Fan Pump EPC Sol. Disc. 1
Action code Failure code Fan Pump EPC Sol. Disc.

Trouble
E11 DX16KA (Pump controller system)
Contents of
• No current flows into hydraulic fan EPC solenoid circuit.
trouble
• Sets the power supply to OFF when disconnection occurs, which can cause the maximum swash
Action of
plate of the fan pump and excessive rotation of the fan, and therefore changes into the mode of pro-
controller
tection to lower the engine speed.
Problem that
appears on • Fan motor speed cannot be controlled.
machine
Related • Output (Current) to EPC solenoid can be checked with monitoring function.
information (Code 31623: EPC solenoid current)

1 EPC solenoid (Internal
V30 (male) Resistance
disconnection)
Between (1) – (2) 10 – 22 z
harness
Wiring harness between C03 (female) (35) – V30
2 (Disconnection or Resistance Max. 1 z
(female) (1)
Possible defective contact with
connector) Wiring harness between V30 (female) (2) – C03
(female) (23)
standard value
Short-circuiting of wir- the ON position during the troubleshooting.
3 Voltage Max. 1 V
(Contact with 24 V cir- (35) – V30 (female) (1) and grounding
cuit) Between wiring harness between V30 (female)
Voltage Max. 1 V
(2) – C03 (female) (23) and grounding
Pump controller defec- the OFF position during the troubleshooting.
4
tive C03 (female) Resistance
Between (35) – (23) 7 – 14 z
16 PC1250-8R
PC1250-8R 17
Failure code [DX16KB] Fan Pump EPC Sol. S/C 1
Action code Failure code Fan Pump EPC Sol. S/C

Trouble
E11 DX16KB (Pump controller system)
Contents of
• Abnormal current flowed in hydraulic fan EPC solenoid circuit.
trouble
• Sets the power supply to OFF when short circuit occurs, which can cause the maximum swash plate
Action of
of the fan pump and excessive rotation of the fan, and therefore changes into the mode of protection
controller
to lower the engine speed.
Problem that
appears on • Fan motor speed cannot be controlled.
machine
Related • Output (Current) to EPC solenoid can be checked with monitoring function.
information (Code 31623: EPC solenoid current)

EPC solenoid V30 (male) Resistance
1
ing or grounding fault) Between (1) – (2) 7 – 14 z
Possible
standard value 2
in normal state (Contact with ground- Between wiring harness between C03 (female)
(35) – V30 (female) (1) and grounding
Pump controller defec- C03 (female) Resistance
3
tive
Between (35) – (23) 7 – 14 z
18 PC1250-8R
PC1250-8R 19
Failure code [DXA0KA] TVC Sol. Disc. 1
Action code Failure code TVC Sol. Disc.

Trouble
E02 DXA0KA (Pump controller system)
Contents of
• Any current does not flow in the TVC solenoid circuit.
trouble
Action of • None in particular. (Since any current does not flow, the solenoid does not operate.)
Problem that
appears on • If the pump load increases, the engine speed lowers largely and the engine may stall.
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
(Code 01300: TVC solenoid current)
Related
• If the solenoid and wiring harness are normal, the machine can be operated with output equivalent
information
to E-mode by setting the emergency pump drive switch in the EMERGENCY position.
• Keep the emergency pump drive switch in the NORMAL position.

TVC solenoid defective the OFF position during the troubleshooting.
1 (Internal short-circuit-
C13 (male) Resistance value
ing or grounding fault)
Between (1) and (2) 10 – 22 z
Emergency pump drive
S25 Resistance value
Emergency pump drive switch
2 switch defective (Inter- OFF Max. 1 z
nal short-circuiting) Between (2) and (3)
ON Min. 1 Mz
OFF Max. 1 z
Between (5) and (6)
ON Min. 1 Mz
Possible
causes and Wiring harness between C03 (female) (16) and Resistance
Disconnection of wiring Max. 1 z
standard value S25 (3) value
in normal state harness
Wiring harness between S25 (2) and C13 Resistance
(female) (1) value
connector) Wiring harness between C03 (female) (3) and Resistance
Max. 1 z
S25 (6) value
Wiring harness between S25 (5) and C13 Resistance
Max. 1 z
(female) (2) value
4 Voltage Max. 1 V
(Contact with 24 V cir- (16) and S25 (3) and grounding
cuit) Between wiring harness between S25 (2) and
Voltage Max. 1 V
C13 (female) (1) and grounding
5
defective C03 (male) Resistance value
Between (16) and (3) 10 – 22 z
20 PC1250-8R
Electrical diagram related to TVC solenoid
PC1250-8R 21
Failure code [DXA0KB] TVC Sol. S/C 1
Action code Failure code TVC Sol. S/C

Trouble
E02 DXA0KB (Pump controller system)
Contents of
• Abnormal current flowed in the TVC solenoid circuit.
trouble
• The controller turns OFF the output to the TVC solenoid circuit.
Action of
controller
Problem that
appears on • If the pump load increases, the engine speed lowers largely and the engine may stall.
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
(Code 01300: TVC solenoid current)
Related • If the solenoid and wiring harness are normal, the machine can be operated with output equivalent
information to E-mode by setting the emergency pump drive switch in the EMERGENCY position. (At this time,
action code [E02] and failure code [DXA0KA] are displayed but they do not indicate abnormality.)
• Keep the emergency pump drive switch in the NORMAL position.

TVC solenoid defective
1 (Internal short-circuit- C13 (Male) Resistance value
Emergency pump drive Emergency pump drive
switch defective S25 (male) Resistance valve
2 switch
Possible ing or grounding fault) Between (3) and (4) Min. 1 Mz
causes and Between (3) and Normal
standard value Min. 1 Mz
grounding
in normal state
ing harness Between wiring harness between C03 (female) Resistance
3 Min. 1 Mz
(Contact with ground- (16) and S25 (female) (3) and grounding value
ing (GND) circuit) Between wiring harness between S25 (female) Resistance
Min. 1 Mz
(2) and C13 (female) (1) and grounding value
Pump controller C03 (female) Resistance value
4
defective
Between (16) and (3) 10 – 22 z
22 PC1250-8R
Electrical diagram related to TVC solenoid
PC1250-8R 23
Failure code [DY20KA] Wiper Working Abnormality 1

Single-wiper specification
Action code Failure code Wiper Working Abnormality
Trouble
— DY20KA (Machine monitor system)
Contents of
• A W signal is not inputted at both ends of movement, when it is in motion.
trouble
Response
from Monitor • Power to the windshield wiper motor is turned OFF.
Panel
Problem that
appears on • The windshield wiper motor does not work.
machine
Related • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 04502: Monitor input 3)

the OFF position for the troubleshooting.
Windshield wiper W04 (female) Windshield wiper blade Resistance value
motor defective
1 At upper end of opera-
(Internal disconnec- Max. 1 z
tion) tion range
Between (6) and (5)
Outside upper end of
Min. 1 Mz
operation range
Possible Disconnection of wiring the OFF position for the troubleshooting.
causes and harness
standard value Wiring harness between P01 (female) (5) and Resistance
in normal state W04 (male) (6) value
faulty contact with con-
nector) Wiring harness between W04 (male) (5) and Resistance
Max. 1 z
grounding value
the ON position for the troubleshooting.
P01 Windshield wiper blade Voltage
Machine monitor
3 At upper end of opera-
defective Max. 1 V
Between (5) and tion range
grounding Outside upper end of
20 – 30 V
operation range
24 PC1250-8R
Electrical diagram related to wiper motor (Single-wiper specification)
PC1250-8R 25
Failure code [DY20MA] Wiper Parking Abnormality 1

Double-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
from Monitor • Power supply to the windshield wiper motor is switched OFF, when the wiper is retracted.
Panel
Problem that
appears on • The windshield wiper cannot be retracted completely.
machine
Related
information

Upper wiper motor the OFF position during the troubleshooting.
defective W04 (female) Wiper blade Resistance value
1
tion) In retraction area Max. 1 z
Between (4) and (5)
In operation area Min. 1 Mz
Lower wiper motor the OFF position during the troubleshooting.
defective W05 (female) Wiper blade Resistance value
2
tion) In retraction area Max. 1 z
Between (4) and (5)
In operation area Min. 1 Mz
Possible
causes and Max. 1 z
standard value Disconnection of wiring W04 (male) (4) value
in normal state harness (Disconnec- Wiring harness between W04 (male) (5) and Resistance
3 Max. 1 z
tion or defective con- grounding value
tact with connector) Wiring harness between P01 (female) (5) and Resistance
Max. 1 z
W05 (male) (4) value
Wiring harness between W05 (male) (5) and Resistance
Max. 1 z
grounding value
P01 Upper wiper blade Voltage
Machine monitor Between (12) and In retraction area Max. 1 V

4 grounding
defective In operation area 20 – 30 V
Lower wiper blade Voltage
Between (5) and
In retraction area Max. 1 V
grounding
In operation area 20 – 30 V
26 PC1250-8R
Electrical diagram related to wiper motor (Double-wiper specification)
PC1250-8R 27
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)

Windshield wiper the OFF position for the troubleshooting.
motor defective W04 (female) Windshield wiper blade Resistance value
1
tion) Retraction range Max. 1 z
Between (4) and (5)
Operation range Min. 1 Mz
Possible Disconnection of wiring the OFF position during the troubleshooting.
causes and harness
standard value Wiring harness between P01 (female) (12) and Resistance
in normal state W04 (male) (4) value
connector) Between wiring harness W04 (male) (5) and Resistance
Max. 1 z
grounding value
Machine monitor P01 Windshield wiper blade Voltage
3
defective
Between (12) and Retraction range Max. 1V
grounding Operation range 20 – 30 V
28 PC1250-8R
PC1250-8R 29
Failure code [DY2CKB] Washer Drive S/C 1
Action code Failure code Washer Drive S/C

Trouble
— DY2CKB (Machine monitor system)
Contents of • Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
trouble was switched ON.
Response
from Monitor • Power supply to the grounding in the window washer motor circuit was switched OFF.
Panel
Problem that
appears on • The window washer stopped moving.
machine
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
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
Machine monitor P01 Window washer switch Voltage
3
defective
Between (3) and OFF 20 – 30 V
grounding ON Max. 1 V
30 PC1250-8R
Electrical diagram related to windshield washer motor
PC1250-8R 31
Failure code [DY2DKB] Wiper Drive (For) S/C 1

Double-wiper specification
Action code Failure code Wiper Drive (For) S/C
Trouble
— DY2DKB (Machine monitor system)
Contents of • Abnormal current flowed when the power for the wiper motor forward revolution circuit is turned
trouble ON.
Response
from Monitor • Power for the wiper motor forward revolution circuit is turned OFF.
Panel
Problem that
appears on • The wiper stops.
machine

Upper wiper motor the OFF position during the troubleshooting.
defective W04 (female) Continuity/Resistance value
1
ing or grounding fault) Between (3) and (1) There is continuity
Lower wiper motor the OFF position during the troubleshooting.
defective W05 (female) Continuity/Resistance value
2
ing or grounding fault) Between (3) and (1) There is continuity
Assembled-type diode the OFF position during the troubleshooting.
D06 defective D06 (male) Resistance value (Continuity)
Possible 3
causes and Between (1) and (5) Min. 1 Mz (No continuity)
ing)
standard value
Between (2) and (6) Min. 1 Mz (No continuity)
in normal state
Between wiring harness between P01 (female)
Grounding fault of wir- Resistance
(9) and W04 (male) (3), P01 (female) (9) to D06 Min. 1 Mz
4 ing harness (Contact value
(female) (1) and grounding
with grounding circuit)
Between wiring harness between P01 (female)
Resistance
(10) to J04 and W05 (male) (3), P01 (female) Min. 1 Mz
value
(10) to D06 (female) (2) and grounding
P01 Wiper switch Voltage
Machine monitor
5 Between (9) and OFF Max. 1 V
defective
grounding
Between (10) and Min. 3 V⇔20 – 30 V
ON
grounding (Fixed period)
32 PC1250-8R
Electrical diagram related to wiper motor (Double-wiper specification)
PC1250-8R 33
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

motor defective W04 (female) Continuity and resistance value
1
ing or grounding fault) Between (3) and (1) Continued
Possible Grounding fault of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
causes and ing harness the OFF position for the troubleshooting.
standard value 2
(Contact with ground- Between wiring harnesses between P01 (female) Resistance
in normal state ing circuit) Min. 1 Mz
(9) and W04 (male) (3) and grounding value
Machine monitor P01 Windshield wiper switch Voltage
3
defective OFF Max. 3 V
Between (9) and
grounding Max. 3 V⇔20 – 30 V
ON
(at constant cycle)
34 PC1250-8R
PC1250-8R 35
Failure code [DY2EKB] Wiper Drive (Rev) S/C 1

Action code Failure code Wiper Drive (Rev) S/C
Trouble
— DY2EKB (Machine monitor system)
Contents of • Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
trouble windshield wiper was set in motion.
Response
from Monitor • Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Panel
Problem that
appears on • The windshield wiper stopped moving.
machine

motor defective W04 (female) Continuity and resistance value
1
ing or grounding fault) Between (1) and (3) Continued
Possible Grounding fault of wir- a Turn the engine starting switch OFF for the preparations, and hold it in
causes and ing harness the OFF position for the troubleshooting.
standard value 2
in normal state ing circuit) Min. 1 Mz
Machine monitor P01 Windshield wiper switch Voltage
3
defective OFF Max. 3 V
Between (10) and
grounding Max. 3 V⇔20 – 30 V
ON
(at constant cycle)
36 PC1250-8R
PC1250-8R 37
Failure code [F@BBZL] High Blowby Pressure (or change of VHMS-LED

display from n3 to 38) 1
Action code Failure code High Blowby Pressure

Trouble
— F@BBZL (VHMS controller system)
Contents of • The signal circuit of the blow-by pressure sensor detected pressure of 12.94 kPa {1320 mmAg} or
trouble higher.
Action of
controller
Problem that
machine
tor.
Related
information
• The blow-by pressure can be checked by downloading the data to a personal computer after per-

Abnormal rise of blow-
by pressure Check the engine and repair all abnormality (including the orifice in the
1
(While system is nor- breather).
Possible mal)
causes and
Blow-by pressure sen- If failure code [DHE5KB] is displayed, perform troubleshooting for it first.
standard value 2
sor system defective If failure code [DHE5KY] is displayed, perform troubleshooting for it first.
in normal state
Turn the engine starting switch OFF for the preparations, and hold it in the
VHMS controller ON position or run the engine during the troubleshooting.
3
defective VC2A (female) (18) –
(12), (13)
38 PC1250-8R
PC1250-8R 39
Failure code [F@BYNR] High F cyl. Exhaust Temp. 2 (or change of

Action code Failure code High F cyl. Exhaust Temp. 2

Trouble
— F@BYNR (VHMS controller system)
• The signal circuit of the front exhaust temperature sensor detected that the temperature had
exceeded exhaust temperature limit line 2 for 10 seconds.
Contents of
(Exhaust temperature limit line 2: The straight line connecting 750°C point in the speed range
trouble
above the rated output speed and 800°C point in the speed range below the maximum torque
speed)
Action of
controller
Problem that
machine
tor.
Related
information
• The exhaust temperature can be checked by downloading the data to a personal computer after

Abnormal rise of front
exhaust temperature
1 Check the engine and repair all abnormality.
mal)
Possible Front exhaust temper- If failure code [DGT4KA] is displayed, perform troubleshooting for it first.
causes and 2 ature sensor system
standard value defective If failure code [DGT4KB] is displayed, perform troubleshooting for it first.
in normal state
3
defective
(13) At 500°C Approx. 2.6 – 3.5 V
40 PC1250-8R
Electrical diagram related to exhaust temperature sensor (front and rear)
PC1250-8R 41
Failure code [F@BYNS] High F cyl. Exhaust Temp. 1 (or change of

Action code Failure code High F cyl. Exhaust Temp. 1

Trouble
— F@BYNS (VHMS controller system)
• The signal circuit of the front exhaust temperature sensor detected that the temperature had
exceeded exhaust temperature limit line 1 for 1 second.
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

Abnormal rise of front
exhaust temperature
mal)
Possible Front exhaust temper- If failure code [DGT4KA] is displayed, perform troubleshooting for it first.
causes and 2 ature sensor system
in normal state
3
defective
(13) At 500°C Approx. 2.6 – 3.5 V
42 PC1250-8R
PC1250-8R 43
Failure code [F@BZNR] High R cyl. Exhaust Temp. 2 (or change of

Action code Failure code High R cyl. Exhaust Temp. 2

Trouble
— F@BZNR (VHMS controller system)
• The signal circuit of the rear exhaust temperature sensor detected that the temperature had
exceeded exhaust temperature limit line 2 for 10 seconds.
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

Abnormal rise of rear
exhaust temperature
mal)
Possible Rear exhaust tempera- If failure code [DGT5KA] is displayed, perform troubleshooting for it first.
causes and 2 ture sensor system
in normal state
3
defective
(13) At 500°C Approx. 2.6 – 3.5 V
44 PC1250-8R
PC1250-8R 45
Failure code [F@BZNS] High R cyl. Exhaust Temp. 1 (or change of

Action code Failure code High R cyl. Exhaust Temp. 1

Trouble
— F@BZNS (VHMS controller system)
• The signal circuit of the rear exhaust temperature sensor detected that the temperature had
exceeded exhaust temperature limit line 1 for 1 second.
Contents of
trouble
speed)
Action of
controller
Problem that
machine
tor.
Related
information

Abnormal rise of rear
exhaust temperature
mal)
Possible Rear exhaust tempera- If failure code [DGT5KA] is displayed, perform troubleshooting for it first.
causes and 2 ture sensor system
in normal state
3
defective
(13) At 500°C Approx. 2.6 – 3.5 V
46 PC1250-8R
PC1250-8R 47
Failure code [F@HCMA] Swing Pump Pres. Sen. Abnormality 1
Action code Failure code Swing Pump Pres. Sen. Abnormality

Trouble
— F@HCMA (Pump controller system)
Contents of
• The signal voltage from the swing pump pressure sensor is below 0.3 V or above 4.42 V.
trouble
• The swing pump pressure is set to 0 MPa {0 kg/cm2} (This does not affect the control of the
Action of
machine).
controller
• If the cause of the failure disappears, the system resets itself.
Problem that
appears on • The swing pump pressure cannot be monitored (Special function of machine monitor).
machine
information • Input (pressure) from the swing pump pressure sensor can be checked in the monitoring function
(Code 09000: Swing pump pressure).

Sensor power supply
1 a If failure code [DA25KP] is displayed, perform troubleshooting for it first.
system defective
Swing pump pressure VH04 Voltage

sensor defective Between (C) and (A) Power supply 4.5 – 5.5 V
2
(Internal short-circuit- Between (B) and (A) Signal 0.5 – 4.5 V
ing)
Max. 1 z
3
causes and
Max. 1 z
4
circuit) Min. 1 Mz
Voltage Max. 1 V
6
tive
Between (22) and (21) 4.5 – 5.5 V
Between (19) and (21) 0.5 – 4.5 V
48 PC1250-8R
Electrical diagram related to swing pump pressure sensor
PC1250-8R 49
Failure code [F@HCZL] Swing Pump Relief Pres. Abnormality 1
Action code Failure code Swing Pump Relief Pres. Abnormality

Trouble
— F@HCZL (Pump controller system)
Contents of • The signal circuit of the swing pump pressure sensor detected pressure of 37.3 MPa or higher {380
trouble kg/cm2 or higher}.
Action of
controller
Problem that
machine
Related • Input (pressure) from the swing pump pressure sensor can be checked in the monitoring function
information (Code 09000: Swing pump pressure).

Abnormal rise of swing
pump pressure
1 Check the relief pressure of the swing pump and repair it if abnormal.
mal)
Possible
causes and Swing pump pressure
2 If failure code [F@HCMA] is displayed, perform troubleshooting for it first.
standard value sensor defective
Pump controller
3 C01 Swing pump pressure Voltage
defective
37.3 MPa
Between (19) and (21) 3.42 – 3.54 V
{380 kg/cm2}
Electrical diagram related to swing pump pressure sensor
50 PC1250-8R
Failure code [J100KA] Cnt. Pump Pre. Sens Failure (or change of
Action code Failure code Cnt. Pump Pre. Sens Failure

Trouble
— J100KA (VHMS controller system)
Contents of
• The signal voltage of the control pump pressure sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
tor.
Related
information
• The control pump pressure can be checked by downloading the data to a personal computer after

Sensor 24-V power
1 If failure code [DBB6KP] is displayed, perform troubleshooting for it first.
supply defective
VH11 Voltage
Control pump pres-
Between (B) and (A) 20 – 30 V
2 sure sensor defective
causes and
standard value Disconnection of wiring Wiring harness between VC1 (female) (2) – J24 Resistance
Max. 1 z
in normal state harness (Disconnec- and VH11 (female) (B) value
3
tion or defective con- Wiring harness between VC2A (female) (6) and Resistance
tact with connector) Max. 1 z
VH11 (female) (C) value
Wiring harness between VC2A (female) (12) Resistance
Max. 1 z
(13), J23, J24, J25 and VH11 (female) (A) value
4
circuit) Min. 1 Mz
(6) and VH11 (female) (C) value
VHMS controller the ON position or run the engine during the troubleshooting.
5
Between (6) and (12), (13) 0.5 – 4.9 V
52 PC1250-8R
Electrical diagram related to control pump pressure sensor
PC1250-8R 53
Failure code [j100KA] Fan Pump Pre. Sens Failure (or change of VHMS-

Trouble
— j100KA (VHMS controller system)
Contents of
• The signal voltage of the fan pump pressure sensor is below 0.5 V.
trouble
Action of
controller
Problem that
machine
tor.
Related
information
• The fan pump pressure can be checked by downloading the data to a personal computer after per-

ply defective
Radiator coding fan P34 Voltage

pump pressure sensor Between (C) and (A) 4.5 – 5.5 V
2
defective Between (B) and (A) 0.3 – 4.7 V
(Internal defect)
Possible
causes and
standard value
in normal state harness (Disconnec- Wiring harness between VC1 (female) (5) and Resistance
3 Max. 1 z
tion or defective con- P34 (female) (C) value
tact with connector) Wiring harness between VC2A (female) (15) and Resistance
Max. 1 z
P34 (female) (B) value
4
circuit) Min. 1 Mz
(15) and P34 (female) (B) and grounding value
5
Between (15) and (12), (13) 0.3 – 4.7 V
54 PC1250-8R
Electrical diagram related to cooling fan pump pressure sensor
PC1250-8R 55
Failure code [J100KB] Cnt. Pump Pre. Sens Failure (or change of
Action code Failure code Cnt. Pump Pre. Sens Failure

Trouble
— J100KB (VHMS controller system)
Contents of
• The signal voltage of the control pump pressure sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine
tor.
Related
information

Sensor 24-V power
supply defective
VH11 Voltage
Control pump pres-
Between (B) and (A) 20 – 30 V
2 sure sensor defective
Possible
causes and The voltage of the pressure sensor is measured with the wiring harness
standard value connected. Accordingly, if the voltage is abnormal, check the wiring har-
in normal state ness and controller for another cause of the trouble, and then judge.
Voltage Max. 1 V
(6) and VH11 (female) (C) and grounding
4
Between (6) and (12), (13) 0.5 – 4.9 V
56 PC1250-8R
PC1250-8R 57
Failure code [j100KB] Fan Pump Pre. Sens Failure (or change of VHMS-

Trouble
— j100KB (VHMS controller system)
Contents of
• The signal voltage of the fan pump pressure sensor is above 4.9 V.
trouble
Action of
controller
Problem that
machine
tor.
Related
information

ply defective
Radiator cooling fan P34 Voltage

pump pressure sensor Between (C) and (A) 4.5 – 5.5 V
2
defective Between (B) and (A) 0.3 – 4.7 V
Possible (Internal defect)
causes and The voltage of the pressure sensor is measured with the wiring harness
standard value connected. Accordingly, if the voltage is abnormal, check the wiring har-
in normal state ness and controller for another cause of the trouble, and then judge.
ing harness with power the ON position during the troubleshooting.
3
source (Contact with Between wiring harness between VC2A (female)
24-V circuit) Voltage Max. 1 V
(15) and P34 (female) (B) and grounding
5
Between (15) and (12), (13) 0.3 – 4.7 V
58 PC1250-8R
PC1250-8R 59
Failure code [J100L6] Abnormal Cnt. gear pump press (or change of
Action code Failure code Abnormal Cnt. gear pump press (Signal during operation is inconsistent
Trouble
— J100L6 with that during stop) (VHMS controller system)
• The signal circuit of the control pump pressure sensor detected that the pressure had been below
Contents of
2.84 MPa {29 kg/cm2} or above 3.73 MPa {38 kg/cm2} for 5 seconds.
trouble
(While the hydraulic oil temperature is above 50°C and the engine speed is above 1,750 rpm)
Action of
controller
Problem that
machine
tor.
Related
information

Abnormal control
pump pressure
1 Check the control pump and repair all abnormality.
mal)
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
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 PC1250-8R
PC1250-8R 61
Failure code [j100L6] Abnormal Fan gear pump press (or change of
Action code Failure code Abnormal Fan gear pump press (Signal during operation is inconsistent
Trouble
— j100L6 with that during stop) (VHMS controller system)
• The signal circuit of the fan pump pressure sensor detected that the pressure had been below 4.91
Contents of
MPa {50 kg/cm2} or above 22.6 MPa {230 kg/cm2} for 5 seconds.
trouble
(While the hydraulic oil temperature is above 50°C and the engine speed is above 1,750 rpm)
Action of
controller
Problem that
machine
tor.
Related
information

Abnormal fan pump
pressure
1 Check the fan pump and repair all abnormality.
mal)
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
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 PC1250-8R
PC1250-8R 63
Failure code [LA10ZL] Fan Pump Relief Press Abnormality (or change
of VHMS-LED display from n5 to 25) 1
Action code Failure code Fan Pump Relief Press Abnormality

Trouble
— LA10ZL (VHMS controller system)
Contents of • Fan pump relief pressure sensor signal circuit detected pressure higher than 35.7 MPa {357 kg/
trouble cm2} for 5 seconds.
Action of
controller
Problem that
appears on • If machine is used as it is, hydraulic equipment may be broken.
machine
operation.

Abnormal radiator fan
1 pump pressure (when Check cooling fan pump pressure. If it is abnormal, repair.
Possible system is normal)
causes and
Defective radiator fan If failure code [DHPTKA], [DHPTKB] or [DBB5KP] is displayed, carry out
standard value 2
pump pressure sensor troubleshooting for it first.
in normal state
1) Prepare with starting switch OFF, then turn starting switch ON and carry
Defective VHMS out troubleshooting.
3
controller
Between VC1 (5) – VC2A (12), (13) Voltage 4.5 – 5.5 V
64 PC1250-8R
PC1250-8R 65
SEN02083-00

© 2006 KOMATSU
All Rights Reserved
66
SEN02085-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
Troubleshooting of electrical system
(E-mode)
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
E-12 Hydraulic oil temperature gauge does not display correctly................................................................. 26
PC1250-8R 1
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
E-29 Electric priming pump does not operate or does not stop automatically .............................................. 54
2 PC1250-8R
Before carrying out troubleshooting of electrical system 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 related to the electrical system, you should check the circuit breakers
first to see if the power is supplied normally.
Type of power Circuit breaker Circuit breaker

Destination of power
supply No. capacity
1 40 A Fuse box (Fuses No. 1 – 14)
2 40 A Breaker (Breaker No.4, 5, 6, and 7)
Switch power supply 4 20 A Machine monitor
(Battery relay
terminal M) 5 20 A Lamp switch
6 20 A Pump controller (Solenoid power source)
7 20 A Lamp relay
3 40 A Breaker (Breaker No.8, 9, 10, and 11)
Constant power 8 20 A Pump controller, starting switch
supply 9 20 A Engine controller
(Battery relay 10 20 A Machine monitor
terminal B) 11 20 A Fuse box (Fuse No.16 – 20)
12 20 A Priming pump
PC1250-8R 3
Connection table of fuse boxes

a This connection table shows the devices to which each power supply of the fuse boxes 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 fuse boxes to see if the
power is supplied normally.
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 PC1250-8R
Information contained in troubleshooting table 1
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

<Contents of description>
• Standard value in normal state to judge possible causes
• Remarks on judgment
1
<Troubles in wiring harness>
• Disconnection
Connector is connected imperfectly or wiring harness is broken.
• Ground fault
Wiring harness which is not connected to chassis ground circuit is in
2 contact with chassis ground circuit.
• Hot short
Wiring harness which is not connected to power source (24 V) circuit is
in contact with the 24 V circuit.
Possible Possible causes of
causes and trouble
standard value (Given numbers are
3
in normal state reference numbers,
<Precautions for troubleshooting>
which do not indicate
(1) Method of indicating connector No. and handling of T-adapter
priority)
Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
• If connector No. has no marks of “male” and “female”, disconnect con-
nector and insert T-adapters in both male side and female side.
4
• If connector No. has marks of “male” and “female”, disconnect connec-
tor and connect T-adapter to only male side or female side.
(2) Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative (–) lead of tester as explained
below for troubleshooting, unless otherwise specified.
• Connect positive (+) lead to pin No. or wiring harness entered on front
5 side.
• Connect negative (–) lead to pin No. or harness entered on rear side.
Relative Electrical Circuit Diagram
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)
• Connector No. and pin No. at diverging and converging points: Indi-
cates the points to diverge or converge for components on the same
wiring harness.
• Arrow : Roughly indicates the location in the machine where it is
installed.
PC1250-8R 5
E-1 Engine does not start (Engine does not rotate) 1
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

Shortage in battery Battery voltage Battery electrolyte specific gravity
1
capacity Min. 24 V Min. 1.26
If a circuit breaker is turned OFF or a fuse is broken, the circuit is probably
Circuit breaker No. 1,
short-circuited with grounding.
2 No. 3 and No. 8, fuse
If the machine monitor does not light up, perform troubleshooting of E-8
(3) defective
first.
Engine starting switch
fault
3 (Internal H15 (male) Position Resistance value
disconnection) OFF Min. 1 Mz
(B – C) Between (1) and (4)
Start Max. 1 z
PPC lock switch fault
4 (Internal S14 (female) Lock lever Resistance value
short-circuiting) Release Min. 1 Mz
Between (1) and (3)
LOCK Max. 1 z
Possible Engine starting motor the OFF position during the troubleshooting.
causes and cut relay, R11 and R13
defective R11 (female) & R13 (male) Resistance value
standard value
5
in normal state (Internal Between (1) and (2) 100 – 500 z
disconnection or short- Between (3) and (5) Min. 1 Mz
circuiting)
Between (3) and (6) Max. 1 z
engine running during the troubleshooting. (If all of the power source,
grounding (GND), generation signal and engine start input are normal
and yet the engine start output is not normal, the engine starting motor
relay is defective)
Engine
Engine starting motor Safety relay starting Voltage
safety relay fault switch
6 (Internal Power source: Between B terminal and ground-
disconnection or short- ing 20 – 30 V
circuiting)
Generation signal: Between R terminal and ST1
Max. 12 V
(2), ST2 (2), grounding
Start
Starting input: Between S terminal and ST1 (1),
20 – 30 V
ST2 (1), grounding
Engine start output: Between C terminal and
20 – 30 V
grounding
6 PC1250-8R

engine running during the troubleshooting. (If all of the power source,
grounding (GND), generation signal and engine start input are normal
and yet the engine start output is not normal, the engine starting motor
Engine starting motor
relay is defective)
fault
7 Engine
tion or damage) Engine starting motor starting Voltage
switch
Power source: B terminal and grounding 20 – 30 V
Start
Engine start input: C terminal and grounding 20 – 30 V
Alternator fault the ON position or running during the troubleshooting.
8
(Regulator fault) Alternator Voltage
Between Terminal R and grounding Max. 12 V
Wiring harness between B28 and H15 (female) Resistance
Max. 1 z
(1) value
Wiring harness from H15 (female) (4) to J01 to Resistance
Max. 1 z
R11 (female) (5) value
Wiring harness between R11 (female) (3) and Resistance
Max. 1 z
Disconnection of wiring ST1, ST2 (female) (1) value
harness Wiring harness between engine starting motor
Resistance
9 (Disconnection or safety relay C terminal and engine starting motor Max. 1 z
value
Possible defective contact with C terminal
causes and connector) Wiring harness between FB1-3 and S14 (female) Resistance
Max. 1 z
standard value (1) value
in normal state Wiring harness between S14 (female) (3) and Resistance
Max. 1 z
Max. 1 z
Wiring harness from R13 (female) (3) to J04 to Resistance
Max. 1 z
grounding value
Between wiring harness from battery relay B ter- Resistance
Min. 1 Mz
minal to circuit breaker No.3 and B18 value
Between wiring harness between B28 and H15 Resistance
Min. 1 Mz
(female) (1) and grounding value
Between wiring harness from H15 (female) (4) to Resistance
Min. 1 Mz
J01 to R11 (female) (5) and grounding value
Grounding fault of wir-
Between wiring harness between R11 (female) Resistance
ing harness Min. 1 Mz
10 (3) and ST1, ST2 (female) (1) and grounding value
(Contact with ground-
ing circuit) Between wiring harness between engine starting
Resistance
motor safety relay C terminal and engine starting Min. 1 Mz
value
motor C terminal and grounding
Between wiring harness between FB1-3 and S14 Resistance
Min. 1 Mz
(female) (1) and grounding value
Between wiring harness between S14 (female) Resistance
Min. 1 Mz
(3) and R11 (female) (1) and grounding value
Between wiring harness from R13 (female) (2) to Resistance
Min. 1 Mz
P02 (female) (14) and grounding value
PC1250-8R 7

Possible ing harness Between wiring harness between ST1 (female)
11
causes and (Contact with 24 V cir- (2), ST2 (female) (2), E08 (female) (C), J21, J02,
standard value D01 (female) (6), and P02 (female) (11) and
in normal state grounding
Detective engine con- As the engine controller power supply can be detective, carry out trouble-
12
troller power supply shooting for "Failure code CA111".
8 PC1250-8R
Electrical diagram related to engine start and battery charging
PC1250-8R 9
E-2 Auto-decelerator does not work 1
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 above this level, the
Related
auto-decelerator does not work.
information
• Confirm the display on the monitor panel, when the engine is running.

If the display on the monitor panel is not normal, proceed to No. E-18
Troubleshooting.
Boom RAISE signal
1 Monitoring code Item Normal display
fault
Lever operation: ON
01900 Boom RAISE
Lever NEUTRAL: OFF
Troubleshooting.
Boom LOWER signal
fault
Lever operation: ON
01900 Boom LOWER
Lever NEUTRAL: OFF
Troubleshooting.
3 Arm IN signal fault Monitoring code Item Normal display
Lever operation: ON
01900 Arm IN
Lever NEUTRAL: OFF
Troubleshooting.
4 Arm OUT signal fault Monitoring code Item Normal display
Possible Lever operation: ON
01900 Arm OUT
causes and Lever NEUTRAL: OFF
standard value If the display on the monitor panel is not normal, proceed to No. E-22
in normal state Troubleshooting.
Bucket CURL signal
fault
Lever operation: ON
01901 Bucket CURL
Lever NEUTRAL: OFF
Troubleshooting.
Bucket DUMP signal
fault
Lever operation: ON
01901 Bucket DUMP
Lever NEUTRAL: OFF
Troubleshooting.
7 Swing signal fault Monitoring code Item Normal display
Lever operation: ON
01900 Swing
Lever NEUTRAL: OFF
Troubleshooting.
8 R.H. travel signal fault Monitoring code Item Normal display
Lever operation: ON
01900 R.H. travel
Lever NEUTRAL: OFF
10 PC1250-8R

Troubleshooting.
Possible 9 L.H. travel signal fault Monitoring code Item Normal display
causes and Lever operation: ON
standard value 01901 L.H. travel
Lever NEUTRAL: OFF
in normal state
As this is an internal failure, troubleshooting cannot be conducted. (If there
10 is none of the causes listed in Item 1 through 9, the controller is judged as
tive
defective.
PC1250-8R 11
E-3 Auto engine warm-up device does not work 1
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.

If the display on the monitor panel is not normal, proceed to No. CA144
Troubleshooting.
Possible Engine coolant tem- Monitoring code Item Normal display
1
causes and perature signal fault Compare with the
standard value Engine coolant temper-
04107 actual engine coolant
in normal state ature
temperature.
As this is an internal failure, troubleshooting cannot be conducted.
2 (If the fault mentioned in the above item is not found, the pump controller
tive
is judged as defective)
12 PC1250-8R
PC1250-8R 13
E-4 Preheater does not work 1
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.

Engine starting switch If preheating does not occur (the heater is not warmed up), refer to Failure
1
fault Phenomenon (2) below.
Possible harness the OFF position during the troubleshooting.
causes and 2 (Disconnection or
standard value defective contact with Wiring harness between P02 (female) (18) and Resistance Max. 1 z
connector) J02 (male) (7) value
in normal state
a Turn the engine starting switch OFF for the preparations.
P02 Engine starting switch Voltage
3 Machine monitor fault
grounding HEAT 20 – 30 V
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.
Engine starting switch
fault H15 (male) Engine starting switch Resistance value
1
(Internal disconnec- OFF Min. 1 Mz
tion) Between (1) and (3)
HEAT Max. 1 z
Heater relay fault Heater relay Continuity and resistance value
2 (Internal disconnec-
Possible tion) Between coil terminal S
Continued
causes and and grounding
standard value Between contact terminals Min. 1 Mz
in normal state
Electrical intake air a Turn the engine starting switch OFF for the preparations, and hold it in
heater the OFF position during the troubleshooting.
3
tion) Between heater terminals Normal if continuity is established.
harness
Wiring harness from H15 (female) (3) to J02 to Resistance
heater relay terminal (S) value
connector) Wiring harness between battery relay M terminal Resistance
Max. 1 z
and heater relay terminal B value
14 PC1250-8R
Electrical diagram related to engine preheater
PC1250-8R 15
E-5 All work equipment, swing and travel do not move 1
Failure
• All the work equipment, swing and travel do not move.
information
Related
—
information

If the fuse is blown, there is a big possibility that grounding fault occurred
1 Fuse No. 3 fault
in the circuit.
PPC lock switch defec- the OFF position during the troubleshooting.
tive S14 (female) Lock lever Resistance value
2
tion) Lock Min. 1 Mz
Between (1) and (2)
Release Max. 1 z
PPC lock solenoid fault
3 (Internal disconnec- V08 (male) Resistance value
tion or short-circuiting) Between (2) and (1) 20 – 60 z
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
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
Max. 1 z
grounding value
Between wiring harness between FB1-3 outlet Resistance
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 PC1250-8R
Electrical diagram related to PPC lock solenoid
PC1250-8R 17
E-6 Machine push-up circuit does not work 1
Failure
• Machine push-up circuit does not work
information
Related
—
information

1 Fuse No. 2 defective If the fuse is broken, the circuit is probably short-circuited with grounding.
Machine push-up Machine push-up
2 switch defective (Inter- M38 (female) Resistance value
switch
nal disconnection)
OFF Min. 1 Mz
Between (1) and (2)
ON Max. 1 z
Machine push-up sole- the OFF position during the troubleshooting.
noid defective (Inter- V05 (male) Resistance value
3
nal short-circuiting or
grounding fault) Between (2) and (1) 20 – 60 z
Collected diode D04 a Turn the engine starting switch OFF for the preparations, and hold it in
defective
causes and 4
standard value
ing) Between (1) and (5) Min. 1 Mz
in normal state
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
Max. 1 z
grounding value
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 PC1250-8R
Electrical diagram related to machine push-up
PC1250-8R 19
E-7 Boom shockless circuit cannot be reset 1
Failure
• Boom shockless circuit cannot be reset
information
Related
—
information

1 Fuse No. 2 defective If the fuse is broken, the circuit is probably short-circuited with grounding.
Boom shockless
2 switch defective (Inter- M39 (female) Boom shockless switch Resistance value
nal disconnection) ON Min. 1 Mz
Between (3) and (2)
OFF Max. 1 z
Machine push-up sole- the OFF position during the troubleshooting.
noid defective (Inter- V09, V10 (male) Resistance value
3
nal short-circuiting or
grounding fault) Between (2) and (1) 20 – 60 z
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
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
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 PC1250-8R
Electrical diagram related to boom shockless control
PC1250-8R 21
E-8 No display in machine monitor at all 1
Failure • When the engine starting switch is turned ON, there appears no display at all in the machine moni-
information tor.
Related
—
information

Circuit breaker No. 2, If the circuit breaker disconnected, there is a big possibility that grounding
1
No. 4 fault fault occurred in the circuit.
harness
Wiring harness from P01 (female) (1) (2) to B24, Resistance
B14 to B22 value
defect contact with
connector) Wiring harness between P01 (female) (6) (7) and Resistance
Max. 1 z
grounding value
ing harness
standard value
3 (Contact with ground- Between wiring harness between P01 (female)
in normal state Resistance
ing (GND) (1), (2) and B24 or between B14 and B22 and Min. 1 Mz
circuit) value
grounding
P01 Voltage and resistance value
Machine monitor
4 Between (1) (2) and grounding Voltage: 20 – 30 V
defective
Between (6) (7) and grounding Resistance value: Max. 1 z
22 PC1250-8R
Electrical diagram related to machine monitor power supply
PC1250-8R 23
E-9 Part of display on machine monitor is missing 1
Failure
• Part of the display in the machine monitor is missing when the starting switch is turned ON.
information
Related
—
information

If all the LCD in the monitor panel light up (i.e. the screen becomes totally
Machine monitor LCD white) by the following switching operation, then the monitor panel is nor-
Possible 1
fault mal.
causes and
• Switching operation: [ ] + [ A ] (simultaneous switching operation)
standard value
in normal state As this is an internal failure, troubleshooting cannot be conducted. (If there
Machine monitor
2 is no problem with the above switching operation, the machine monitor is
defective
judged as defective)
E-10 Machine monitor displays contents irrelevant to the model 1
Failure • The machine monitor displays contents that have nothing to do with the model on which it is
information installed.
Related
—
information

If the display on the monitor panel is normal, proceed to failure code
Possible Model code signal fault [DA2SKQ].
1
causes and (Internal failure) Monitoring code Item Normal display
standard value 02201 Controller model code 1250
in normal state
As this is an internal failure, troubleshooting cannot be conducted. (If there
Machine monitor
2 is no problem with the above item, the machine monitor is judged as
defective
defective)
24 PC1250-8R
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 • Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No. 04200: Fuel level sensor)

Fuel level lowered
1 (system in normal con- a Refill fuel.
dition)
Fuel level sensor fault
2 (Internal P06 (male) Fuel level Resistance value
disconnection) Between (1) and FULL (Upper limit) Approx. 12 z
Possible grounding EMPTY (Lower limit) 85 – 110 z
causes and
standard value Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in
in normal state harness the OFF position during the troubleshooting.
3 (Disconnection or
detective contact with Wiring harness between P02 (female) (2) and Resistance
Max. 1 z
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
Electrical diagram related to fuel level sensor
PC1250-8R 25
E-12 Hydraulic oil temperature gauge does not display correctly 1
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)

Hydraulic oil tempera- Engine coolant
ture sensor fault P10 Resistance value
1 temperature
tion or short-circuiting) Between (1) and (2) 90 – 3.5 kz
Between (1) and 10 – 100 °C
Min. 1 Mz
grounding
harness
connector) Wiring harness between P02 (female) (13) and Resistance
Max. 1 z
Possible P10 (female) (2) value
in normal state 3 (Contact with ground-
ing (GND) Between wiring harness between P02 (female) Resistance
Min. 1 Mz
circuit) (12) and P10 (female) (1) and grounding value
4
(Contact with 24 V cir- Between wiring harness between P02 (female)
(12) and P10 (female) (1) and grounding
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
Electrical diagram related to hydraulic oil temperature sensor
26 PC1250-8R
E-13 Fuel gauge does not display correctly 1
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)

Fuel level sensor fault
1 (Internal disconnec- P06 (male) Fuel level Resistance value
tion or short-circuiting) Between (1) and FULL (Upper limit) Approx. 12 z
harness the OFF position during the troubleshooting.
2 (Disconnection or
Max. 1 z
Possible
causes and
standard value
in normal state Between wiring harness between P02 (female) Resistance
ing (GND) Min. 1 Mz
circuit) (2) and P06 (female) (1) and grounding value
4
(Contact with 24 V cir- Between wiring harness between P02 (female)
(2) and P06 (female) (1) and grounding
Machine monitor P02 Fuel level Resistance value
5
defective
Between (2) and FULL (Upper limit) Approx. 12 z
Electrical diagram related to fuel level sensor
PC1250-8R 27
E-14 Swing lock monitor does not display correctly 1
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.

