Shop Manual Komatsu PC1250-7

SEBM027301
MACHINE MODEL SERIAL No.

PC1250-7 20001 and up
PC1250SP-7 20001 and up
PC1250LC-7 20001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
• PC1250-7 mounts the SAA6D170E-3 engine.

For details of the engine, see the 6D170-3 Series Engine Shop Manual.
© 2002
All Rights Reserved
Printed in Japan 06-02 (01)
00-1
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY ..................... Will be issued 7-30-2002
90 OTHERS ................................................................................................................................ 90-1
00-2 PC1250-7
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Page to be newly added Add
Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
00-1 01-1 10-20 10-49 10-77
00-2 01-2 10-21 10-50 10-78
00-2-1 01-3 10-22 10-51 10-79
00-2-2 01-4 10-23 10-52 10-80
00-2-3 01-5 10-24 10-53 10-81
00-2-4 01-6 10-25 10-54 10-82
00-3 01-7 10-26 10-55 10-83
00-4 01-8 10-27 10-56 10-84
00-5 10-28 10-57 10-85
00-6 10-29 10-58 10-86
00-7 10-1 10-30 10-59 10-87
00-8 10-2 10-32 10-60 10-88
00-9 10-3 10-33 10-61 10-89
00-10 10-4 10-34 10-62 10-91
00-11 10-6 10-35 10-63 10-92
00-12 10-7 10-36 10-64 10-93
00-13 10-8 10-37 10-65 10-94
00-14 10-9 10-38 10-66 10-95
00-15 10-10 10-39 10-67 10-96
00-16 10-11 10-40 10-68 10-97
00-17 10-12 10-41 10-69 10-98
00-18 10-13 10-42 10-70 10-99
00-19 10-14 10-43 10-71 10-100
00-20 10-15 10-44 10-72 10-101
00-21 10-16 10-45 10-73 10-102
00-22 10-17 10-46 10-74 10-103
10-18 10-47 10-75 10-104
10-19 10-48 10-76 10-105
PC1250-7 00-2-1

10-106 10-147 10-187 20-119 20-159
10-107 10-148 10-188 20-120 20-160
10-108 10-149 10-189 20-121 20-161
10-109 10-150 10-190 20-122 20-162
10-110 10-151 10-191 20-123 20-163
10-111 10-152 10-192 20-124 20-164
10-112 10-153 10-193 20-125 20-165
10-113 10-154 10-194 20-126 20-166
10-114 10-155 20-127 20-167
10-116 10-156 20-128 20-168
10-117 10-157 20-1 20-129 20-169
10-118 10-158 20-2 20-130 20-170
10-119 10-159 20-3 20-131 20-171
10-120 10-160 20-4 20-132 20-172
10-121 10-161 20-5 20-133 20-173
10-122 10-162 20-6 20-134 20-174
10-123 10-163 20-7 20-135 20-175
10-124 10-164 20-8 20-136 20-176
10-125 10-165 20-9 20-137 20-177
10-126 10-166 20-10 20-138 20-178
10-127 10-167 20-11 20-139 20-179
10-128 10-168 20-140 20-180
10-129 10-169 20-101 20-141 20-181
10-130 10-170 20-102 20-142 20-182
10-131 10-171 20-103 20-143 20-183
10-132 10-172 20-104 20-144
10-133 10-173 20-105 20-145 20-201
10-134 10-174 20-106 20-146 20-202
10-135 10-175 20-107 20-147 20-203
10-136 10-176 20-108 20-148 20-204
10-137 10-177 20-109 20-149 20-205
10-138 10-178 20-110 20-150 20-206
10-139 10-179 20-111 20-151 20-207
10-140 10-180 20-112 20-152 20-208
10-141 10-181 20-113 20-153 20-209
10-142 10-182 20-114 20-154 20-210
10-143 10-183 20-115 20-155 20-211
10-144 10-184 20-116 20-156 20-212
10-145 10-185 20-117 20-157 20-213
10-146 10-186 20-118 20-158 20-214
00-2-2 PC1250-7

20-215 20-256 20-337 20-378 20-436
20-216 20-257 20-338 20-379 20-437
20-217 20-258 20-339 20-380 20-438
20-218 20-259 20-340 20-382 20-439
20-219 20-260 20-341 20-383 20-440
20-220 20-261 20-342 20-384 20-441
20-221 20-343 20-442
20-222 20-301 20-344 20-401 20-443
20-223 20-302 20-345 20-402 20-444
20-224 20-304 20-346 20-403 20-445
20-226 20-305 20-347 20-404 20-446
20-227 20-306 20-348 20-405 20-447
20-228 20-307 20-349 20-406
20-229 20-308 20-350 20-407 20-501
20-230 20-309 20-351 20-408 20-502
20-231 20-310 20-352 20-409 20-503
20-232 20-312 20-353 20-410 20-504
20-233 20-313 20-354 20-411 20-505
20-234 20-314 20-355 20-412 20-506
20-235 20-315 20-356 20-414 20-507
20-236 20-316 20-357 20-415 20-508
20-237 20-317 20-358 20-416 20-509
20-238 20-318 20-359 20-417 20-510
20-239 20-319 20-360 20-418 20-511
20-240 20-320 20-362 20-419 20-512
20-241 20-322 20-363 20-420 20-513
20-242 20-323 20-364 20-421 20-514
20-243 20-324 20-365 20-422 20-515
20-244 20-325 20-366 20-423 20-516
20-245 20-326 20-367 20-424 20-517
20-246 20-327 20-368 20-425 20-518
20-247 20-328 20-369 20-426 20-519
20-248 20-329 20-370 20-427 20-520
20-249 20-330 20-371 20-428 20-521
20-250 20-331 20-372 20-429 20-522
20-251 20-332 20-373 20-430 20-523
20-252 20-333 20-374 20-431 20-524
20-253 20-334 20-375 20-432 20-525
20-254 20-335 20-376 20-433 20-526
20-255 20-336 20-377 20-434 20-527
PC1250-7 00-2-3

20-528
20-529
20-530
20-531
20-532
20-534
20-535
20-536
20-537
20-538
20-539
20-540
20-541
20-542
20-543
20-551
20-552
20-553
20-554
20-555
20-556
20-557
20-558
90-1
90-3
90-5
90-7
90-9
90-11
90-13
00-2-4 PC1250-7
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is 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 ¤ is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
¤ Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
are necessary when per-
4
number.
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
Weight when selecting hoisting
3
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
Places that require special
2
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
Places to be coated with
5
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
6
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
¤ Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
¤
but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
¤ Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
¤
tank.
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.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ 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. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl or ide) ,
rubber, metal and non-metal.
• Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene • Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz • Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
• Quick hardening type adhesive

Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.
• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
• Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene • Resistance to heat, chemicals

79A-129-9110 50 cc • Used at joint portions subject to
648-50 container
high temperatures.
• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
• Features: Silicon based, resist-

ance to heat, cold
• Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond • Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.
SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 13.2 0 1.4 1.35 0 0.15

8 13 31 03 3.2 0 0.3
10 17 66 07 6.7 0 0.7
12 19 113 0 10 11.501
14 22 177 0 19 1802
16 24 279 0 30 28.5 0 3
18 27 382 0 39 39 0 4
20 30 549 0 59 56 0 6
22 32 745 0 83 76 0 8.5
24 36 927 0 103 94.5 0 10.5
27 41 1320 0 140 135 0 15

30 46 1720 0 190 175 0 20
33 50 2210 0 240 225 0 25
36 55 2750 0 290 280 0 30
39 60 3290 0 340 335 0 35
Thread diameter Width across

of bolt flats
mm mm Nm kgm
6 10 0
7.85 1.95 0.8 0 0.2
8 13 0
18.6 4.9 1.9 0 0.5
10 14 0
40.2 5.9 4.1 0 0.6
12 27 0
82.35 7.85 8.4 0 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
SAD00483
the table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 0
24.5 4.9 0
2.5 0.5
18 24 0
49 19.6 5 2 0
22 27 0
78.5 19.6 8 2 0
24 32 0
137.3 29.4 14 3 0
30 36 0
176.5 29.4 18 3 0
33 41 0
196.1 49 20 5 0
36 46 0
245.2 49 25 5 0
42 55 0
294.2 49 30 5 0
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 0
65.7 6.8 0
6.7 0.7
12 17 112 9.80 11.5 1 0
16 22 279 290 28.5 3 0
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 0
34.3 4.9 3.5 0 0.5
03, 04 20 Varies depending 0
93.1 9.8 9.5 01
05, 06 24 on type of 0
142.1 19.6 14.5 02
10, 12 33 connector. 0
421.4 58.8 43 06
14 42 0
877.1 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 0
7.35 1.47 0.75 0.15 0
10 10 17 0
11.27 1.47 1.15 0.15 0
12 12 19 0
17.64 1.96 1.8 0.2 0
14 14 22 0
22.54 1.96 2.3 0.2 0
16 16 24 0
29.4 4.9 3 0.5 0
18 18 27 0
39.2 4.9 4 0.5 0
20 20 30 0
49 4.9 5 0.5 0
24 24 32 0
68.6 9.8 7 1 0
30 30 32 0
107.8 14.7 11 1.5 0
33 33 n 0
127.4 19.6 13 2 0
36 36 36 0
151.9 24.5 15.5 2.5 0
42 42 n 0
210.7 29.4 21.5 3 0
52 52 n 0
323.4 44.1 33 4.5 0
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 0
10 2 1.02 0 0.20
8 0
24 4 2.45 0 0.41
10 0
43 6 4.38 0 0.61
12 0
77 12 7.85 0 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 0
8 2 0.81 0 0.20
8 0
10 2 1.02 0 0.20
10 0
12 2 1.22 0 0.20
12 0
24 4 2.45 0 0.41
14 0
36 5 3.67 0 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.
mm Nm kgm
1 / 16 0
3 1 0.31 0 0.10
1/8 0
8 2 0.81 0 0.20
1/4 0
12 2 1.22 0 0.20
3/8 0
15 2 1.53 0 0.41
1/2 0
24 4 2.45 0 0.41
3/4 0
36 5 3.67 0 0.51
1 0
60 9 6.12 0 0.92
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
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.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters 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 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.
B
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
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
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
00-16
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
00-17
Liter to U.S. Gallon

l
1 = 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
Liter to U.K. Gallon

l
1 = 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 7.969 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
00-18
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
00-19
kg/cm2 to lb/in2
1kg/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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
Specification dimension drawings ............... 01-2

Specifications ................................................. 01-4
Weight table .................................................. 01-6
Fuel, coolant and lubricants ........................ 01-8
PC1250-7 01-1
GENERAL SPECIFICATION DIMENSION DRAWINGS
SPECIFICATION DIMENSION DRAWINGS

DIMENSIONS
WORKING RANGES
01-2 PC1250-7
GENERAL SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
PC1250LC-7
Item Unit PC1250-7 PC1250SP-7
(Only North America)
A Overall length mm 16,020 14,790 16,020
B Overall height mm 6,040 6,265 6,040
C Overall width mm 5,355 5,355 5,355
D Track shoe width mm 700 700 1,000
E Height of cab mm 4,120 4,120 4,120
F Tail swing radius mm 4,870 4,870 4,870
G Track overall length mm 6,425 6,425 7,400
H Length of track on ground mm 4,995 4,995 5,970
I Min. ground clearance mm 990 990 990
WORKING RANGES
PC1250LC-7
Item Unit PC1250-7 PC1250SP-7
(Only North America)
A Max. digging reach mm 15,350 14,070 15,350
B Max. digging depth mm 9,350 7,900 9,350

C Max. digging height mm 13,400 13,000 13,400
D Max. vertical wall depth mm 7,610 5,025 7,610
E Max. dumping height mm 8,680 8,450 8,680
F Max. reach at ground level mm 15,000 13,670 15,000
PC1250-7 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model PC1250-7 PC1250SP-7 PC1250LC-7

Serial Number 20001 and up 20001 and up 20001 and up
Bucket capacity m3 5.0 6.7 5.0
Weight of machine kg 105,600 (108,700) 109,500 112,600

Max. digging depth mm 9,350 7,900 9,350
Working ranges
Max. vertical wall depth mm 7,610 5,025 7,610
Max. digging reach mm 15,350 14,070 15,350

Max. reach at ground level mm 15,000 13,670 15,000
Max. digging height mm 13,400 13,000 13,400

Performance
Max. dumping height mm 8,680 8,450 8,680

Max. digging force kN {kg} 479 {48,800} 569 {58,100} 479 {48,800}
Swing speed rpm 5.5 5.5 5.5
Swing max. slope angle deg. 12 12 12

Travel speed km/h Lo: 2.1 Hi: 3.2 Lo: 2.1 Hi: 3.2 Lo: 2.7 Hi: 3.2
Gradeability deg. 35 35 35
Ground pressure
kPa {kg/cm2} 135 {1.38} 140 {1.43} 85 {0.87}
[standard double grouser shoe width] [700 mm] [700 mm] [1,000 mm]
Overall length mm 16,020 14,790 16,020
Overall width mm 5,355 5,355 5,355

Overall width of track mm 4,965 4,965 5,265
Overall height (for transport) mm 6,040 6,265 6,040
Overall height to top of machine mm 4,880 4,880 4,880

Ground clearance of upper structure mm 1,790 1,790 1,790
Dimensions
Min. ground clearance mm 990 990 990
Tail swing radius mm 4,870 4,870 4,870

Min. swing radius of work equipment mm 7,965 6,415 7,965
Height of work equipment at min. swing radius mm 11,390 11,020 11,390
Length of track on ground mm 4,995 4,995 5,970

Track gauge mm 3,900 3,900 3,900
Height of machine cab mm 3,985 3,985 3,985
01-4 PC1250-7
GENERAL SPECIFICATIONS

Model SAA6D170E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore x stroke mm 6 – 170 x 170

Piston displacement ¬ {cc} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 485/1,800 {651/1,800}
Performance
Engine
Max. torque Nm/rpm {kgm/rpm} 2,908/1,300 {296.5/1,300}

Max. speed at no load rpm 2,000
Min. speed at no load rpm 900
Min. fuel consumption g/kWh {g/HPh} 203 {151}
Starting motor 24V, 11 kW x 2
Alternator 24V, 50A
Battery 12V, 200 Ah x 2
Radiator core type CWX-5
Carrier roller 3 on each side 3 on each side
carriage
Under-
Track roller 8 on each side 10 on each side

Track shoe Assembly-type double Assembly-type double
grouser, 48 on each side grouser, 55 on each side
Type Variable displacement piston type:
Hydraulic
HPV160+160, HPV95+95 x 2; gear type SAR100+020+010

pump
Delivery ¬/min Piston type: 494+494+600, gear type: 158+33+16

Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Control
Type x No. 4-spool type x 2, + 5-spool type x 1

valve
Control method Hydraulic

Travel motor Piston type (with brake valve, shaft brake):
Hydraulic
x 2 (MSF340VP-EH)
motor
Hydraulic system
Swing motor Piston type (with safety valve, shaft brake):

x 2 (KMF160AB-2)
ª1, ª2 Bucket
ª1 Boom ª1, ª2 Arm
STD SP version
Hydraulic cylinder
Cylinder type Double-acting piston Double-acting piston

Inside diameter of cylinder mm 225 250 160 160
Outside diameter of piston rod mm 160 170 110 110
Stroke mm 2,390 2,435 1,825 1,950
Max. distance between pins mm 5,839 3,620 2,535 2,660
Min. distance between pins mm 3,449 6,055 4,360 4,610
Hydraulic tank Box-shaped, with breather
Hydraulic filter Tank return side
Hydraulic cooler Air cooled (J5)
ª1: Head side with cushion ª2: Bottom side with cushion
PC1250-7 01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
¤ This weight table is a guide for use when transporting or handling components
Unit: kg

Engine assembly 3,978 3,978 3,978
• Engine 2,952 2,952 2,952
• PTO (incl. lubricating piping) 505 505 505
• No. 1 pump 157 157 157
• No. 2 pump 148 148 148
• No. 3 pump 191 191 191
• Control pump (for control, PTO lubrication 24.5 24.5 24.5
and aftercooler fan drive)
Radiator assembly 259 259 259
Oil cooler assembly 238 238 238
Hydraulic tank (excl. hydraulic oil) 776 776 776
Revolving frame (incl. left and right decks) 10,630 10,630 10,630
Operator’s cab 323 323 323
Swing machinery 488 x 2 488 x 2 488 x 2
Swing motor assembly 126 x 2 126 x 2 126 x 2
Travel motor assembly 130 x 2 130 x 2 130 x 2
L.H. 5-spool control valve 260 260 260
R.H. 4-spool control valve 253 253 253
Swing 4-spool control valve 240 240 240
Center swivel joint 69 69 69
Counterweight 18,000 18,000 18,000
Track frame assembly 28,374 28,374 30,814
• Center frame 7,400 7,400 7,400
• Track frame 4,390 x 2 4,390 x 2 5,230 x 2
• Carrier roller 80 x 6 80 x 6 80 x 6
• Track roller 190 x 16 190 x 16 190 x 20
• Idler cushion assembly 1,000 x 2 1,000 x 2 1,000 x 2
• Idler 788 x 2 788 x 2 788 x 2
• Final drive assembly 1,869 x 2 1,869 x 2 1,869 x 2
• Swing circle assembly 2,165 2,165 2,165
01-6 PC1250-7
GENERAL WEIGHT TABLE
Unit: kg
Track shoe assembly

• Standard shoe (700 mm) 10,630 10,630 —
• Wide shoe (1,000 mm) 12,940 12,940 14,820
• Wide shoe (1,200 mm) — — 16,350

Boom assembly (excl. piping) 10,380 10,275 10,380
Arm assembly (excl. piping) 3,520 3,915 3,520
Bucket assembly (excl. piping) 4,579 6,191 4,579

Boom cylinder assembly 1,174 x 2 1,174 x 2 1,174 x 2
Arm cylinder assembly 1,538 1,538 1,538
Bucket cylinder assembly 442 x 2 459 x 2 442 x 2

Boom foot pin 72 x 2 72 x 2 72 x 2
Boom cylinder foot pin 43.8 x 2 43.8 x 2 43.8 x 2

Boom cylinder top pin 43.2 x 2 43.2 x 2 43.2 x 2
Boom-arm connecting pin 168.6 168.6 168.6
Arm cylinder foot pin 92.9 101.3 92.9

Arm cylinder top pin 97.9 97.9 97.9
Link-arm connecting pin 103 103 103
Link-bucket connecting pin 110.4 110.4 110.4

Bucket cylinder top pin 37.9 37.9 37.9
Bucket cylinder foot pin 37.9 37.9 37.9
Arm-bucket connecting pin 120.4 120.4 120.4

Link assembly 817 878 817
Link connecting pin 103 103 103
PC1250-7 01-7
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY (¬)
KIND OF
RESERVOIR –22 –4 14 32 50 68 86 104°F
FLUID Specified Refill
–30 –20 –10 0 10 20 30 40°C
SAE 30
SAE 10W
Engine oil pan 68 55.3
SAE 10W-30
SAE 15W-40
SAE 30
PTO case Engine 13.5 13.5
oil SAE 10W
Swing machinery case (each side) 24.3 24.3

SAE 30
Final drive case (each side) 22 22
SAE 10W
Hydraulic system 800 670
Hydraulic
oil HO46-HM fl
Idler (1 each) 0.75 – 0.83 0.75 – 0.83

Gear
Track roller (1 each) oil GO 140B 0.80 – 0.85 0.80 – 0.85
Carrier roller (1 each) 0.45 – 0.50 0.45 – 0.50
ASTM D975 No. 2

Fuel tank Diesel 1,360 —
fuel ASTM D975A No.1
Cooling system Coolant Add antifreeze 140 —
fl For HO46-HM, use the oil we recommend.

ª Use only diesel fuel.
01-8 PC1250-7
STRUCTURE, FUNCTION AND
10 MAINTENANCE STANDARD
PTO ................................................................ 10- 2 Line oil filter ............................................... 10- 76

PTO lubrication system ............................... 10- 4 Pilot oil filter ............................................... 10- 77
Radiator, oil cooler, aftercooler and Return oil filter ........................................... 10- 78
fuel cooler .............................................. 10- 6 Drain oil filter ............................................. 10- 79
Power train ................................................... 10- 8 L.H. 5-spool control valve ......................... 10- 80
Swing machinery ......................................... 10-10 R.H. 4-spool control valve ......................... 10- 84
Swing circle .................................................. 10-12 Swing. 4-spool control valve .................... 10- 88
Final drive ..................................................... 10-13 Straight-travel valve .................................. 10- 94
Track frame ................................................... 10-16 Swing motor ............................................... 10- 97
Idler ................................................................ 10-18 Center swivel joint ..................................... 10- 99
Carrier roller ................................................. 10-20 Travel motor ............................................... 10-100
Track roller .................................................... 10-21 PPC control relief valve ............................. 10-110
Track shoe .................................................... 10-22 Accumulator ............................................... 10-112
Air piping diagram ....................................... 10-26 Valve control .............................................. 10-113
Air circuit diagram ....................................... 10-27 Work equipment, swing PPC valve .......... 10-114
Air governor ................................................. 10-28 Travel PPC valve ........................................ 10-120
Air tank .......................................................... 10-28 Solenoid valve ............................................ 10-124
Safety valve .................................................. 10-29 Hydraulic cylinder ...................................... 10-130
Horn valve .................................................... 10-29 Work equipment ........................................ 10-132
Grease pump ................................................ 10-30 Dimensions of work equipment ............... 10-134
Hydraulic equipment layout drawing ........ 10-32 Air conditioner ........................................... 10-138
Hydraulic tank .............................................. 10-37 Engine control ............................................ 10-139
Hydraulic pump ............................................ 10-38 HPI Engine control system ....................... 10-145
NO. 1 pump .................................................. 10-39 Machine control system ............................ 10-147
NO. 2 pump .................................................. 10-62 Monitor system .......................................... 10-175
NO. 3 pump .................................................. 10-67 Sensor ......................................................... 10-192
PC1250-7 10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO
PTO
10-2 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO
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
8. Breather
A. Center of HPV160+160 shaft

B. Center of crankshaft (SAR100+020+010)
C. Center of HPV95+95 shaft
D. Center of HPV95+95 shaft
Specifications
Lubricating oil : 13.5 ¬
Reduction ratio: SAR100+020+010 shaft = 1
HPV160+160 shaft = 49 = 0.875
56
HPV95+95 shaft = 42 = 0.750
56
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit

Backlash between drive
9 gear and driven shaft
(for HPV160+160) 0.07 – 0.18 —

10 gear and driven gear 0.273 – 0.374 —
(for SAR100+020+010) Adjust
Backlash between
11 drive gear and driven gear 0.2 – 0.74 —

12 gear and driven shaft 0.07 – 0.18 —
(for HPV95+95)
PC1250-7 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO LUBRICATION SYSTEM
PTO LUBRICATION SYSTEM

Hydraulic circuit diagram
Hydraulic piping diagram
1. PTO case Outline

2. Divider block The lubricating oil inside PTO case (1) passes
3. Lubricating pipe through oil filter (5), is sent to top divider block
4. Control, PTO lubricating, aftercooler fan drive (2), and is then divided to various parts of the
pump (SAR100+020+010) PTO to lubricate and cool the gears.
5. Oil filter
10-4 PC1250-7
RADIATOR, OIL COOLER,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCOOLER AND FUEL COOLER
RADIATOR, OIL COOLER, AFTERCOOLER AND FUEL COOLER
10-6 PC1250-7
RADIATOR, OIL COOLER,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AFTERCOOLER AND FUEL COOLER
1. Aftercooler Specifications
2. Reservoir tank 1. Fan
3. Aftercooler fan Outside diameter: 1,350 mm
4. Fan guard No. of vanes: 6
5. Fan pulley Rotating speed: Standard 999 rpm
6. Radiator inlet tube (At rated engine speed of
7. Fan 1,800 rpm)
8. Radiator upper tank 2. Radiator
9. Oil cooler Core type: CWX-5
10. Radiator lower tank Fin pitch: 3.5 mm
11. Radiator outlet tube Cracking pressure for pressure valve:
12. Fuel cooler 49 ± 9.8 kPa
{0.5 ± 0.1 kg/cm2}
Cracking pressure for vacuum valve:
0 – 4.9 kPa
{0 – 0.05 kg/cm2}
3. Oil cooler
Core type: J5
Fin pitch: 3 mm
4. Aftercooler fan
Outside diameter: 620 mm
No. of vanes: 8
Rotating speed: Standard 1,430 rpm
(At rated engine speed of
1,800 rpm)
5. Fuel cooler
Core type: 3A-CS
Fin pitch: 3.5 mm
PC1250-7 10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
10-8 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
1. Idler 9. PTO 15. Swing brake solenoid valve

2. Center swivel joint 10. No. 3 pump (HPV160+160) 16. Travel speed solenoid valve
3. Swing motor (KMF160AB-2) 11. No. 1 pump (HPV95+95) 17. Swing machinery
4. L.H. 5-spool control valve 12. No. 2 pump (HPV95+95) 18. Swing circle
5. R.H. 4-spool control valve 13. Control, PTO lubricating,
6. Final drive, sprocket aftercooler fan drive pump A. Swing 4-spool control valve
7. Travel motor (MSF340VP) (SAR100+020+010) B. Swing brake solenoid valve
8. Engine (SAA6D170E-3) 14. Swing 4-spool control valve
PC1250-7 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
10-10 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
1. Swing pinion (No. of teeth: 13)

2. Cover
3. Case
4. Coupling
5. No. 2 planet 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 x 19 + 97
20 19
= 35.716
Unit: mm

Backlash between swing
16 motor shaft and No. 1 sun
gear 0.19 – 0.29 —
Backlash between No. 1 sun

17 gear and No. 1 planet gear 0.19 – 0.51 0.90
Backlash between No. 1

18 planet gear and ring gear 0.24 – 0.70 0.90

19 planetary carrier and 0.06 – 0.24 —
coupling
20 planetary carrier and No. 2 0.38 – 0.78 1.10
sun gear Replace
21 gear and No. 2 planet gear 0.17 – 0.52 1.00

22 planet gear and ring gear 0.21 – 0.64 1.10
Backlash between coupling

23 and swing pinion 0.08 – 0.25 —
Backlash between swing

24 pinion and swing circle 0 – 1.13 2.00
Clearance between plate

25 and coupling 0.06 – 0.86 —
Standard size Repair limit

Repair hard
Wear of swing pinion oil chrome plating
26 seal contact surface 0
150 –0.100 — or replace
PC1250-7 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 132) Specifications

2. Ball Reduction ratio: 183 =14.077
3. Swing circle outer race 13
Amount of grease: 65 ¬ (G2-LI)
a. Inner race soft zone “S” position
b. Outer race soft zone “plug” position
Unit: mm
Standard clearance Repair limit

Clearance of bearing in
4 axial direction (when Replace
mounted on machine) 0.5 – 2 4
10-12 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
1. Level plug
2. Drain plug
3. Cover
6. Drive gear (No. of teeth: 19)
9. Hub
10. Sprocket
11. Floating seal
12. Case
13. Coupling
15. Travel motor
16. Idler gear (No. of teeth: 27)
17. No. 1 ring gear (No. of teeth: 68)
20. No. 2 ring gear (No. of teeth: 63)
Specifications
13 + 68 19 + 69
Reduction ratio: – ( )×( )
13 19
63
× ( 13 ) = –139.852
PC1250-7 10-13
10-14 PC1250-7
Unit: mm

21 planetary carrier and case
0.08 – 0.27 —
Backlash between drive gear

22 and No. 1 planetary carrier 0.47 – 0.97 —

23 sun gear and No. 1 0.47 – 0.97 —
planetary carrier
24 sun gear and No. 2 0.25 – 0.82 —
planet gear
25 planetary carrier and No. 2 0.29 – 0.82 —
ring gear
26 Backlash between coupling 0.38 – 0.72 — Replace

and drive gear

27 ring gear and case 0.08 – 0.26 —

28 sun gear and travel motor 0.07 – 0.85 —
coupling
29 gear and idler gear 0.15 – 0.53 —
Backlash between No.1

30 ring gear and idler gear 0.19 – 0.62 —
Backlash between driven

31 gear and No. 1 planet gear 0.19 – 0.62 —
32 Wear of sprocket tooth shape Repair limit: 6

Rebuild or
33 Sprocket tooth width replace
114 108
PC1250-7 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
fl The diagram shows the PC1250LC-7.
1. Idler • 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
5. Final drive • No. of track rollers
6. Track roller
7. Track shoe Model No. of rollers (each side)
8. Idler cushion
PC1250-7
9. Front guard 8
PC1250SP-7
PC1250LC-7 10
10-16 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME
TRACK SHOE
Standard shoe
Model PC1250-7 PC1250SP-7 PC1250LC-7
Item
Shoe width
(double shoe) 700 mm 700 mm 1000 mm
Link pitch 280 mm 280 mm 280 mm

No. of shoes
(each side) 48 48 55
Unit: mm
Standard size Tolerance Repair limit

Rebuild or
Track frame 200 200±2 205 replace
10 Top-to-bottom width of
idler guide
Idler support 195 195±1.2 185 Replace
Track frame 395 395±2 405 Rebuild or

Left-to-right width of idler replace
11 guide
+1.4
Idler support 391 391 –0.8 383

Replace
Free length Installation Installation Installation
Free length
12 Recoil spring x O.D. length load load
578.2 kN 460.9 kN
1,508 x 351 1,280 —
{58,957 kg} {47,000 kg}
PC1250-7 10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
10-18 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
Unit: mm

Outside diameter of
1
protruding part 962 —
Outside diameter of tread

2 920 908 Rebuild or
surface
replace
3 Depth of tread 21 —
4 Overall width 290 —
5 Width of tread 77 —
Tolerance
Standard Standard Clearance
Clearance between shaft size Shaft Hole clearance limit
6 and bushing
–0.080 +0.313 0.353 – Replace
125 –0.120 +0.273 0.433 1.5 bushing
Tolerance
Standard Standard Interference
Interference between idler size Shaft Hole interference limit
7 and bushing
+0.096 –0.098 0.140 –
135 +0.042 –0.148 0.244 —
PC1250-7 10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm

1 Outside diameter of flange
220 —
2 Outside diameter of tread 205 185
4 Thickness of tread 67.6 —
5 Width of foange 17 — Replace
Tolerance
Interference between size Shaft Hole interference limit
6 bearing and roller
125 0 0 0 – 0.040 —
–0.020 –0.040
Interference between +0.390 0.059 0.020 –

7 bearing and shaft 70 +0.020 –0.015 0.054 —
Standard size Clearance limit

Play of roller in axial
8
direction 0 – 0.110 0.3
10-20 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm

1 Outside diameter of flange
320 —
Outside diameter of tread

2 surface 275 263
3 Thickness of tread 77.5 —

Rebuile or
replace
4 Overall width 370 —
5 Inside width 136 —
7 Width of flange 35 —
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance between shaft
8 and bushing
110 –0.120 +0.360 0.380 – 1.5
–0.207 +0.260 0.567 Replace
Tolerance bushing
Interference between roller size Shaft Hole interference limit
9 and bushing
120 +0.087 +0.020 0.017 – —
+0.037 –0.015 0.102
PC1250-7 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
fl P portion shows the link of bushing press fitting end.
10-22 PC1250-7
Unit: mm

1 Link pitch
280.3 283.3
When turned Reverse or

Standard size replace
Normal load Impact load
2 Bushing outside diameter
98 93 —
Repair or
3 Link height replace
181 168
Thickness of link metal

4 (bushing press-fitting portion) 56
5 256.6
Replace
6 Shoe bolt pitch 183
7 79.5
8 Inside width 135
9 Link Overall width 86.1 Repair or

replace
10 Tread width 75
11 Protrusion of pin 4.5
12 Protrusion of regular bushing 8.7
13 Overall length of pin 324.4

Adjust or
replace
14 Overall length of bushing 225.6
15 Thickness of bushing metal 18.8
16 Thickness of spacer 10.93
17 Bushing 215 – 304 kN {22 – 31 ton}

Press-fitting
18 force Regular pin 637 – 745 kN {65 – 76 ton} —
ª
19 Master 235 – 294 kN {24 – 30 ton}
ª : Dry type track link
PC1250-7 10-23
Unit: mm
Tightening torque Additional tightening

(Nm {kgm}) angle (deg.)
a. Regular link
1,372±137 {140±14} 150±10
Shoe bolt Retighten
20 Tightening torque Additional tightening Lower limit torque
(Nm {kgm}) angle (deg.) (Nm {kgm})
b. Master link
— — —
No. of shoes (each side) 48 —
Standard Tolerance Standard

size Shaft Hole interference
Interference between
21 bushing and link
98 +0.622 +0.087 0.435 – 0.622
+0.522 0
Interference between +0.426 –0.126
22 60 0.452 – 0.626
regular pin and link +0.326 –0.200
Clearance between size Shaft Hole clearance
23
regular pin and bushing
–0.174 +0.666 Adjust or
60.5 0.340 – 0.740 replace
–0.074 +0.166
ª size interference
Interference between Shaft Hole
24
master pin and link +0.228 –0.126
60 0.324 – 0.428
+0.198 –0.200
ª Clearance between size Shaft Hole clearance
25 master pin and bushing
60.5 –0.51 +0.666 0.676 – 1.276
–0.61 +0.166
ª : Dry type track link
10-24 PC1250-7
DOUBLE SHOE
Unit: mm

1 Height
50 25
2 Height 50 25
3 Thickness 25
Rebuild or
39 replace
4
Length at bottom
5 —
6 30
Length at top
7 30
PC1250-7 10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR PIPING DIAGRAM
AIR PIPING DIAGRAM
1. Grease gun Outline

2. Grease reel This machine uses pressurized air to operate
3. Grease pump the air horn and automatic greasing system.
4. Air governor The pressurized air is supplied by air compres-
5. Air compressor sor (5) installed to the engine and is stored in
6. Safety valve air tank (7).
7. Air tank When the pressure in the air tank reaches 0.71
8. Horn valve MPa {7.2 kg/cm2}, the air compressor is unloaded;
9. Air horn when the tank pressure drops below 0.59 MPa
10. Lock valve {6.0 kg/cm2}, the air compressor again starts to
supply pressurized air.
10-26 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CIRCUIT DIAGRAM
AIR CIRCUIT DIAGRAM
1. Air compressor (capacity: 70 ¬/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
PC1250-7 10-27
AIR GOVERNOR
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR TANK
AIR GOVERNOR
1. Body
2. Spring
3. Exhaust stem
4. Piston
5. Inlet valve
6. Filter
A : From air tank

B : From air compressor
C : Exhaust
Function Specifications
• Port A is connected to the air tank and port • Cut-out pressure: 0.71 ± 0.03 MPa
B is connected to the unloader valve of the {7.2 ± 0.3 kg/cm2})
air compressor. The air governor maintains • Cut-in pressure: 0.59 ± 0.03 MPa
the air pressure inside the air tank within {6.0 ± 0.3 kg/cm2})
the specified range. If the pressure exceeds
the specified pressure, it stops the operation
of the air compressor to prevent the air pres-
sure from rising any higher.
AIR TANK
Specifications
• Capacity: 15 ¬
10-28 PC1250-7
SAFETY VALVE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HORN VALVE
SAFETY VALVE
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})
Function
• The safety valve is installed to the air tank,
and if any pressure above the set pressure
is generated in the air circuit, it acts to re-
lease the compressed air inside the air tank
to the atmosphere in order to maintain the
safety of the air circuit.
HORN VALVE
1. Spring
2. Magnet
3. Wire
4. Wire
5. Coil
6. Cover
7. Piston
8. Body
A : From air tank

B : To horn
PC1250-7 10-29
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD GREASE PUMP
GREASE PUMP
1. Silencer Function
2. Valve • The pump is divided into air chamber (4)
3. Cover and grease chamber (6). As the amount of
4. Air chamber grease in grease chamber (6) goes down,
5. Follow plate follow plate (5) is pulled down to push down
6. Grease chamber the grease stuck to the edge of grease cham-
7. Grease tank ber (6).
A : Air inlet port

B : Grease outlet port
10-30 PC1250-7
HYDRAULIC EQUIPMENT
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LAYOUT DRAWING
HYDRAULIC EQUIPMENT LAYOUT DRAWING

(1/2)
10-32 PC1250-7
HYDRAULIC EQUIPMENT
PC1250-7 10-33
HYDRAULIC EQUIPMENT
(2/2)
10-34 PC1250-7
HYDRAULIC EQUIPMENT
PC1250-7 10-35
HYDRAULIC EQUIPMENT
1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Aftercooler fan drive motor
6. Line oil filter (for R.H. 4-spool control valve)
7. Oil cooler
8. Line oil filter (for L.H. 5-spool control valve)
9. Line oil filter (for swing 4-spool control valve)
10. Return oil filter
11. L.H. travel motor
12. Drain oil filter
13. Hydraulic tank
14. Center swivel joint
15. R.H. 4-spool control valve
16. L.H. 5-spool control valve
17. Swing 4-spool control valve
18. Swing priority selector solenoid valve
19. CO cancel solenoid valve
20. Straight-travel solenoid valve
21. Heavy lift solenoid valve
22. Machine push-up solenoid valve
23. Travel speed selector solenoid valve
24. Pilot oil filter
25. Swing holding brake solenoid valve
26. Safety lock valve
27. No. 3 pump
28. Control, PTO lubrication, aftercooler fan drive pump
29. No. 2 pump
30. Oil filter
31. No. 1 pump
32. PPC control relief valve
33. Accumulator
34. Boom control valve
35. L.H. PPC valve
36. Travel PPC valve
37. R.H. PPC valve
10-36 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
1. Hydraulic tank Specifications

2. Strainer Tank capacity: 1,146 ¬
3. Oil filler cap Amount of oil inside tank: 664 ¬ (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 guage Suction cracking pressure: 0 – 0.49 kPa
9. Hydraulic oil temperature gauge {0 – 0.005 kg/cm2}
10. Suction strainer
11. Drain valve
PC1250-7 10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
1. No. 3 pump (HPV160+160) Outline

2. Control pump assembly (SAR100+020+010) The hydraulic pumps consist of three variable
2A. For PPC valve control (SAR100) displacement swash plate type piston pumps
2B. For aftercooler fan drive motor (SAR020) and a control pump. The piston pumps have the
2C. For PTO lubrication (SAR010) valves shown in the table below, and the con-
3. No. 2 pump (HPV95+95) trol pump is used for the PPC valve control,
4. No. 1 pump (HPV95+95) aftercooler fan drive, and PTO lubrication.
Pump No.1 (HPV95+95) No.2 (HPV95+95) No.3 (HPV160+160)
(type)
Valve Front Rear Front Rear Front Rear
TVC — — — — —
CO — — —
NC — — —
Servo
10-38 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD NO. 1 PUMP
NO. 1 PUMP
HPV95+95
1. Front pump P3 : Swing pump pressure IN port Pd : Jet sensor downstream

2. Front servo valve PA1 : Discharge port pressure IN port
3. Front CO, NC valve PA2 : Discharge port Ps : Suction port
4. Rear servo valve Pd11 : Drain port Pt : Jet sensor upstream pressure
5. Rear CO, NC valve Pd21 : Drain port IN port
6. TVC valve Pc : CO selector pilot port Psv : Servo basic pressure IN port
7. Rear pump
PC1250-7 10-39
1. No. 1 main pump
Pac : Servo actuator port

Psv : Servo basic pressure IN port
10-40 PC1250-7
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
PC1250-7 10-41
2. No. 1 pump front servo assembly
1. CO, NC valve Pc : CO selector pilot port

2. Servo valve Pd : Jet sensor downstream pressure IN port
Pt : Jet sensor upstream pressure IN port
PA1 : Main pump pressure IN port Pdr : Servo valve drain OUT port
Pe1 : TVC valve output pressure detection port Psv : Servo basic pressure IN port
Pe2 : TVC valve output pressure front, rear in- Pecn : CO, NC valve output pressure OUT port
terconnection port
10-42 PC1250-7
No. 1 pump front servo valve
PA2(IN) : Main pump pressure IN port Pdr(OUT) : Servo valve drain OUT port
PA2(OUT) : Main pump pressure OUT port Psv1 : Servo basic pressure IN port
Pac : Servo actuator port Pecn : CO, NC valve output pressure IN port
Pdr : CO, NC valve drain port
PC1250-7 10-43
3. No. 1 pump rear servo assembly
1. TVC valve Pd : Jet sensor downstream pressure IN port

