Komatsu Excavator PC1250-11R PC1250SP-11R workshop service manual

Description Komatsu Excavator PC1250-11R PC1250SP-11R workshop service manual

Komatsu Hydraulic Excavator PC1250-11R, PC1250SP-11R pdf workshop service & repair manual

Serial numbers:
50090 and up
50121 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
INDEX AND FOREWORD
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

SPECIFICATIONS
SPECIFICATION DRAWING
WORKING RANGE DRAWINGS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE

STRUCTURE AND FUNCTION
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTO-DECELERATION SYSTEM
AUTOMATIC LOW IDLE SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM
OVERHEAT PREVENTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
FAN SPEED CONTROL SYSTEM OF HYDRAULIC FAN
ENGINE OUTPUT CONTROL SYSTEM OF HYDRAULIC FAN
FAN REVERSE ROTATION SYSTEM OF HYDRAULIC FAN
COMPONENT PARTS OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
MACHINE MONITOR SYSTEM
KomVision SYSTEM
KOMTRAX Plus SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
OLSS
ENGINE AND PUMP COMBINED CONTROL SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
MACHINE PUSH-UP SYSTEM
HEAVY LIFT SYSTEM
BOOM SHOCKLESS CONTROL SYSTEM
PPC LOCK SYSTEM
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
SWING CONTROL SYSTEM DIAGRAM
SWING PRIORITY SYSTEM DIAGRAM
SWING COMPENSATION SYSTEM DIAGRAM
COMPONENT PARTS OF SWING SYSTEM
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
TRAVEL CONTROL SYSTEM DIAGRAM
COMPONENT PARTS OF TRAVEL SYSTEM
LIFTING SYSTEM
HYDRAULICALLY OPERATED STAIRWAY SYSTEM
COMPONENT PARTS OF LIFTING SYSTEM
UNDERCARRIAGE AND FRAME
LAYOUT DRAWING OF UNDERCARRIAGE
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
BUCKET CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
CAB
CAB MOUNT
CAB TIPPING STOPPER

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: PC1250-11R
STANDARD VALUE TABLE FOR ENGINE: PC1250SP-11R
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: PC1250-11R
STANDARD VALUE TABLE FOR MACHINE: PC1250SP-11R
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TEST EXHAUST GAS TEMPERATURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
TEST SUPPLY PUMP
HANDLE CYLINDER CUT-OUT MODE OPERATION
TEST ALTERNATOR
HANDLE NO-INJECTION CRANKING OPERATION
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
TEST SPROCKET WEAR
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TEST AND ADJUST OIL PRESSURE OF CONTROL CIRCUIT
TEST AND ADJUST PISTON PUMP CONTROL OIL PRESSURE
TEST SERVO PISTON STROKE
TEST OUTLET PRESSURE OF SOLENOID VALVE
TEST PPC VALVE OUTLET PRESSURE
TEST SWING PPC SHUTTLE VALVE OUTLET PRESSURE
ADJUST WORK EQUIPMENT AND SWING PPC VALVES
TEST TRAVEL DEVIATION
TEST COOLING FAN SPEED
TEST AFTERCOOLER FAN SPEED
TEST OIL PRESSURE IN FAN PUMP CIRCUIT
TEST AFTERCOOLER FAN PUMP CIRCUIT OIL PRESSURE
TEST FAN PUMP EPC ELECTRIC CURRENT
TEST FAN PUMP EPC SOLENOID VALVE OUTLET PRESSURE
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TEST OIL LEAKAGE
BLEED AIR FROM HYDRAULIC CIRCUIT
CAB AND ITS ATTACHMENTS
TEST CAB TIPPING STOPPER
METHOD FOR ADJUSTING MIRRORS
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
START UP KOMTRAX TERMINAL
DEFAULT SETTING OF KOMTRAX Plus CONTROLLER
SETTING DEFAULT OF WIRELESS LAN MODEM
DOWNLOAD OF KOMTRAX Plus CONTROLLER DATA
ADJUST WHEN KOMTRAX Plus CONTROLLER IS REPLACED
ADJUST WHEN WIRELESS LAN MODEM IS REPLACED
ADJUST KomVision CAMERA ANGLE
ADJUST KomVision RELATED ITEMS
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE BATTERY DISCONNECT SWITCH
TEST DIODES
Pm CLINIC
Pm CLINIC SERVICE
PERFORMING QUICK Pm

TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
PROCEDURE FOR TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTOR LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
FAILURE CODE TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL COOLING FAN MOTOR ASSEMBLY
REMOVE AND INSTALL ENGINE, PTO, AND HYDRAULIC PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL MUFFLER ASSEMBLY
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
DISASSEMBLE AND ASSEMBLE PTO ASSEMBLY
REMOVE AND INSTALL PTO ASSEMBLY
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
UNDERCARRIAGE AND FRAME
REMOVE AND INSTALL IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE RECOIL SPRING
REMOVE AND INSTALL TRACK ROLLER ASSEMBLY
REMOVE AND INSTALL CARRIER ROLLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE ONE TRACK LINK ASSEMBLY IN FIELD
SEPARATION AND CONNECTION OF TRACK ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE AIDLER ADJUSTMENT CYLINDER ASSEMBLY
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBL
HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL HYDRAULIC PUMP ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE GREASE GUN ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY
REMOVE AND INSTALL BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY
REMOVE AND INSTALL ARM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY
REMOVE AND INSTALL BOOM CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)
REMOVE AND INSTALL BUCKET ASSEMBLY
REMOVE AND INSTALL BUCKET ASSEMBLY (LOADING SHOVEL SPECIFICATION)
REMOVE AND INSTALL ARM ASSEMBLY
REMOVE AND INSTALL ARM ASSEMBLY (LOADING SHOVEL SPECIFICATION)
REMOVE AND INSTALL BOOM ASSEMBLY
REMOVE AND INSTALL BOOM ASSEMBLY (LOADING SHOVEL SPECIFICATION)
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL SPECIFICATION)
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL TOP GUARD ASSEMBLY
REMOVE AND INSTALL OPERATORS CAB ASSEMBLY
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL OPERATORS SEAT
REMOVE AND INSTALL SEAT BELT
REMOVE AND INSTALL FRONT WIPER ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL CRANKCASE PRESSURE SENSOR
REMOVE AND INSTALL KomVision CAMERA
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
REMOVE AND INSTALL KOMTRAX Plus CONTROLLER ASSEMBLY
REMOVE AND INSTALL WIRELESS LAN UNIT ASSEMBLY

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD FOR PTO
MAINTENANCE STANDARD OF COOLING SYSTEM
MAINTENANCE STANDARD OF COOLING FAN PUMP
MAINTENANCE STANDARD OF COOLING FAN MOTOR
POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE
MAINTENANCE STANDARD OF SWING MACHINERY
MAINTENANCE STANDARD OF FINAL DRIVE
MAINTENANCE STANDARD OF SPROCKET
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER
MAINTENANCE STANDARD OF CARRIER ROLLER
MAINTENANCE STANDARD OF TRACK SHOE
MAINTENANCE STANDARD OF DOUBLE SHOE
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF SWING MOTOR
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
MAINTENANCE STANDARD OF TRAVEL PPC VALVE
MAINTENANCE STANDARD OF SOLENOID VALVE
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
MAINTENANCE STANDARD OF BOOM CYLINDER
MAINTENANCE STANDARD OF ARM CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER

APPENDIX
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
AIR CONDITIONER CONTROLLER
COMPRESSOR
CONDENSER
RECEIVER DRIER
SENSORS FOR AIR CONDITIONER SYSTEM
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TESTING AIR LEAKAGE (DUCT)
METHOD FOR TESTING AIR LEAKAGE (DUCT)
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
TEST VENT (MODE) CHANGEOVER
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST SUNLIGHT SENSOR
METHOD FOR TESTING SUNLIGHT SENSOR
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING CHART
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
TROUBLESHOOTING USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL

CIRCUIT DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

Engine SAA6D170E-7 workshop service manual