Swing lock switch fault
1 (Internal disconnec- X05 (female) Swing lock switch Resistance value
tion or short-circuiting) OFF Min. 1 Mz
Between (1) and (2)
ON Max. 1 z
harness
Wiring harness from P02 (female) (17) to J02 to Resistance
X05 (male) (1) value
connector) Wiring harness from X05 (male) (2) to J05 to Resistance
Max. 1 z
Possible grounding value
ing (GND) Between wiring harness from P02 (female) (17) Resistance
Min. 1 Mz
circuit) to J02 to X05 (male) (1) and grounding value
4
(Contact with 24 V cir- Between wiring harness from P02 (female) (17)
to J02 to X05 (male) (1) and grounding
Machine monitor P02 Swing lock switch Voltage
5
defective
Between (17) and OFF 20 – 30 V
grounding ON Max. 1 V
28 PC1250-8R
Electrical diagram related to swing lock switch
PC1250-8R 29
E-15 When the monitor switch is operated, no display appears 1
Failure
• When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Related
—
information

causes and
standard value Machine monitor
1 As this is an internal failure, troubleshooting cannot be conducted.
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

causes and
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.

causes and
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

causes and
• 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

causes and
30 PC1250-8R
PC1250-8R 31
E-16 Windshield wiper does not work 1
Failure
• The windshield wiper does not work.
information
Related
information

W06 (Switch side)
Lower wiper switch Resistance value
(When 2 wipers are set)
Window wiper switch
fault ON Max. 1 z
1 Between (1) and (2)
(Internal disconnec- OFF Min. 1 Mz
tion or short-circuiting) W03 (Switch side)
Front window Resistance value
(When 1 wiper is set)
When installed at front Min. 1 Mz
Between (1) and (2)
When retracted at rear Max. 1 z
Windshield wiper
motor fault W05, W04 (female) Continuity and resistance value
2
(Internal disconnec- Between (3) and (1) Continued
tion or short-circuiting)
Between W05 (1) (3), W04 (1) (3)
Min. 1 Mz
and grounding
harness Wiring harness between P01 (female) (9) and
Resistance
3 (Disconnection or W04 (male) (3) or between P01 (female) (10) Max. 1 z
Possible value
defective contact with and W05 (male) (3)
causes and connector)
standard value Wiring harness between W04 (male) (1) or Resistance
Max. 1 z
in normal state between W05 (male) (1) and grounding value
4
P02
Lower wiper switch Voltage
(When 2 wipers are set)
Between (15) and ON 20 – 30 V
Machine monitor fault grounding OFF Max. 1 V
(Lower wiper switch
system) P02
Front window Voltage
(When 1 wiper is set)
Between (15) and When installed at front 20 – 30 V
grounding When retracted at rear Max. 1 V
5 a Turn the engine starting switch OFF for the preparations, and hold it in
P02 Wiper switch Voltage
Machine monitor fault OFF Max. 3 V
(Windshield wiper Between (9) and When 2 wipers are set :
motor system) grounding 20 – 30 V
Between (10) and ON When 1 wiper is set
grounding Max. 3 V ⇔ 20 – 30 V :
(Constant cycle)
32 PC1250-8R
Electrical diagram related to wiper motor (Cab with front window fixed) (When 2 wipers are set)
PC1250-8R 33
E-17 “Boom RAISE” is not correctly displayed in monitor function 1
Failure
• “Boom RAISE” is not correctly displayed in the monitor function on the machine monitor.
information
Related
—
information

Boom RAISE PPC engine running during the troubleshooting.
hydraulic switch fault S02 (male) Boom control lever Resistance value
1
tion or short-circuiting) NEUTRAL Min. 1 Mz
Between (1) and (2)
RAISE Max. 1 z
harness
S02 (female) (2) value
connector) Wiring harness between S02 (female) (1) and Resistance
Max. 1 z
ing (GND) Between wiring harness between C03 (female) Resistance
Min. 1 Mz
circuit) (10) and S02 (female) (2) and grounding value
4
(10) and S02 (female) (2) and grounding
Pump controller defec- C03 Boom control lever Voltage
5
tive
Between (10) and NEUTRAL 20 – 30 V
grounding RAISE Max. 1 V
Electrical diagram related to boom RAISE PPC hydraulic switch
34 PC1250-8R
E-18 “Boom LOWER” is not correctly displayed in monitor function 1
Failure
• “Boom LOWER” is not correctly displayed in the monitor function on the machine monitor.
information
Related
—
information

Boom LOWER PPC engine running during the troubleshooting.
hydraulic switch fault S04 (male) Boom control lever Resistance value
1
Between (1) and (2)
LOWER Max. 1 z
harness
Max. 1 z
Min. 1 Mz
4
Pump controller defec- C03 Boom control lever Voltage
5
tive
grounding LOWER Max. 1 V
Electrical diagram related to boom LOWER PPC hydraulic switch
PC1250-8R 35
E-19 “Arm DIGGING” is not correctly displayed in monitor function 1
Failure • “Arm DIGGING” is not correctly displayed in the monitor function (special function) on the machine
information monitor.
Related
—
information

Arm DIGGING PPC engine running during the troubleshooting.
hydraulic switch fault S05 (male) Arm control lever Resistance value
1
Between (1) and (2)
DIGGING Max. 1 z
harness
Max. 1 z
Min. 1 Mz
4
Pump controller defec- C03 Arm control lever Voltage
5
tive
grounding DIGGING Max. 1 V
Electrical diagram related to arm DIGGING PPC hydraulic switch
36 PC1250-8R
E-20 “Arm DUMPING” is not correctly displayed in monitor function 1
Failure • “Arm DUMPING” is not correctly displayed in the monitor function (special function) on the machine
Related
—
information

Arm DUMPING PPC
hydraulic switch defect
1 (Internal disconnec- S03 (male) Arm control lever Resistance value
tion and short-circuit- NEUTRAL Min. 1 Mz
ing) Between (1) and (2)
DUMPING Max. 1 z
harness
Max. 1 z
Min. 1 Mz
4
Pump controller defec- C03 Arm control lever Voltage
5
tive
grounding DUMPING Max. 1 V
Electrical diagram related to arm DUMPING PPC hydraulic switch
PC1250-8R 37
E-21 “Bucket CURL” is not correctly displayed in monitor function 1
Failure • “Bucket CURL” is not correctly displayed in the monitor function (special function) on the machine
Related
—
information

Bucket CURL PPC
hydraulic switch fault
1 (Internal disconnec- S06 (male) Bucket control lever Resistance value
ing) Between (1) and (2)
CURL Max. 1 z
harness
Max. 1 z
Min. 1 Mz
4
Pump controller defec- C03 Bucket control lever Voltage
5
tive
grounding CURL Max. 1 V
Electrical diagram related to bucket CURL PPC hydraulic switch
38 PC1250-8R
E-22 “Bucket DUMPING” is not correctly displayed in monitor function1
Failure • “Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the
information machine monitor.
Related
—
information

Bucket DUMPING a Turn the engine starting switch OFF for the preparations, and keep the
PPC hydraulic switch engine running during the troubleshooting.
fault S07 (male) Bucket control lever Resistance value
1
Between (1) and (2)
ing) DUMPING Max. 1 z
harness
Max. 1 z
Min. 1 Mz
4
Pump controller defec- C03 Bucket control lever Voltage
5
tive
grounding DUMPING Max. 1 V
Electrical diagram related to bucket DUMP PPC hydraulic switch
PC1250-8R 39
E-23 “SWING” is not correctly displayed in monitor function 1
Failure • “SWING” is not correctly displayed in the monitor function (special function) on the machine moni-
information tor.
Related
—
information

Swing PPC hydraulic engine running during the troubleshooting.
switch, left, fault S10 (male) Swing control lever Resistance value
1
Between (1) and (2)
Left Max. 1 z
Swing PPC hydraulic engine running during the troubleshooting.
switch, right, fault S08 (male) Swing control lever Resistance value
2
Between (1) and (2)
Right Max. 1 z
Disconnection of wiring Wiring harness between C03 (female) (29) and
Resistance
harness S10 (female) (2), or wiring harness between C03 Max. 1 z
value
3 (Disconnection or (female) (29) and S08 (female) (2)
Possible defective contact with Wiring harness between S10 (female) (1) and Resistance
connector) Max. 1 z
causes and grounding value
standard value Wiring harness between S08 (female) (1) and Resistance
in normal state Max. 1 z
grounding value
ing harness
4 (Contact with ground- Wiring harness between C03 (female) (29) and
ing (GND) S10 (female) (2), or wiring harness between C03 Resistance
Min. 1 Mz
circuit) (female) (29) and S08 (female) (2) and ground- value
ing
ing harness Wiring harness between C03 (female) (29) and
5
(Contact with 24 V cir- S10 (female) (2), or wiring harness between C03
(female) (29) and S08 (female) (2) and ground-
ing
Pump controller defec- C03 Swing control lever Voltage
6
tive
grounding Right or left Max. 1 V
40 PC1250-8R
Electrical diagram related to right and left swing PPC hydraulic switches
PC1250-8R 41
E-24 “TRAVEL” is not correctly displayed in monitor function 1
Failure • “TRAVEL” is not correctly displayed in the monitor function (special function) on the machine mon-
information itor.
Related
—
information

Travel PPC hydraulic
switch fault S01, S11, S12, S13
1 Travel control lever Resistance value
(Internal disconnec- (male)
Between (1) and (2)
Forward or reverse Max. 1 z
Disconnection of wiring Wiring harness from C02 (female) (16) to J18 to Resistance
harness Max. 1 z
S12, S13 (female) (2) value
2 (Disconnection or
defective contact with Wiring harness from C03 (female) (39) to S01, Resistance
Max. 1 z
connector) S11 (female) (2) value
Wiring harness from S01, S11, S12, S13 Resistance
Max. 1 z
(female) (1) to grounding value
causes and Grounding fault of wir- the OFF position during the troubleshooting.
standard value ing harness
in normal state 3 (Contact with ground- Wiring harness from C02 (female) (16) to J18 to Resistance Min. 1 Mz
ing (GND) S12, S13 (female) (2) and grounding value
circuit) Wiring harness from C03 (female) (39) to S01, Resistance
Min. 1 Mz
S11 (female) (2) and grounding value
ing harness Wiring harness from C02 (female) (16) to J18 to
4 Voltage Max. 1 V
(Contact with 24 V cir- S12, S13 (female) (2) and grounding
cuit) Wiring harness from C03 (female) (39) to S01,
Voltage Max. 1 V
S11 (female) (2) and grounding
Controller connector Travel control lever Voltage
5 Between C02 (16) and
tive NEUTRAL 20 – 30 V
grounding
Between C03 (39) and
grounding Forward or backward Max. 1 V
42 PC1250-8R
Electrical diagram related to travel PPC pressure switch and travel alarm
PC1250-8R 43
E-25 Air conditioner does not work 1
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.

When the fuse is blown, there is a big possibility that grounding fault
1 Fuse No. 11 fault
occurred in the circuit.
harness
Wiring harness between FB1-11 outlet and M26 Resistance
(male) (4) (5) value
connector) Wiring harness between M26 (male) (8) and Resistance
Possible Max. 1 z
grounding value
causes and
ing (GND) Between wiring harness between FB1-11 outlet
Voltage Min. 1 Mz
circuit) and M26 (male) (4) (5) and grounding
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 PC1250-8R
Electrical diagram related to air conditioner
PC1250-8R 45
E-26 Travel alarm does not sound 1
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
If the monitor display is not correct, proceed to No. E-24 Troubleshooting.
Monitoring code Item Normal display

1 Travel signal fault
01900 R.H. travel Control lever operation:
ON
Control lever NEU-
01901 L.H. travel TRAL: OFF
harness
F01 (female) (1) value
Possible connector) Wiring harness between F01 (female) (2) and Resistance
Max. 1 z
causes and grounding value
Min. 1 Mz
circuit) (8) to F01 (female) (1) and grounding value
As this is an internal failure, troubleshooting cannot be conducted. (If none

4 Travel alarm fault of the causes listed in Item 1 through 3 above is found, the travel alarm is
judged as defective)
a Turn the engine starting switch OFF for the preparations, and travel dur-
ing the troubleshooting.
C03 Travel control lever Voltage
5 NEUTRAL Max. 1 V
tive
Between (8) and Left forward, left
grounding reverse, or right for- 20 – 30 V
ward, right reverse
Electrical diagram related to travel alarm
46 PC1250-8R
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

Circuit breaker No. 2 or If a circuit breaker is turned OFF, the circuit probably has a grounding
1
No. 5 turned OFF fault.
2 Light switch defective Between M07 (female) (1) and (2) Resistance value
Light switch ON Max. 1 z
Light switch OFF Min. 1 Mz
Wiring harness between circuit
Wiring harness discon- Voltage between A10
Possible breaker No. 2 B22 and A10 (female) 20 – 30 V
nected (2), (4) and grounding
causes and (2) (4)
3 (Disconnection or
standard value defective contact of Wiring harness between circuit
Voltage between M07
in normal state connector) breaker No. 5 B25 and M07 (male) 20 – 30 V
(1) and grounding
(1)
Wiring harness between M07 (male) Voltage between J01
20 – 30 V
(2) and J01 (male) (5) (5) and grounding
Grounding fault of wir- Between wiring harness between circuit breaker
Resistance
ing harness No. 2 B22 and A10 (female) (2) (4) and ground- Min. 1 Mz
value
4 (Contact with grounding
ing (GND) Between wiring harness between circuit breaker Resistance
circuit) Min. 1 Mz
No. 5 B25 and M07 (male) (1) and grounding value
Between wiring harness between M07 (male) (2) Resistance
Min. 1 Mz
and J01 (male) (5) value
PC1250-8R 47
Failure
• Head lamp and working lamp do not light up.
information (2)
Related
• Machine monitor and additional lamp light up.
information

Head lamp or working
The head lamp or working lamp may be defective. Check their bulbs for
1 lamp defective (Break-
breakage.
age of bulb)
Wiring harness between J01 (male) Voltage between J11
20 – 30 V
(9) and J11 (female) (8) (8) and grounding
Wiring harness between J11
Voltage between M08,
Disconnection of wiring (female) (1) and M08, M09 (female) 20 – 30 V
M09 (1) and grounding
harness (1)
2 (Disconnection or Wiring harness between J11 Voltage between M42
Possible 20 – 30 V
defective contact with (female) (2) and M42 (female) (1) (1) and grounding
causes and connector) a Turn the engine starting switch OFF for the preparations, and hold it in
standard value
in normal state
Wiring harness between M08, M09 (female) (2) Resistance
Max. 1 z
and chassis ground (T02) value
Wiring harness between M42 (female) (2) and Resistance
Max. 1 z
chassis ground (T03) value
Grounding fault of wir- Between wiring harness between J01 (male) (9) Resistance
and J11 (female) (8) and grounding value
ing (GND) Between wiring harness between J11 (female) Resistance
Min. 1 Mz
circuit) (1) and M08, M09 (female) (1) and grounding value
Between wiring harness between J11 (female) Resistance
Min. 1 Mz
(2) and M42 (female) (1) value
Failure
• Panel lamp does not light up.
information (3)
Related
• Head lamp and working lamp light up.
information

1 Night lamp defective The night lamp may be defective. Check its bulb for breakage.
Wiring harness discon- a Turn the engine starting switch OFF for the preparations, and hold it in
nected the ON position during the troubleshooting.
2 (Disconnection or
defective contact of Wiring harness between J01 (male) Voltage between P02
20 – 30 V
Possible connector) (7) and P02 (female) (19) (19) and grounding
causes and
standard value Wiring harness short- a Turn the engine starting switch OFF for the preparations, and hold it in
circuited to grounding the OFF position during the troubleshooting.
in normal state 3
(Contact with GND cir- Between wiring harness between J01 (male) (7) Resistance
cuit) Min. 1 Mz
and P02 (female) (19) and grounding value
Machine monitor the ON position during the troubleshooting.
4
defective Between P02 (19) and
Light switch ON Voltage 20 – 30 V
grounding
48 PC1250-8R
Failure
• Additional lamp does not light up.
information (4)
Related
• Head lamp and working lamp light up.
information

Additional lamp defec-
1 The additional lamp may be defective. Check its bulb for breakage.
tive (Breakage of bulb)
Circuit breaker No. 7 If the circuit breaker is turned OFF, the circuit probably has a grounding
2
turned OFF fault.
Working lamp relay the ON position during the troubleshooting.
3 defective (Internal dis- Replace the relay with another one with the starting switch OFF, and then
connection) turn the starting switch and light switch ON. If the working lamp lights up at
this time, the working lamp relay (R10) is defective.
Voltage between B17
breaker No. 2 B22, A10 (4) and No. 20 – 30 V
and grounding
7 B17
Voltage between R10
breaker No. 7 B27 and R10 (female) 20 – 30 V
(3) and grounding
(3)
Wiring harness between J01 (male) Voltage between R10
20 – 30 V
Disconnection of wiring (6) and R10 (female) (1) (1) and grounding
harness Wiring harness between R10 Voltage between J03
4 (Disconnection or 20 – 30 V
(female) (5) and J03 (male) (3) (3) and grounding
Possible defective contact with
causes and connector) Wiring harness between J03 (male) Voltage between M40
20 – 30 V
standard value (1) and M40 (female) (1) (1) and grounding
in normal state Wiring harness between J03 (male) Voltage between M41
20 – 30 V
(2) and M41 (female) (1) (1) and grounding
Max. 1 z
chassis ground (T03) value
Wiring harness between M40, M41 (female) (2) Resistance
Max. 1 z
and chassis ground value
Between wiring harness between circuit breaker Resistance
Min. 1 Mz
No. 2 B22, A10 (4) and No. 7 B17 and grounding value
Between wiring harness between circuit breaker Resistance
Grounding fault of wir- Min. 1 Mz
No. 7 B27 and R10 (female) (3) and grounding value
ing harness
Between wiring harness between J01 (male) (6) Resistance
5 (Contact with ground- Min. 1 Mz
and R10 (female) (1) and grounding value
ing (GND)
circuit) Between wiring harness between R10 (female) Resistance
Min. 1 Mz
(5) and J03 (male) (3) and grounding value
Min. 1 Mz
and M40 (female) (1) and grounding value
Min. 1 Mz
and M41 (female) (1) and grounding value
PC1250-8R 49
Electrical diagram related to panel lamp, head lamp and working lamp
50 PC1250-8R
E-28 Step light does not light up or go off 1

Failure (1) When the switch is pressed, the light does not
• Step light does not light up or go off.
phenomenon keep lighting up for 1 minute.
Related • If failure code [D195KB] is also displayed for step light relay (R15), carry out troubleshooting for it
information first.

1 Defective fuse FB1-20 If the fuse is broken, the circuit probably has grounding fault (See cause 6).
2 Defective step light The step light may be defective. Check the bulb directly for breakage.
Defective step light the OFF position during the troubleshooting.
switch M81 (male) Step light switch Resistance
3
tion) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
Step light relay defec- the OFF position during the troubleshooting.
4
tive (Internal defect) Replace the step light relay with another one. If trouble is
R09
repaired, the relay is defective (5-pole relay).
Wiring harness between FB1-20 outlet – M81
(female) (2) or between FB1-20 outlet – R15 Resistance Max. 1 z
(female) (1), (3)
Disconnection of wiring Wiring harness between M81 (female) (1) – J03 –
harness C01 (female) (24) or between M81 (female) (1) – Resistance Max. 1 z
5 (Disconnection or D04 – C03 (female) (14), (24)
connector) Wiring harness between C02 (female) (19) – R15
Resistance Max. 1 z
(female) (2)
Possible
Wiring harness between R15 (female) (5) – M75
(female) (1)
standard value
in normal state Wiring harness between M75 (female) (2) – chassis
Resistance Max. 1 z
ground
Wiring harness between FB1-20 outlet – M81
Grounding fault of wir- (female) (2) or between FB1-20 outlet – R15 Resistance Min. 1 Mz
ing harness (female) (1) (3) and chassis ground
6
(Contact with ground- Wiring harness between M81 (female) (1) – J03 –
ing circuit) C01 (female) (24) or between M81 (female) (1) – Resistance Min. 1 Mz
D04 – C03 (female) (14), (24) and chassis ground
Wiring harness between R15 (female) (5) – M75
Defective pump con-
troller (Step light switch C01 Step light switch Voltage
input system) Between Released Max. 1 V
(24) – chassis ground Pressed 20 – 30 V
Defective pump con- C02 Step light switch Voltage
troller (Step light relay
output system) 20 – 30 V
Between Released
(60 seconds)
(19) – chassis ground
Pressed Max. 1 V
PC1250-8R 51
Failure (2) While the switch is not pressed, the light lights
• Step light does not light up or go off.
phenomenon up.
Related
information

switch M81 (male) Step light switch Resistance
1
tion) Released Min. 1 Mz
Between (1) – (2)
Pressed Max. 1 z
2
relay (Internal defect) Replace the step light relay with another one. If trouble is
R15
repaired, the relay is defective.
Short-circuiting of wir-
Possible Wiring harness between M81 (female) (1) – J03 –
ing harness
causes and 3 C01 (female) (24) or between M81 (female) (1) – Voltage Max. 1 V
(Contact with 24 V cir-
standard value D04 (female) (8) and chassis ground
cuit)
in normal state Wiring harness between C02 (female) (19) – R15
Voltage Max. 1 V
Defective pump con-
troller (Step light switch C01 Step light switch Voltage
input system) Between Released Max. 1 V
(24) – chassis ground Pressed 20 – 30 V
Defective pump con- C02 Step light switch Voltage
troller (Step light relay
output system) 20 – 30 V
Between Released
(60 seconds)
(19) – chassis ground
Pressed Max. 1 V
52 PC1250-8R
Electrical diagram related to step light
PC1250-8R 53
E-29 Electric priming pump does not operate or does not stop
automatically 1
Failure
• Electric priming pump does not operate or does not stop automatically
phenomenon
Relative
information
Cause Standard value in normalcy and references for troubleshooting

1 Low battery charge level Battery charge level may be low. Check battery directly.
Defective circuit breaker If circuit breaker No. 12 is turned OFF, circuit probably has ground fault.
2
No. 12 (Check cause No. 5.)
Disconnection in wiring a Prepare with battery ground cable disconnected, then connect it and
harness (Power supply carry out troubleshooting (since power supply is unswitched).
system)
3
(Disconnection in wiring
or defective contact in Between S50 (1) – (2) Voltage 20 – 30 V
connector)
a Prepare with battery ground cable disconnected, then connect battery
and turn electric priming pump ON and carry out troubleshooting.
Disconnection in wiring • Lamp blinks but stops in about 5 seconds.
harness (Drive power
Between EFP (1) – (2) Voltage 20 – 30 V
supply system)
4 a Prepare with battery ground cable disconnected, then carry out
(Disconnection in wiring
or defective contact in troubleshooting without reconnecting (since power supply is
connector) unswitched).
Resis-
Between S50 (female) (2) – ground Max. 1 z
tance
Presumed a Prepare with battery ground cable disconnected, then carry out
cause and troubleshooting without reconnecting (since power supply is
standard value unswitched).
in normalcy Wiring harness between S50 (female) (1) – circuit Resis-
Min. 1 Mz
Ground fault in wiring breaker B2A and ground tance
5 harness (Contact with Wiring harness between S50 (female) (3) – EFP Resis-
Min. 1 Mz
GND circuit) (female) (1) and ground tance
Wiring harness between S50 (female) (4) – EFP Resis-
Min. 1 Mz
(female) (2) and ground tance
Resis-
Between EFP (female) (1) – (2) 1–3z
tance
a Prepare with battery ground cable disconnected, then connect battery
and turn electric priming pump ON and carry out troubleshooting.
Between S50 (3) – (4) Voltage 20 – 30 V
Defective electric prim-
ing pump switch (Mal- • Lamp blinks but output voltage is improper.
6 • Results of troubleshooting steps 1 – 4 are normal and lamp does not
function or automatic
stop failure) blink.
a When electric priming pump does not stop automatically, electric
priming pump switch may be defective. (Turn toggle switch OFF to
stop pump and then replace switch.)
• Lamp blinks but stops in about 5 seconds.
Overload on electric
7 a If pump is overloaded, power supply is turned OFF automatically to
priming pump
protect circuit (Priming switch is reset automatically).
54 PC1250-8R
Cause Standard value in normalcy and references for troubleshooting

a Prepare with battery ground cable disconnected, then carry out
troubleshooting without reconnecting (since power supply is
Presumed unswitched).
cause and Resis-
Trouble in electric priming Between EFP (male) (1) – (2) 1–3z
standard value 8 tance
in normalcy pump
Resis-
Between EFP (male) (1) – pump body Min. 1 Mz
tance
Resis-
Between EFP (male) (2) – pump body Min. 1 Mz
tance
Circuit diagram related to electric priming pump
PC1250-8R 55
SEN02085-01

© 2007 KOMATSU
All Rights Reserved
56
SEN02086-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
Troubleshooting of hydraulic and
mechanical system (H-mode)
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
H-13 Boom shockless function cannot be turned ON or OFF....................................................................... 24
PC1250-8R 1
H-14 Machine deviates in one direction ........................................................................................................ 24

H-15 Machine deviates largely at start.......................................................................................................... 26
H-16 Machine deviates largely during compound operation ......................................................................... 27
H-17 Travel speed or power is low................................................................................................................ 27
H-18 Machine does not travel (only one track) ............................................................................................. 28
H-19 Travel speed does not change ............................................................................................................. 29
H-20 Machine does not swing....................................................................................................................... 30
H-21 Swing speed or acceleration is low ...................................................................................................... 31
H-22 Swing speed or power is low in compound operation of travel and bucket.......................................... 32
H-23 Swing speed or power is low in compound operation of travel and boom
in swing priority mode ............................................................................................................................... 32
H-24 Upper structure overruns largely .......................................................................................................... 33
H-25 Large shocks are made when upper structure stops swinging ............................................................ 34
H-26 Large abnormal sounds are made when upper structure stops swinging ............................................ 35
H-27 Hydraulic drift of swing is large............................................................................................................. 36
H-28 Fan revolution is abnormal (Sound and vibration of the fan is abnormally large,
and the fan is overheated) ........................................................................................................................ 37
2 PC1250-8R
Before troubleshooting for hydraulic and mechanical systems 1
PC1250-8R 3
1. Actuation and combination of hydraulic 2. Judgement procedure if work equipment is

pumps slow and there is travel deviation to the left:
q Three tandem pumps (total of 6 pumps) q The cause is probably one of the follow-
are used in the work equipment, travel, ing:
and swing circuits: No. 1 pump 1) Defective main relief valve of L.H. 5-
(HPV95+95), No. 2 pump (HPV95+95), spool control valve
and No. 3 pump (HPV160+160). 2) Defective jet sensor of L.H. 5-spool
q The oil from the No. 1 front pump and No. control valve
2 front pump merges and flows to the R.H. 3) Defective CO • NC valve of No. 1 rear
4-spool valve; the oil from the No. 1 rear pump
pump and No. 2 rear pump merges and 4) Defective servo valve of No. 1 rear
flows to the L.H. 5-spool valve; and the oil pump
from the No. 3 front pump and No. 3 rear 5) Defective No. 1 rear pump
pump merges and flows to the swing 4- 6) Defective servo valve of No. 2 rear
spool valve. pump
q The TVC control for the No. 1 pump, No. 2 7) Defective No. 2 rear pump
pump, and No. 3 pump is all carried out in q If the problem occurs, measure the follow-
the same way by the TVC valve installed ing to judge if the related part is defective.
to the No. 1 rear pump. 1) Measure relief pressure to judge main
q The CO • NC control for the No. 1 front relief valve
pump and No. 2 front pump is carried out 2) Measure differential pressure to judge
in the same way by the CO • NC valve jet sensor
installed to the No. 1 front pump and by 3) Measure output pressure to judge CO
the jet sensor installed to the R.H. 4-spool • NC valve
control valve. q As mentioned above, the oil flow in the
q The CO • NC control for the No. 1 rear No. 1 rear pump and No. 2 rear pump
pump and No. 2 rear pump is carried out merges, so to judge if the problem is in the
in the same way by the CO • NC valve No. 1 rear pump servo valve and pump
installed to the No. 1 rear pump and by the proper or in the No. 2 rear pump servo
jet sensor installed to the L.H. 5-spool valve and pump proper, interchange the
control valve. outlet port hoses of the No. 2 rear pump
q The CO • NC control for the No. 3 front between the front and rear. It is then pos-
pump and No. 3 rear pump is carried out sible to judge as follows which pump is
in the same way by the CO • NC valve defective.
installed to the No. 3 front pump and by 1) If deviation is to left (no change), No.
the jet sensor installed to the swing 4- 1 rear pump is defective
spool control valve. 2) If deviation is to right (opposite direc-
tion), No. 2 rear pump is defective
3) If the travel speed becomes slow, the
jet sensor is defective or the CO • NC
valve is defective (if the left and right
relief pressures are normal).
q Next, to judge if the problem is in the
servo valve or the pump proper, remove
the servo valve and test the individual
part, or judge from the stroke of the servo
piston.
a For the actual procedure for judgement,
follow the “5. Troubleshooting chart for
judgement when work equipment is slow
and there is travel deviation to the left”.
4 PC1250-8R
3. Judgement procedure if work equipment is 4. Judgement procedure if work equipment is

slow and there is travel deviation to the slow and swing is also slow (but travel
right: speed is normal):
q The cause is probably one of the follow- q The cause is probably one of the follow-
ing: ing:
1) Defective main relief valve of L.H. 4- 1) Defective main relief valve of swing 4-
spool control valve spool control valve
2) Defective jet sensor of L.H. 4-spool 2) Defective jet sensor of swing 4-spool
control valve control valve
3) Defective CO • NC valve of No. 1 3) Defective CO • NC valve of No. 3
front pump front pump
4) Defective servo valve of No. 1 front 4) Defective servo valve of No. 3 front
pump pump
5) Defective No. 1 front pump 5) Defective No. 3 front pump
6) Defective servo valve of No. 2 front 6) Defective servo valve of No. 3 rear
pump pump
7) Defective No. 2 front pump 7) Defective No. 3 rear pump
q If the problem occurs, measure the follow- q If the problem occurs, measure the follow-
ing to judge if the related part is defective. ing to judge if the related part is defective.
1) Measure relief pressure to judge main 1) Measure relief pressure to judge main
relief valve relief valve
2) Measure differential pressure to judge 2) Measure differential pressure to judge
jet sensor jet sensor
3) Measure output pressure to judge CO 3) Measure output pressure to judge CO
• NC valve • NC valve
q As mentioned above, the oil flow in the q To judge if the problem is in the servo
No. 1 front pump and No. 2 front pump valve or the pump proper of the No. 3 front
merges, so to judge if the problem is in the pump, or in the servo valve or the pump
No. 1 front pump servo valve and pump proper of the No. 3 rear pump, remove the
proper or in the No. 2 front pump servo servo valve and test the individual part, or
valve and pump proper, interchange the judge from the stroke of the servo piston.
outlet port hoses of the No. 2 front pump a It is impossible to judge if the problem is in
between the front and rear. It is then pos- the front pump or the rear pump while the
sible to judge as follows which pump is pumps are mounted on the machine, so
defective. remove the No. 3 pump assembly and test
1) If deviation is to right (no change), individually.
No. 1 front pump is defective
2) If deviation is to left (opposite direc-
tion), No. 2 front pump is defective
3) If the travel speed becomes slow, the
jet sensor is defective or the CO • NC
valve is defective (if the left and right
relief pressures are normal).
q Next, to judge if the problem is in the
servo valve or the pump proper, remove
the servo valve and test the individual
part, or judge from the stroke of the servo
piston.
a For the actual procedure for judgement,
follow the “5. Troubleshooting chart for
judgement when work equipment is slow
and there is travel deviation to the left”.
PC1250-8R 5
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 main relief valve
Defective main relief valve

piston at the specified repair shop.
Defective CO • NC valve
Defective CO • NC valve
2. If there is a big drop in speed and it seems that
Defective servo valve
Defective jet sensor
Defective jet sensor

there is an abnormality in the pump, check the
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
No. 2 pump outlet hoses Machine deviates to right

4 ● ●
are interchanged between (opposite direction)
front and rear Left and right travel speeds
5 ● ●
both become slow
6 In Item 3, No. 1 rear servo valve is normal ●
7 In Item 4, No. 2 rear servo valve is normal ●
In Item 5, jet sensor differential pressure of L.H. 5-spool
8 ●
control valve is defective
Item 8 is normal, but No. 1 rear NC valve output pressure
9 ●
is defective
There is travel deviation to right, and work equipment
10 ● ● ● ● ● ● ●
speed is slow
11 Travel relief pressure of front pump is low ●
Machine deviates to right (no
12 ● ●
Item 2 is normal, and when change)
Travel deviates to right
No. 2 pump outlet hoses Machine deviates to left

13 ● ●
are interchanged between (opposite direction)
front and rear Left and right travel speeds
14 ● ●
both become slow
15 In Item 12, No. 1 front servo valve is normal ●
16 In Item 13, No. 2 front servo valve is normal ●
In Item 14, jet sensor differential pressure of R.H. 5-spool
17 ●
control valve is defective
Item 17 is normal, but No. 1 front NC valve output pres-
18 ●
sure is defective
a Remedy A: Adjust X: Repair or replace
6 PC1250-8R
Interchange method of No. 2 pump outlet hoses between front and rear
q (1): No. 1 pump

(2): No. 2 pump
(3): No. 3 pump
q Interchange hose (4) and hose (5).
Hydraulic circuit after interchanging hoses
PC1250-8R 7
Information in troubleshooting table 1
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 PC1250-8R
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 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.

Internal defect of con- Since the control pump may have a defect in it, check the inside of the
1
trol pump pilot filter for metal chips.
a Prepare with the engine stopped, then carry out troubleshooting with
the engine at high idle.
Control levers Control relief pressure
Defective adjustment +0.5
2 or malfunction of con- 3.1 0 MPa
All levers in neutral
+5.0
trol relief valve {32 0 kg/cm2}
If the oil pressure cannot be set normally by adjustment, check cause 5. If
the result of check of cause 5 is normal, the control relief valve may have a
malfunction. Check the control relief valve directly.
a Stop the engine and block (1) – (13) in the drawing in order, then carry
out troubleshooting with the engine at high idle.
Work equipment, swing, and travel
Possible Leakage in control sys- Control relief pressure
3 levers
causes and tem devices
+0.5
standard value 3.1 0 MPa
in normal state All levers in neutral
+5.0
{32 0 kg/cm2}
the engine at high idle. (Check cause 3 and confirm that the result is
normal before troubleshooting.)
Switches and control levers TVC valve output pressure
Min. 1.8 MPa
Defective adjustment All control levers in neutral
{Min. 18 kg/cm2}
4 or malfunction of TVC
valve Heavy lift switch OFF + Boom 1.08 ± 0.2 MPa
relieved in RAISE position {11 ± 2 kg/cm2}
Heavy lift switch ON + Boom 0.98 ± 0.2 MPa
If the oil pressure cannot be set normally by adjustment, the TVC valve
may have a malfunction. Check the TVC valve directly.
If the results of check of causes 1 – 4 are normal, the engine may be
5 Defective engine
defective. Check the engine (Refer to Shop Manual for 170E-5 engine.)
PC1250-8R 9
Figure 1: Circuit diagram of control system devices
10 PC1250-8R
H-2 Engine speed lowers remarkably or engine stalls 1
Failure
• Engine speed lowers remarkably or engine stalls
information
Related
information

Switches and control levers TVC valve output pressure
Min. 1.8 MPa
All control levers in neutral
Defective adjustment {Min. 18 kg/cm2}
1 or malfunction of TVC Heavy lift switch OFF + Boom 1.08 ± 0.2 MPa
valve relieved in RAISE position {11 ± 2 kg/cm2}
Heavy lift switch ON + Boom 0.98 ± 0.2 MPa
Possible If the oil pressure cannot be set normally by adjustment, the TVC valve
causes and may have a malfunction. Check the TVC valve directly.
standard value
in normal state
Switches and control levers CO • NC valve output pressure
Defective adjustment
or malfunction of CO • Heavy lift switch OFF + Boom Max. 1.37 MPa
2
NC valve of pump No. relieved in RAISE position {Max. 14 kg/cm2}
1 1.03 ± 0.24 MPa
Heavy lift switch ON + Boom
relieved in RAISE position {10.5 ± 2.5 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC
valve may have a malfunction. Check the CO • NC valve directly.
If the results of check of causes 1 and 2 are normal, the engine may be
3 Defective engine
defective. Check the engine (Refer to Shop Manual for 170E-5 engine.)
PC1250-8R 11
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
information

Defective PPC lock
1 Since the PPC lock valve linkage may be defective, check it directly.
valve linkage
Since the control pump may not revolve because of an internal defect of
2 Internal defect of PTO
the PTO, check the PTO directly.
Internal defect of con- Since control pump may have a defect in it, check the inside of the pilot fil-
3
trol pump ter for metal chips.
Control relief pressure
Possible levers
causes and +0.5
4 or malfunction of con- 3.1 0 MPa
standard value All levers in neutral
trol relief valve +5.0
in normal state {32 0 kg/cm2}
If the oil pressure cannot be set normally by adjustment, check cause 3. If
the result of check of cause 5 is normal, the control relief valve may have a
malfunction. Check the control relief valve directly.
a Stop the engine and block (1) – (13) in the drawing in order, then carry
out troubleshooting with the engine at high idle.
Leakage in control sys- Control relief pressure
5 levers
tem devices
+0.5
3.1 0 MPa
All levers in neutral
+5.0
{32 0 kg/cm2}
12 PC1250-8R
Figure 1: Circuit diagram of control system devices
PC1250-8R 13
H-4 Abnormal sound is heard from around pump 1
Failure
• Abnormal sound is heard from around pump
information
Related
information

Low hydraulic oil tem-
1 Since the hydraulic oil temperature may be low, check it directly.
perature
Since a piping clamp between the hydraulic tank and hydraulic pump may
Possible 2 Loosened piping clamp
be loosened, check it directly.
causes and
standard value Clogged hydraulic tank
3 Since the hydraulic tank strainer may be clogged, check it directly.
in normal state strainer
Internal defect of
4 Since the hydraulic pump may have a defect in it, check it directly.
hydraulic pump
Observation of condi- If a cause cannot be found by troubleshooting, operate the machine as it is
5
tion for a while and observe the condition for change.
14 PC1250-8R
H-5 Speed or power of boom is low 1
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

Malfunction of right Right control lever (boom) PPC valve output pressure
1 PPC valve (boom cir-
cuit) +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
Malfunction of swing Swing priority mode switch Solenoid valve outlet pressure
2
priority solenoid valve
OFF 0 MPa {0 kg/cm2}
Possible ON 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
causes and
standard value Malfunction of boom Since the spool of the boom control valve (Lo, Hi, Plus) may have a mal-
3
in normal state control valve (spool) function, check it directly.
Since the safety & suction valve of the boom control valve (Lo) may have
a malfunction, check it directly. (When checking by replacing the safety &
Malfunction of boom
suction valve with one of another work equipment circuit, stop the oil in the
4 control valve (safety &
machine pushup solenoid hose securely. After checking, be sure to return
suction valve)
the safety & suction valve since its set pressure and structure are different
from the others.)
Defective boom control Since the body of the boom control valve (Lo, Hi, Plus) may have a mal-
5
valve (body) function, check it directly.
Defective seal of boom the engine at high idle.
6
cylinder Right control lever (boom) Leakage from cylinder
Relieved in RAISE position Max. 28 cc/min
PC1250-8R 15
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.
Related (If they are abnormal, carry out the related troubleshooting.)
information • Check that the machine does not deviate.

the engine at high idle. (Raise the boom singly in the heavy lift mode.)
Malfunction of CO can- Right control lever (boom) Solenoid valve outlet pressure
1
cel solenoid valve
Neutral 0 MPa {0 kg/cm2}
RAISE position 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
Possible Malfunction of 2-stage Right control lever (boom) Solenoid valve outlet pressure
2
causes and relief solenoid valve
standard value
in normal state RAISE position 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
Right control lever (boom) Solenoid valve outlet pressure
Malfunction of boom +1.0
3 control valve (main 33.3 –2.5 MPa
Relieved in RAISE position
relief valve) +10
{340 –25 kg/cm2}
If the condition cannot be set normally by adjustment, the main relief valve
(high pressure side of Lo, Hi, Plus) may have a malfunction. Check the
main relief valve directly.
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.
Related (If they are abnormal, carry out the related troubleshooting.)
information • Check that the machine does not deviate.