2. CO, NC valve Pe : TVC valve output pressure front, rear inter-
3. Connector connection port
4. Servo valve Pt : Jet sensor upstream pressure IN port
P1 : Main pump pressure IN port Pdr : Servo valve drain OUT port
P2 : Main pump pressure IN port Psv : Servo basic pressure IN port
Pc : CO selector pilot port
10-44 PC1250-7
No. 1 pump rear servo valve
PA1(IN) : Main pump pressure IN port Pdr : CO, NC valve drain port
PA1(OUT) : Main pump pressure OUT port Pdr(OUT) : Servo valve drain OUT port
PA2(IN) : Main pump pressure IN port Psv1 : Servo basic pressure IN port
PA2(OUT) : Main pump pressure OUT port Psv2 : Servo basic pressure OUT port
PC1250-7 10-45
1. Plug 7. Spring 13. Plug

2. Locknut 8. Plug 14. Spring
3. Control piston 9. Cover 15. Piston
4. Pin 10. Locknut 16. Sleeve
5. Arm 11. Locknut 17. Cover
6. Valve body 12. Cover 18. Locknut
Function
Discharge amounts Q1 and Q2 of main pumps
PA1 and PA2 are controlled individually by the
respective servo valves. The relationship be-
tween pump discharge amount Q and input sig-
nal Pecn to the servo valve is as shown in the
graph on the right. Q varies in proportion to
Pecn.
10-46 PC1250-7
Operation
1) Operation in direction of increase of pump discharge amount (max. angle)
• The control pump pressure Psv is taken to drain chamber e. As a result, servo piston
port a. chamber f is also interconnected with cham-
Signal pressure Pecn from the NC valve is ber e through port g and port d.
taken from port b to chamber c. At the same time, port a is interconnected
• When signal pressure Pecn rises, control pis- with port h, so the oil flows through port i to
ton (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 discharge amount.
At the same time, arm (6) uses servo piston • When servo piston (19) moves, arm (6) ro-
(19) as a fulcrum and sways to the left in the tates clockwise with its center at pin (7).
same way as control piston (8). This moves Guide spool (13) is moved to the right and
guide spool (13) to the left. closes port a, port d and port h, so the dis-
• When guide spool (13) moves, port a and charge increases by an amount that matches
port d are closed and port d is connected to signal pressure Pecn.
PC1250-7 10-47
2) Operation in direction of decrease of pump discharge amount (min. angle)
• When signal pressure Pecn goes down, con- At the same time, port a is interconnected
trol piston (8) moves to the right and stops with port d, so the oil flows through port g
at a point where the hydraulic pressure in to servo piston chamber f, pushes servo pis-
chamber c balances the pressure of springs ton (19) to the right, decreases the swash
(4) and (4A). plate angle in the main piston pump and
At the same time, arm (6) uses servo piston decreases the pump discharge amount.
(19) as a fulcrum and sways to the right in • When servo piston (19) moves, arm (6) ro-
the same way as control piston (8). This tates counterclockwise with its center at pin
moves guide spool (13) to the right. (7). Guide spool (13) is moved to the left and
• When guide spool (13) moves, port a and closes port a, port d and port h, so the dis-
port h are closed and port h is connected to charge decreases by an amount that matches
drain chamber e. As a result, servo piston signal pressure Pecn.
chamber j is also interconnected with cham-
ber e through port i and port h.
10-48 PC1250-7
4. TVC valve
PA1 : Main pump pressure IN port

PA2 : Main pump pressure IN port 1. Spring 6. Piston
PA3 : Swing pump pressure IN port 2. Spool 7. Body
Pd : TVC valve drain OUT port 3. Piston 8. Solenoid
Pe : TVC valve output pressure OUT port 4. Piston 9. Sleeve
Psv : Servo basic pressure IN port 5. Sleeve 10. Piston
PC1250-7 10-49
OPERATION AND FUNCTION OF TVC VALVE

1) When command current value from controller is small in DH and H mode
Function Operation
• When the power mode is at DH mode or H • The command current sent from the con-
mode, the pump discharge amount is controller actuates solenoid push pin (9) and
trolled to the optimum amount by the com- spool (2) moves. When this happens, the
mand current sent from the controller in ac- piston stops at a point where it balances the
cordance with the variation in the engine total of the force of spring (1), the force of
speed. push pin (9), and the force of
• In G mode or when the pump prolix switch TVC output pressure Pe acting on piston (3).
is ON, the pump discharge amount is con- The command current at this point is small,
trolled according to the pump discharge pres- so spool (2) is balanced at the bottom.
sure (load) by hydraulic sensing which fol- As a result, port a and port b are almost
lows a constant pump absorption torque. completely open, so the pressure oil from
the control pump is almost all output as TVC
fl For details, see MACHINE CONTROL SYS- output pressure Pe.
TEM. In this way, the pump discharge amount be-
comes the maximum.
10-50 PC1250-7
2) When command current value from controller is large in DH and H mode
Operation
• The command current sent from the con-
troller 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). The command current at
this point is large, so spool (2) is balanced at
the top.
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.
In this way, TVC output pressure Pe goes
down, and the pump discharge amount de-
creases.
PC1250-7 10-51
3) When pump load is small in G mode (pump prolix switch ON)
• When G mode is selected (pump prolix • Main pump discharge pressures PA1 and
switch ON) solenoid push pin (9) is pushed PA2 are low, so spool (2) is pushed down
up, increases the set pressure of spring (1), fully by spring (1). As a result, control pump
and this condition is maintained. discharge pressure Psv and TVC valve out-
• As a result, the pump absorption torque be- put pressure Pe are equal.
comes constant, so TVC output pressure Pe At this point, TVC valve output pressure Pe
(= pump discharge amount) is controlled by becomes the maximum, and the main pump
the pump discharge pressure. discharge amount is also the maximum.
10-52 PC1250-7
4) When pump load is large in G mode (pump prolix switch ON)
• When main pump discharge pressure PA1

(or PA2) increases, spool (2) is moved up by
piston (4) or piston (6). 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. In this way, TVC
output pressure Pe goes down, and the
pump discharge amount decreases.
PC1250-7 10-53
5. No. 1 pump front CO, NC valve
PA1i : Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
Pe1 : TVC valve output pressure front, rear Pt : Jet sensor upstream pressure IN port
interconnection port Pdr2 : Servo valve drain OUT port
Pe2 : TVC valve output pressure detection port Pecn : CO, NC valve output pressure OUT port
10-54 PC1250-7
6. No. 1 pump rear CO, NC valve
PA1i :Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
PA1o :Main pump pressure OUT port Pt : Jet sensor upstream pressure IN port
PA2i :Main pump pressure IN port Pdr1 : Servo valve drain IN port
PA2o :Main pump pressure OUT port Pdr2 : Servo valve drain OUT port
Pe1 : TVC valve output pressure front, rear in- Psv1 : Servo basic pressure IN port
terconnection port Psv2 : Servo basic pressure OUT port
Pe2 : TVC valve output pressure IN port Pecn : CO, NC valve output pressure OUT port
PC1250-7 10-55
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
10-56 PC1250-7
FUNCTION AND OPERATION OF CO VALVE

1) When main pump discharge pressure is lower than relief pressure
Function Operation
• When the load becomes large during opera- • Spool (4) is being pushed down fully by
tions and the main pump discharge pres- spring (3).
sure rises to a point close to relief pressure, As a result, port a and port b are fully open
the cut-off function of the CO valve acts to and TVC valve output pressure Pe and CO
reduce the pump discharge in order to re- valve output pressure Pec are equal.
duce relief loss. In this way, CO valve output pressure Pec
• At the same time, it has a cut-off cancel becomes the maximum and the main pump
function actuated by the pilot pressure from discharge amount also becomes the maxi-
the heavy-lift solenoid valve. mum.
• The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure PA and CO valve output pressure
Pec.
PC1250-7 10-57
2) When main pump discharge pressure becomes close to relief pressure
• If the load increases and main pump dis-

charge pressure PA comes close to the relief
pressure, main pump discharge pressure PA
pushes piston (5). At the same time, CO valve
output pressure Pec pushes piston (5), and
spool (4) moves up.
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.
In this way, CO valve output pressure Pec
goes down, and the pump discharge amount
becomes the minimum.
10-58 PC1250-7
3) When cut-off function is canceled by heavy-lift solenoid valve
• When the heavy-lift solenoid valve is excited

and is switched, pilot pressure Pc is sent to
the port, and piston (2) is pushed down fully.
For this reason, seat (6) contacts seat (7)
and spool (4) is locked.
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.
PC1250-7 10-59
FUNCTION AND OPERATION OF NC VALVE

1) When control valve is at neutral
Function Operation
• The NC valve controls the main pump dis- • When control valve is at neutral, jet sensor
charge amount according to the amount that differential pressure (Pt – Pd) becomes the
the control valve spool is operated. This flow maximum, and the force of jet sensor out-
control function reduces the neutral loss and put pressure Pt pushing piston (10) becomes
fine control loss. larger than the total of the force of spring
• The NC valve is controlled by balancing the (12) and the force of jet sensor output pres-
total of the jet sensor output pressure Pt sure Pd pushing the bottom of spool (11).
and the NC valve output pressure Pecn with As a result, spool (11) is pushed down, so
the total of the force of NC valve spring (12) the flow to port c and port b is throttled, and
and the jet sensor output pressure Pd. the area of the opening of port b and port a
• The jet sensor picks up the flow of oil re- (drain port) becomes larger. In this way, NC
turning to the tank through the control valve valve output pressure Pecn becomes the
and takes them as Pt and Pd of the NC valve. minimum, and the main pump discharge
amount also becomes the minimum.
10-60 PC1250-7
2) When control lever is operated
• When the control valve is moved, the jet

sensor 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.
In this way, NC valve output pressure Pecn
becomes larger and the discharge amount
from the main pump increases. In other
words, the pump discharge amount in-
creases according to the amount the control
lever is operated.
PC1250-7 10-61
NO. 2 PUMP
HPV95+95
1. Front pump PA1 : Front discharge port Psv : Servo basic pressure IN
2. Front servo valve PA2 : Rear discharge port port
3. Rear servo valve Pd1 : Drain port Pecn : CO + NC valve output
4. Rear pump Pd2 : Drain port pressure
Ps : Pump suction port
10-62 PC1250-7
1. No. 2 main pump

PC1250-7 10-63
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case 10. Impeller 17. Rear cradle
10-64 PC1250-7
2. No. 2 pump front servo
1. Servo valve PA1 : Main pump pressure IN port

PA2 : Main pump pressure IN port
Pdr : Servo valve drain OUT port
Pecn : CO, NC valve output pressure IN port
PC1250-7 10-65
3. No. 2 pump rear servo
1. Servo valve P2 : Main pump pressure IN port

Pecn : CO, NC valve output pressure IN port
10-66 PC1250-7
NO. 3 PUMP
HPV160+160
1. Front pump PA1 : Discharge port Pe : TVC valve output

2. Front servo valve PA2 : Discharge port pressure IN port
3. Front CO, NC valve Pd11 : Drain port Ps : Suction port
4. Rear servo valve Pd21 : Drain port Pt : Jet sensor upstream
5. Rear pump Pc : CO selector pilot port pressure IN port
Pd : Jet sensor downstream Psv : Servo basic pressure
pressure IN port IN port
PC1250-7 10-67
1. No. 3 main pump
PA1 : Pump discharge port Psv1A : Servo piston output port

PA2 : Pump discharge port Psv1B : Servo valve output port
Psv1 : Servo valve basic pressure port Psv2A : Servo piston output port
Psv2 : Servo valve basic pressure port Psv2B : Servo valve output port
10-68 PC1250-7
1. Front shaft 8. Front end cap 15. Rocker cam

2. Front cradle 9. Impeller 16. Rear case
3. Front case 10. Coupling 17. Rear cradle
PC1250-7 10-69
2. No. 3 pump front servo assembly
1. CO, NC valve Pc : CO selector pilot port

2. Servo valve Pd : Jet sensor downstream pressure IN port
Pt : Jet sensor upstream pressure IN port
PA1 : Main pump pressure IN port Pdr : Servo valve drain OUT port
Pe1 : TVC valve output pressure IN port Psv : Servo basic pressure IN port
Pe2 : TVC valve output pressure front, rear in- Pecn : CO, NC valve output pressure OUT port
terconnection port
10-70 PC1250-7
No. 3 pump front servo valve
PA2(IN) : Main pump pressure IN port Pdr(OUT) : Servo valve drain OUT port
PA2(OUT) : Main pump pressure OUT port Psv1 : Servo basic pressure IN port
Pdr(IN) : CO, NC valve drain Pdr IN port
PC1250-7 10-71
3. No. 3 pump rear servo
1. Servo valve PA1 : Main pump output pressure P1 IN port

PA2 : Main pump output pressure P2 IN port
10-72 PC1250-7
4. No. 3 pump CO, NC valve
PA1i : Main pump pressure IN port Pd : Jet sensor downstream pressure IN port
Pe1 : TVC valve output pressure IN port Pt : Jet sensor upstream pressure IN port
Pe2 : TVC valve output pressure detection port Pdr2 : Servo valve drain OUT port
Pc : CO selector pilot port Pecn : CO, NC valve output pressure OUT port
PC1250-7 10-73
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
10-74 PC1250-7
Function and operation of CO valve for No. 3 pump:

fl Structurally, the CO valve for the No. 3 pump does not function.
• Structurally, the CO valve for the No. 3 pump

is set so that it does not function. As a re-
sult, when main pump discharge pressure
PA rises and reaches the relief pressure,
spool (4) is not actuated and CO valve out-
put pressure Pec always remains at the maxi-
mum.
PC1250-7 10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LINE OIL FILTER
LINE OIL FILTER
1. Element Outline
2. Case There are three line oil filters installed to the
3. Cover discharge side of the main pump. They protect
the circuit and equipment by removing all dirt
A : From main pump and dust from the oil.
B : To control valve
10-76 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PILOT OIL FILTER
PILOT OIL FILTER
1. Relief valve Outline

2. Case The pilot oil filter is installed to the discharge
3. Element side of the control pump and protects the PPC
4. Center bolt valve and other pilot pressure equipment.
PC1250-7 10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER
1. Cover Outline
2. Spring There are two return oil filters installed to the
3. Bypass valve rear face of the hydraulic tank. They remove the
4. Bypass valve spring dirt and dust in the return oil.
5. Element
6. Housing Specifications
• Bypass valve set pressure:
A : From control valve 0.10 ± 0.02 MPa {1.05 ± 0.2 kg/cm2}
B : To hydraulic tank
10-78 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRAIN OIL FILTER
DRAIN OIL FILTER
1. Bracket Outline
2. Safety valve The drain oil filters are installed between the
3. Cartridge hydraulic tank and the travel motor, swing mo-
4. Filter tor, and aftercooler fan drive motor. They re-
move the dirt and dust in the oil from each
motor drain port.
Specifications
• Safety valve set pressure:
0.10 MPa {1.05 kg/cm2}
PC1250-7 10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD L.H. 5-SPOOL CONTROL VALVE
L.H. 5-SPOOL CONTROL VALVE
A1 : Plug P : From No. 1, No. 2 main pump PB3 : From L.H. PPC valve
A2 : To boom cylinder P1 : To R.H. 4-spool control valve P2 PB4 : From R.H. PPC valve
A3 : To arm cylinder T : To hydraulic tank PB5 : From L.H. travel PPC
A4 : To bucket cylinder PA1 : Plug valve
A5 : To L.H. travel motor P2 PA2 : From R.H. PPC valve PP : 2-stage main relief
B1 : Plug PA3 : From L.H. PPC valve solenoid valve
B2 : Plug PA4 : From R.H. PPC valve NCA : To NC valve at rear
B3 : To arm cylinder PA5 : From L.H. travel PPC valve of No. 1 main pump
B4 : To bucket cylinder PB1 : Plug NCB : To NC valve at rear
B5 : To L.H. travel motor P1 PB2 : From R.H. PPC valve of No. 1 main pump
10-80 PC1250-7
1. Main relief valve 6. Spool (boom Hi) 11. Throttle valve

2. Spool return spring 7. Spool (bottom) 12. Check valve with orifice
3. Spool (L.H. travel) 8. Jet sensor orifice 13. Check valve spring
4. Spool (bucket Hi) 9. Jet sensor relief valve 14. Suction-safety valve
5. Spool (arm Lo) 10. Valve body 15. Suction valve
PC1250-7 10-81
10-82 PC1250-7
Unit: mm

Main relief valve, main Free length
1 valve spring x O.D. length load load
394.2 N 315.2 N
34.7 x 10.4 32.5 —
{40.2 kg} {32.2 kg}
Jet sensor relief valve, 30 N 24.3 N

2 34.5 x 10.8 29.4 —
pilot poppet spring {3.1 kg} {2.5 kg}

3 37.4 x 11.4 33 —
main valve spring {5.0 kg} {4.0 kg}
Replace
431 N 345 N spring if
4 Spool return spring 69.9 x 57 63 — damaged or
{44 kg} {35.2 kg}
deformed
0N 0N
5 Spool return spring 75 x 37 74.5 —
{0 kg} {0 kg}
369 N 296 N
6 Spool return spring 83.4 x 35 78.5 —
{37.7 kg} {30.2 kg}
1N 0.78 N
7 Throttle valve spring 31.8 x 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
8 Check valve spring 78.2 x 26.6 52 —
{1.92 kg} {1.54 kg}
PC1250-7 10-83
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD R.H. 4-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
A1 : To R.H. travel motor P1 P2 : To L.H. 5-spool control PB4 : From L.H. PPC valve
A2 : To boom cylinder valve P1 PP : From control pump
A3 : To bucket cylinder T : To hydraulic tank PR : From 2-stage main
A4 : To arm cylinder PA1 : From R.H. travel PPC valve relief solenoid valve
B1 : To R.H. travel motor P2 PA2 : From R.H. PPC valve PS : From 2-stage safety
B2 : To boom cylinder PA3 : From R.H. PPC valve solenoid valve
B3 : To bucket cylinder PA4 : From L.H. travel PPC valve PT : To hydraulic tank
B4 : To arm cylinder PB1 : From R.H. travel PPC valve NCA : To NC valve at front
P : From No. 1, No. 2 main pump PB2 : From R.H. PPC valve of No. 1 main pump
P1 : From No. 1, No. 2 main pump PB3 : From R.H. PPC valve NCB : To NC valve at front
of No. 1 main pump
10-84 PC1250-7
1. Main relief valve 6. Spool return spring 11. Check valve spring
2. Spool (R.H. travel) 7. Valve body 12. Straight-travel valve
3. Spool (boom Lo) 8. Jet sensor orifice 13. Suction valve
4. Spool (bucket Lo) 9. Jet sensor relief valve 14. Suction-safety valve
5. Spool (arm Hi) 10. Check valve 15. Suction-safety valve
PC1250-7 10-85
10-86 PC1250-7
Unit: mm

394.2 N 315.2 N
34.7 x 10.4 32.5 —
{40.2 kg} {32.2 kg}

2 34.5 x 10.8 29.4 —
Replace
3 37.4 x 11.4 33 — spring if
main valve spring {5.0 kg} {4.0 kg} damaged or
deformed
431 N 345 N
4 Spool return spring 69.9 x 57 63 —
{44 kg} {35.2 kg}
0N 0N
{0 kg} {0 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
7 Check valve spring 53.6 x 31 39 —
{1.92 kg} {1.54 kg}
PC1250-7 10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING 4-SPOOL CONTROL VALVE
SWING 4-SPOOL CONTROL VALVE
A1 : To boom cylinder P : From No. 3 main pump PB3 : From R.H. PPC valve
A2 : To swing motor MB T : To hydraulic tank PB4 : From L.H. PPC valve
A3 : To bucket cylinder PA1 : From control pump PR : From 2-stage main relief
A4 : To arm cylinder PA2 : From L.H. PPC valve solenoid valve
B1 : Plug PA3 : From L.H. PPC valve NCA : To NC valve at front of
B2 : To swing motor MA PA4 : From L.H. PPC valve No. 3 main pump
B3 : Plug PB1 : From L.H. PPC valve NCB : To NC valve at front of
B4 : To arm cylinder PB2 : From L.H. PPC valve No. 3 main pump
10-88 PC1250-7
1. Main relief valve 6. Spool return spring 11. Piston

2. Spool (for swing) 7. Valve body 12. Check valve spring
3. Spool (for boom plus) 8. Jet sensor orifice 13. Check valve
4. Spool (for bucket plus) 9. Jet sensor relief valve 14. Safety valve with suction
5. Spool (for arm plus) 10. Check valve with orifice
PC1250-7 10-89
PC1250-7 10-91
10-92 PC1250-7
Unit: mm

394.2 N 315.2 N
34.7 x 10.4 32.5 —
{40.2 kg} {32.2 kg}

2 34.5 x 10.8 29.4 —

3 37.4 x 11.4 33 —
main valve spring {5.0 kg} {4.0 kg}
431 N 345 N Replace

4 Spool return spring 69.9 x 57 63 — spring if
{44 kg} {35.2 kg}
damaged or
0N 0N deformed
{0 kg} {0 kg}
1N 0.78 N
6 Throttle valve spring 31.8 x 7.6 26.5 —
{0.1 kg} {0.08 kg}
18.8 N 15.1 N
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
8 Check valve spring 65.3 x 14 46 —
{1.92 kg} {1.54 kg}
18.8 N 15.1 N
9 Check valve spring 41.3 x 35.5 25.5 —
{1.92 kg} {1.54 kg}
PC1250-7 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STRAIGHT-TRAVEL VALVE
STRAIGHT-TRAVEL VALVE
Outline
• The straight-travel valve is installed to the
R.H. 4- spool control valve. It acts to prevent
any deviation in the direction of travel if the
boom, arm, or bucket are operated when
the machine is traveling.
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
control valve
P3 : To bucket, boom spool
P4 : To arm spool
PP : From control pump
PT : To hydraulic tank
10-94 PC1250-7
1. Orifice 5. Body
2. Check valve 6. Spool
3. Spring 7. Cover
4. Spool return spring
Unit: mm

Free length
8 Spool return spring x O.D. length load load Replace
156.9 N spring if
117.5 x 27.9 68 — — damaged or
{16 kg} deformed
0.98 N
9 Throttle valve spring 31.8 x 7.6 26.5 — —
{0.1 kg}
PC1250-7 10-95
Function
• When the travel is operated at the same time
as the boom, arm, or bucket, the pressure
oil flowing to the left and right travel circuits
is divided and sent to the boom, arm, or
bucket circuit. If the oil in one travel circuit
is divided off, the amount of oil supplied to
the travel motor will 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.
• To prevent this, the straight-travel valve is
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
When travel is operated independently (straight-
travel solenoid valve de-energized)
• The straight-travel solenoid valve is de-en-
ergized, so no pilot pressure flows, and spool
(6) remains pushed to the left.
• Because of this, port P2 (left travel circuit)
and port P1 (right travel circuit) are not in-
terconnected, and each circuit remains inde-
pendent.
When travel and work equipment are operated

at same time (straight-travel solenoid valve ex-
cited)
• The straight-travel solenoid valve is excited,
so the pilot pressure flows and spool (6) is
pushed to the right.
• Because of this, port P2 and port P1 are
interconnected, so the amount of oil sup-
plied to the left and right travel motors is
the same. As a result, the left and right travel
motors both rotate at the same speed, so
there is no travel deviation.
10-96 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
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
2. SAFETY VALVE
1. Safety valve Specifications

2. Housing Safety valve set pressure:
3. Check valve 27 MPa {275 kg/cm2} (at 300 ¬/min)
4. Check valve spring Cracking pressure:
Min. 19.6 MPa {200 kg/cm2} (at 5 ¬/min)
Check valve set pressure: 0.03 MPa {0.3 kg/cm2}
10-98 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
1. Cover B2 : To L.H. travel motor port P2

2. Body C1 : From R.H. travel control valve port B1
3. Slipper seal C2 : To R.H. travel motor port P2
4. Oil seal D1 : From R.H. travel control valve port A1
5. Shaft D2 : To R.H. travel motor port P1
P1 : From travel speed selector solenoid valve
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
Unit: mm
Standard size Standard clearance Clearance limit

6 Clearance between rotor Replace
and shaft 110 0.056 – 0.105 0.111
PC1250-7 10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
MSF-340VP-EH
1. Travel selector valve Specifications

2. Motor Model : MSF-340VP-EH
3. Travel brake valve Theoretical delivery : 1st 337.2 cc/rev
: 2nd 228.6 cc/rev
Rated pressure : 34.3 MPa {350 kg/cm2}
P1 : From control valve Rated speed : 1st 1,465 rpm
P2 : From control valve (at 494 ¬/min.)
P1 : From travel speed solenoid valve : 2nd 2,161 rpm
T : To hydraulic tank (at 494 ¬/min.)
Brake release pressure : 1.8 MPa {18.4 kg/cm2}
10-100 PC1250-7
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
PC1250-7 10-101
3. Rear cover 10. Piston assembly 17. Plate

4. Collar 11. Case 18. Brake piston
5. Valve plate 12. Shaft 19. Spring
6. Cylinder block assembly 13. Bearing collar
7. Piston assembly 14. Rocker cam
8. Holder 15. Preload spring
9. Retainer 16. Disc
10-102 PC1250-7
1-1 Motor
• There are 9 pistons (7) assembled in cylin-

der block (6). The end face of the cylinder
block has a spherical surface and is in con-
tact with valve plate (5), which has two half-
moon shaped ports (divider valve for high/
low speed selector).
• 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
carried 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 se-
lector 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 these provide propulsion force to
the rocker cam.
PC1250-7 10-103
1-2 Speed selector valve

Operation
1) At low speed (pilot pressure PI = 0)
• When pilot pressure PI from the control (1a) and is drained into the motor case. There
pump is 0, spool (1a) of travel speed selec- is no angle propulsion force acting on rocker
tor valve (1) is not switched. cam (14), so the low-speed surface is kept in
In this condition, the oil from the chamber a static condition.
of control piston (10) passes through spool
10-104 PC1250-7
2) At high speed (automatic 2nd)
• When the pilot signal is ON, pilot pressure When this happens, the main oil pres-
PI from the control pump acts on travel speed sure (M1, M2) passes through spool (1a)
selector valve (1) and the capacity is auto- and goes to the control piston chamber.
matically changed by the drive pressure of Rocker cam (14) overcomes moment Mx
the travel motor. with hydraulic force from propulsion
force Fc of control piston (10). It rotates
Balance of force for travel speed selector and holds the moment balance at the
valve high speed surface and is held in posi-
F1 [Force pushing spool (1a) to right (high- tion (Mx < Fc, L).
speed side)] = A (area of spool (1a) re- ii) When operating the steering or travel-
ceiving pressure) x PI ing uphill, if the motor drive pressure is
F2 [Force pushing spool (1a) to left (low- high, and it goes above the set pressure,
speed side)] = A (area of spool (1a) re- the condition becomes F1 < F2, and spool
ceiving pressure) x PH (motor drive pres- (1a) is pushed to the left.
sure) + force of spring (1b) When this happens, the main oil pres-
sure (M1, M2) passes through spool (1a)
i) When traveling on level ground, if the and is drained to the motor case. This
travel motor drive pressure is low, the creates the low-speed condition in the
condition becomes F1 > F2, and spool same way as when PI = 0.
(1a) is pushed to the right.
PC1250-7 10-105
1-3 Parking brake
The parking brake is a hydraulic release, wet

type, multiple disc negative brake. The re-
lease pressure employs a self-pressure re-
lease method using the travel motor drive
pressure through the oil passage in the coun-
terbalance valve spool of the travel brake
valve.
When the machine is traveling, the drive

pressure is sent to port P of the parking
brake circuit, acts on the piston in the brake
cylinder chamber, overcomes the force of
the spring and releases the brake.
When the machine is parked or stopped, the
counterbalance valve spool returns to neu-
tral, and the oil in the cylinder chamber is
released to the tank through the counterbal-
ance 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 neutral position and parking brake cir-
cuit P is closed.
The pressurized oil in chamber e of the brake
piston passes through the counterbalance
valve spool, 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.
When parking brake is OFF

When the travel lever is operated, the pres-
surized oil from the pump actuates the coun-
terbalance valve spool, opens the circuit to
the parking brake, and flows into chamber e
of brake piston (18). It overcomes the force
of spring (19), and pushes brake piston (18)
to the right.
When this happens, the force pushing plate
(17) and disc (16) together is lost, so the
plate and disc separate and the brake is re-
leased.
10-106 PC1250-7
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
pressure increase function). This acts to reduce
the shock generated at the beginning when the
speed is reduced (when the machine is stopped).
PC1250-7 10-107
1-5 Travel brake valve
Function 1. Cap assembly

• The brake valve consists of counterbalance 2. Return spring
valve (3) and check valve (4). 3. Counterbalance valve
• The counterbalance valve acts to prevent the 4. Check valve
piston motor from stopping or overrunning. 5. Check valve spring
• When traveling downhill, the weight of the
machine makes it try to travel at a speed
faster than the rotation of the motor. Specification
For this reason, if the machine is traveling Safety valve set pressure: 34 MPa {350 kg/cm2}
with the engine running at low speed, the Counterbalance switching pressure:
motor will rotate under no load or may run 1.0 ± 0.1 MPa {10 ± 1 kg/cm2}
away, which is extremely dangerous. Check valve switching pressure:
To prevent this, this valve controls the 0.02 ± 0.01 MPa {0.2 ± 0.1 kg/cm2}
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 mo-
tor.
10-108 PC1250-7
Operation when oil is supplied

• When the travel lever is operated, the pres-
surized oil from the control valve is supplied
to port P1. It pushes open check valve (5a)
and flows from motor inlet port M1 to mo-
tor outlet port M2.
However, the motor outlet port is closed by
check valve (5b) and spool (3), so the pres-
sure at the supply side rises.
• 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.
Operation of brake when traveling downhill

• If the machine tries to run away when trav-
eling downhill, the motor will turn under
no load, so the pressure at the motor inlet
port will drop, and the pressure in chamber
A through orifice a will also drop.
When the pressure in chamber A drops be-
low the spool switching pressure, spool (3)
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 ro-
tation of the motor, and this prevents the
machine from running away.
In other words, spool (3) moves to a posi-
tion where the pressure at outlet port M2
balances 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.
PC1250-7 10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC CONTROL RELIEF VALVE
PPC CONTROL RELIEF VALVE
1. Relief valve A: From PPC valve Specifications

2. Valve body B: From solenoid valve Set pressure: 3.1 +0.3 +3 2
+0 MPa {32 +0 kg/cm }
3. Check valve spring C: From pilot valve (at 182 ¬/min)
4. Check valve D: To PPC valve
E: To accumulator
F : To solenoid valve
P: From control pump
T: To tank
10-110 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC CONTROL RELIEF VALVE
Unit: mm

Free length
3 Check valve spring x O.D. length load load Replace
6.9 N 3.9 N
56 x 21.4 37 —
{0.7 kg} {0.4 kg}
PC1250-7 10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR
ACCUMULATOR
For PPC 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}
Function
• The accumulator is installed between the PPC
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
• After the engine stops, when the PPC valve
is at neutral, chamber A inside the bladder
is compressed by the oil pressure in cham-
ber B.
• 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 entering chamber B is sent as the
pilot pressure to actuate the main control
valve.
10-112 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
1. R.H. 4-spool control valve Lever positions

2. L.H. 5-spool control valve 1 HOLD 9 Swing right
3. Accumulator 2 Boom RAISE 0 Swing left
4. Swing 4-spool control valve 3 Boom LOWER A Neutral
5. Safety lock solenoid valve 4 Bucket DUMP B Travel REVERSE
6. Safety lock lever 5 Bucket CURL C Travel FORWARD
7. Left PPC valve 6 HOLD D LOCK
8. Left work equipment lever 7 Arm IN E FREE
9. Travel PPC valve 8 Arm OUT
10. L.H. travel lever
11. R.H. travel lever
12. Right PPC valve
13. Right work equipment lever
PC1250-7 10-113
WORK EQUIPMENT,
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
P. From control pump P2. Left: Swing left, Right: Bucket CURL
T. To hydraulic tank P3. Left: Arm OUT, Right: Boom LOWER
P1. Left: Swing right, Right: Bucket DUMP P4. Left: Arm IN, Right: Boom RAISE
10-114 PC1250-7
WORK EQUIPMENT,
1. Spool 6. Nut (for connecting lever)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
10-116 PC1250-7
WORK EQUIPMENT,
Unit: mm
Free length Installation Installation Free Installation

11 Centering spring (for P3, P4) × OD length load length load Replace
spring if
17.6 N 13.7 N
42.48 × 15.5 34 {1.8 kg} — {1.4 kg}
damaged
or
16.6 N 13.2 N deformed
12 Metering spring 26.7 × 8.14 24.9 {1.69 kg} — {1.35 kg}
9.8 N 7.8 N
13 Centering spring (for P1, P2) 38.71 × 15.5 34 {1 kg} — {0.8 kg}
PC1250-7 10-117
WORK EQUIPMENT,
Operation
1) At neutral
Ports A and B of the control valve and ports
P1, P2, P3, and P4 of the PPC valve are con-
nected to drain chamber D at the bottom.
(Fig. 1)
2) Fine control (neutral → fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed. Spool (1) is also
pushed by metering spring (2) and moves
down.
When this happens, port P1 is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, and the pilot pressure of the control
pump is sent from port P1 to port A.
When the pressure at port P1 rises, spool (1)
is pushed back. Port P1 is shut off from pump
pressure chamber PP. At almost the same
time, it is connected to drain chamber D, so
the pressure at port P1 escapes.
As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port P1.
The relationship of the positions of spool (1)
and body (10) does not change until retainer
(9) contacts spool (1).
Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
In this way, the spool of the control valve
moves to a 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.
10-118 PC1250-7
WORK EQUIPMENT,
3) Fine control (control lever returned)

When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, port P1 is connected to drain
chamber D, and the pressurized oil at port
P1 is released.
If the pressure at port P1 drops too much,
spool (1) is pushed down by metering spring
(2), so port P1 is shut off from drain cham-
ber D. At almost the same time, it is con-
nected to pump pressure chamber PP, so
the pressure at port P1 supplies the pump
pressure until the pressure recovers to a
pressure equivalent to the position of the
lever.
When the control valve returns, oil in drain
chamber D flows in from the valve on the
side that is not moving. It passes through
port P2 and goes to chamber B to charge
the oil.
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), port P1
is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
Therefore, the pilot pressure oil from the
control pump flows to chamber A from port
P1 to push the control valve spool.
The return oil from chamber B passes from
port P2 and flows to drain chamber D.
PC1250-7 10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
P : From control pump

T : To tank
P1 : Left travel forward
P2 : Left travel reverse
P3 : Right travel forward
P4 : Right travel reverse
10-120 PC1250-7
1. Plate 5. Centering spring

2. Body 6. Metering spring
3. Piston 7. Valve
4. Collar 8. Bolt
Unit: mm
Basic dimension Allowable limit

Free length Installed Installed Free Installed
× Outside length load length load
If damaged
9 Metering spring diameter or de-
formed,
16.6 N 13.7 N replace
26.7 × 8.14 24.9 {1.69 kg} — {1.40 kg} spring
107.9 N 86.3 N
10 Centering spring 48.57 × 15.5 32.5 {11 kg} — {8.8 kg}
PC1250-7 10-121
OPERATION
1. At neutral
• Ports A and B of the control valve and ports
P1 and P2 of the PPC valve are connected to
drain chamber D through fine control hole f
in spool (1). (Fig. 1)
2. During fine control (neutral → fine control)

• When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (1) is also
pushed by metering spring (2) and moves
down.
• When this happens, fine control hole f is
shut off from drain chamber D. At almost
the same time, it is connected to pump pres-
sure chamber PP, and the pilot pressure of
the control pump is sent from port A through
fine control hole f to port P1.
• When the pressure at port P1 rises, spool (1)
is pushed back. Fine control hole f is shut
off from pump pressure chamber PP. At al-
most the same time, it is connected to drain
chamber D to release the pressure at port
P1.
• As a result, spool (1) moves up and down
until the force of metering spool (2) is bal-
anced with the pressure of port P1.
• The relationship in the position of spool (1)
and body (10) (fine control hole f is in the
middle between drain hole D and pump pres-
sure chamber PP) does not change until re-
tainer (9) contacts spool (1).
• Therefore, metering spring (2) is compressed
in proportion to the travel of the control le-
ver, so the pressure at port P1 also rises in
proportion to the travel of the control lever.
• In this way, the control valve spool moves
to a 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. (Fig. 2)
10-122 PC1250-7
3. Fine control (control lever returned)

• When disc (5) starts to be returned, spool (1)
is pushed up by the force of centering spring
(3) and the pressure at port P1.
Because of this, fine control hole f is con-
nected to drain chamber D, and the pressur-
ized oil at port P1 is released.
• If the pressure at port P1 drops too much,
spool (1) is pushed up by metering spring
(2), so fine control hole f is shut off from
drain chamber D. At almost the same time,
it is connected to pump pressure chamber
PP, so the pressure at port P1 supplies the
pump pressure until the pressure recovers
to a pressure equivalent to the position of
the lever.
• When the control valve returns, oil in drain
chamber D flows in from fine control hole f
of the valve on the side that is not moving.
It passes through port P2 and enters cham-
ber B to fill the chamber with oil. (Fig. 3)
4. At full stroke
• Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1). Fine control hole
f is shut off from drain chamber D, and is
connected to pump pressure chamber PP.
• Therefore, the pilot pressure oil from the
main pump passes through fine control hole
f and flows to chamber A from port P1 to
push the control valve spool.
• The return oil chamber B passes from port
P2 through fine control hole f and flows to
drain chamber D. (Fig. 4)
PC1250-7 10-123
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
FOR RESETTING CO, STRAIGHT TRAVEL, HEAVY LIFTING, PUSHING UP MACHINE (AT CENTER OF
MACHINE BODY), TRAVEL SPEED
1. CO resetting solenoid valve T : To tank

2. Straight travel solenoid valve A1 : To No. 1 pump (CO valve)
3. Heavy lift solenoid valve A2 : To straight travel valve
4. Machine push-up solenoid valve A3 : To main valve (Relief valve)
5. Travel speed solenoid valve A4 : To boom LOWER 2-stage safety valve
A5 : To left and right travel motor
P1 : From control pump
ACC : Blind
PPC : Blind
10-124 PC1250-7
PC1250-7 10-125
FOR SWING PRIORITY (ON LEFT SIDE OF MACHINE BODY)
1. Swing priority solenoid valve
T : To tank
A : To swing 4-spool control valve
10-126 PC1250-7
1. Plug 5. Connector
2. Spring 6. Solenoid
3. Spool 7. Movable iron core
4. Block
Operation
When solenoid is de-energized
• When the signal current does not flow from
the PPC lock switch or swing lock switch,
solenoid (6) is de-energized.
For this reason, spool (3) is pushed fully to
the left by spring (2).
As a result, the circuit between ports P and
A closes and the pressurized oil from the
control pump does not flow to the actuator.
At the same time, the pressurized oil from
the actuator flows from port A to port T, and
is then drained to the tank.
When solenoid is energized

• When the signal current flows from the PPC
lock switch or swing lock switch to solenoid
(6), solenoid (6) is energized.
For this reason, spool (3) is pushed to the
right in the direction of the arrow.
As a result, the pressurized oil from the con-
trol pump flows from port P through the
inside of spool (3) to port A, and then flows
to the actuator. At the same time, port T is
closed, and this stops the oil from flowing
to the tank.
PC1250-7 10-127
FOR SWING HOLDING BRAKE (ON RIGHT SIDE OF MACHINE BODY), SAFETY LOCK
1. Swing holding brake solenoid valve
T : To tank
A : To front and rear swing motors (For swing holding brake)
To PPC valve (To safety lock)
10-128 PC1250-7
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 deenergized
• No signal current flows from the controller,
so solenoid (2) is deenergized.
• Accordingly, spool (11) is pushed up and
spool (7) is pushed to the left by spring (6).
• 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

• When the signal current flows from the con-
troller to solenoid (2), solenoid (2) is ener-
gized.
• 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.
• 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.
PC1250-7 10-129
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Boom
Arm
Bucket
10-130 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
Boom 160 –0.043 +0.256 0.082 – 0.662

Clearance bet- –0.106 +0.039 0.362 Replace
1 ween piston rod bushing
and bushing Arm 170 –0.043 +0.255 0.081 – 0.661
–0.106 +0.038 0.361
–0.036 +0.261 0.083 –