Possible Malfunction of machine Machine pushup switch Solenoid valve outlet pressure
1
causes and pushup solenoid valve
standard value OFF 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
in normal state ON 0 MPa {0 kg/cm2}
Malfunction of boom The safety & suction valve (high pressure side of Lo, Hi, Plus) of the boom
2 control valve (safety & control lever (Lo) may have a malfunction. Check the safety & suction
suction valve) valve directly.
16 PC1250-8R
H-6 Speed or power of arm is low 1
Failure
• Speed or power of arm is low
information
Related
information

Malfunction of left PPC Left control lever (arm) PPC valve output pressure
1
valve (arm circuit) +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
Possible Malfunction of arm Since the spool of the arm control valve (Lo, Hi, Plus) may have a mal-
2
causes and control valve (spool) function, check it directly.
standard value Malfunction of arm Since the safety & suction valve of the arm control valve (Lo, Hi, Plus) may
in normal state 3 control valve (safety & have a malfunction, check it directly. (The safety & suction valve may be
suction valve) checked by replacing it with the one of the bucket circuit.)
Defective arm control Since the body of the arm control valve (Lo, Hi, Plus) may have a malfunc-
4
valve (body) tion, check it directly.
Defective seal of arm the engine at high idle.
5
cylinder Left control lever (arm) Leakage from cylinder
Relieved in IN position Max. 28 cc/min
PC1250-8R 17
H-7 Speed or power of bucket is low 1
Failure
• Speed or power of bucket is low
information
Related
information

Malfunction of right Right control lever (bucket) PPC valve output pressure
1 PPC valve (bucket cir-
cuit) +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
Possible Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi, Plus) may have a mal-
2
causes and control valve (spool) function, check it directly.
standard value Malfunction of bucket Since the safety & suction valve of the bucket control valve (Lo, Hi, Plus)
in normal state 3 control valve (safety & may have a malfunction, check it directly. (The safety & suction valve may
suction valve) be checked by replacing it with the one of the arm circuit.)
Defective bucket con- Since the body of the bucket control valve (Lo, Hi, Plus) may have a mal-
4
trol valve (body) function, check it directly.
Defective seal of the engine at high idle.
5
bucket cylinder Right control lever (bucket) Leakage from cylinder
Relieved in CURL position Max. 28 cc/min
18 PC1250-8R
H-8 Boom does not move 1
Failure
• Boom does not move
information
• Check that operations of the other work equipment, travel, and swing are normal.
Related
information

Possible Malfunction of right Right control lever (boom) PPC valve output pressure
causes and 1 PPC valve (boom cir-
standard value cuit) +0.6
2.9 –0.2 MPa
in normal state Full stroke
+5.5
{30 –1.5 kg/cm2}
Malfunction of boom Since the spool of the boom control valve (Lo, Hi, Plus) may have a mal-
2
control valve (spool) function, check it directly.
PC1250-8R 19
H-9 Arm does not move 1
Failure
• Arm does not move
information
Related
information

Possible Left control lever (arm) PPC valve output pressure
Malfunction of left PPC
causes and 1
valve (arm circuit) +0.6
standard value 2.9 –0.2 MPa
+5.5
{30 –1.5 kg/cm2}
Malfunction of arm Since the spool of the arm control valve (Lo, Hi, Plus) may have a mal-
2
20 PC1250-8R
H-10 Bucket does not move 1
Failure
• Bucket does not move
information
Related
information

Possible Malfunction of right Right control lever (bucket) PPC valve output pressure
causes and 1 PPC valve (bucket cir-
standard value cuit) +0.6
2.9 –0.2 MPa
+5.5
{30 –1.5 kg/cm2}
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi, Plus) may have a mal-
2
PC1250-8R 21
H-11 Hydraulic drift of work equipment is large 1
Failure
• Hydraulic drift of boom is large
information (1)
Related
information

Defective seal of boom Since the spool of the boom control valve (Lo, Hi, Plus) may have a mal-
1
Since the safety & suction valve (bottom side) of the boom control valve
Possible Malfunction of boom (Lo) may have a malfunction, check it directly. (The safety & suction valve
causes and 2 control valve (safety & may be checked by replacing it with one of another work equipment cir-
standard value suction valve) cuit. After checking, however, be sure to return the safety & suction valve
in normal state since its set pressure and structure are different from the others.)
Defective seal of boom the engine at high idle.
3
cylinder Right control lever (boom) Leakage from cylinder
Relieved in RAISE position Max. 28 cc/min
Failure
• Hydraulic drift of arm is large
information (2)
Related
information

Defective seal of arm Since the spool of the arm control valve (Lo, Hi, Plus) may have a mal-
1
Possible Malfunction of arm Since the safety & suction valve (bottom side) of the arm control valve (Lo,
causes and 2 control valve (safety & Hi, Plus) may have a malfunction, check it directly. (The safety & suction
standard value suction valve) valve may be checked by replacing it with one of the bucket circuit.)
in normal state a Prepare with the engine stopped, then carry out troubleshooting with
Defective seal of arm the engine at high idle.
3
cylinder Left control lever (arm) Leakage from cylinder
Relieved in IN position Max. 28 cc/min
Failure
• Hydraulic drift of bucket is large
information (3)
Related
information

Defective seal of
Since the spool of the bucket control valve (Lo, Hi, Plus) may have a mal-
1 bucket control valve
function, check it directly.
(spool)
Possible Malfunction of bucket Since the safety & suction valve (bottom side) of the bucket control valve
causes and 2 control valve (safety & (Lo, Hi, Plus) may have a malfunction, check it directly. (The safety & suc-
standard value suction valve) tion valve may be checked by replacing it with one of the arm circuit.)
in normal state
Defective seal of the engine at high idle.
3
bucket cylinder Right control lever (bucket) Leakage from cylinder
Relieved in CURL position Max. 28 cc/min
22 PC1250-8R
H-12 Time lag of work equipment is large 1
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

causes and Malfunction of arm Since the safety & suction valve (bottom side) of the arm control valve (Lo,
standard value 1 control valve (safety & Hi, Plus) may have a malfunction, check it directly. (The safety & suction
in normal state suction valve) valve may be checked by replacing it with one of the bucket circuit.)
Failure
• Time lag of bucket is large
information (3)
Related
information

causes and Malfunction of bucket Since the safety & suction valve (bottom side) of the bucket control valve
standard value 1 control valve (safety & (Lo, Hi, Plus) may have a malfunction, check it directly. (The safety & suc-
in normal state suction valve) tion valve may be checked by replacing it with one of the arm circuit.)
PC1250-8R 23
H-13 Boom shockless function cannot be turned ON or OFF 1
Failure
• Boom shockless function cannot be turned ON or OFF
information
Related
information

a Prepare with starting switch OFF, then carry out troubleshooting with
Possible Malfunction of boom the starting switch ON.
causes and 1 shockless solenoid Remove the solenoid valve from the valve assembly and connect the con-
standard value valve nector and operate the boom shockless switch. If the spool moves at this
in normal state time, the solenoid valve is normal.
Malfunction of boom
2 Since the boom shockless valve may have a malfunction, check it directly.
shockless valve
H-14 Machine deviates in one direction 1
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.

Troubleshooting with Carry out troubleshooting by using the judgment matrix in Before trouble-
1
judgment matrix shooting for hydraulic and mechanical systems.
Malfunction of travel Travel lever PPC valve output pressure
2
PPC valve +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
Malfunction of travel Since the spool of the travel control valve may have a malfunction, check it
3
control valve (spool) directly.
Defective travel con- Since the body of the travel control valve may have a malfunction, check it
Possible 4
trol valve (body) directly.
causes and
standard value a Prepare with the engine stopped, then carry out troubleshooting with
in normal state the engine at high idle.
Defective seal of cen- Travel lever Leakage from swivel joint
5
ter swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1.
Leakage in travel the engine at high idle.
6
motor Travel lever Leakage from travel motor
Relieved on one side Max. 40 l/min
7 Defective travel motor Since the travel motor may be defective, check it directly.
Since the final drive may have a defect in it, check it directly. (The defect
Internal defect of final
8 can be judged by abnormal sound, abnormal heat, metal chips in drained
drive
oil, etc.)
24 PC1250-8R
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.

Malfunction of travel Travel lever PPC valve output pressure
1
PPC valve +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
2
Possible
causes and a Prepare with the engine stopped, then carry out troubleshooting with
standard value the engine at high idle.
in normal state Defective seal of cen- Travel lever Leakage from swivel joint
3
ter swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig.
Low set pressure of Travel lever Travel relief pressure
4 travel motor safety
valve +1.0
34.3 –2.5 MPa
Relieved on one side
+10
{350 –25 kg/cm2}
Figure 2: Defective seals in center swivel joint and travel deviation directions
PC1250-8R 25
H-15 Machine deviates largely at start 1
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

Malfunction of hydrau- Since the servo-valve of hydraulic pumps (No. 1 & No. 2) may have a mal-
1
lic pump servo-valve function, check it directly. (Test the servo-valve unit or measure its stroke.)
Possible
causes and 2
standard value
in normal state Defective seal of cen- Since the seal of the center swivel joint may have a malfunction, check it
3
ter swivel joint directly.
Internal defect of travel
4 Since the travel motor may have a defect in it, check it directly.
motor (body)
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

Travel lever CO • NC valve output pressure
1 or malfunction of CO • Neutral Max. 0.4 MPa {Max. 4.1 kg/cm2}
NC valve
Full stroke on one side (Idle travel) Min. 1.7 MPa {Min. 17 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC
Possible valve may have a malfunction or may be adjusted defectively. Check the
causes and CO • NC valve directly.
standard value Malfunction of hydrau- Since the servo-valve of hydraulic pump may have a malfunction, check it
in normal state 2
lic pump servo-valve directly. (Test the servo-valve unit or measure its stroke.)
Travel lever Differential pressure of jet sensor
Neutral Min. 1.5 MPa {Min. 15 kg/cm2}
3 or malfunction of jet
sensor Full stroke on one side (Idle travel) Max. 0.2 MPa {Max. 2 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve
may have a malfunction or the orifice may be defective. Check the relief
valve and orifice directly.
26 PC1250-8R
H-16 Machine deviates largely during compound operation 1
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

Prepare with the engine stopped, then carry out troubleshooting with the
engine at high idle.
Control levers Solenoid valve outlet pressure
Possible Malfunction of straight
1 All levers in neutral 0 MPa {0 kg/cm2}
causes and travel solenoid valve
standard value Operation of work equipment or
in normal state swing 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
+ Travel
Malfunction of travel
Since the straight travel valve of the travel control valve may have a mal-
2 control valve (Straight
travel valve)
H-17 Travel speed or power is low 1
Failure
• Travel speed or power is low
information
Related
information

Malfunction of CO can- Travel lever Solenoid valve outlet pressure
1
cel solenoid valve
Possible Neutral 0 MPa {0 kg/cm2}
causes and
Operation on one side 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
standard value
in normal state a Prepare with the engine stopped, then carry out troubleshooting with
Malfunction of 2-stage Travel lever Solenoid valve outlet pressure
2
relief solenoid valve
Operation on one side 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
PC1250-8R 27
H-18 Machine does not travel (only one track) 1
Failure
• Machine does not travel in either direction.
information (1)
Related
information

Malfunction of travel Since the parking brake of the travel motor may have a malfunction, check
1
Possible motor (parking brake) it directly.
causes and Internal defect of travel
standard value 2 Since the travel motor may have a defect in it, check it directly.
motor (body)
in normal state
Since the final drive may have a defect in it, check it directly. (The defect
Internal defect of final
3 can be judged by abnormal sound, abnormal heat, metal chips in drained
drive
oil, etc.)
Failure
• Machine does not travel forward or in reverse
information (2)
Related
information

Malfunction of travel Travel levers (Both) PPC valve output pressure
1
PPC valve +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
Malfunction of travel Since the spool of the travel control valve may have a malfunction, check
2
control valve (spool) it directly.
Possible
causes and Defective travel con- Since the suction valve of the travel control valve may have a malfunc-
standard value 3 trol valve (suction tion, check it directly. (The suction valve can be checked by replacing it
in normal state valve) with normal one.)
Malfunction of travel Travel levers (Both) Travel relief pressure
4
motor (safety valve) +1.0
34.3 –2.5 MPa
Relieved
+10
{350 –25 kg/cm2}
Since the counterbalance valve of the travel motor may have a malfunc-
5 motor (counterbal-
tion, check it directly.
ance valve)
28 PC1250-8R
H-19 Travel speed does not change 1
Failure
• Travel speed does not change
information
• Check that the Lo and Hi travel speeds are normal.
• 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}.

Possible Malfunction of travel Switches and control levers Solenoid valve outlet pressure
1
causes and speed solenoid valve Travel speed switch: Lo 0 MPa {0 kg/cm2}
standard value
in normal state Travel speed switch: Hi +
2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
Operation of travel lever
Since the servo mechanism of the travel motor may have a malfunction,
2 motor (servo mecha-
check it directly.
nism)
PC1250-8R 29
H-20 Machine does not swing 1
Failure
• Machine does not swing in either direction
information (1)
• Check that the work equipment and travel are normal.
Related
information

Malfunction of swing
1 holding brake solenoid Left control lever (swing) Solenoid valve outlet pressure
valve Neutral (At least 5 sec after) 0 MPa {0 kg/cm2}
Possible
causes and Operation 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
standard value Malfunction of swing Since the holding brake of the swing motor may have a malfunction, check
in normal state 2
motor (holding brake) it directly.
Internal defect of swing
3 Since the swing motor may have a defect in it, check it directly.
motor (body)
Since the swing machinery may have a defect in it, check it directly. (The
4 defect can be judged by abnormal sound, abnormal heat, metal chips in
machinery
drained oil, etc.)
Failure
• Machine does not swing in one direction
information (2)
Related
information

Malfunction of left PPC Left control lever (swing) PPC valve output pressure
1
valve (swing circuit) +0.6
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
Malfunction of swing Since the spool of the swing control valve may have a malfunction, check
2
Possible a Prepare with the engine stopped, then carry out troubleshooting with
causes and the engine at high idle.
standard value
Left control lever (swing) Swing relief pressure
in normal state
+1.0
Defective adjustment 31.4 –2.5 MPa
3 or malfunction of swing Relieved
+10
motor (safety valve) {320 –25 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the safety valve
may have a malfunction. Check the safety valve directly. (The malfunction
can be judged from change of phenomenon after exchanging the safety
valves with each other.)
Since the suction valve of the swing motor may have a malfunction, check
4 it directly. (The malfunction can be judged from change of phenomenon
machinery
after exchanging the suction valves with each other.)
30 PC1250-8R
H-21 Swing speed or acceleration is low 1
Failure
• Swing speed or acceleration is low in both directions
information (1)
Related
information
• Carry out all the troubleshooting with the swing lock switch turned OFF in working mode P.

Leakage in swing the engine at high idle.
1
motor Left control lever (swing) Solenoid valve outlet pressure
Possible Relieved Max. 28 l/min
causes and Malfunction of swing Since the holding brake of the swing motor may have a malfunction, check
standard value 2
in normal state
motor (body)
machinery
drained oil, etc.)
Failure
• Swing speed or acceleration is low in one direction
information (2)
Related
information

1
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
2
standard value
in normal state
+1.0
+10
machinery
PC1250-8R 31
H-22 Swing speed or power is low in compound operation of travel and

bucket 1
Failure
• Swing speed or power is low in compound operation of travel and bucket
information
Related
information

Swing PPC shuttle valve outlet pres-
Malfunction of swing Left control lever (swing)
1 sure
PPC shuttle valve
Possible +0.6
2.9 –0.2 MPa
causes and Full stroke
+5.5
standard value {30 –1.5 kg/cm2}
in normal state
Since the compensation valve of the swing control valve may have a mal-
2 control valve (compen-
sation valve)
Since the compensation pilot valve of the swing control valve may have a
3 control valve (compen-
malfunction, check it directly.
sation pilot valve)
H-23 Swing speed or power is low in compound operation of travel and

boom in swing priority mode 1
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

Possible
causes and Swing priority mode switch Solenoid valve outlet pressure
standard value Malfunction of swing
1
in normal state priority solenoid valve
OFF 0 MPa {0 kg/cm2}
ON 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
32 PC1250-8R
H-24 Upper structure overruns largely 1
Failure
• Upper structure overruns largely in both directions
information (1)
Related
information
Possible
causes and
standard value Leakage in swing
1 Left control lever (swing) Solenoid valve outlet pressure
in normal state motor
Relieved Max. 28 l/min
Failure
• Upper structure overruns largely in one direction
information (2)
Related
information

1
2.9 –0.2 MPa
Full stroke
+5.5
{30 –1.5 kg/cm2}
2
standard value
in normal state
+1.0
+10
motor (suction valve)
PC1250-8R 33
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
information

1 holding brake solenoid Left control lever (swing) Solenoid valve outlet pressure
valve Neutral (At least 5 sec after) 0 MPa {0 kg/cm2}
Possible
causes and Operation 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
standard value Malfunction of swing Since the holding brake of the swing motor may have a malfunction, check
in normal state 2
motor (body)
machinery
drained oil, etc.)
Failure
• Large shocks are made when upper structure stops swinging in one direction
information (2)
Related
information

Possible
causes and +1.0
standard value 1 or malfunction of swing Relieved
+10
in normal state motor (safety valve) {320 –25 kg/cm2}
34 PC1250-8R
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
machinery
drained oil, etc.)
Failure
• Large abnormal sounds are made when upper structure stops swinging in one direction
information (2)
Related
information

+1.0
Possible Relieved
1 or malfunction of swing +10
causes and {320 –25 kg/cm2}
motor (safety valve)
standard value
in normal state If the oil pressure cannot be set normally by adjustment, the safety valve
motor (suction valve)
PC1250-8R 35
H-27 Hydraulic drift of swing is large 1
Failure
• Hydraulic drift of swing is large
information
Related
information

Possible Malfunction of swing
causes and 1 holding brake solenoid Left control lever (swing) Solenoid valve outlet pressure
standard value valve Neutral (At least 5 sec after) 0 MPa {0 kg/cm2}
in normal state
Operation 2.9 ± 0.6 MPa {30 ± 5.5 kg/cm2}
Malfunction of swing Since the holding brake of the swing motor may have a malfunction, check
2
36 PC1250-8R
H-28 Fan revolution is abnormal (Sound and vibration of the fan is

abnormally large, and the fan is overheated) 1
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.

1. At high idle
Control lever Fan pump EPC current
Operate work equipment lever to the Standard specification: 609.3 ± 60 mA
Malfunction in fan extent that machine does not move. 55°C specification: 581.7 ± 60 mA
1 pump EPC current out-
put 2. At high idle down
Control lever Fan pump EPC current
Standard specification: 574 ± 60 mA
All levers at neutral
55°C specification: 542.4 ± 60 mA
1. At high idle
Possible Output pressure of fan pump EPC
Control lever
causes and solenoid valve
standard value Standard specification:
in normal state Operate work equipment lever to the 1.62 ± 0.49 MPa {16.5 ± 5.0 kg/cm2}
extent that machine does not move. 55°C specification:
Defective fan pump 1.47 ± 0.49 MPa {15.0 ± 5.0 kg/cm2}
2
EPC solenoid valve 2. At high idle down
Output pressure of fan pump EPC
Control lever
solenoid valve
Standard specification:
1.42 ± 0.49 MPa {14.5 ± 5.0 kg/cm2}
All levers at neutral
55°C specification:
1.27 ± 0.49 MPa {13.0 ± 5.0 kg/cm2}
Defective fan pump If the results of checking causes 1 – 2 are normal, check fan pump and fan
3
and fan motor inside motor directly since they can be defective.
PC1250-8R 37
SEN02086-01

© 2007 KOMATSU
All Rights Reserved
38
SEN02087-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 7
S-3 Engine does not pick up smoothly.......................................................................................................... 10
S-4 Engine stops during operations ...............................................................................................................11
S-5 Engine does not rotate smoothly ............................................................................................................ 12
S-6 Engine lacks output (or lacks power) ..................................................................................................... 13
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 15
S-9 Oil becomes contaminated quickly ......................................................................................................... 16
S-10 Fuel consumption is excessive............................................................................................................. 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 18
S-12 Oil pressure drops ................................................................................................................................ 19
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 20
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 21
S-15 Abnormal noise is made....................................................................................................................... 22
PC1250-8R 1
S-16 Vibration is excessive ........................................................................................................................... 23

S-17 Air cannot be bled from fuel circuit ....................................................................................................... 24
2 PC1250-8R
Method of using troubleshooting chart 1

The troubleshooting chart consists of the “questions”, “check items”, “causes”, and “troubleshooting” blocks.
The questions and check items are used to pinpoint high probability causes by simple inspection or from
phenomena without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are applied to check the narrowed causes in order from the
most probable one to make final confirmation according to the troubleshooting procedure.
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.
E : Causes to be referred to for questions and

check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked
with
a When narrowing the “causes”, apply the items
marked with w before those marked with Q.
When narrowing the “causes”, do not apply the
items marked with E (If no items have other
marks and the causes cannot be narrowed,
however, you may apply them.)
PC1250-8R 3
<Example of troubleshooting> Exhaust gas color is black (incomplete combustion)

Let us assume that a trouble of “Exhaust gas color is black” occurred and we checked the [Questions] and
[Check items] and found the following 3 items to be the causal symptoms; [Exhaust gas color slowly became
black], [Power slowly became weaker], and [Dust indicator is lighting red].
4 PC1250-8R
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.
PC1250-8R 5
S-1 Starting performance is poor 1

General causes why starting performance is poor Causes
Leaking or clogged fuel piping, entry of air

Defective electrical system
Clogged air breather hole of fuel tank cap

q
Defective contact of valve and valve seat
Defective alternator (generator section)

Defective alternator (regulator section)
q Insufficient supply of fuel
Stuck, seized supply pump plunger

Insufficient intake of air
Defective intake air heater system

q
Defective or deteriorated battery

Clogged feed pump gauze filter
q Improper selection of fuel
Clogged air cleaner element
Clogged fuel filter, element

q Coolant in exhaust pipe
Worn piston ring, cylinder

a The common rail fuel injection system (CRI) recognizes
Defective injector
the fuel injection timing electrically. Accordingly, 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
machine
Became worse gradually Q w w Q Q
Questions
Starting performance
Engine starts easily when warm w w
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Manual w w w Q Q
Oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does not indicate nor-
w
mally (if installed)
During operation, charge level monitor indicates abnormal charge w w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly w
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow out w w
cranked with starting If spill hose from injector is disconnected,
motor, w
little fuel spills
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylin-
w
ders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Troubleshooting
Inspect fuel filter, strainer directly q

Inspect fuel feed pump gauze filter directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 25 – 30 V between alternator terminal and terminal E with engine at low Yes q
idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
*1: Failure code [CA559] and failure code [CA2249]
6 PC1250-8R
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective starting motor (safety relay section)

General causes why engine does not turn
Defective connection of battery terminal
Defective starting motor (motor section)

q Internal parts of engine seized:
Defective or deteriorated battery

See “S-4 Engine stops during operations”
Defective steering circuit wiring

q Water hammer caused by coolant which entered cylinder
Broken flywheel ring gear

q Defective electrical system
Defective starting switch

Defective battery relay
q Defective hydraulic pump

Questions
Degree of use of
machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned
ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is
turned to START, start- Makes grating noise w w
ing pinion moves out, Soon disengages again w
but
Makes rattling noise and does not turn Q Q w
Inspect flywheel ring gear directly q
Carry out troubleshooting

Troubleshooting
There is not voltage (20 – 30 V) between battery relay terminal B and ter-
q
minal E
in H mode
Turn starting switch When terminal B and terminal C of starting switch are connected, engine
q
OFF, connect cord, and starts
carry out troubleshoot- When terminal B and terminal C at safety relay outlet are connected,
ing 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
Correct
Remedy
—
PC1250-8R 7
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke
comes out

q Fuel is not being supplied
Wrong connection of supply pump PCV

q Supply of fuel is extremely small
Seized, abnormally worn feed pump

q Improper selection of fuel (particularly in winter)
Defective operation flow damper

Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Degree of use of
Questions
machine Operated for long period E E E
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w w E E

Replacement of filters has not been carried out according to Operation and
w w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, there is not fuel in it w w
Check items
Fuel is leaking from fuel piping w
While engine is If air bleeding plug of fuel filter is removed, fuel does not flow Q Q w Q
cranked with out
starting motor, If spill hose from injector is disconnected, little fuel spills Q w w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump gauze filter directly q

Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q q q q
Carry out troubleshooting according to “Abnormality in PCV1 (*2) or Abnormality q
in PCV2 (*3)”
Inspect overflow valve directly q
Engine can be started in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Remedy
Add

8 PC1250-8R
c) Exhaust smoke comes out but engine does not Causes
start (fuel is being injected)
Leaking or clogged fuel system, entry of air

Defective coolant temperature sensor,

General causes why exhaust smoke comes out but
Defective intake air heater system

Clogged injector, defective spray
engine does not start
Worn piston ring, cylinder liner
Defective, deteriorated battery

Worn dynamic valve system
Clogged fuel filter, strainer

(Valve, rocker lever, etc.)
q Lack of rotating force due to defective electrical
Use of improper fuel

system
wiring harness
q Insufficient intake of air

Degree of use of
machine Operated for long period E E E E
Questions
Suddenly failed to start w w Q

Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w w w
Manual
When engine is preheated or when temperature is low, preheating monitor does not indi-
w
cate normally
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w w
When fuel filter is removed, there is not fuel in it w
Starting motor cranks engine slowly w
When engine is cranked, abnormal sound is generated around cylinder head w
Check items
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
w
some cylinders is low

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

When injector unit is tested, spray condition is bad q
Coolant temperature gauge does not indicate normally
q
(if coolant temperature gauge is installed)
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
PC1250-8R 9
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Causes
Seized turbocharger, interference of turbocharger

Insufficient supply of fuel

q

q Defective injection condition of fuel
Defective operation of flow damper

Clogged injector, defective spray

Controller is controlling in derate mode

q
(Large leakage from injector)

(limiting injection rate (output) because of an error in

Improper valve clearance
electrical system)
q EGR valve is stuck open
(There is much EGR gas and intake of air is insufficient)

Degree of use of
Operated for long period E E E E E
machine
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation and Maintenance Man-
w w w
ual
When priming pump is operated, it makes no reaction or it is heavy w Q Q

Q w
ders is low
Blue under light load w
Exhaust smoke color
w Q w w
Check items
Black
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

Inspect valve clearance directly q
Troubleshooting
When turbocharger is rotated by hand, it is found to be heavy q

When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
10 PC1250-8R
S-4 Engine stops during operations 1
General causes why engine stops during operations Causes
Broken dynamic valve system (valve, rocker arm, etc.)

q Seized parts inside engine
Defective power supply wiring for engine controller

q There is overheating
Broken auxiliary equipment (pump, etc.)

q Defective hydraulic pump
Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Defective starting switch wiring

Broken supply pump shaft, key
Leaking, clogged fuel piping
Problem in hydraulic pump

Broken, seized feed pump

Broken, seized gear train
Degree of use of machine Operated for long period E E
Abnormal noise was heard and engine stopped sud-
w w w w Q w Q w w
denly
Condition when engine Engine overheated and stopped w Q Q
Questions
stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation and Mainte-
w w
nance Manual
Fuel level monitor indicates low level w
Metal particles are found when oil is drained w w Q Q
Check items
Does not turn at all w w
When engine is cranked by Turns in opposite direction w

hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w
Inspect piston, connecting rod directly q

Carry out troubleshooting in H mode
Inspect crankshaft bearing directly q
Inspect gear train directly q

Troubleshooting
Inspect feed pump directly q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q q
Engine rotates when pump auxiliary equipment (pump, etc.) is removed q
Check power supply wiring for engine controller q
Check starting switch wiring q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
PC1250-8R 11
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes
Defective operation of flow damper (Large leakage from injector)

q Air in fuel system
q Defective speed sensor (Error at degree that it is not
indicated)
q Defective EGR valve
Clogged injector, defective spray (dirt in injector)

q Defective bypass valve
Defective Bkup speed sensor, wiring harness

Defective Ne speed sensor, wiring harness
Defective operation of bypass valve

Low setting of low idle speed

Degree of use of machine Operated for long period E E E
Occurs at a certain speed range Q Q Q Q
Questions
Occurs at low idle w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Maintenance Man-
w w
ual
Check
items
Rust and water are found when fuel tank is drained Q Q

Carry out troubleshooting according to “Abnormality in bypass valve servo (*1)” q

Troubleshooting

Carry out troubleshooting according to “Abnormality in engine Ne speed sensor (*2)” q
Carry out troubleshooting according to “Abnormality in engine Bkup speed sensor (*3)” q
or replace
or replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy
Clean
Add

*2: Failure code [CA689]
*3: Failure code [CA778]
12 PC1250-8R
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Causes
Defective fuel temperature sensor, wiring harness

Defective charge pressure sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Defective installation of charge pressure sensor

Insufficient supply of fuel
Air leakage from air intake piping, aftercoder

q
Defective drive of injector (signal, solenoid)

Improper selection of fuel

q

There is overheating:

q
Leaking, clogged fuel piping

See “S-14 Coolant temperature becomes too

high (Overheating)”
q Controller is controlling in derate mode
(limiting injection rate (output) because of an
(air leakage)
error in electrical system)
Degree of use of Operated for long period E E E E E

machine
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Replacement of filters has not been carried out according to Operation and Maintenance w
Manual
Oil must be added more frequently Q Q Q
Output becomes insufficient after short stop of operation w
Black w w
Exhaust smoke color
When exhaust manifold is touched immediately after starting engine, temperature of some w
cylinders is low

Check items
High idle speed is too low Q
High idle speed under no load is normal, but speed suddenly drops when load is applied w w Q
Engine does not pick up smoothly and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q

Troubleshooting
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
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to “Abnormality in charge pressure sensor (*2)” q
Carry out troubleshooting according to “Abnormality in fuel temperature sensor (*3)” q

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy

PC1250-8R 13
S-7 Exhaust smoke is black (incomplete combustion) 1

General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head
Defective coolant temperature sensor, wiring harness

• Insufficient intake of air

q Excessive injection of fuel
Clogged fuel spill piping (on cylinder head side)


q There is overheating:

See “S-14 Coolant temperature becomes too high
Improper fuel injection pressure

(Overheating)”

Controller is controlling in derate mode (limiting injec-
Crushed, clogged muffler
Abnormally worn injector

q
Improper injection timing

Clogged, seized injector
tion rate (output) because of an error in electrical sys-
tem)
q EGR valve is stuck open
(There is much EGR gas and intake of air is insuffi-
cient)

Degree of use of
machine
Suddenly became black w Q Q
Questions
Exhaust smoke color Gradually became black w Q Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w

Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some cyl-
Q w
inders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
If spill hose from injector is disconnected, abnormally much fuel spills w

Troubleshooting

When muffler is removed, exhaust color improves q
Carry out troubleshooting according to “No-pressure feed by supply pump (*1)” q q
Inspect fuel spill piping (on cylinder head side) directly q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

14 PC1250-8R
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

q Abnormal consumption of oil
Worn, damaged valve (stem, guide, seal)

q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system
Clogged breather, breather hose

continuously)
Worn seal at turbocharger end
Oil leakage from oil drain plug

External leakage of oil
Worn, damaged rear oil seal

q
Oil leakage from oil cooler
Oil leakage from oil piping

q Wear of parts in lubrication system
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

Degree of use of
E E E E
Questions
machine Operated for long period
Oil consumption suddenly increased w Q

Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Inspect breather and breather hose directly 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
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
PC1250-8R 15
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Causes
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Entry of exhaust gas into oil due to internal wear
q Clogging of lubrication passage
q Use of improper fuel
Clogged breather, breather hose

Use of improper oil

q
Defective oil filter safety valve

q Operation under excessive load
Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Degree of use of machine Operated for long period E E E
Questions
Non-specified fuel is being used Q

Even when engine oil temperature rises, oil filter clogging monitor indicates clogging (If the moni-
Q
tor is installed)
Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items
Exhaust smoke color

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play (wear) of turbocharger shaft q

Troubleshooting
Inspect breather and breather tube directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
—
16 PC1250-8R
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes
Defective coolant temperature sensor, wiring harness

q Leakage of fuel
q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective feed pump oil seal
Defective spray by injector

Degree of use of E E E
Questions
Operated for long period

machine
More than for other machines of same model Q Q Q
Condition of fuel
consumption Gradually increased Q Q
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
w
ders is low
Check items
Low idle speed is high Q

Torque converter stall speed or pump relief speed is high Q
Exhaust smoke Black Q Q Q

color White Q
Remove and inspect head cover directly q

Troubleshooting
Inspect feed pump oil seal directly q

If spill hose from injector is disconnected, much fuel spills q
Carry out troubleshooting according to “Abnormality in coolant temperature sensor (*2)” q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Remedy

PC1250-8R 17
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
Damaged cylinder liner O-ring, hole caused by pitting

q Internal leakage in lubrication system
q Internal leakage in cooling system
Insufficient protrusion of cylinder liner

Broken cylinder head, head gasket
Broken oil cooler core, O-ring

Cracks inside cylinder block
Degree of use of E E
Questions
Increase of oil Suddenly occurred Q Q

level Gradually occurred Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
Check
items
There are excessive air bubbles in radiator, coolant spurts back w w
Pressure-tightness test of cylinder head shows there is leakage q

Troubleshooting
Inspect cylinder block, liner directly q q

Inspect cylinder liner directly q
Pressure-tightness test of oil cooler shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
18 PC1250-8R
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes
Defective oil pressure sensor, wiring harness

Leaking, crushed, clogged hydraulic piping
q Leakage, clogging, wear of lubrication system
q Defective oil pressure control
q Improper selection of fuel (improper viscosity)
q Deterioration of oil due to overheating
Clogged, broken pipe in oil pan
Defective oil pump relief valve
Leaking EGR hydraulic piping

Clogged strainer in oil pan
Defective EGR oil pump

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Degree of use of
Questions
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
Oil pressure moni- Indicates pressure drop at low, high idle Q w w w Q Q Q

tor (if installed) Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q Q
Metal particles are found in oil filter q

Inspect oil pan strainer, pipe directly q q
Troubleshooting
Oil pump rotation is heavy, there is play in oil pump q

See S-13
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
PC1250-8R 19
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level rises Causes
Clogged or defective seal of water pump drain hole

q Coolant in oil (milky)
q Fuel in oil (smells diluted diesel fuel)
Detective seal of auxiliary equipment (pump)

a If oil is in coolant, carry out troubleshooting for “S-11 Oil is in
coolant”

Fuel leakage inside head cover
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Cracks inside cylinder block
Defects in supply pump

(breather hole)
Questions
Degree of use of Operated for long period E E E E

machine
Fuel must be added more frequently w w
Coolant must be added more frequently Q
There is oil in coolant Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles w Q
appears, or coolant spurts back
Check items
Exhaust smoke is white Q

Water pump drain hole (breather hole) is clogged w
When water pump drain hole (breather hole) is cleaned, water is found w
Oil level in damper chamber is low w

Remove and inspect head cover directly q
Troubleshooting
Inspect cylinder block, liner directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect water pump directly q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20 PC1250-8R
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too high Causes

q Lack of cooling air (deformation, damage of fan)
q Drop in heat dissipation efficiency
Drop in performance of fan pump, fan motor

q Problem in coolant circulation system
Defective radiator cap (pressure valve)

q Rise in hydraulic oil temperature
Defective coolant temperature gauge

Defective operation of thermostat
Damage and deformation of fan

Clogged, crushed radiator fins
Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of use of
machine
Questions
Condition of over- Suddenly overheated Q w Q

heating Always tends to overheat Q w w Q
Coolant temperature Rises quickly Q w
gauge
(if installed) Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level (if monitor is installed) w
Engine oil level has risen, oil is milky w Q
Fan speed is low w
Milky oil is floating on coolant w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
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

Inspect cylinder liner directly q
Inspect oil cooler directly q Carry out troubleshooting
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large q

in H mode
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
Correct
Correct
Correct
Check
Remedy
—
Add
PC1250-8R 21
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes
Defective inside of muffler (dividing board out of position)

Leakage of air between turbocharger and cylinder head
q Abnormality due to defective parts
Abnormal combustion
Broken dynamic valve system (valve, rocker lever)

q
Interference of turbocharger, seized turbocharger

q Air sucked in from intake system
Excessive wear of piston ring, cylinder liner

a Judge if the noise is an internal noise or an external noise
Removed, seized gear train bushing

before starting troubleshooting.
Cracked, leaking EGR gas piping

a The engine is operated in the low-temperature mode while
Improper gear train backlash

it is not warmed up sufficiently. Accordingly, the engine
Deformed, damaged fan

Clogged, seized injector
sound becomes a little larger. This does not indicate abnor-
Dirt caught in injector

mality, however.
a When the engine is accelerated, it is operated in the accel-
eration mode and its sound becomes a little larger for up to
about 5 seconds. This does not indicate abnormality, how-
ever.
Degree of use of
Operated for long period E
machine
Questions
Gradually occurred Q Q Q
Abnormal noise
Suddenly occurred Q Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained Q w w
Air leaks between turbocharger and cylinder head 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
w Q
is low
Exhaust smoke Blue under light load w

color Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q

Inspect EGR gas piping directly q
Troubleshooting
When muffler is removed, abnormal noise disappears q

Inspect gear train directly q q
Inspect fan directly q
Abnormal noise is heard only when engine is started q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Remedy
22 PC1250-8R
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

q Defective parts (abnormal wear, breakage)
Worn main bearing, connecting rod bearing

q Misalignment between engine and chassis
q Abnormal combustion
Worn front support spigot joint portion

Broken output shaft, parts in damper
a If abnormal noise is made and vibration is excessive, carry
out troubleshooting for “S-15 Abnormal noise is made”, too.
Improper gear train backlash

Worn camshaft bushing
Degree of use of
E E E E
Questions
Condition of vibra- Suddenly increased Q Q

tion Gradually increased Q Q Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Inspect engine mounting bolts and cushions directly q
Inspect front support spigot joint portion directly q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
PC1250-8R 23
S-17 Air cannot be bled from fuel circuit 1

(After filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but
stalls.)
General causes why air cannot be bled Cause
q Electric priming pump does not operate.
Defective wiring harness of electric priming pump

Fuel is not supplied or is supplied very little.
Improper setting of air bleeding valve (Closed)

q
Fuel valve or air bleeding valve is not set properly.
Malfunction of electric priming pump switch

q
Leaking or clogged fuel piping or air in it

q Air bleeding piping is clogged.
Improper setting of fuel valve (Closed)

Fuel return piping is clogged.
Malfunction of electric priming pump

q
Clogged fuel tank cap breather hole
Clogged water separator screen

Clogged air bleeding piping
Low battery charge level

Clogged fuel filter
Low fuel level
Questions
Degree of use of
Operated for long period E E
machine
Fuel tank is empty w
Fuel tank cap breather hole is clogged Q w
Check items
Switch lamp does not blink w w Q

When electric priming Lamp blinks but pump operation sound is not heard w w
pump switch is operated
Pump operation sound is heard but fuel does not flow out
Q Q w w w Q Q
of hose soon
Air bleeding valve is closed q

Fuel valve (supply side) is closed q
Fuel valve (return side) is closed q
Water drain valve and air intake plug of water separator are loosened q
Troubleshooting
Water drain valve of fuel prefilter is loosened q

There is flaw or dirt on sealing face of fuel prefilter or main filter q
Check air bleeding piping and orifice directly (See Note 1) q
Check fuel piping (supply side and return side) directly (for clogging and breakage) q
Check electric priming pump directly q
Check electric priming system directly (See E-29) q q
Check water separator screen directly q
Check fuel filter for clogging (See failure code CA559, Note 2) q
Replace
Replace
Replace
Replace
Charge
Correct
Correct
Correct
Correct
Correct
Clean
Add
Remedy
24 PC1250-8R
Note 1: Check of air bleeding piping for clogging
q Remove joint bolt (1) and blow clean compressed air into hole (b) of the orifice to check for clogging.
q Remove air bleeding piping (2) and blow compressed air against its both ends to check for clogging.
PC1250-8R 25
SEN02087-01

© 2007 KOMATSU
All Rights Reserved
26
SEN02785-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
50 Disassembly and assembly1

General information on disassembly and
assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 13
PC1250-8R 1
SEN02785-01 50 Disassembly and assembly
How to read this manual 1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are deemed neces- q The [Removal] section contains procedures
sary for removal or installation of parts are and precautions for implementing the work,
described as A1,•••X1 etc. and their part know how and the amount of oil or coolant to
names, part numbers and quantities are be drained.
described in the special tool list. q General tools that are necessary for removal
q Also the following information is described are described as [1], [2]•••etc. and their part
in the special tool list. names, part numbers and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in the Removal Section
tuted and should always be used are explained and listed below.
(installed). k : This mark indicates safety-related precau-
q : Special tools that will be useful if avail- tions that must be followed when imple-
able and are substitutable with com- menting the work.
mercially available tools. a: Know-how or precautions for work
2) Distinction of new and existing special [*1] : This mark shows that there are instructions or
tools precautions for installing parts.
N: Tools newly developed for this 6 : This mark shows the amount of oil or coolant
model. They respectively have a to be drained.
new part number. 4 : Weight of part or component
R: Tools with upgraded part numbers.
They are remodeled from already
available tools for other models.
Installation
Blank: Tools already available for other
models. They can be used without q Except where otherwise instructed, installation
any modification. of parts is done in the r evers e order of
removal.
3) Circle mark Q in sketch column:
q Instructions and precautions for installing parts
q The sketch of the special tool is pre-
are shown with [*1] mark in the Installation
sented in the section of "Sketches of
Section, identifying which step the instructions
special tools".
are intended for.
q This mark means part No. of special
q General tools that are necessary for installa-
* *** ****
tools starting with 79 T- -
and that they can not be supplied
tion are described as [1], [2]•••etc. and their
part names, part numbers and quantities are
from Komatsu in Japan (i.e. locally
not described.
made parts).
q Marks shown in the Installation Section stand
for the following.
k : Precautions related to safety in execution
of work.
a : This mark gives guidance or precautions
when doing the procedure.
2 : Type of coating material
3 : Tightening torque
5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
2 PC1250-8R
2. Disassembly and assembly of assemblies Disassembly

q In Disassembly section, the work procedures,
Special tools precautions and know-how for carrying out
q Special tools which are deemed neces- those procedures, and quantity of the oil and
sary for disassembly or assembly of parts coolant drained are described.
are described as A1,•••X1 etc. and their q General tools that are necessary for disassem-
part names, part numbers and quantities bly are described as [1], [2]•••etc. and their part
are described in the special tool list. names, part numbers and quantities are not
q Also the following information is described described.
in the special tool list. q The meanings of the symbols used in Disas-
1) Necessity sembly section are as follows.
t : Special tools that cannot be substi- k : This mark indicates safety-related precau-
tuted and should always be used tions that must be followed when imple-
(installed). menting the work.
q : Special tools that will be useful if avail- a : Know-how or precautions for work
able and are substitutable with com- 6: Quantity of oil or coolant drained
mercially available tools.
2) Distinction of new and existing special
tools
N : Tools newly developed for this Assembly
model. They respectively have a q In Assembly section, the work procedures, pre-
new part number. cautions and know-how for carrying out those
R : Tools with upgraded part numbers. procedures, and quantity of the oil and coolant
They are remodeled from already added are described.
available tools for other models. q General tools that are necessary for assembly
Blank : Tools already available for other are described as [1], [2]•••etc. and their part
models. They can be used without names, part numbers and quantities are not
any modification. described.
3) Circle mark Q in sketch column: q The meanings of the symbols used in Assem-
q The sketch of the special tool is pre- bly section are as follows.
sented in the section of "Sketches of k : Precautions related to safety in execution
special tools". of work
q This mark means part No. of special a : This mark gives guidance or precautions
* *** ****
tools starting with 79 T- -
and that they can not be supplied
when doing the procedure.
2 : Type of coating material
from Komatsu in Japan (i.e. locally 3 : Tightening torque
made parts). 5 : Quantity of oil or coolant to be added
Sketches of special tools

q Various special tools are illustrated for the con-
venience of local manufacture.
PC1250-8R 3
Coating materials list 1

(Rev. 2007.05)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
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-
Gasket sealant
tant 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.
• Features: Silicon-based, heat and cold-resis-
LG-8
tant, vibration-resistant, impact-resistant seal-
ThreeBond 419-15-18131 100 g Tube
ant.
1207B
• Used to seal transfer case, etc.
4 PC1250-8R
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
• Used for rough surfaces such as the circle gear
LG-9 top seal which does not need to be clamped,
ThreeBond 790-129-9310 200 g Tube water resistance of the clearance at the welded
1206D area, etc.
• Can be coated with paint.
Gasket sealant
LG-10 • Used as lubricant/sealant when the radiator

ThreeBond 790-129-9320 200 g Tube hoses are inserted.
1206E • Can be coated with paint.
LG-11 • Feature: Can be used together with gaskets.
ThreeBond 790-129-9330 200 g Tube • Used for covers of the transmission case and
1121 steering case etc.
ThreeBond
790-129-9090 100 g Tube • Gasket sealant used to repair engine.
1211
Molybdenum
• Used to prevent scuffing and seizure of press-fit-

lubricant
disulfide
ted portions, shrink-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
• Used to lubricate linkages, bearings, etc.
• Feature: Seizure and scuffing prevention com-

prevention
compound
pound with metallic super-fine-grain, etc.

Seizure
LC-G
— — Can • Used for the mounting bolt in the high tempera-
NEVER-SEEZ
ture area of the exhaust manifold and the turbo-
charger, etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI • Feature: Lithium grease with extreme pressure
SYG2-160LI
G0-LI Various Various lubrication performance.
SYGA-160CNLI
*: For cold district • General purpose type.
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
• Used for parts under heavy load.
Caution:
Molybdenum SYG2-400M 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like
disulfide grease SYG2-400M-A 400 g x 20 container swing circle bearings, etc. and spline.
LM-G (G2-M) SYGA-16CNM 16 kg Can • The grease should be applied to work equipment
pins at their assembly only, not applied for
Grease
greasing afterwards.
• Seizure resistance, heat resistance and water
Hyper White SYG2-400T-A
400 g Bellows-type resistance higher than molybdenum disulfide
Grease G2-T, SYG2-16CNT
container grease.
G0-T (*) SYG0-400T-A (*)
16 kg Can • Not conspicuous on machine since color is
*: For cold district SYG0-16CNT (*)
white.
Biogrease SYG2-400B
G2-B, G2-BT (*) SYGA-16CNB 400 g Bellows-type • Since this grease is decomposed by natural bac-
*: For use at high SYG2-400BT (*) container teria in short period, it has less effects on micro-
temperature and SYGA-16CNBT 16 kg Can organisms, animals, and plants.
under high load (*)
• Feature: Silicone grease with wide using tem-
G2-S perature range, high resistance to thermal-oxi-
ThreeBond — 200 g Tube dative degradation and performance to prevent
1855 deterioration of rubber and plastic parts.
• Used for oil seals of the transmission, etc.
PC1250-8R 5
Cate-
Komatsu code Part number Q'ty Container Main features and applications
gory
SUNSTAR • Used as primer for cab side.
Glass
PAINT PRIMER 20 ml (Using limit: 4 months after date of manu-
container
580 SUPER facture)
SUNSTAR 417-926-3910
• Used as primer for glass side.
GLASS Glass
20 ml (Using limit: 4 months after date of manu-
PRIMER 580 container
facture)
Adhesive for cab glass

SUPER
• Used as primer for painted surface on cab
SUNSTAR
Glass side.
Primer
PAINT PRIMER 22M-54-27230 20 ml

container (Using limit: 4 months after date of manu-
435-95
facture)
• Used as primer for black ceramic-coated
SUNSTAR
surface on glass side and for hard polycar-
GLASS
22M-54-27240 150 ml Can bonate-coated surface.
PRIMER
(Using limit: 4 months after date of manu-
435-41
facture)
SUNSTAR • Used as primer for sash (Almite).
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months after date of manu-
container
GP-402 facture)
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
• Used as adhesive for glass.

Sika Japan, Polyethylene
20Y-54-39850 310 ml (Using limit: 6 months after date of manu-
Sikaflex 256HV container
Adhesive for cab glass
facture)
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months after date of manu-
SUPER 560 container) facture)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months after date of manu-
container
SEAL No. 2505 facture)
Caulking material
SEKISUI • Used to seal front window.

Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months after date of manu-
container
SEALANT facture)
• Used to seal joint of glasses.
GE TOSHIBA
Translucent white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Using limit: 12 months after date of manu-
TOSSEAL 381
facture)
6 PC1250-8R
Special tools list 1
a Tools with part number 79QT-QQQ-QQQQ cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t ........... Cannot be substituted, must always be installed (used)

q ........... Extremely useful if available or can be substituted with commercially available
part
a New/Remodel: N............ Tools with new part numbers, newly developed for this model
R:........... Tools with upgraded part numbers, remodeled from items already available for
other models
Blank: ... Tools already available for other models, can be used without any modification
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
795-799-5410 Adapter t 1 Removal and installation of fuel

Removal of fuel 1
795-799-5420 Remover t 1 injector assembly
injector and cylinder
head assembly Removal and installation of
2 795T-675-1110 Socket q 1 N Q
high-pressure pipe
Engine rear seal Removal of engine front seal
3 795-931-1100 Seal puller q 1
and front seal and rear seal
795T-621-1180 Push tool t 1 N Q Press-fitting of oil seal
795T-621-1171 Push tool t 1 R Q Press-fitting of dust seal
Engine front seal A 4
795-902-1460 Bolt t 3 Press-fitting of oil seal and dust
01582-02218 Nut t 3 seal
795T-621-1161 Push tool t 1 R Q
795T-621-1190 Push tool t 1 N Q
Engine rear seal 5 Press-fitting of engine rear seal
01050-32235 • Bolt t 5
01050-32245 • Bolt t 5
Cylinder head
6 790-331-1120 Wrench (Angle) q 1 Angle tightening of bolt
assembly
1 796T-627-1630 Push tool q 1 Q Removal of shaft
2 790-201-2350 Push tool t 1 Removal of bearing
3 790-201-2510 Push tool t 1 Press fitting of bearing
790-101-5401 Push tool kit t 1
790-101-5531 • Plate 1
Swing motor and 4 Press fitting of oil seal
swing machinery D 790-101-5421 • Grip 1
assembly 01010-51240 • Bolt 1
Press fitting of bearing inner
5 790-201-2870 Push tool t 1
race
Press fitting of bearing inner
6 790-201-2770 Push tool t 1
race
7 796T-626-1110 Push tool t 1 Q Press fitting of bearing
PC1250-8R 7
New/Remodel
Necessity
Symbol
Sketch
Q’ty

790-101-5541 • Plate 1
1 Press-fitting of oil seal
790-101-5421 • Grip 1
Swing machinery
F 01010-51240 • Bolt 1
assembly
2 796T-826-1110 Plate t 1 Q Press-fitting of bearing
3 796T-826-1130 Push tool t 1 Q Press-fitting of bearing
4 796T-826-1120 Push tool t 1 Q Extraction of pinion shaft
1 796-627-1200 Wrench assembly t 1 Tightening of hub nut
796T-827-1130 Spacer t 1 Q
2 01017-52450 Bolt t 1 Disassembly of No. 3 carrier
01580-12419 Nut t 1 assembly
3 790-201-2820 Spacer q 1
790-101-5401 Push tool kit (C) q 1
790-101-5491 • Push tool 1 Press-fitting of No. 3 carrier
4
790-101-5421 • Grip 1 assembly outer race
01010-51240 • Bolt 1
Installation of hub side outer
6 796-627-1030 Push tool t 1
race
Final drive assembly J
790-101-2300 Push-puller t 1
790-101-2310 • Block 1
790-101-2350 • Leg 2
790-101-2360 • Plate 2
02215-11622 • Nut 2
7 Installation of hub inner bearing
791-181-1010 Adapter t 2
796T-627-1340 Push tool t 1 Q
Puller
790-101-2102 t 1
(294.2 kN {30 ton})
790-101-1102 Hydraulic pump t 1
8 796-627-1050 Installer t 1 Installation of floating seal
Travel motor Removal and installation of
J 9 796-660-1560 Guide bolt t 2
assembly travel motor assembly
790-101-5541 • Plate 1
1 Press-fitting of bushing
790-101-5421 • Grip 1
01010-51240 • Bolt 1
Front idler assembly L
791-601-1000 Oil pump t 1
10 791-646-8002 Oil lubricator t 1 Refilling oil
790-701-3000 Seal checker t 1
8 PC1250-8R
New/Remodel
Necessity
Symbol
Sketch
Q’ty
790-101-5401 Push tool kit (C) t 1

790-101-5441 • Plate 1
1 Press-fitting of outer race
790-101-5421 • Grip 1
Carrier roller 01010-51240 • Bolt 1
L
assembly Removal and installation of
2 796T-830-1130 Push tool t 1 Q
bearing
3 796T-830-1140 Adapter t 2 Q Press-fitting of roller
790-401-1700 Lifting tool t 1
790-401-1761 Adapter t 1 Removal and installation of
7
Track roller 790-401-1540 Shackle t 2 track roller assembly
L
assembly 790-401-1770 T-bolt t 2
791-601-1000 Oil pump t 1
10 791-646-8002 Oil lubricator t 1 Refilling oil
791-685-8502 Compressor t 1
791-635-3160 Extension 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})
PC1250-8R 9
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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})
Hydraulic pump
S 796-770-1301 Oil stopper t 1 Stopping oil leak
assembly
790-101-2501 Push-puller t 1
790-101-2510 • Block t 1
790-101-2520 • Screw t 1
791-112-1180 • Nut t 1
Center swivel joint Disassembly of center swivel
T 790-101-2540 • Washer t 1
assembly joint assembly
790-101-2630 • Leg t 2
790-101-2570 • Plate t 2
790-101-2560 • Nut t 2
790-101-2660 • Adapter t 2
10 PC1250-8R
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Disassembly and assembly of

1 790-502-1003 Repair stand q 1
hydraulic cylinder
2 790-720-1000 Expander t 1 Installation of piston ring
796-720-1690 Ring t 1
Bucket (L/S)
07281-02169 Clamp t 1
796-720-1680 Ring t 1
Bucket (B/H)
07281-01589 Clamp t 1
3
796-720-1710 Ring t 1
Arm
07281-02709 Clamp t 1
796-720-1720 Ring t 1
Boom
07281-02429 Clamp t 1
790-101-5021 • Grip t 1 Press-fitting of bushing
01010-50816 • Bolt t 1
Hydraulic cylinder 790-201-1861 • Push tool t 1 Bottom dump
U 4
assembly 790-201-1881 • Push tool t 1 Bucket (L/S)
792-103-4102 Push tool t 1 Boom
790T-201-4010 Push tool t 1 N Q Arm
790T-201-4020 Push tool t 1 N Q Bucket (B/H)
790-101-5021 • Grip t 1 Press-fitting of dust seal
01010-50816 • Bolt t 1
790-201-1690 • Push tool t 1 Bucket (L/S)
5
790-201-1670 • Plate t 1 Bottom dump
790-201-1920 Push tool t 1 Arm
792-715-1400 Push tool t 1 Boom
790T-201-4110 Plate t 1 N Q Bucket (B/H)
790-102-4300 Wrench assembly t 1 Bucket (B/H) Removal and
6 and installation of
790-102-4310 Pin t 2 Bottom dump piston
(L/S): Loading shovel specification.

(B/H): Backhoe specification.
PC1250-8R 11
New/Remodel
Necessity
Symbol
Sketch
Q’ty
790-445-4120 Sleeve t 1
790-445-4140 Screw t 1
02215-11622 Nut t 1 Removal and installation of
boom assembly
Boom assembly V 2 01643-32780 Washer t 1 (boom foot pin of backhoe
Puller specification)
790-101-4200 t 1
(294.2 kN {30 ton})
796T-870-1150 Sleeve t 1 Q
790-438-1110 Screw t 1
796-775-1110 Adapter t 1
Removal and installation of arm
791-112-1180 Nut t 1
Arm assembly V 4 assembly (boom foot pin of
790-101-2540 Washer t 1 backhoe specification)
Puller
790-101-2102 t 1
(490.3 kN {50 ton})
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
12 PC1250-8R
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for any special tools manufactured according to these
sketches.
A2 Socket
A4 Push tool (For dust seal)
PC1250-8R 13
sketches.
A4 Push tool (For oil seal)
A5 Push tool (For both standard and sleeved seal)
14 PC1250-8R
sketches.
A5 Push tool (For sleeved seal)
D1 Push tool
PC1250-8R 15
sketches.
D7 Push tool
F2 Plate
16 PC1250-8R
sketches.
F3 Push tool
F4 Push tool
PC1250-8R 17
sketches.
J2 Spacer
J7 Push tool
18 PC1250-8R
sketches.
L2 Push tool
L3 Adapter
PC1250-8R 19
sketches.
M1 Plate
M1 Spacer
20 PC1250-8R
sketches.
U4 Push tool (for arm)
U4 Push tool (for bucket (backhoe))
PC1250-8R 21
sketches.
U5 Plate (for bucket (backhoe))
V4 Sleeve
22 PC1250-8R
PC1250-8R 23
SEN02785-01

© 2007 KOMATSU
All Rights Reserved
24
SEN02786-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Engine and cooling system (SAA6D170E-5)
Removal and installation of engine, PTO and hydraulic pump assembly ....................................................... 2
Removal and installation of radiator and hydraulic oil cooler assembly........................................................ 12
Removal of air aftercooler assembly............................................................................................................. 17
Removal and installation of fuel cooler and air conditioner condenser assembly......................................... 20
Removal and installation of fan motor assembly .......................................................................................... 22
Removal and installation of fuel tank assembly ............................................................................................ 28
PC1250-8R 1
Removal and installation of 6. Remove undercover (5).

engine, PTO and hydraulic pump
assembly 1
Removal
k Lower the work equipment completely to
the ground, stop the engine and then
relieve inner pressure of the hydraulic tank.
k Collect refrigerant (R134a) beforehand.
k Disconnect the negative terminal (–) of the
battery before starting with the work.
a Before disconnecting the hose and tube,

attach them a tag and the like to enable con-
firming their destination.
7. Drain the engine coolant.
1. Turn the assembly 90°.
6 Coolant: 142 l
2. Remove counterweight assembly (1), referring
to “Removal and installation of counterweight
8. Drain hydraulic oil.
assembly”.
6 Hydraulic tank: 670 l (Hydraulic tank refill
3. Remove exhaust pipe (2). oil capacity)
4. Remove cover (3).

9. Remove covers (6).
5. Lift and remove cover assembly (4).
10. Lift and remove cover (7).
a Remove cover (C) at the same time.
2 PC1250-8R
11. Disconnect fuel hose (83). a 55°C specification (18. – 22.)

18. Disconnect connector P11 (8).
12. Remove water separator assembly (84).
19. Disconnect clamps (9).
13. Remove brackets (85) and (86).
20. Disconnect air hose (87). [*1-1]

a Standard specification (14. – 17.)
14. Disconnect connector P11 (8) from the top of
air cleaner (A).
16. Disconnect hose (10).
17. Disconnect hose (11). [*1]
21. Remove hose (88).
22. Remove tube (89).
PC1250-8R 3
23. Lift and remove engine hood (12). 26. Disconnect hoses (15) and (16). [*2]
27. Remove tube (17). [*3]

a In the case of 55°C specification, tube (17)
is not equipped.
a To prevent the lifting tool contact it.
24. Remove frame (13).
28. Disconnect air hoses (18) and (19). [*4]

a Apply a marking to the hose end and tube
so that their original insertion positions
may be identified in later reference. (See
the following figure)
25. Lift and remove frame and cover assembly

(14).
4 PC1250-8R
29. Disconnect air intake terminal (20). 33. Disconnect fuel hoses (25) and (26).
attach them a tag and the like to enable
confirming their destination.
30. Disconnect air conditioner hose (21) from the

air conditioner compressor.
attach them a tag and the like to enable 34. Disconnect connectors CE03 (27) and CE02
confirming their destination. (28) from the engine controller.
31. Disconnect hoses (22) and (23) from the air 35. Disconnect connectors E08 (29), E09 (30) and
conditioner compressor. grounding wire T09 (30-1).
32. Disconnect fuel hose (24). 36. Disconnect clamps (31) to (33).
a Before disconnecting the hoses and tubes

in the succeeding operations, attach them
a tag and the like to enable confirming
their destination.
PC1250-8R 5
37. Disconnect hoses (34) and (35). 43. Disconnect hoses (51) and (52) from the fan
and pilot pumps (F) and (P).
38. Disconnect filter (36) from the bracket.
44. Disconnect hoses (53) and (54) from No. 2
39. Disconnect hoses (37) and (38) from No.3 pump.
pump.
45. Disconnect connector V30 (55).
46. Disconnect clamp (56).
47. Disconnect hose (57) from the filter.
40. Disconnect hoses (39), (42) and (43).
41. Disconnect hoses (45) to (49).
42. Disconnect connector C13 (50).
6 PC1250-8R
48. Disconnect clamp (58) from the bottom of 50. Disconnect tubes (61) and (62).
PTO.
q Standard specification 51. Disconnect hose (63).
q Standard specification
q 55°C specification
52. Disconnect hose (87). (55°C specification only)
q 55°C specification
49. Disconnect hoses (59) from No.1 pump.
53. Disconnect tube (60).
55. Hoses (E) and (G) are not disconnected since

MIKALOR clamp is used for them. [*5]
PC1250-8R 7
56. Disconnect tube (65) from the engine. [*6] q 55°C specification
65. Disconnect starting motor terminal (74).
58. Disconnect heater hose (67). 66. Disconnect clamp (75).
59. Disconnect clamp (68). 67. Disconnect grounding wire (76).
a Standard specification only (60. – 64.) 68. Install eyebolt on (B).

60. Disconnect air cleaner hose (69). [*7]
69. Remove mounting bolts (77). [*9]
61. Disconnect dust indicator hose (70).
62. Remove air cleaner (71). [*8]
63. Disconnect hoses (72).
64. Remove tubes (73).

70. Disconnect muffler drain hose (80).
71. Remove mounting bolt (81). [*9]
8 PC1250-8R
72. Lift engine, PTO and hydraulic pump assembly Installation

(78) temporarily. q Carry out installation in the reverse order to
a Remove air cleaner bracket (79) if con- removal.
tacts with the lifting tool.
[*1]
73. Lift and remove engine, PTO and hydraulic 3 Hose clamp of Komaclone tube assembly:
pump assembly (78). 5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
a When lifting the assembly, make sure that
every wire and hose are disconnected as [*1-1]
3
specified. Air hose clamp:
4 Engine, PTO and hydraulic pump 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
assembly: Approx. 4,850 kg
[*2]
3 Radiator hose (15) clamp:
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
[*3]
3 Hose clamp of Komaclone tube assembly:
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*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
a Muffler side supporting point q Air hose (18) (Top side)
q Air hose (19) (Bottom side)
PC1250-8R 9
2) Place the bridge (BR) under the clamping

bo l t a n d a d j us t th e ov er l a p pi n g ( b)
between the bridge (BR) and band to Min.
5 mm.
(b) dimension: Min. 5 mm
3) Tightening of the clamp.
2 Threaded portion (BC) of clamping bolt:
Lubricant (PANDO 18B from Three-
Bond)
a Impact wrench is not applicable to use.
q When the current hose is reused

Align the clamp position to the trace
of the clamp left on the hose.
3 Clamp tightening bolt:
(marked position).
a Reference: Clamping position and hose
Min. 6 Nm {0.6 kgm}
insertion depth
q Hose (E)
q When a new hose is used
Tighten the bolt until (a) dimension
meets the following.
q Top side hose (18): 17 – 20 mm
q Bottom side hose (19): 7 – 10 mm
q Hoses (F), (G) and (H)
[*5]
q Suction hoses (E) – (H)
2 Entire perimeter of hose (E) on the tube side:
Adhesive (ThreeBond No.4314)
a Apply the adhesive uniformly along the entire
perimeter
10 PC1250-8R
2) Place the bridge (BR) under the clamping q Refilling with oil (Hydraulic tank)
bo l t a n d a d j us t th e ov er l a p pi n g ( 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
Hydraulic tank (Hydraulic tank refill oil capacity):
Approx. 670 l
Bond) q Refilling with coolant
Add coolant through the coolant filler to the
a Impact wrench is not applicable to use. specified level. Run the engine to increase
coolant temperature and then confirm the cool-
q When the current hose is reused ant level again.
Align the clamp position to the trace 5 Coolant: 142 l
Min. 6 Nm {0.6 kgm} q Bleed air from the main pump, referring to
“Bleeding air from each part” in Testing and
adjusting.
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)
PC1250-8R 11
Removal and installation of 6. Lift and remove cover (5).

radiator and hydraulic oil cooler
7. Remove covers (6) and (7).
assembly 1
Removal

assembly”.
2. Remove exhaust pipe (2) and hand rail (3).
8. Disconnect fuel hose (36).
3. Turn the assembly 90° and remove undercover

(4).

6 Coolant: 142 l

6 Hydraulic tank: 670 l (Hydraulic tank refill
oil capacity)
12 PC1250-8R
a Standard specification only (11. – 14.) 18. Remove hose (41).

air cleaner (A). 19. Remove tube (42).
20. Lift and remove engine hood (12).
a 55° specification (15. – 19.)

21. Open ducts (13) and (14).
17. Disconnect air hose (40). [*2]
PC1250-8R 13
22. Lift and remove duct (13). 25. Disconnect the hose clamp and disconnect air
a Insert bar [1] to the bolt hole to prevent the conditioner condenser (17).
lifting tool from approaching.
26. Disconnect the hose clamp and disconnect
23. Lift and remove frame (15). fuel cooler (18).

PTO cooler (19).
a Let air conditioner condenser (17), fuel
cooler (18) and PTO cooler (19) droop
downward.
a In the case of 55°C specification, PTO
cooler (19) is not equipped.
24. Lift and remove frame, duct and cover assem-

bly (16).
14 PC1250-8R
28. Disconnect hoses (20) and (21). [*3] 33. Lift radiator and hydraulic oil cooler assembly
(32) temporarily.
hose (22). [*4] 34. Remove top side mount bolt (33).
35. Remove 4 mounting bolts (34) on both sides.
36. Lift and remove radiator and hydraulic oil cooler

assembly (32).
4 Radiator and hydraulic oil cooler assembly:
665 kg
30. Disconnect hoses (23) and (24).

a Disconnect the hose clamp.
31. Disconnect oil cooler hose (28).
32. Disconnect radiator hoses (29) to (31). [*5]
PC1250-8R 15
Installation
q Carry out installation in the reverse order to
removal.
[*1]
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*2]
3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
[*4]
3 Radiator hose clamp:
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
[*5]
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
q Refilling with oil (Hydraulic tank)

Add oil through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
5 Hydraulic tank (Hydraulic tank refill oil capacity):
Approx. 670 l
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to increase
coolant temperature and then confirm the cool-
ant level again.
5 Coolant: 142 l
16 PC1250-8R
Removal of air aftercooler 5. Lift and remove duct (5).

assembly 1 a Insert bar [1] to the bolt hole to prevent the
lifting tool from approaching.
the ground, stop the engine and then 6. Lift and remove frame (7).
a Prepare in advance 2 gaskets to be used

between the air aftercooler and air connector.
1. Remove hand rail (1).
2. Lift and remove cover (2).
4. Open ducts (5) and (6).
7. Lift and remove frame, duct and cover assem-

bly (8).
PC1250-8R 17
11. Disconnect air connector (10) from air after- Installation

cooler (9). q Carry out installation in the reverse order to
a Gasket (G) is provided here. removal.
12. Disconnect hose clamps (11). Reference

q Air hoses (A) and (B)
13. Disconnect air connector (12).
a Gasket is provided here.
14. Remove bracket (13).
15. Lift air aftercooler assembly (9) temporarily.
16. Remove the mounting bolt and then lift and

remove air aftercooler assembly (9).
4 Air aftercooler assembly: 65 kg
a When disconnecting the hoses, apply a mark-

ing to the tube in the hose end so that their
original insertion positions may be identified in
later reference.

depth: 80 mm)
18 PC1250-8R

5 mm.
Bond)
a Impact wrench is not applicable to

use.

Min. 6 Nm {0.6 kgm}

becomes 7 – 10 mm. (Common to
hoses (A) and (B))
PC1250-8R 19
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
force) when removing the elbow at the fuel
Removal cooler inlet and outlet. (To prevent damag-
k Disconnect the negative terminal (–) of the ing weld on the fuel cooler.)
battery before starting with the work. 4. Remove fuel cooler assembly (5).
k Collect the air conditioner refrigerant
(R134a) from the air conditioner circuit in
advance.
a Ask professional traders for collecting and fill-
ing operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to the
atmosphere.
k If refrigerant gas (R134a) gets in your eyes,

you may lose your sight. Accordingly, put
on protective goggles while you are collect-
ing the refrigerant (R134a) or filling the air
conditioner circuit with the refrigerant
(R134a). Collecting and filling work must be
conducted by a qualified person.
k Close the fuel tank valve in advance. 5. Disconnect clamp (6).
1. Open radiator duct (1). 6. Disconnect hose (7) from the air conditioner
compressor. [*2]
2. Remove net (2).
7. Disconnect hose (8) to the receiver tank. [*1]
8. Remove 4 mounting bolts (9) and remove air

conditioner condenser assembly (10).
20 PC1250-8R
Installation
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.
3 Hose thread M16 × 1.5:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
q Filling air conditioner circuit with the refrig-

erant (R134a)
Fill the air conditioner circuit with the refriger-
ant (R134a).
a Filling amount: 1200 ± 50 g
PC1250-8R 21
Removal and installation of fan 6. Lift and remove cover (5).

motor assembly 1
Removal

assembly”.
2. Remove exhaust pipe (2) and hand rail (3).
3. Turn the assembly 90° and remove undercover

(4).

6 Coolant: 142 l

6 Hydraulic tank: 670 l (Hydraulic tank
refill oil capacity)
22 PC1250-8R
a Standard specification (11. – 14.) 18. Remove hose (49).

air cleaner (A). 19. Remove tube (50).
20. Lift and remove engine hood (12).
a 55°C specification (15. – 19.)

21. Lift and remove bracket (12-1).
PC1250-8R 23
22. Disconnect hoses (13) and (14). [*3] 27. Disconnect air hoses (22). [*5]
may be identified in later reference (See
the following figure).
23. Disconnect hose clamps (15).
24. Disconnect hoses (16) to (19). [*4]
25. Remove upper tank (20).
26. Remove fan guard (21).
24 PC1250-8R
28. Remove the portion of the cover indicated as 33. Disconnect fan motor hoses (28) to (30).
(C).
34. Disconnect connector V17 (31) from the bot-
29. Remove bracket (23). tom of cover (B).
30. Remove tube (24). [*6]

32. Remove tube (27). [*7]

35. Remove shroud (32).
36. Lift fan and support assembly (33) temporarily

and remove 3 mounting bolts (34) on both
sides.
a Employ three-point lifting for the assembly
to prevent its surging.
a Use case not to damage the radiator core.
37. Lift and remove fan and support assembly

(33).
4 Fan and support assembly: 190 kg
PC1250-8R 25
38. Remove cover (35). Installation

removal.
[*1]
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*2]
3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
39. Remove tubes (36) to (38) from fan motor
assembly (39). [*4]
4.4 ± 0.5 Nm {0.45 ± 0.05 kgm}
11.3 ± 0.5 Nm {1.15 ± 0.05 kgm}
[*5] – [*7]
q Air hoses clamps (A) to (D) for tubes (24) and
(27)
40. Remove mounting bolt (40) and remove lock

plate (41). [*8]
41. Remove nut (42). [*9]
42. Lift and remove fan assembly (43).

a When removing fan assembly (43), use a
puller rather than hitting it with a hammer.
43. Remove fan motor assembly (39) (noted in the

foregoing).
26 PC1250-8R
a Use brand new article for MIKALOR clamp. q When a new hose is used
1) Align the hose to the original position Tighten the bolt until (a) dimension
(marked position). (Air hose insertion meets the following.
depth: 80 mm) q Engine side of top side hose
a Reference: Clamping position (a) dimension: 17 – 20 mm
q Air hoses (A) – (C) q Hoses (A) – (C) and air after-
cooler side of hose (D)
(a) dimension: 7 – 10 mm
q Air hose (D)
[*8]
When aligning the bolt hole of the lock plate, turn
the nut in the retightening direction.
[*9]
3 Nut: 933 – 982 Nm {95 – 100 kgm}

5 Hydraulic tank (Hydraulic tank refill oil
capacity): Approx. 670 l
5 mm. q Refilling with coolant
(b) dimension: Min. 5 mm Add coolant through the coolant filler to the
3) Tightening of the clamp. specified level. Run the engine to increase
2 Threaded portion (BC) of clamping bolt: coolant temperature and then confirm the cool-
Lubricant (PANDO 18B from Three- ant level again.
5
Bond)
Coolant: 142 l
a Impact wrench is not applicable to
use.

Min. 6 Nm {0.6 kgm}
PC1250-8R 27
Removal and installation of fuel 6. Disconnect hoses (6) to (8).

tank assembly 1
Removal
1. Drain fuel from the tank.

6 Fuel tank: 1,000 l
2. Remove hand rail (1).
3. Remove step (2).
4. Open duct (3).

7. Remove step (9).
8. Disconnect fuel injector pump return hose (10).
5. Disconnect fuel level sensor wiring clamp (4)

and wiring connector P06 (5).
28 PC1250-8R
9. Remove mounting bolts (11) and (12). [*1] Installation

(11): Remove the bolt in the front side of the q Carry out installation in the reverse order to
machine through the top. removal.
(12): Remove the bolt in the rear side of the
machine through the bottom. [*1]
3 Fuel tank mounting bolt (machine front side):
M24: 927 ± 103 Nm {94.5 ± 10.5 kgm}
3 Fuel tank mounting bolt (machine rear side):
M20: 549 ± 59 Nm {56 ± 6 kgm}
10. Lift and remove fuel tank assembly (13).

4 Fuel tank assembly: 1,050 kg (weight
of tank alone)
PC1250-8R 29
SEN02786-00

© 2007 KOMATSU
All Rights Reserved
30
SEN02787-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Engine (SAA6D170E-5)
Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of cylinder head assembly ...................................................................................... 7
Removal and installation of fuel injector assembly ....................................................................................... 26
Removal and installation of engine front seal ............................................................................................... 31
Removal and installation of engine rear seal ................................................................................................ 33
PC1250-8R 1
Removal and installation of fuel 7. Remove mounting bolt (4-4) and then lift
supply pump assembly 1 breather tube assembly (4) slightly.
Removal 8. Remove wiring harness covers (5-1) – (5-3).

k Stop the machine on level ground. a Use care so that the washer may not fall
k Lower the work equipment to the ground off.
completely and stop the engine. a Care must be exercised in removing cover
k Disconnect the negative terminal (–) of the (5-3). Removing cover (5-3) forcibly with-
battery before starting with the work. out slightly lifting breather tube assembly
(4) may generate cracks in (B) portion of
a Work for aligning 1.6TOP is not necessary the breather since the breather is made of
a No special tool is required for pulling the gear plastics.
out a An O-ring instead of a gasket is provided
in breather installation position.
1. Open engine side covers (1) and remove
them.
2. Disconnect connector (2-1).
3. Remove electrical priming pump switch·bracket

assembly (2).
4. Remove joint bolt (3-1) and filter·bracket

assembly (3). [*1]
• Y view • Z view
5. Disconnect the clamp of breather tube (4-1)

and the fixing bolt (4-2).
6. Disconnect the breather hose (4-3) from Y

side, too.
2 PC1250-8R
13. Disconnect fuel hoses (10) – (13). [*2]

a Prepare an oil pan since fuel flows out
when disconnecting fuel hose (13).

a 5 mounting bolts.
14. Disconnect connectors INJ (14) and G (15).
15. Disconnect connectors PCV1 (16) and PCV2

(17).
16. Remove fuel hose (18). [*3]
10. Disconnect connector PFUEL (7).
PC1250-8R 3
17. Remove clamps (19) to (21). 22. Disconnect clamp (27).
18. Remove covers (22) and (23). 23. Remove tube (28) from the bottom of fuel sup-
ply pump assembly (30).
19. Remove high-pressure piping (24).
a Before removing the high-pressure piping 24. Remove bracket (29).
(24), clean the area around carefully so
that inside of the supply pump and com- 25. Remove fuel supply pump assembly (30).
mon rail may not be contaminated by for-
eign substances.
26. Remove the followings from fuel supply pump

assembly (30).
20. Remove bracket (25). 1) Oil tube (31)
2) Plate (32)
21. Disconnect connector G (26). 3) Overflow piping adapter (33)
4 PC1250-8R
Installation
1. Install the followings to fuel supply pump

assembly (30).
1) Plate (32)
2) Oil tube (31)
a Exchange gaskets (GA) and (G10).
q GA: Accessory gaskets of the
supply pump.
q G10: Part number is 07005-
01012.
3) Overflow valve (34)
3 Plate (32) mounting bolt:

19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Oil tube (31) joint bolt 3. Install fuel supply pump assembly (30).
3 Fuel supply pump mounting bolt:
Top side: 7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Bottom side: 59 – 74 Nm {6 – 7.5 kgm}
9.8 – 12.7 Nm {1.0 – 1.3 kgm} 3 Bracket (29) mounting bolt:
3 Overflow valve (34): 59 – 74 Nm {6.0 – 7.5 kgm}

14.8 – 19.6 Nm {1.51 – 1.99 kgm}
4. Install oil tube (28).
3 Oil tube (28) joint bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
a Exchange 4 gaskets (G): part number is
07005-01012.
2. Install the fuel supply pump assembly by align-

ing (A) and (AA) at the position where a gear
tooth is missing.
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.
PC1250-8R 5
k Before installing the high-pressure pip- q Carry out the succeeding installation in the
ing, check it for the following defects. If reverse order of removal.
there is any of these defects, it can [*1]
c a us e f ue l l e a k a g e. A c c o r di n gl y, 3 Filter (3)
replace the high-pressure piping. Joint bolt (3-1):
q Check the taper seal of the connect- 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
ing part (Part (a): Part of 2 mm from
the end) for visible lengthwise slit (b) [*2]
and dent (c). 3 Fuel hose (10)
q Check part (d) (end of the taper seal: Joint bolt (Supply pump side):
Part at 2 mm from the end) for 14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3
stepped-type wear (fatigue) which Fuel hose (10) nut:
your nail can feel. 43 – 47 Nm {4.4 – 4.8 kgm}
3 Fuel hose (11): 90 – 95 Nm {9.2 – 9.7 kgm}
3 Fuel hoses (12) and (13) joint bolt (Supply
pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Fuel hoses (12) and (13) sleeve nut:
43 – 47 Nm {4.4 – 4.8 kgm}
[*3]
3 Fuel hose (18)
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Joint bolt (Overflow valve of supply pump):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
5. Tighten high-pressure piping (24) temporarily. Sleeve nut (Fuel block side):
24 – 27 Nm {2.4 – 2.7 kgm}
6. Tighten clamps (19) to (21) temporarily.
7. Tighten high-pressure piping (24) securely.

3 High-pressure piping sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
8. Tighten clamps (19) to (21) permanently.