Bucket 110 –0.090 +0.047 0.351 0.651
Boom 140 –0.043 +0.025 0.043 – 1.0

–0.106 +0.370 0.131
Clearance bet-
ween piston rod Arm –0.043 +0.025 0.043 –
2 160 –0.106 +0.370 0.131 1.0
support shaft
and bushing
Bucket 100 –0.036 +0.457 0.406 – 1.0
–0.090 +0.370 0.547
Replace pin,
bushing
Boom 140 –0.043 +0.025 0.043 – 1.0
Clearance bet- –0.106 +0.370 0.131
ween cylinder
3 bottom support Arm 160 –0.043 +0.457 0.406 – 1.0
shaft and –0.106 +0.370 0.547
bushing
Bucket 100 –0.036 +0.475 0.406 – 1.0
–0.090 +0.370 0.565
PC1250-7 10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
10-132 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between bushing size Shaft Hole clearance limit
1 and mounting pin of boom
and revolving frame 160 –0.043 +0.436 0.393 – 1.5
–0.106 +0.350 0.542
Clearance between bushing
2 and mounting pin of boom 160 –0.043 +0.172 0.128 – 1.5
and arm –0.106 +0.085 0.278
Clearance between bushing –0.043 +0.404 0.364 –
3 and mounting pin of arm 140 –0.106 +0.321 0.510 1.5 Replace
and link
4 and mounting pin of arm 140 –0.106 +0.312 0.503 1.5
and bucket
5 and mounting pin of link 140 –0.106 +0.312 0.503 1.5
and link
6 and mounting pin of link 140 –0.106 +0.321 0.510 1.5
and bucket
7 Bucket clearance 0.5 – 1.0 Adjust

shims
PC1250-7 10-133
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT

1. ARM
10-134 PC1250-7
Unit: mm
Model
PC1250-7 PC1250SP-7 PC1250LC-7
with 3.4 m with 4.5 m with 3.4 m with 3.4 m with 4.5 m
No. heavy-duty arm heavy-duty arm heavy-duty arm arm arm
1 160 160 160 160 160
2 120 120 120 120 120
3 636 636 636 636 636
4 160 160 160 160 160
5 489 550 496 489 550
6 635 635 635 635 635
7 1,348 1,326 1,348 1,348 1,326
8 3,340 4,455 3,340 3,340 4,455
9 4,108 4,087 4,274 4,108 4,087
10 610 610 590 610 610
11 1,223 1,223 1,290 1,223 1,223
12 977 977 1,028 977 977
13 840 840 915 840 840
14 2,653 2,600 2,690 2,600 2,600
15 140 140 140 140 140
16 636 636 636 636 636
17 140 140 140 140 140

Arm as individual
part 637 637 637 637 637
18
When press-
fitting bushing 653 653 653 653 653
Min. 2,535 2,535 2,660 2,535 2,535

19
Max. 4,360 4,360 4,610 4,360 4,360
20 20 0 20 20 0
PC1250-7 10-135
2. BUCKET
10-136 PC1250-7
Unit: mm
Model
PC1250-7 PC1250SP-7 PC1250LC-7
3.4 m3 4.0 m3 5.0 m3 5.2 m3 6.7 m3 3.4 m3 4.0 m3 5.0 m3
No. bucket bucket bucket bucket bucket bucket bucket bucket
1 837 837 837 837 911 837 837 837
2 76 76 76 76 82 76 76 76
3 95° 95° 95° 95° 95° 95° 95° 95°
4 840 840 840 840 915 840 840 840
5 2,576 (2,618) 2,576 (2,618) 2,576 (2,618) 2,622 2,662 2,576 (2,618) 2,576 (2,618) 2,576 (2,618)
6 353 (404) 353 (404) 353 (404) 407 392 353 (404) 353 (404) 353 (404)
a φ 170 φ 170 φ 170 φ 170 φ 170 φ 170 φ 170 φ 170

7
b φ 170 φ 170 φ 170 φ 170 φ 170 φ 170 φ 170 φ 170
8 637.5 637.5 637.5 637.5 637.5 637.5 637.5 637.5
9 100 100 100 100 100 100 100 100
10 100 100 100 100 100 100 100 100
11 φ 280 φ 280 φ 280 φ 280 φ 280 φ 280 φ 280 φ 280
12 φ 310 φ 310 φ 310 φ 310 φ 310 φ 310 φ 310 φ 310
13 210.6 210.6 210.6 203 218 210.6 210.6 210.6
14 241 241 241 241 222 241 241 241
15 174 174 174 174 174 174 174 174
16 160 160 160 160 160 160 160 160
17 679.5 679.5 679.5 679.5 679.5 679.5 679.5 679.5
18 83 83 83 83 83 83 83 83
fl The figures in ( ) show the value for the long life tooth.
PC1250-7 10-137
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
STD CAB SPECIFICATION
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
10-138 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Battery Outline
2. Battery relay • The engine can be started and stopped sim-
3. Starting switch ply by using starting switch (3).
4. Fuel control dial • With the dial type engine controller, the con-
5. Fuel pump trol signal from fuel control dial (4) is re-
6. Engine controller ceived by engine controller (6). A drive sig-
7. Starting motor nal is sent to fuel pump (5), and the rack
position is controlled to control the engine
speed.
PC1250-7 10-139
1. Operation of system
Starting engine
• When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, so the starting motor ro-
tates and starts the engine.
When this happens, the engine controller
confirms the signal voltage from the fuel
control dial and sets the engine speed to the
set speed.
10-140 PC1250-7
Engine speed control

• The fuel control dial sends a signal voltage
that matches the angle position to the en-
gine controller.
The engine controller calculates the engine
speed to match that signal voltage and con-
trols the control valve and fuel pump so that
the engine runs at that speed.
PC1250-7 10-141
Stopping engine
• If the starting switch is turned to the STOP
position and the input to terminal ACC of
the engine controller is turned off, the en-
gine controller closes the fuel shut-off valve
in the control valve unit to stop the engine.
10-142 PC1250-7
2. Function
• 2-mode selector type engine output control
function
The engine controller receives the A and E
mode switch signals from the monitor
through the network signal and controls the
engine output according to each mode.
(For details of the engine output control func-
tion for each mode, see the section on the
machine control system.)
• Auto-deceleration function
The pump controller receives the auto-de-
celeration switch from the monitor panel
through the network signal. The pump con-
troller outputs the deceleration actuation/can-
cel commands to the engine controller ac-
cording to the signals from the travel and
work equipment control lever oil pressure
switches.
(For details of the auto-deceleration function
for each mode, see the section on the ma-
chine control system.)
• Automatic engine warming-up, overheat pre-

vention function
The engine controller receives the signal
from the engine water temperature sensor.
The engine controller then controls the en-
gine speed when carrying out automatic
warming up of the engine and prevention of
overheating.
(For details of the engine automatic warm-
ing-up function for each mode, see the sec-
tion on the machine control system.)
• Error display function

The engine controller itself has a self-diag-
nostic display function, but it has the func-
tion of displaying on the monitor the overall
errors (user code, service code) for the pump
controller, monitor, and the machine over-
all.
Note: The error code displayed on the moni-

tor and the error code displayed by
the engine controller itself are not the
same.
PC1250-7 10-143
3. Components of system
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed at the bot-
tom of the monitor panel. 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 and pump con-
troller.
• The hatched area in the graph on the right is
the abnormality detection area and the en-
gine speed is set at low idling.
10-144 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HPI ENGINE CONTROL SYSTEM
HPI ENGINE CONTROL SYSTEM

fl HPI is an abbreviation of High Pressure Injection.
System drawing
Outline
• The signals detected by various sensors are
input to the engine controller.
• The input signals are operated arithmetically
by the controller. A signal is issued to each
actuator and controls a fuel injection level
and fuel injection timing.
PC1250-7 10-145
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HPI ENGINE CONTROL SYSTEM
1. Fuel tank OUTLINE OF HPI SYSTEM

2. Fuel filter • The HPI system consists of injector assem-
3. Fuel pump assembly bly (5), control valve assembly (4), and fuel
3A. Gear pump pump assembly (3).
3B. Pump regulator • Injector assembly (5) controls the amount of
3C. Check valve fuel injection and the injection timing by
3D. Fuel pump actuator controlling the amount of fuel passing through
3E. Fuel pump pressure sensor fuel orifice (5B).
4. Control valve assembly In order to control the fuel flow, it is neces-
4A. Timing rail actuator valve sary to control the fuel rail pressure and
4B. Fuel leak throttle (220 cc/min) timing rail pressure. To control these pres-
4C. Timing rail pressure sensor sures, control valve assembly (4) has 2 pres-
4D. Shut-off valve sure sensors and 2 actuator valves built in.
4E. Fuel rail actuator valve These carry out control so that the fuel rail
4F. Fuel leak throttle (110 cc/min) pressure and timing rail pressure become
4G. Fuel rail pressure sensor the target value. Shut-off valve (4D), used to
5. Injector assembly stop the engine, is installed in the fuel rail
5A. Timing orifice line.
5B. Fuel orifice • Fuel pump assembly controls the basic pres-
5C. Gravity check valve sure of the fuel. The fuel supplied from fuel
5D. Bypass orifice tank (1) passes through fuel filter (2), is then
5E. Injector sucked up by gear pump (3A), and is sup-
5F. Plunger plied to control valve assembly (4). The dis-
5G. Gravity check valve charge pressure of the fuel pump is con-
6. Fuel cooler trolled to a suitable level by adjusting the
7. ECM controller opening angle of fuel pump actuator (3D).
8. Engine speed sensor
9. Atmospheric pressure sensor
10. Boost pressure sensor
11. Boost temperature sensor
10-146 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM

CONTROL FUNCTIONS
1 OFF (Cancel)
Auto deceleration function
ON
2 2-mode selector type engine torque control function
2-mode selector type pump torque control
Electronic OLSS function
Cut-off control
Flow control
3 OFF
Heavy-lift function
ON
4 OFF (Digging improvement mode)
2-stage boom pushing force
selector function
ON (Machine push-up mode)
(Machine push-up)
5
Swing control function
Machine
6
control
Engine automatic warming up,
system
overheat prevention function
7 Travel pressure
rise function
Travel speed selector
function Lo (Low speed) fixed
Travel speed
selector function
Hi (High speed) →
← Lo (low speed)
automatic gear shift
8 ON
Boom shockless control
function
Cancel
9
Straight-travel function
10
Swing priority function
11
Swing assurance function
PC1250-7 10-147
MACHINE CONTROL SYSTEM DIAGRAM
10-148 PC1250-7
PC1250-7 10-149
1. Auto deceleration function
Function
• If all the control levers are at neutral when
waiting for work or waiting for a dump truck,
the engine speed is automatically reduced
to a midrange speed to reduce fuel consump-
tion and noise.
• If any lever is operated, the engine speed
returns immediately to the set speed.
10-150 PC1250-7
Operation
Control levers at neutral When control lever is operated
• If the engine is running at above the decel- • If any control lever is operated when the
eration actuation speed (approx. 1300 rpm), engine speed is at No. 2 deceleration, the
and all the control levers are returned to engine speed will immediately rise to the
neutral, the engine speed drops immediately speed set by the fuel control dial.
to approx. 100 rpm below the set speed to
the No. 1 deceleration position.
• 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.
PC1250-7 10-151
2. Electronic OLSS function

Pump control system
• Interconnected control of all pumps is car-

ried out by one TVC valve.
• A mode: Total horsepower control by en-
gine speed sensing
E mode: Total horsepower control by en-
gine speed sensing
• Prolix circuit: Absorption torque equivalent
to G mode
10-152 PC1250-7
1) Control method in each mode

A, E mode
• Matching point in A, E mode: Rated output

point
Model
PC1250-7
Mode
A 485 kW/1,800 rpm {651 HP/1,800 rpm}
E 402 kW/1,710 rpm {539 HP/1,710 rpm}
• 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 that the
pump discharge amount is increased until
the engine speed reaches close to the rated
speed.
By repeating this control, the engine can al-
ways be used at near the rated output point.
• Compared with the A mode, which provides
the maximum output, the E mode lowers
the engine output to provide matching at a
point which gives better fuel consumption
efficiency than the A mode.
2) Cut-off function
• If the load during operation increases and
the pump discharge pressure rises to near
the relief pressure, the main pump cut-off
valve is actuated to reduce the relief loss.
PC1250-7 10-153
3. Heavy lift function
10-154 PC1250-7
Outline
• This function increases the boom lifting
power by approx. 10%.
• It can be actuated only when the boom
RAISE is being actuated independently. If
the arm IN or bucket CURL are operated at
the same time, the heavy-lift function is au-
tomatically canceled.
Operation
Lever operation
Heavy-lift Heavy-lift Main relief Boom
switch Boom Arm IN or solenoid valve set CO valve lifting
RAISE bucket CURL valve pressure force
De- 31.4 MPa

OFF Operated — Actuated Normal
energized {320 kg/cm2}
34.3 MPa
Neutral Excited {350 kg/cm2} Canceled 10% up
ON Operated
If the arm IN or bucket CURL are operated dur-
Operated ing boom RAISE operations, this function is au- Normal
tomatically canceled, and the condition becomes
the same as when the switch is turned OFF.
fl Heavy-lift solenoid valve

For details of the structure and function, see SOLENOID VALVE.
fl CO valve
For details of the structure and function, see NO. 1 PUMP.
fl Main relief valve
For details of the structure and function, see L.H. 5-SPOOL VALVE.
PC1250-7 10-155
4. 2-stage boom pushing force selector

function
10-156 PC1250-7
Outline
• This function switches the pushing force of
the boom. It is aimed to provide both in-
creased digging efficiency by reducing the
digging resistance of the boom, and in-
creased ease of operation by increasing the
thrusting force for excavation, digging square
holes, carrying out twist turns, or escaping
from soft ground.
Operation
• 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
Mode Safety valve Effect
push-up push-up
set pressure
switch solenoid valve
By reducing the boom pushing force, it is

Boom made easier for the boom to escape auto-
pushing 14.7 MPa
Excited matically in the RAISE direction and to re-
force (low {150 kg/cm2} duce the number of times that the boom is
mode) operated. At the same time it also makes
the digging operation smoother.
Boom By increasing the thrust force for boom

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

For details of the structure and function, see SOLENOID VALVE.
fl Boom safety valve
For details of the structure and function, see R.H. 4-SPOOL VALVE.
PC1250-7 10-157
5. Swing control function
Function
• The system is provided with a swing lock
and swing holding brake function.
10-158 PC1250-7
1) Swing lock, swing holding brake function

• The swing lock (manual) can be locked at fl Swing brake solenoid valve
any desired position, and the swing lock and For details of the structure and function, see
swing holding brake (automatic) are inter- SOLENOID ASSEMBLY.
connected with the swing, so they prevent fl Swing motor
any hydraulic drift after the swing is stopped. For details of the structure and function, see
SWING MOTOR.
Actuation
Swing lock Swing lock Swing brake
Mode switch lamp solenoid valve Actuation
When swing and work equipment levers are placed at

neutral, swing brake is applied after approx. 5 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.

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

• If any abnormality should occur in the con-
Swing
troller, and the swing holding brake is not lock
ON OFF
(when controller (when controller
actuated normally and the swing cannot be prolix is abnormal) is normal)
operated, the swing lock prolix switch can switch
be operated to cancel the swing lock and Swing
allow the swing to be operated. lock ON OFF ON OFF
switch
fl Even when the swing lock prolix switch is
turned ON, the swing lock switch stays ON Swing hold-
Swing Swing lock Swing lock Swing lock
ing brake
and the swing brake is not canceled. brake applied canceled applied
applied
fl When the swing brake is canceled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
PC1250-7 10-159
6. Automatic warming-up and engine overheat

prevention function
Function
• If the water temperature is low, this auto-
matically raises the engine speed to warm
up the engine after it is started. In addition,
if the water temperature rises too high dur-
ing operations, it automatically lowers en-
gine speed to low idling, and reduces the
load of the pump to prevent overheating.
10-160 PC1250-7
1) Engine automatic warming-up function

• After the engine is started, if the engine cool-
ant 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) Cancellation

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

• This function protects the engine by lower-
ing the pump load and engine speed to pre-
vent overheating when the engine coolant
temperature has risen too high.
• This system is actuated at 105°C and above.
Actuation condition Actuation, remedy
Water temperature: Working mode : In any mode

105°C and above Engine speed : Low idling
(Water temperature gauge: Monitor warning lamp : Lights up
Red range) Alarm buzzer : Sounds
Cancel condition
Water temperature: Below 105°C
PC1250-7 10-161
7. Travel speed selector function

1) Travel pressure rise function
10-162 PC1250-7
Outline
• To maintain the drawbar pull when traveling,
the cut-off is canceled and the main relief
pressure 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
34.3 MPa
When traveling Energized Energized Canceled
{350 kg/cm2}
31.4 MPa
When not traveling Deenergized Deenergized Actuated
{320 kg/cm2}
PC1250-7 10-163
2) Travel speed selector function
The travel pressure (self pressure) changes the

swash plate angle of the travel motor and auto-
matically shifts the speed range.
• 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 pres-
sure shifts to low speed travel. If the ma-
chine 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

Travel speed Remarks
switch solenoid valve swash plate angle
Low speed Suitable for traveling on rough

Lo Deenergized Max.
(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
10-164 PC1250-7
8. 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 Boom shockless
Remarks
switch valve control
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF Suitable for compacting or

Excited Canceled
(Contacts closed) skeleton work
• 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 pressure 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.
• 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 position to prevent any shock.
PC1250-7 10-165
9. Straight-travel function
10-166 PC1250-7
Outline
• When the travel is operated at the same time • To prevent this, the straight-travel valve is
as the boom, arm, or bucket, the pressure switched to interconnect the left and right
oil flowing to the left and right travel circuits travel circuits. This ensures that the amount
is divided and sent to the boom, arm, or of oil supplied to the left and right travel
bucket circuit. motors is equal, so the left and right travel
If the oil in one travel circuit is divided off, motors both rotate at the same speed, and
the amount of oil supplied to the travel mo- this prevents any travel deviation.
tor will 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 ma-
chine to deviate.
Operation
Left and right Work equipment Straight-travel Straight-travel

Remarks
travel levers control lever solenoid valve valve
Left and right travel motor

Neutral De-energize Not actuated
circuits independent
Operation
Left and right travel motor
Operated Excited Actuated
circuits actuated
PC1250-7 10-167
10. Swing priority function

• There is a swing priority mode switch on
the monitor panel. By turning this switch
ON/OFF it is possible to change the match-
ing of the boom RAISE and swing. This di-
vides the flow to provide a swing speed
which matches the swing angle, thereby ena-
bling 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
Number of
Swing priority
Solenoid boom riase
selector valve
control valve
Swing priority
OFF
mode OFF OFF 3
(de-energized)
(standard)
Swing priority
ON
mode ON ON 2
(excited)
(swing priority)
10-168 PC1250-7
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.)
PC1250-7 10-169
11. Swing assurance function

• If the swing is operated at the same time as the arm or bucket, the throttle valve in the arm or
bucket circuit acts to ensure the flow of oil to the swing to ensure good performance during
combined operations.
Operation
• There is a throttle valve in the arm circuit of the swing 4-spool control valve, and when the swing
PPC pressure goes above 1.5 MPa {15 kg/cm2} (when the control lever is operated approx. half
way), the swing assurance selector valve is actuated and the swing drive pressure locks the pilot
check valve of the bucket throttle valve in the swing 4-spool control valve.
• 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.
10-170 PC1250-7
12. Components of system

Pump controller
PC1250-7 10-171
Input and output signals

CN-1 (CN-C01) CN-2 (CN-C02) CN-3 (CN-C03)
Pin No. Signal name I/O Pin No. Signal name I/O Pin No. Signal name I/O
CN-1 NC Input CN2-1 NC Output CN3-1 Controller PWR Input
CN-2 NC Input CN2-2 Swing lock prolix SW Input CN3-2 Solenoid PWR Input
CN-3 NC Input CN2-3 NC Input CN3-3 TVC solenoid (–) Input
CN-4 NC CN2-4 232C R x D (FLASH Write) Input CN3-4 Battery relay holding Output
CN-5 Trouble in auto Input CN2-5 NC Input CN3-5 Step light power drive relay Output
grease controller
CN-6 NC Input CN2-6 NC Input CN3-6 NC Output
CN-7 NC Input CN2-7 Model selection 4 Input CN3-7 Travel straight SOL Output
CN-8 NC Input CN2-8 Working mode Output CN3-8 Travel alarm Output
(For Hi regulation)
CN-9 NC Input CN2-9 Auto deceleration Output CN3-9 Bucket curl pressure SW Input
CN-10 NC Input CN2-10 NC Input CN3-10 Boom raise pressure SW Input

CN-11 NC Input CN2-11 NC Output CN3-11 Controller PWR Input
CN-12 NC Input CN2-12 CAN SH CN3-12 Solenoid PWR Input
CN-13 NC Input CN2-13 Travel left pressure SW Input CN3-13 NC Input

CN-14 NC Input CN2-14 232C T x D (FLASH Write) Output CN3-14 Controller PWR Input
CN-15 NC Input CN2-15 NC Input CN3-15 Step light drive relay Output
CN-16 NC Output CN2-16 NC Input CN3-16 TVC solenoid (+) Output

CN-17 Key SW (Terminal C) Input CN2-17 Model selection 3 Input CN3-17 CO cancel SOL Output
CN-18 NC Input CN2-18 Working mode
(For full curve) Output CN3-18 NC Output
CN-19 NC Input CN2-19 Hi down (When lever
is in neutral: GND) Output CN3-19 Bucket dump pressure SW Input
CN-20 NC Input CN2-20 NC Input CN3-20 Boom lower pressure SW Input

input/
CN-21 NC Input CN2-21 S-NET output CN3-21 Controller GND Input
input/
CN-22 NC Output CN2-22 CAN0 L output CN3-22 NC Input
input/
CN-23 Key SW (Terminal Acc) Input CN2-23 NC output CN3-23 NC Input
FWE SW (FLASH
CN-24 Step light SW Input CN2-24 Write signal input) Input CN3-24 Controller PWR Input
CN2-25 Horn SW Input CN3-25 Flash write drive relay Output
CN2-26 Engine oil level Input CN3-26 NC Output

CN2-27 Model selection 2 Input CN3-27 Travel Hi/Lo selector SOL Output
CN2-28 Travel right pressure SW Input CN3-28 2-step relief SOL Output
CN2-29 Pulse GND CN3-29 Swing pressure SW Input

CN2-30 NC Input CN3-30 Arm in pressure SW Input
CN2-31 S NET GND CN3-31 Controller GND Input
input/
CN2-32 CANO H output CN3-32 Controller GND Input
input/
CN2-33 NC output CN3-33 Controller GND Input
CN2-34 232C GND (FLASH Write) CN3-34 NC Input
CN2-35 NC Input CN3-35 NC Output

CN2-36 Radiator water level Input CN3-36 NC Output
CN2-37 Model selection 1 Input CN3-37 Swing holding brake SOL Output
CN2-38 Swing lock SW Input CN3-38 Swing priority SOL Output

CN2-39 Pulse GND CN3-39 NC Input
CN2-40 Engine speed sensor Input CN3-40 Arm out pressure SW Input
10-172 PC1250-7
Engine speed sensor
1. Sensor Function
2. Connector • 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.
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
• There are 8 switches installed
to the PPC shuttle valve. The
operating condition of each ac-
tuator is detected from the PPC
pressure, and this is sent to the
engine throttle and pump con-
troller.
PC1250-7 10-173
TVC prolix resistor
1. Resistor
2. Connector
Specification Function
Resistance: 20 Ω • This resistor acts to allow a suitable current
to flow to the TVC solenoid when the TVC
prolix switch is ON.
• No current flows when the TVC prolix switch
is OFF.
Fuel control dial

fl See ENGINE CONTROL.
Monitor panel
fl See MACHINE MONITOR SYSTEM.
TVC valve
fl See HYDRAULIC PUMP.
10-174 PC1250-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

CN1 CN3
Pin Signal name Input/ Pin Signal name Input/
No. output No. output
1 Key switch (Battery) Input 1 NC

3 Washer motor output Output 3 NC
4 Key switch (Terminal C) Input 4 NC
5 Wiper contact W (Lower wiper contact P) Input 5 NC

6 GND 6 NC
7 GND 7 NC
8 VB + (24 V) Input 8 NC
9 Wiper motor (+) <Upper wiper motor (+)> Output 9 NC
10 Wiper motor (–) <Lower wiper motor (–)> Output 10 NC
11 NC Input 11 NC
12 Wiper contact P (Upper wiper contact P) Input 12 NC
13 NC
CN2 14 CAN (Shield)
Pin Signal name Input/
No. output 15 CAN (+)
1 NC Input 16 CAN (–)
2 Fuel Input
3 Radiator water level Input
4 NC Input
5 Air cleaner clogging sensor Input

6 NC Input
7 NC Input
8 Engine oil level sensor Input

Input/
9 N/W (S-NET signal) output
Input/
11 Charge level Input
12 Hydraulic oil temperature (Analog) Input
13 GND (For analog signal) Input
14 ªPersonal code relay (Lo) Input

15 Window limit switch <Lower wiper switch> Input
16 Buzzer cancel Input
17 Swing lock Input

18 Preheating Input
19 Light switch Input
20 N/W (S-NET GND)
PC1250-7 10-177

CN1 CN3
Pin Signal name Input/ Pin Signal name Input/
No. output No. output

3 Washer motor output Output 3 NC
4 Key switch (Terminal C) Input 4 NC
5 Wiper contact W (Lower wiper contact P) Input 5 NC

6 GND 6 NC
7 GND 7 NC
8 VB + (24 V) Input 8 NC
9 Wiper motor (+) <Upper wiper motor (+)> Output 9 NC
10 Wiper motor (–) <Lower wiper motor (–)> Output 10 NC
11 NC Input 11 NC
12 Wiper contact P (Upper wiper contact P) Input 12 NC
13 NC
CN2 14 CAN (Shield)
Pin Signal name Input/
No. output 15 CAN (+)
1 NC Input 16 CAN (–)
2 Fuel Input
3 Radiator water level Input
4 NC Input
5 Air cleaner clogging sensor Input

6 NC Input
7 NC Input
8 Engine oil level sensor Input

Input/
Input/
11 Charge level Input
12 Hydraulic oil temperature (Analog) Input
13 GND (For analog signal) Input
14 ªPersonal code relay (Lo) Input

15 Window limit switch <Lower wiper switch> Input
16 Buzzer cancel Input
17 Swing lock Input

18 Preheating Input
19 Light switch Input
20 N/W (S-NET GND)
PC1250-7 10-177
MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine water temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Radiator water level caution
6. Engine water temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Engine oil pressure caution
8. Service monitor 18. Engine oil level caution
9. Travel speed monitor 19. Air cleaner clogging
10. Fuel gauge 20. Maintenance time warning caution
10-178 PC1250-7
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 water
temperature
Hydraulic oil
temperature See gauge display on the next page
Fuel level
PC1250-7 10-179
Gauge Range Temperature, volume Indicator Buzzer sound
A1 105 Red fi
A2 102 Red
Engine water A3 100 Green

temperature (°C) A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
B2 102 Red
B3 100 Green
Hydraulic oil
temperature (°C) B4 80 Green
B5 40 Green
B6 20 White
C1 774 Green
C2 711 Green
C3 634 Green
Fuel level (¬)
C4 484 Green
C5 300 Green
C6 211 Red
10-180 PC1250-7
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
following cautions are displayed.
Symbol Display item Check before When engine is When engine is

starting item stopped running
When abnormal,
Engine oil pressure ‡ — lights up and buzzer
sounds
Lights up when
Battery charge ‡ — abnormal
Lights up when When abnormal,

Radiator water level ‡ abnormal lights up and buzzer
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 displayed.
Condition of hydraulic oil Color of symbol
Low temperature (below B6 or equivalent) Black on white background
Normal (B6 – B2) No display
High temperature (below B2) White on red letters
PC1250-7 10-181
Display category Symbol Display item Display range Display method
ON INT OFF Displays set

Wiper
condition
Working Displays set

mode mode
Monitor
Displays set
Travel speed speed
Auto-decel- Displays actua-

ON ⇔ OFF tion status
eration
Service Lights up when

Service meter meter indica- When service meter is working service meter is
tor working
10-182 PC1250-7
SWITCHES
1. Working mode selector switch

2. Display brightness, contrast adjustment switch
3. Control switch
4. Window washer switch
5. Wiper switch
6. Maintenance switch
7. Travel speed selector switch
8. Auto-deceleration switch
PC1250-7 10-183
• Working mode selector switch

Switch that is Working mode status
The condition of the machine changes ac- Display
pressed after setting
cording to the switch that is pressed (A, E, L,
B). It is possible to check the condition on [A] A A mode (default)
the working mode monitor display. The re-
[E] E E mode
lationship between each working mode and
the monitor display is shown in the table on Heavy-lift mode
the right.
• Maintenance switch Swing priority mode

Check the condition of the maintenance
items. (For details, see MAINTENANCE
FUNCTION.)
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the auto-deceleration monitor display
to check the present condition.
When the working mode switch is operated
to switch the working mode, it is automati-
cally set to ON.
• Travel speed selector switch

Each time the travel speed selector switch is Display Setting
pressed, the travel speed changes.
Lo → Hi → Lo . . . . . . Crawler symbol + Lo Low speed (default)
Use the travel speed monitor display to check Crawler symbol + Hi High speed
the present condition.
The relationship between the set speed and
the monitor display in the table on the right.
• Wiper switch
Each time the wiper switch is pressed, the
wiper setting changes OFF → INT → ON →
Wiper actuation
OFF → . . . . . . Display Setting
status
Use the wiper monitor display to check the
present condition. None OFF Stowing stopped
The relationship between the wiper setting or now stowing
and the monitor display is as shown in the Intermittent
Wiper symbol + INT INT
table on the right. actuation
Wiper symbol + ON ON Continuous

actuation
10-184 PC1250-7
• Window washer switch

While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
• Control switch
This is used for control when using the main-
tenance function or select function.
(For details, see each function.)
• Display brightness, contrast adjustment

switch
Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
PC1250-7 10-185
MAINTENANCE FUNCTION
When the maintenance time for replacement,

inspection, or filling has approached for the 10
maintenance items, press maintenance switch
(1) and the caution display (yellow or red) ap-
pears on the monitor display for 30 seconds
after the key is turned ON to remind the opera-
tor to carry out lubrication maintenance.
fl Maintenance items
Replacement
No. Item
interval (hours)
01 Engine oil 500
02 Engine oil filter 500

03 Fuel filter 500
04 Hydraulic filter 500
05 Hydraulic tank breather 1,000
06 Corrosion resistor ª (1,000)
07 Damper case oil 1,000
08 Final case oil 2,000
09 Machinery case oil 1,000
10 Hydraulic oil 5,000
ª Option, so not set
fl The above replacement intervals are set for

each item, and the time remaining to main-
tenance is reduced as the machine is oper-
ated.
The content of the caution display differs
according to the ramaining time. The rela-
tionship is as shown in the table below.
Display Condition
Remaining time for

maintenance for all
None
items is more than 30
hours
Notice display (black There is one or more

symbol displayed on items with less than 30
hours remaining time
yellow background)
for maintenance
There is one or more

Warning display (wiper
symbol displayed on items with less than 0
red background) hours remaining time
for maintenance
10-186 PC1250-7
METHOD OF CHECKING STATUS

MAINTENANCE ITEMS
fl Operate as follows when on the operator

screen.
1. Press maintenance switch (1) and switch to
the maintenance list display screen.
fl The maintencance items are displayed
as symbols on the screen.
2. Press control switch (2), or use the 10-key
pad to input the number (01 – 10) of the
maintenance item to select the item.
fl The cursor moves and the item is high-
lighted.
fl The display method is the same as de-
scribed on the previous page (relation-
ship between remaining time and cau-
tion display). If the remaining time is less
than 30 hours, the item is displayed in
yellow, and if it is less than 0 hours, it is
displayed in red.
MAINTENANCE OPERATION
1. After completing the selection, press input

confirmation 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 any 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 confirma-
tion switch (3) to reset the maintenance time.
After the reset is completed, the screen re-
turns 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.
fl The check screen shows the symbol for
the maintenance item and the set time
in large letters.
fl 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.
PC1250-7 10-187
BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION
This function is used to adjust the brightness

and contrast of the display.
ADJUSTMENT METHOD
fl Operate as follows when on the operator

screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment
screen.
fl Relationship between menu symbol and con-
tent.
No. Symbol Content
01 Return mark Return
02 Contrast
03 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
pas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.
Control switch Actuation
Flow level bar graph

extends to the right
Flow level bar graph

retracts to the left
10-188 PC1250-7
SERVICE METER CHECK FUNCTION
• 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 dis-
play.
• This display is shown only while the two
switches are being pressed. When the
switches are released, the display goes out.
Note that it takes 3 – 5 seconds after the
switches are pressed for the service meter
display to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the nor-

mal 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.
• If any part of the display is black, the LCD is
broken.
PC1250-7 10-189
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the ma-

chine, the user code is displayed on the
monitor to advise the operator of the steps
to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is
displayed on the portion for the hydraulic
oil temperature gauge.
• If more than one user code is generated at

the same time, the user codes are displayed
in turn for 2 seconds each to display all the
user codes.
10-190 PC1250-7
• While the user code is being displayed, if

the input confirmation switch is pressed, the
service code and failure code can be dis-
played.
• If there is more than one service code or

failure code, the display switches every 2
seconds and displays all the service codes/
failure codes that caused the user code to
be displayed.
Even if service codes/failure codes have oc-
curred, if they did not cause the user code
to be displayed, this function does not dis-
play them.
• If the telephone number has been set using

the telephone number input on the service
menu, it is possible to switch on the service
code/failure code and display the telephone
symbol and telephone number.
For details of inputting and setting the tele-
phone number, see SPECIAL FUNCTIONS OF
MONITOR PANEL in the TESTING AND AD-
JUSTING section.
PC1250-7 10-191
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of
contact type is always connected to the chas-
sis ground.
Sensor name Type of sensor When When

normal abnormal
Engine oil ON OFF

Contact
level (Closed) (Open)
Hydraulic oil
Resistance — —
temperature
Fuel level Resistance — —
Air cleaner OFF ON

Contact
clogging (Closed) (Open)
Engine oil level sensor

1. Connector
2. Bracket
3. Float
4. Switch
10-192 PC1250-7
Hydraulic oil temperature sensor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
PC1250-7 10-193
Air cleaner clogging sensor
10-194 PC1250-7
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ..........................................................20-2
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ........................................................20-3
TESTING AND ADJUSTING .................................................................................................................20-101
TROUBLESHOOTING ..........................................................................................................................20-201
★ Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
the safety pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
PC1250-7 20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
Machine model PC1250-7

Engine SAA6D170E-3
Standard value
Item Measurement condition Unit Service limit value
for new machine
High idling 2,000±40 1,900±30
Engine speed Low idling rpm 900±25 720±30
Rated speed 1,800 1,800
Air supply (boost pres- kPa Min. 107 93
At rated output
sure) {mmHg} {Min. 800} {700}
Whole speed range
Exhaust temperature °C Max. 680 700
(ambient temperature: 20°C)
At sudden acceleration Bosch Max. 4.0 6.0
Exhaust gas color
At high idling 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) (210 – 250) (210 – 250)
Water temperature: Within operating range kPa Max. 4.9 7.9

Blow-by pressure
At rated output {mmH2O} {Min. 500} {800}
Water temperature: Within operating range

At high idling
SAE30 or SAE15W-40 oil 0.38 – 0.59 0.21
{4.0 – 6.0} {2.1}
SAE10W oil 0.34 – 0.54 0.18
MPa
Oil pressure {3.5 – 5.5} {1.8}
{kg/cm2}
At low idling
SAE30 or SAE15W-40 oil Min. 0.12 0.07
{Min. 1.2} {0.7}
SAE10W oil Min. 0.10 0.05
{Min. 1.0} {0.5}
Oil temperature Whole speed range (inside oil pan) °C 90 – 110 120
Fuel temperature Ambient temperature: 50°C °C Max. 71 Max. 71
Fan belt tension mm Auto tension Auto tension
Deflection when pressed with finger force of
Alternator belt tension mm Approx. 15 Approx. 15
approx. 58.8 N {6 kg}
Air conditioner com- Deflection when pressed with finger force of
mm Approx. 16 Approx. 16
pressor belt tension approx. 98 N {10 kg}
★ When measuring the low idling speed after reducing speed suddenly from high speed, wait for several sec-
onds for the speed to stabilize before measuring.
20-2 PC1250-7
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Applicable model PC1250-7
Cate- Standard value for

Item Measurement conditions Unit Service limit value
gory new machine
• Engine at full throttle
• Hydraulic oil temperature: 45 – 55°C
All pumps at relief 1,850 ± 100 1,850 ± 100
• Engine oil pressure:
Within operating range
Engine speed
• Engine water temperature:

All pumps at relief
Within operating range
+ rpm 1,800 ± 50 1,800 ± 100
• In A 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 stopped N→
Boom control lever 85 ± 10 85 ± 10
• Center of lever RAISE • LOWER
knob N→
Arm control lever • Read max. 85 ± 10 85 ± 10
Control lever stroke
IN • OUT
value to end of
N→
Bucket control lever travel 85 ± 10 85 ± 10
CURL • DUMP
mm
N → Left •
Swing control lever 85 ± 10 85 ± 10
Right swing
N → Forward •
Travel control lever 115 ± 15 115 ± 15
Reverse (both sides)
Control lever play Work equipment •
Max. 10 Max. 10
amount swing, travel
PC1250-7 20-3
Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
• Engine stopped
Operating effort of control levers
15.7 ± 4.9 15.7 ± 4.9

Boom control lever • Oil temperature: 45 – 55°C {1.6 ± 0.5} {1.6 ± 0.5}
• Fit push-pull scale to center of control lever
knob 15.7 ± 4.9 15.7 ± 4.9
Arm control lever
• Measure max. value to end of travel {1.6 ± 0.5} {1.6 ± 0.5}
N {kg} 12.7 ± 3.9 12.7 ± 3.9

Bucket control lever
{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}
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 –1.5
• Oil temperature: OFF +10 +10
RAISE
45 – 55°C {320 –15 } {320 –15 }

• In A 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
31.4 –1.5 31.4 –2.5
Swing +10 +10
{320 –15 } {320 –25 }
• Engine at full throttle +0.4 +0.4
3.1 0 3.1 0
Control pump • Oil temperature: 45 – 55°C +3.5 +3.5
• All control levers at neutral {32 0 } {32 0 }
• Engine at full throttle All control levers at 2.3 ± 0.3 Min. 1.8
• Oil temperature: neutral {23 ± 3} {18}
45 – 55°C Heavy lift 1.13 ± 0.2 1.08 ± 0.2
Boom RAISE
TVC valve output • In A 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}
20-4 PC1250-7
Applicable Model PC1250-7
Cate- Standard value Service limit

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 A 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
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 A mode
output pres- All control levers at MPa
sure Swing 4- Min. 1.5 {15} Min. 1.5 {15}
neutral {kg/cm2}
spool control
valve Swing under no
Max. 0.2 {2} Max. 0.2 {2}
load
• Engine at full throttle +0.6 +0.6
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 pres- • Hydraulic oil temperature: 45 – 55°C 2.9 ± 0.6 2.9 ± 0.6
sure • Operate only solenoid being meas- {30 ± 5.5} {30 ± 5.5}
ured
• 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 idling
Work equipment posture
Swing
Overrun when stopping deg. Max. 85 Max. 105

swing (mm) (Max. 1,805) (Max. 2,230)
• In A mode
• Bucket: No load
• Stop after swinging one turn and
measure distance that swing circle
moves
Value in ( ) shows distance at outside
circumference of swing circle
PC1250-7 20-5
Cate Standard value Service limit

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

swing • Engine at full throttle
• Hydraulic oil temperature:
45 – 55°C
• In A 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 ± 2.6 Max. 59

Swing

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

swing • Engine stopped (mm) (0) (0)
• 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.
l/min
Leakage from swing
• Hydraulic oil temperature: 45 – 55°C Max. 14 Max. 28
motor
• Relieve swing circuit.
20-6 PC1250-7

Low speed
95 – 117 95 – 117
Travel speed (1) sec
High speed
• In A mode 63 – 77 63 – 77
• Raise track on one side at a time,
rotate one turn, then measure time
taken for next 5 turns with no load.
Low speed
30 – 40 30 – 40
Travel speed (2) sec

High speed

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

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

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

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.
l/min
Leakage of travel
Max. 20 Max. 40
motor

• Lock shoes and relieve travel circuit.
20-8 PC1250-7

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 exten- (Max. 55) (Max. 85)
of cylinder) sion or retraction of each cylinder and down-
ward movement at tip of bucket teeth.
• Engine stopped
• Horizontal, flat ground mm
Arm cylinder • All control levers at neutral
(amount of • Bucket: Rated load or full load of soil Max. 160 Max. 240
extension of STD, LC specification: 75.9 kN {7,740 kg} (Max. 70) (Max. 105)
cylinder) SP specification: 100.6 kN {10,260 kg}
Work equipment
• Start measuring immediately after setting.

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

specifi- specifi- specifi- specifi-
cation cation cation cation
RAISE
Boom
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 A mode 4.0 ± 0.4 4.4 ± 0.4 Max. 4.8 Max. 5.2
extended
• Bucket: No load
PC1250-7 20-9

gory new machine
• Work equipment posture STD, LC SP STD, LC SP
specifi- specifi- specifi- specifi-
cation cation cation cation
IN
Arm
Cylinder 5.0 ± 0.5 5.0 ± 0.5 Max. 6.0 Max. 6.0
fully
retracted sec
Fully
OUT
Work equipment speed
extended • Engine at full throttle 4.0 ± 0.4 4.0 ± 0.4 Max. 4.8 Max. 4.8
• In A mode
• Bucket: No load
Bucket CURL 3.3 ± 0.4 3.5 ± 0.4 Max. 4.1 Max. 4.3
Cylinder
fully
Work equipment
retracted sec
Fully
DUMP
extended • Engine at full throttle 3.1 ± 0.4 3.3 ± 0.4 Max. 3.9 Max. 4.1
• In A mode
• Bucket: No load
Time lag
Boom sec Max. 5 Max. 7

• Engine at low idling
• Retract arm and bucket cylinder fully, then
lower boom from max. RAISE point and meas-
ure time taken from point where bucket con-
tacts ground to point where chassis rises from
ground.
20-10 PC1250-7
Cate- Standard value

gory for new machine
Arm Max. 2 Max. 4

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

sec
Work equipment
Bucket Max. 2 Max. 4

• Set top surface of boom horizontal, retract
arm cylinder fully, then extend bucket cylinder
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
PC1250-7 20-11
TESTING AND ADJUSTING
MEASURING ENGINE SPEED...................................................................................................................20-102
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) ...............................................................20-103
MEASURING EXHAUST TEMPERATURE (TOTAL ENGINE) ...................................................................20-104
TROUBLESHOOTING OF INJECTOR .......................................................................................................20-105
MEASURING EXHAUST COLOR ...............................................................................................................20-106
ADJUSTING VALVE CLEARANCE .............................................................................................................20-107
TESTING AND ADJUSTING INJECTOR LIFT............................................................................................20-108
MEASURING COMPRESSION PRESSURE ..............................................................................................20-109
MEASURING BLOW-BY PRESSURE ........................................................................................................20- 110
MEASURING ENGINE OIL PRESSURE ....................................................................................................20- 111
HANDLING EQUIPMENT IN FUEL SYSTEM .............................................................................................20- 112
MEASURING FUEL PUMP OUTLET PORT PRESSURE ..........................................................................20- 112
MEASURING FUEL PUMP INLET PORT PRESSURE (NEGATIVE PRESSURE) ....................................20- 114
INSPECTING RETURN OF FUEL VISUALLY ............................................................................................20- 114
BLEEDING AIR FROM FUEL CIRCUIT ......................................................................................................20- 115
ADJUSTING ENGINE SPEED SENSOR ....................................................................................................20- 117
REPLACING AND ADJUSTING FAN BELT ................................................................................................20- 118
TESTING AND ADJUSTING ALTERNATOR AND AIR COMPRESSOR BELT TENSION .........................20- 119
TESTING CLEARANCE OF SWING CIRCLE BEARING ...........................................................................20-121
MEASURING WEAR OF SPROCKET ........................................................................................................20-122
TESTING AND ADJUSTING TRACK SHOE TENSION..............................................................................20-123
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT.................................................................................................................................20-124
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE .........................................................20-129
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE ......................................................20-130
MEASURING SERVO PISTON STROKE ...................................................................................................20-137
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING SWING PPC SHUTTLE VALVE..........20-138
MEASURING SOLENOID VALVE OUTPUT PRESSURE...........................................................................20-142
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE ...........................................................................20-144
TESTING TRAVEL DEVIATION ..................................................................................................................20-145
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ....................................20-146
MEASURING OIL LEAKAGE ......................................................................................................................20-147
BLEEDING AIR ...........................................................................................................................................20-151
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................20-153
INSPECTION PROCEDURES FOR DIODE ...............................................................................................20-154
SPECIAL FUNCTION OF MONITOR PANEL .............................................................................................20-155
PC1250-7 20-101
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

★ Measure the engine speed under the following 3) Measuring all-pump relief speed
condition. i) Set the working mode switch to the DH
• Engine water temperature: Within operating mode position.
range ii) Turn the heavy-lift switch OFF.
• Torque converter oil temperature: Within op- iii) Turn the fuel control dial to the high
erating range idling position.
• Hydraulic oil temperature: 45 – 55°C iv) Relieve the arm digging circuit and
measure the engine speed.
1. Preparation work 4) Measuring all-pump relief + heavy-lift ON
Turn the starting switch ON and set the monitor speed
panel in the "Monitoring mode" to prepare for i) Set the working mode switch to the DH
measurement of the engine speed. mode position.
★ For the operating method, see "Special func- ii) Turn the heavy-lift switch ON.
tions of monitor panel". iii) Turn the fuel control dial to the high
• Monitoring code: 010 (Engine speed) idling position.
★ The unit of displayed engine speed is 1 rpm. iv) Relieve the boom raising circuit and
2. Run the engine under the given measurement

condition and measure the engine speed.
1) Measuring low idling and high idling speeds:
i) Set the working mode switch to the A
mode position.
ii) Turn the auto-deceleration switch OFF.
★ Only when measuring the high idling
speed
iii) Turn the fuel control dial to the low idling
(MIN) position and high idling (MAX)
position and measure the engine speed
at those positions.
★ When measuring the high idling speed,
release the safety lock lever and turn the
swing lock switch ON and swing the ma-
chine finely.
2) Measuring auto-deceleration speed:
i) Turn the auto-deceleration switch ON.
ii) Turn the fuel control dial to the high
idling position.
iii) Set the all control levers in neutral and
20-102 PC1250-7
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)

★ Tools for measuring air supply pressure (boost ★ Insert the connection of the hose and pres-
pressure) sure gauge about half way, repeat the action
to open the self-seal portion at the hose end,
Symbol Part No. Part Name and bleed the oil.
A 799-201-2202 Boost gauge kit ★ If Pm kit (A) is available, the air bleed cou-
pling (790-261-1130) inside the kit can be
k
used.
Be careful not to touch any hot parts when re- ★ If there is oil inside the hose, the gauge will
moving or installing the measuring tools. not work, so always bleed the oil.
★ Measure the air supply pressure (boost pres-
sure) under the following conditions. 4. Run the engine at high idling, turn the working
• Coolant temperature: Within operating range mode switch to the A mode, turn the heavy-lift
• Torque converter oil temperature: Within op- switch ON, relieve the boom raising circuit, and
erating range measure the air supply pressure (boost pres-
• Hydraulic oil temperature: 45 – 55°C sure).
1. Remove air supply pressure measurement plug

(1).
5. After completing the measurement, remove the

measuring equipment and set to the original
condition.
2. Fit nipple 1 of boost gauge kit A, then connect
gauge 2.
3. Run the engine at a mid-range speed or above

to bleed the oil from the hose.
PC1250-7 20-103
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE (TOTAL ENGINE)
MEASURING EXHAUST TEMPERATURE (TOTAL ENGINE)

★ Tools for measuring exhaust temperature (total 2. Fit sensor 1 of digital temperature gauge B,
engine) (standard specification) then connect to meter 2.
★ Clamp the wiring harness of the digital tem-
Symbol Part No. Part Name perature gauge to prevent it from touching
Digital temperature any hot part during measurement.
B 799-101-1502
gauge
★ Tools for measuring exhaust temperature (total

engine) (Pm specification)
Symbol Part No. Part Name

Digital temperature
— 799-101-1502
gauge
Sensor
— 6166-15-8180
(already installed)
— 799-201-1150 Adapter connector
3. Procedure when measuring the maximum value
k Wait for the manifold temperature to go down during troubleshooting.
before removing or installing the measuring Measure the maximum exhaust gas tempera-
equipment. ture when the arm circuit is relieved.
★ Measure the exhaust temperature under the fol- ★ Use the PEAK mode of the digital tempera-
lowing conditions. ture gauge.
• Coolant temperature: Within operating range ★ The exhaust temperature varies greatly ac-
• Torque converter oil temperature: Within op- cording to the ambient temperature (temper-
erating range ature of the engine intake air), so if any
• Hydraulic oil temperature: 45 – 55°C abnormal value is obtained, carry out tem-
perature compensation using the following
1. Remove exhaust temperature measurement formula.
plug (1). • Compensation value [°C] = Measured
value + 2 x (20 – ambient temperature)
20-104 PC1250-7
TESTING AND ADJUSTING TROUBLESHOOTING OF INJECTOR
TROUBLESHOOTING OF INJECTOR
★ Tools for measuring exhaust temperature (each 4. Compensate the measured value for each cylin-
cylinder) der to judge which cylinder is defective.
★ Compensation value
Cylinder No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
C 795-799-5510 Thermometer Compensa-
+20°C +5°C 0°C 0°C +5°C +20°C
tion value
★ If the engine output drops or there is any other
problem, if there is the possibility of defective ★ Method of judgment
combustion due to defective injection by the in- Add up the temperatures after compensat-
jector, measure the exhaust temtemperature of ing, then calculate the average temperature.
each cylinder as follows to locate the cylinder If the temperature of any cylinder is more
with the defective injection (defective combus- than 20°C lower than the average, judge
tion). that the cylinder is abnormal.
1 Measurement and judgment example 1
1. Stop the engine and leave it to cool down.
★ When cooling the engine down, as a guide-
line, wait for the temperature of the exhaust Measured
85°C 62°C 79°C 112°C 89°C 82°C
mainfold to cool down to a temperature of value
"ambient temperature + 20°C". Compen-
sation 105°C 67°C 79°C 112°C 94°C 102°C
value
2. Start the engine and run it at low idling for at
least 10 minutes. Average
93°C
★ Run it for at least 10 minutes to stabilize the value
exhaust temperature.
No. 2 cylinder is more than 20°C lower than
3. Using thermometer C, measure the temperature the avearage value, so judge that No. 2 cyl-
at the outlet of the exhaust manifold of each cylinder is abnormal.
inder. 2 Measurement and judgment example 2:
★ Measure the exhaust temperature at the bot-
tom of the exhaust manifold of each cylinder.
Measure at the same positon for the all cylin- Measured
86°C 96°C 73°C 91°C 94°C 103°C
ders. value
★ A ladder is prepared on the machine body. Compen-
Remove the undercover before starting the sation 106°C 101°C 73°C 91°C 99°C 123°C
value
measurement.
Average
99°C
value
No. 3 cylinder is more than 20°C lower than

the average value, so judge that No. 3 cylin-
der is abnormal.
3 Measurement and judgment example 3:
Measured
85°C 62°C 79°C 112°C 89°C 82°C
value
Compen-
sation 105°C 67°C 79°C 112°C 94°C 102°C
value
Average
93°C
value
No cylinder is more than 20°C lower than

the average value, so judge that all cylin-
ders are normal.
PC1250-7 20-105
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

★ Tools for measuring exhaust color

Handy Smoke
1 799-201-9000
Checker
D
Commerccially
2 Smoke Meter
available
k Be careful not to touch any hot parts when re-

moving or installing the measuring tools.
★ When measuring in the field where there is no air
or electric power supply, use Handy Smoke
Checker D1; when recording formal data, use 2) Connect the air hose and the socket of the
Smoke Meter D2. prove hose and accelerator switch to Smoke
★ Measure the exhaust color under the following Meter D2.
conditions. ★ Keep the pressure of the air supply be-
• Coolant temperature: Within operating range low 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC100V
1. Measuring with Handy Smoke Checker D1. socket.
1) Install filter paper to Handy Smoke Checker ★ Before connecting the cord, check that
D1. the power switch of the Smoke Meter is
2) Insert the exhaust gas suction port into the OFF.
exhaust pipe. 4) Loosen the cap nut of the suction pump and
3) Start the engine. fit the filter paper.
4) Accelerate the engine suddenly or run at ★ Fit the filter paper securely so that the
high idling, and operate the handle of Handy exhaust gas cannot leak.
Smoke Checker D1 at the same time to col- 5) Turn the power switch of Smoke Meter D2
lect the exhaust gas on the filter paper. ON.
5) Remove the filter paper and compare it with 6) Start the engine.
the scale supplied to judge the condition. 7) Accelerate the engine suddenly or run at
6) After completing the measurement, remove high idling, and depress the accelerator
the measuring equipment and set to the pedal of Smoke Meter D2 at the same time
original condition. 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
2. Measuring with Smoke Meter D2 sheets of unused filter paper inside the filter
1) Insert probe 1 of Smoke Meter D2 into the paper holder, and read the value shown.
outlet port of the exhaust pipe, and tighten 9) After completing the measurement, remove
the clip to secure it to the exhaust pipe. the measuring equipment and set to the
original condition.
20-106 PC1250-7
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

★ Tools for adjusting valve clearance 3. Insert feeler gauge E into clearance b between
rocker arm (3) and crosshead (4), and adjust the
Symbol Part No. Part Name valve clearance with adjustment screw (5).
Commercially ★ Insert the feeler gauge and turn the adjust-
E Feeler gauge ment screw until the clearance is a sliding fit.
available
4. Hold adjustment screw (5) in position, then

tighten locknut (6).
3 Locknut:
1. Remove all cylinder head covers (1).
57.8 – 77.4 Nm {5.9 – 7.9 kgm}

★ After tightening the locknut, check the valve
clearance again.
2. Rotate the crankshaft in the normal direction, to

set the No. 1 cylinder at compression top dead
center, and align [1.6TOP] line a on the damper
with pointer (2).
★ Use a barring device on the flywheel housing 5. Rotate the crankshaft 120° each time in the nor-
to carry out cranking. mal direction and repeat the procedure in Steps
★ At compression top dead center, the rocker 3 – 5 to adjust the valve clearance of each cylin-
arm of the No. 1 cylinder can be moved by der according to the firing order.
hand an amount equal to the valve clear- • Firing order: 1-5-3-6-2-4
ance. If the rocker arm does not move, it is
not at compression top dead center, so ro- 6. After completing the adjustment, set to the origi-
nal condition.
3 Cylinder head cover mounting bolt:
tate the crankshaft one more turn.
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
PC1250-7 20-107
TESTING AND ADJUSTING TESTING AND ADJUSTING INJECTOR LIFT
TESTING AND ADJUSTING INJECTOR LIFT

★ Tools for testing and adjusting injector lift

Commercially Dial gauge
F
available (Stroke: Min. 30 mm)
1. Remove all cylinder head covers (1).
3. Set dial gauge F to the plunger head of the

injector to be tested. Set the long pointer to 0
and check the position of the short pointer.
★ Use a dial gauge with a stroke of at least 30
mm.
2. Rotate the crankshaft in the normal direction,

align [1.6TOP] line a on the damper with pointer
(2), and set the No. 1 cylinder at compression
top dead center.
★ Use a barring device on the flywheel housing
to carry out cranking.
★ At compression top dead center, the rocker
arms of both suction valve and exhaust valve
can be moved with the hand by the valve
clearance. If the rocker arms cannot be
moved, the cylinder is not at the compres-
sion top dead center. In this case, rotate the 4. Rotate the crankshaft, and measure the lift of
crankshaft one more turn. the plunger at the point where the deflection of
★ The cylinder where the injector is inspected the dial gauge is the maximum.
is different from the cylinder at compression • Max lift b: 20.00 mm
top dead center, so check the chart below
when carrying out the operation.
• Cylinder at compression top dead center and
cylinder where injector is inspected.
Compression top
1 5 3 6 2 4
dead center
Injector to check 2 4 1 5 3 6
20-108 PC1250-7
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
Adjusting
★ If the lift is not correct, or if parts related to the in- 5. After completing the testing and adjusting, set to
jector have been removed and installed, adjust the original condition.
as follows. 3 Cylinder head cover mounting bolt:
1. Follow Step 3 of the testing procedure and set 9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
the cylinder for the injector to be adjusted to
compression top dead center.
★ The cylinder where the injector is inspected
is different from the cylinder at compression
top dead center, so check the chart below
when carrying out the operation.
• Cylinder at compression top dead center and
cylinder where injector is inspected
Compression
1 5 3 6 2 4
top dead center
Injector to check 2 4 1 5 3 6
2. Completely loosen adjustment screw (3) of the MEASURING COMPRESSION

injector to be adjusted, then tighten with your fin- PRESSURE
gers.
★ Check that the bearing at the tip of the rocker ★ For details of the method for measuring the blow-
arm and the ball at the push rod end are fit- by pressure, see the 170-3 Series engine shop
ted securely in the injector and push rod re- manual.
spectively.
3. Repeat the tightening and loosening operation

for adjustment screw (3), and finally tighten.
3 Adjustment screw:
1st pass: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2nd pass: Loosen completely
3rd pass: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4th pass: Loosen completely
5th pass: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4. Hold adjustment screw (3) in position, then

tighten locknut (4).
3 Locknut:
205.8 – 245 Nm {21 – 25 kgm}
★ After tightening the locknut, repeat the test-
ing procedure to check the lift again.
PC1250-7 20-109
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

★ Tools for measuring blow-by pressure 3. After completing the measurement, remove the
measuring equipment and set to the original
Symbol Part No. Part Name condition.
G 799-201-1504 Blow-by kit
★ Measure the blow-by pressure under the follow-

ing conditions.
• Coolant temperature: Within operating range
• Torque converter oil temperature: Within op-
erating range
1. Install nozzle [1] of blow-by checker G to blow-

by hose (1), then connect to gauge G.
2. Run the engine at high idling, turn the working

mode switch to the A mode, relieve the arm dig-
ging circuit, and measure the blow-by pressure.
★ Blow-by varies greatly according to the con-
dition of the engine. Therefore, if the blow-
by value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defec-
tive exhaust gas color, and prematurely dirty
or deteriorated oil.
20-110 PC1250-7
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

★ Tools for measuring engine oil pressure 2) Fit nipple [1] of hydraulic tester H1, then
connect to hydraulic tester H2.
799-101-5002 Hydraulic tester
1 Digital type hydraulic
790-261-1203
H tester
Hydraulic tester
2 799-401-2320
(1.0 MPa {10kg/cm2})
★ Measure the engine oil pressure under the fol-

lowing conditions.
• Engine oil temperature: Min. 80°C
• Coolant temperature: Within operating range
1. Measuring in monitoring mode 3) Start the engine, and measure the oil pres-
★ It is also possible to check the engine oil sure at low idling and high idling.
pressure with the monitoring mode of the
monitor panel. For details of the method of
operation, see SPECIAL FUNCTIONS OF
MONITOR PANEL.
• Monitoring code: 372 (Engine oil pres-
sure)
★ The engine oil pressure is displayed in units
of 1 kPa.
4) After completing the measurement, remove

the measuring equipment and set to the
original condition.
2. Measuring with oil pressure gauge

1) Remove oil pressure measurement plug (1).
PC1250-7 20-111
HANDLING EQUIPMENT IN FUEL SYSTEM
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
HANDLING EQUIPMENT IN MEASURING FUEL PUMP

FUEL SYSTEM OUTLET PORT PRESSURE
★ Precautions for inspection and maintenance of ★ Tools for measuring fuel pump outlet port pres-
fuel system sure
The HPI type fuel injection system is con-
structed of more precise components than the Symbol Part No. Part Name
conventional fuel injection pump and nozzle, so 1 795-799-5460 Cable
problems may occur if dirt or dust get in.
When carrying out inspection and maintenance J Commercially
2 Tester
of the fuel system, pay more attention than available
usual to prevent dirt or dust from getting in. If
there is any dirt stuck to any part, use clean fuel
to wash it off completely.
★ Precautions when replacing fuel filter cartridge Symbol Part No. Part Name
Always use a genuine Komatsu part for the fuel
filter cartridge.
The HPI type fuel injection system is con- 1 Digital hydraulic
structed of more precise components than the H 790-261-1203
tester
conventional fuel injection pump and nozzle, so
a special filter with high efficiency filtering ability 3 795-799-5550 Adapter
is used to prevent dirt or dust from getting in.
For this reason, if any filter is used as a substi-
tute for the genuine filter, there is danger that 1. Measuring by pressure sensor signal voltage
problems will occur with the fuel system. To pre- 1) Disconnect PMPR connector (1) of the fuel
vent this, never use such filters. pump pressure sensor, then connect cable
J1 to the male and female ends.
2) Start the engine, switch the monitor panel to

the monitoring mode display, and prepare to
★ For details of the method of operation,
see SPECIAL FUNCTIONS OF MONI-
TOR PANEL.
• Monitoring code: 010 (Engine speed)
★ The engine speed is displayed in units of
1 rpm.
20-112 PC1250-7
TESTING AND ADJUSTING MEASURING FUEL PUMP OUTLET PORT PRESSURE
3) Run the engine at low idling and check that

the source voltage of the fuel pump pres-
★ Source voltage of sensor (Between A –

sure sensor is in the following range.
B): 4.75 – 5.25 V

4) Run the engine at each speed in the follow-
ing table and check that the signal voltage of
the fuel pump pressure sensor is in the cor-
★ Signal voltage of sensor (Between C –

responding range shown in the same table.
B):
Table : Engine speed and signal voltage
Engine Fuel pump outlet port 3) Start the engine, switch the monitor panel to
Signal voltage the monitoring mode display, and prepare
speed pressure (Reference)
for to measure the engine speed.
1000 0.76 ± 0.14 MPa ★ For details of the method of operation,
1.68 ± 0.21V
rpm {7.76 ± 1.43 kg/cm2} see SPECIAL FUNCTIONS OF MONI-
1.57 ± 0.14 MPa TOR PANEL.
1300
3.00 ± 0.21V • Monitoring code: 010 (Engine speed)
rpm {16.0 ± 1.43 kg/cm2}
★ The engine speed is displayed in units of
1500 1.78 ± 0.14 MPa 1 rpm.
3.26 ± 0.21V 4) Run the engine at the speed shown in Table
rpm {18.15 ± 1.43 kg/cm2}
and check that the pump outlet port pres-
sure is in the range shown in the table.
2. Measuring directly with pressure gauge
1) Fit adapter H3 to nipple (2) for measuring
the pump outlet port pressure.
2) Install nipple [1] of hydraulic tester H1 to

adapter H3, install them to coupler (2) of the
fuel pump, and connect hydraulic tester H1.
PC1250-7 20-113
MEASURING FUEL PUMP INLET PORT PRESSURE
TESTING AND ADJUSTING INSPECTING RETURN OF FUEL VISUALLY
MEASURING FUEL PUMP INLET PORT PRESSURE

(NEGATIVE PRESSURE)
★ Tools for measuring fuel pump inlet port pressure
(negative pressure)

1 Digital hydraulic
790-261-1203
tester
H 3 795-799-5550 Adapter
Negative pressure
4 795-799-5560 gauge (0 to –0.1
MPa) {0 to –1 kg/cm2}
★ If Pm kit (A) is available, the air bleed
coupling (790-261-1130) inside the kit
1. Fit adapter H3 to pump inlet port pressure mea- can be used.
suring nipple (3). ★ If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
2. Fit nipple [1] of hydraulic tester H1 to adapter
H3, install them to coupler (3) of the fuel pump, 4. Run the engine at each engine speed and mea-
and connect negative pressure gauge H4. sure the pump inlet port pressure.
★ Fuel pump inlet port pressure
Fuel filter Fuel pump inlet port pressure

Max. –13.60 kPa
New
{Max. –102 mmHg}
Max. –27.10 kPa
Used
{Max. –203 mmHg}
INSPECTING RETURN OF
FUEL VISUALLY
1. Disconnect fuel return hose (1) on the fuel tank
side and inspect the returning condition of the
fuel visually.
3. Run the engine at a medium speed to bleed the

oil from the hose.
★ Insert the connection of the hose and
negative pressure gauge about halfway,
repeat the action to open the self-seal
portion at the hose end, and bleed the
oil.
20-114 PC1250-7
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
★ If the engine does not start or is difficult to start ★ Add fuel from the inlet port a (8 places). Por-
after the following operations or conditions, tion b is the outlet port after filtering (clean
bleed the air from the fuel circuit as follows. side), so never add fuel from portion b.
• When starting the engine for the first time
• After cleaning the fuel tank
• After adding fuel when the engine has stalled
• After replacing the fuel filter (only when the
air is not bled easily)
1. Open the stop valve at the fuel tank supply side.

★ Check that there is ample fuel in the fuel
tank.
2. Remove fuel filter, fill it with fuel, then install it
again.
★ Carry out this operation only if the fuel filter
has been replaced.
★ If the fuel filter is not to be replaced, there is
danger of dirt getting in, so do not remove
the fuel filter.
PC1250-7 20-115
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Crank the engine with the starting motor, push

air bleed valve (1), and bleed the air from the
vent circuit.
★ There is no problem with starting even if
some air is in the circuit, so if the fuel flows
out the bleeding operation is completed.
4. Start the engine and run at low idling.
★ The injector is an open circuit, so while the
engine is running the air remaining in the cir-
cuit is released from the injector to the inside
of the engine or the fuel tank.
★ After the engine is started, the engine rota-
tion will be slightly unstable until the air re-
maining in the circuit is completely bled, so
continue to run the engine at low idling until
it stabilizes.
★ If the engine will still not start after the above op-
eration, fill the fuel pump with fuel as follows.
1) Remove air bleed valve (1).
2) Fill with clean fuel through the hole in the
valve until it overflows.
★ Amount of fuel to add: Approx. 30 cc
(reference)
3) Install air bleed plug (1).
3 Air bleed plug: 12.7 Nm {1.3 kgm}
4) Crank the engine with the starting motor.
20-116 PC1250-7
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

★ If the engine speed sensor has been removed 5. After completing the adjustment, switch the
and installed or the flywheel has been removed monitor panel to the monitoring mode display,
or installed, adjust as follows. and check that the engine speed is displayed
normally.
1. Remove the floor inspection cover, then remove ★ For details of the method of operation, see
engine speed sensor (1). SPECIAL FUNCTIONS OF MONITOR PAN-
★ Before adjusting, remove the engine speed EL.
sensor, check that the tip of the sensor is not • Monitoring code: 010 (Engine speed)
scratched and that there are no iron particles
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.
★ Angle to return: 1/2 – 3/4 turns
★ 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 with nut (3).

3 Nut: 33.9 – 47.5 Nm {3.5 – 4.8 kgm}
PC1250-7 20-117
TESTING AND ADJUSTING REPLACING AND ADJUSTING FAN BELT
REPLACING AND ADJUSTING FAN BELT

Replacing Adjusting
1. Loosen locknut (1) and return adjustment screw ★ If the fan belt whines during operation, or a gap
(2) to the position of bracket (3). forms between the tension pully lever and the ad-
justment screw, adjust as follows.
2. Insert bar (approx. 50 cm) into hole (4) (φ18) in
tension pulley bracket, pull strongly and keep 1. Screw in adjustment screw (2) until the tip con-
the tension of the fan belt loosened. tacts tension pulley lever (5).
★ After replacing the belts, set the adjustment 2. From this position, tighten adjustment screw (2)
screw back to its original condition. a further 2 turns, then secure in position with
locknut (1).
3. Remove the old fan belts and replace them with 3 Locknut:
new belts. 245.0 – 308.7 Nm {25.0 – 31.5 kgm}
20-118 PC1250-7
TESTING AND ADJUSTING ALTERNATOR AND
TESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR AND

AIR COMPRESSOR BELT TENSION
Testing Adjusting alternator belt tension
• Press the belt at the middle point between the 1. Insert a bar between alternator (5) and cylinder
alternator pulley and air compressor pulley (or block to secure the alternator.
idler pulley) with the finger and measure deflec- ★ Put a wood panel, etc. between the bar and
tion. alternator so that the alternator will not be
★ Alternator belt damaged.
• Deflection: Approx. 15 mm
• Pressing force: Approx. 59 N {Approx. 6 2. Loosen bolts and nuts (1) – (4) in the order of
kg} the numbers so that alternator (5) can be
★ Air compressor belt moved.
• Deflection: Approx. 16 mm • If nut (4) is tightened, the belt tension is in-
• Pressing force: Approx. 98 N {Approx. creased. If the former is loosened, the latter
10 kg} is lowered.
3. After adjusting the belt tension, tighten bolts and

nuts (1) – (4) in the reverse order.
• Check each pulley for breakage and wear of
the V-grooves and check the V-belt for wear.
In particular, check that the V-belt is not in
contact with the bottom of the V-groove.
• If the V-belt is so lengthened that its tension
cannot be adjusted any more or if it has a cut
or a crack, replace it.
• If the V-belt is replaced, adjust its tension
again after operating the machine for about
1 hour.
PC1250-7 20-119
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR AND
Adjusting compressor belt tension
1. Loosen bolts (1) – (4) in the order of the num-

bers so that the compressor can be moved.
• If nut (4) is tightened, the belt tension is in-
creased. If the former is loosened, the latter
is lowered.
2. After adjusting the belt tension, tighten bolts (1)

– (4) in the reverse order.
• Check each pulley for breakage and wear of
the V-grooves and check the V-belt for wear.
In particular, check that the V-belt is not in
contact with the bottom of the V-groove.
• If the V-belt is so lengthened that its tension
cannot be adjusted any more or if it has a cut
or a crack, replace it.
• If the V-belt is replaced, adjust its tension
again after operating the machine for about
1 hour.
20-120 PC1250-7
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF SWING CIRCLE BEARING

★ Measure the clearance of the swing circle bear- 3. Set the dial gauge to the zero point.
ing as follows when it is mounted on the ma-
chine. 4. Set the arm more or less at right angles to the
k When carrying out the measurement, do not put ground surface, then lower the boom until the
your hand or feet under the undercarriage. front of the machine comes off the ground.
★ When this is done, the upper structure will tilt
1. Fix a dial gauge to the outer race (or track back, so the front will rise and the rear will go
frame) of the swing circle, then put the tip of the down.
probe in contact with the track frame (or outer
race).
★ Set the dial gauge at the front or rear.
5. Read the value on the dial gauge at this point.

★ The value on the dial gauge is the clearance
of the swing circle bearing.
2. Extend the work equipment to the maximum
reach, and set the tip of the bucket to the same 6. Return to the condition in Step 2, and check that
height as the bottom of the revolving frame. the dial gauge has returned to the zero point.
★ When this is done, the upper structure will tilt ★ If it has not returned to the zero point, repeat
forward, so the front will go down and the Steps 3 to 5.
rear will rise.
PC1250-7 20-121
TESTING AND ADJUSTING MEASURING WEAR OF SPROCKET
MEASURING WEAR OF SPROCKET
1. Align wear gauge K with the portion of the

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

★ If the sprocket wave pattern is above the
wear limit line, it is possible to use the
sprocket as it is.
★ If the sprocket wave pattern has reached the
wear limit line, replace the sprocket with a
new part.
20-122 PC1250-7
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING ADJUSTING
1. Travel the machine forward by the length of ★ If the track shoe tension is not proper, adjust it in
track on ground, keeping the engine at low the following manner.
idling, and stop the machine slowly.
1. When the tension is too strong
2. Place wood bar [1] on the track shoe between Discharge grease by loosening valve (1).
second carrier roller (1) and third carrier roller k Do not loosen valve (1) by more than one
(2). turn, because grease will spurt due to its in-
★ L beam is recommended for bar [1], because ternal high pressure.
of its deflection-free nature.
2. When the tension is too weak
3. Measure max. clearance a between bar [1] and Add grease through grease fitting (2).
the track shoe. ★ If the normal track shoe tension is not re-
• Max. standard clearance a: 10 – 30 mm stored even after greasing, move the ma-
chine slowly back and forth.
PC1250-7 20-123
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK

EQUIPMENT, SWING, TRAVEL CIRCUIT
Testing tools 1. Measuring front pump (No. 1 F + No. 2 F) cir-
cuit pressure
Sym- Part 1) Connect oil pressure gauge H1 (58.8 MPa
Part No. Remarks
bol name {600 kg/cm2}) to quick coupler (1) or (2) for
Pressure gauge: the circuit to be measured.
Analog • (1): No. 1 front pump
2.5, 5.9, 39.2,
799-101-5002 hydraulic • (2): No. 2 front pump
58.8 MPa {25, 60,
tester 2) Set the working mode switch to the A mode.
H 1 400, 600 kg/cm2}
Digital Pressure gauge
790-261-1203 hydraulic 58.8 MPa
tester {600 kg/cm2}
Measuring
★ Oil temperature when measuring: 45 – 55°C
k Lower the work equipment to the ground and
stop the engine. Oprate the control levers sev-
eral times to release the remaining pressure in
the hydraulic piping. Then loosen the oil filler
cap slowly to release the pressure inside the hy-
draulic tank.
★ The relief pressure of the boom LOWER circuit
can be measured only for the front pump circuit.
★ The relief pressure of the bucket DUMP circuit
cannot be measured for the No. 3 pump circuit.
3) Run the engine at full throttle and measure

the pressure under each of the following
conditions.
4) Measuring main relief pressure when heavy
lift is OFF (normal):
i) Turn the heavy-lift switch OFF.
ii) Measure the oil pressure when the actu-
ator to be measured is relieved.
lift is ON (raised pressure):
i) Turn the heavy-lift switch ON.
ii) Measure the oil pressure with the circuit
relieved at boom RAISE.
20-124 PC1250-7
6) Measureing boom LOWER relief pressure 2. Measuring rear pump (No. 1 R + No. 2 R) cir-
when machine push-up is OFF (normal): cuit pressure
i) Turn the machine push-up switch OFF. 1) Connect oil pressure gauge H1 (58.8 MPa
ii) Measure the oil pressure with the circuit {600 kg/cm2}) to quick coupler (3) or (4) for
relieved at boom LOWER. the circuit to be measured.
★ Under these conditions, the set pressure • (3): No. 1 rear pump
of the safety valve for the boom LOWER • (4): No. 2 rear pump
circuit is lower than the main relief pres-
sure, so the value measured will be the
relief pressure of the safety valve.
7) Measuring boom LOWER relief pressure

when machine push-up is ON (raised pres-
sure):
i) Turn the machine push-up switch ON.
relieved at boom LOWER.
★ Under these conditions, the set pressure
of the safety valve for the boom LOWER
circuit is higher than the main relief pres-
sure, so the value measured will be the
relief pressure of the safety valve.
★ Condition of actuators when measuring 2) Set the working mode switch to the A mode.
• For the work equipment, operate each 3) Run the engine at full throttle and measure
cylinder to the end of its stroke. the pressure under each of the following
k For the travel circuit, put block 1 be- conditions.
tween the sprocket and frame to lock the 4) Measuring main relief pressure when heavy
track, and relieve each side at a time. lift is OFF.
i) Turn the machine heavy-lift switch ON.
PC1250-7 20-125
★ Condition of actuators when measuring 2) Set the working mode switch to the A mode.
• For the work equipment, operate each cylin- 3) Run the engine at full throttle and measure
der to the end of its stroke. the pressure under each of the following
k For the travel circuit, put block 1 between conditions.
the sprocket and frame to lock the track, 4) Measuring main relief pressure when heavy
and relieve each side at a time. lift is OFF (normal):
i) Turn the heavy-lift switch ON.
★ Under these conditions, the set pressure of
the safety valve for the swing circuit is lower
than the main relief pressure, so the value
measured will be the relief pressure of the
safety valve.
3. Measuring No. 3 pump circuit pressure ★ Condition of actuators when measuring
1) Connect oil pressure gauge H1 (58.8 MPa • For the work equipment, operate each cylin-
{600 kg/cm2}) to quick coupler (5) or (6) for der to the end of its stroke.
the circuit to be measured. • For the swing, turn the swing lock switch ON
• (5): Front pump to lock the swing.
• (6): Rear pump
20-126 PC1250-7
Adjusting ★ After conpletion of adjustment, repeat

★ Adjust only the swing motor safety valve. the procedure in above to check the set
Never adjust any other safety valve. pressure again.
1. Adjusting R.H. 4-spool valve main relief

valve
★ If the relief pressure of the front pump circuit
is not correct, adjust the main relief valve of
the R.H. 4-spool valve as follows.
1) Disconnect hose (7).
2) Loosen locknut (8) so that elbow (9) can
move.
2. Adjusting L.H. 5-spool valve main relief valve

★ If the relief pressure of the rear pump circuit
the L.H. 5-spool valve as follows.
★ Adjust in the same way as for the R.H. 4-
spool valve.
3) Adjusting high-pressure setting

Loosen locknut (10), then turn holder (11) to
adjust.
★ Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUN-
TERCLOCKWISE.
★ Amount of adjustment for one turn of
holder:
Approx. 21.8 MPa {222 kg/cm2}
3 Locknut:
3. Adjusting swing 4-spool valve main relief
valve
78 – 93 Nm {8 – 9.5 kgm}
★ If the relief pressure of the No. 3 pump circuit
★ When the high-pressure setting is
changed, the low-pressure setting will
the swing 4-spool valve as follows.
also change, so adjust the low-pressure
setting also.
spool valve.
4) Adjusting low-pressure setting
Loosen locknut (12), then turn holder (13) to
adjust.
★ Turn the holder to adjust as follows.
To INCREASE pressure, turn CLOCK-
WISE.
To DECREASE pressure, turn COUN-
TERCLOCKWISE.
holder:
Approx. 21.8 MPa {222 kg/cm2}
3 Locknut:
93 – 123 Nm {9.5 – 12.5 kgm}
PC1250-7 20-127
4. Adjusting swing motor safety valve

★ If the relief pressure of the swing motor is not
correct, adjust the safety valve (16) or (17) of
the swing motor as follows.
Loosen locknut (14), then turn adjustment
screw (15) to adjust.
• Swing motor safety valves (16) and (17)
are for the front motor and rear motor re-
spectively.
★ Turn the adjustment screw to adjust as fol-
lows.
• To INCREASE pressure, turn CLOCK-
WISE.
• To DECREASE pressure, turn COUN-
TERCLOCKWISE.
★ Amount of adjustment for one turn of adjust-
ment screw:
Approx. 4.7 MPa {47.9 kg/cm2}
3 Locknut: 147 – 196 Nm {15 – 20 kgm}
★ After completion of adjustment, repeat the
procedure in above to check the set pres-
sure again.
20-128 PC1250-7
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE

Testing tools Adjusting
★ If the relief pressure of the control circuit is not
Sym- Part correct, adjust control relief valve (5) as follows.
Part No. Q'ty Remarks
bol name 1. Remove cap (2).
Pressure 2. Loosen locknut (3) and turn adjustment screw
gauge: 2.5, (4) to adjust.
Analog ★ Turn the adjustment screw as follows.
5.9, 39.2,
799-101-5002 hydraulic 1SET • To INCREASE pressure, turn CLOCK-
58.8 MPa
tester WISE.
{25, 60, 400,
H 1 • To DECREASE pressure, turn COUN-
600 kg/cm2}
TERCLOCKWISE.
Pressure ★ Amount of adjustment for one turn of adjust-
Digital
gauge ment screw:
790-261-1203 hydraulic 1SET
58.8 MPa Approx. 4.4 MPa {45 kg/cm2}
3 Locknut: 9.8 Nm {1 kgm}
tester
{600 kg/cm2}
★ After completion of adjustment, repeat the
Measuring procedure in above to check the set pres-
★ Oil temperature when measuring: 45 – 55°C sure again.
1. Install oil pressure gauge H1 (5.9 MPa {60 kg/
cm2}) to quick coupler (1).
2. Start the engine at full throttle, and measure the

oil pressure with all the control levers at neutral.
PC1250-7 20-129
TESTING AND ADJUSTING TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
TESTING AND ADJUSTING PISTON PUMP CONTROL

PRESSURE
Testing tools 2) Install nipple 1 of oil pressure gauge H1,
then connect oil pressure gauge H1 (5.9
Sym- MPa {60 kg/cm2})
Part No. Part name Remarks
bol 3) Set the working mode switch to A mode.
Pressure gauge: 4) Run the engine at full throttle, and measure
Analog the pressure under the following conditions.
2.5, 5.9, 39.2,
799-101-5002 hydraulic 5) Measuring with all control levers at neutral:
58.8 MPa {25, 60,
tester Set all the control levers to neutral and
1 400, 600 kg/cm2}
measure the output pressure.
Digital Pressure gauge 6) Measuring with circuit relieved at heavy-lift
790-261-1203 hydraulic 58.8 MPa OFF + boom RAISE
tester {600 kg/cm2} i) Turn the heavy-lift switch OFF.
H ii) Measure the output pressure with the
Differential circuit relieved at boom RAISE.
2 799-401-2701 pressure 7) Measuring with circuit relieved at heavy-lift
gauge ON + boom RAISE
Both male and i) Turn the heavy-lift switch ON.
799-401-2930 Nipple female 11/16- ii) Measure the output pressure with the
3 16UN (RC1/8) circuit relieved at boom RAISE.
02896-11009 O-ring
Measuring
★ Oil temperature when measuring: 45 – 55°C
1. TVC valve output pressure

★ The TVC valve output pressure varies with
the discharge pressure of each valve, so al-
ways check that the oil pressure of the work
equipment, swing, and travel circuits is nor-
mal before measuring.
★ The TVC valve output pressure uses the
control circuit pressure as the basic pres-
sure, so always check that the oil pressure of
the control circuit is normal before measur-
ing.
1) Remove oil pressure measurement plug (1)
(Thread dia. = 10mm, Pitch = 1.25 mm) of
the No. 3 front pump.
2. Measuring output pressure of No. 1 and No.