3 Clamping bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
9. Install covers (22) and (23).
10. Install bracket (25).
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
q Bleeding air
Bleed air from the fuel system, referring to
“Bleeding air from fuel system” in Testing and
adjusting.
6 PC1250-8R
Removal and installation of 6. Remove air hose (2). [*2]

cylinder head assembly 1
7. Disconnect dust indicator hose (4).
Special tools
a Disconnect the clamp.
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.
completely and stop the engine.
1. Turn the assembly 90°.
2. Remove counterweight assembly, referring to

“Removal of counterweight assembly”.
3. Remove the engine hood and covers, referring 12. Remove fuel tubes (9). [*4]
to “Removal and installation of engine, PTO
and hydraulic pump assembly”. 13. Remove filter assembly (10).

6 Coolant: 142 l
5. Remove Komaclone hose and tube assembly

(1). [*1]
PC1250-8R 7
14. Remove fuel hose (11). [*5] 21. Disconnect connectors TOIL (20) and POIL
(21) in the following procedure.
15. Remove fuel tube (12). [*6] 1) Pull out connector TOIL (20) by driving
lock (L) upward.
2) When disconnecting connector POIL (21),
slide lock (L1) rightward.
3) Pull out connector POIL (21) while push-
ing lock (L2).
22. Remove tube assembly (22).
23. Lift and remove filter assembly (23).
16. Disconnect fuel hose (13). [*7]
17. Disconnect tubes (14) and (15). [*8]
18. Remove filter assembly (16).
19. Disconnect fuel tube (17). [*9]
20. Remove bracket assembly (18).
24. Disconnect wiring harnesses (24).
8 PC1250-8R
25. Disconnect air hose (25-1). [*10] 27. Remove turbocharger coolant tube assembly
a Apply a marking to the hose end and tube (26). [*11]
may be identified in later reference. (See 28. Remove turbocharger lubrication tubes (27)
the following figure.) and (28).
26. Lift and remove air tube and bracket assembly 29. Remove turbocharger coolant tube (29).
(25). [*10]
30. Disconnect connectors V30 (30) and V29 (31).
PC1250-8R 9
31. Lift and remove turbocharger and exhaust 36. Disconnect 6 injector connectors (38).
manifold assembly (32). [*12]
4
37. Disconnect connector INJ (39).
Turbocharger and exhaust manifold
assembly: 120 kg
38. Remove wiring harness bracket (40).
32. Remove breather and tube assembly (33).

39. Disconnect high-pressure piping clamps (41)
to (43).
33. Remove wiring harness covers (34) and (35).
40. Remove tubes (44) to (46). [*13]
34. Disconnect connector PFUEL (36).
35. Remove high-pressure piping cover (37).

and (50).
43. Remove fuel tube (51). [*14]
10 PC1250-8R
44. Remove clamp (52). 51. Disconnect wiring harness clamp (59) from the
rear side of the fuel supply pump.
52. Disconnect the connector from the bottom of
46. Loosen clamps (55) and (56). harness clamp (59).
47. Remove high-pressure piping tube assembly

(57).
48. Disconnect connector G (58).
49. Disconnect fuel hose (112). [*15]
50. Disconnect connector PIM (113).
53. Disconnect connectors PCV1 (60) and PCV2

(61).
54. Disconnect wiring harness clamp (62).
55. Remove fuel tubes (63), (64) and fuel hose

(65). [*16]
56. Remove fuel supply pump assembly (66).
PC1250-8R 11
a Do not loosen overflow valve (ofv). 61. Remove bracket (71) from intake manifold
a Do not remove oil tube (t) and plate (p). assembly (72).
62. Remove diffuser (73).
58. Disconnect water tubes (68) from corrosion 63. Disconnect sleeve nut (75) on the high-pres-
resistor. [*17] sure piping injector side.
a Tool A2 allows implementing this work
from the side face rather than from the
top.
59. Disconnect sleeves (69).
60. Remove high-pressure pipings (70).

a Tool A2
12 PC1250-8R
64. Remove high-pressure pipings (74). 69. Lift and remove air intake manifold assembly
(72).
4
65. Lift air intake manifold assembly (72) tempo-
Air intake manifold assembly: 110 kg
rarily.
a Using eyebolt [1] and lifting tool [2], lift the
assembly temporarily on to the mounting
bolt hole of bracket (71) (noted in the fore-
going).
66. Remove the mounting bolts of air intake mani-

fold assembly (72). Note, at this step, that sev-
eral mounting bolts are left in the current
position.
a Use the filter mounting bolts as the guide
bolts [3].
67. Remove 4 mounting bolts (76) from the radia-

tor side of intake manifold assembly (72).
70. Remove brackets (77).
68. Remove all mounting bolts of air intake mani-
fold assembly (72).
71. Remove turbocharger lubrication tube (78) and
coolant tube (79).
72. Remove air vent tube (80).
PC1250-8R 13
73. Pull out pin (A) and then push in bolt (B). 76. Disconnect terminal mounting nuts (82).
a Loosen the 2 terminal nuts alternately.
74. Barring bolt (B) and then align 1.6TOP. (Con-
firm the result after removing bolt (BB).) 77. Remove wiring harness assembly mounting
a For above operation, see “Testing and bolts (83) and spacer (84).
adjusting valve clearance” in Testing and
adjusting. 78. Loosen locknut (85) and then loosen adjust-
ment screw (86).
79. Remove rocker arm assembly (87).
80. Remove push rod (88).
81. Remove crosshead assembly (89).
82. Remove rocker housing (90).
83. Remove fuel injector holder (91).
75. Remove cylinder head cover (81).

a Referencing play of the rocker arm, con-
firm which is currently selected No. 1 TOP
or No. 6 TOP.
14 PC1250-8R
84. Using tool A1, remove fuel injector assembly

(92).
a Remove the assembly by hitching tip of
tool A1 to hole (H) of the fuel injector
adapter.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector.
85. Lift and remove cylinder head assembly (93).

4 Cylinder head assembly: 50 kg
86. Remove the cylinder head gasket.
PC1250-8R 15
Installation
Cylinder head assembly
1. Install the cylinder head gasket.
2. Lift and install cylinder head assembly (93).

4 Cylinder head assembly: 50 kg
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 Tighten the mounting bolts in the following
order.
2 Cylinder head assembly mounting bolt: a After tightening the main bolt, apply a
Molybdenum disulfide grease (LM-P) punch mark (a) on its head (this mark shall
3 Cylinder head assembly mounting bolts not be applied to a new bolt).
(1 – 7):
1st time: 245 ± 9.8 Nm {25 ± 1 kgm}
2nd time: 382.5 ± 9.8 Nm {39 ± 1 kgm}
3rd time: 90 – 120° retightening
a For retightening, use tool A6 (see Special
tools). When not using tool A6, apply a
marking to the cylinder head and bolt with
a felt pen and then retighten the bolt by 90
– 120° (target is 120°).
3 Cylinder head assembly mounting bolts
(8 and 9):
93.2 – 103 Nm {9.5 – 10.5 kgm}
16 PC1250-8R
Fuel injector a Tightening of injector holder (91) is done

a Check that the inside of the injector sleeve is permanently after installing the intake
free from dirt. manifold and tightening the high-pressure
2 O-ring: Engine oil (EO30-DH) piping temporarily.
3. Assemble gasket (94) and O-rings (95) and 6. Install push rods (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 Spherical washer: a Do not forget to install O-ring (OR).
Engine oil (EO30-DH) 3 Rocker housing mounting bolt:
78.4 – 93.2 Nm {8.0 – 9.5 kgm}
8. Install crossheads (89).
PC1250-8R 17
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 slit
(B) toward the outside.
Rocker arm assembly

10. Install rocker arm assembly (87).
a Insert respective rocker arm as the riveted
12. Install terminal mounting nuts (82) and wiring
side of the shaft faces direct the front side
harness fixing bolts (83).
of the engine.
a Tighten the terminal mounting nuts alter-
a When installing, direct the wider seat of
nately.
the shaft to the rocker arm housing.
3 Terminal mounting nut:
a Make sure that the ball of adjustment
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
screw (86) is securely fitted to the push
rod socket.
a When tightening the mounting bolt, make
sure adjustment screw (86) is not pushing
the push rod.
2 Threaded portion and seat of rocker
arm assembly mounting bolt:
Engine oil (EO30-DH)
3 Rocker arm assembly mounting bolt:
235.2 – 254.8 Nm {24 – 26 kgm}
a Adjust valve clearance, referring to “Test-
ing and adjusting valve clearance” in Test-
ing and adjusting.
3 Locknut (85):
57.8 – 77.4 Nm {5.9 – 7.9 kgm}
18 PC1250-8R
13. Install air intake manifold assembly (72). k Before installing the high-pressure pip-
a Tighten the mounting bolts in the following ing, check it for the following defects. If
order. there is any of these defects, it can
c a u s e f u e l l e a k a ge . A c c o r di n gl y,
replace the high-pressure piping.
q Check the taper seal of the connect-
ing 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.
High-pressure piping (Between the fuel

injector and common rail)
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.
excessive, potentially damaging
the high-pressure piping.
PC1250-8R 19
14. Install O-ring (106) to high-pressure piping 19. Install cylinder head cover (81).
sleeve (101). a A different tightening torque is employed
2 O-ring: Engine oil (EO30-DH) for No. 2 cylinder mounting bolt alone.
3 Cylinder head cover mounting bolt:
15. 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 59 – 74 Nm {6 – 7.5 kgm}
pushing sleeve nut (75) end toward the
injector by use of a short bar and the like.
20. Install air vent tube (80).
3 Air bleeding tube joint bolt (Cylinder
16. Tighten the common rail side sleeve nut (69)
head side):
temporarily, too.
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
17. Tighten injector holder (91) permanently.
3 Injector holder mounting bolt:
21. Install turbocharger coolant tube (79) and lubri-
58.9 – 73.5 Nm {6.0 – 7.5 kgm} cating oil tube (78).
22. Install brackets (77).

18. Tighten high-pressure piping sleeve nuts (69)
and (75) permanently using the spanner type
torque wrench.
3 Sleeve nut:
39.2 – 44.1 Nm {4 – 4.5 kgm}
a After above operation is completed, check
O-ring (106) for protrusion from sleeve nut
(75).
20 PC1250-8R
High-pressure piping clamp Fuel supply pump

23. Install the clamp on the high-pressure piping in a See "Installation of fuel supply pump" about
the following procedure. installation of the overflow valve (ofv), the oil
1) Manually tighten 17 high-pressure piping tube (t) and the plate (t).
clamps (107) temporarily in the position
indicated in the figure.
2) Manually tighten common rail slide clamp
bracket (108) and clamp (52) temporarily
and then tighten clamp (52).
3 Common rail side clamp bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3) Tighten common rail side clamp bracket
(108) to the specified torque.
4) Tighten high-pressure piping clamp (107).
3 High-pressure piping side clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
5) Install cover (53) on the common rail side
sleeve nut.
a When installing it, direct the slit down- 24. Install the fuel supply pump assembly by align-
ward. ing (A) and (AA) at the position where a gear
tooth is missing.
PC1250-8R 21
3 Fuel supply pump (66) mounting bolt: High-pressure piping (Between the fuel supply
59 – 74 Nm {6 – 7.5 kgm} pump and common rail)
3 Bottom bracket (111) mounting bolt: k Handle the high-pressure piping and
59 – 74 Nm {6.0 – 7.5 kgm} clamp in the same way as “the high-
pressure piping (between the fuel
injector and common rail)” (noted in
the foregoing) is handled.
25. Tighten high-pressure piping (57) temporarily.
26. Tighten clamps (55), (56) and (109) tempo-

rarily.
27. Tighten bracket (110) temporarily.
28. Tighten high-pressure piping (57) permanently.

3 High-pressure piping sleeve nut:
39.2 – 44.1 Nm {4.0 – 4.5 kgm}
29. Tighten clamps (55), (56) and (109) perma-

nently.
3 Clamping bolt:
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
30. Tighten bracket (110) permanently.
31. Install cover (54).
q Carry out the succeeding installation in the

reverse order of removal.
[*1]
5.9 ± 0.49 Nm {0.6 ± 0.05 kgm}
[*2]
3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*3]
3 Air cleaner band:
12.8 – 17.7 Nm {1.3 – 1.8 kgm}
22 PC1250-8R
[*4] 2) Place the bridge (BR) under the clamping

3 Fuel tube (9) joint bolt: b o l t a n d a d j us t th e ov e r l a pp i n g ( b )
24.5 – 34.3 Nm {2.5 – 3.5 kgm} between the bridge (BR) and band to Min.
3 Fuel tube (9) sleeve nut: 5 mm.
24 – 27 Nm {2.4 – 2.7 kgm} (b) dimension: Min. 5 mm
[*5]
3 Fuel hose (11) joint bolt: Lubricant (PANDO 18B from Three-
24.5 – 34.3 Nm {2.5 – 3.5 kgm} (Filter side) Bond)
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
a Impact wrench is not applicable to use.
(Supply pump side)
3 Fuel hose (11) nut: q When the current hose is reused
43 – 47 Nm {4.4 – 4.8 kgm} Align the clamp position to the trace
[*6] of the clamp left on the hose.
3 Fuel tube (12) joint bolt: 3 Clamp tightening bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm} Min. 6 Nm {0.6 kgm}
[*7]
3 Fuel hose (13) joint bolt: q When a new hose is used
90 – 95 Nm {9.2 – 9.7 kgm} Tighten the bolt until (a) dimension is:
17 – 20 mm
[*8]
3 Tube (15) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3 Tube (14) joint bolt:
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
3 Tube (14) sleeve nut:
43 – 47 Nm {4.4 – 4.8 kgm}
[*9]
3 Fuel tube (17) joint bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
[*10]
3 Air tube clamp (Turbocharger side):
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm} [*11]
q Air hose (Aftercooler side) 3 Coolant tube assembly (26) joint bolt:
a Use brand new article for MIKALOR clamp. 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
depth: 80 mm)
q Air hose (25-1)
PC1250-8R 23
[*12] Reference
Exhaust manifold assembly Installation of turbocharger assembly
1. When the exhaust manifold assembly was dis- 1. Lift and install turbocharger assembly (112).
4
assembled, apply connection (A) (2 locations)
Turbocharger assembly: 55 kg
with the adhesive (heat resistant sealing
agent) before assembling it. 2 Turbocharger mounting bolt and nut:
2 Exhaust manifold connection: Seizure prevention compound (LC-G)
Liquid adhesive (Holtz MH 705) (NEVER-SEEZ (Bostik, Inc) or equiva-
lent)
3 Turbocharger mounting bolt and nut:
78.5 – 88.3 Nm {8.0 – 9.0 kgm}
aTighten the mounting bolts in the following

order.
2 Exhaust manifold mounting bolt:
Seizure prevention compound (LC-G)
[*13]
3
(NEVER-SEEZ (Bostik, Inc) or equiva-
Fuel tube (44) joint bolt:
lent)
3 Exhaust manifold mounting bolt:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
3 Tubes (45) and (46) sleeve nut:
1st time: 39.2 – 58.8 Nm {4.0 – 6.0 kgm}
2nd time: 98.1 – 122.6 Nm {10 – 12.5 24 – 27 Nm {2.4 – 2.7 kgm}
kgm} 3 Tubes (45) and (46) joint bolt:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*14]
3 Tubes (51) joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*15]
3 Fuel hose (112)
Joint bolt (Supply pump side):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
Sleeve nut (Fuel block side):
24 – 27 Nm {2.4 – 2.7 kgm}
24 PC1250-8R
[*16]
a Exchange 4 gaskets: part number is 07005-
01012.
3 Oil tube (63) joint bolt (Supply pump side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Oil tube (63) joint bolt (Block side):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
3 Fuel hose (65)
joint bolt (Supply pump side):
14.8 – 19.6 Nm {1.51 – 1.99 kgm}
sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
3 Fuel tubes (64):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
[*17]
3 Water tube (68) joint bolt (Corrosion resistor
side): 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
k Make sure that a clearance of 10 mm mini-

mum is provided between the high-pres-
sure piping and adjacent wiring harness. If
not, secure the clearance by adjusting the
wiring harness position.
q Bleeding air
adjusting.
PC1250-8R 25
Removal and installation of fuel 3. Disconnect high-pressure piping clamps (1) to

injector assembly 1 (3).
Special tools 4. Remove tubes (4) and (5). [*1]
Necessity
Symbol
Sketch
Q’ty
N/R
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.
completely and stop the engine.
1. Remove the engine hood and covers, referring and (8).
to “Removal and installation of engine, PTO a A clamp is provided on the fuel supply
and hydraulic pump assembly”. pump side.
2. Remove the filter, air tube and injector wiring

harness brackets, referring to “Removal and
installation of cylinder head assembly”.
q Overall view of top surface
7. Remove clamp (9).
26 PC1250-8R
9. Disconnect 6 sleeve nuts (11) and (12). 12. Disconnect terminal mounting nuts (15).
a Loosen the nuts alternately.
10. Remove high-pressure pipings (13).
13. Remove wiring harness assembly mounting
11. Remove cylinder head cover (14). bolts (16) and spacer (17).
14. Remove fuel injector holder (21).
15. Using tool A1, remove fuel injector assembly

(22).
a Remove the assembly by hitching tip of
tool A1 on hole (H) of the fuel injector.
a Do not grip the solenoid valve at the top of
the injector to pull off the injector.
a When tool A2 is not available, disconnect

sleeve (12) through the top.
q Tool A2
PC1250-8R 27
Installation Injector wiring harness

4. Install spacer (17).
Fuel injector a When installing the spacer, direct its slit
a Check that the inside of the injector sleeve is (B) toward the outside.
free from dirt.
2 O-ring: Engine oil (EO30-DH)
1. Assemble gasket (24) and O-rings (25) and

(26) on fuel injector (22).
a Take care not to install O-ring (25) in
groove (A) at the center.
2. Insert fuel injector (22) to adapter (27) and

injector holder (21).
3. Attach spherical washer (30) to bolt (29) and

then tighten injector holder (31) temporarily.
2 Spherical washer:
a Tightening of injector holder (21) perma- 5. Install terminal mounting nuts (15) and wiring
nently after tightening the high-pressure harness fixing bolts (16).
piping temporarily. a Tighten the terminal mounting nuts alter-
nately.
3 Terminal mounting nut:
2 ± 0.2 Nm {0.2 ± 0.02 kgm}
28 PC1250-8R
High-pressure piping 9. Tighten injector holder (21) permanently.

k When handing the high-pressure piping 3 Injector holder mounting bolt:
and clamp, pay attention to the following. 59 – 74 Nm {6.0 – 7.5 kgm}

q It is strictly prohibited to bend the high-
pressure piping to use it again or using it 10. 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).
excessive, potentially damaging the 11. 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
59 – 74 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.
6. Install O-ring (32) to sleeve (31) of high-pres-

sure piping (13).
2 O-ring: Engine oil (EO30-DH)
7. Tighten sleeve nut (12) temporarily aligning it

connector (28) of the injector.
a When it is difficult to hitch sleeve nut (12)
to the threaded portion, turn the spanner
while pushing sleeve nut (12) end toward
the injector using a short bar and the like.
8. Tighten the common rail side sleeve nut (11)

temporarily, too.
PC1250-8R 29
High-pressure piping clamp q Carry out the succeeding installation in the

12. Install the clamp on the high-pressure piping in reverse order of removal.
the following procedure.
1) Manually tighten 17 high-pressure piping [*1]
clamps (33) temporarily in the position 3 Tube (4) joint bolt:
indicated in the figure. 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
2) Manually tighten common rail slide clamp 3 Tube (5) joint bolt:
bracket (34) and clamp (9) temporarily 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
and then tighten clamp (9). 3 Tube (5) sleeve nut:
3 Common rail side clamp bolt: 24 – 27 Nm {2.4 – 2.7 kgm}
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
3) Tighten common rail side clamp bracket a Refer to the precautions in “Installation of cylin-
(34) to the specified torque. der head” for the installation.
4) Tighten high-pressure piping clamp (33).
3 High-pressure piping side clamp bolt: k Make sure that a clearance of 10 mm mini-
11.8 – 14.7 Nm {1.2 – 1.5 kgm} mum is provided between the high-pres-
5) Install covers (10) on the common rail side sure piping and adjacent wiring harness. If
sleeve nut. not, secure the clearance by adjusting the
a When installing it, direct the slit down- wiring harness position.
ward.
q Bleeding air
adjusting.
30 PC1250-8R
Removal and installation of 5. Remove dust seal (7).

engine front seal 1
6. Remove front seal (8) in the following proce-
Special tools dure.
Necessity
Symbol
Sketch
Q’ty
N/R
3 795-931-1100 Seal puller assembly t 1

Push tool
795T-621-1180 t 1 N Q
(For oil seal)
A Push tool
4 795T-621-1170 (For dust seal) t 1 N Q
795-902-1460 • Bolt t 3
01582-02218 • Nut t 3
Removal 1) Replace the tip of tool A3 with the hook

k Stop the machine on level ground. 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. (8).
3) Remove front seal with impact of slide
1. Remove counterweight assembly, referring to hammer (SH).
“Removal of counterweight assembly”.
q Tool A3
2. Remove the fan support assembly, referring to
“Removal of fan motor assembly”.
3. Lift pulley and damper assembly (1) tempo-

rarily.
4. Lift and remove pulley and damper assembly

(1). [*1]
4 Pulley and damper assembly (1): 50 kg
a CS: Crankshaft
PC1250-8R 31
Installation a Take care not to mistake the direction

of the plastic inside cylinder.
1. Clean, degrease and then dry the contact sur- 2) Using tool A4, press fit oil seal (8) to the
face between the front cover and front seal. front case in such that dimension (a) in the
figure is met.
2. Using a clean cloth, remove foreign matter a Oil seal press fitting dimension (a):
deposited the crankshaft flange. 18.5 mm (when measured from the
a Clean foreign matter deposited on the seal front cover end face)
lip surface (surface around the crankshaft)
and then degrease and dry the surface.
a Check the crankshaft end face corner and
lip siding surface for scratches due to the
housing, burrs or rusts.
3. Install front oil seal (8) according to the follow-

ing procedure.
a Before installing the seal, check that the
end corners and lip sliding surfaces of the
crankshaft are free from flaw, burr, and
rust of the housing.
a When installing the seal, do not apply oil
or grease to the shaft and seal lip. Wipe
off the oil from the shaft. 3) Using tool A4 (for dust seal), press fit dust
1) Install the oil seal directing its side seal (7) to the front case in such that
stamped with “IN” toward the inside of the dimension (b) in the figure is met.
engine. a Dust seal press fitting dimension (b):
a The “OUT” stamped side is directed toward 2 mm (Projection out of the front
the outside of the engine. cover end face)
q Carry out the succeeding installation in the

reverse order of removal.
[*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}
32 PC1250-8R
Removal and installation of 3. Remove rear seal (2).

engine rear seal 1 a Take care in the removal not to damage
the seal installation position on the fly-
Special tools wheel housing and the seal contact face
on the crankshaft.
a Before removing, slightly drive the seal in
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.
795T-621-1161 Push tool t 1 R Q 1) Replace the tip of tool A3 with the drill
A 795T-621-1190 Push tool t 1 N Q type one.
5
01050-32235 • Bolt t 5 2) Drill several holes about 3 mm in
diameter into rear seal (2).
01050-32245 • Bolt t 5
3) Set tool A3 to the drilled hole. (Tip:
Drill type)
4) Remove rear seal with impact of slide
Removal hammer (SH).
k Stop the machine on level ground. a When the sleeve is attached, cut sleeve
k Lower the work equipment to the ground (5) using a gad and hammer to remove it.
completely and stop the engine. a Take care not to damage crankshaft (4).
k Disconnect the negative terminal (–) of the a Remove all the chips.
1. Remove the PTO assembly and hub assembly,

referring to “Removal and installation of PTO
assembly”.
2. Lift and remove flywheel (1). [*1]

4 Flywheel assembly: 84 kg
q Tool A3
PC1250-8R 33
Installation q Procedure for installing standard seal

a Don't apply grease or oil to the seal lip surface.
Rear seal (2) 1) Contact larger inner diameter side (b) of
a Check the Teflon seal (Laydown lip seal) by plastic inside cylinder (3) of rear seal (2)
checking the wear of the shaft and replace it against the end face of crankshaft (4).
with the “Standard seal” or “Sleeved seal”. a Take care not to mistake the direction
a When wear on the shaft is not serious and only of the plastic inside cylinder.
makes it look lustrous (depth of wear is 10 mm
or less when checked with finger cushion) and
no scratch is recognized, assemble the stan-
dard seal (A). When the above is not applica-
ble, assemble sleeved seal (B).
a (3): Shows the plastic inside cylinder doubling
the assembly guide.
a (5): Shows the sleeve.
a Don't remove assembly guide (3) from rear
seal (2) until the assembling is complete.
a Handle rear seal (2) and sleeve (5) as an inte-
gral part. Don't try to separate them.
2) Applying equal force to both hands, push

in the hoop of rear seal (2).
3) After pushing in rear seal (2), remove
plastic inside cylinder (3).
a When removing the inside cylinder,
take care not to damage the seal lip.
a Clean, degrease and then dry the contact sur-

face between the flywheel housing and rear
seal.
a Clean foreign matter deposited on the seal lip
surface (surface around the crankshaft) and
then degrease and dry the surface.
a Check the crankshaft end face corner and lip
siding surface for scratches due to the hous-
ing, burrs or rusts.
34 PC1250-8R
4) Tighten the bolts evenly to press fit rear 3) Remove tool A5 (for sleeved seal) and
seal (2) until the end of tool A5 reaches install tool A5 (for standard seal).
the end of crankshaft (4). 4) Tighten the 5 bolts evenly to press fit
a Oil seal press fitting dimension (when sleeve and rear seal assembly (6) until the
measured from the shaft end face) end of tool A5 (for standard seal) reaches
(a): 20 mm the end of crankshaft (4).
a After press fitting the rear seal, a Tighten tool A5 (for standard seal)
remove the red sealant layer from its first until it reaches the bolt (45 mm)
periphery. and then tighten the bolt (35 mm).
a Rear seal driving depth (a): 20 mm
from end of crankshaft
a After press fitting the seal, remove the
red sealant layer from its periphery.
q Procedure for installing sleeved seal

a When installing the rear seal, do not apply oil
or grease to the shaft and sleeve inside cylin-
der surface (C). q Carry out the succeeding installation in the
1) Set sleeve and rear seal assembly (6) to reverse order of removal.
tool A5 (for sleeved seal).
2 Sleeve inside cylinder surface (C):
Gasket sealant (LG-7)
2) Set sleeve (5) of the rear seal to the end
of crankshaft (4) and tighten the 5 bolts
(45 mm) evenly to press fit sleeve and
rear seal assembly (6) until the end of tool
A5 reaches the end of crankshaft (4).
PC1250-8R 35
[*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:
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.)
36 PC1250-8R
q Measure radial runout or facial runout of the

flywheel using dial gauge [1].
a Standard radial and facial runout:
Measuring
Tolerance (mm)
items
Radial runout 0.13
0.0005 × Diameter of
Facial runout
measuring point
a When the measured value is out of the stan-

dard, determine the cause by disassembling
the flywheel again.
PC1250-8R 37
SEN02787-01

© 2007 KOMATSU
All Rights Reserved
38
SEN02788-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Power train
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 .......................................................................... 13
Disassembly and assembly of swing motor and swing machinery assembly ............................................... 20
Removal and installation of swing circle assembly ....................................................................................... 27
Disassembly and assembly of final drive assembly...................................................................................... 28
PC1250-8R 1
Removal and installation of PTO

assembly 1
Removal
1. Remove the counterweight assembly, referring
assembly”.
2. Remove the engine hood, side cover, frame,

partitioning cover between engine and pump,
under guard, etc., referring to “Removal and
installation of engine, PTO and hydraulic pump
assembly”.
3. Remove respective pumps, referring to “Removal

and installation of hydraulic pump assembly”. 13. Disconnect clamp (8).
4. Disconnect bracket (1) from PTO. 14. Install eyebolt in the position indicated as (C).
5. Drain oil in the PTO case (lubricating oil). 15. Remove mount bolts (10) and (11). [*3]
6 Amount of lubricating oil: 13.5 l
16. Lift PTO assembly (9) temporarily.
6. Disconnect hose (2) between flywheel housing

and PTO.
17. Remove oil pan mounting bolts (12) situated in

the top of the rear frame (RF).
a Except for 55°C specification (7. – 12.) 18. Place the block between the rear frame (RF)
7. Disconnect dust indicator hose (3). and oil pan (BL).
10. Remove air cleaner bracket.
12. Remove tube (7).
2 PC1250-8R
19. Float PTO assembly (9) (described in the Installation

above) and support PTO assembly (9) with the q Carry out the installation in the reverse order of
block. removal.
a Loosen the lifting tool to confirm whether
or not the block can support PTO assem- [*1]
bly (9) (described in the above). 3 Air hose clamp:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
20. Remove 30 mounting bolts (13) and then lift
and remove PTO assembly (9). [*4] [*2]
4 PTO assembly: 505 kg 3 Air cleaner band:
12.8 – 17.7 Nm {1.3 – 1.8 kgm}
[*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]
[*6]
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
PC1250-8R 3
Disassembly and assembly of 2. Gear assembly

PTO assembly 1 1) Remove 2 gears (6) (for No. 1, 2 pump
drive).
Disassembly 2) Remove gear (7) (for No. 3 pump drive).
a If the gear assembly will not come
1. Front Cover out, remove nipple (8), then use a
1) Remove oil gauge and bracket assembly puller to remove the gear 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) Remove snap ring (3) from cover (2), then

remove bearing (4).
3. Removal of bearing
Using puller [2], remove bearing from each
gear.
4 PC1250-8R
4. Rear cover Assembly

1) Remove snap ring (9) from rear cover (5).
1. Rear cover
1) Press fit bearing (12) to rear cover (5),
then install snap ring (11).
a Coat the rolling surface with grease.
2 Bearing: Lubrication oil (G2-LI)
2) Using push tool [3], pull out gear (10).

a After pulling out gear (10), turn over
rear cover (5).
2) Using push tool [4], press fit gear (10).
3) Remove snap ring (11) from rear cover

(5), then remove bearing (12).
3) After press fitting gear (10), install snap

ring (9).
PC1250-8R 5
2. Press fitting bearing 3. Gear assembly

1) Using tool [5], press fit bearing to gear (6) 1) Install nipples (8).
for No. 1, 2 pump drive. 2) Press fit 2 gears (6) to rear cover (5).
3) Press fit gear (7) to rear cover.
a Before press-fitting, coat the rolling
surface of the bearing with grease.
a Put wooden sheet [6] in contact with

the gear, and tap lightly with a ham-
mer to press fit.
2) Using tool [5], press fit bearing to gear (7)

for No. 3 pump drive.
4. Front cover
1) After coating front cover (2) and bearing
(4) with grease, press fit, then install snap
ring (3).
6 PC1250-8R
2) Set guide bolts [7] (2 places) to rear cover

(5), then align front cover (2), and lower
slowly.
a Coat the mating surface of the rear
cover with gasket sealant.
2 Mating surface of cover:
3) Tighten mounting bolts (1) in turn on diag-
onally opposite sides.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
PC1250-8R 7
Removal and installation of swing a Front of chassis

machinery assembly 1 1. Disconnect hoses (9) and (10) coming from
swing motor at center of chassis.
2. Disconnect drain hose (11).
Removal
k Lower the work equipment completely to 3. Disconnect swing brake release hose (12).
the ground and stop the engine. Then
loosen the oil filter cap slowly to release 4. Disconnect hose (13) going to boom LOWER
the pressure inside the hydraulic tank. regeneration valve.
a Center of chassis 5. Disconnect drain hose (14).

1. Disconnect swing motor hose clamp (1).
6. Remove mounting bolts (15), then lift off swing
2. Disconnect hoses (2) and (3) going to swing motor assembly (16).
motor at front of chassis. 4 Swing motor assembly: 126 kg
7. Remove mounting bolts, then lift off swing

4. Disconnect hose (5) coming from the control machinery assembly (17). [*1]
valve. 4 Swing machinery assembly: 532 kg
5. Disconnect swing brake release hose (6).
6. Remove mounting bolts (7) and lift off swing

motor assembly (8).
8 PC1250-8R
Installation
removal.
[*1]
3 Mounting bolt:
927 ± 103 Nm {94.5 ± 10.5 kgm}
q Refilling with oil

Add oil to the hydraulic tank to the specified
level. Run the engine to circulate the oil
through the system. Then check the oil level
again.
5 Oil in swing machinery case:
Approx. 21.5 l
PC1250-8R 9
Removal and installation of swing 2. Disconnect the swing motor and swing
motor and swing machinery machinery assembly (6), using forcing screw
[1] after removing the mounting bolts. [*1]
assembly 1
Serial number: 35017 and up
Removal
k Release the residual pressure in the
hydraulic circuit. Refer to the “Releasing
residual pressure from hydraulic circuit”
section in the Testing and adjusting chap-
ter of this manual.
for oil filler cap on the fuel tank to release
the residual pressure inside the tank and
move the work equipment lock lever to the
LOCK position.
3. Lift and remove swing motor and swing
a Center of chassis machinery assembly (6).
1. Disconnect five swing motor hoses (1) through a When lifting the swing motor and swing
(5). machinery assembly for removal, do so
q (1): Between swing motor and control slowly so that the hoses and other parts
valve (MA port) will not be damaged.
q (2): Between swing motor and control a Take good care, when lifting the assembly,
valve (MB port) until the spigot joint portion is pulled out.
q (3): Suction hose (S port)
4
q (4): Drain hose (T port) Swing motor and swing machinery
q (5): Swing brake releasing pilot hose (B assembly: 550 kg
port)
10 PC1250-8R
a Front of chassis 3. Lift and remove swing motor and swing

1. Disconnect five swing motor hoses (7) through machinery assembly (12).
(11). a When lifting the swing motor and swing
q (7): Between swing motor and control machinery assembly for removal, do so
valve (MA port) slowly so that the hoses and other parts
q (8): Between swing motor and control will not be damaged.
valve (MB port) a Take good care, when lifting the assembly,
q (9): Suction hose (S port) until the spigot joint portion is pulled out.
q (10): Drain hose (T port)
q (11): Swing brake releasing pilot hose (B 4 Swing motor and swing machinery
port) assembly: 550 kg
2. Disconnect the swing motor and swing

machinery assembly (12), using forcing screw
[1] after removing the mounting bolts. [*1]
PC1250-8R 11
Installation [*1]
q Install in reverse order of removal. 3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
a While the pinion shaft teeth are meshed with
the circle teeth, if the mounting bolts holes are q Refilling hydraulic oil
not aligned, perform the following procedure. Refill hydraulic oil through the oil filler port to
1) Draining of oil the specified level. Let the oil circulate in the
Loosen the drain plug and drain a part of hydraulic system by starting the engine. Then
the oil in the swing machinery case. check the oil level again.
6 Quantity oil to be drained:
Approx. 5 l q Air bleeding
Refer to the “Bleeding air from various parts” in
2) Disconnection of swing motor assembly
the Testing and adjusting chapter of this man-
Remove the 10 mounting bolts and sling
ual.
the swing motor assembly (1).
4 Swing motor assembly: 105 kg
3) While aligning the mounting bolt holes of
the swing machinery assembly, install the
swing machinery (10).
4) Install the swing motor assembly (1).
a Take care not to damage the O-ring
(13).
5) Refilling with oil
Tighten the drain plug and add oil through
the oil filler by the quantity of the drained
oil and check that the oil level is normal.
12 PC1250-8R
Disassembly and assembly of 3. No. 1 carrier assembly

swing machinery assembly 1 1) Remove thrust washer (2).
2) Remove No. 1 sun gear (3).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty

790-101-5541 • Plate 1
1
790-101-5421 • Grip 1
F 01010-51240 • Bolt 1
2 796T-826-1110 Plate t 1 Q
3 796T-826-1130 Push tool t 1 Q 3) Remove No. 1 carrier assembly (4).
4 796T-826-1120 Push tool t 1 Q
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).
4. Disassemble No. 1 carrier assembly as follows.

1) Push in pin (5) and knock out shaft (6)
from carrier (7).
a After removing the shaft, remove pin
(5).
2) Remove thrust washer (8), gear (9), bear-
ing (10), and thrust washer (11).
PC1250-8R 13
5. Ring gear 7. No. 2 carrier assembly

Lift off ring gear (12). Lift off No. 2 carrier assembly (17).
6. No. 1 sun gear 8. Disassemble No. 2 carrier assembly as fol-

1) Remove thrust washer (13) and collar (14). lows.
2) Remove No. 1 sun gear (15). 1) Push in pin (18), and knock out shaft (19)
from carrier (17).
(18).
2) Remove thrust washer (20), gear (21),
bearing (22), and thrust washer (23).
3) Remove thrust washer (16).
9. Pinion shaft assembly

1) Remove bolt (24), then remove holder
(25).
2) Remove gear (26).
14 PC1250-8R
3) Turn over case and pinion assembly, then 10. Disassemble pinion shaft assembly as follows.
remove mounting bolts (28) of cover 1) Using push tool [2], remove cover assem-
assembly (27). bly (27) and bearing (31) from shaft (32).
2) Remove oil seal (33) from cover (27).
4) Turn over case and pinion assembly (29), 11. Bearing

and set on press stand. Using push tool, remove bearing (34) from
5) Using push tool F4, remove pinion shaft case (35).
assembly (30) with press.
a Set a wooden block under the press,
preparing for falling pinion shaft
assembly down and be careful not to
damage the pinion shaft assembly
when removing it.
PC1250-8R 15
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:
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.
2) Fit cover assembly (27) to case (35), and

tighten mounting bolts (28).
2 Cover mounting surface:
2 Lip of oil seal: Grease (G2-Ll)
a Be careful not to let the gasket seal-
ant (LG-6) get on the oil seal lip when
press fitting.
16 PC1250-8R
3) Gear, holder 3) Insert pin (18).