2 pump CO and NC valves
1) Remove oil pressure measurement plugs
(2) or (3) (Thread dia. = 10 mm, Pitch = 1.25
mm) of the No. 2 pump.
• (2): For front pump circuit
• (3): For rear pump circuit
20-130 PC1250-7
2) Fit nipple 1 of oil pressure gauge H1, then

connect oil pressure gauge H1 (5.9 MPa {60
kg/cm2}).
3) Run the engine at full throttle and measure
the pressure under each of the following
conditions.
4) Measuring when work equipment control
levers are at newtral:
mode.
ii) Measure the output pressure when all
control levers area at neutral.
5) Measuring when track is rotating under no
load:
3. Measuring No. 3 pump CO, NC valve output
pressure
mode.
1) Remove oil pressure measurement plug (4)
ii) Using the boom and arm, jack up the
(Thread dia. = 10 mm, Pitch = 1.25 mm).
track on the side to be measured.
2) Fit nipple 1 of oil pressure gauge H1, then
iii) Measure the output pressure when the
connect oil pressure gauge H1 (5.9 MPa {60
track is rotating under no load.
★ The output pressure of the CO, NC valve dif- kg/cm2}).
fers according to the jet sensor output differ- 3) Run the engine at full throttle and measure
ential pressure, so if the CO, NC valve output the pressure under each of the following
pressure is not normal, always measure the conditions.
jet sensor output differential pressure.
PC1250-7 20-131
4) Measuring when work equipment control 4. Measuring R.H. 4-spool valve and L.H. 5-
levers are at neutral: spool valve jet sensor output differential
i) Set the working mode switch to the A pressure
mode. k Loosen the oil filler cap slowly to release the
ii) Measure the output pressure when all pressure inside the hydraulic tank.
control levers area at neutral. 1) Disconnect high-pressure hose (5) (PT 1/8)
5) Measuring when upper structure is swinging and low-pressure hose (6) (PT 1/8). Fit nip-
under no load: ple H3 to those hoses and connect them.
i) Set the working mode switch to the A R.H. 4-spool valve
mode.
ii) Measure the output pressure when the
upper structure is swinging under no
load.
★ The output pressure of the CO, NC valve dif-
fers according to the jet sensor output pres-
sure differential pressure, so if the CO, NC
valve output pressure is not normal, always
measure the jet sensor output differential
pressure.
L.H. 5-spool valve
2) Fit nipple [3] of oil pressure gauge H1, then

connect differential gauge H2 or oil pressure
gauge H1 (5.9 MPa {60 kg/cm2}).
3) Set the working mode switch to the A mode.
20-132 PC1250-7
4) Start the engine, then using the boom and 2) Install nipple 3 of oil pressure gauge H1,
arm, jack up the track on the side to be then connect to differential gauge H2 or oil
measured. pressure gauge H1 (58.8 MPa {600 kg/
5) Run the engine at full throttle and measure cm2}).
the output differential pressure when all ★ When using oil pressure gauge H1 (58.8
levers are at neutral and when the track is MPa {600 kg/cm 2 }), exchange with a
rotating under no load. 0.98 MPa {10 kg/cm 2 } unit gauge to
measure the high pressure and low
pressure.
3) Set the working mode switch to A mode.
4) Run the engine at full throttle, and measure
the output differential pressure with all the
control levers at neutral and with the swing
operated under no load.
5. Measuring swing 4-spool valve jet sensor

output differential pressure
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1) Remove high-pressure oil pressure meas-
urement plug (7) (PT1/8) and low-pressure
oil pressure measurement plug (8) (PT1/8).
PC1250-7 20-133
Adjusting 2. Adjusting No. 1 and No. 2 pump CO and NC

1. Adjusting TVC valve valves
★ If the TVC valve output pressure is not cor- ★ If the CO, NC valve output pressure is not
rect, adjust the TVC valve of the No. 1 pump correct, adjust the CO, NC valve of the No. 1
as follows. pump as follows.
1) Loosen locknut (9). 1) Adjusting CO valve
2) Turn adjustment screw (10) to adjust. i) Loosen locknut (11).
★ Turn the adjustment screw to adjust as ii) Turn adjustment screw (12) to adjust.
follows. ★ Turn the adjustment screw to adjust
• To INCREASE pressure, turn as follows.
CLOCKWISE. • To INCREASE pressure, turn
• To DECREASE pressure, turn CLOCKWISE.
COUNTERCLOCKWISE. • To DECREASE pressure, turn
★ Amount of adjustment for one turn of ad- COUNTERCLOCKWISE.
justment screw: ★ Amount of adjustment for one turn of
Approx. 0.4 MPa {4.1 kg/cm2} adjustment screw:
3 Locknut: Approx. 2.2 MPa {22.4 kg/cm2}
5.9 – 9.8 Nm {0.6 – 1.0 kgm} 3 Locknut:
★ After completion of adjustment, repeat 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
the procedure in above to check the set ★ After completion of adjustment, re-
pressure again. peat the procedure in above to
check the set pressure again.
20-134 PC1250-7
2) Adjusting NC valve 3. Adjusting No. 3 pump CO and NC valves

i) Loosen locknut (13). ★ If the CO, NC valve output pressure is not
ii) Turn adjustment screw (14) to adjust. correct, adjust the CO, NC valve as follows.
★ Turn the adjustment screw to adjust
as follows. 1) Adjusting CO valve
• To INCREASE pressure, turn ★ Adjust in the same way as for the No. 1
CLOCKWISE. and No. 2 pump CO and NC valves
• To DECREASE pressure, turn
COUNTERCLOCKWISE.
adjustment screw:
3 Locknut:
5.9 – 9.8 Nm {0.6 – 1.0 kgm}
★ After completion of adjustment, re-
peat the procedure in above to
check the set pressure again.
2) Adjusting NC valve
★ Adjust in the same way as for the No. 1
and No. 2 pump CO and NC valves
PC1250-7 20-135
4. Adjusting R.H. 4-spool valve and L.H. 5-

spool valve jet sensor
★ If the output differential pressure of the jet
sensor is not correct, adjust the jet sensor re-
lief valves (17) and (18) as follows.
1) Loosen locknut (15).
2) Turn adjustment screw (16) to adjust.
★ Turn the adjustment screw to adjust as
follows.
• To INCREASE pressure, turn
CLOCKWISE.
• To DECREASE pressure, turn
COUNTERCLOCKWISE.
★ Amount of adjustment for one turn of ad-
justment screw:
5. Adjusting swing 4-spool valve jet sensor
3 Locknut:
★ If the jet sensor output differential pressure is
not correct, adjust the jet sensor relief valve
59 – 78 Nm {6 – 8 kgm}
(19) as follows.
★ After completion of adjustment, repeat
the procedure in above to check the set
spool valve and L.H. 5-spool valve jet sen-
pressure again.
sor.
R.H. 4-spool valve
L.H. 5-spool valve
20-136 PC1250-7
TESTING AND ADJUSTING MEASURING SERVO PISTON STROKE
MEASURING SERVO PISTON STROKE

★ When judging the condition of the servo valve, 2. Measuring stroke
measure the stroke of the servo valve as follows. 1) Remove the cap at the servo piston spring
chamber end, then install the measuring
1. Measurement tools to prepare tool.
1) Prepare new servo piston cover (1). ★ Install the tool for measuring the cap O-
★ The same part is used for the No. 1 ring.
pump and No. 2 pump. 2) Stop the engine, push in the rod of the
measurement tool fully, and measure
dimension a1 of the rod.
3) Start the engine and use the work equip-
ment to jack up the track shoe from the
ground on the side to be measured.
4) Run the engine at full throttle, rotate the
track under no load, and measure dimen-
sion a2 of the rod.
5) Calculate stroke b of the servo piston from
dimensions a1 and a2.
★ Standard stroke b of servo piston
• No. 1 pump, No. 2 pump: 9.37 mm
• No. 3 pump: 12.2 mm
2) Machine a PT1/4 tap hole in the center of
cap (1).
3) Install disc gauge P in cap (1).
3. Pass/Fail judgment
★ If the servo piston stroke is not correct, be-
fore judging the condition, remove the servo
valve, servo piston cap, and spring, then
move the servo piston by hand and check
that it moves smoothly.
1) If servo piston stroke is correct:
The servo valve is normal.
2) If servo piston stroke is not correct:
• If the servo piston moves smoothly:
The servo valve is defective.
• If the servo piston does not move
smoothly: The servo valve is normal.
PC1250-7 20-137
MEASURING PPC VALVE OUTPUT PRESSURE AND
TESTING AND ADJUSTING TESTING SWING PPC SHUTTLE VALVE
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING

SWING PPC SHUTTLE VALVE
Testing tools 2) Install nipple [3] of oil pressure gauge H1,
Sym- MPa {60 kg/cm2}).
bol
Pressure gauge:
Analog
2.5, 5.9, 39.2,
799-101-5002 hydraulic
58.8 MPa {25, 60,
tester
1 400, 600 kg/cm2}
Digital Pressure gauge
H 790-261-1203 hydraulic 58.8 MPa
tester {600 kg/cm2}
Both male and
799-401-2930 Nipple female 11/16-
3 16UN (RC1/8)
02896-11009 O-ring
3) Run the engine at full throttle, operate the
control lever of the circuit to be measured,
★ Oil temperature when measuring: 45 – 55°C and measure the oil pressure.
★ Measure with the lever operated fully.
1. Measuring PPC valve output pressure ★ Condition of actuators when measuring
1) Disconnect hose (1) of the circuit to be • For the work equipment, operate
measured, install nipple H3, and connect each cylinder to the end of its stroke.
hose (1). • For the swing, turn the swing lock
★ See the diagram on 20-140 page for de- switch ON to lock the swing.
tails of the hose to disconnect.
k For the travel circuit, put block 3

between the sprocket and frame to
lock the track.
20-138 PC1250-7
2. Measuring swing PPC shuttle valve

1) Disconnect hose (2), install nipple H3, and
connect the hose.
2) Install nipple [3] of oil pressure gauge H1,

MPa {60 kg/cm2}).
3) Run the engine at full throttle, swing the

upper structure to the left and right, and
measure the oil pressure in each direction.
★ If the oil pressure is correct for both the
left and right swing, the shuttle valve is
normal.
★ If the oil pressure is not correct for either
the left or right swing, the shuttle valve
ball is probably stuck.
PC1250-7 20-139
Measuring PPC valve output pressure and testing swing PPC valve
20-140 PC1250-7
PC1250-7 20-141
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE

Testing tools • (7): Swing priority solenoid valve
Sym-
bol
Pressure gauge:
Analog
2.5, 5.9, 39.2,
799-101-5002 hydraulic
58.8 MPa {25, 60,
tester
1 400, 600 kg/cm2}
H Digital Pressure gauge

790-261-1203 hydraulic 58.8 MPa
tester {600 kg/cm2}
799-401-2930 Nipple
2
02896-11009 O-ring • (8): Safety lock solenoid valve
k Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank.
1. Disconnect outlet hose (9) of the solenoid valve
(1) – (8) to be measured
• (1): CO cancel solenoid valve
• (2): Straight-travel solenoid valve
• (3): 2-stage relief solenoid valve
• (4): Machine push-up solenoid valve
• (5): Travel speed solenoid valve
2. Install nipple [3] of oil pressure gauge H1, then

connect oil pressure gauge H1 (5.9 MPa {60 kg/
cm2}).
3. Start the engine and measure the output pres-

sure when set or operated to the conditions in
the table below.
★ When operating the work equipment, swing,
or travel levers, operate slightly (enough for
the PPC pressure switch to be turned ON).
• (6): Swing holding brake solenoid valve
20-142 PC1250-7
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
Table
Condition Oil pressure

No. Solenoid Measurement conditions Operating condition
of solenoid (MPa {kg/cm2})
When travel lever is in
neutral and heavy-lift switch OFF 0 Pump CO function actuated
1 CO cancel is OFF
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
All levers at neutral OFF 0
and rear pump circuit divided
Straight
2 When work equipment and
travel 2.9 ± 0.6 Flow from front pump circuit
both travel levers are ON
{30 ± 5.5} and rear pump circuit merged
operated simultaneously
When heavy-lift switch is Main relief valve at low-
OFF 0
OFF pressure setting
2-stage
3 When heavy-lift switch is ON
main relief 2.9 ± 0.6 Main relief valve at high-
and boom is raised singly or ON
{30 ± 5.5} pressure setting
when travel lever is operated
When machine push-up
Boom LOWER safety valve at
switch is at high-pressure OFF 0
high-pressure setting
Machine setting
4
push-up When machine push-up
2.9 ± 0.6 Boom LOWER safety valve at
switch is at low-pressure ON
{30 ± 5.5} low-pressure setting
setting
Travel motor swash plate angle
Travel speed switch at Lo OFF 0
Travel at MAX
5
speed Travel speed switch at Hi and 2.9 ± 0.6 Travel motor swash plate angle
ON
travel lever operated {30 ± 5.5} at MIN
11 sec after all work
equipment and swing levers OFF 0 Swing holding brake applied
Swing hold- are returned to neutral
6
ing brake
Swing or work equipment 2.9 ± 0.6
ON Swing holding brake canceled
lever operated {30 ± 5.5}
Swing priority switch is OFF OFF 0 Boom Plus spool actuated
Swing When swing priority switch is
7 2.9 ± 0.6
priority ON and swing lever is ON Boom Plus spool stopped
{30 ± 5.5}
operated
When safety lock lever is at
OFF 0 Circuit to PPC valve closed
LOCK (upper) position
8 Safety lock
When safety lock lever is at 2.9 ± 0.6
ON Circuit to PPC valve opened
FREE (lower) position {30 ± 5.5}
PC1250-7 20-143
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE

★ If there is excessive play at the tip of the work
equipment or swing lever, adjust at the PPC
valve end as follows.
• 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.
★ 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).
20-144 PC1250-7
TESTING AND ADJUSTING TESTING TRAVEL DEVIATION
TESTING TRAVEL DEVIATION

★ When traveling on level ground.
1. Set the machine in the travel posture.
★ 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.
★ Install the oil pressure gauge and measure
the pump discharge pressure at the same
time.
PC1250-7 20-145
TESTING LOCATIONS CAUSING HYDRAULIC
TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK

EQUIPMENT
★ 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 con-
trol valve.
1. Checking boom and bucket cylinders
1) Set in the same posture as when measuring
hydraulic drift, and stop the engine.
2) Operate the boom control lever to RAISE or
the bucket control lever to CURL.
• If the lowering speed increases, the
packing is defective.
• If there is no change, the boom lock
valve (boom) or the control valve (buck-
et) is defective.
★ If the pressure in the accumulator has [Reference] If the cause of the hydraulic drift is in
dropped, run the engine for approx. 10 the packing, and the above operation
seconds to charge the accumulator is carried out, the downward move-
again before operating. ment becomes faster for the following
reasons.
1) If the work equipment is set to the above
posture (holding pressure applied to the bot-
tom end), the oil at the bottom end leaks to
the head end. However, the volume 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 pressure (this dif-
2. Checking arm cylinder fers according to the amount of leakage) by
1) Stop the arm cylinder at a point approx. 100 repeating this procedure.
mm before the end of the IN stroke, then 3) When the pressure is balanced, the down-
stop the engine. ward movement becomes slower. If the
2) Operate the control lever to arm IN. lever is then operated according to the pro-
• If the lowering speed increases, the cedure given above, the circuit at the head
packing is defective. end is opened to the drain circuit (the bot-
• If there is no change, the control valve is tom end is closed by the check valve), so
defective. the oil at the head end flows to the drain cir-
★ If the pressure in the accumulator has cuit and the downward movement becomes
dropped, run the engine for approx. 10 faster.
seconds to charge the accumulator
again before operating.
20-146 PC1250-7
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE

★ Oil temperature when measuring: 45 – 55°C 4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one
1. Work equipment cylinder minute.
1) Fully extend the rod of the cylinder to be
measured, then stop the engine.
2. Swing motor
k Loosen the hydraulic tank oil filler cap slow-
2) Disconnect piping (1) at the head end, then ly to release the pressure inside the tank.
block the piping at the chassis end with a 1) Disconnect drain hoses (2), (3) from the
blind plug. swing motor, then install a blind plug at the
k Be careful not to disconnect the piping tank end.
at the bottom end.
2) Turn the swing lock switch LOCK.

3) Start the engine and apply the relief pres- 3) Start the engine and operate the swing relief
sure to the bottom end of the cylinder with with the engine at full throttle.
the engine at full throttle.
• Boom cylinder: RAISE
• Arm cylinder: IN
• Bucket cylinder: CURL
PC1250-7 20-147
4) Continue this condition for 30 seconds, then 4. Center swivel joint

measure the oil leakage for the next one Table (inspection port and measurement port)
minute.
★ After measuring, swing 180° and measure Swivel joint Direction of Swivel joint
again. inspection rotation of travel measurement
• Hoses (2) and (3) are for the front motor port motor port
and rear motor respectively. A L.H. FORWARD T•B
3. Travel motor B L.H. REVERSE A•P
k Loosen the hydraulic tank oil filler cap slow-
C R.H. FORWARD P•D
ly to release the pressure inside the tank.
1) Disconnect drain hose (4) from the travel D R.H. REVERSE T•C
motor, then fit a blind plug at the hose end.
P Speed selection B•C
1) Put block 1 between the sprocket and

frame to lock the rotation of the travel motor
where the port is to be inspected, and stop
the engine.
2) Fit block 1 between the sprocket and frame

to lock the track.
k Loosen the hydraulic tank oil filler cap

slowly to release the pressure inside the
tank.
3) Start the engine and operate the travel relief

with the engine at full throttle.
k When measuring the oil leakage from
the travel motor, mistaken operation of
the control lever may lead to a serious
accident, so always 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.
★ 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.
20-148 PC1250-7
2) Disconnect the hoses at the botom of the

swivel joint for the measurement port at both
sides of the port to be inspected, and fit
blind plugs in the hoses.
★ When measuring at port T, disconnect
and block the hoses at the top of the
swivel joint to prevent the oil from the
other circuits from flowing in. At the bot-
tom, disconnect the hoses, and do not
block them. Catch the oil in an oil pan.
3) Run the engine at full throttle, and measure
as follows.
i) Ports A, B, C, D
Relieve the travel motor slowly in the
direction of rotation for the port to be
inspected.
k If the lever is operated mistakenly, it
may lead to serious injury or dam-
age, so be sure to confirm signals
and signs carefully.
ii) Port P
Set the travel speed switch to Hi.
4) Continue for one minute, then measure the
oil leakage for the next one minute.
PC1250-7 20-149
20-150 PC1250-7
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
1. Bleeding air from hydraulic pumps 2. Bleeding air from travel motor
★ If the hydraulic pump or related piping has ★ If the travel motor, center swivel joint, or re-
been removed and installed again, bleed the lated piping has been removed and installed
air from the hydraulic pumps as follows. again, bleed the air from the hydraulic
1) Loosen air bleed plugs (1), (2), and (3) 4 pumps as follows.
turns. 1) Loosen air bleed plug (5).
2) Start the engine and use the boom and arm
to jack up the track shoe from the ground on
the side where the air is to be bled.
3) Run the engine at low idling 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.
★ 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 idling.
★ Set the safety lock lever to the LOCK po-
sition 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).
PC1250-7 20-151
TESTING AND ADJUSTING BLEEDING AIR
3. Bleeding air from swing motor 4) Run the engine at high idling, operate the
★ When the swing motor has been removed or cylinder slowly (take at least 10 seconds)
installed again, or when the related piping from a point approx. 100 mm before the end
has been disconnected or connected, do as of the stroke, extend the cylinder to the end
follows to bleed the air from the swing motor. of its stroke to relieve the circuit, and hold in
1) Run the engine at low idling, then start and the relief position for 1 minute.
stop the swing several times.
★ This operation will bleed the air inside
the swing motor automatically.
4. Bleeding air from hydraulic cylinders

★ When the hydraulic cylinders have been re-
moved or installed again, or when the related
piping has been disconnected or connected,
do as follows to bleed the air from the hy-
draulic cylinders.
1) Start the engine and run at idling for approx.
5 minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 – 5 times in succession.
★ Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circum-
stances.
3) Keep the engine running at low idling, oper-
ate the cylinder slowly (take at least 10 sec-
onds) 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.
20-152 PC1250-7
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

★ If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
The travel circuit is an open circuit, so there is
no remaining pressure. It is enough to remove
the oil filler cap.
1. Loosen the oil filler cap slowly to release the

pressure inside the tank.
2. Operate the control levers.

★ When the levers are operated 2 – 3 times,
the pressure stored in the accumulator is re-
moved.
3. Start the engine, run at low idling for approx. 5

minutes, then stop the engine and operate the
control levers.
★ Repeat the above operation 2 – 3 times to re-
lease all the remaining pressure.
PC1250-7 20-153
TESTING AND ADJUSTING INSPECTION PROCEDURES FOR DIODE
INSPECTION PROCEDURES FOR DIODE

★ Check an assembled-type diode (8 pins) and sin- 3) Determine if a specific diode is good or no
gle diode (2 pins) in the following manner. good with the indicated value.
★ The continuity direction of an assembled-type di- • No change in the indicated value: No
ode is as shown in the diagram below. continuity (defective).
★ The continuity direction of a single diode is • Change in the indicated value: Continui-
shown on the diode surface. ty established (normal) (Note)
Note: A silicon diode shows a value between
400 and 600.
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.
1. When using digital type circuit tester • If the needle does not swing in Case i),
1) Switch the testing mode to diode range and but swings in Case ii): Normal (but the
confirm the indicated value. breadth of swing (i.e. resistance value)
★ Voltage of the battery inside is displayed will differ depending on a circuit tester
with conventional circuit testers. type or a selected measurement range)
2) Put the red probe (+) of the test lead to the • If the needle swings in either case of i)
anode (P) and the black probe (–) to the and ii): Defective (short-circuited inter-
cathode (N) of diode, and confirm the dis- nally)
played value. • If the needle does not swing in any case
of i) and ii): Defective (short-circuited in-
ternally)
20-154 PC1250-7
TESTING AND ADJUSTING SPECIAL FUNCTION OF MONITOR PANEL
SPECIAL FUNCTION OF MONITOR PANEL
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] 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
PC1250-7 20-155
Monitor panel functions - conventional and special

The monitor panel 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 monitor panel 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 contents
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, adjustment, trou-
ble-shooting or special setting of machines.
Operator's Menu Service Menu

1 Function for showing KOMATSU logo 14 Function for monitoring [01]
2 Function for check before starting Function for fail- Electrical system
15
3 Function for showing machine maintenance ure history [02] Mechanical system
4 Function for showing caution items 16 Function for maintenance history [03]
Function for confirming working mode and 17 Function for maintenance mode change [04]
5
travel speed
18 Function for recording phone No. [05]
6 Function for display of ordinary items
Mode with key on
Function for adjusting display luminance and Function for ini-
7 tial value set- Language
contrast 19
ting and default Unit
Function for confirming maintenance informa- [06]
8 Wiper select
tion
9 Function for showing service meter reading
10 Function for checking display LCD
Function for showing occurrence of caution
11
item
12 Function for showing users' code No.
Function for showing error code No. and fail-
13
ure code No.
20-156 PC1250-7
Operation of Operator's Menu and

Display (Outline)
★ This section introduces only the outline of the op-
erator's menu. For details on the contents and
operation steps of each menu, refer to the oper-
ation and maintenance manual or the chapter of
"STRUCTURE AND FUNCTION" in this shop
manual.
1. Function for showing KOMATSU logo

When a password is inputted, or when the
engine starting switch is turned ON, KOMATSU
logo is shown for two seconds.
2. Function for machine inspection before

starting day's work
Following the KOMATSU logo, the display of
machine inspection before starting day's work is
shown for 2 seconds.
3. Function for 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 fil-
ter whose maintenance time is approaching or
has just passed.
★ This display appears only when the mainte-
nance function is set.
4. Function for showing precaution items

If there is any item of machine inspection before
starting day's work that indicates some abnor-
mality, a corresponding symbol mark is shown
after the display of machine inspection before
starting day's work.
PC1250-7 20-157
5. Function for confirming working mode and

travel speed
After the display of machine inspection before
day's work, amplified symbol marks for working
mode and travel speed are shown for two sec-
onds to urge an operator to confirm the setting.
6. Function for display of ordinary items

The display of confirming working mode and
travel speed is switched to this display of ordi-
nary items.
★ If the working mode setting or travel speed
setting is changed, or auto-deceleration or
windshield wiper setting is activated while
this is in display, an amplified corresponding
symbol mark is shown for two seconds.
★ In this display, a symbol mark for preheat
monitor is shown only when preheating is
carried out.
7. Function for adjusting display luminance

and contrast
Luminance as well as contrast of the display can
be adjusted by operating the display adjusting
switch.
8. Function for confirming maintenance infor-

mation
Detailed information on maintenance items (set
time and elapse of time) can be confirmed and
resetting after the confirmation is feasible by
operating the maintenance switch.
★ Use service Menu for setting or releasing
maintenance items and setting maintenance
time.
20-158 PC1250-7
9. Function for showing service meter reading

Only the service meter reading can be shown by
the following switching operation, when the
engine starting switch is turned OFF.
• Switching operation: [ ] + [ ] (synchro-
nized switching operation)
10. Function for checking display LCD

Display of the Display LCD can be confirmed by
the following switching operation in the display
of inputting and setting password as well as in
the display of ordinary items
• Switching operation: [ ] + [A] (synchro-
nized switching operation)
★ All the LCD light up, turning the entire screen
white. If there is no showing in black, the dis-
play is normal.
★ This display returns to the immediately pre-
ceding one, if making any other switching
operation.
11. Function for showing occurrence of caution

item
If any of the caution items occurs, the magnified
corresponding symbol mark is shown for two
seconds and thereafter stays on the display as a
small symbol mark until it is dissolved.
12. Function for showing users' 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 atten-
tion of the operator for a proper action.
★ This display turns to the display of error code
and failure code, if operating the switch (Re-
fer to Item No. 13)
PC1250-7 20-159
★ Relation between User Code and Action Directed to Operator
User
Failed System Action Directed to Operator
Code
Ordinary work may be resumed by turning the emergency pump drive
E02 TVC Valve
switch ON, but call for the inspection service immediately.
Release the brake after turning emergency swing and parking brake
switch ON. When applying the swing brake, operate the swing lock
E03 Swing Brake switch manually. The swing brake may not be released depending on
the nature of the trouble. In either case, call for the inspection service
immediately.
Engine stopped (Engine
E10 Call for the inspection service immediately.
cannot be started)
Decrease of output for
protection of engine Set the machine in a safe position and call for the inspection service
E11
Abnormal output caused immediately.
by engine trouble
Set the machine in a safe position and call for the inspection service
E14 Throttle system trouble
immediately.
Engine output is normal Ordinary operation is possible, but call for the inspection service immedi-
E15
but trouble has occurred ately.
20-160 PC1250-7
13. Function for showing error code No. and fail-

ure code No.
If the following switching operation is made
while the users' code No. is shown, a phone
symbol (if registered), phone numbers (if regis-
tered), error code No. and failure code No. are
shown in turn.
• Switching operation: [ ] (keep the switch
depressed)
★ The following display is repeated in turn,
while the switch is depressed.
Telephone symbol mark
Telephone No.
Error code No. and failure code No.

★ The telephone symbol mark and telephone
No. are shown only when they are registered
in the monitor panel.
For registration, correction and deletion of
telephone No., use Service Menu.
★ For details on the displayed error code No.
and failure code No., refer to the Table for
Error and Failure Code Nos.
PC1250-7 20-161
Table for Error and Failure Code Nos.
classification
Error Code Fault code
User Code
History
Code Contents Code. Portion Trouble
— E101 Abnormality in error history data DAF0KT Fault history Abnormal data
Short circuit in wiper motor drive forward revo- Wiper motor (Forward revo-
— E112 DY2DKB Short circuit
lution system lution)
Short circuit in wiper motor drive reverse revo- Wiper motor (Reverse revo-
— E113 DY2EKB Short circuit
lution system lution)
— E114 Short circuit in windshield washer drive system DY2CKB Windshield washer motor Short circuit
— E115 Abnormality in operation of wiper DY20KA Wiper motor Disconnection
— E116 Abnormality in storage of wiper DY20MA Wiper motor Malfunction
— E201 Short circuit in CO cancel solenoid DW48KB CO cancel solenoid valve Short circuit
Travel junction solenoid
— E202 Short circuit is travel junction solenoid DW91KB Short circuit
valve
Solenoid valve for swing
E03 E203 Short circuit in swing holding brake solenoid DW45KB Short circuit
holding brake
— E204 Short circuit in 2-stage relief solenoid valve DWK0KB 2-stage relief solenoid valve Short circuit
— E205 Short circuit in swing priority solenoid DW41KB Swing priority solenoid valve Short circuit
Travel speed HI-LO selec-
— E206 Short circuit in travel speed selector solenoid DW43KB Short circuit
tor solenoid valve
— E207 Short circuit in flash light relay D163KB Flash light relay Short circuit
— E211 Disconnection in CO cancel solenoid DW48KA CO cancel solenoid valve Disconnection
Travel junction solenoid
— E212 Disconnection in travel junction solenoid DW91KA Disconnection
valve
Solenoid valve for swing
E03 E213 Disconnection in swing holding brake solenoid DW45KA Disconnection
holding brake
Electrical system
— E214 Disconnection in 2-stage relief solenoid DWK0KA 2-stage relief solenoid valve Disconnection
— E215 Disconnection in swing priority solenoid DW41KA Swing priority solenoid valve Disconnection
Disconnection in travel speed selector sole- Travel speed HI-LO selec-
— E216 DW43KA Disconnection
noid tor solenoid valve
Disagreement of
— E217 Abnormality in model code input DA2SKQ S-NET model selection sig-
nals
— E218 Disconnection in S-NET signal line DA2SKA S-NET Disconnection
Defective communi-
— E221 Abnormality in J1939 network DA2RKR J1939 network
cation
Short circuit in working mode (full curve) out-
— E222 D5ZJKB Working mode signal line Short circuit
put line
Disconnection in working mode (full curve)
— E223 D5ZJKA Working mode signal line Disconnection
output line
Short circuit in working mode (Hi regulation)
— E224 D5ZLKB Working mode signal line Short circuit
output line
Disconnection in working mode (Hi regulation)
— E225 D5ZLKA Working mode signal line Disconnection
output line
Auto-deceleration signal
— E226 Disconnection in auto-deceleration output line DW42KA Disconnection
line
— E227 Abnormality in engine speed sensor DLE2MA Engine speed sensor Malfunction
Auto-deceleration signal
— E228 Short circuit in auto-deceleration output line DW42KB Short circuit
line
E02 E232 Short circuit in TVC solenoid DXA0KB TVC solenoid valve Short circuit
E02 E233 Disconnection in TVC solenoid DXA0KA TVC solenoid valve Disconnection
— E234 Short circuit in lever neutral output line D5ZFKB Lever neutral signal Short circuit
— E235 Disconnection in lever neutral output line D5ZFKA Lever neutral signal Disconnection
— E302 Short circuit in step light relay D195KB Step light relay Short circuit
20-162 PC1250-7
classification
User Code
History
Short circuit in step light power source drive Step light power source
— E304 D194KB Short circuit
relay drive relay
— E315 Short circuit in battery relay output line D110KB Battery relay Short circuit
E10 C111 Abnormality in engine controller memory C111KT Engine controller Internal defect
Defective actuator
E11 C112 Abnormality in timing rail actuator C112LK Timing actuator
control
Disconnection or
E11 C113 Abnormal current in timing rail actuator C113KZ Timing actuator
short circuit
Disconnection or
E10 C115 Error in engine speed sensor 2 system C115KZ Engine speed sensor
short circuit
Abnormally high level at timing rail pressure Out of input signal
E11 C116 C116KX Timing rail pressure sensor
sensor range
Abnormally low level at timing rail pressure Out of input signal
E11 C117 C117KX Timing rail pressure sensor
sensor range
Abnormally high level at fuel pump pressure Out of input signal
E11 C118 C118KX Fuel pump pressure sensor
sensor range
Abnormally low level at fuel pump pressure Out of input signal
E11 C119 C119KX Fuel pump pressure sensor
sensor range
Disagreement of
Engine speed sensor
E15 C121 Error in engine speed sensor 1 system C121LC input signals of 2
(1 system)
systems
Abnormally high level at boost pressure sen- Out of input signal
E11 C122 C122KX Boost pressure sensor
sor range
Out of input signal
E11 C123 Abnormally low level at boost pressure sensor C123KX Boost pressure sensor
Electrical system
range
Out of input signal
E14 C131 Abnormally high level at throttle sensor C131KX Throttle sensor
range
Out of input signal
E14 C132 Abnormally low level at throttle sensor C132KX Throttle sensor
range
Abnormally high level at engine oil pressure Out of input signal
E15 C135 C135KX Engine oil pressure sensor
sensor range
Abnormally low level at engine oil pressure Out of input signal
E15 C141 C141KX Engine oil pressure sensor
sensor range
Detection of pres-
E11 C143 Abnormal lowering of engine oil pressure C143ZG Engine oil pressure sensor sure lower than set
oil pressure
Abnormally high level at engine water temper- Engine water temperature Out of input signal
E15 C144 C144KX
ature sensor sensor range
Abnormally low level at engine water tempera- Engine water temperature Out of input signal
E15 C145 C145KX
ture sensor sensor range
Detection of temper-
Engine water temperature
E11 C151 Abnormal rise of engine water temperature C151NS ature higher than
sensor
set temperature
Intake air temperature sen- Out of input signal
E15 C153 Abnormally high level at intake air temperature C153KX
sor range
Intake air temperature sen- Out of input signal
E15 C154 Abnormally low level at intake air temperature C154KX
sor range
Abnormally high level at atmospheric pressure Atmospheric pressure sen- Out of input signal
E11 C221 C221KX
sensor sor range
Abnormally low level at atmospheric pressure Atmospheric pressure sen- Out of input signal
E11 C222 C222KX
sensor sor range
Detection of speed
E11 C234 Abnormally high engine speed C234NI Engine speed sensor higher than set
engine speed
PC1250-7 20-163
classification
User Code
History
Disconnection or
E10 C254 Abnormal voltage at fuel shut-off valve C254KZ Fuel shut-off valve
short circuit
E11 C259 Abnormality in fuel shut-off valve C259FS Fuel shut-off valve Valve is kept open.
Detection of temper-
E11 C261 Abnormally high fuel temperature C261NS Fuel temperature sensor ature higher than
set temperature
Abnormally high level at fuel temperature sen- Out of input signal
E15 C263 C263KX Fuel temperature sensor
sor range
Abnormally low level at fuel temperature sen- Out of input signal
E15 C265 C265KX Fuel temperature sensor
sor range
Disconnection or
E11 C316 Abnormal current in fuel pump actuator C316KZ Fuel pump actuator
short circuit
Defective actuator
E11 C318 Abnormality in fuel pump actuator C318LK Fuel pump actuator
control
E15 C346 Engine controller power down C346KT Engine controller Internal defect
Electrical system
Abnormal in-range of timing rail pressure sen- Detection of abnor-
E11 C423 C423L6 Timing rail pressure sensor
sor mal pressure
Source voltage is
E15 C441 Abnormally low level at battery voltage C441KK Engine controller
below 12 V.
Source voltage is
E15 C442 Abnormally high level at battery voltage C442KG Engine controller
above 38 V.
Abnormally high level at fuel rail pressure sen- Out of input signal
E10 C451 C451KX Fuel rail pressure sensor
sor range
Abnormally low level at fuel rail pressure sen- Out of input signal
E10 C452 C452KX Fuel rail pressure sensor
sor range
Disconnection or
E10 C455 Abnormal current in fuel rail actuator C455KZ Fuel rail actuator
short circuit
Defective actuator
E11 C467 Abnormal control of timing rail actuator C467LK Timing rail actuator
control
Defective actuator
E11 C468 Abnormal control of fuel rail actuator C468LK Fuel rail actuator
control
Defective actuator
E10 C514 Abnormality in fuel rail actuator C514LK Fuel rail actuator
control
Detection of abnor-
E11 C554 Abnormal in-range of fuel rail pressure sensor C554L6 Fuel rail pressure sensor
mal pressure
— None Clogging of air cleaner AA10NX Air cleaner element Clogging
— None Abnormal lowering of charge voltage AB00KE Alternator Charge trouble
Mechanical system
Lowering of oil pres-

— None Abnormal lowering of engine oil pressure B@ BAZG Engine oil
sure
— None Abnormal lowering of engine oil level B@ BAZK Engine oil Lowering of oil level
— None Overheating of engine water B@ BCNS Cooling water Overheating
Lowering of cooling
— None Abnormal lowering of radiator water level B@ BCZK Cooling water
water level
— None Overheating of hydraulic oil B@ HANS Hydraulic oil Overheating
— None Abnormality in auto grease system D A80M A Auto grease controller Malfunction
★ This table is arranged in the sequence of Error Code No.