Assemble gear (26), then fit holder (25) a After inserting the pin, caulk the pin
and tighten bolt (24). portion of the carrier.
2 Mounting bolt: a After assembling the carrier assembly,
Thread tightener (LT-2) check that gear (21) rotates smoothly.
3 Mounting bolt:
343 – 427 Nm {35 – 43.5 kgm}
5. No. 2 carrier assembly

Raise No. 2 carrier assembly (17) and install.
4. Assemble No. 2 carrier assembly as follows.
a There are the remains of the caulking
when the pin is inserted at the end face of
hole (h) at the side of the carrier, so
remove the caulked metal from the inside
diameter of the hole before starting to
assemble.
1) Assemble bearing (22) to gear (21), fit top
and bottom thrust washers (23) and (20)
and set gear assembly to carrier (17).
6. No. 2 sun gear

1) Assemble thrust washer (16).
2) Align position of pin holes of shaft and car-

rier, then tap with a plastic hammer to
install shaft (19).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
PC1250-8R 17
2) Install No. 2 sun gear (15) to No. 2 carrier,

then install collar (14) and thrust washer
(13).
2) Align position of pin holes of shaft and car-

rier, then tap with a plastic hammer to
install shaft (6).
7. Ring gear a When installing the shaft, rotate the
Raise ring gear (12) and install. planetary gear, and be careful not to
a Align with the drain hole and assemble. damage the thrust washer.
2 Mating surface of ring gear and case: 3) Insert pin (5).
Gasket sealant (LG-6) a After inserting the pin, caulk the pin
portion of the carrier.
a After assembling the carrier assembly,
check that gear (9) rotates smoothly.
8. Assemble No. 1 carrier assembly as follows.

when the pin is inserted at the end face of
hole (h) at the side of the carrier, so 9. No. 1 carrier assembly
remove the caulked metal from the inside Install No. 1 carrier assembly (4).
diameter of the hole before starting to
assemble.
1) Assemble bearing (10) to gear (9), fit top
and bottom thrust washers (8) and (11)
and set gear assembly to carrier (7).
18 PC1250-8R
10. No. 1 sun gear

1) Assemble No.1 sun gear (3) to carrier
assembly.
2) Install thrust washer (2).
11. Cover
Install cover (1).
2 Cover mounting surface:
3 Mounting bolt:
1st time: 98 Nm {10 kgm}
2nd time: 120 ± 5°
12. Refilling with oil

Tighten drain plug and add oil through oil filler.
5 Swing machinery case: Approx. 21.5 l
PC1250-8R 19
Disassembly and assembly of 3. No. 1 sun gear

swing motor and swing Remove No. 1 sun gear (2).
machinery assembly 1
Serial number: 35017 and up
Special tools
Necessity
Symbol
Sketch
Q’ty
N/R
1 796T-627-1630 Push tool q 1 Q

2 790-201-2350 Push tool t 1
3 790-201-2510 Push tool t 1
790-101-5531 • Plate 1 4. No. 1 carrier assembly
D 4 1) Remove No. 1 carrier assembly (3).
790-101-5421 • Grip 1
01010-51240 • Bolt 1
5 790-201-2870 Push tool t 1
6 790-201-2770 Push tool t 1
7 796T-626-1110 Push tool t 1 Q
Disassembly
1. Draining oil
Loosen the drain plug and drain the oil from
the swing machinery case.
6 Swing machinery case: Approx. 21 l
2. Swing motor assembly 2) Disassemble the No. 1 carrier assembly

1) Set the swing motor and swing machinery according to the following procedure.
assembly on block [1]. Remove snap ring (4), and then remove
2) Remove 10 mounting bolts and lift off shaft (5), gear (6), bearing (7), thrust
swing motor assembly (1). washer (8), and plate (9).
4 Swing motor assembly: 115 kg
20 PC1250-8R
5. Ring gear 8. No. 2 carrier assembly

Remove the mounting bolts and ring gear (10). 1) Lift of No. 2 carrier assembly (13).
6. No. 2 sun gear 2) Disassemble the No. 2 carrier assembly

Remove No. 2 sun gear (11). according to the following procedure.
i) Push in pin (14) and drive out shaft
(15) from carrier (16).
(14).
ii) Remove thrust washer (17), gear
(18), bearing (19), and thrust washer
(20).
iii) Remove plate (21).
7. Bolt
Remove holder mounting bolt (12).
9. Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of
cover assembly (22).
PC1250-8R 21
2) Turn over case and pinion assembly (24) 11. Bearing

and set it on the press stand. Using push Using multiple push tools [3], remove bearing
tool [2], D1 and the press, pull out pinion (30) from case (31).
shaft assembly (25). a Push tool to be set contact with bearing:
a Set a wood block under the press so D2
that the pinion shaft will not be dam-
aged when it comes off.
a A rough standard pressing force is 20
odd tons.
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with
10. Disassemble the pinion shaft assembly (25) engine oil before installing.
1) Using the push tool, remove cover assem- 1. Bearing
bly (22) and bearing (26) from shaft (27). Using push tool D3 and [4], press fit bearing
a A rough standard pressing force is 30 (26) to case (31).
tons. a A rough standard pressing force is several
2) Remove oil seal (28) from cover (29). tons.
22 PC1250-8R
2. Cover assembly 3. Case assembly

1) Using push tool D4, press fit oil seal (28) 1) Turn over case assembly (32) and set it to
to cover (29). shaft (27). Using push tools D5 and D6 [5],
2 Periphery of oil seal: press fit the bearing inner race.
Gasket sealant (LG-6) a When setting the case assembly to
a Take care that the gasket sealant the shaft, take care extremely not to
(LG-6) will not stick to the oil seal lip damage the oil seal.
and shaft. a A rough standard pressing force is 30
tons.
2) Install cover assembly (22) to case (31)

and tighten mounting bolts (23). 2) Bearing
a Match the oil path of cover (22) to the Using too D7, press fit bearing (30).
drilled hole of case (31). a Press both inner race and outer race
2 Cover fitting face: of the bearing simultaneously. Do not
Gasket sealant (LG-6) press only the inner race.
3 Mounting bolt:
a A rough standard pressing force is 20
98 – 123 Nm {10 – 12.5 kgm} odd tons.
a After press fitting the bearing, check
2 Oil seal lip: Grease (G2-LI)
that the case turns smoothly.
PC1250-8R 23
4. No. 2 carrier assembly a When inserting the pin, do not set the
1) Assemble the No. 2 carrier assembly 3 claws (a) on the periphery to the
according to the following procedure. thin part of the carrier (b).
a There is a caulking mark made when The thin part may be on the opposite
the pin was inserted at the end of car- side, however. Check each carrier
rier side hole (a) and the inside wall of and avoid setting a claw to the thin
the hole is swelled at that mark. Flat- part.
ten the swelled part in advance.
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fit
top and bottom thrust washers (17)
and (20) , and then set the gear
assembly to carrier (16).
a After inserting the pin, caulk the pin

part of the carrier.
2) Install No. 2 carrier assembly (13).
5. Bolt and O-ring

1) Tighten bolt (12).
iii)Aligning the pin holes of shaft (15) 2 Threads of mounting bolt:
and carrier, lightly hit the shaft with a Adhesive (LT-2)
plastic hammer, etc. to install. 3 Mounting bolt:
a When installing the shaft, revolve the 343 – 427 Nm {34 – 43.5 kgm}
planetary gear and take care not to
damage the thrust washers.
iv) Insert pin (14).
2) Fit the O-ring to case (31).
24 PC1250-8R
6. No. 2 sun gear

Install No. 2 sun gear (11).
a Degrease the mating faces of ring gear

(10) and case (29).
7. Ring gear a Never stick gasket sealant to the mating
Using the eyebolt (M12 x 1.75), install ring faces of ring gear (10) and case (29).
gear (10). 3 Mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
a Add engine oil (EO30-CD) at this time.

1) Assemble the No. 1 carrier assembly
i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap
ring groove is seen.
ii) After installing snap ring (4), press
back the shaft from the opposite side
until the snap ring is fitted to face (P)
of the carrier. At this time, take care
not to press back too much.
a When installing ring gear (10), set its
match mark (d) and the projection of the
case flange (c) as shown in the following
figure.
PC1250-8R 25
iii) After installing plate (9), install thrust a Take care not to install the No. 1 sun gear
washer (8), bearing (7), gear (6), and upside down.
snap ring (4). a Install the No. 1 sun gear with the tooth (e)
down.
2) Install No. 1 carrier assembly (3).

10. Swing motor assembly
Install swing motor assembly (1) to ring gear
(10).
a When installing the swing motor assembly,
set the relief valve (f) and the projection of
the case (c) as shown in the following fig-
ure.
a Degrease the mating faces of swing motor
assembly (1) and ring gear (10).
2 Mating faces of swing motor

assembly (1) and ring gear (10):
3 Mounting bolt:
9. No. 1 sun gear assembly 98 – 123 Nm {10 – 12.5 kgm}
Install No. 1 sun gear (2). 4 Swing motor assembly: 115 kg

Tighten the drain plug and add engine oil
(EO30-CD, or SHC 5W-30K for extremely cold
district) through the oil filler to the specified
level.
5 Swing machinery case: Approx. 21 l
26 PC1250-8R
Removal and installation of swing 5. Remove seal (4).

circle assembly 1
Removal
1. Remove revolving frame assembly.

For details, see “Removal and installation of
revolving frame assembly”.
2. Remove grease tubes (1).
Installation
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.
PC1250-8R 27
Disassembly and assembly of 3. Cover

final drive assembly 1 Using forcing screws and eyebolts [1], remove
cover (1).
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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).
6 796-627-1030 Push tool t 1
J
790-101-2300 Push puller t 1
790-101-2310 • Block 1
790-101-2350 • Leg 2
790-101-2360 • Plate 2
02215-11622 • Nut 2
7
791-181-1010 Adapter t 2
796T-627-1340 Push tool t 1 Q
Puller (294.2 kN
790-101-2102 t 1
{30 ton})
8 796-627-1050 Installer t 1
3) Disassemble No. 3 carrier assembly as

follows:
Disassembly
i) Remove mounting bolts (3).
ii) Using tool J2, remove holder (4).
1. Draining oil
Remove drain plug and drain oil from final
drive case.
6 Final drive case: Approx. 21 l
2. Setting
Put travel motor at bottom and set on block
(height approx. 350 mm).
a If the travel motor is removed, No.1 sun
gear will fall off (See item 15.).
28 PC1250-8R
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).
PC1250-8R 29
3) Using eyebolts [4], remove hub assembly

(15) together with bearing (16) from shaft
(41).
4) Remove bearing (16) from hub (49).
iii)Pull out gear (23) from carrier (27),

then remove thrust washer (24) and
bearing (25).
iv) Remove thrust bearing assembly (26)
5) Remove floating seal (17a) from hub (49) from carrier (27).
a If the seal is to be used again, be
careful not to damage the contact sur-
face, and keep in a safe place.
6) Remove outer races (18).
8. Spacer
1) Remove spacer (19) from shaft (41).
10. No. 2 sun gear

1) Remove No. 2 sun gear (28).
11. No. 2 ring gear

1) Remove No. 2 ring gear (30).
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.
30 PC1250-8R
13. No. 1 carrier assembly 14. No. 1 ring gear

1) Using eyebolts [6], remove No. 1 carrier Remove No.1 ring gear (39).
assembly (32).
2) Disassemble No. 1 carrier assembly as 15. No. 1 sun gear
follows. Remove No.1 sun gear (40).
i) Knock pin (33) into shaft (34).
ii) Knock out shaft (34) towards pin end. 16. Thrust washer
a Remove the pin from the shaft. Remove thrust washer (48) from travel motor.
17. Floating seal

Remove floating seal (17b) from shaft (41).
a If the seal is to be used again, be careful
not to damage the contact surface, and
keep in a safe place.
3) Pull out gear (35) from carrier (36), then

remove thrust washer (37) and bearing
(38).
PC1250-8R 31
Assembly 5. No. 1 carrier assembly

1) Assemble No. 1 carrier assembly as fol-
1) Clean all parts, check for dirt or damage, lows.
and correct all dents and burrs. a There are the remains of the caulking
2) Coat the bearings and surfaces of all parts when the pin is inserted at the end
with engine oil before installing. face of hole (h) at the side of the car-
rier, so remove the caulked metal
1. Thrust washer from the inside diameter of the hole
1) Set shaft assembly on block (height: before starting to assemble.
approx. 350 mm). i) Assemble bearing (38) to gear (35),
2) Install thrust washer (48) of travel motor. put thrust washers (37) in contact at
both sides, then set to carrier (36).
2. No. 1 sun gear

1) Install No. 1 sun gear (40). ii) Align position of pin holes of carrier
and shaft, then tap with a plastic ham-
3. No. 1 ring gear mer to install shaft (34).
1) Install No. 1 ring gear (39). a When installing the shaft, rotate
a Set with the side with the cut outside the planetary gear, and be care-
circumference facing the motor. ful not to damage the thrust
washer.
4. Spacer iii) Install pin (33).
1) Install spacer (31). a Check that the pin groove and
protruding part of the pin are not
modified. If the pin is defective,
replace it with a new part.
a When assembling the pin again,
avoid the position previously
used for caulking.
a After inserting the pin, caulk the
pin portion (marked by arrows) of
the carrier.
a After assembling the carrier assem-
bly, check that gear (35) rotates
smoothly.
32 PC1250-8R

1) Assemble No. 2 carrier assembly as fol-
lows.
i) Press fit thrust washer (44) to plate
(43).
ii) Press fit thrust assembly (26) to car-
rier (27).
2) Using eyebolt [6], install No. 1 carrier

assembly (32).

when the pin is inserted at the end
face of hole (h) at the side of the car-
rier, so remove the caulked metal
from the inside diameter of the hole
before starting to assemble.
iii) Assemble bearing (25) to gear (23),
put thrust washers (24) in contact at
both sides, then set to carrier (27).
6. No. 2 sun gear

1) Press fit button (29) to No. 2 sun gear (28).
2) Install No. 2 sun gear (28).
7. No. 2 ring gear

Install No. 2 ring gear (30).
PC1250-8R 33
iv) Align position of pin holes of carrier 10. Hub assembly

and shaft, then tap with a plastic ham- 1) Floating seal at shaft end
mer to install shaft (22). Using tool J8, install floating seal (17b) to
a When installing the shaft, rotate shaft (41).
the gear, and be careful not to a Remove all oil and grease from the
damage the thrust washer. O-ring and O-ring contact surface,
v) Install pin (21). and dry the parts before installing the
a Check that the pin groove and floating seal.
protruding part of the pin are not
modified. If the pin is defective,
replace it with a new part.
a When assembling the pin again,
avoid the position previously
used for caulking.
a After inserting the pin, caulk the
pin portion (marked by arrows) of
the carrier. (See Step 5-1)-iii).)
a After assembling the carrier
assembly, check that gear (23)
rotates smoothly.
2) Using eyebolts [5], install No. 2 carrier
assembly (20).
a After installing the floating seal, check

that the angle of the floating seal is
within 1 mm.
a After installing the floating seal, coat
the sliding surface thinly with engine
oil.
2) Inside bearing
Shrink fit bearing (16) to shaft (41), or use
tool J3 to install.
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.
34 PC1250-8R
a When using tool J7, see the drawing

below.
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.
7) Install nuts as follows.

i) Set tool J7 in position.
ii) Push bearing inner race portion with
specified force.
a Pushing force:
4) Floating seal at hub end 34.3 – 38.2 kN {3.5 – 3.9 ton}
Using tool J8, install floating seal (17a) to iii) Rotate hub assembly 2 – 3 times to
hub (49). settle bearing.
a For precautions and details of the
tool, see step 10-1).
a When turning over the hub, the float-
ing seal will be at the bottom, so
install it temporarily with several of
bolts [8].
5) Installation of hub assembly
Using eyebolts [4], install hub assembly
(15) to shaft (41).
PC1250-8R 35
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).
v) Measure thickness (b) of nut (14) as

an individual part.
vi) Calculate (a) – (b) = (c).
vii) Using tool J1, tighten nut (14) to a point
where dimension (c) +0.15/-0.05 mm.

1) Assemble No. 3 carrier assembly as follows.
i) Using tool J4, press fit outer race (9)
to gear (46).
8) Install lock plate (13) as shown in the dia-

gram below.
2 Mating surface of cover:
Thread tightener (LT-2)
3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm} ii) Assemble bearing (7) and spacer (8)
to gear (46), and set to carrier (47).
a Align the carrier and bearing and
spacer holes accurately.
36 PC1250-8R
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).
13. No. 3 sun gear

1) Install thrust washer (11) to No. 3 sun gear
(10).
2) Install No. 3 sun gear (10).
a Be careful not to get your finders
caught.
v) Tighten bolt (3).

2 Bolt: Thread tightener (LT-2)
3 Bolt:
931 – 1,030 Nm {90 – 105 kgm}
vi) Install thrust washer (50).
14. Cover
Using eyebolts [1], install cover (1).
2 Mounting surface:
2 Bolt: Thread tightener (LT-2)
3 Bolt: 982 – 1,030 Nm {90 – 105 kgm}
2) Using eyebolts [2], install No. 3 carrier

assembly (2).
a Align the low portion (4 places) of
spacer (19) and shaft (41) with the
carrier assembly holder.
PC1250-8R 37
SEN02788-01

© 2007 KOMATSU
All Rights Reserved
38
SEN02789-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Undercarriage and frame
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
PC1250-8R 1
Removal and installation of track Removal

shoe assembly 1
1. Positioning master pin
Special tools a Move the track so that the master pin is
midway between the idler and the carrier
New/Remodel
roller. The track shoe is opened to the
Necessity
Symbol
rear, so be sure that there is enough
Q’ty
space to lay it out.
2. Loosen track shoe tension. [*1]

796-832-1110 Remover & installer t 1 k Never loosen lubricator (1) more than
791-685-9510 Frame 1 one turn.
791-685-9520 Frame 1 a If the track tension is not relieved even
when the lubricator is loosened, move the
791-685-9530 Rod 1
machine backwards and forwards.
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
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}
2 PC1250-8R
4. Fit block or hydraulic jack [1] (100 kN {10 ton}) Installation

under shoe at idler end, then remove guide pin q Carry out installation in the reverse order to
[2]. [*2] removal.
[*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.
5. Raise tip of track shoe with crane, and move

machine slowly to rear to open track shoe
assembly (3).
PC1250-8R 3
Removal and installation of idler

assembly 1
Removal
1. Remove track shoe assembly.

track shoe assembly”.
2. Remove idler assembly (1).

a Pull out the idler assembly, then lift off the
idler and adjustment cylinder.
4 Idler assembly: 1,000 kg
Installation
removal.
4 PC1250-8R

idler assembly 1
Special tools
Necessity
Symbol
Q’ty

790-101-5541 • Plate 1
1
790-101-5421 • Grip 1
01010-51240 • Bolt 1
L
5 796-675-1510 Installer t 1
791-601-1000 Oil pump t 1
6. Turn over idler assembly, remove bolt and nut
10 791-646-8002 Oil lubricator t 1
(8), then remove support (9).
Disassembly
1. Remove plug and drain oil.
6 Idler: Approx. 750 – 830 cc
2. Set idler assembly (1) on blocks [1], remove

bolt and nut (2), then remove support (3).
7. Remove O-ring (10).
8. Remove plate (11), then remove dowel pin (12)

from plate.
9. Remove floating seal (7).
3. Remove O-ring (4).
4. Remove plate (5), then remove dowel pin (6)

from plate.
5. Remove floating seal (7).
PC1250-8R 5
10. Remove shaft (13) from idler. Assembly

a Clean all parts, and check for dirt or damage.
1. Using tool L5, assemble floating seals (7) to

supports (3) and (9).
a Check that the angle of the seal is less
than 1 mm.
11. Remove bushings (14) and (15) from idler.
2. Using tool L1, press fit bushings (14) and (15)

to idler (1).
q Press-fitting force:
114 – 200 kN {11.6 – 20.4 t}
12. Remove floating seal (7) from supports (3) and

(9).
3. Using tool L5, assemble floating seal (7) to

idler (1).
than 1 mm.
6 PC1250-8R
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).
15. Using tool L10, add oil to specified level, then

tighten plug.
5 Idler: Approx. 750 – 830 cc (GO 140)
3 Plug: 274.4 – 367.5 Nm {28 – 37.5 kgm}
8. Assemble plate (11) to idler (1).
9. Assemble dowel pin (12) to plate (11).
10. Fit O-ring (10) to shaft (13).
PC1250-8R 7
Disassembly and assembly of Assembly

idler adjustment cylinder
assembly 1 1. Install wear ring (6) to plunger (2).
Disassembly 2. Assemble backup ring (5) and packing (4) to

plunger (2), then install snap ring (3).
1. Remove plunger assembly (1).
3. Fill inside with grease (G2-Ll), then assemble
2. Remove snap ring (3), then remove packing plunger assembly (1) to piston.
(4), backup ring (5), and wear ring (6) from
plunger (2). 4. Install dust seal (7).
3. Remove dust seal (7).
8 PC1250-8R
Removal and installation of recoil Installation

spring assembly 1 q Carry out installation in the reverse order to
removal.
Removal a To check that the spring is securely fitted
a The coil portion of the recoil spring assembly is inside the track frame, look through the
hooked on the rib inside the track frame, so side hole on the inside (at the 5th track
prepare a special tool for disassembly. roller from the front).
1. Remove track shoe assembly.

track shoe assembly”.
2. Remove idler assembly.

idler assembly”.
3. Recoil spring assembly

1) Remove No. 2 and No. 3 track roller
assemblies.
For details, see “Removal and installation
of track roller assembly”.
2) After removing track roller assembly,
install tool [1].
a When making tool [1], see Fig. 1.
a Lower the track frame on top of the
track shoe.
3) Using eyebolts (Thread dia. = 16 mm,

Pitch = 2.0 mm), pull out recoil spring
assembly (1) and lift off.
4 Recoil spring assembly: 1,000 kg
PC1250-8R 9
Fig. 1 (for tool [1])
10 PC1250-8R
Disassembly and assembly of 2. Apply hydraulic pressure slowly to compress

recoil spring assembly 1 spring, then remove lock plate, and remove nut
(2).
Special tools
3. Release hydraulic pressure gradually to relieve
New/Remodel
tension of spring, then remove recoil spring
Necessity
assembly (1) from tool M1.
Symbol
Sketch
Q’ty
791-685-8502 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 (686.47 kN t 1
{70 tons})
4. Remove rear pilot (4) and rod (5) from spring

Disassembly (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}
PC1250-8R 11
Installation
1. Install tool M1 to tip of rod (5).

a Tool M1 is to prevent damage to the
thread when inserting the rear pilot.
2. Install rod (5) to spring (3).

Assemble rear pilot (4), and set to tool M1.
k The recoil spring is under a large
installed load, so be sure to set the
parts properly. Failure to do this is dan-
gerous.
3. Apply hydraulic pressure slowly to compress

spring so that installed length of spring is stan-
dard dimension.
a Installed length (a) of spring: 1,280 mm
4. Fit nut (2) and secure with lock plate.
5. Release hydraulic pressure gradually to relieve

tension of spring, then remove recoil spring
assembly (1) from tool M1.
12 PC1250-8R
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
790-401-1700 Lifting tool t 1

790-401-1761 Adapter t 1
L 7
790-401-1540 Shackle t 2
790-401-1770 T-bolt t 2
Removal
1. Loosen track shoe tension.

track shoe assembly”. Installation
2. Remove track roller guards (1) and (2). removal.
4 Track roller guard: 170 kg
[*1]
3 Roller mounting bolt:
1,370 ± 98 Nm {140 ± 10 kgm}
3. Using work equipment, push up track frame on

side, which is to be removed.
k After jacking up the chassis, set a
block on the track shoe.
PC1250-8R 13
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
6 790-434-1620 Installer t 1
791-601-1000 Oil pump t 1
L
10 791-646-8002 Oil lubricator t 1
Disassembly

a Rotate the shaft while draining the oil. 5. Remove floating seal (6) on opposite side from
6 Track roller: Approx. 800 – 850 cc roller (4) and collar (8).
6. Remove pin (7), then remove collar (8) from

2. Remove pin (1), then remove collar (2). shaft (5).
7. Remove bushings (9) and (10) from roller (4).
3. Remove floating seal (3) from collar (2) and

roller (4).
14 PC1250-8R
Assembly 5. Assemble shaft (5) to roller (4).
1. Using tool [1], press fit bushings (9) and (10) to

roller (4).
2. Assemble collar (8) to shaft (5), and install pin

(7).
3. Using tool L6, install floating seal (6) to shaft

(5).
6. Turn over roller (4) and shaft (5) assembly.
7. Using tool L6, install floating seal (3) to collar

(2).
a For details of the precautions when install-
ing floating seals (3a) and (3b), see the
precautions marked a for Step 3.
a When assembling the floating seal, clean

the contact surface (hatched position) of
O-ring (6c) and floating seal (6a), remove
all grease and oil, and dry it. Make sure
that no dirt or dust sticks to the contact
surface of the floating seal.
a After inserting the floating seal, check that
the angle of the seal is less than 1 mm.
a After inserting the floating seal, check that
the protrusion of seal is 5 – 7 mm.
8. Assemble collar (2) to shaft (5), and install pin

(1).
4. Using tool L6, install floating seals (6) and (3)

to roller (4).
a For details of the precautions when install-
ing floating seals (6b) and (6d), and (3b)
and (3d), see the precautions marked a
for Step 3.
PC1250-8R 15
9. Using tool L10, apply standard pressure to

roller oil filler port, and check for leakage of air
from seal.
a Standard pressure: 0.1 MPa {1 kg/cm2}
a Method of checking
The standard pressure shall be main-
tained for 10 seconds and the indicator of
the gauge shall not go down.
10. Using tool L10, fill track roller assembly with

oil, then tighten plug (11).
5 Track roller oil: 800 – 850 cc (EO30-DH)
3 Plug: 17 – 37 Nm {1.7 – 3.8 kgm}
16 PC1250-8R
Removal and installation of Installation

carrier roller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
1. Loosen track shoe slightly.

For details, see Testing and adjusting, “Adjust-
ing track shoe tension”.
2. Using hydraulic jack [1], push up track shoe.
3. Remove 4 mounting bolts (1).
4. Lift off carrier roller assembly (2).

a Pull the carrier roller assembly to the out-
side to a point where it does not fall.
4 Carrier roller assembly: 80 kg
PC1250-8R 17
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
790-101-5401 Push tool kit (C) t 1

790-101-5441 • Plate 1
1
790-101-5421 • Grip 1
L 01010-51240 • Bolt 1
2 796T-830-1130 Push tool t 1 Q
3 796T-830-1140 Adapter t 2 Q
4 796-570-1020 Installer t 1
8. Remove floating seal (5) from roller (4).
9. Using tool L2, remove bearing (6) from shaft

Disassembly (3).

6 Carrier roller assembly:
Approx. 450 – 500 cc
2. Set carrier roller assembly (1) on press stand.

a When support (2), shaft (3), and roller (4)
come away from roller assembly (1), they
will fall, so set something to catch them
under the roller.
3. Push with press, and remove support (2), shaft

(3), and roller (4) as one unit.
a Remove floating seal (5) from support (2).
4. Remove shaft (3) and bearing (6) as one unit 10. Remove bearing outer race (7) from support
from support (2). (2).
11. Using tool [1], remove bushing (8) from sup-

port (2).
5. Remove roller (4) and floating seal (5) (on top

of support (2)) as one unit.
18 PC1250-8R
Assembly 6. Assemble floating seal (5) to roller (4), then set

roller (4) on tool L3.
1. Using tool [1], press fit bushing (8) to support
(2). 7. Assemble floating seal (5) to support (2), then
a Press fit so that the protrusion is the same press fit support (2) and shaft (3) as one unit to
on the left and right. roller (4).
a Make sure that there is no dirt stuck to the
2. Using tool L1, press fit bearing outer race (7) seal surface.
to support (2).
8. Press fit bearing (6) to shaft (3).

3. Using tool L2, press fit bearing (6) to shaft (3).
a Push in approx. 80 mm from the end face 9. Install floating seal (5) to support (2).
of the shaft.
10. Assemble floating seal (5) to roller (4), then
4. Install bearing (6) to shaft (3), install bushing press fit roller (4) to shaft (3).
(8) to support (2), then press fit shaft (3) to a Press fit roller (4) to the end face of the
support (2). shaft, then use tool L3 to press fit finally.
a Check that the inner race of the bearing is a Ensure that the press-fitting force for the
in contact with bushing (8). shaft and each roller is at least 230 kN {23
tons).
11. After assembling carrier roller assembly (1), fill

with oil.
5 Lubricating oil: 450 – 500 cc (GO 140)
12. After filling carrier roller assembly with oil,

tighten plug.
3 Plug: 157 – 255 Nm {16 – 26 kgm}
5. Using tool L4, install floating seal (5) to roller

(4).
than 1 mm.
a Wash the O-ring and O-ring contact sur-
face, remove all oil and grease, then dry
thoroughly.
PC1250-8R 19
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
1. Remove counterweight assembly.

counterweight assembly”.
2. Remove work equipment assembly.

For details see “Removal and installation of
work equipment assembly”.
3. Disconnect hose (1) coming from filter.
4. Disconnect hoses (2) and (3) coming from

swing motor.
10. Lift off revolving frame assembly (9).
5. Disconnect hoses (4) coming from 5-spool
4 Revolving frame assembly:
control valve.
Approx. 24,300 kg
6. Disconnect hoses (5) coming from 4-spool
control valve.
7. Disconnect hose (6) coming from travel speed

selector solenoid valve.
Installation
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]
3 Mounting bolt:
1,960 – 2,450 Nm {200 – 250 kgm}
20 PC1250-8R
Removal and installation of

counterweight assembly 1
Removal
1. Sling counterweight assembly (1).
3. Lift off counterweight assembly (1).

4 Counterweight assembly: 17,900 kg
Installation
removal.
[*1]
3 Counterweight mounting bolt:
3,822 ± 392 Nm {390 ± 40 kgm}
PC1250-8R 21
SEN02789-01

© 2007 KOMATSU
All Rights Reserved
22
SEN02790-01
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Hydraulic system
Removal and installation of hydraulic tank assembly...................................................................................... 2
Removal and installation of hydraulic pump assembly ................................................................................... 4
Removal and installation of main pump input shaft oil seal .......................................................................... 10
Removal and installation of 5-spool control valve assembly (No. 1)..............................................................11
Removal and installation of 4-spool control valve assembly (No. 2)............................................................. 13
Removal and installation of 4-spool control valve assembly (No. 3)............................................................. 15
Disassembly and assembly of control valve assembly (No. 1) ..................................................................... 17
Removal and installation of swing motor assembly ...................................................................................... 28
Removal and installation of center swivel joint assembly ............................................................................. 32
Disassembly and assembly of center swivel joint assembly......................................................................... 33
Removal and installation of travel motor assembly....................................................................................... 35
Disassembly and assembly of work equipment PPC valve assembly .......................................................... 36
Disassembly and assembly of travel PPC valve assembly........................................................................... 38
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 40
PC1250-8R 1

hydraulic tank assembly 1
Removal
relieve internal pressure of the hydraulic
tank.
k Disconnect the negative (–) terminal of the
battery beforehand.
a Before disconnecting the hose, attach them a

tag and the like to enable confirming their des-
tination.
1. Turn the assembly 90°. 8. Disconnect filler (8).
2. Remove undercover (1). 9. Disconnect clamps (9) and (10).
3. Drain hydraulic oil. 10. Disconnect hose (11) from lower.
6 Hydraulic tank: 11. Disconnect hose (11-1).

670 l (Hydraulic tank refill oil capacity)
4. Remove plate (2). 12. Disconnect connector VH11 (12).
5. Remove bracket (3). 13. Disconnect connector P10 (13).
6. Lift and remove cover and handrail assembly

(4).
7. Disconnect hoses (5) to (7).
2 PC1250-8R
19. Remove 12 mounting bolts (20). [*1]
14. Disconnect hoses (14) and (15).
15. Remove the clamps, disconnect hose (16).

20. Lift and remove hydraulic tank (21).
4
16. Remove valve assembly (17).
Hydraulic tank assembly: 780 kg
17. Disconnect washer tanks (18).

Installation
q Carry out installation in reverse order of
removal.
[*1]
2 Mounting bolt: Adhesive (LT-2)
3 Hydraulic tank mounting bolt:
549 ± 59 Nm {56 ± 6 kgm}

5 Hydraulic tank (Hydraulic tank refill oil capacity):
Approx. 670 l
q Bleeding air
Bleed air from the parts, refer to “Bleeding air
from various system” in Testing and adjusting.
PC1250-8R 3

hydraulic pump assembly 1
Special tool
New/Remodel
Necessity
Symbol
Sketch
Q’ty
S 796-770-1301 Oil stopper t 1
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. q No. 3 pump
k Disconnect the negative (–) terminal of the q Fan and pilot pump (F • P)
battery beforehand.
1. Remove undercover (1).
a Before disconnecting the hoses and tubes in

the succeeding operations, attach them a tag
and the like to enable confirming their destina-
2. Remove the strainer of the hydraulic oil tank, tion.
and use tool S (see Special tool) to stop the oil.
6. No. 3 pump
3. When not using tool S, drain hydraulic oil. 1) Disconnect hoses (5) to (11).
6 Hydraulic tank:
670 l (Hydraulic tank refill oil capacity)
5. Lift and remove cover assembly (4).
4 PC1250-8R
2) Disconnect clamp (12). 7. No. 2 pump

3) Disconnect hoses (13) and (14). 1) Disconnect hoses (17) to (19).
2) Disconnect clamp (20).
3) Disconnect hoses (21) to (23).
4) Disconnect suction tube (15).

a Suction hose (E) is not disconnected
since MIKALOR clamp is used for
them.

5) Lift and remove No. 3 pump (16).
4 No. 3 pump assembly: 200 kg
PC1250-8R 5
q 55°C specification 2) Disconnect connector (29).

3) Disconnect clamp (30).

a Suction hose (G) is not disconnected 4) Disconnect suction tube (35).
them.
6) Remove No. 2 pump (28).
4 No. 2 pump assembly: 150 kg

a Suction hose (H) is not disconnected
them.
8. Fan and pilot pump (F • P) 6) Lift and remove fan and pilot pump (F • P).
1) Disconnect hoses (31) to (34). 4 Fan and pilot pump assembly: 90 kg
6 PC1250-8R
9. No. 1 pump 6) Disconnect 2 suction tubes (50).

1) Remove the No. 3 pump.
7) Disconnect 4 hoses (51).

8) Remove No. 1 pump (52).
3) Disconnect hoses (41). 4 No. 1 pump assembly: 160 kg

5) Disconnect connector C13 (49).
PC1250-8R 7
Installation 1) Align the hose to the original position (marked

q Carry out installation in reverse order of position).
removal. a Reference: Clamping position and hose inser-
tion depth
Reference q Hose (E)
q Suction hoses (E) – (H)
a The MIKALOR clamps shall be new ones.
2 Entire perimeter of hose (E) on the tube side:
Adhesive (ThreeBond No.4314)
a Apply the adhesive uniformly along the entire
perimeter
q Hoses (F), (G) and (H)
2) Place the bridge (BR) under the clamping bolt

and adjust the overlapping (b) between the
bridge (BR) and band to Min. 5 mm.
Dimensions (b): Min. 5 mm
Lubricant (PANDO 18B from ThreeBond)
a Impact wrench must not be used.

Align the clamp position to the trace of the
clamp left on the hose.
Min. 6 Nm {0.6 kgm}
8 PC1250-8R

Tighten th e bolt until (a) dimens ion
becomes 7 – 10 mm. (Common to hoses
(E) to (H))

5 Hydraulic tank (Hydraulic tank refill oil
capacity): Approx. 670 l
q Bleeding air
Bleed air from the parts, referring to “Bleeding
air from various system” in Testing and adjust-
ing.
PC1250-8R 9
Removal and installation of main Installation

pump input shaft oil seal 1 q Carry out installation in the reverse order to
removal.
Removal
[*1]
1. Remove main pump assembly. 2 Lip of oil seal: Grease (G2-LI)
For details, see “Removal and installation of 2 Coat the outside circumference of the oil
hydraulic pump assembly”. seal with grease (G2-LI) thinly, then press
fit.
2. Remove cover (1). a Using tool [1], press fit oil seal (4).
a Be careful not to lose shims (2) and (3).
3. Remove oil seal (4) from cover (1). [*1]
10 PC1250-8R
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 ni ng pr e s su re f r om
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.
1. Disconnect tubes (1), hose bracket (2), and

hose clamp (3) of the swing motor and keep
them by the swing motor.
7. Disconnect L.H. PPC hoses (12) (boom Hi),
2. Disconnect tube (4) coming from line filter. (13) (arm Lo), (14) (bucket Hi), and (15) (L.H.
travel).
3. Disconnect branch hoses (5).
4. Remove clamp, then disconnect tube (6) com-

ing from main pump.
PC1250-8R 11
8. Disconnect tube (16) for boom (RAISE) con- Installation

trol. q Carry out installation in the reverse order to
removal.
9. Disconnect tube (17) for arm (OUT) control.
[*1]
10. Disconnect tube (18) for bucket (CURL) con- a Check the hydraulic pressure and speed of the
trol. work equipment, travel, and swing circuits. For
details, see “Testing and adjusting”.
11. Disconnect tube (19) for arm (IN) control. q Aligning position when installing valve,
1) Install jig bolts [1] and [2] as shown in the
12. Disconnect tube (20) for bucket (DUMP) con- diagram below.
trol. 2) Install tube [3] (normal piping).
3) Replace jig bolts with normal bolts.
13. Disconnect tube (21) for L.H. travel (FOR-
WARD) control.
14. Disconnect tube (22) for L.H. travel

(REVERSE) control.
15. Disconnect hose (23) going to filter.

a Disconnect 2 hoses between the bottom
of the control valve and the main pump.
16. Remove mounting bolts and lift off 5-spool con-

trol valve assembly (24). [*1]
4 5-spool control valve assembly: 260 kg
q Refilling with oil (hydraulic tank)

Add oil through the oil filler to the specified
again.
12 PC1250-8R
Removal and installation of 4-spool 3. Disconnect hose (4) between main relief valve
control valve assembly (No. 2) 1 and solenoid valve of 2-stage safety valve.
Removal 4. Disconnect drain hose (straight travel valve)

k Lower the work equipment completely to (5).
loosen the oil filler cap slowly to release the 5. Disconnect R.H. PPC hoses (6) (R.H. travel),
pressure inside the hydraulic tank. (7) (boom Lo), (8) (bucket Lo), and (9) (arm
k Release the remaining pressure inside the Hi).
hydraulic circuit.
For details, see Testing and adjusting, 6. Disconnect hose (10) from solenoid valve of 2-
“Releasing remaining pressure in hydraulic stage safety valve.
circuit”.
a After disconnecting the PPC hoses, make
positions.
blind plugs.
1. Disconnect tube (1) coming from main pump.
2. Disconnect branch hoses (2) and (3).
7. Disconnect hose (12) from straight travel valve

solenoid.
8. Disconnect L.H. PPC hoses (13) (R.H. travel),

(14) (boom Lo), (15) (bucket Lo), and (16) (arm
Hi).
PC1250-8R 13
9. Disconnect tube (17) from line filter. Installation

10. Disconnect tube (18) going to 5-spool control removal.
valve (L.H. travel).
[*1]
11. Disconnect tube (19) for R.H. travel (FOR- a Check the hydraulic pressure and speed of the
WARD) control. work equipment, travel, and swing circuits. For
details, see Testing and adjusting.
12. Disconnect tube (20) for R.H. travel (REVERSE)
control. q Aligning position when installing valve.
1) Install jig bolts [1] and [2] as shown in the
13. Disconnect tube (21) for boom (LOWER) control. diagram below.
2) Install tube [3] (normal piping).
14. Disconnect tube (22) for boom (RAISE) control. 3) Replace jig bolts with normal bolts.
15. Disconnect tube (23) for bucket (CURL) control.
16. Disconnect tube (24) for bucket (DUMP) control.
17. Disconnect tube (25) for arm (IN) control.
18. Disconnect tube (26) for arm (OUT) control.
19. Remove step (27).

a Disconnect 2 hoses between the bottom
of the control valve and the main pump.
20. Remove mounting bolts and lift off 4-spool con-

trol valve assembly (28). [*1]

Add oil through the oil filler to the specified
again.
14 PC1250-8R
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
loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
k Release the remaining pressure inside the
hydraulic circuit.
“Releasing remaining pressure in hydraulic
circuit”.
a Before disconnecting the PPC hoses, make
positions.
blind plugs. 9. Disconnect hoses (9) coming from the pilot
valve.
1. Remove control valve cover (1).
10. Disconnect swing control tube (10).
11. Disconnect arm control tube (11).
12. Remove pilot hoses (12), (13), (14), and (15),

and then disconnect main relief valve (16).
2. Remove tubes (2) and clamp.
3. Remove line filter tube (3).
4. Remove tube (4) for boom control valve.
5. Remove tube (5) for swing control.
6. Remove tube (6) for bucket control.
7. Remove tube (7) for arm control.
PC1250-8R 15
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).
15. Disconnect PPC hose (23). Add oil through the oil filler to the specified
16. Remove 4-spool control valve assembly (No. 3) through the system. Then check the oil level
(24). again.
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”.
16 PC1250-8R
Disassembly and assembly of 10. Remove main relief valve (17).

control valve assembly (No. 1) 1
11. Remove plug (18), then remove (19) (O-ring,
Disassembly backup ring, and O-ring).
1. Remove bolt (2) from valve body (1), then 12. Remove orifice (20).
remove case (3).
13. Remove jet sensor relief valve (21).
2. Remove O-ring (4) from case (3).
14. Remove plug (22), then remove O-ring (23)
3. Remove spring (5), tube (6), and retainer (9) from plug.
from bottom control valve mount, then pull out
spool (10). 15. Remove plug (24), then remove backup ring
and O-ring (24A) from plug.
4. Remove tube (7) and retainer (9) from boom Hi
control valve mount.
5. Remove springs (5) and (8), and retainer (9)

from boom Hi control valve mount, then pull
out spool (11).
6. Remove springs (5) and (8), and retainer (9)

from arm Lo, bucket Hi, and L.H. travel control
valve mount.
7. Pull out arm Lo spool (12), bucket Hi spool (13)

and LH. travel spool (14).
16. Remove bolts (25), remove plate (26), then

remove O-ring (27), spring (28), and check
valve (29).
17. Remove plug (30), then remove backup ring

(31) and O-ring (32).
18. Remove nut (35), then remove sleeve (36).
19. Remove spring (33) and check valve (34) from

sleeve (36).
20. Remove backup ring (37) and O-ring (38) from

sleeve (36).
8. Remove 2 suction valves (15).
9. Remove 5 suction-safety valves (16).
PC1250-8R 17
Assembly 12. Assemble main relief valve (17) to valve body

(1).
1. Fit backup ring (37) and O-ring (38) to sleeve 3 Main relief valve:
(36), then assemble to valve body. 275 – 368 Nm {28 – 37.5 kgm}
2 Sleeve: Thread tightener (Seal end 242)
3 Sleeve: 177 – 216 Nm {18 – 22 kgm} 13. Assemble suction-safety valve (16) to valve
body (1).
2. Assemble nut (35) to sleeve (36). 3 Suction-safety valve:
3 Nut: 177 – 216 Nm {18 – 22 kgm} 216 – 235 Nm {22 – 24 kgm}
3. Assemble check valve (34) and spring (33) to 14. Assemble suction valve (15) to valve body (1).
sleeve (36). 3 Suction valve:
294 – 314 Nm {30 – 32 kgm}
4. Fit backup ring (31) and O-ring (32) to plug
(30), then assemble to sleeve (36).
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm}
5. Insert check valve (29) in valve body then

assemble spring (28).
6. Fit O-ring to plate (26) and tighten to valve

body with bolt (25).
3 Mounting bolt:
78.5 – 98 Nm {8 – 10 kgm}
7. Fit backup ring and O-ring (24A), and plug

(24), then assemble to valve body (1).
2 Plug: Thread tightener (Loctite No. 638)
3 Plug: 117.7 – 161.8 Nm {12.0 – 16.5 kgm}
8. Fit O-ring (23) to plug (22), then assemble to

valve body (1).
3 Plug: 58.8 – 78.5 Nm {6 – 8 kgm}
9. Assemble jet sensor relief valve (21) to valve

body (1).
3 Jet sensor relief valve:
177 – 196 Nm {18 – 20 kgm}
10. Assemble orifice (20) to valve body (1).

3 Orifice: 127 – 177 Nm {13 – 18 kgm}
11. Fit O-ring, backup ring, and O-ring (19) to plug

(18), then assemble to valve body (1).
18 PC1250-8R
15. Assemble spools (10) (bottom), (11) (boom Hi),

(12) (arm Lo), (13) (bucket Hi), and (14) (L.H.
travel) to valve body (1).
a Coat the spool with engine oil.
a Be careful not to mistake the location and
direction of the spool.
16. Assemble retainer (9), tube (6), and spring (5)

to bottom control valve mount.
17. Fit O-ring (4) to case (3) and tighten to valve

body (1) with bolt (2).
18. Assemble retainer (9) and tube (7) to boom Hi

control valve mount.

20. Assemble retainer (9) and springs (8) and (5)

to spool (12) (boom Lo control valve mount),
spool (13) (bucket Hi control valve mount), and
spool (14) (L.H. travel control valve mount).

PC1250-8R 19

control valve assembly (No. 2) 1
Disassembly
1. Remove mounting bolts (2) and (3) from valve

body (1) then remove straight travel valve (4).
2. Remove O-rings (5) and (6) from straight travel

valve (4).
9. Remove 2 suction valves (22).
10. Remove suction-safety valves (23) and (24) (1

each) and 4 suction-safety valves (25).
11. Remove orifice (26).
13. Remove main relief valve (28).

each port of valve body (1). 14. Remove plug (29),
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).
16. Remove plug (31).
5. Remove mounting bolts (12) from each control

valve mount, then remove case (13).
6. Remove O-ring (14) from each case (13).
7. Remove springs (15) and (16) from each con-

trol valve mount, then remove retainer (17).
8. Pull out spool (18) for R.H. travel, spool (19)

for boom Lo, spool (20) for bucket Lo, and
spool (21) for arm Hi from valve body.
20 PC1250-8R
17. Disassembly of straight travel valve assembly Assembly

cover (33). 1. Assembly of straight travel valve
2) Remove plug (34). 1) Fit O-ring and plug (43), assemble to
3) Remove backup ring and O-ring (35) and spool (42), then insert together with spring
(36) from plug (34). (41) in valve body (4).
4) Loosen nut (46) and remove sleeve (47). 2) Fit O-ring to flanges (38) and (39), and
5) Remove plug (44), spring (48), and check tighten with mounting bolts (37) from left
valve (49) from sleeve (47). and right.
6) Remove backup ring and O-ring (45) and 2 Flange:
(50) from plug (44) and sleeve (47). Liquid sealant (Seal end 242)
7) Remove mounting bolts (37), then remove 3) Fit backup ring and O-ring (50) to sleeve
flanges (38), (39) and O-ring (40). (47), then assemble to valve body.
2 Sleeve:
8) Remove spring (41) and spool (42).
9) Remove plug (43) and O-ring (40) from Liquid sealant (Seal end 242)
3 Sleeve:
spool (42).
177 – 216 Nm {18 – 22 kgm}
4) Tighten nut (46) in sleeve (47).
3 Nut: 177 – 216 Nm {18 – 22 kgm}
5) Fit backup ring and O-ring (45) to plug
(44).
6) Insert check valve (49) and spring (48) in
sleeve (47), then assemble plug (44).
3 Plug: 29.4 – 39.2 Nm {3 – 4 kgm}
7) Fit backup ring, O-rings (35) and (36) to
plug (34), then insert in valve body (4).
8) Install cover (33), then install bolt (51).
2 Cover:
Liquid sealant (Seal end 242)
3 Bolt:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
9) Put cover (33) on valve body, fit washer to
bolt (32), then insert into valve body (4).
PC1250-8R 21
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).
177 – 196 Nm {18 – 20 kgm}
6. Install orifice (26).

3 Orifice: 127 – 177 Nm {13 – 18 kgm}
7. Install suction-safety valves (23), (24) and (25).

3 Suction-safety valve:
216 – 235 Nm {22 – 24 kgm}
8. Install suction valve (22).

3 Suction valve:
294 – 314 Nm {30 – 32 kgm}
12. Insert check valve (8) and spring (7) in valve

body (1).
13. Insert check valve (11), spring (10), and seat

(9) in valve body (1).
22 PC1250-8R
14. Fit O-rings (5) and (6) to straight travel valve

(4), and set to valve body (1).
15. Fit washers to mounting bolts (2) and (3) and

tighten.
a Tighten in the order shown in the diagram
below.
3 Mounting bolt (2) × 12:
78.5 – 98.1 Nm {8 – 10 kgm}
157 – 177 Nm {16 – 18 kgm}
PC1250-8R 23
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.
10. Remove bolt (14), then remove case (15),

springs (17) and (18), and retainer (19).
11. Pull out swing spool (23).
12. Remove bolt (14), then remove case (15), tube

(21), and retainer (19).
13. Pull out spool (24) for Bucket Plus.
14. Remove bolt (14), then remove case (15),

springs (17) and (18), and retainer (19).
15. Pull out spool (25) for Arm Plus.

each port of valve body (1). 16. Remove O-ring (16) from each case.
4. Remove spring (9), seat (10), and check valve

(11) from valve body (1).

valve body (1).
17. Remove 6 plugs (26) from valve body (1).
18. Remove O-ring (27) and backup ring and O-

ring (28) from plug (26).
19. Remove 2 suction-safety valves (29).
20. Remove orifice (30).
22. Remove main relief valve (32).
23. Remove plug (33).
24 PC1250-8R
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).
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).
flange (50) and O-ring (51).
2. Fit O-ring to plug (35) and install.

3 Plug: 58.8 – 78.5 Nm {6 – 8 kgm}
3. Fit backup ring and O-ring (34) to plug (33) and

install.
3 Plug: 118 – 162 Nm {12 – 16.5 kgm}
4. Install main relief valve (32).

3 Main relief valve:
275 – 368 Nm {28 – 37.5 kgm}
5. Install jet sensor relief valve (31).

177 – 196 Nm {18 – 20 kgm}
6. Install orifice (30).

3 Orifice: 127 – 177 Nm {13 – 18 kgm}
PC1250-8R 25
7. Install suction-safety valve (29).

3 Suction-safety valve:
216 – 235 Nm {22 – 24 kgm}
8. Fit O-ring (27) and backup ring and O-ring (28)

to plug (26), then install.
3 Plug: 177 – 196 Nm {18 – 20 kgm}
18. Assemble main relief valve in same way.
19. Insert check valve (8) and spring (7) in valve

body (1).
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.
10. Assemble retainer (19) and tube (20).
11. Fit O-ring (16) to case (15), and tighten with

bolt (14).
12. Assemble retainer (19) and springs (18) and

(17).
13. Fit O-ring to case (15) and tighten with bolt

(14).
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).
16. Assemble retainer (19) and springs (18) and

(17).
17. Fit O-ring (16) to case (15) and tighten with

bolt (14).
26 PC1250-8R
23. Fit washers to bolts (2) and (3), then tighten.

a Tighten in the order shown in the diagram
below.
78.5 – 98.1 Nm {8 – 10 kgm}
157 – 177 Nm {16 – 18 kgm}
PC1250-8R 27
Removal and installation of swing a Front of chassis

motor assembly 1
1. Disconnect hoses (9) and (10) coming from
Serial number: 35001 – 35016 swing motor at center of chassis.
Removal 2. Disconnect drain hose (11).

and stop the engine. Then loosen the oil 3. Disconnect swing brake release hose (12).
filler cap slowly to release the pressure
inside the hydraulic tank. 4. Disconnect hose (13) going to boom LOWER
regeneration valve.
a Center of chassis
5. Disconnect drain hose (14) from control valve.
1. Disconnect swing motor hose clamp (1).
6. Remove mounting bolts (15), then lift off swing
2. Disconnect hoses (2) and (3) going to the motor assembly (16).
swing motor on the front side of the machine 4 Swing motor assembly: 126 kg
body.
4. Disconnect hose (5) coming from the control

valve.

motor assembly (8).
28 PC1250-8R
Installation
removal.
a If the mounting bolt holes of the motor installed

later are not aligned, remove plug [1] for
releasing the brake and apply oil pressure.

a Add oil through the oil filler to the specified
through the system. Then, check the oil level
again.
a Add new oil by the quantity of the oil that
leaked when the motor assembly was
removed.
PC1250-8R 29
Serial number: 35017 and up a Front of chassis
Removal 1. Disconnect hoses (9) and (10) coming from

k Lower the work equipment to the ground swing motor at center of chassis.
and stop the engine. Then loosen the oil
filler cap slowly to release the pressure 2. Disconnect drain hose (11).
inside the hydraulic tank.
a Center of chassis
4. Disconnect hose (13) going to boom LOWER
1. Disconnect swing motor hose clamp (1). regeneration valve.
2. Disconnect hoses (2) and (3) going to the 5. Disconnect drain hose (14) from control valve.
swing motor on the front side of the machine
body. 6. Remove mounting bolts (15), then lift off swing
motor assembly (16).
4
3. Disconnect drain hose (4). Swing motor assembly: 105 kg
4. Disconnect hose (5) coming from the control
valve.

motor assembly (8).
30 PC1250-8R
Installation
removal.
a If the mounting bolt holes of the motor installed

later are not aligned, apply oil pressure
through port (B) used to release the brake.

through the system. Then, check the oil level
again.
a Add new oil by the quantity of the oil that
leaked when the motor assembly was
removed.
PC1250-8R 31
Removal and installation of center

swivel joint assembly 1
Removal
and stop the engine. Then loosen the oil
filler cap slowly to release the pressure
inside the hydraulic tank.
1. Disconnect piping and wiring crossing at top of

center swivel joint.
2. Disconnect hose (1) between swivel joint bot-

tom – L.H. and R.H. travel motors.
3. Disconnect travel speed selector hose (2) 11. Disconnect hose (15) between the travel
between swivel joint bottom and L.H. and R.H. speed selector solenoid valve and swivel joint.
travel motors.
12. Disconnect inside and outside swing motor
4. Disconnect tubes (3) and (4) between swivel drain hoses (16) and (17).
joint bottom and L.H. travel motor.
a Remove the clamps. 13. Lift off center swivel joint assembly (18).
4 Center swivel joint assembly: 70 kg
5. Disconnect tubes (5) and (6) between swivel
joint bottom and R.H. travel motor.
a Disconnect the clamps.
Installation
6. Disconnect swing motor hoses (7) and (8) from removal.
the upper part of the center swivel joint.
a Add oil to replace the oil that leaked out during
7. Disconnect hoses (9) and (10) between the 4- the removal operation.
spool control valve and swivel joint.
8. Disconnect hoses (11) and (12) between the 5-

spool control valve and swivel joint.
9. Disconnect hose (13) going to the filter.
10. Remove the pin of stopper link (14).
32 PC1250-8R

center swivel joint assembly 1 1
Special tools
2
Necessity
Symbol
Sketch
Q’ty
3
N/R
790-101-2501 Push-puller t 1
790-101-2510 • Block t 1 4
790-101-2520 • Screw t 1
791-112-1180 • Nut t 1
T 790-101-2540 • Washer t 1
7
790-101-2630 • Leg t 2
790-101-2570 • Plate t 2
790-101-2560 • Nut t 2 6
790-101-2660 • Adapter t 2
Disassembly 5
2. Remove snap ring (2). CEP00381
3. Using push-puller (T), pull out swivel rotor (4)

and ring (3) from swivel shaft (5).
4. Remove O-rings (6) and slipper seals (7) from

swivel rotor (4).
PC1250-8R 33
Assembly
1. Assemble slipper seals (7) and O-rings (6) to 1
swivel rotor.
2. Set swivel shaft (5) on block [2], then using 2

push tool [1], tap swivel rotor (4) with a plastic
hammer to install. 3
2 Contact surface of rotor, shaft:
Grease (G2-LI)
a When installing the rotor, be extremely
4
careful not to damage the slipper seal and
O-ring.
CEP00381
3. Install ring (3) and secure with snap ring (2).
4. Fit O-ring and install cover (1).

3 Mounting bolt:
66.15 ± 7.35 Nm {6.75 ± 0.75 kgm}
34 PC1250-8R
Removal and installation of travel 5. Remove mounting bolts on diagonally opposite

motor assembly 1 sides, set guide bolts J9 in position, then lift off
travel motor assembly (5).
Special tool a Set guide bolts in position, sling the travel
motor, then remove the mounting bolts,
New/Remodel
and use forcing screws to pull out the
Necessity
motor assembly.
Symbol
Sketch
Q'ty
4 Travel motor assembly: 60 kg
J 9 796-660-1560 Guide bolt t 2
Removal
k Swing the work equipment 90º, then lower it
completely to the ground and stop the
engine.
k Loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
Installation
removal.
a Be sure to install the thrust rings and O-rings.
2. Disconnect travel speed selector hose (2).
4. Disconnect hoses (4) coming from control

valve.
PC1250-8R 35

work equipment PPC valve
assembly 1
Disassembly
1. Remove nut (1), then remove disc (2) and boot

(3).
2. Remove bolts, then remove plate (5).

a Do not remove joint (4) unless it is to be
replaced.
3. Remove seal (6) and collar (7).
4. Pull out piston (8), then remove retainer (9),

springs (10) and (11), and shim (12).
a Spring (10) consists of 2 each of 2 types of
springs with different installed loads, so
check the mounting position (oil pressure
port) and mark with tags to prevent mis-
takes when installing.
5. Pull out valve (13) from body (14).
36 PC1250-8R
Assembly
1. Assemble valve (13) to body (14).
2. Assemble shim (12) and spring (11) to valve

(13).
a When assembling spring (11), set the end
with the small coil diameter (inside diame-
ter) at shim (12) end.
3. Assemble spring (10), retainer (9), and piston

(8).
a The number of loops in the coil for spring
(10) is different for each of the hydraulic
ports below, so be careful when installing.
Position of port Free length of spring (mm)
P1, P2 38.71
P3, P4 42.48
a The position of each port is marked on the

bottom of the valve body.
2 Piston: Grease (G2-LI)
a When assembling piston (8), coat the out-
side of the piston and the inside of the
hole in the body with grease.
4. Fit O-ring to collar (7) and assemble in body

(14), then install seal (6).
5. Install plate (5).

3 Mounting bolt:
13.23 ± 1.47 Nm {1.35 ± 0.15 kgm}
6. Install joint (4).

2 Rocking portion of joint: Grease (G2-LI)
2 Female thread of body:
Thread tightener (LT-2)
a Coat 2 places on the female thread with
one drop each of Loctite as shown in the
diagram on the right
3 Joint: 44.1 ± 4.9 Nm {4.5 ± 0.5 kgm}
a Keep strictly to the tightening torque for
the joint.
7. Assemble boot (3) and disc (2), and tighten

with nut (1).
3 Nut: 112.7 ± 14.7 Nm (11.5 ± 1.5 kgm)
a After assembling the disc, adjust the
height of the disc.
“Adjusting work equipment, swing PPC
valve”.
PC1250-8R 37

travel PPC valve assembly 1
Disassembly
1. Remove screws (1), then remove levers (2).
2. Remove mounting bolts (3), then remove case

and shaft assembly (4).
3. Remove 4 mounting bolts (5), then remove

plate and damper assembly (6).
a Check the thickness and mounting posi-
tion of washer (7).
4. Remove mounting bolts (8), then remove

damper assembly (9) from plate (10).
5. Remove seal (11) and collar (12).
6. Pull out piston (13), then remove retainer (14),

springs (15) and (16), and shim (17).
a Check the number and thickness of shim
(17) for each mounting position, and keep
in sets in a safe place.
7. Remove valve (18) from body (19).
8. Disassembly of case and shaft assembly

1) Kock pin (20) into shaft, and remove shaft
(21).
2) Remove lever (22).
3) Pull out pin (20) from shaft (21).
38 PC1250-8R
Assembly 8. Install levers (2) and tighten screws (1).

1. Assemble valve (18) in body (19) 2 Rocking portion of lever pin and plate:
Grease (G2-LI)
2. Assemble shim (17) and spring (16) to valve 3 Screw: 8.82 ± 0.98 Nm {0.9 ± 0.1 kgm}
(18).
a Check the number and thickness of shim
(17) for each mounting position, and
assemble in the same position as before
disassembly.
Standard thickness of shim: 0.3 mm
a The top and bottom of spring (16) are not
symmetrical, so set the small coil diameter
(inside diameter) at the shim end when
assembling.
3. Assemble spring (15), retainer (14), and piston

(13).
2 Outside circumference of piston, hole in
body: Grease (G2-Ll)
4. Fit O-ring to collar (12) and assemble in body

(19), then install seal (11).
5. Install damper assembly (9) to plate (10) and

3 Mounting bolt:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}
6. Install plate and damper assembly (6), and

a Temporarily assemble a standard washer
(1.6 mm) for washer (7).
After the completion of assembly, mea-
sure the difference in the angle when the
left and right levers are operated fully. If
the difference in angle is greater than 0.7°,
change the thickness of washer (7) to
make the difference less than 0.7°.
q Thickness of washer: 1.0. 1.3, 1.6 mm
a If the thickness of the washer is
reduced by 0.3 mm, the angle when
the lever is fully operated will be
increased by 0.39°.
3 Mounting bolt:
30.87 ± 3.43 Nm {3.15 ± 0.35 kgm}
7. Install case and shaft assembly (4) and tighten

mounting bolts (3).
2 Rocking portion of shaft, connection of
lever and piston: Grease (G2-LI)
3 Mounting bolt:
27.93 ± 3.43 Nm {2.85 ± 0.35 kgm}
PC1250-8R 39
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1
1. Piston rod assembly
Backhoe specification 1) Secure bottom end of cylinder assembly
(1) with tool U1 or press, then remove
Special tools mounting bolts, and disconnect head
assembly (2).
New/Remodel
Necessity
Bolt width across flats Unit mm
Symbol
Sketch
Q’ty
Part number Part name Cylinder Boom Arm Bucket
PC1250 46 50 30
1 790-502-1003 Repair stand q 1 2) Pull out piston rod assembly (3).

2 790-720-1000 Expander t 1 a Place a container under the cylinder
796-720-1680 Ring t 1 to catch the oil.
07281-01589 Clamp t 1
796-720-1710 Ring t 1
3
07281-02709 Clamp t 1
796-720-1720 Ring t 1
07281-02429 Clamp t 1
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
790-201-1861 • Push tool t 1
4
790-201-1881 • Push tool t 1
U
792-103-4102 Push tool t 1
790T-201-4010 Push tool t 1 N Q
790T-201-4020 Push tool t 1 N Q
790-101-5021 • Grip t 1
01010-50816 • Bolt t 1
790-201-1690 • Push tool t 1
5
790-201-1670 • Plate t 1
790-201-1920 Push tool t 1
792-715-1400 Push tool t 1
790T-201-4110 Plate t 1 N Q
790-102-4300 Wrench assembly t 1
6
790-102-4310 Pin t 2
40 PC1250-8R
3) Fix the head side of piston rod assembly q Arm cylinder

(3) with tool U1 or a press. 1) Remove bolts (7), piston assembly (26),
and spacer (8).
2) Remove pin (27), 10 balls (5), and plunger
(6).
3) Remove piston assembly (9), O-ring, and
backup ring (10).
4) Remove plunger (11).
2. Piston assembly
q Boom cylinder and bucket cylinder (Loading
shovel specification)
1) Remove bolts (7), piston assembly (9),
and spacer (8).
2) Remove the O-ring and backup ring (10).
3) Remove plunger (11). 5) Disassembly of piston assembly (26).
i) Remove ring (12).
ii) Remove wear ring (13).
4) Disassembly of piston assembly.

i) Remove rings (12).
ii) Remove wear rings (13). 6) Disassembly of piston assembly (9).
iii) Remove piston ring (14). i) Remove ring (12).
ii) Remove wearing rings (13).
iii) Remove piston ring (14).
PC1250-8R 41
q Bucket cylinder (Backhoe specification) 2) Using tool U6, remove piston assembly
The whole figure. (9).
a See the following items about the number. q When not using tool U6, use the drill
holes (H) (2 places) and loosen the
piston assembly.
a Drill holes: ø10 mm
1) Remove piston assembly stopper screw

(30).
Screw size:
M12 × pitch 1.75 3) Remove cap (4), 12 balls (5), and plunger
(6).
4) Remove plunger (11).
a If screw (30) has been punched

strongly and cannot be removed,
screw it in fully, then fit a tap to the 5) Disassembly of piston assembly
thread and pull it out. i) Remove rings (12).
ii) Remove wear rings (13).
iii) Remove piston ring (14).
iv) Remove the O-ring and backup ring
(31).
42 PC1250-8R
q Bottom dump cylinder 3. Collar assembly and head assembly

1) Remove screw (30) and piston assembly 1) Remove collar assembly (15) from piston
(9) referring to “bucket cylinder (backhoe rod (3).
specification)”. a Except for bucket cylinder (loading
2) Remove plunger (11). shovel specification)
2) Remove head assembly (2).
3) Disassembly of piston assembly

i) Remove rings (12). 3) Disassembly of head assembly
ii) Remove wear rings (13). i) Remove the O-ring and backup ring
iii) Remove piston ring (14). (20).
iv) Remove the O-ring and backup ring ii) Remove snap ring (21) and dust seal
(31). (22).
iii) Remove rod packing (23).
iv) Remove backup ring (24).
v) Remove bushing (25).
PC1250-8R 43
4) Disassembly of collar assembly Assembly

q Bucket cylinder (backhoe specification) a Take care not to damage the packings, dust
and bottom dump cylinder seals, O-rings, etc.
i) Remove the O-ring and backup ring a Do not fit the backup rings forcibly. Warm them
(16). in water of about 50 – 60°C before fitting them.
ii) Remove ring (18) and collar (19) from
collar (17). 1. Assembly of head assembly
1) Using tool U4, press fit bushing (25).
2) Fit backup ring (24).
3) Fit rod packing (23).
4) Using tool U5, fit dust seal (22) and fix it
with snap ring (21).
5) Fit the O-ring and backup ring (20).
q Arm cylinder and boom cylinder

i) Remove ring (18) from collar (17).
44 PC1250-8R
2. Assembly of collar assembly 3. Assembly of piston assembly

1) Fit rings (19) and (18) to collar (17). 1) Using tool U2, expand piston ring (14).
a Fit ring (19) to only the bucket cylin- a Set the piston ring to tool U2 and
der (backhoe specification) and bot- rotate the handle 8 – 10 turns to
tom dump cylinder. expand the piston ring.
2) Fit the O-ring and backup ring (16). 2) Fit piston ring (14) to the piston.
a Fit the O-ring and backup ring (16) to 3) Set tool U3 and tighten piston ring (14).
only the bucket cylinder.
q Bucket cylinder and bottom dump cylinder
4) Fit wear rings (13) to piston (9).

5) Fit rings (12).
q Boom cylinder and arm cylinder a Fit only 1 ring (12) to the arm cylinder.
a Take care not to open the closed gap
too much.
2 Ring groove: Grease (G2-LI)
6) Fit the O-ring and backup ring (31).
a Bottom dump cylinder and bucket cyl-
inder only.
q Except for bucket cylinder (backhoe

specification) and bottom dump cylin-
der
PC1250-8R 45
q Bottom dump cylinder 5. Assembly of piston assembly

q Boom cylinder and bucket cylinder (loading
shovel specification)
1) Install plunger (11), O-ring, and backup
ring (10).
2) Install piston assembly (9) and spacer (8)
and tighten bolts (7).
a Clean and degrease the bolts and
bolt holes and apply “hardening
accelerator” to them.
2 Bolt: Adhesive LOCTITE 262
3 Bolt: 277 ± 32 Nm {28.25 ± 3.25 kgm}
q Bucket cylinder (backhoe specification)
q Arm cylinder
1) Install plunger (11), O-ring, and backup
ring (10).
2) Set plunger (6) to the piston rod and install
balls (5) and pin (27).
4. Piston rod assembly a When installing 10 balls (5), count
1) Fix the head side of the piston rod to tool them.
U1 or a press. a After installing the pin, check that the
2) Install head assembly (2) to the rod. plunger end has play.
3) Install collar assembly (15). 3) Install piston assembly (9), spacer (8), and
a Except for bucket cylinder (loading piston assembly (26) and tighten bolts (7).
shovel specification). a Clean and degrease the bolts and
bolt holes and apply “hardening
accelerator” to them.
2 Bolt: Adhesive LOCTITE 262
3 Bolt:
277 ± 32 Nm {28.25 ± 3.25 kgm}
46 PC1250-8R
q Bucket cylinder (backhoe specification) and q When using a new part for either or
bottom dump cylinder both of piston rod assembly (3) or pis-
1) Install plunger (11) to piston rod. ton assembly (9)
2) Set plunger (6) to the piston rod, install a For the rod with bottom cushion,
balls (5) and cap (4). mark the drill hole position on the
a Bucket cylinder (backhoe specifica- end face of the rod.
tion) only (See the item of 2))
a When installing 12 balls, count them. 1] Screw in until piston assembly
a Put a mark on the end surface of the (9) contacts end face of rod, then
rod so that the machined hole posi- use tool U6 to tighten.
tion on cap (4) can be identified from 3 Piston assembly (4):
outside. 294 ± 29.4 Nm {30 ± 3.0 kgm}
a After installing, check that the cushion a After tightening the piston,
plunger end has a little play. check that there is play in
plunger (11).
3) Assemble piston assembly (9) as follows.

q When using piston rod assembly (3)
and piston assembly (9) again
a Wash thoroughly and remove all
metal particles and dirt.
1] Screw in piston assembly (9),
then use tool U6 to tighten piston
assembly (9) so that position of
scr ew thread hole on piston
assembly (9) and piston rod
assembly (3) matches.
a Remove all burrs and flashes
with a file.
PC1250-8R 47
2] Machine one hole used to install 6. Cylinder assembly

screw (30). 1) Fix the bottom side of cylinder assembly
a Apply the drill to the V-groove (1) with tool U1 or a press.
between piston (9) and 2) Install the piston rod assembly.
threaded part of rod (3), and 2 Sealing part: Grease (G2-LI)
make a hole horizontally. a When inserting the piston rod assem-
a For the cylinder with bottom bly, set the closed gaps of the rings
cushion (bucket cylinder horizontally (to the sides of the piston
(backhoe specification)), rod assembly) and align the piston
avoid the drill hole position rod with the cylinder tube.
when machining. a After inserting the piston rod assem-
q Screw machining dimension bly, check that the rings are not bro-
(mm) ken or removed, and then push in the
piston rod assembly to the end.
Bottom
Cylinder Drill hole Tap Tap
diameter depth used depth
Bucket 10.3 36 12 × 1.75 29

Bottom
10.3 24 12 × 1.75 20
dump
3] After machining, wash thor-

oughly to remove all metal parti-
cles and dust.
4) Tighten screw (30).
2 Threaded part: Thread tightener
(Locktite No. 262 or equivalent)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
(boom)
5) Punch thread at 4 places (a) of screw (30). 3) Secure head assembly (2) with the mount-
ing bolts.
3 Mounting bolt:
Cylinder Tightening torque

Boom 1.67 ± 0.25 kNm {170 ± 25 kgm}
Arm 2.11 ± 0.34 kNm {215 ± 35 kgm}
Bucket
(backhoe
529.7 ± 78.5 Nm {54 ± 8 kgm}
specification),
bottom dump
Bucket
(loading shovel 1.27 ± 0.2 kNm {130 ± 20 kgm}
specification)
48 PC1250-8R
PC1250-8R 49
SEN02790-01

© 2007 KOMATSU
All Rights Reserved
50
SEN02791-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Work equipment
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
Removal and installation of bucket assembly ............................................................................................... 16
Removal and installation of arm assembly ................................................................................................... 20
Removal and installation of boom assembly................................................................................................. 23
PC1250-8R 1
Removal and installation of 2. Disconnect 2 left and right cylinder bottom

bucket cylinder assembly 1 grease hoses (3).
Backhoe specification 3. Disconnect right cylinder bottom hose (4) and

head hose (5).
Removal
k Set mounting pin (1) and link (2) at the 4. Disconnect left cylinder bottom hose (6) and
bucket cylinder rod end to a position where head hose (7).
there is no interference, then set the back a If there is remaining pressure in the
face of the bucket on a block. hydraulic circuit, the oil may spurt out, so
k Lower the work equipment completely to check while disconnecting.
the ground and stop the engine. Operate a Plug the hose to stop oil flow-out.
the control levers several times to release
the remaining pressure in the hydraulic pip-
ing.
1. Remove stopper, then remove rod pin (1) from

link (2). [*1]
a After removing the pin, start the engine, and
retract the piston rod, then tie the piston rod
with wire to prevent it from coming out.
a Extend the arm and set block [1] between
the cylinder and the arm.
a The bucket and link are still installed, so
be careful when extending the arm.
a There are shims installed, so check the 5. Sling right bucket cylinder assembly (8) and
number and thickness, and keep in a safe remove lock plate (9), then remove pin (10).
place. [*2]
a Pull out pin (10) to a position where the
right cylinder comes off.
a There are shims installed, so check the
number and thickness, and keep in a safe
place.
6. Lift off right bucket cylinder assembly (8).
7. Remove the cylinder assembly on the left side

in the same way.
4 Bucket cylinder assembly: 700 kg
2 PC1250-8R
Installation q Bleeding air

q Carry out installation in the reverse order to a Bleed the air.
removal. For details, see Testing and adjusting,
“Bleeding air from each part”.
[*1]
2 Inside surface of bushing when assembling q Refilling with oil (hydraulic tank)
pin: Anti-friction compound (LM-P) a Add oil through the oil filler to the specified
2 Grease after assembling pin: Grease (LM-G) level. Run the engine to circulate the oil
k When aligning the position of the pin hole, through the system. Then check the oil
never insert your fingers in the pin hole. level again.
a Adjust with shims so that clearance (a)
between link (2) and the end face of the head
of cylinder (8) is 2 – 3 mm.
q Shim thickness: 0.8 mm (STD)
1.0 mm (SP)
[*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)
PC1250-8R 3
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
levers several times to release the remain-
ing pressure in the hydraulic piping.
1. Sling bucket cylinder assembly, and remove

lock plate, then using forcing screws (Thread
dia. = 24 mm, Pitch = 3.0 mm), remove rod pin
(1). [*1]
4 Pin: 42.9 kg
6. Raise bucket cylinder assembly (7) carefully
and remove.
2. Start engine and retract piston rod fully.
3. Disconnect grease hose (2).
4. Disconnect bucket cylinder hose (3).

a If there is remaining pressure in the
hydraulic circuit, the oil may spurt out, so
check while disconnecting.
a Plug the hose to stop oil flow-out.
4 PC1250-8R
Installation
removal.
[*1] [*2]
never insert your fingers in the hole.
q Bleeding air
a For details, see Testing and adjusting,

a Add oil through oil filler to the specified
through the system. Then check the oil
level again.
PC1250-8R 5
Removal and installation of 4. Remove hose (3).

bottom dump cylinder assembly 1 a If there is remaining pressure in the
Loading shovel check while disconnecting.
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.
2. Sling bottom dump cylinder assembly, and

remove lock plate, then using forcing screws
(Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (2). [*1]
5. Remove 3 mounting bolts, then using forcing

screws (Thread dia. = 16 mm, Pitch = 2.0 mm),
pull out pin (4). [*2]
4 Pin: 23.1 kg
6. Lift off bottom dump cylinder assembly (5).

4 Bottom dump cylinder assembly: 194 kg

k After stopping the engine, release the
pressure inside the piping by operating
the control levers several times.
“Releasing pressure in PPC circuit”.
6 PC1250-8R
Installation
removal.
[*1]
k When aligning the mounting position of the
pin, do not insert your fingers in the pin
hole.
[*2]
hole.
q Bleeding air
a Bleed the air from the work equipment cir-
cuit. For details, see Testing and adjust-
ing, “Bleeding air from each part”.

a Add oil to the specified level, and run the
engine to circulate the oil through the sys-
tem. Then check the oil level again.
PC1250-8R 7
Removal and installation of arm 5. Disconnect bottom grease hose (5).

cylinder assembly 1
6. Remove lock plate, then remove pin (6). [*2]
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
ing pressure in each cylinder.
1. Disconnect piston rod grease hose (1).
2. Remove lock plate, then remove piston rod pin

(2). [*1]
a Sling arm cylinder assembly (7).

place.
7. Lift off arm cylinder assembly (7).

4 Arm cylinder assembly: 610 kg
a Set block [2] between the arm cylinder

and the boom.
3. Disconnect 2 bottom hoses (3).
4. Disconnect head hose (4).

8 PC1250-8R
Installation
removal.
[*1]
[*2]
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.

level again.
PC1250-8R 9
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. a If there is remaining pressure in the
Operate the control levers several times to hydraulic circuit, the oil may spurt out, so
release the remaining pressure in the check while disconnecting.
hydraulic piping. a Plug the hose to stop oil flow-out.
the pressure inside the hydraulic tank. 5. Sling piston rod end and bottom end, and
remove plate, then using forcing screws
1. Disconnect grease tube (1) at piston rod end. (Thread dia. = 16 mm, Pitch = 2.0 mm), pull out
pin (4). [*2]
a Pull out the pin to a position where the cyl-
inder bottom can be disconnected.
4 Pin: 24.2 kg
2. Sling arm cylinder assembly, and remove

plate, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), pull out pin (2). [*1]
a Pull out the pin to a position where the pis-
ton rod can be disconnected. 6. Lift off arm cylinder assembly (5) carefully.
4 Pin: 24.2 kg 4 Arm cylinder assembly: 602 kg
10 PC1250-8R
Installation
removal.
[*1]
hole.
[*2]
hole.
a Adjust with shims so that the clearance at the
cylinder bottom end is less than 1 mm.
q Bleeding air
a Bleed the air from the work equipment cir-
cuit. For details, see Testing and adjust-
ing, “Bleeding air from each part”.

a Add oil to the specified level, and run the
engine to circulate the oil through the sys-
tem. Then check the oil level again.
PC1250-8R 11
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.
Removal 5. Disconnect head hose (4).

k Retract the arm and bucket cylinder rods a If there is remaining pressure in the
fully; lower the work equipment completely hydraulic circuit, the oil may spurt out, so
to the ground, and put the lock lever in the check while disconnecting.
LOCK position. a Plug the hose to stop oil flow-out.
k Stop the engine and operate the control
levers several times to release the remain- 6. Disconnect bottom hose (5).
ing pressure in the hydraulic circuit. a If there is remaining pressure in the
1. Disconnect grease hose (1). check while disconnecting.
2. Remove lock plate, then remove pin (2). [*1]
a Sling the boom cylinder assembly.
3. Retract rod (3).
7. Sling boom cylinder assembly (7) and remove

lock plate, then remove pin (6). [*2]
a Use forcing screws when removing.
8. Lift off boom cylinder assembly (7).

4 Boom cylinder assembly: 1,049 kg
12 PC1250-8R

q Carry out installation in the reverse order to a Bleed the air.
removal. For details, see Testing and adjusting,
[*1]
2 Inside surface of bushing when assembling q Refilling with oil (hydraulic tank)
pin: Anti-friction compound (LM-P) a Add oil through the oil filler to the specified
2 Grease after assembling pin: Grease (LM-G) level. Run the engine to circulate the oil
k When aligning the position of the pin hole, through the system. Then check the oil
never insert your fingers in the pin hole. level again.
[*2]
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
PC1250-8R 13
Removal and installation of boom 5. Lower boom cylinder assembly onto stand,
cylinder assembly 1 then disconnect hoses (4).
Loading shovel hydraulic circuit, the oil may spurt out, so
Removal a Plug the hose to stop oil flow-out.
k Extend the arm and bucket fully, lower the
work equipment completely to the ground
ing pressure in the hydraulic piping.
1. Disconnect grease hoses (1).
2. Remove plate (2).
3. Sling boom cylinder assembly, then using forc-

ing screws (Thread dia. = 16 mm, Pitch = 2.0
mm), pull out pin (3), and disconnect piston rod
from boom. [*1] 6. Sling boom cylinder assembly, and remove
plate, then using forcing screws (Thread dia. =
16 mm, Pitch = 2.0 mm), pull out foot pins (5).
[*2]

k Tie the rod with wire to prevent it from
coming out.
k After stopping the engine, release the
7. Remove boom cylinder assembly (6).
pressure inside the piping. 4 Boom cylinder assembly: 1,073 kg
“Releasing pressure in PPC circuit”.
14 PC1250-8R

q Carry out installation in the reverse order to a For details, see Testing and adjusting,
removal. “Bleeding air from each part”.
[*1] q Refilling with oil (hydraulic tank)

2 Inside surface of bushing when assembling a Add oil through oil filler to the specified
pin: Anti-friction compound (LM-P) level. Run the engine to circulate the oil
2 Grease after assembling pin: Grease (LM-G) through the system. Then check the oil
k When aligning the position of the pin hole, level again.
[*2]
between bracket (6) and the bottom end face
of boom cylinder (5) is less than 1 mm.
PC1250-8R 15

bucket assembly 1
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.
1. Remove 3 link pin lock bolts (2) of bucket (1),

then remove stopper (3).
5. Remove connecting pin (9) between arm and

bucket. [*2]
a If it is difficult to remove the pin, move the
arm up and down a small amount to find a
position where it is easier to remove the
pin.
6. Remove 4 cover lock bolts (8) and cover (10)

from bucket (1), then remove shims (11), bush-
ing (12), and O-ring (13).
2. Remove link pin (4). [*1] place.
a If it is difficult to remove the pin, raise the 7. Start engine, then raise work equipment to dis-
bucket and move it backward and forward connect arm (14) from bucket.
to find a position where it is easier to 4 Bucket assembly: 4,600 kg
remove the pin.
a If the bucket is not in contact with the
ground, set a block under the back face of
the bucket.
a After removing the pin, retract the bucket
cylinder and lift up link (5).
3. Remove 3 lock bolts (6) of connecting pin

between arm and bucket, then remove stopper
(7).
4. Loosen 4 cover lock bolts (8).
16 PC1250-8R
Installation
removal.
[*1]
[*2]
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).
PC1250-8R 17
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.
1. Disconnect covers (1).
2. Disconnect bottom dump cylinder hoses (2).

5. Lift off bucket assembly (7).
4 Bucket assembly: 9,730 kg
3. Sling bucket cylinder assembly, and remove

plate (3), then pull out bottom pin (4).
a Remove the pin on the other side in the
same way. [*1]
4 Pin: 50 kg
18 PC1250-8R
Installation
removal.
[*1] [*2]
q Bleeding air
a Bleed the air.

level again.
PC1250-8R 19
Removal and installation of arm 5. Sling arm assembly (6) and remove pin (5). [*2]
assembly 1 a If it is difficult to remove the pin, use tool V4.
Backhoe specification 6. Lift off arm assembly (6).

4 Arm assembly: 4,000 kg
Special tools
New/Remodel
Necessity
Symbol
Sketch
Q’ty
796T-870-1150 Sleeve t 1 Q
790-438-1110 Screw t 1
796-775-1110 Adapter t 1
791-112-1180 Nut t 1
V 4
790-101-2540 Washer t 1
Puller
790-101-2102 t 1
(490 kN {50 tons})
Installation
Removal removal.
1. Remove bucket assembly. [*1]

bucket assembly”. pin: Anti-friction compound (LM-P)
a Secure the bucket link to the arm.
2. Disconnect grease hose (1). never insert your fingers in the pin hole.
3. Disconnect 4 bucket cylinder hoses (2). [*2]

a Disconnect at the tip of the boom.
4. Sling arm cylinder assembly (3) and remove
pin (4). [*1]
a When you put arm cylinder down, set never insert your fingers in the pin hole.
block between the arm cylinder and the a Adjust with shims so that clearance (a)
boom at (P). between the end face of the bottom of arm (6)
and boom (7) is less than 1 mm.
q Shim thickness: 1.0 mm
20 PC1250-8R
q Bleeding air
a Bleed the air.

level again.
PC1250-8R 21
Removal and installation of arm

assembly 1
Loading shovel
Removal
1. Remove bucket assembly.

bucket assembly”.
2. Start engine, and set work equipment so that

bucket cylinder is perpendicular.
3. Disconnect 2 bottom cylinder hoses (1).
4. Remove bucket cylinder hose bracket (2) from Installation

arm (Do not disconnect the hose). q Carry out installation in the reverse order to
removal.
5. Disconnect arm cylinder from arm.
For details, see “Removal and installation of [*1]
arm cylinder assembly”.
a Secure the arm cylinder assembly to the pin: Anti-friction compound (LM-P)
boom with lever block.
6. Sling arm assembly, and remove 3 mounting never insert your fingers in the hole.
bolts, then using forcing screws, pull out pin
(3). [*1] q Bleeding air
a For details, see Testing and adjusting,
4 Pin: 80.6 kg “Bleeding air from each part”.
7. Lift off arm assembly (4). q Refilling with oil (hydraulic tank)
4 Arm assembly: 4,970 kg level. Run the engine to circulate the oil
level again.
22 PC1250-8R
Removal and installation of boom

assembly 1
Special tools
Necessity
Symbol
Q’ty
790-445-4120 Sleeve t 1
790-445-4140 Screw t 1
02215-11622 Nut t 1
V 2 01643-32780 Washer t 1
5. Disconnect wiring connector (4) for working
Puller
790-101-4200 t 1 lamp.
(294 kN {30 tons})
6. Sling boom assembly (7).
7. Remove lock plate (5).