★ In case there is no number assigned in the column of User Code No., or in case "none" is described in the
column of Code No. of Error Code, the corresponding error code or failure code is not shown in the display
of ordinary items, even if some abnormality occurs. It is recorded only in the failure history (either in electrical
system or mechanical system) of Service Menu.
★ History Classification indicates that a specific failure is classified as belonging to either electrical system or
mechanical system, when it is recorded in Service Menu.
20-164 PC1250-7
★ "E" or "C" at the head of Code No. of Error Code means the following status of a specific failure.
• With "E" or "C": The failure is yet to be dissolved and continues.
• Without "E" or "C": The failure has already been dissolved.
Separate sheet: Trouble codes table
Trouble Trouble
Detail of trouble Detail of trouble
code code
FS Sticking NI Overrun
KA Disconnection NS Overheating
KB Short circuit NX Clogging
KK Lowering of source voltage (input) ZG Lowering of oil pressure
KQ Disagreement of model selection signals ZK Lowering of level
KR Defective communication
Engine speed signal, terminal C signal, oil
pressure switch signal, water temperature sen-
KT Internal defect of controller L6
sor signal, etc. do not agree with operating
condition or stopping condition.
KX Out of input signal range
Speed signals of 2 systems do not agree with
KZ Disconnection or short circuit LC
each other.
KG Rise of source voltage KE Abnormal lowering of charge voltage
MA Malfunction LK Abnormal control of actuator
PC1250-7 20-165
Operation and Display of Service Menu
Way of switching to Service Menu

★ When using Service Menu, change the display to
Service Menu display through the following spe-
cial operation.
1) Confirmation of display
Confirm that the display of ordinary items is
shown.
★ Changing to Service Menu cannot be made
from displays other than this.
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] ➝ [2] ➝ [3]
(Enter a figure, depressing [ ])
3) Showing Service Menu display

The display is changed to the initial display of
Service Menu program. Select an appropriate
item from among the menu.
No. Service Menu

00 Return (Termination of Service Menu)
01 Monitoring
02 Abnormality Record
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
06 ✩✩✩✩✩ / Default
07 Adjustment
4) Termination of Service Menu function

When terminating the initial display or any sub-
sequent display of Service Menu, do that
through any one of the following methods.
Depress [ ] switch. (This method may be
used for terminating any display)
If "Return" switch is shown, depress it.
If "Return" menu is shown, call that menu
and depress [ ] switch.
20-166 PC1250-7
14. Function of Monitoring [01]

The monitor panel monitors signals from an
assortment of switches, sensors and actuators
installed in various parts of the machine. Moni-
tored information can be put in display or con-
firmed on a real time basis through the following
operations.
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
2) Setting of monitoring item

Select or register an item to be monitored
through the following switch operation.
• [ ] switch: Selection
• [ ] switch: Selection
• [ ] switch: Registration
★ A monitoring item can be set in any number
between the min. one to the max. four. (De-
pending upon the selected item, the max.
number is less than four)
★ In case of monitoring 1 to 3 items, move to
the monitored information display through
any of the following switch operations, after
the registration work has been completed.
• Keep [ ] switch depressed. (For about
3 seconds)
• Select Menu 999 and depress [ ]
switch.
★ The display automatically moves to the dis-
play of monitored information, when all of the
registrable items have been duly registered.
★ Monitored information are transmitted via
communication circuits. Thus the number of
selected items can impact the communica-
tion speed. If truly real time monitoring is re-
quired, reduce the selected items to the
minimum.
★ For details on the monitoring items, display
unit, etc., refer to the Table for Monitoring
Items.
PC1250-7 20-167
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
4) Monitored information holding function

If [ ] switch is depressed while monitoring,
all the monitored information are put on
hold. If [ ] switch is depressed in this con-
dition, information holding is released.
5) Machine setting mode switching function

If it becomes necessary to change settings
of working mode, travel speed and auto-
decel while monitoring, depress the corre-
sponding switch, then the mode confirma-
tion display is shown.
★ An illustration at right shows the display in A
mode and E mode.
★ When a specific setting is confirmed, de-
press [ ] switch, then the display returns to
that of monitoring.
★ In case a specific setting has been changed
while monitoring, the new setting is still
maintained when returning from Service
Menu to Operator's Menu after the monitor-
ing is finished.
20-168 PC1250-7
Table for Monitoring Items

Code Unit (Default: ISO)
Item to be monitored Remark
No. ISO Meter Inch
000 Return (Not displayed) Termination menu
Execute
999 To Display Screen (Not displayed)
Command menu
002 Controller Model Select Figure
010 Engine Speed r/min rpm rpm
013 TVC current mA mA mA
016 2nd throttle command r/min rpm rpm
019 Pressure switch 1 — — —
021 Pressure switch 2 — — —
022 Switch input 1 — — —
023 Solenoid 1 — — —
030 Fuel dial voltage V V V
032 Source voltage V V V
037 Controller output 1 — — —
038 Controller output 2 — — —
041 Engine water temperature °C °C °F
042 Fuel sensor voltage V V V
043 Charge voltage ABN•NOR ABN•NOR ABN•NOR
044 Hydraulic oil temperature °C °C °F
045 Monitor input 1 — — —
142 Fuel temperature °C °C °F
200 Program version (Monitor) — — —
210 Program version (Pump controller) — — —
372 Engine oil pressure kPa kg/cm2 PSi
Swing ON/OFF
R.H. travel ON/OFF
Pressure Boom Lower ON/OFF
019
Switch 1 Boom Raise ON/OFF
Arm Curl ON/OFF
Arm Dump ON/OFF
Bucket Curl ON/OFF
Pressure
021 Bucket Dump ON/OFF
Switch 2
R.H. travel ON/OFF
Step light 5W ON/OFF
Horn switch ON/OFF
022 Switch Input 1
Swing brake release switch ON/OFF
Swing holding brake switch ON/OFF
CO cancel ON/OFF
Travel junction ON/OFF
Swing holding brake ON/OFF
023 Solenoid valve 1
Swing priority ON/OFF
2-stage relief ON/OFF
Travel speed selector ON/OFF
PC1250-7 20-169
Code Unit (Default: ISO)

Item to be monitored Remark
No. ISO Meter Inch
Model Select 1 ON/OFF
027 Switch Input 2
Switch Input 3 Starting switch (C) ON/OFF
036
(Pump controller) Starting switch (ACC) ON/OFF
Battery relay ON/OFF
Lever neutral ON/OFF
Controller output
Auto-deceleration ON/OFF
037 1 (Pump control-
ler) Working mode 1 ON/OFF
Travel alarm ON/OFF
Working mode 2 ON/OFF
Controller output Power source for step light ON/OFF
038 2 (Pump control- Step light ON/OFF
ler) Flash light ON/OFF
Starting switch ON/OFF
Start ON/OFF
045 Monitor Input 1 Preheating ON/OFF
Light ON/OFF
Radiator water level ON/OFF
Air cleaner ON/OFF
Engine oil level ON/OFF
046 Monitor Input 2
Spare ON/OFF
Charge voltage ABN•NOR
Swing holding brake switch ON/OFF
Buzzer cancel switch ON/OFF
Only when wiper 1
Window limit switch ON/OFF
is set
049 Monitor Input 3 Only when wiper 1
W limit switch ON/OFF
is set
Only when wiper 2
P limit switch (Upper) ON/OFF
is set
Only when wiper 2
P limit switch (Lower) ON/OFF
is set
★ Select the most favorite display unit from among the prepared three kinds, i.e. ISO, meter and inch. When
changing one display unit for another, refer to "Unit" in the initial value setting of Service Menu.
★ Abbreviations, ABN and NOR, stand for the following conditions.
ABN: Abnormal, NOR: Normal
20-170 PC1250-7
15. Function for Abnormality Record [02]

The monitor panel records failures that occurred
on the machines in the past after classifying
them into failures in the electric system and
those in the mechanical system. Information on
them can be displayed through the following
operation.
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical Systems
02 Mechanical Systems
3) Information shown in display of Abnormality

Record in the electrical system
: The numerator expresses sequence of
failure occurrence, counting from the
latest one. The denominator expresses
the total number of a specific failure
recorded.
: Error Code
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Time elapsed since the occurrence of
the first failure
: Contents of failure
★ Refer to "Table for Error Code and Ab-
normality Code" in Operator's Menu.
4) Information shown in display of Failure His-

tory in the mechanical systems
: Record No.
: Contents of Abnormality
: Abnormality Code No. (system in 4 dig-
its and phenomenon in 2 digits)
: Total number of occurrence
: Service meter reading at the initial
occurrence
★ Refer to "Table for Error Code and Ab-
normality Code" in Operator's Menu.
PC1250-7 20-171
5) Resetting Electrical Systems

★ Resetting Electrical Systems (deletion)
is possible only with the electrical sys-
tem. The failure history in the mechani-
cal system cannot be reset.
★ For resetting any specific or all informa-
tion in the Electrical Systems, follow the
operation explained below.
i) Through the following switch operation,
call the resetting display in the display of
Electrical Systems.
• Switch operation: [ ] +[1] ➝ [2] ➝ [3]
★ This is the same switch operation in
changing the display to Service Menu.
ii) Operate the switch, following the instruc-
tions shown in the resetting display.
★ When resetting specific information
only, call the display of that specific
information and reset it with either
[ ] switch or [ ] switch.
★ When resetting all the information, a
display of any information will do.
20-172 PC1250-7
16. Function for Maintenance Record [03]

The monitor panel records information on the
maintenance of filters and oils. The stored infor-
mation can be displayed through the following
switch operation.
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
: Name of oils and filters
: Times of replacement to date
: Service meter reading at the latest
replacement
PC1250-7 20-173
17. Function for Maintenance Mode Change [04]

Conditions set for controlling maintenance dis-
play function can be changed in the following
manner.
• Turn the function effectual or ineffectual.
• Change the set interval for replacement.
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of item to be changed

Select an item to be changed in the display
of Maintenance Mode Change Selecting
Menu.
No. Maintenance mode change item
00 Return
01 Maintenance Mode On/Off
02 Engine Oil Exch. Int.
03 Engine Oil Filter Exch. Int.
04 Fuel Filter Exch. Int.
05 Hydr. Oil Filter Exch. Int.
06 H/Tank Breather Exch. Int.
07 Corro. Resis. Exch. Int.
08 PTO Oil Service Int.
09 Final Drive Oil Exch. Int.
10 S/Machinery Oil Exch. Int.
11 Hydraulic Oil Exch. Int.
12 Use Default Values
★ 01 and 12 menus are provided for setting the

whole maintenance mode, while those from
02 through 11 are for setting individual items.
3) Contents of Maintenance Mode On/Off

• Use: The maintenance display function
of all oil and filter-related items are
turned effectual. (Irrespective of whether
"On" or "Off" set for individual items, this
setting prevails)
• 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)
20-174 PC1250-7
4) Set contents of individual items

: Default: The maintenance time set in
the monitor (recommended by the man-
ufacturer and cannot be changed).
: Set: Maintenance time that can be
freely set. The maintenance mode pro-
gram functions based on this mainte-
nance time. (The maintenance time can
be increased or decreased by 50 hours
with [ ] or [ ] switch)
: On: Maintenance display function with
this instruction becomes effectual.
: Off: Maintenance display with this
instruction becomes ineffectual.
★ The lowest maintenance time is 50 h.
5) Set contents of "Use Default Values"

When selecting this menu and depressing
the switch [ ], all individual time settings
are reduced to the initial settings.
PC1250-7 20-175
18. Function for Phone Number Entry [05]

In the display of User Code, a telephone number
and Service Code are shown alternately. Phone
number can be inputted or modified in the fol-
lowing manner.
★ If there is no Phone number registered, the
display for Phone numbers does not appear.
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
2) Changing the display

Select Entry next to change the display to
the Phone Number Entry display.
★ Even if a Phone number is already input-
ted, it is deleted, upon switching to the
Phone Number Entry display.
3) Entry and setting Phone number

Following the method explained below,
Entry a Phone number in the Phone
Number 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.
★ Numbers can be entered up to the max.
12 digits, but omit unnecessary digits.
★ When entering a wrong number, de-
press [B] switch, then the cursor goes
back by one digit.
★ When input is finished, the display
changes to Entry display shown above.
If the inputted Phone number is shown in
this display, the input is normal.
20-176 PC1250-7
19. Function for ✩✩✩✩✩/Default

✩✩✩✩✩ [06]
It is possible to change the following settings for
the monitor panel as well as the machine. Make
a change as is required.
• Working mode when the engine starting
switch is in the ON position.
• Display language in Service Menu
• Display unit in the monitoring function
• With/Without Service Cir.
Select 06 "✩✩✩✩✩/Default menu" in the
initial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No. ✩✩✩✩✩/Default submenu
00 Return (termination of ✩✩✩✩✩/Default)
01 Key-on Mode
02 ✩✩/Language
03 Unit
04 Wiper Select
3) Function for Key-on Mode

When the engine starting switch is turned
ON, a working mode can be set that is
shown in the monitor panel.
• A Mode, E Mode, Heavy Lift Mode OFF/
ON, 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.
• 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.
• Default Value: If this mode is set, the
machine ramps up with the default mode
(A mode) that was originally set at the
time of delivery from the factory.
PC1250-7 20-177
4) Function for ✩✩/Language

In Service Menu, the language in use can
be changed between Japanese and Eng-
lish.
★ English is used as the language for de-
fault setting in the monitor panel.
★ If the monitor panel for spare parts is to
be used in a Japanese-speaking region
or organization, change the language
from English to Japanese, using this
function.
5) Function for unit selection

As the unit to be used in the monitoring
function display of Service Menu, three
kinds of unit are provided.
★ Unit used for default setting in the moni-
tor panel is SI, i.e. International System
of Units.
6) Function for selection of wiper specification

The wiper specification can be set.
• 1 wiper: When cab with pull-up front
window is installed (Only up-
per wiper)
• 2 wipers: When cab with fixed front win-
dow is installed (Upper and
lower wipers)
★ The 1 wiper specification is optional
for North America.
20-178 PC1250-7
Pm-CLINIC SERVICE
INSPECTION SHEET for PC1250(SP,LC)-7
BASE INFORMATION
CUSTOMER NAME LOCATION DELIVERY
Month Day 'Year
/ /
CUSTOMER'S No. SERIAL No. ENGINE No.
SPECIFICATION
PC1250-7 PC1250SP-7 PC1250LC-7

Basement digging Crash hard rock Crash hard rock Basement digging
3.4 m3 narrow
4.0 m3 narrow
5.0 m3 standard
Bucket 5.2 m3 crash rock
5.2 m3 strength crash rock
6.5 m3 wide
6.5 m3 strength wide
3.4 m
3.4 m strength
3.4 m strength
Arm
4.5 m
4.5 m strength
5.7 m
9.1 m
Boom
7.8 m
1000 mm
Track shoe width
700 mm
KIND OF JOB
Mining Construction High way & Road Water supply
Forestry Scrap Demolition ( )
KIND OF OPERATION
Digging & Loading Basement digging Crash hard rock
Other
KIND OF SOIL
Rock Soft Medium Hard
Gravel Sand Clay Soil
SCHEDULED WORKING HOUR

Shifts/day Hours/shift
1 2 3 hrs.
DISTRIBUTOR NAME
PC1250-7 20-179
Pm-clinic measuring points for PC1250(SP,LC)-7 (1/2)
"Reference Page for Measurement Procedure" designated.

1. Engine speed : 20-102
2. Blow-by pressure : 20-110
3. Engine oil pressure : 20-111
4. Boost pressure : 20-103
5. Exhaust temperature : 20-104
20-180 PC1250-7
Pm-Clinic measuring points for PC1250(SP,LC)-7 (2/2)
HYDRAULIC PRESSURE
4-2 P 2 TVC Output Pressure 4-5 P 8 No.3 Swing Pump Pressure
Side of No.3 Front Pump CO No.3 Rear Pump Outlet Block
No.3 Pump
(HPV160+160)
Control Pump Ass'y
(SAR100+020+010)
Z
4-1 P 1 Control Pump Pressure 4-5 P 7 No.3 Swing Pump NC

No.2 Pump (HPV95+95)
Control Pump Outlet Block No. 3 Side of Rear Pump Servo
No.1 Pump (HPV95+95)
PPC valve control (SAR100)

For aftercooler drive motor (SAR)
For PTO Lubricating (SAR010)
4-3 P 4 No.1,2 Front Pump Pressure 4-3 P 3 No.1,2 Front Pump NC

No.2 Front Outlet Block Bottom of No.2 Front Pump Servo
2-2
4-4 P 6 No.1,2 Rear Pump Pressure 4-4 P 5 No.1,2 Rear Pump NC

No.2 Rear Pump Outlet Block Bottom of No.2 Rear Pump Servo
M0000098
PARTS LIST KOMATSU provide the special tools. PM KIT(A): 799-401-2300 Pressure gauge group.
No. ITEM PARTS No. DESCRIPTION Q'TY
4-1 P Control Pump Pressure 799-101-5220 QUICK COUPLER (10 1.25) (1)
4-2 P TVC Output Pressure 799-101-5220 (
QUICK COUPLER 10 1.25) 1
P No.1,2 Front Pump NC Output Pressure 799-101-5220 QUICK COUPLER (10 1.25) 1
4-3
P No.1,2 Front Pump Pressure 799-101-5220 QUICK COUPLER (10 1.25) (1)
P No.1,2 Rear Pump NC Output Pressure 799-101-5220 QUICK COUPLER (10 1.25) 1
4-4
P No.1,2 Rear Pump Pressure 799-101-5220 QUICK COUPLER (10 1.25) (1)
P No.3 Swing Pump NC Output Pressure 799-101-5220 QUICK COUPLER (10 1.25) 1
4-5
P No.3 Swing Pump Pressure 799-101-5220 QUICK COUPLER (10 1.25) (1)
799-101-6720 5E-75 THERMO-LABEL 1
2-2 PTO Center Bearing Temperature
799-101-6730 5E-100 THERMO-LABEL 1
* ( ): Pre-installed
PC1250-7 20-181
Pm-CLINIC SERVICE PC1250(SP,LC)-7
STD.spec. SERIAL No.
SP spec.
LC spec. ENGINE No. SAA6D170E-3
HOUR INSPECTION
WORK ORDER No. CARRIED OUT DATE SERVICE METER INSPECTED BY
MM-DD-'YY
Hrs.
OPERATOR'S OPINION & WORK AROUND CHECK

Before starting, Any abnormally? Ambient Temp.
Max. o
C(oF)
Min. o
C(oF)
Altitude
m(Ft)
COOLANT, OIL LEVEL & MONITOR CHECKING Sat Us
Eng. Coolant Eng. Oil Hyd. Oil Monitor ( ) Damper case Oil
Final case Oil Swing machinery Oil
If machine is cool, warm up completely.
STD.: Standard Value

1. ENGINE AFTER STARTING ENGINE! ( ): Reference Value PMS.: Permissible Value
ITEM Condition Unit STD. PMS. Result Sat Us
1-1 Eng. Low idling 875 - 925 875 - 925
Eng. Speed Eng. Full rpm 1960 - 2040 1960 - 2040
A Mode Heavy Lift ON, Boom RAISE relief 1750 - 1850 1750 - 1850
1-2 Eng. Full, Heavy Lift ON, Max. 4.9 Max. 7.9
*1
Blow-by Press Boom RAISE relief kPa {Max. 500} {Max. 800}
1-3 {mmH2O} Min. 0.12 Min. 0.07
Eng. Low idling (SAE30,SAE15W-40)
Eng. Oil Press. {Min. 1.2} {Min. 0.7}
0.38 - 0.59 Min. 0.21
Eng. Full (SAE30,SAE15W-40)
{4.0 - 6.0} {Min. 2.1}
MPa Min. 0.1 Min. 0.05
Eng. Low idling (SAE10W)
{kg/cm2} {Min. 1.0} {Min. 0.5}
0.34 - 0.54 Min. 0.18
Eng. Full (SAE10W)
{3.5 - 5.5} {Min. 1.8}
1-4 Eng. Full, Heavy Lift ON, kPa Min. 107 Min. 93
*1
Boost Press. Boom RAISE relief {mmHg} {Min. 800} {Min. 700}
1-5 Max. 680 Max. 700 *1
oC[oF]
Exhaust Gas Temp. Ambient Temperature
*1: Trend analyses must be done.
2. PTO
Strainer visual check No excessive metallic
Center bearing THERMO-LABEL check o
C Not 150oC Range Blackened
HYD. OIL TEMP. o

C 45 - 55
Dip the oil themometer sensor into the middle of the hyd. oil tank.
3. CYCLE TIME
Boom RAISE 5.4 - 6.6 Max. 7.4
Eng. Full
STD. LC spec. Arm IN 4.5 - 5.5 Max. 6.0
A mode
Oil Temp. Bucket CURL 2.9 - 3.7 Max. 4.1
45 - 55oC Boom RAISE 5.7 - 7.1 Max. 7.8
SP spec. Arm IN Sec. 4.5 - 5.5 Max. 6.0
Bucket CURL 3.1 - 3.9 Max. 4.3
*Travel
speed: Swing 5 Turns 49.4 - 54.6 Max. 59.0
STD. SP spec. High R.H. Travel 5 Turns 63 - 77 63 - 77
LC spec.
L.H. Travel 5 Turns 63 - 77 63 - 77
20-182 PC1250-7
Pm-CLINIC SERVICE PC1250(SP,LC)-7
STD.: Standard Valve
4. HYD. PRESS. Temperature 45 - 55oC ( ): Reference Valve PMS.: Permissible Valve
ITEM Condtioin Unit STD. PMS. Result Sat Us
4-1 A mode Eng. Full P 3.1 - 3.5 3.1 - 3.5
Auto-deceleration: OFF PC {32.0 - 35.5} {32.0 - 35.5}
Control Pump Control levers
Eng. Low idling (Min. 2.6) (Min. 2.1)
at neutral Auto-deceleration: OFF {(Min. 26)} {(Min. 21)}
4-2 Control levers A Mode P 2.0 - 2.6 Min. 1.8
at neutral Eng. Full TVC {20 - 26} {Min. 18}
TVC Valve Auto-
deceleration: E Mode (1.6 - 2.2) (Min. 1.4)
Output Pressure OFF Eng. Full {(16 - 22)} {(Min. 14)}
4-3 P Max. 0.25 Max. 0.4
Control levers at
No.1,2 CO.NC {Max. 2.6} {Max. 4.1}
neutral
Auto-deceleration: OFF P (1.5 - 2.5) (1.5 - 2.5)
Front Pump {(15 - 25)} {(15 - 25)}
Main
Main Oil Pressure P Max. 1.33 Max. 1.37
CO.NC Valve Boom RAISE relief CO.NC {Max. 13.5} {Max. 14}
Output Pressure Heavy lift: OFF P 29.9 - 32.4 28.9 - 32.4
Main {305 - 330} {295 - 330}
P 0.83 - 1.23 0.78 - 1.27
Boom RAISE relief CO.NC {8.5 - 12.5} {8.0 - 13.0}
Heavy lift: ON P 31.8 - 34.3 30.8 - 34.3
Main {325 - 350} {315 - 350}
P (1.7 - 2.3) (Min. 1.6)
Boom LOWER relief CO.NC {(17.5 - 23)} {(Min. 16)}
Machine push-up: OFF P 16.7 - 20.5 16.7 - 20.5
Main {170 - 210} {170 - 210}
P Max. 1.33 Max. 1.37
Arm In relief
CO.NC {Max. 13.5} {Max. 14}
P 29.9 - 32.4 28.9 - 32.4
Main {305 - 330} {295 - 330}
P Max. 1.33 Max. 1.37
CO.NC {Max. 13.5} {Max. 14}
Bucket CURL relief
P 29.9 - 32.4 28.9 - 32.4
Main {305 - 330} {295 - 330}
P (Max. 1.7) (Max. 1.7)
R.H. Travel under no CO.NC {(Max. 17)} {(Max. 17)}
load P (7.8 - 15.7) (7.8 - 15.7)
Main {(80 - 160)} {(80 - 160)}
R.H. Travel forward P 32.9 - 35.3 31.8 - 35.3
relief Main {335 - 360} {325 - 360}
A mode R.H. Travel reverse P 32.9 - 35.3 31.8 - 35.3
relief Main MPa {335 - 360} {325 - 360}
Eng. Full
4-4 Control levers at
P {kg/cm2} Max. 0.25 Max. 0.4
CO.NC {Max. 2.6} {Max. 4.1}
No.1,2 neutral
(1.5 - 2.5) (1.5 - 2.5)
P
Rear Pump Auto-deceleration: OFF {(15 - 25)} {(15 - 25)}
Main
NC Valve Boom RAISE relief CO.NC {Max. 13.5} {Max. 14}
Main {305 - 330} {295 - 330}
P (Min. 1.7) (Min. 1.7)
L.H. Travel under no CO.NC {(Min. 17)} {(Min. 17)}
load P (7.8 - 15.7) (7.8 - 15.7)
Main {(80 - 160)} {(80 - 160)}
L.H. Travel forward P 32.9 - 35.3 31.8 - 35.3
relief Main {335 - 360} {325 - 360}
L.H. Travel reverse P 32.9 - 35.3 31.8 - 35.3
relief Main {335 - 360} {325 - 360}
Control levers at P Max. 0.25 Max. 0.4
4-5 CO.NC {Max. 2.6} {Max. 4.1}
No.3 neutral
P (1.5 - 2.5) (1.5 - 2.5)
Front & Rear Pump Auto-deceleration: OFF
Main {(15 - 25)} {(15 - 25)}
NC Valve Boom RAISE relief CO.NC {Max. 13.5} {Max. 14}
Main {305 - 330} {295 - 330}
P (Min. 1.7) (Min. 1.7)
CO.NC {(Min. 17)} {(Min. 17)}
Swing under no load
P (7.8 - 15.7) (7.8 - 15.7)
Main {(80 - 160)} {(80 - 160)}
R.H. Swing relief
P 29.9 - 32.4 28.9 - 32.4
Main {305 - 330} {295 - 330}
P 29.9 - 32.4 28.9 - 32.4
L.H. Swing relief
Main {305 - 330} {295 - 330}
5. HYD. DRIFT
Entire work equipment no load specific position mm Max. 650 Max. 1000
6. HYD. OIL RETURN STRAINER

Hyd. Return Strainer Visual check No excecssive Metallic Power & Rubber Pieces
PC1250-7 20-183
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM
FOR EACH SYSTEM ........................................................................................................................... 20-217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-240
TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM"

AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED (CODE DISPLAY) ..................... 20-301
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (CODE DISPLAY) ................................... 20-401
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) ......................................... 20-551
PC1250-7 20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

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 two 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 connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
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 symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or ★ When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the ★ The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1)Start from the simple points.
problems with the machine condition before 2)Start from the most likely points.
this? 3)Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 PC1250-7
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC1250-7 20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors 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, dur-
ing 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 care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC1250-7
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 solder-
ing 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 structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, 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-circuited 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 connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
★ When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
★ If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
PC1250-7 20-205
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
★ Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
★ If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
★ If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC1250-7
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
★ 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 connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
★ If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
★ If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal):a, b, d
• Incomplete locking state (Diagonal):c
PC1250-7 20-207
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
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.
★ If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move 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.
★ 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 re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
★ After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC1250-7
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
★ If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
★ If there is any change, there is probably defective contact in that circuit.
PC1250-7 20-209
3. 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 cir-
cuit. When adding hydraulic oil, or when disassem-
bling 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 confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed 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 enter-
ing. 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 on to the ground, col-
lect 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 refill-

ing 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.
20-210 PC1250-7
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 con-
taminants 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
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 ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC1250-7 20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Judgement
Item Action
value
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil,
4. Check hydraulic oil strainer — Clean, drain

coolant
5. Check swing machinery oil level — Add oil

6. Check engine oil level (oil pan oil level) — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
mechanical equipment
1. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

Hydraulic, Electrical
2. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace

3. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
equipment
1. Check for abnormal noise, smell — Repair

2. Check for oil leakage — Repair
3. Carry out air bleeding — Bleed air
1. Check battery voltage (engine stopped) 20 – 30V Replace
2. Check battery electrolyte level — Add or replace
Electrics, electrical equipment
3. Check for discolored, burnt, exposed wiring — Replace

4. Check for missing wiring clamps, hanging wiring — Repair
5. Check for water leaking on wiring (be particularly careful attention — Disconnect
to water leaking on connectors or terminals) connector and dry
6. Check for blown, corroded fuses — Replace
7. Check alternator voltage (engine running at 1/2 throttle or above) After Replace
running for
several
minutes :
27.5 – 29.5V
8. Check operating sound of battery relay — Replace
(when switch is turned ON/OFF)
20-212 PC1250-7
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Troubleshooting when Error Code (electrical system) and Failure Code (mechanical sys-
Code display
tem) are displayed.
Code display Troubleshooting when error code is displayed
(Engine) Troubleshooting of engine assembly (refer to the shop manual for engine in 170-3 series)
H mode Troubleshooting of hydraulic and mechanical systems
Steps for troubleshooting

If some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error
Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is
recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system
Failure Code, using the failure history function of the monitor panel.
★ If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
★ Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among "Failure like Phenomena and Troubleshooting No." and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
PC1250-7 20-213
Failure-looking Phenomenon and Troubleshooting No.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode (Engine)
display
Action to be taken concerning Error Code, User Code and Failure Code
1 Display User Code in monitor panel Accord-
Display Service Code in electrical system after checking failure ing to
2
history dis-
Display Failure Code in mechanical system after checking failure played
3 code
history
Engine-related failure
Engine does not start up easily. (It always takes some time to start
4 S-1
up the engine)
5 Engine does not rotate E-1 S-2 a)
6 Engine rotates, but there is no exhaust gas S-2 b)
Engine does not start
There is exhaust gas, but engine does not
7 S-2 c)
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
Engine cooling water is mixed with engine oil, spurts out or
16 S-11
decreases
17 Engine oil amount increases. (Water 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
Speeds of all work equipment, travel and swing are slow, or they
24 S-6
lack power
25 Engine rotation drops sharply or stalls S-4
26 All work equipment, travel and swing do not move E-5
27 There are abnormal noises from around hydraulic pump
20-214 PC1250-7
Troubleshooting
display
Work equipment-related failure
28 Boom moves slowly or lacks power
29 Arm moves slowly or lacks power
30 Bucket moves slowly or lacks power
31 Boom does not move
32 Arm does not move
33 Bucket does not move
34 Natural drift of work equipment is too fast
35 Work equipment time lag is too big
36 Boom shockless function does not work or cannot be reset E-7
Compound operation-related failure
37 Travel deviation is large during compound operation
Swing speed is low or acceleration is low during compound opera-
38
tion of bucket and swing
Swing speed is low or acceleration is low during compound opera-
39
tion of boom and swing when swing priority is ON
Travel-related failure
40 Machine deviates during travel
41 Machine deviates largely at start
42 Travel speed or power is low
43 Track shoe does not move (only on one side)
44 Travel speed cannot be shifted
Swing-related failure
45 Machine does not swing
46 Swing speed is slow or acceleration is low
47 Upper structure overruns excessively, when stopping swing
48 There is a big shock caused when stopping swing
49 There is abnormal noise generated when stopping swing
50 There is natural drift while in swing
Monitor panel-related failure (Operator's Menu: ordinary display)
51 No display appears in monitor panel at all E-8
52 Part of display is missing in monitor panel E-9
53 Descriptions on monitor panel do not apply to the machine model E-10
In startup inspection, radiator water level monitor lamp lights up
54 B@BCZK
red
55 In startup inspection, engine oil level monitor lamp lights up red B@BAZK
PC1250-7 20-215
Troubleshooting
display
Refer to Operation and Maintenance
56 In startup inspection, maintenance hour monitor lamp lights up red
Manual
While engine is running, battery charging level monitor lamp lights
57 AB00KE
up red
58 While engine is running, fuel level monitor lamp lights up red E-11
While engine is running, air cleaner clogging monitor lamp lights up
59 AA10NX
red
While engine is running, engine cooling water temperature monitor
60 B@BCNS
lamp lights up red
While engine is running, hydraulic oil temperature monitor lamp
61 B@HANS
lights up red
62 Engine cooling water temperature gauge does not display correctly
63 Hydraulic oil temperature gauge does not display correctly E-12
64 Fuel gauge does not display correctly E-13
65 Swing lock monitor does not display correctly E-14
66 When operating monitor switch, no display appears E-15
67 Windshield wiper does not work E-16
68 Warning buzzer cannot be stopped E-17
Monitor panel-related failure (Service Menu: Special Function Display)
In monitoring function, "Boom RAISE" cannot be displayed cor-
69 E-18
rectly
In monitoring function, "Boom LOWER" cannot be displayed cor-
70 E-19
rectly
In monitoring function, "Arm DIGGING" cannot be displayed cor-
71 E-20
rectly
In monitoring function, "Arm DUMPING" cannot be displayed cor-
72 E-21
rectly
In monitoring function, "Bucket DIGGING" cannot be displayed
73 E-22
correctly
In monitoring function, "Bucket DUMPING" cannot be displayed
74 E-23
correctly
75 In monitoring function, "Swing" cannot be displayed correctly E-24
76 In monitoring function, "Travel" cannot be displayed correctly E-25
Other failure
80 Air conditioner does not work E-26
81 Travel alarm does not sound E-27
20-216 PC1250-7
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL

CIRCUIT DIAGRAM FOR EACH SYSTEM
★ The address shows the approximate position in the connector 3-dimensional drawing and the circuit dia-
grams for each system.
Address
Connector Connector No.
Place of use 3-dimen- C E M
No. Type of pin sional Others
drawing circuit circuit circuit
1939 HD10 9 Engine controller communication AI2 L7 C9 H1 —

232C X 4 RS232C junction connector S9 — — — —
A01 X 4 Intermediate connector T1 G7 G6 H7 H6
A02 X 4 Intermediate connector T2 G7 G6 H6 H6
A03 DT 6 Intermediate connector Q1 G6 G6 — —
A04 DT 12 Intermediate connector P1 G6 G5 — —
A05 DT 12 Intermediate connector T2 G6 — H6 H5
A06 DT 12 Intermediate connector Q1 G5 — H6 —
A07 SWP 16 Intermediate connector S1 G5 H5 H4 —
A08 DT 8 Intermediate connector P1 G5 H4 H4 H5
A09 SWP 8 Intermediate connector O2 G4 — — —
A10 DT 12 Intermediate connector Q1 G4 H4 H4 H4
A11 DT 8 Intermediate connector O1 — — — —
AG01 X 3 Auto grease pressure switch A4 G8 — — —
AG02 X 2 Auto grease solenoid I9 G8 — — —
AAPR Cummins 3 Atmospheric pressure sensor AH2 — C2 — —
ALBR Terminal 1 Alternator (Terminal B) AE3 L7 — — K4
ALBS Terminal 1 Alternator (Terminal E) AE4 L7 H9 — K4
ALR Terminal 1 Alternator (Terminal R) AE4 L7 H9 K4 K4
B Terminal 1 Battery relay (Terminal B) A6, D9 L8 F8, F9 J7 K8, K9
B01 DT 8 Intermediate connector (Circuit breaker) U9 G4 K2 K9 K8
B02 DT 8 Intermediate connector (Circuit breaker) U9 G3 K1 K8 K7
B1A Terminal 1 Circuit breaker M8 G2 L1 L8 L6
B2A Terminal 1 Circuit breaker N7 G2 L1 L8 L6
B1B Terminal 1 Circuit breaker N7 G2 — — L6
B2B Terminal 1 Circuit breaker N7 G2 — — L6
B11 Terminal 1 Circuit breaker C1 — — — L9
B12 Terminal 1 Circuit breaker B1 L8 F8 L7 L9
B13 Terminal 1 Circuit breaker A3 L8 F8 L7 L9
B14 Terminal 1 Circuit breaker N9 G3 L2 L9 —
B15 Terminal 1 Circuit breaker M9 — — — L8
B16 Terminal 1 Circuit breaker M9 G3 L2 — L7
B17 Terminal 1 Circuit breaker M8 — — — L7
B18 Terminal 1 Circuit breaker M8 G2 L1 L8 L7
B19 Terminal 1 Circuit breaker M8 G2 L1 L8 —
B21 Terminal 1 Circuit breaker B2 — — — L9
PC1250-7 20-217
Address
B22 Terminal 1 Circuit breaker A2 B8 F8 L7 L9

B23 Terminal 1 Circuit breaker A4 B8 F8 L7 L9
B24 Terminal 1 Circuit breaker O9 G3 L2 L9 —
B25 Terminal 1 Circuit breaker O8 — — — L8
B26 Terminal 1 Circuit breaker O8 G3 L2 L8 L7
B27 Terminal 1 Circuit breaker O8 — — — L7
B28 Terminal 1 Circuit breaker O8 G2 L1 — L7
B29 Terminal 1 Circuit breaker N7 G2 — L8 —
BR Terminal 1 Battery relay (Terminal BR) A5, E9 K8 E8, E9 J7 J8, J9
C01 DRC 24 Pump controller V9 A7 K4 — A6
C02 DRC 40 Pump controller V8 A7 K3 A3 A6
C03 DRC 40 Pump controller V8 A6 K3 A3 A6
C09 S 8 Model selection connector W6 D1 — — —
C13 DT 2 TVC solenoid K5 H8 — — —
CAN DT 3 CAN termination resistor (Engine controller) AJ4 L5 E9 K1 —
CH1 HD10 6 Engine controller communication P8 E1 H9 — —
CLTP Cummins 2 Engine water temperature sensor AE6 — B2 — —
D01 SWP 8 Diode unit W7 A4 L7 — —
D02 SWP 8 Diode unit W7 A4 — A8 A8
D03 SWP 8 Diode unit S1 A4 — — —
D04 SWP 8 Diode unit S1 A3 — — A7
D05 SWP 8 Diode unit R1 A3 — — —
D06 SWP 8 Diode unit R1 D9 — A8 —
D07 KES1 2 Diode S9 D9 J9 A8 A7
D08 KES1 2 Diode U9 — J9 A8 A8
E Terminal 1 Battery relay (Terminal E) A5, D9 K8, K9 E8, E9 J7 J8, J9
E06 M 3 Fuel dial O7 — K9 — —
E08 (VHL) HD30 14 Intermediate connector (Engine) AJ5 L7 H9 J4 J5
E12 (POW) HD30 21 Intermediate connector (Engine) AJ5 K4 E6 H3 —
E13 (SIG) HD30 31 Intermediate connector (Engine) AJ5 K4 E6 J3 —
ECB2 DT 2 Diode AE7 — E2 — —
ECMA DRC 40 Engine controller AF2 L4 A7 — —
ECMB DRC 40 Engine controller AF7 L4 A6 K2 —
F01 X 2 Travel alarm (If equipped) K8 H8 — — —
F02 YAZAKI 2 Rotary lamp AA9 — — — —
FB1 — Fuse W3 G7 — H9 G9
FLTP Cummins 2 Fuel temperature sensor AF7 — B2 — —
Description in ( ) is the symbol of wiring harness on the engine side.
20-218 PC1250-7
Address
FSO+ Terminal 1 Fuel cut-off valve AE5 — E2 — —

FSO– Terminal 1 Fuel cut-off valve AE5 — E2 — —
H08 M 8 Intermediate connector (Speaker) W4 — — — D6
H09 S 8 Intermediate connector (Optional light) W4 — — — D5
H10 S 16 Intermediate connector (To cab wiring harness) T9 E2 J5 D7 D4
H11 S 16 Intermediate connector (To cab wiring harness) T9 F2 — D6 D3
H12 S 12 Intermediate connector T9 — J5 D5 —
H14 DT 12 Intermediate connector (Switch box) P7 — — — —
H15 S090 20 Intermediate connector O6 B2 J8 C2 B2
HEAT DT 2 Heater control AI8 — B9 — —
HEF Terminal 1 Intake air heater AG8 — — — —
HES Terminal 1 Intake air heater AI8 — — — —
IMPR Cummins 3 Boost pressure sensor AE6 — C2 — —
IMTP Cummins 2 Boost temperature sensor AE7 — B2 — —
J01 J (Black) 20 Joint connector S9 A9 H9 C9 C9
J02 J (Black) 20 Joint connector W8 A9 I9 C9 C9
J03 J (Green) 20 Joint connector W8 A9 — D9 D9
J04 J (Green) 20 Joint connector W8 B9 I9 D9 D9
J05 J (Pink) 20 Joint connector W7 B9 I9 D9 E9
J06 J (Orange) 20 Joint connector W7 C9 — — —
J07 J (Orange) 20 Joint connector U9 C9 I9 E9 E9
J08 J (Pink) 20 Joint connector U9 D9 — F9 —
J11 DT 8 Joint connector G1 H9 — — H9
J12 DT 8 Joint connector G1 H9 — — —
J13 DT 8 Joint connector H1 I9 — — —
J14 DT 8 Joint connector K8 I9 — — H9
J15 DT 8 Joint connector K8 I9 — H9 I9
J16 DT 8 Joint connector K3 I9 — H9 —
J17 DT 8 Joint connector H1 J9 — — —
J18 DT 8 Joint connector H1 J9 — — —
J19 DT 8 Joint connector K7 J9 G9 I9 —
J20 DT 8 Joint connector K8 K9 G9 I9 I9
J21 DT 8 Joint connector K8 K9 G9 I9 I9
JC01 DT 6 Joint connector AI3 — A4 — —
JC02 DT 8 Joint connector AI3 — A4 — —
JC03 DT 8 Joint connector AH2 — A3 — —
JC04 DT 8 Joint connector AG2 L5 A3 — —
PC1250-7 20-219
Address
JC11 DT 6 Joint connector AG2 — — — —

JC12 DT 6 Joint connector AG2 L6 D9 J1 —
JC13 DT 8 Joint connector AI3 L6 C9 J1 —
JC14 DT 8 Joint connector AI3 L6 D9 J1 —
JC15 DT 6 Joint connector AJ3 L5 D9 — —
K19 M 2 Resistor (Hydraulic pump drive circuit) U2 D1 — — —
K31 DT 3 CAN termination resistor N4 F1 K5 A4 —
LINK DT 6 Data link crossover AJ4 K5 B9 G1 —
M Terminal 1 Battery relay (Terminal M) C9, D9 L8, L9 F8, F9 J7 K8, K9
M07 M 3 Light switch P7 — — — B1
M08 DT 2 Working lamp (Boom) C8 — — — K2
M09 DT 2 Working lamp (Boom) C8 — — — K2
M10 DT 2 Intermediate connector (Working lamp) E9 — — — J2
M13 KES0 2 Right speaker AB8 — — — —
1 pin
M16 1 Horn valve H9 — — — K3
connector
1 pin
M17 1 Horn valve I9 — — — K3
connector
M19 YAZAKI 2 Cigarette lighter N3 — — — —
M21 PA 9 Radio U2 — — — —
M22 Y090 2 Horn switch O6 — — — E1
M26 S 12 Air conditioner unit W5 — — — —
M27 SWP 16 Air conditioner unit W5 — — — —
M29 040 20 Air conditioner control panel W3 — — — —
M30 040 16 Air conditioner control panel V3 — — — —
M31 M 2 Power connector (If equipped) U3 — — — —
M32 M 2 Power connector (If equipped) S9 — — — —
M33 M 2 12-V outlet W5 — — — —
M35 X 1 Air conditioner compressor H9 — — — —
M38 M 2 Machine push-up switch Q8 A1 — — —
M39 M 2 Boom shockless switch P7 E1 — — —
M40 YAZAKI 2 Working lamp Z8 — — — A5
M41 YAZAKI 2 Working lamp Y7 — — — A5
M42 YAZAKI 2 Right working lamp A3 — — — K2
M45 DT 12 Network bus connector U2 F8 L9 — —
M71 M 2 Room lamp S9 — — — —
M72 M 4 DC/DC converter U2 — — — —
20-220 PC1250-7
Address
M73 KES0 2 Left speaker AC8 — — — —

M75 YAZAKI 1 Step light (If equipped) AD8 — — — A5
M79 YAZAKI 2 12V socket (If equipped) V9 — — — —
M80 DT 2 Flash light F1 — — — K1
M81 M 2 Step light switch O7 E1 — — B8
M95 KES0 2 Windshield washer motor J2 — — K9 —
M96 KES0 2 Windshield washer motor I2 — — K9 —
OLV DT 2 Engine oil level sensor AH2 — — K3 —
OLPR Cummins 3 Engine oil pressure sensor AE3 — C2 — —
P01 070 12 Monitor panel N6 E1 L6 A7 A4
P02 040 20 Monitor panel N4 F1 L6 A6 A4
P03 M 2 Buzzer cancel switch Q8 — — C1 —
P05 M 2 Rotary lamp switch W5 — — — —
P06 DT 2 Fuel level sensor E9 — — K4 —
P08 X 2 Coolant level sensor G9 — — K5 —
P10 DT 2 Hydraulic oil high temperature sensor J3 — — K6 —
P11 DT 2 Air cleaner clogging sensor J9 — — K5 —
P15 Y050 2 Sunlight sensor N5 — — — —
P16 YAZAKI 2 Air conditioner fresh air sensor F9 — — — —
P20 X 2 Coolant level sensor G9 — — K5 —
P70 040 16 Monitor panel N4 F1 L6 A5 —
PMPR Cummins 3 Fuel pump pressure sensor AE2 — C2 — —
PUMP Cummins 3 Fuel pump actuator AE2 — D2 — —
R10 R 5 Relay (Light) P7 — — — C1
R11 R 5 Relay (Starting motor cut) Q8 — — — D1
R13 R 5 Relay (Personal code) Q8 — — E2 D1
R14 R 5 Relay (Step light power drive) W6 E9 — — F1
R15 R 5 Relay (Step light) W6 E9 — — G1
R20 R 5 Relay (Horn) W6 — — — G1
R21 R 5 Relay (Flash light) W7 D9 — — H1
RAIL Cummins 3 Fuel rail actuator AF2 D2 — — —
RLB Terminal 1 Intake air heater relay AG8 — — — L3
RLF Terminal 1 Intake air heater relay AH8 — — — L3
RLR Terminal 1 Intake air heater relay AH8 — — — L3
RLS Terminal 1 Intake air heater relay AH8 — — — L3
RPR Cummins 3 Fuel rail pressure sensor AJ3 D2 — — —
S01 X 2 Right travel forward PPC pressure switch J1 K3 — — —
PC1250-7 20-221
Address
S02 X 2 Boom RAISE PPC pressure switch K1 K3 — — —

S03 X 2 Arm OUT PPC pressure switch L2 K3 — — —
S04 X 2 Boom LOWER PPC pressure switch K1 K3 — — —
S05 X 2 Arm IN PPC pressure switch L2 K3 — — —
S06 X 2 Bucket CURL PPC pressure switch L2 K3 — — —
S07 X 2 Bucket DUMP PPC pressure switch K1 K2 — — —
S08 X 2 Swing RIGHT PPC pressure switch L2 K2 — — —
S10 X 2 Swing LEFT PPC pressure switch L2 K2 — — —
S11 X 2 Right travel REVERSE PPC pressure switch J1 K2 — — —
S12 X 2 Left travel FORWARD PPC pressure switch K1 K2 — — —
S13 X 2 Left travel REVERSE PPC pressure switch K1 K1 — — —
S14 M 3 Safety lock lever T2 F8 — — F8
S21 — Emergency pump drive switch R9 C2 — — —
S22 — Emergency swing brake reset switch R8 D2 — — —
Intermediate connector
S25 S090 16 R8 C2 — — —
(To right console emergency switch)
ST1 DT 2 Starting motor AG7 — B2 — K5
ST2 DT 2 Starting motor AF7 — B2 — K5
SP1 Cummins 2 Engine speed sensor (Main) AJ6 — — — —
SP2 Cummins 2 Engine speed sensor (Sub) AJ6 — — — —
STB Terminal 1 Starting motor (Terminal B) AI6 — — — K5, K6
SSW Terminal 5 Starting switch O7 — — — —
T02 Terminal 1 Revolving frame ground C1 L7 F1 J6 I1
T03 Terminal 1 Revolving frame ground D1 K9 E9 J6 I1
T04 Terminal 1 Revolving frame ground D1 — — — —
T05 Terminal 1 Floor ground V3 — — — —
T06 Terminal 1 Floor ground V3 — — — —
T06A M 1 Intermediate connector T2 — — — —
T06B Terminal 1 Radio body ground V3 — — — —
T11 Terminal 1 Cab ground AD4 — — — —
TIMG Cummins 3 Timing rail actuator AF7 — E2 — —
TPR Cummins 3 Timing rail pressure sensor AJ4 — D2 — —
V01 DT 2 Swing priority solenoid valve K3 G2 — — —
V02 DT 2 2-stage relief solenoid valve K5 G2 — — —
V03 DT 2 Straight travel solenoid valve K4 G2 — — —
V04 DT 2 Swing holding brake solenoid valve K5 G1 — — —
V05 DT 2 Machine push-up solenoid valve K6 G1 — — —
V06 DT 2 Travel speed solenoid valve K7 G1 — — —
20-222 PC1250-7
Address
V07 DT 2 CO cancel solenoid valve K3 G1 — — —

V08 DT 2 PPC pressure lock solenoid valve E1 K1 — — K6
V09 DT 2 Boom RAISE shockless solenoid valve J9 K1 — — —
V10 DT 2 Boom LOWER shockless solenoid valve I2 K1 — — —
Intermediate connector
VHI DT 8 J9 — — — —
(Main pump, oil pressure sensor)
VHM DT 12 Intermediate connector (VHMS controller) V3 G8 L9 — —
Rear window limit switch
W03 X 2 AB9 — — — —
(Optional for North America)
W04 M 6 Wiper motor N5 — — B9 —
W05 M 6 Wiper motor P1 — — F9 —
W06 M 2 Lower wiper switch W5 — — F2 —
X05 M 4 Swing lock switch Q8 A1 — D1 —
PC1250-7 20-223
Connector No. Detailed information

D or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
070 Product of Japan AMP 070 type connector
Y050 Product of Yazaki 050 type connector
S090 Product of Sumitomo 090 type connector
Y090 Product of Yazaki 090 type connector
YAZAKI Yazaki-made connector
KES0 KES0 type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
KES1 KES1 type connector (08027-1XXXX)
HD10 Japanese and German makes HD10-6-12P type connector
HD30 Japanese and German makes HD30 type connector
20-224 PC1250-7
CONNECTOR ARRANGEMENT DIAGRAM
20-226 PC1250-7
PC1250-7 20-227
20-228 PC1250-7
PC1250-7 20-229
20-230 PC1250-7
PC1250-7 20-231
ELECTRICAL CIRCUIT DIAGRAM FOR PUMP CONTROLLER SYSTEM (C circuit)
20-232 PC1250-7
PC1250-7 20-233
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE CONTROLLER SYSTEM (E circuit)
20-234 PC1250-7
PC1250-7 20-235
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR PANEL SYSTEM (M circuit)
20-236 PC1250-7
PC1250-7 20-237
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE SYSTEM (Others)
20-238 PC1250-7
PC1250-7 20-239
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-240 PC1250-7
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
PC1250-7 20-241
SWP type connector

No. of
pins T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-242 PC1250-7
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7390
Part No.: 08056-00871 Part No.: 08056-00881
PC1250-7 20-243
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-244 PC1250-7
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
PC1250-7 20-245
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
13 799-601-2720
20-246 PC1250-7
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
PC1250-7 20-247
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
★ Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-248 PC1250-7
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
PC1250-7 20-249
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-250 PC1250-7
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
PC1250-7 20-251
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-252 PC1250-7
F type connector
No.of
pins T-adapter
Part No.
4 —
— —
PC1250-7 20-253
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-254 PC1250-7

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

799-601-9240
18-21 Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
PC1250-7 20-255

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-256 PC1250-7

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
PC1250-7 20-257

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-258 PC1250-7
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC1250-7 20-259
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
10
12G: 799-601-9130
12BR: 799-601-9140
20-260 PC1250-7
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
PC1250-7 20-261
TROUBLESHOOTING WHEN ERROR CODE
"ELECTRICAL SYSTEM" AND FAILURE CODE
"MECHANICAL SYSTEM" ARE INDICATED
(CODE DISPLAY)
Information in Troubleshooting Table .......................................................................................................... 20-304

Error Code in Electrical System E101 (Abnormal data in Error History) ................................................... 20-306
Error Code in Electrical System E112
(Short-circuiting in normal rotation system of windshield wiper motor drive) ....................................... 20-308
(Short-circuiting in reverse rotation system of windshield wiper motor drive) ...................................... 20-312
Error Code in Electrical System E114 (Short-circuiting in window washer drive system) ......................... 20-314
Error Code in Electrical System E115 (Abnormal Windshield Wiper Motion) ........................................... 20-316
Error Code in Electrical System E116 (Abnormality in retracting windshield wiper) ................................. 20-318
Error Code in Electrical System E201 (Short-circuiting in CO cancel solenoid) ....................................... 20-322
Error Code in Electrical System E202 (Short-circuiting in straight travel solenoid)................................... 20-324
Error Code in Electrical System E203 (Short-circuiting in swing parking brake solenoid) ........................ 20-326
Error Code in Electrical System E204 (Short-circuiting in 2-stage relief solenoid) ................................... 20-328
Error Code in Electrical System E205 (Short-circuiting in swing priority solenoid) ................................... 20-330
Error Code in Electrical System E206 (Short-circuiting in travel speed solenoid)..................................... 20-332
Error Code in Electrical System E207 (Abnormality in flash light relay coil (Short-circuiting)).................. 20-334
Error Code in Electrical System E211 (Disconnection in CO cancel solenoid) ......................................... 20-336
Error Code in Electrical System E212 (Disconnection in straight travel solenoid) .................................... 20-338
Error Code in Electrical System E213 (Disconnection in Swing Parking Brake Solenoid)........................ 20-340
Error Code in Electrical System E214 (Disconnection in 2-stage relief solenoid)..................................... 20-342
Error Code in Electrical System E215 (Disconnection of swing priority solenoid) .................................... 20-344
Error Code in Electrical System E216 (Disconnection in travel speed solenoid) ...................................... 20-346
Error Code in Electrical System E217 (Abnormality in inputting model code) .......................................... 20-348
Error Code in Electrical System E218 (Disconnection of S-NET signal)................................................... 20-350
Error Code in Electrical System E221 (Abnormality in J1939 Network).................................................... 20-352
(Short-circuiting in output system of working mode [1] (full curve))...................................................... 20-354
Error Code in Electrical System E223 (Disconnection in output system of working mode [1] (full curve)) 20-355
(Short-circuiting in output system of working mode [2] (Hi regulation))................................................ 20-356
(Disconnection in output system of working mode [2] (Hi regulation)) ................................................. 20-357
Error Code in Electrical System E226 (Disconnection in output system of auto-decelerator) .................. 20-358
Error Code in Electrical System E227 (Abnormality in engine speed sensor) .......................................... 20-359
Error Code in Electrical System E228 (Short-circuiting in output system of auto-decelerator) ................. 20-360
Error Code in Electrical System E232 (Short-circuiting in TVC solenoid) ................................................. 20-362
Error Code in Electrical System E233 (Disconnection in TVC solenoid) .................................................. 20-364
Error Code in Electrical System E234 (Short-circuiting in lever-neutral output system) ........................... 20-366
Error Code in Electrical System E235 (Disconnection in lever-neutral output system)............................. 20-367
Error Code in Electrical System E302 (Short-circuiting in step light relay system) ................................... 20-368
Error Code in Electrical System E304 (Short-circuiting in step light power source drive relay circuit)...... 20-370
PC1250-7 20-301
TROUBLESHOOTING
Error Code in Electrical System E315 (Short-circuiting in battery relay output system) ........................... 20-372
Failure Code in Mechanical System AA10NX (Air cleaner clogging) ........................................................ 20-374
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)............................. 20-376
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pressure) ...................... 20-378
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level) ............................. 20-379
Failure Code in Mechanical System B@BCNS (Overheating of engine water) ........................................ 20-380
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)....................... 20-382
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating).............................................. 20-384
20-302 PC1250-7
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION IN TROUBLESHOOTING TABLE

★ Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.
Failure Code Error Code Failure

Phenomenon on Machine
Display on panel Display on panel Phenomenon
Failure Content State when the panel or the controller detected a failure.
Action Taken by Action to be taken for protecting systems and devices when the monitor panel or the controller detected
Panel or Controller a failure.
Failure Phenome-
Phenomenon on machine when the monitor panel or the controller took action(above).
non on Machine
Related
Information concerning to failure or troubleshooting.
Information
Cause Standard value, Remarks for Troubleshooting

<Contents>
• Standard values for judgement of possible causes.
• Remarks for judgement
1
<Phenomenon of Defective Wiring Harness>
• Disconnection
Connector is disconnected or disconnection in wiring harness
• Short circuit with ground
Possible Causes and Standard Values
Wiring harness isolated from the ground is short circuited with the ground
2 • Short circuit with power source
Harness which is not connected to power source (24 V) circuit is in contact
with power source (24 V) circuit.
• Short circuit
Possible causes of failure Independent harnesses are in contact with each other abnormally.
(The sequence number is only
3 for reference and does not state <Points to Remember at Troubleshooting>
priority.) 1) Indication of connector number and handling method of T-adapter
Unless otherwise specified, insert or connect T-adapter as follows before trou-
bleshooting:
• When (Male) or (Female) is not indicated to Connector No., disconnect the
connector and insert T-adapter in both the male side and the female side.
• When (Male) or (Female) is indicated to Connector No., disconnect the con-
nector and connect T-adapter to either of the male side or the female side.
2) Pin number and handling of tester lead wire
4 Unless otherwise specified, contact the tester (+) lead wire and (–) lead wire as
follows before troubleshooting:
• Contact the (+) lead wire to the pin of the number or the wiring harness stated
first
• Connect the (–) lead wire to the pin of the number or the wiring harness stated
at second
20-304 PC1250-7
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)

• Arrow (⇔) : Roughly indicates the location in the machine where it is installed.
PC1250-7 20-305
TROUBLESHOOTING E101
Error Code in Electrical System E101 (Abnormal data in Error History)
User Code Error Code Failure Code Failure Abnormal data in the error history
— E101 DAF0KT phenomenon (in Monitor Panel system)
• The voltage in the firm power source circuit for Monitor Panel (battery) has dropped below 12 V or
Failure content
exceeded 36 V.
Response from
• None in particular
Monitor Panel
Phenomenon
occurring on • A display for information on the failure history (in the electrical system) cannot be called.
machine
Cause Standard value in normalcy and references for troubleshooting

Circuit breaker No. 10
1 If the circuit breaker is turned OFF, the circuit probably has a grounding fault.
defective
defective
Presumed cause and standard value in normalcy
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
for the troubleshooting.
Disconnection of wiring Wiring harness between P01 (female) 8 and circuit Resistance
Min. 1 Ω
harness breaker B2A value
3
(Disconnection or Wiring harness between circuit breaker B1A and circuit Resistance
connector contact fault) Min. 1 Ω
breaker B23 value
Wiring harness between circuit breaker B13 and battery Resistance
Min. 1 Ω
relay (Terminal B) value
Grounding fault of wiring Between wiring harness between P01 (female) 8 and cir- Resistance
Min. 1 MΩ
harness cuit breaker B2A and grounding value
4
(Contact with grounding Between wiring harness between circuit breaker B1A and Resistance
circuit) Min. 1 MΩ
circuit breaker B23 and grounding value
Between wiring harness between circuit breaker B13 and Resistance
Min. 1 MΩ
battery relay (Terminal B) and grounding value
5 Monitor Panel defective
P01 Voltage
Between 8 and 6 7 20 – 30 V
20-306 PC1250-7
Monitor Panel Power Source Electric Circuit Diagram
PC1250-7 20-307

(Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure Short-circuiting in normal rotation system of wind-
— E112 DY2DKB phenomenon shield wiper motor drive (in monitor panel system)
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stops moving.
machine
1. Cab with fixed front window (When 2 wipers are set)

Windshield wiper motor for the troubleshooting.

defective W05, W04 (female) Continuity and resistance value
1
(Internal short-circuiting
or grounding fault) Between 3 and 1 Continued
Between 3 and grounding Min. 1 MΩ
Grounding fault of wiring for the troubleshooting.
harness
2 Between wiring harnesses between P01 (female) 9 and
(Contact with grounding Resistance
circuit) W04 (male) 3 and between P01 (female) 0 and W05 Min. 1 MΩ
value
(male) 3 and grounding
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
P01 Windshield wiper switch Voltage
3 Monitor panel defective
OFF Max. 3 V
Between 9 and grounding
Between 0 and grounding Max. 3 V⇔20 – 30 V
ON
(at constant cycle)
2. Cab with pull-up front window (When 1 wiper is set) (If equipped, for North America)
defective W04 (female) Continuity and resistance value
1
Grounding fault of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
harness for the troubleshooting.
2
(Contact with grounding Between wiring harnesses between P01 (female) 9 and Resistance
W04 (male) 3 and grounding value
OFF Max. 3 V
ON
(at constant cycle)
20-308 PC1250-7
Electrical circuit diagram related to wiper motor (cab with fixed front window)
PC1250-7 20-309
Electrical circuit diagram related to wiper motor (cab with pull-up front window)
20-310 PC1250-7

(Short-circuiting in reverse rotation system of windshield wiper motor drive)
Cab with pull-up front window (When 1 wiper is set) (If equipped, for North America)
User Code Error Code Failure Code Failure Short-circuiting in reverse rotation system of wind-
— E113 DY2EKB phenomenon shield wiper motor drive (in Monitor Panel system)
• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
Failure content
windshield wiper was set in motion.
Response from
• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper stopped moving.
machine

defective W04 (female) Continuity and resistance value
1
harness for the troubleshooting.
2
(Contact with grounding Between wiring harness between P01 (female) 0 and Resistance
W04 (male) 1 and grounding value
OFF Max. 3 V
ON
(at constant cycle)
20-312 PC1250-7
Electrical circuit diagram related to wiper motor (cab with pull-up front window)
PC1250-7 20-313

(Short-circuiting in window washer drive system)
Cab with fixed front window (When 2 wipers are set)

User Code Error Code Failure Code Failure Short-circuiting in window washer drive system
— E114 DY2CKB phenomenon (in Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power was
Failure content
switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine

Window washer drive for the troubleshooting.
1 motor defective
M95, M96 (male) Resistance value
(Internal short-circuiting)
Between 1 and 2 5 – 20 Ω
Short-circuiting of wiring for the troubleshooting.
harness
2 Between wiring harness between P01 (female) 3 and
(Contact with 24 V
circuit) M95, M96 (female) 2 or between H10 (female) 3 and Voltage Max. 1 V
D05 (female) 7 and grounding
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
ON Max. 1 V
20-314 PC1250-7
Electrical circuit diagram related to windshield washer of monitor panel (When 2 wipers are set)
PC1250-7 20-315
Error Code in Electrical System E115 (Abnormal Windshield Wiper Motion)
User Code Error Code Failure Code Failure Abnormal operation of windshield wiper
— E115 DY20KA phenomenon (in Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No. 049: Monitor input 3)

Windshield wiper motor W04 (female) Windshield wiper blade Resistance value
1 defective At upper end of operation
(Internal disconnection) Max. 1 Ω
range
Between 6 and 5
Outside upper end of
Min. 1 MΩ
operation range
Disconnection of wiring for the troubleshooting.
harness Wiring harness between P01 (female) 5 and W04 (male) Resistance
2 Max. 1 Ω
(Disconnection or faulty 6 value
contact with connector) Resistance
Wiring harness between W04 (male) 5 and grounding Max. 1 Ω
value
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of operation
Max. 1 V
range
Outside upper end of
20 – 30 V
operation range
20-316 PC1250-7
Electric circuit diagram related to wiper
PC1250-7 20-317
Error Code in Electrical System E116 (Abnormality in retracting windshield wiper)
User Code Error Code Failure Code Failure Abnormal operation of retracting windshield wiper
— E116 DY20MA phenomenon (in Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No. 049: Monitor Input 3)
1. Cab with fixed front window (When 2 wipers are set)


Windshield wiper motor
1 defective W04, W05 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Max. 1 Ω
Between 4 and 5
Operation range Min. 1 MΩ
Disconnection of wiring during the troubleshooting.
harness
Wiring harness between P01 (female) B and W04 (male) Resistance
2 (Disconnection or defec- Max. 1 Ω
4, and P01 (female) 5 and W05 (male) 4 value
tive contact with connec-
tor) Between wiring harness W04 (male) 5, W05 (male) 5 Resistance
Max. 1 Ω
and grounding value
during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Between B and grounding Retraction range Max. 1V
Between 5 and grounding Operation range 20 – 30 V
2. Cab with pull-up front window (When 1 wiper is set) (If equipped, for North America)

Windshield wiper motor
1 defective W04 (female) Windshield wiper blade Resistance value
(Internal disconnection) Retraction range Max. 1 Ω
Between 4 and 5
Operation range Min. 1 MΩ
harness
Wiring harness between P01 (female) B and W04 (male) Resistance
4 value
tor) Resistance
Between wiring harness W04 (male) 5 and grounding Max. 1 Ω
value
3 Monitor panel defective P01 Windshield wiper blade Voltage
Retraction range Max. 1V
Between B and grounding
Operation range 20 – 30 V
20-318 PC1250-7
Electric circuit diagram related to wiper (cab with fixed front window)
PC1250-7 20-319
Electric circuit diagram related to wiper (cab with pull-up front window)
20-320 PC1250-7

(Short-circuiting in CO cancel solenoid)
User Code Error Code Failure Code Failure Short-circuiting in CO cancel solenoid
— E201 DW48KB phenomenon (in pump controller system)
Failure content • Abnormal current flew to the CO cancel circuit, when power was supplied to the circuit.
• Power supply to the CO cancel circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • When the machine travels or the boom is raised, power is insufficient.
machine
Relative • Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function. (Code No.
information 023: Solenoid)

CO cancel solenoid during the troubleshooting.
defective V07 (male) Resistance value

1
or grounding fault) Between 1 and 2 20 – 60 Ω
Assembled-type diode during the troubleshooting.
2 D03 defective
D03 (male) Resistance value
Between 1 and 5 Min. 1 MΩ
Grounding fault of wiring during the troubleshooting.
harness
3 Between wiring harness between C03 (female) G, J06,
circuit) and V07 (female) 2 or between D03 (female) 1 and J06 Min. 1 MΩ
value
★Turn the engine starting switch OFF for the preparations, and hold it running during the
troubleshooting.
Pump controller C03 Heavy lift switch Voltage
4
defective
OFF Max. 1 V
Between G and grounding
ON 20 – 30 V
20-322 PC1250-7
Electric circuit diagram related to CO cancel solenoid
PC1250-7 20-323

(Short-circuiting in straight travel solenoid)
User Code Error Code Failure Code Failure Short-circuiting in straight travel solenoid
Failure content • Abnormal current flew to the straight travel circuit, when power was supplied to the circuit.
• Power supply to the straight travel circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
occurring on • When both tracks and work equipment are operated simultaneously, the machine deviates.
machine
Relative • Operation of the straight travel solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 023: Solenoid)

Straight travel solenoid during the troubleshooting.
1
2 D03 defective
harness
3 Between wiring harness between C03 (female) 7, J06,
value
troubleshooting.
Pump controller C03 Travel control lever Voltage
4
defective NEUTRAL Max. 1 V
Between 7 and grounding Both tracks operation +
20 – 30 V
Work equipment operation
20-324 PC1250-7
Electric circuit diagram related to straight travel solenoid
PC1250-7 20-325

(Short-circuiting in swing parking brake solenoid)
User Code Error Code Failure Code Failure Short-circuiting in swing parking brake solenoid
E03 E203 DW45KB phenomenon (in pump controller system)
• Abnormal current flew to the swing parking brake solenoid circuit, when power was supplied to the cir-
Failure content
cuit.
• Power supply to the swing parking brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the swing and steering brake does not return to normal-
controller
cy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The machine cannot swing.
machine
• Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
Relative
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
information
the emergency swing brake releasing switch to the FREE position.
(In this case, however, the parking brake does not work, when stopping the machine)

Swing parking brake during the troubleshooting.
solenoid defective V04 (male) Resistance value

1
2 D03 defective
harness
3 Between wiring harness between C03 (female) [, D01,
circuit) J02, X05, J06, and V04 (female) 2 or between D03 Min. 1 MΩ
value
(female) 4 and J06 (male) C and grounding
troubleshooting.
Pump controller C03 Swing control lever Voltage
4
defective
NEUTRAL Max. 1 V
Between [ and grounding
Swing 20 – 30 V
20-326 PC1250-7
Electric circuit diagram related to swing parking brake of pump controller
PC1250-7 20-327
Error Code in Electrical System E204 (Short-circuiting in 2-stage relief solenoid)
User Code Error Code Failure Code Failure Short-circuiting in 2-stage relief solenoid
— E204 DWK0KB phenomenon (in pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• 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.
Phenomenon
occurring on • The heavy-lift function does not work.
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

2-stage relief solenoid during the troubleshooting.
1
2 D03 defective
harness
3 Between wiring harness between C03 (female) R, J06,
value
Pump controller C03 Working mode Voltage
4
defective Heavy lift mode Max. 1 V
Between R and grounding Boom is raised singly in
20 – 30 V
heavy lift mode
20-328 PC1250-7
Electric circuit diagram related to 2-stage relief solenoid
PC1250-7 20-329

(Short-circuiting in swing priority solenoid)
User Code Error Code Failure Code Failure Short-circuiting in swing priority solenoid
Failure content • Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.
• Power supply to the swing priority solenoid circuit is switched OFF.
Response from
controller
Phenomenon
occurring on • When the boom is raised and swung in the swing priority mode, the swing speed is low.
machine
Relative • Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 023: Solenoid 1)

Swing priority solenoid during the troubleshooting.

1
2 D04 defective
harness
3 Between wiring harness between C03 (female) \, J07,
value
(male) A and grounding
troubleshooting.
Pump controller C03 Swing priority mode switch Voltage
4
defective
OFF Max. 1 V
Between \ and grounding
ON + Swing operation 20 – 30 V
20-330 PC1250-7
Electric circuit diagram related to swing priority solenoid
PC1250-7 20-331

(Short-circuiting in travel speed solenoid)
User Code Error Code Failure Code Failure Short-circuiting in travel speed solenoid
Failure content • Abnormal current flew to the travel speed solenoid, when power was supplied to the circuit.
• Power supply to the travel speed solenoid circuit is switched OFF.
Response from
controller
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The display in the monitor panel changes correctly)
machine
Relative • Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function. (Code
information No. 023: Solenoid 1)

Travel speed solenoid during the troubleshooting.

1
2 D04 defective
harness
3 Between wiring harness between C03 (female) Q, J06,
value
(male) I and grounding
troubleshooting.
Pump controller C03 Travel speed Voltage
4
defective
Lo Max. 1 V
Between Q and grounding
Hi + Travel operation 20 – 30 V
20-332 PC1250-7
Electric circuit diagram related to travel speed solenoid
PC1250-7 20-333

(Abnormality in flash light relay coil (Short-circuiting))
User Code Error Code Failure Code Failure Abnormality in flash light relay coil (Short-circuiting)
— E207 D163KB phenomenon (in pump controller system)
• When the output on the flash light relay coil side is ON, the voltage of the output circuit on the coil side
Failure content
is above 5.7 V.
• The controller turns OFF the output to the coil circuit of the flash light relay.
Response from
controller
Phenomenon
occurring on • The flash light does not flash.
machine
Relative • Output on the coil side of the flash light relay (ON or OFF) can be checked in the monitoring function.
information (Code No. 038: Controller output 2)

Flash light relay defec- during the troubleshooting.
1 tive
R21 (male) Resistance value
Short-circuiting of wiring during the troubleshooting.
2 harness
(Contact with 24V circuit) Between wiring harness between C03 (female) O and Voltage Max. 1 MΩ
R21 (female) 1 and grounding
Pump controller C03 Horn switch Voltage
3
defective ON 20 – 30 V
Between O and grounding
OFF Max. 1 V
20-334 PC1250-7
Electric circuit diagram related to flash light relay
PC1250-7 20-335
Error Code in Electrical System E211 (Disconnection in CO cancel solenoid)
User Code Error Code Failure Code Failure Disconnection in CO cancel solenoid
— E211 DW48KA phenomenon (in pump controller system)
Failure content • No current flows to the CO cancel solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring 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. (Code No.
Relative 023: Solenoid 1)
information ★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code [E201].)

CO cancel during the troubleshooting.
1 solenoid defective
V07 (male) Resistance value
(Internal disconnection)
harness
Wiring harness from C03 (female) G to J06 to V07 Resistance
(female) 2 value
tor) Resistance
Wiring harness between V07 (female) 1 and grounding Max. 1 Ω
value
harness
3 Between wiring harness between C03 (female) G, J06,
(Contact with 24 V cir-
cuit) and V07 (female) 2 or between D03 (female) 1 and J06 Voltage Max. 1 V
Pump controller during the troubleshooting.
4
defective C03 (female) Resistance value
Between G and grounding 20 – 60 Ω
20-336 PC1250-7
Electric circuit diagram related to CO cancel solenoid
PC1250-7 20-337
Error Code in Electrical System E212 (Disconnection in straight travel solenoid)
User Code Error Code Failure Code Failure Disconnection in straight travel solenoid
Failure content • No current flows to the straight travel solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
Phenomenon
occurring 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. (Code
Relative No. 023: Solenoid 1)

Straight travel during the troubleshooting.
1 solenoid defective
harness
Wiring harness from C03 (female) 7 to J06 to V03 Resistance
(female) 2 value
tor) Resistance
value
harness
3 Between wiring harness between C03 (female) 7, J06,
4
Between 7 and grounding 20 – 60 Ω
20-338 PC1250-7
Electric circuit diagram related to straight travel solenoid
PC1250-7 20-339

(Disconnection in Swing Parking Brake Solenoid)
User Code Error Code Failure Code Failure Disconnection in swing parking brake solenoid
E03 E213 DW45KA phenomenon (in pump controller system)
Failure content • No current flows to the swing parking brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
Phenomenon
occurring on • The machine cannot swing.
machine
• Operation of the swing parking brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 023: Solenoid 1)
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can swing
by moving the emergency swing brake release switch to the FREE position. (In this case, however, the
Relative
parking brake does not work, when stopping the machine)
information
★While in troubleshooting, hold both the swing lock switch and the emergency swing release switch in the
OFF position.
★The solenoid detects disconnection, when power is ON. Hence be sure to check it with power ON after
Swing parking brake ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
solenoid defective during the troubleshooting.
1
(Internal disconnec- V04 (male) Resistance value
tion) Between 1 and 2 20 – 60 Ω
Swing lock switch during the troubleshooting.
defective X05 (female) Swing lock switch Resistance value
2
(Internal disconnec-
tion) OFF Max. 1 Ω
Between 3 and 4
LOCK Min. 1 MΩ
Assembled-type ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 defective during the troubleshooting.
3
(Internal disconnec- D01 (male) Digital type circuit tester Continuity
tion) Between 7 and 3 Diode mode Continued
Resistance
Disconnection of Wiring harness between C03 (female) [ and D01 (female) 7 Max. 1 Ω
value
wiring harness
Resistance
4 (Disconnection or Wiring harness from D01 (female) 3 to J02 to X05 (male) 3 Max. 1 Ω
value
defective contact
with connector) Resistance
Wiring harness from X05 (male) 4 to J06 to V04 (female) 2 Max. 1 Ω
value
Resistance
value
Short-circuiting of ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Wiring harness ing the troubleshooting.
5
(Contact with 24V Between wiring harness between C03 (female) [ and D01
circuit) Voltage Max. 1 V
(female) 7 and grounding
Pump controller
6 C03 (female) Disconnect D01 and con- Resistance value
defective
nect pins 3 and 7 of the
Between [ and grounding male side. 20 – 60 Ω
20-340 PC1250-7
Electric circuit diagram related to swing parking brake of pump controller
PC1250-7 20-341
Error Code in Electrical System E214 (Disconnection in 2-stage relief solenoid)
User Code Error Code Failure Code Failure Disconnection in 2-stage relief solenoid
— E214 DWK0KA phenomenon (in pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring 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.
Relative (Code No. 023: Solenoid 1)

2-stage relief solenoid during the troubleshooting.
1 defective
harness
Wiring harness from C03 (female) R to J06 to V02 Resistance
(female) 2 value
tor) Resistance
value
harness
3 Between wiring harness between C03 (female) R, J06,
4
Between R and grounding 20 – 60 Ω
20-342 PC1250-7
Electric circuit diagram related to 2-stage relief solenoid
PC1250-7 20-343
Error Code in Electrical System E215 (Disconnection of swing priority solenoid)
User Code Error Code Failure Code Failure Disconnection in swing priority solenoid
Failure content • No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.
Phenomenon
occurring on • When the boom is raised and swing 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.
Relative (Code No. 023: Solenoid 1)

Swing priority solenoid during the troubleshooting.
1 defective
harness
Wiring harness from C03 (female) \ to J07 to V01 Resistance
(female) 2 value
tor) Resistance
value
harness
3 Between wiring harness between C03 (female) \, J07,
(male) A and grounding
4
Between \ and grounding 20 – 60 Ω
20-344 PC1250-7
Electric circuit diagram related to swing priority solenoid
PC1250-7 20-345

(Disconnection in travel speed solenoid)
User Code Error Code Failure Code Failure Disconnection in travel speed solenoid
Failure content • No current flows to the travel speed solenoid circuit, when power is supplied to the circuit.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The display changes normally in the monitor panel)
machine
• Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function. (Code
Relative No. 023: Solenoid 1)

Travel speed solenoid during the troubleshooting.
1 defective
harness
Wiring harness from C03 (female) Q to J06 to V06 Resistance
(female) 2 value
tor) Resistance
value
harness
3 Between wiring harness between C03 (female) Q, J06,
(male) I and grounding
4
Between Q and grounding 20 – 60 Ω
20-346 PC1250-7
Electric circuit diagram related to travel speed solenoid
PC1250-7 20-347
Error Code in Electrical System E217 (Abnormality in inputting model code)
User Code Error Code Failure Code Failure Abnormality in inputting model code
— E217 DA2SKQ phenomenon (in pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC1250).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC1250 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 002: Controller Model Code)
information ★Input of model selecting signals (ON or OFF) can be confirmed in the monitoring
function.(Code No. 027:Switch Input 2)

Model selecting connec- during the troubleshooting.
tor defective C09 (female) Resistance value
1
(Internal disconnection
or short-circuiting) Between 4 and 7, 1 and 8 Max. 1 Ω
Between 2, 3 and 7, 8 Min. 1 MΩ

Disconnection of wiring Wiring harness between C02 (female) 7 and C09 Resistance
harness Max. 1 Ω
(male) 4 value
2 (Disconnection or defec-
Between wiring harness between C02 (female) [ and Resistance
tive contact with connec- Max. 1 Ω
tor) C09 (male) 1 value
Between wiring harness between C09 (male) 7, 8 and Resistance
Max. 1 Ω
J05 and grounding value
harness Between wiring harness between C02 (female) G and Resistance
3 Min. 1 MΩ
(Contact with grounding C09 (male) 3 and grounding value
circuit) Between wiring harness between C02 (female) Q and Resistance
Min. 1 MΩ
C09 (male) 2 and grounding value
Pump controller C02 Voltage
4
defective
Between G, Q and grounding 20 – 30 V
Between 7, [ and grounding Max. 1 V
20-348 PC1250-7
Electric circuit diagram related to model code
PC1250-7 20-349
Error Code in Electrical System E218 (Disconnection of S-NET signal)
User Code Error Code Failure Code Failure Disconnection in S-NET signal
— E218 DA2SKA phenomenon (in pump controller system)
• A failure occurred in S-NET communication between the monitor and controller in the past.
Failure content
(The machine operation returned to normalcy, when the display was resumed)
• While the failure is still continuing, the machine operation is controlled by the following default setting.
1) Working mode: E mode
Response from
2) Travel speed: Lo
controller
3) Auto-decelerator: ON
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The working mode cannot be changed. (The display changes normally in the monitor panel)
occurring on • The travel speed cannot be shifted. (The display changes normally in the monitor panel)
machine • The auto-decelerator cannot be released. (The display changes normally in the monitor panel)
• This Error Code No. is displayed to inform that there was a failure occurred in the past, when S-NET
communication between the monitor panel and the pump controller is returned to normalcy.
Relative
• The communication has already returned to normalcy by the time this Error Code No. is displayed. But
information
thoroughly diagnose all the related equipment and circuits, and remove all potential causes for a failure
in order to prevent recurrence of failures.

harness
Wiring harness between P02 (female) 9 0 and C02 Resistance
(female) K value

tor) Wiring harness between P02 (female) J and C02 Resistance
Max. 1 Ω
(female) U value
harness during the troubleshooting.
2
(Contact with grounding Between wiring harness between P02 (female) 9 0 and Resistance
C02 (female) K and grounding value
Short-circuiting of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position
3
(Contact with 24 V cir- Between wiring harness between P02 (female) 9 0 and
cuit) Voltage Max. 1 V
C02 (female) K and grounding
P02 (male) Voltage
Between 9 0 and J 6–9V
5
defective C02 (male) Voltage
Between K and U 6–9V
20-350 PC1250-7
Electrical Circuit Diagram for S-NET Communication between Monitor Panel and Pump Controller
PC1250-7 20-351
Error Code in Electrical System E221 (Abnormality in J1939 Network)
User Code Error Code Failure Code Failure Abnormality in J1939 Network
— E221 DA2RKR phenomenon (in pump controller system)
• There is a failure in J1939 communication between the engine controller and pump controller.
Failure content
• While there is the failure, the controller controls in the following mode.
Response from 1) Working mode: E mode
controller 2) Torque limiting under abnormal condition
Phenomenon • The working mode cannot be changed (The display changes normally in the monitor panel, however).
occurring on • Since the machine is operated in E mode and the torque is limited under abnormal condition, the work
machine equipment speed is lowered.
Relative
• While there is the failure, the monitoring function related to engine control does not display normally.
information

Disconnection of wiring Wiring harness between C02 (female) L and ECMB Resistance
harness Max. 1 Ω
(female) L value
Wiring harness between C02 (female) V and ECMB Resistance
tor) (female) V value
Wiring harness between C02 (female) B and ECMB Resistance
Max. 1 Ω
(female) U value
harness Between wiring harness between C02 (female) L and Resistance
2 Min. 1 MΩ
(Contact with grounding ECMB (female) L and grounding value
circuit) Between wiring harness between C02 (female) V and Resistance
Min. 1 MΩ
ECMB (female) V and grounding value
harness Between wiring harness between C02 (female) L and
3 Voltage Max. 1 V
(Contact with 24 V cir- ECMB (female) L and grounding
cuit) Between wiring harness between C02 (female) V and
Voltage Max. 1 V
ECMB (female) V and grounding
Engine controller ECMB (male) Voltage
4
defective
Between L and grounding 1.5 – 5 V
Between V and grounding 1.5 – 5 V
Pump controller C02 (male) Voltage
5
defective
Between L and grounding 1.5 – 5 V
Between V and grounding 1.5 – 5 V
20-352 PC1250-7
Electric circuit diagram related to J1939 network communication
PC1250-7 20-353
Error Code in Electrical System E222 (Short-circuiting in output system of working

mode [1] (full curve))
User Code Error Code Failure Code Failure Short-circuiting in output system of working mode [1]
— E222 D5ZJKB phenomenon (full curve) (in pump controller system)
• The working mode [1] (full curve) output is short-circuited with power source in wiring harness between
Failure content
the pump controller and engine controller.
• The controller turns OFF the output to the working mode [1] (full curve) output circuit (taken in GND).
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy, un-
controller
less the engine starting switch is once turned OFF.
Phenomenon
• The working mode of the engine controller does not change to E mode.
occurring on
(The display changes normally in the monitor panel.)
machine
Relative • Operation of the working mode [1] (full curve) output (ON or OFF) can be checked in the monitoring func-
information tion. (Code No. 037: Controller output 1)

harness
1 After C02 H and ECMB J are disconnected, between
cuit) wiring harness between C02 (female) H and ECMB Voltage Max. 1 V
(female) J and grounding
Engine controller
2 Working
defective After C02 H is disconnected, between ENMB (male) J Voltage
mode
and grounding
A mode 5 – 15 V
Pump controller Working
3 Voltage
defective mode
Between C02 H and grounding
A mode 5 – 15 V
E mode Max. 1 V
Electric circuit diagram related to working mode (full curve) output
20-354 PC1250-7
Error Code in Electrical System E223 (Disconnection in output system of working

mode [1] (full curve))
User Code Error Code Failure Code Failure Disconnection in output system of working mode [1]
— E223 D5ZJKA phenomenon (full curve) (in pump controller system)
• The working mode [1] (full curve) output is disconnected or short-circuited with grounding in wiring har-
Failure content
ness between the pump controller and engine controller.
Response from • None in particular.
Phenomenon
occurring on • The working mode of the engine cannot be changed.
machine
• Operation of the working mode [1] (full curve) output (ON or OFF) can be checked in the monitoring func-
Relative tion. (Code No. 037: Controller output 1)
information ★The output system detects disconnection, when power is OFF. Hence be sure to check it with power
OFF after the repairs (A mode).