Removal 8. Using tool V2, remove boom foot pins (6). [*2]
1. Remove arm assembly.
arm assembly”.
2. Set tip of boom on support [1] and stop engine,

then operate boom control lever to release any
remaining pressure in boom cylinder.
9. Lift off boom assembly (7) slowly.

a Boom assembly (7) will rock when the
crane is operated, so fit rope [2] to the tip
of the boom and apply tension to control
the boom and prevent it from rocking.
4 Boom assembly: 11,500 kg
3. Sling boom cylinder (1) and remove pin (2).[*1]

a Lower the boom cylinder slowly and insert
a wedge between the cylinder bottom and
the frame.
4. Disconnect 7 hoses (3) for bucket and arm.
PC1250-8R 23
Installation
removal.
[*1]
[*2]
between the end face of the foot of boom (7)
and bracket (8) is less than 1 mm.
q Bleeding air
a Bleed the air.

level again.
24 PC1250-8R
Removal and installation of boom

assembly 1 5. Disconnect bottom dump cylinder hoses (3),
bucket cylinder hoses (4), and arm cylinder
Loading shovel hoses (5).
a When the hoses are disconnected, oil may
Removal spurt out, so loosen the hose flanges
slowly before disconnecting.
1. Remove arm assembly.
For details, see “Removal and installation of 6. Disconnect grease hose, tube and head lamp
arm assembly”. harness (6).
2. Sling bucket cylinder assembly (1), remove

lock plate, then using forcing screws, pull out
rod pin (2), and remove bucket cylinder
assembly. [*1]
4 Pin: 42.9 kg
a Remove the bucket cylinder on the other
side in the same way.
7. Remove lock plate, and using forcing screws

(Thread dia. = 24 mm, Pitch = 3.0 mm), pull out
left and right boom foot pins (12), then lift off
boom (13). [*2]
a Check the number and thickness of the
shims, and keep in a safe place.
4 Boom: 6,190 kg
3. Sling boom, set stand [1] at tip of boom to sup-

port boom.
4. Disconnect boom cylinder from boom.

boom cylinder assembly”.
a Disconnect the boom cylinder on the other
side from the boom in the same way.
PC1250-8R 25
Installation
removal.
[*1] [*2]
between bracket (14) and the end face of the
foot of boom (13) is less than 1 mm.
q Bleeding air
For details, see Testing and adjusting, “Bleed-
ing air from each part”.

level again.
26 PC1250-8R
PC1250-8R 27
SEN02791-00

© 2007 KOMATSU
All Rights Reserved
28
SEN02792-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Cab and its attachments
Removal and installation of operator cab assembly ....................................................................................... 2
Removal and installation of operator’s cab glass (Stuck glass) ...................................................................... 5
Removal and installation of front window assembly ..................................................................................... 15
PC1250-8R 1
Removal and installation of 8. Disconnect clamp (9).

operator cab assembly 1
9. Disconnect circuit breaker bracket (10).
Removal
k Disconnect the negative (–) terminal of the 10. Remove cover (11).
battery beforehand.
1. Remove plate (1).
2. Remove floor mat (2).
3. Remove bottom cover (3) of the monitor panel.

a When removing cover (3), disconnect cig-
arette lighter wiring M19 and then remove
the cover.
4. Remove bottom cover (4) of seat.
5. Pull lever (B) and lever (R) situated at the bot-

tom of the seat to draw the seat forward.
a Remove duct mounting bolt (40) situated
in the front side of duct (13).
a Provide some play to duct (13).
12. Remove duct (13) on the right side.
13. Remove cab wiring intermediate connectors

M71 (14), H10 (15), H11 (16) and H12 (17).
6. Remove rear covers (5) – (7).
2 PC1250-8R
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
21. Disconnect radio antenna (28).
16. Remove left plates (20) and (21).
17. Remove ducts (22) and (23).
22. Disconnect window washer hose (29).
23. Remove 5 mounting bolts (30).

a Confirm the bolt length.
24. Remove 5 mounting nuts (31).

a A nut is provided under the seat, too.
PC1250-8R 3
25. Lift and remove guards (32) and (33). Installation

q Carry out the installation in the reverse order of
26. Lift and remove operator cab assembly (34). removal.
4 Operator cab assembly: 310 kg
4 PC1250-8R
Removal and installation of operator’s cab glass (Stuck glass) 1
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”.
PC1250-8R 5
Special tools (The figure shows the operator's cab of a

wheel loader.)
New/Remodel
Necessity
Symbol
Sketch
Q’ty
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
1. Using seal cutter [1], cut the adhesive between

a If the window glass is broken finely, it may be
broken window glass (7) and operator's cab
removed with knife [4] and a screwdriver.
(metal sheet) (8).
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape with
knife [4].
(The figure shows the operator's cab of a

wheel loader.)
a If a seal cutter is not available, make holes on

the adhesive and both-sided adhesive tape
with a drill and pass a fine wire (piano wire,
etc.) [2] through the holes. Grip the both ends
of the wire with pliers [3], etc. (or hold them by
winding them onto something) and move the
2. Remove the window glass.
wire to the right and left to cut the adhesive
and both-sided adhesive tape. Since the wire
may be broken by the frictional heat, apply
lubricant to it.
6 PC1250-8R
Installation 3. Apply primer (10).

a The using limit of primer (10) is 4 months
1. Using a knife and scraper [5], remove the after the date of manufacture. Do not use
remaining adhesive and both-sided adhesive primer (10) after this limit.
tape from the metal sheets (glass sticking sur- a Use the primer within 2 hours after
faces) of the operator's cab. unpacking it.
a Remove the adhesive and both-sided a Even if the primer is packed again just
adhesive tape to a degree that they will after it is unpacked, use it within 24 hours
not affect adhesion of the new adhesive. after it is unpacked for the first time. (Dis-
Take care not to scratch the painted sur- c a r d t h e p r i m e r 2 4 h o u r s a ft e r i t i s
f a c e s . ( I f t h e pa i n t e d s u r f a c e s a r e unpacked.)
scratched, adhesion will be lowered.) 1) Stir the primers for paint and glass suffi-
ciently before using them.
(The figure shows the operator's cab of a a If the primer has been stored in a
wheel loader.) refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accordingly,
leave the primer at the room tempera-
ture for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (8) and window glass (9) with
white gasoline.
a If the sticking surfaces are not cleaned
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a

wheel loader.)
PC1250-8R 7
3) Evenly apply paint primer to the surfaces

to stick both-sided adhesive tapes and the
surfaces out of those surfaces on opera-
tor's cab (8) which will be coated with the
adhesive.
2 Paint primer:
SUNSTAR PAINT PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
a Parts to be coated with primer: Apply

the primer all over dimension (a).
q Dimension to apply primer (a): 25 mm
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it
off with white gasoline.
4) Evenly apply glass primer to the sticking

surfaces of window glass (9).
2 Glass primer:
SUNSTAR GLASS PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
a In addition to the above parts, apply

the primer to right side window glass
(1) and door lower window glass (3).
q Range to apply primer additionally for
right side window glass (1): (b)
q Range to apply primer additionally for
door lower window glass (3): (c)
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
8 PC1250-8R
a Parts to be coated with primer: Apply the a When sticking both-sided adhesive tape
primer to the sticking surfaces of window (6) around a frame, do not lap its finishing
glass (9) and all over dimension (d) which end over the starting end but make clear-
will be on both-sided adhesive tape (6) ance (e) of about 5 mm between them.
and operator's cab (8).
a Do not apply the primer to the boarder 1) Stick both-sided adhesive tape (6) for right
about 5 mm wide between the black part side window glass (1) as shown in the fig-
and transparent part of the glass. ure.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the paint
primer is applied by mistake, wipe it off
with white gasoline.
a Stick both-sided adhesive tape (6a) addi-

tionally for right side window glass (1).
q Positions to stick additional both-sided
adhesive tape for right side window glass:
(f) : 250 mm
4. Stick both-sided adhesive tape (6) along the (g) : 290 mm
inside edge of the glass sticking section. (h) : 250 mm
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Take care that the both-sided adhesive tape
will not float at each corner of the window
frame.
PC1250-8R 9
2) Stick both-sided adhesive tape (6) for left 4) Stick both-sided adhesive tape (6) for front
side rear window glass (2) as shown in the window glass (4) as shown in the figure.
figure.
a Stick both-sided adhesive tape (6c) of

3) Stick both-sided adhesive tape (6) for door the lower side of the front window
lower window glass (3) as shown in the glass along the outside edge of the
figure. 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.)
a Stick both-sided adhesive tape (6b) addi-

tionally for door lower window glass (3).
a Positions to stick additional both-sided
adhesive tape for door lower window
glass: 5. Position the new window glass.
(j) : 110 mm 1) Check the clearance between the window
(k) : 190 mm glass and the operator's cab on the right,
(m): 200 mm left, upper, and lower sides, and then
adjust it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw position-
ing line (n).
a Stick tapes [6] to the right, left, and
lower parts of the right side window
glass, left side rear window glass, and
door lower window glass for accurate
positioning.
10 PC1250-8R
3) Cut the tape between window glass (9) 6. Apply adhesive.

and operator's cab (8) with a knife, and a Use either of the 2 types of the adhesive.
then remove the window glass. 2 Adhesive (Summer):
a Do not remove the tapes left on the SUNSTAR PENGUINE
window glass and operator's cab SEAL 580 SUPER “S”
before installing the window glass. 2 Adhesive (Winter):
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.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
2) Cut the tip of the adhesive nozzle (14) so

a When positioning front window glass
that dimensions (q) and (r) will be as fol-
(4), set its horizontal position to the
lows.
frame width and set its vertical posi-
q Dimension (q) : 10 mm
tion so that height difference (p)
q Dimension (r) : 15 mm
between it and the frame top will be 3
mm.
PC1250-8R 11
3) Set adhesive cartridge (12) to caulking a Apply adhesive (15) to dimensions (s)
gun [7]. and (t) of both-sided adhesive tape
a An electric caulking gun is more effi- (6) of operator's cab (8).
cient. q Dimension (s) : 10 mm
q Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
4) Remove the release tape of the both-

sided adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-
sided adhesive tape (6) of the operator's
cab. a Apply adhesive (15) additionally for
additional both-sided adhesive tape
(6a) of the right side window glass
and additional both-sided adhesive
tape (6b) of door lower window glass.
12 PC1250-8R
7. Install the window glass. a After installing front window glass (4),
1) Install window glass (9), matching it to the fill the clearances between it and cen-
lines of the positioning tapes drawn in step ter trim seal (16) with caulking mate-
5. rial in range (s) to dimensions (t) and
a Since the window glass cannot be (u).
removed and stuck again, stick it very After applying the primer to glass (4)
carefully. of section (A) – (A), apply adhesive
a Stick the glass within 5 minutes after as caulking material.
applying the adhesive. q Caulking dimension (t) : 2 mm
2) After sticking window glass (9), press all q Caulking dimension (u): 5 mm
around it until it is stuck to the both-sided a When caulking, mask the glass side
adhesive tape. and form the adhesive with a rubber
a Press the corners of the window glass spatula as shown in the figure.
firmly. a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS
PRIMER 580 SUPER
2 Adhesive:
SUNSTAR PENGUINE
SEAL 580 SUPER “S” or “W”
a You can perform this work efficiently

by pulling window glass (9) from
inside of the operator's cab with suc-
tion cup (Y1).
PC1250-8R 13
8. Fix the window glass. 2) Using styrene foam blocks [9] and rubber
1) After installing right window glass (1) to bands [10], fix the window glass and both-
the operator's cab, insert stopper rubbers sided adhesive tape to fit them completely.
(Y2) to 2 places (v) at the bottom of the
glass to fix the glass.
9. After installing the window glass, remove the

primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glass, do not give an
impact to it.
10. Protect the stuck window glass.

1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humid-
ity of 60%).
2) After removing the stopper rubbers, sty-
rene foam blocks, and rubber bands, wait
at least 14 hours, at least 24 hours in total,
before operating the machine actually.
14 PC1250-8R
Removal and installation of front 7. Remove rollers (8) and (9) under the both
window assembly 1 sides of the front window.
a For the front window pull-up specification

only

a To replace the front window glass, the front
window assembly must be removed from the
operator's cab. The procedure for removing
and installing the front window assembly (front
frame and front window glass) is explained
below.
Removal
1. Raise the front window assembly to the ceiling

and fix it with the rear locks (on both sides).
2. Remove left corner blocks (1) and (2) and right

corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt (5),

left corner block bracket, and right corner block
bracket (7). [*2]
8. Remove left lower pin (10). [*3]
4. Install left striker bolt (4) to the operator's cab a If left lower pin (10) is removed, plate (12)
again and tighten it lightly. at the end of pull-up assist cable (11)
a This bolt will be used to hang the pull-up comes off.
assist cable in step 8. a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied
to the rear of the operator's cab. Accord-
ingly, take care when removing left lower
pin (10) to disconnect pull-up assist
cable (11).
5. Release the rear locks.
6. Lower the front window assembly carefully a

little. Put out rollers (8) and (9) under the both
sides of the front window through the portion
from which the corner blocks were removed in
step 3 (the portion where the rail is open) and
hold them.
PC1250-8R 15
11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and
(15) from the rails, and then remove front win-
dow assembly (13).
9. Put out the bottom of front window assembly

(13) through the rail opening portion and lower
it gradually.
10. Lower front window assembly (13) completely.

a Do not let the front window assembly
touch the monitor.
16 PC1250-8R
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 (Q) 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 do not hitch. surface of the roller.
a Secure roller clearance (c) at part (P).
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}
3. Raise the front window assembly and fix it with

the rear locks (on both sides).
a Check that the locks in the rear of the
operator's cab are applied securely.
PC1250-8R 17
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 PC1250-8R
2) Open and close the front window assem-

bly and check the working condition of
both locks (20) and (21).
i) If both locks do not work normally,
move the striker bolts toward the rear
of the cab and tighten them again.
ii) After moving the striker bolts, check
the fitness of the front window glass
and cab-side trim seal which was
checked in step 1).
iii) Repeat the work in i) and ii) until the
fitness of the front window and the
working condition of both locks (20)
and (21) are acceptable, and then
tighten the striker bolts.
9. Adjust the front window stoppers.

1) After adjusting “closing” lock of the front
7. After adjusting the striker bolts, splash water window assembly in step 8, check the
heavily over the front window glass and check contact of both front window stoppers
that the water does not leak into the cab. (23).
2) If both stoppers (23) do not contact nor-
8. Adjust the “opening” lock of the front window mally, adjust and fix them at places where
assembly. they contact normally.
1) After adjusting the “closing” lock of the
front window in steps 6 and 7, raise the
front window assembly to the ceiling.
2) Set the right and left front window assem-
bly locks at the rear of the operator's cab
to the “OPEN” positions, and then check
the following items.
q Check that right and left locks (20)
and (21) are closed normally.
q Check that right and left locks (20)
and (21) are inserted in parallel in
right and left striker plates (22).
q Check that right and left rubber stop-
pers (24) are in contact with the front
window assembly and their deflec-
tion allowance is 1.5 – 3.0 mm.
3) After checking the above items, if neces-
sary, adjust them by moving right and left
striker plates (22) at the rear of the opera-
tor's cab.
PC1250-8R 19
10. Check the latching effort of the front window

assembly.
1) After finishing steps 6 – 9, check that
latching efforts of both locks (20) and (21)
are even.
a Check the latching efforts on both
“closing” side (in the front of the oper-
ator's cab) and “opening” side (in the
rear of the operator's cab).
[*3]
3 Left lower pin:
27 – 34 Nm {2.75 – 3.47 kgm}
2 Mounting bolt: Adhesive (LT-2)
20 PC1250-8R
PC1250-8R 21
SEN02792-00

© 2007 KOMATSU
All Rights Reserved
22
SEN02793-00
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up

Electrical system
Removal and installation of air conditioner unit assembly .............................................................................. 2
Removal and installation of monitor assembly................................................................................................ 5
Removal and installation of pump controller assembly ................................................................................... 6
Removal and installation of Orbcomm terminal assembly for VHMS.............................................................. 7
Removal and installation of VHMS controller assembly ................................................................................. 8
Removal and installation of engine controller assembly ................................................................................. 9
PC1250-8R 1
Removal and installation of air 2. Remove rear covers (1) – (3).

conditioner unit assembly 1
Removal
battery beforehand.
k In the case that you do not drain the cool-
ant, if you disconnect the heater hose when
the coolant temperature in the radiator is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then disconnect the heater hose.
k Collect refrigerant (R134a) beforehand.
a Ask professional traders for collecting and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere. 4. Disconnect clamp (5).
k If the refrigerant (R134a) gets inside one's 5. Disconnect circuit breaker bracket (6).
eyes, it may cause blindness. Therefore,
make sure to wear protective glasses when 6. Remove cover (7).
collecting or filling the refrigerant. Collect-
ing and filling work must be conducted by a
qualified person.
1. Pull bar (B) and lever (R) situated at the bot-

8. Remove bolt (9).
9. Remove duct (10) on the right side.
2 PC1250-8R
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.
12. Remove left plates (13) and (14).
13. Remove ducts (15) and (16).

21. Disconnect heater hoses (30) and (31).
22. Disconnect air conditioner tubes (32) and (33).
[*1]
23. Remove the 8 mounting bolts to remove air

conditioner unit assembly (34).
a When removing the air conditioner unit
assembly, do not forget to disconnect the
2 air conditioner hoses connected to the
bottom.
16. Remove duct (22).
17. Disconnect connectors at the following 7 loca-

tions.
q (23): D01 (Assembled-type diode connector)
q (24): D02 (Assembled-type diode connector)
q (25): C09 (Model selection switch connector)
q (26): Air conditioner unit connectors. From
the top: M26, M27, M28 and optional
power connector M33.
PC1250-8R 3
Installation
removal.
[*1]
a When installing the air conditioner circuit
hoses, take 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)).
3 Hose clamp: 8.83 – 14.7 Nm {0.9 – 1.5 kgm}

11.8 – 14.7 Nm {1.2 – 1.5 kgm}
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
q Filling air conditioner circuit with the refrig-

erant (R134a)
Fill the air conditioner circuit with the refriger-
ant (R134a).
a Filling amount: 1200 ± 50 g
q Refilling engine coolant

Refill coolant through the coolant filler port up
to the specified level. Start the engine and cir-
culate the coolant, and then check the coolant
level.
4 PC1250-8R

monitor assembly 1
Removal
battery beforehand.
1. Remove cover (1) and then disconnect the wir-

ing connector P15 for air conditioner sunlight
sensor (2).
a Lift the cover up to remove it.
2. Remove the 3 mounting screws to remove air

conditioner unit assembly (3).
a Disconnect monitor panel wiring connec-
tors P01, P02 and P03 and then remove
the monitor assembly.
Installation
removal.
PC1250-8R 5
Removal and installation of pump

controller assembly 1
Removal
battery beforehand.
2. Disconnect governor and pump controller wir-

ing connectors C01 (2), C02 (3) and C03 (4).
3. Remove 4 mounting bolts and remove pump

control assembly (5).
Installation
removal.
6 PC1250-8R

Orbcomm terminal assembly for
VHMS 1
Removal
battery beforehand.
1. Pull bar (B) and lever (R) situated at the bot-

Installation
removal.
3. Disconnect antenna wire (2).

a Push and turn this portion.
a Depending on the specification, it will be
required to disconnect the connector situ-
ated adjacent to antenna wire (2).
a Pull it out while pushing the lock.
4. Disconnect connector CK01 (3).
5. Remove 4 mounting bolts and remove

Orbcomm terminal assembly (4) for VHMS.
PC1250-8R 7
Removal and installation of VHMS

controller assembly 1
Removal
battery beforehand.
a Before proceeding to removal of VHMS con-

troller, download the data saved on the target
controller of removal and also confirm its setup
information. For above procedure, refer to
“VHMS controller setup procedure after its
replacement” in Testing and adjusting.
1. Remove Orbcomm terminal assembly for

VHMS, refer to “Removal and installation of
Orbcomm terminal assembly for VHMS”.
3. Remove the following connectors from VHMS

controller (2).
q Upper stage
(3): VC4A, (4): VC4B, (5): VC3A and
(6): VC3B
q Lower stage
(7): VC2B, (8): VC2A and (9): VC1
4. Remove 4 mounting bolts (10) and (11).

5. Take out VHMS controller assembly (2) along
with the bracket. Installation
removal.
a After installing VHMS controller, set up the
installed VHMS controller again, refer to
“VHMS controller setup procedure after its
replacement” in Testing and adjusting.
8 PC1250-8R
Removal and installation of Installation

engine controller assembly 1 q Carry out installation in the reverse order to
removal.
Removal
k Disconnect the negative terminal (–) of the [*1]
battery before starting with the work. q Make sure inside (particularly the bottom) of
the controller connector is free from sands,
1. Open engine side covers (1) and (2). dusts or water. If such foreign substances are
present, clean them completely with the air
blow. (Sands, dusts or water can cause defect
contact or allow commingling of water.)
a Reference
q Replacement procedure of O-ring seal on
power supply connector J3P (5)
O-ring seal:
1010-074-0406 (Nihon-Deutsch Ltd.)
1) Remove cover (8) by pressing the claw

with tweezers [1].
3. Disconnect connectors CE03 (5), CE02 (6)

and (7) from engine controller (4). [*1]
a Hexagonal wrench (4 mm) is used.
a Disconnect the clamp, too.
4. Remove engine controller (4).
2) Remove O-ring (9) using tweezers [1].
PC1250-8R 9
SEN02793-00

© 2007 KOMATSU
All Rights Reserved
10
SEN02069-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
90 Diagrams and drawings 1

Hydraulic circuit diagrams
Hydraulic circuit diagram (1/2) Serial number 35001 – 35016........................................................................ 3
Hydraulic circuit diagram (2/2) Serial number 35001 – 35016........................................................................ 5
Hydraulic circuit diagram (1/3) Serial number 35017 and up.......................................................................... 7
Hydraulic circuit diagram (2/3) Serial number 35017 and up.......................................................................... 9
Hydraulic circuit diagram (3/3) .......................................................................................................................11
PC1250-8R 1
SEN02069-02 90 Diagrams and drawings
2 PC1250-8R
Hydraulic circuit diagram (1/2)
Hydraulic circuit diagram (1/2) Serial number 35001 – 35016 PC1250-8R
1
SEN02069-02
PC1250-8R 3
Hydraulic circuit diagram (2/2) Serial number 35001 – 35016 PC1250-8R
1
SEN02069-02
PC1250-8R 5
Hydraulic circuit diagram (1/3) Serial number 35017 and up PC1250-8R
1
SEN02069-02
PC1250-8R 7
Hydraulic circuit diagram (2/3) Serial number 35017 and up PC1250-8R
1
SEN02069-02
PC1250-8R 9
Hydraulic circuit diagram (3/3) 1

PC1250-8R
PC1250-8R 11
PC1250-8R 13
SEN02069-02

© 2007 KOMATSU
All Rights Reserved
14
SEN02070-02
PC1250-8R
PC1250SP-8R

PC1250-8R 35001 and up
90 Diagrams and drawings 1

Electrical diagrams and drawings
Electrical circuit diagram (1/7)......................................................................................................................... 3
Electrical circuit diagram (5/7)........................................................................................................................11
Electrical circuit diagram (6/7)....................................................................................................................... 13
Electrical circuit diagram (7/7)....................................................................................................................... 15
Connector arrangement diagram .................................................................................................................. 17
PC1250-8R 1
SEN02070-02 90 Diagrams and drawings
2 PC1250-8R
Electrical circuit diagram (1/7)
Electrical circuit diagram (1/7) PC1250-8R 1
SEN02070-02
PC1250-8R 3
Electrical circuit diagram (2/7) 1 PC1250-8R
SEN02070-02
PC1250-8R 5
SEN02070-02
PC1250-8R 7
SEN02070-02
PC1250-8R 9
SEN02070-02
PC1250-8R 11
SEN02070-02
PC1250-8R 13
SEN02070-02
PC1250-8R 15
Connector arrangement diagram
Connector arrangement diagram PC1250-8R PC1250-8R
Connector Number Arrangement Connector Number Arrangement Connector Number Arrangement

Type Component name Type Component name Type Component name
No. of pins drawing No. of pins drawing No. of pins drawing
A01 X 4 Intermediate connector (Power supply system) V-1 J1939 DT 3 CAN connector AK-5 S02 X 2 Boom raise pressure switch M-1
A02 X 4 Intermediate connector (GND, Power supply system) W-2 J11 DT 8 Junction connector J-9 S03 X 2 Arm dump pressure switch N-2
A03 DT 6 Intermediate connector (Ambient temperature sensor) S-1 J12 DT 8 Junction connector I-9 S04 X 2 Boom lower pressure switch M-1
A04 DT (Black) 12 Intermediate connector (TVC system etc.) S-1 J13 DT 8 Junction connector I-1 S05 X 2 Arm in pressure switch N-2
A05 DT (Gray) 12 Intermediate connector (Solenoid system) W-1 J14 DT 8 Junction connector M-7 S06 X 2 Bucket curl pressure switch N-2
A06 DT (Brown) 12 Intermediate connector (Solenoid and sensor system) S-1 J15 DT 8 Junction connector M-7 S07 X 2 Bucket dump pressure switch M-1
A07 SWP 16 Intermediate connector (Heater system etc.) V-1 J16 DT 8 Junction connector L-2 S08 X 2 Right swing pressure switch N-2
A08 DT (Gray) 8 Intermediate connector (CAN system etc.) R-1 J17 DT 8 Junction connector I-1 S10 X 2 Left swing pressure switch N-2
A09 SWP 8 Intermediate connector (Pressure switch) Q-2 J18 DT 8 Junction connector K-9 S11 X 2 Right travel pressure switch (Reverse) L-1
A10 DT (Gray) 12 Intermediate connector (Circuit breaker) T-1 J20 DT 8 Junction connector M-4 S12 X 2 Left travel pressure switch (Forward) L-1
A11 DT (Black) 12 Intermediate connector (Pump pressure sensor system) R-1 J21 DT 8 Junction connector M-4 S13 X 2 Left travel pressure switch (Reverse) M-1
Intermediate connector J23 J (Pink) 20 Junction connector Q-8 S14 M 3 PPC oil pressure lock switch X-2
A12 DT (Gray) 8 V-1
(Blow-by pressure sensor and PTO temperature sensor)
J24 J (Pink) 20 Junction connector R-8 S15 X 2 Bottom dump open pressure switch (Loader specification)
Intermediate connector
A13 DT (Black) 8 V-1 J25 J (Green) 20 Junction connector R-8 S16 X 2 Bottom dump close switch (Loader specification)
(Aftercooler pump pressure sensor system)
J26 — Centralized terminal (Engine) M-8 S25 090 16 Intermediate connector (Right console emergency switch) T-8
Intermediate connector
A16 DT 3 E-1
(Radiator fan pump pressure sensor system) J27 — Centralized terminal (Engine) M-8 S21 — Emergency pump drive switch U-9
AG01 X 3 Auto grease pressure switch C-3 J28 — Centralized terminal (Engine) M-8 S22 — Swing holding brake release switch T-8
AG02 X 2 Auto grease solenoid C-6 JB1 — 18 Centralized terminal (Engine) AK-5 S50 DT 6 Priming pump switch timer K-9
AG07 M 6 Auto grease timer Z-2 JB2 — 22 Centralized terminal (Engine) AL-5 S50 DT 2 Priming pump
AG08 SINAGAWA 5 Auto grease relay AB-2 JC22 DT 8 Junction connector C-4 ST1 DT 2 Starting motor (Terminals R and S) AL-5
AG09 M 4 Auto grease cycle timer AA-1 K02 DT 3 CAN terminal resistor AN-2 ST2 DT 2 Starting motor (Terminals R and S) AK-5
AG10 1 Auto grease pilot lamp (Green) P-3 K19 DT 2 Resistor (27z) X-2 T02 Terminal 1 Revolving frame ground C-9
AG11 1 Auto grease pilot lamp (Green) P-3 K31 DT 3 CAN terminal resistor Q-4 T03 Terminal 1 Revolving frame ground C-9
AG12 1 Manual grease pilot lamp (Green) P-3 M07 M 3 Light switch S-7 T04 Terminal 1 Revolving frame ground D-9
AG13 1 Manual grease pilot lamp (Green) P-3 M08 DT 2 Working lamp (Boom) D-7 T05 Terminal 1 Floor ground Y-3
AG14 1 Abnormality indicator lamp (Red) O-3 M09 DT 2 Working lamp (Boom) D-8 T06 Terminal 1 Radio body ground Y-3
AG15 1 Abnormality indicator lamp (Red) O-3 M10 DT 2 Intermediate connector (Working lamp) G-9 T06A M 1 Intermediate connector (Cab ground) W-2
B Terminal 1 Starting motor terminal B AI-7, AK-5 M13 KES 2 Speaker (Right) AF-9 T06B Terminal 1 Cab ground Y-3
B01 DT (Gray) 8 Intermediate connector (Circuit breaker) W-9 M14 DT 2 Travel alarm (When auto grease system is installed) D-5 T09 Terminal 1 Engine body ground AM-1
B02 DT (Black) 8 Intermediate connector (Circuit breaker) X-9 M17 M 2 Horn valve C-6 T11 Terminal 1 Cab ground AH-4
B03 X 2 Intermediate connector (Circuit breaker) X-9 M19 YAZAKI 2 Cigarette lighter Q-3 TFUEL PACKARD 2 Fuel temperature sensor AL-1
B11 Terminal 1 Circuit breaker 1 A-1 M21 PA 9 Radio X-2 TIM PACKARD 2 Boost temperature senor AM-6
B12 Terminal 1 Circuit breaker 2 B-1 M22 90 2 Horn switch (Right knob switch) R-7 TOIL PACKARD 2 Engine oil temperature sensor AN-3
B13 Terminal 1 Circuit breaker 3 B-3 M22 90 6 Horn and bottom dump open switch (Loader specification) TWTR PACKARD 2 Engine coolant temperature sensor AL-5
B14 Terminal 1 Circuit breaker 4 AA-9 M23 90 6 Bottom dump close switch (Loader specification) V01 DT 2 Swing priority selector solenoid N-8
B15 Terminal 1 Circuit breaker 5 AA-9 M24 Terminal 1 Intake air heater AK-4 V02 DT 2 Main 2-stage relief solenoid N-9
B16 Terminal 1 Circuit breaker 6 AA-9 M26 S 12 Air conditioner unit Z-5 V03 DT 2 Travel straight solenoid N-9
B17 Terminal 1 Circuit breaker 7 AA-8 M27 SWP 16 Intermediate connector (air conditioner control panel) Z-5 V04 DT 2 Swing holding brake solenoid L-3
B18 Terminal 1 Circuit breaker 8 Z-8 M28 SWP 12 Intermediate connector (air conditioner control panel) Z-5 V05 DT 2 Boom head 2-stage safety valve solenoid N-9
B19 Terminal 1 Circuit breaker 9 Z-8 M28 KES0 2 Window washer J-1 V06 DT 2 Travel speed selector solenoid N-9
B21 Terminal 1 Circuit breaker 1 A-1 M29 Air conditioner control panel Y-3 V07 DT 2 CO cancel solenoid N-8
B22 Terminal 1 Circuit breaker 2 B-1 M30 Air conditioner control panel Y-3 V08 DT 2 PPC oil pressure lock solenoid C-2
B23 Terminal 1 Circuit breaker 3 B-3 M31 M 12 OPT power supply 2 X-3 V09 DT 2 Boom shockless control solenoid (Raise side) J-1
B24 Terminal 1 Circuit breaker 4 AB-8 M32 M 2 OPT power supply 1 U-9 V10 DT 2 Boom shockless control solenoid (Lower side) J-1
B25 Terminal 1 Circuit breaker 5 AB-8 M33 M 2 Service connector (12 V) Z-4 V12 DT 2 Bottom dump open solenoid (Loader specification)
B26 Terminal 1 Circuit breaker 6 AB-8 M35 DT 2 Air conditioner compressor electromagnetic clutch AK-1 V13 DT 2 Bottom dump close solenoid (Loader specification)
B27 Terminal 1 Circuit breaker 7 AB-8 M38 M 2 Machine pushup switch T-8 V17 DT 2 Fan motor reverse solenoid I-9
B28 Terminal 1 Circuit breaker 8 AB-7 M39 M 2 Boom shockless control switch T-8 V30 DT 2 Fan pump EPC solenoid M-6
B29 Terminal 1 Circuit breaker 9 AB-7 M40 SWP 2 Headlamp AD-8 VC1 70 20 VHMS controller P-6
B1A Terminal 1 Circuit breaker 10 Z-7 M41 SWP 2 Headlamp AC-7 VC2A 70 18 VHMS controller P-6
B1B Terminal 1 Circuit breaker 11 Z-7 M42 SWP 2 Right headlamp A-2 VC2B 70 14 VHMS controller O-6
B1C Terminal 1 Circuit breaker 12 B-1 M44 DT (Green) 8 Intermediate connector (Auto grease) AA-5 VC3A 70 18 VHMS controller Q-9
B2A Terminal 1 Circuit breaker 10 AB-7 M45 DT (Gray) 12 Network bus X-2 VC3B 70 12 VHMS controller Q-9
B2B Terminal 1 Circuit breaker 11 AB-7 M71 M 2 Room lamp U-9 VC4A 70 14 VHMS controller P-9
B2C Terminal 1 Circuit breaker 12 B-1 M72 M 4 DC/DC converter W-2 VC4B 70 10 VHMS controller Q-9
C01 DRC 24 Pump controller X-9 M73 KES 2 Speaker (Left) AG-8 VH01 DT (Black) 8 Intermediate connector (Pump pressure sensor etc.) C-4
C02 DRC 40 Pump controller Y-8 M75 SWP 2 Headlamp AH-8 VH02 AMP 3 Main pressure sensor (Front pump) A-6
C03 DRC 40 Pump controller Y-8 M79 M 2 12V socket X-8 VH03 AMP 3 Main pressure sensor (Rear pump) B-6
C09 S 8 Model selection Z-6 M80 DT 2 Intermediate connector (Flashlight) H-1 VH04 AMP 3 Main pressure sensor (Swing pump) B-6
C13 DT 2 TVC solenoid M-4 M81 KES 2 Step light switch O-3 VH06 DT 3 Intermediate connector (Exhaust temperature sensor) D-1
CE02 DRC 50 Engine controller AN-3 M82 SWP 2 Flashlight G-1 VH07 DT 3 Intermediate connector (Exhaust temperature sensor etc.) D-1
CE03 DTP 4 Engine controller AN-2 M95 KES 2 Window washer K-2 VH08 DT 3 Blow-by pressure sensor AM-1
CK01 DRC 40 ORBCOMM controller P-9 NE FRAMATOME 3 NE sensor AN-3 VH09 DT 2 PTO temperature sensor M-5
D01 SWP 8 Diode array Z-7 OLV DT 2 Engine oil level sensor AM-1 VH11 DT 3 Gear pump pressure sensor K-2
D02 SWP 8 Diode array Z-6 P01 70 12 Machine monitor Q-6 VH12 DT 3 Gear pump pressure sensor (Aftercooler fan) M-3
D03 SWP 8 Diode array V-1 P02 40 20 Machine monitor Q-4 VH13 BENDIX 5 VHMS data download connector Q-2
D04 SWP 8 Diode array T-1 P03 40 16 Machine monitor Q-4 VH14 DT 2 Intermediate connector (Exhaust temperature sensor) (Front side) D-1
D05 SWP 8 Diode array T-1 P05 M 2 Rotary lamp Z-5 VH15 DT 2 Intermediate connector (Exhaust temperature sensor) (Rear side) E-1
D06 SWP 8 Diode array T-1 P06 DT 2 Fuel level sensor G-9 VH16 DT 2 Exhaust temperature sensor (Front side) AJ-9
E06 M 3 Fuel control dial R-7 P08 X 2 Radiator coolant level sensor H-9 VH17 DT 2 Exhaust temperature sensor (Rear side) AI-8
E08 DT (Black) 12 Intermediate connector (Starting motor) AN-1 P10 DT 2 Hydraulic oil high temperature sensor L-2 W03 M 2 Rear limit switch AF-9
E09 DT (Black) 8 Intermediate connector (Exhaust temperature sensor etc.) AN-2 P11 DT 2 Air cleaner clogging sensor L-9 W04 M 6 Upper wiper motor Q-5
ENG DRC 60 Engine controller AN-2 P15 50 2 Air conditioner daylight sensor Q-5 W05 M 6 Lower wiper motor (Quarry specification) R-1
F01 DT 2 Travel alarm C-6 P16 DT 2 Air conditioner outside temperature sensor F-9 W06 M 2 Lower wiper switch (Quarry specification) Z-5
F02 SWP 2 Intermediate connector (Rotary lamp) AE-9 P20 X 2 Radiator coolant level sensor H-9 X05 M 3 Swing lock switch S-8
F03 DT 2 Rotary lamp AG-8 P29 DT 2 Ambient temperature sensor F-9 B Terminal 1 Starting motor terminal B
FB1 — 20 Fuse box Z-3 P34 AMP 3 Radiator fan pump pressure sensor M-3 R Terminal 1 Starting motor terminal R AI-6, AK-5
G DT 3 G sensor AN-5 PAMB AMP 3 Ambient pressure sensor AN-3 S Terminal 1 Starting motor terminal S AI-6, AK-5
H08 M 8 Intermediate connector Z-4 PCV1 SUMITOMO 2 Supply pump #1 AN-4 B Terminal 1 Alternator terminal B AK-1
H09 S 8 Intermediate connector Z-4 PCV2 SUMITOMO 2 Supply pump #2 AN-4 E Terminal 1 Alternator terminal E AJ-2
H10 S 16 Intermediate connector (Machine monitor) V-9 PFUEL AMP 3 Common rail pressure sensor AL-5 R Terminal 1 Alternator terminal R AJ-1
H11 S 16 Intermediate connector (Machine monitor) V-9 PIM SUMITOMO 3 Boost pressure sensor AM-6 ACC Terminal 1 Starting switch terminal ACC O-5
H12 S 12 Intermediate connector (Machine monitor) W-9 POIL FRAMATOME 3 Engine oil pressure sensor AM-1 B Terminal 1 Starting switch terminal B P-5
H14 HD30 21 Intermediate connector (Step light switch, download, etc.) Q-2 R10 SINAGAWA 5 Light relay S-7 BR Terminal 1 Starting switch terminal BR O-5
H15 90 20 Intermediate connector (Right console upper wiring harness) R-7 R11 SINAGAWA 5 Starting motor cut relay (PPC oil pressure cut) S-8 C Terminal 1 Starting switch terminal C O-6
INJ DT 12 Intermediate connector (Injector) AN-5 R13 SINAGAWA 5 Starting motor cut relay (Personal code) T-8 R1 Terminal 1 Starting switch terminal R1 P-4
J01 J (Black) 20 Junction connector U-9 R15 SINAGAWA 5 Step light relay Z-6 B Terminal 1 Battery relay terminal B B-9
J02 J (Black) 20 Junction connector Y-8 R16B Terminal 1 Intake air heater relay terminal B B-7 BR Terminal 1 Battery relay terminal BR A-7, C-7
J03 J (Orange) 20 Junction connector Y-8 R16L Terminal 1 Intake air heater relay terminal L B-7 E Terminal 1 Battery relay terminal E A-8, C-7
J04 J (Green) 20 Junction connector Z-8 R16S Terminal 1 Intake air heater relay terminal S B-7 M Terminal 1 Battery relay terminal M B-9, C-9
J05 J (Pink) 20 Junction connector Z-7 R18 SINAGAWA 5 Intake air heater relay drive relay Z-6
J06 J (Orange) 20 Junction connector Z-7 R20 SINAGAWA 5 Horn relay Z-6
J07 J (Green) 20 Junction connector W-9 R21 SINAGAWA 5 Flashlight relay Z-7
J08 J (Pink) 20 Junction connector W-9 RES DT 2 Resistor (620) AM-1
J09 J (Black) 20 Junction connector V-9 S01 X 2 Right travel pressure switch (Forward) L-1
SEN02070-02
PC1250-8R
17
PC1250-8R 19
SEN02070-02

© 2007 KOMATSU
All Rights Reserved
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SEN02048-05

HYDRAULIC PC1250 -8R

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN02048-05

00 Index and foreword SEN02049-05

10 Structure, function and maintenance standard SEN02054-03

20 Standard value table SEN02064-02

30 Testing and adjusting SEN02065-02

50 Disassembly and assembly SEN02067-01

90 Diagrams and drawings SEN02068-04

Foreword and general information SEN02051-01

10 Structure, function and maintenance standard

Air system SEN02058-00

20 Standard value table

30 Testing and adjusting

Classification and troubleshooting steps ..................................................................................... 5

Failure code [DW43KB] Travel Speed Sol. S/C .......................................................................... 52

E-9 Part of display on machine monitor is missing........................................................................ 24

S-4 Engine stops during operations ............................................................................................ 11

50 Disassembly and assembly

Hydraulic system SEN02790-01

90 Diagrams and drawings

PC1250-8R, PC1250SP-8R Hydraulic excavator

HYDRAULIC EXCAVATOR 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Safety notice 1 (Rev. 2007/03)

1. General precautions 7) If welding repairs are needed, always

4. Precautions for sling work and making

8. Precautions for disconnecting and con-

a Example of O-ring (Fitted to every joint of

a For tightening torque, see the precautions for

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

2 Coat Places to be coated with adhesives, etc. during assembly.

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

q Usually, the size of a hole and the size of

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector

3. Removing, installing, and drying connec-

2] When removing from clips