Disconnection of wiring ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Wiring harness between C02 (female) H and ECMB Resistance

tor) (female) J value
harness
2 Working Resistance
(Contact with grounding Between wiring harness between C02 (female) H and mode value
circuit) ECMB (female) J and grounding
A mode Min. 1 MΩ
Engine controller
3 Working
defective After C02 H is disconnected, between ENMB (male) J Voltage
mode
and grounding
A mode 5 – 15 V
Pump controller
4 Working
defective Voltage
Between C02 H and grounding mode
A mode 5 – 15 V
Electric circuit diagram related to working mode (full curve) output
PC1250-7 20-355
Error Code in Electrical System E224 (Short-circuiting in output system of working

mode [2] (Hi regulation))
User Code Error Code Failure Code Failure Short-circuiting in output system of working mode [2]
— E224 D5ZLKB phenomenon (Hi regulation) (in pump controller system)
• The working mode [2] (Hi regulation) output is short-circuited with power source in wiring harness be-
Failure content
tween the pump controller and engine controller.
• The controller turns OFF the output to the working mode [2] (Hi regulation) output circuit (taken in GND).
Response from
controller
Phenomenon
• The working mode of the engine controller does not change to E mode.
occurring on
machine
Relative • Operation of the working mode [2] (Hi regulation) output (ON or OFF) can be checked in the monitoring
information function. (Code No. 037: Controller output 1)

harness
1 After C02 8 and ECMB I are disconnected, between
cuit) wiring harness between C02 (female) 8 and ECMB Voltage Max. 1 V
(female) I and grounding
Engine controller
2 Working
defective After C02 8 is disconnected, between ENMB (male) I Voltage
mode
and grounding
A mode 5 – 15 V
3 Voltage
defective mode
Between C02 8 and grounding
A mode 5 – 15 V
E mode Max. 1 V
Electric circuit diagram related to working mode (Hi regulation) output
20-356 PC1250-7
Error Code in Electrical System E225 (Disconnection in output system of working

mode [2] (Hi regulation))
User Code Error Code Failure Code Failure Disconnection in output system of working mode [2]
— E225 D5ZLKA phenomenon (Hi regulation) (in pump controller system)
• The working mode [2] (Hi regulation) output is disconnected or short-circuited with grounding in wiring
Failure content
harness between the pump controller and engine controller.
Phenomenon
occurring on • The working mode of the engine cannot be changed.
machine
• Operation of the working mode [2] (Hi regulation) output (ON or OFF) can be checked in the monitoring
Relative function. (Code No. 037: Controller output 1)
OFF after the repairs (A mode).

Wiring harness between C02 (female) 8 and ECMB Resistance

tor) (female) I value
harness
2 Working Resistance
(Contact with grounding Between wiring harness between C02 (female) 8 and mode value
circuit) ECMB (female) I and grounding
A mode Min. 1 MΩ
Engine controller
3 Working
defective After C02 8 is disconnected, between ENMB (male) I Voltage
mode
and grounding
A mode 5 – 15 V
Pump controller
4 Working
defective Voltage
Between C02 8 and grounding mode
A mode 5 – 15 V
Electric circuit diagram related to working mode (Hi regulation) output
PC1250-7 20-357
Error Code in Electrical System E226 (Disconnection in output system of auto-decel-

erator)
User Code Error Code Failure Code Failure Disconnection in output system of auto-decelerator
• The auto-decelerator output is disconnected or short-circuited with grounding in wiring harness between
Failure content
the pump controller and engine controller.
Phenomenon
• The engine auto-decelerator does not work.
occurring on
• The engine auto-decelerator cannot be turned off.
machine
• Operation of the auto-decelerator output (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 037: Controller output 1)
OFF after the repairs (decelerator OFF).

Wiring harness between C02 (female) 9 and ECMB Resistance
tor) (female) Y value
harness Working Resistance
2
(Contact with grounding Between wiring harness between C02 (female) 9 and mode value
circuit) ECMB (female) Y and grounding Decelerator
Min. 1 MΩ
OFF
Engine controller Working
3 Voltage
defective After C02 9 is disconnected, between ENMB (male) Y mode
and grounding Decelerator
5 – 15 V
OFF
4 Voltage
defective mode
Between C02 9 and grounding
Decelera-
5 – 15 V
tor OFF
Electric circuit diagram related to auto-decelerator output
20-358 PC1250-7
Error Code in Electrical System E227 (Abnormality in engine speed sensor)
User Code Error Code Failure Code Failure Abnormality in engine speed sensor
— E227 DLE2MA phenomenon (in pump controller system)
Failure content • Normal pulse inputs are not input to the engine speed signal input circuit.
Response from • The controller controls in a mode equivalent to E mode.
Phenomenon
occurring on • Power is insufficient.
machine
Relative • Input of the engine speed signal input circuit (Engine speed) can be checked in the monitoring function.
information (Code No. 010: Engine speed)

Wiring harness between C02 (female) ^ – ECMB Resistance
tor) (female) O value
harness
2 After C02 ^ and ECMB O are disconnected, between
cuit) wiring harness between C02 (female) ^ and ECMB Voltage Max. 1 V
(female) O and grounding
★Turn the engine starting switch OFF for the preparations, and run the engine for the
Engine controller troubleshooting.
3
defective
Between ECMB O and grounding Voltage 10 – 30 V
★Turn the engine starting switch OFF for the preparations, and run the engine for the
Pump controller troubleshooting.
4
defective
Between C02 ^ and grounding Voltage 10 – 30 V
Electric circuit diagram related to engine speed sensor
PC1250-7 20-359
Error Code in Electrical System E228 (Short-circuiting in output system of auto-decel-

erator)
User Code Error Code Failure Code Failure Short-circuiting in output system of auto-decelerator
• The auto-decelerator output is short-circuited with power source in wiring harness between the pump
Failure content
controller and engine controller.
• The controller turns OFF the output to the auto-decelerator output circuit (taken in GND).
Response from
controller
Phenomenon
• The engine auto-decelerator does not work.
occurring on
machine
Relative • Operation of the auto-decelerator output (ON or OFF) can be checked in the monitoring function.

harness
1 After C02 9 and ECMB Y are disconnected, between
cuit) wiring harness between C02 (female) 9 and ECMB Voltage Max. 1 V
(female) Y and grounding
Engine controller during the troubleshooting.
2
defective After C02 9 is disconnected, between ENMB (male) Y Deceleration Voltage
and grounding OFF 5 – 15 V
Pump controller Deceleration Voltage
3
defective
Between C02 9 and grounding OFF 5 – 15 V
ON Max. 1 V
Electric circuit diagram related to auto-decelerator output
20-360 PC1250-7
Error Code in Electrical System E232 (Short-circuiting in TVC solenoid)
User Code Error Code Failure Code Failure Short-circuiting in TVC solenoid
E02 E232 DXA0KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the TVC solenoid circuit.
• The controller turns OFF the output to the TVC solenoid circuit.
Response from
controller
Phenomenon
occurring 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 13: TVC solenoid current)
Relative • If there is no abnormality with the solenoid or wiring harness, the machine can operate with the output
information equivalent to E mode by turning the emergency drive switch. (At this time, user code E02 and error code
E233 are displayed. They do not indicate abnormality, however.)
★Hold the emergency pump switch in the OFF position during troubleshooting.

TVC solenoid defective
1 (Internal short-circuiting C13 (Male) Resistance value
harness
2 Between wiring harness between C03 (female) F, S25
(GND) circuit) 3, emergency drive switch, S25 2, and C13 (female) 1 Min. 1 MΩ
value
and grounding
Pump controller C03 (female) Resistance value
3
defective
Between F and 3 10 – 22 Ω
Between F and grounding Min. 1 MΩ
20-362 PC1250-7
Electric circuit diagram related to TVC solenoid
PC1250-7 20-363
Error Code in Electrical System E233 (Disconnection in TVC solenoid)
User Code Error Code Failure Code Failure Disconnection in TVC solenoid
E02 E233 DXA0KA phenomenon (Pump controller system)
Failure content • Any current does not flow in the TVC solenoid circuit.
Response from • None in particular. (Since any current does not flow, the solenoid does not operate.)
Phenomenon
occurring 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 13: TVC solenoid current)
Relative • If there is no abnormality with the solenoid or wiring harness, the machine can operate with the output
information equivalent to E mode by turning the emergency drive switch. (At this time, user code E02 and error code
E233 are displayed. They do not indicate abnormality, however.)
★Hold the emergency pump switch in the OFF position during troubleshooting.

TVC solenoid defective during the troubleshooting.
1 (Internal short-circuiting
C13 (male) Resistance value
or grounding fault)
S25 Switch Resistance value
Emergency pump drive
2 switch defective (Inter- OFF Max. 1 Ω
Between 2 and 3
nal short-circuiting) ON Min. 1 MΩ
OFF Max. 1 Ω
Between 5 and 6
ON Min. 1 MΩ
Resistance
Disconnection of wiring Wiring harness between C03 (female) F and S25 3 Max. 1 Ω
value
harness
Resistance
3 (Disconnection or defec- Wiring harness between S25 2 and C13 (female) 1 Max. 1 Ω
value
tor) Resistance
Wiring harness between C03 (female) 3 and S25 6 Max. 1 Ω
value
Resistance
Wiring harness between S25 5 and C13 (female) 2 Max. 1 Ω
value
harness Between wiring harness between C03 (female) F and
4 Voltage Max. 1 V
(Contact with 24 V cir- S25 3 and grounding
cuit) Between wiring harness between S25 2 and C13
Voltage Max. 1 V
5
defective C03 (male) Resistance value
Between F and 3 10 – 22 Ω
20-364 PC1250-7
Electric circuit diagram related to TVC solenoid
PC1250-7 20-365
Error Code in Electrical System E234 (Short-circuiting in lever-neutral output system)
User Code Error Code Failure Code Failure Short-circuiting in lever-neutral output system
— E234 D5ZFKB phenomenon (in pump controller system)
• The lever-neutral output is short-circuited with power source in wiring harness between the pump con-
Failure content
troller and engine controller.
• The controller turns OFF the output to the lever-neutral output circuit (taken in GND).
Response from
controller
Phenomenon
• When the engine is set in the lever-neutral mode, the Hi idle-down control does not work.
occurring on
machine
Relative • Operation of the lever-neutral output (ON or OFF) can be checked in the monitoring function.

harness
1 After C02 I and ECMB [ are disconnected, between
cuit) wiring harness between C02 (female) I and ECMB Voltage Max. 1 V
(female) [ and grounding
2
defective After C02 I is disconnected, between ENMB (male) [ Deceleration Voltage
and grounding ON 5 – 15 V
Pump controller Deceleration Voltage
3
defective ON 5 – 15 V
Between C02 I and grounding
OFF
Max. 1 V
Lever neutral
Electric circuit diagram related to lever-neutral output
20-366 PC1250-7
Error Code in Electrical System E235 (Disconnection in lever-neutral output system)
User Code Error Code Failure Code Failure Disconnection in lever-neutral output system
— E235 D5ZKFKB phenomenon (in pump controller system)
• The lever-neutral output is disconnected or short-circuited with grounding in wiring harness between the
Failure content
pump controller and engine controller.
Phenomenon
• When the engine is set in the lever-neutral mode, the Hi idle-down control does not work.
occurring on
• When the engine is set in the lever-neutral mode, the Hi idle-down control cannot be turned off.
machine
• Operation of the lever-neutral output (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 037: Controller output 1)
OFF after the repairs (deceleration ON).

Wiring harness between C02 (female) I and ECMB Resistance
tor) (female) [ value
harness
2 Resistance
(Contact with grounding Between wiring harness between C02 (female) I and Deceleration
value
circuit) ECMB (female) [ and grounding
ON Min. 1 MΩ
3
defective After C02 I is disconnected, between ENMB (male) [ Deceleration Voltage
and grounding ON 5 – 15 V
4
defective Deceleration Voltage
Between C02 I and grounding
ON 5 – 15 V
Electric circuit diagram related to lever-neutral output
PC1250-7 20-367
Error Code in Electrical System E302 (Short-circuiting in step light relay system)
User Code Error Code Failure Code Failure Short-circuiting in step light relay system
• When a signal is output to the step light drive relay circuit (the primary circuit of the relay), abnormal
Failure content
current flowed.
• The controller turns OFF the output to the step light drive relay circuit.
Response from
controller
Phenomenon
occurring 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 checked
Relative
in the monitoring function. (Code No. 038: Controller output 2)
information
★The pump controller cannot detect abnormality in the secondary circuit of the relay.

Step light drive relay ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
defective (Internal short- during the troubleshooting.
1
circuiting or grounding Resistance
fault) Between R15 (female) 1 and 2 250 – 350 Ω
value
2
(Contact with grounding Between wiring harness between C03 (female) E and Resistance
R15 (female) 1 and grounding value
Pump controller C03 Step light Voltage

3
defective
ON 20 – 30 V
Between E and grounding
OFF Max. 1 V
20-368 PC1250-7
Electric circuit diagram related to step light
PC1250-7 20-369
Error Code in Electrical System E304 (Short-circuiting in step light power source drive
relay circuit)
User Code Error Code Failure Code Failure Short-circuiting in step light power source drive relay
— E304 D194KB phenomenon circuit (in pump controller system)
• When a signal is output to the step light power source drive relay circuit (the primary circuit of the relay),
Failure content
abnormal current flowed.
• The controller turns OFF the output to the step light power source drive relay circuit.
Response from
controller
Phenomenon
occurring on • The step light cannot be kept ON.
machine
• Operation of the step light power source drive relay circuit (the primary circuit of the relay) (ON or OFF)
Relative
can be checked in the monitoring function. (Code No. 038: Controller output 2)
information
★The pump controller cannot detect abnormality in the secondary circuit of the relay.

Step light power source ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
drive relay defective during the troubleshooting.
1
(Internal short-circuiting Resistance
or grounding fault) Between R14 (female) 1 and 2 250 – 350 Ω
value
harness etween wiring harness between C03 (female) 5 and D02 Resistance
2 Min. 1 MΩ
(Contact with grounding (female) 8 and grounding value
circuit) Between wiring harness between D02 (female) 4 and Resistance
Min. 1 MΩ
R14 (female) 1 and grounding value
Pump controller C03 Step light Voltage
3
defective
ON 20 – 30 V
OFF Max. 1 V
20-370 PC1250-7
Electric circuit diagram related to step light
PC1250-7 20-371
Error Code in Electrical System E315 (Short-circuiting in battery relay output system)
User Code Error Code Failure Code Failure Short-circuiting in battery relay output system
Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit.
Phenomenon
• When this fault occurs, if the key is turned to the OFF position with the Hi idle switch and auto-deceler-
occurring on
ation switch ON, the engine speed rises for a while and then stops.
machine
Relative • Operation of the battery relay (ON or OFF) can be checked in the monitoring function.

Battery relay defective Battery relay Continuity/Resistance value
1
(Internal fault)
Between terminals BR and E There is continuity
Between terminal BR and grounding Min. 1 MΩ
2
(Contact with grounding Between wiring harness between C03 (female) 4, D01, Resistance
J01, and battery relay terminal BR and grounding value
Pump controller
3 03 (female) Starting switch Voltage
defective
20 – 30 V
Between 4 and grounding ON → OFF
(For 0.5 sec)
20-372 PC1250-7
Circuit diagram related to battery relay output
PC1250-7 20-373
TROUBLESHOOTING AA10NX
Failure Code in Mechanical System AA10NX (Air cleaner clogging)
User Code Error Code Failure Code Failure Air cleaner clogged
— — AA10NX phenomenon (in mechanical system)
• While the engine was running, the signal circuit in the air cleaner clogging switch was opened (i.e. dis-
Failure content
connected from grounding circuit).
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine is damaged, if it is used continuously without corrective action.
machine
• This Failure Code is recorded, when the air cleaner clogging caution symbol is displayed in the monitor
Relative panel while the engine is running.
information • Input from the air cleaner clogging switch (ON or OFF) can be confirmed in the monitor panel.
(Code No. 046: Monitor input 2)

Air cleaner clogged
1 (when the system is in ★Check the air cleaner for clogging. If it is clogged, clean or replace it with new one.
normal condition)
★Turn the engine starting switch OFF for the preparations, and keep the engine running
Air cleaner clogging
2 switch defective P11 (male) Air cleaner Resistance value
(Internal disconnection) When in normal condition Max. 1 Ω
Between 1 and 2
When clogged Min. 1 MΩ
Disconnection of wiring troubleshooting.
harness
Wiring harness between P02 (female) 5 and P11 Resistance
(female) 1 value
tor) Resistance
Between wiring harness P11 (female) 2 and grounding Max. 1 Ω
value
4 Monitor panel defective P02 Air cleaner Voltage
When in normal condition Max. 1 V
When clogged 20 – 30 V
20-374 PC1250-7
TROUBLESHOOTING AA10NX
Electrical Circuit for Air Cleaner Clogging Switch in Monitor Panel
PC1250-7 20-375
TROUBLESHOOTING AB00KE
Failure Code in Mechanical System AB00KE (Abnormally lowered charging voltage)
User Code Error Code Failure Code Failure Charging voltage abnormally lowered
— — AB00KE phenomenon (in mechanical system)
Failure content • Generation signal from the alternator is not inputted, while the engine is running.
Response from
controller
Phenomenon
• There is a possibility that the battery may not be charged, if charging is continued without corrective
occurring on
action.
machine
• This Failure Code is recorded, if the charging caution symbol is displayed in the monitor panel, while the
Relative engine is running.
information • Input from the alternator (voltage) can be confirmed in the monitor function.
(Code No. 043: Charging voltage)

Alternator defective troubleshooting.

1
(short generating output) E08 (male) Engine rotation Voltage
Between C and grounding Above medium speed 27.5 – 29.5 V
Wiring harness from P02 (female) A to J02 to J21 to E08
(female) C
Resistance
tor) value
harness
3 Between wiring harness between P02 (female) A, J02,
J21, and E08 (female) C or between D01 (female) 6 and
value
J02 (male) A and grounding
P02 Engine rotation Voltage
Between A and grounding Above medium speed 27.5 – 29.5 V
20-376 PC1250-7
TROUBLESHOOTING AB00KE
Electric circuit diagram related to charging voltage
PC1250-7 20-377
TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System B@BAZG (Abnormally lowered engine oil pres-
sure)
User Code Error Code Failure Code Failure Abnormally lowered of engine oil pressure
— — B@BAZG phenomenon (in mechanical system)
• The engine oil pressure lowers below the lower limit of the engine oil pressure while the engine is run-
Failure content
ning.
Response from
• The controller limits the fuel injection rate to 50% after 10 seconds.
controller
Phenomenon
occurring on • If the engine is used without repairing the fault, it may be seized.
machine
• If the engine oil pressure caution symbol is displayed on the monitor panel while the engine is running,
Relative this failure code is saved.
information • Input condition of engine oil pressure (pressure) can be checked in the monitoring function.
(Code 372: Engine oil pressure)

Engine oil pressure low-

1 ered (System in normal ★Perform troubleshooting for Error code [C143].
condition)
Engine oil pressure sen-
sor system defective
2 ★Perform troubleshooting for Error codes [C135] and [C141].
(Engine controller sys-
tem)
20-378 PC1250-7
TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System B@BAZK (Abnormally lowered engine oil level)
User Code Error Code Failure Code Failure Engine oil level abnormally lowered
— — B@BAZK phenomenon (in mechanical system)
• The signal circuit in the engine oil level switch was opened (i.e. disconnected from grounding), when the
Failure content
engine is stopped (with the starting switch in the ON position).
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine seizes if it is kept running without a corrective action.
machine
• This Failure Code is recorded if the engine oil level caution symbol is displayed, when the engine is
Relative stopped (with the starting key in the ON position).
information • Input from the engine oil level switch (ON or OFF) can be confirmed in the monitor function. (Code No.
046: Monitor input 2)

Engine oil level lowered
★Check the engine oil level, and refill oil.
1 (System in normal condi-

(If the phenomenon occurs frequently, check the cause)
tion)
Engine oil level switch
2 defective 0LV (male) Engine oil level Resistance value
When lowered Min. 1 MΩ
Wiring harness between P02 (female) 8 and 0LV (female) Resistance
tor) 1 value
4 Monitor panel defective P02 Engine oil pressure Voltage
When lowered 20 – 30 V
Electrical Circuit Diagram for Engine Oil Level Switch in Monitor Panel
PC1250-7 20-379
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System B@BCNS (Overheating of engine water)
User Code Error Code Failure Code Failure Overheating of engine water
— — B@BCNS phenomenon (in mechanical system)
Failure content • Engine water temperature sensor input temperature of 105°C or higher while the engine is running.
Response from • The controller run the engine at low idling.
controller • The controller limits the fuel injection rate to 50% after 10 seconds.
Phenomenon
occurring on • If the engine is used without repairing the fault, it may be seized.
machine
• If the engine water temperature gauge enters the red range on the monitor panel while the engine is
Relative running, this failure code is saved.
information • Input condition of engine water temperature (temperature) can be checked in the monitoring function.
(Code 041: Engine water temperature)

Engine overheated (Sys-

1 ★Perform troubleshooting for Error code [C151].
tem in normal condition)
Engine water tempera-
ture sensor system
2 ★Perform troubleshooting for Error codes [C144] and [C145].
defective (Engine con-
troller system)
20-380 PC1250-7
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System B@BCZK (Abnormally lowered radiator water level)
User Code Error Code Failure Code Failure Radiator water level abnormally lowered
— — B@BCZK phenomenon (in mechanical system)
Failure content • The signal circuit in the radiator water level switch was opened (i.e. disconnected from grounding).
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the radiator water level caution symbol is displayed in the monitor panel,
Relative when the engine is running.
information • Input from the radiator water level switch (ON or OFF) can be confirmed in the monitor function.
(Code No. 045: Monitor input 1)

Radiator water level low-
★Check the water level and refill cooling water.
1 ered (system in normal
(If this phenomenon occurs frequently, check the cause)
condition)
Radiator water level
2 switch defective P08, P20 (male) Engine cooling water level Resistance value
Between 1 and 2
When lowered Min. 1 MΩ
harness Wiring harness between P02 (female) 3 and P20
Resistance
3 (Disconnection or defec- (female) 1 or between P20 (female) 2 and P08 (female) Max. 1 Ω
value
tive contact with connec- 1
tor) Resistance
Wiring harness between P08 (female) 2 and grounding Max. 1 Ω
value
4 Monitor panel defective P02 Engine water temperature Resistance value
When lowered 20 – 30 V
20-382 PC1250-7
TROUBLESHOOTING B@BCZK
Electrical Circuit Diagram for Radiator Water Level Switch in Monitor Panel
PC1250-7 20-383
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System B@HANS (Hydraulic oil overheating)
User Code Error Code Failure Code Failure Hydraulic oil overheated
— — B@HANS phenomenon (in mechanical system)
Failure content • The hydraulic oil temperature sensor inputted a signal of 102°C, while the engine was running.
Response from
controller
Phenomenon
occurring on • There is a possibility that the engine seizes, if it is kept running without a corrective action.
machine
• This Failure Code is recorded, if the hydraulic oil temperature gauge is displayed in the red range, when
Relative the engine is running.
information • Input from the hydraulic oil temperature sensor (temperature) can be confirmed in the monitor function.
(Code No. 044: Engine cooling water temperature)

Hydraulic oil overheat-
1 ing (system in normal ★Check the cause and damage to the hydraulic equipment, and repair it.
condition)
Hydraulic oil temperature
2 sensor defective P10 (male) Hydraulic oil temperature Resistance value
(Internal short-circuiting) Between 1 and 2 90 – 3.5kΩ
10 – 100°C
3
(Contact with grounding Between wiring harness between P02 (female) B and Resistance
P10 (female) 1 and grounding value
4 Monitor panel defective P02 (female) Engine water temperature Resistance value
Between B and C 90 – 3.5kΩ
10 – 100 °C
Between B and grounding Min. 1 MΩ
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor in Monitor Panel
20-384 PC1250-7
TROUBLESHOOTING WHEN ERROR CODE IS
DISPLAYED (CODE DISPLAY)
INFORMATION IN TROUBLESHOOTING TABLE ..................................................................................... 20-402

Error code C111 (Abnormality in engine controller memory) .................................................................... 20-404
Error code C112 (Abnormality in timing rail actuator) ............................................................................... 20-404
Error code C113 (Abnormal current in timing rail actuator system) .......................................................... 20-405
Error code C115 (Abnormality in engine speed sensor 2 systems) .......................................................... 20-406
Error code C116 (Abnormally high level in timing rail pressure sensor system) ....................................... 20-408
Error code C117 (Abnormally low level in timing rail pressure sensor system) ........................................ 20-409
Error code C118 (Abnormally high level in fuel pump pressure sensor system)....................................... 20-410
Error code C119 (Abnormally low level in fuel pump pressure sensor system) ........................................ 20-412
Error code C121 (Abnormality in engine speed sensor 1 systems) .......................................................... 20-412
Error code C122 (Abnormally high level in boost pressure sensor system) ............................................. 20-414
Error code C123 (Abnormally low level in boost pressure sensor system)............................................... 20-415
Error code C131 (Abnormally high level in throttle sensor system) .......................................................... 20-416
Error code C132 (Abnormally low level in throttle sensor system)............................................................ 20-417
Error code C135 (Abnormally high level in engine oil pressure sensor system)....................................... 20-418
Error code C141 (Abnormally low level in engine oil pressure sensor system) ........................................ 20-420
Error code C143 (Lowering of engine oil pressure) .................................................................................. 20-420
Error code C144 (Abnormally high level in engine coolant temperature sensor system) ......................... 20-421
Error code C145 (Abnormally low level in engine coolant temperature sensor system)........................... 20-423
Error code C151 (Rise of engine coolant temperature) ............................................................................ 20-423
Error code C153 (Abnormally high level in air intake temperature sensor system) .................................. 20-424
Error code C154 (Abnormally low level in air intake temperature sensor system).................................... 20-425
Error code C221 (Abnormally high level in atmospheric pressure sensor system)................................... 20-426
Error code C222 (Abnormally low level in atmospheric pressure sensor system) .................................... 20-428
Error code C234 (Over-speed) ................................................................................................................. 20-428
Error code C254 (Abnormal voltage of fuel shut-off valve) ....................................................................... 20-429
Error code C259 (Abnormality in fuel shut-off valve) ................................................................................ 20-430
Error code C261 (Abnormal rise of fuel temperature) ............................................................................... 20-430
Error code C263 (Abnormally high level in fuel temperature sensor system) ........................................... 20-431
Error code C265 (Abnormally low level in fuel temperature sensor system) ............................................ 20-432
Error code C316 (Abnormal current of fuel pump actuator) ...................................................................... 20-433
Error code C318 (Abnormality in fuel pump actuator)............................................................................... 20-434
Error code C346 (Abnormality in power-down unit of engine controller)................................................... 20-436
Error code C423 (Abnormality in in-range of timing rail pressure sensor system).................................... 20-438
Error code C441 (Abnormally low level in battery voltage system)........................................................... 20-440
Error code C442 (Abnormally high level in battery voltage system) ......................................................... 20-440
Error code C451 (Abnormally high level in fuel rail pressure sensor system)........................................... 20-441
Error code C452 (Abnormally low level in fuel rail pressure sensor system) ............................................ 20-442
Error code C455 (Abnormal current of fuel rail actuator) .......................................................................... 20-443
Error code C467 (Abnormality in timing rail actuator control) ................................................................... 20-444
Error code C468 (Abnormality in fuel rail actuator control) ....................................................................... 20-444
Error code C514 (Abnormality in fuel rail actuator) ................................................................................... 20-445
Error code C554 (Abnormality in in-range of fuel rail pressure sensor system)........................................ 20-446
PC1250-7 20-401
INFORMATION IN TROUBLESHOOTING TABLE

★ Tables and related circuit diagrams concerning troubleshooting contains the following information. Please
understand the contents sufficiently before carrying out troubleshooting.
Failure Code Error Code Failure

Phenomenon on Machine
Display on panel Display on panel Phenomenon
Failure Content State when the panel or the controller detected a failure.
Action Taken by Action to be taken for protecting systems and devices when the monitor panel or the controller detected
Panel or Controller a failure.
Failure Phenome-
Phenomenon on machine when the monitor panel or the controller took action(above).
non on Machine
Related
Information concerning to failure or troubleshooting.
Information
Cause Standard value, Remarks for Troubleshooting

<Contents>
• Standard values for judgement of possible causes.
• Remarks for judgement
1
<Phenomenon of Defective Wiring Harness>
• Disconnection
Connector is disconnected or disconnection in wiring harness
• Short circuit with ground
Possible Causes and Standard Values
Wiring harness isolated from the ground is short circuited with the ground
2 • Short circuit with power source
Harness which is not connected to power source (24 V) circuit is in contact
with power source (24 V) circuit.
• Short circuit
Possible causes of failure Independent harnesses are in contact with each other abnormally.
(The sequence number is only
3 for reference and does not state <Points to Remember at Troubleshooting>
priority.) 1) Indication of connector number and handling method of T-adapter
Unless otherwise specified, insert or connect T-adapter as follows before trou-
bleshooting:
• When (Male) or (Female) is not indicated to Connector No., disconnect the
connector and insert T-adapter in both the male side and the female side.
• When (Male) or (Female) is indicated to Connector No., disconnect the con-
nector and connect T-adapter to either of the male side or the female side.
2) Pin number and handling of tester lead wire
4 Unless otherwise specified, contact the tester (+) lead wire and (–) lead wire as
follows before troubleshooting:
• Contact the (+) lead wire to the pin of the number or the wiring harness stated
first
• Connect the (–) lead wire to the pin of the number or the wiring harness stated
at second
20-402 PC1250-7

• Arrow (⇔) : Roughly indicates the location in the machine where it is installed.
PC1250-7 20-403
TROUBLESHOOTING C111, C112
Error code C111 (Abnormality in engine controller memory)
User code Error code Failure Code Abnormality in engine controller memory
Trouble
E10 C111 C111KT (Engine controller system)
Contents of
• Memory in controller has trouble or processor in controller has communication trouble.
trouble
Action of
• Flashes caution lamp and turns on caution buzzer.
controller
Problem that
appears on • Engine cannot be started.
machine
Related
• Method of reproducing error code: Turn starting switch ON.
information
Cause Standard value in normal state/Remarks on troubleshooting

Possible causes Reset according to following procedure. If error code E is displayed at
and standard this time, engine controller is defective.
value in normal 1 Defective engine controller 1) Keep starting switch at OFF position for 5 seconds.
state 2) Run engine at low idling.
3) Check error code.
Error code C112 (Abnormality in timing rail actuator)
User code Error code Failure Code Abnormality in timing rail actuator
Trouble
E11 C112 C112LK (Engine controller system)
• Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of
• Judgment value (for reference):
trouble
Error is above 400 mm3/st or below –750 mm3/st (When water temperature is below 0°C).
Action of • Flashes caution lamp and turns on caution buzzer.
controller • Limits engine speed to 1,500 rpm.
Problem that
appears on • Engine speed lowers.
machine
Related
• Method of reproducing error code: Start engine.
information

Check displayed error codes. If code related to engine controller is
1 Defective related systems
displayed, carry out troubleshooting for it first.
Clogging, looseness, break-
Check fuel filter/piping directly for clogging, looseness, breakage, and
Possible causes 2 age, or leakage of fuel filter/
leakage.
and standard piping
value in normal 3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
state Clogging of timing rail actu-
4 Check timing rail actuator screen directly for clogging.
ator screen
5 Breakage of injector O-ring Check injector O-ring directly for breakage.
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller
(Since trouble is in system, troubleshooting cannot be carried out.)
20-404 PC1250-7
TROUBLESHOOTING C113
Error code C113 (Abnormal current in timing rail actuator system)
User code Error code Failure Code Abnormal current in timing rail actuator system
Trouble
E11 C113 C113KZ (Engine controller system)
Contents of • Current in timing rail actuator is out of normal range.
trouble • Normal range (for reference): 0.40 ± 0.35 A (When engine is stopped)
Action of
controller
Problem that
• Engine output lowers.
appears on
• Exhaust gas becomes white.
machine
Related • Special cable (795-799-5470) is necessary for troubleshooting for timing rail actuator.
information • Method of reproducing error code: Turn starting switch ON (or start engine).

★Prepare with starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective timing rail actuator TIMG (male) Resistance value
1
Between A – C
(Internal trouble)
7–9Ω
Between A, C – chassis ground Min. 100 kΩ
Disconnection in wiring har- turning starting switch ON.
ness
Wiring harness between ECMA (female) 1 –
TIMG (female) A
Resistance
2 (Disconnection in wiring or Max. 10 Ω
value
defective contact in connec-
Wiring harness between ECMA (female) J –
TIMG (female) C
tor) Resistance
Max. 10 Ω
Possible causes value
and standard ★Prepare with starting switch OFF, then carry out troubleshooting without
value in normal turning starting switch ON.
state
(female) 1 – TIMG (female) A with wiring har-

Short circuit in wiring har- Short circuit of wiring harness between ECMA
Resistance
ness Min. 1 MΩ
3 value
(with another wiring harness around it
ness)
(female) J – TIMG (female) C with wiring har-
Short circuit of wiring harness between ECMA
Resistance
Min. 1 MΩ
value
ness around it
ECMA (female) Resistance value
Between 1 – J 7–9Ω
Wiring harness between 1, J –
Min. 1 MΩ
wiring harness around it
Circuit diagram related to timing rail actuator
PC1250-7 20-405
Error code C115 (Abnormality in engine speed sensor 2 systems)
User code Error code Failure Code Abnormality in engine speed sensor 2 systems
Trouble
Contents of
• Signal is not input to either of engine speed sensor circuit 2 systems.
trouble
controller • Outputs speed signal of 0 rpm.
Problem that
appears on • Engine stops.
machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related (Code 010: Engine speed)
information • Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.

★Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
SP1 (male), SP2 (male) Resistance value
Between A – B
Defective engine speed
1 sensor 1 k – 2 kΩ
(Internal trouble) Between A – A Max. 10 Ω
Between B – B Max. 10 Ω
Between A – chassis ground Min. 10 MΩ
Damage of engine speed
2 Check engine speed sensor directly.
sensor
Wiring harness between ECMA (female) Q –
SP1 (female) A
Resistance
Disconnection in wiring har- Max. 10 Ω
value
ness
Wiring harness between ECMA (female) R –
SP1 (female) B
Resistance
value
Wiring harness between ECMA (female) [ –
SP2 (female) A
Resistance
tor) Max. 10 Ω
value
Wiring harness between ECMA (female) \ –
SP2 (female) B
Resistance
Possible causes Max. 10 Ω
and standard value
value in normal ★Prepare with starting switch OFF, then carry out troubleshooting with-
state out turning starting switch ON.
(female) Q – SP1 (female) A with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
(female) R – SP1 (female) B with wiring har-

Resistance
ness Min. 1 MΩ
4 value
ness)
(female) [ – SP2 (female) A with wiring har-
Resistance
Min. 1 MΩ
value
ness around it
(female) \ – SP2 (female) B with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
★Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
5 Defective engine controller Between Q – R 1 k – 2 kΩ
Between Q, R – chassis ground Min. 1 MΩ
Between [ – \ 1 k – 2 kΩ
Between [, \ – chassis ground Min. 1 MΩ
20-406 PC1250-7
Circuit diagram related to engine speed sensor
PC1250-7 20-407
Error code C116 (Abnormally high level in timing rail pressure sensor system)
User code Error code Failure Code Abnormally high level in timing rail pressure sensor system
Trouble
E11 C116 C116KX (Engine controller system)
Contents of
• Signal voltage of timing rail pressure sensor circuit is above 4.78 V.
trouble
Action of
• Opens and controls timing rail.
controller
• Limits engine speed to 1,500 rpm.
Problem that
• Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on
1,500 rpm.
machine
Related • Special cable (795-799-5460) is necessary for troubleshooting for timing rail pressure sensor.
information • Method of reproducing error code: Start engine.

★Prepare with starting switch OFF, then turn starting switch ON and carry
out troubleshooting.
Defective timing rail pres-
1 sure sensor TIMG Voltage
(Internal trouble) Between A – B 4.75 – 5.25 V
Between C – B 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) 5 –
TPR (female) A
Resistance
ness Max. 10 Ω
value
2 (Disconnection in wiring or
Wiring harness between ECMA (female) H –
TPR (female) B
Resistance
defective contact in connec- Max. 10 Ω
tor) value
Wiring harness between ECMA (female) W –
TPR (female) C
Resistance
Max. 10 Ω
state
(female) 5 – TPR (female) A with wiring har-

Resistance
Min. 1 MΩ
Short circuit in wiring har- value
ness around it
ness
3
(female) H – TPR (female) B with wiring har-
(with another wiring har- Short circuit of wiring harness between ECMA
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) W – TPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
4 Defective engine controller ECMA Voltage
Between 5 – H 4.75 – 5.25 V
Between W – H 0.42 – 0.58 V
20-408 PC1250-7
Circuit diagram related to engine speed sensor
Error code C117 (Abnormally low level in timing rail pressure sensor system)
User code Error code Failure Code Abnormally low level in timing rail pressure sensor system
Trouble
Contents of
• Signal voltage of timing rail pressure sensor circuit is below 0.30 V.
trouble
Action of
• Opens and controls timing rail.
controller
• Limits engine speed to 1,500 rpm.
Problem that
• Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
appears on
1,500 rpm.
machine
Related
information
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for error code [C116].
state
PC1250-7 20-409
Error code C118 (Abnormally high level in fuel pump pressure sensor system)
User code Error code Failure Code Abnormally high level in fuel pump pressure sensor system
Trouble
Contents of
• Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.
trouble
controller • Opens and controls fuel pump.
Problem that
appears on
machine
Related • Special cable (795-799-5460) is necessary for troubleshooting for fuel pump pressure sensor.

★Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
Defective fuel pump pres-
1 sure sensor PMPR (male) Voltage
Between C – B 0.42 – 0.58 V
Disconnection in wiring har- Wiring harness between ECMA (female) 5 – Resistance
PMPR (female) A
ness Max. 10 Ω
value
Wiring harness between ECMA (female) H – Resistance
PMPR (female) B
tor) value
Wiring harness between ECMA (female) V – Resistance
PMPR (female) C
Max. 10 Ω
and standard ★Prepare with starting switch OFF, then carry out troubleshooting with-
value in normal out turning starting switch ON.
state
ECMA (female) 5 – PMPR (female) A with
Short circuit of wiring harness between
Resistance
Min. 1 MΩ
ness
3
ECMA (female) H – PMPR (female) B with
(with another wiring har- Short circuit of wiring harness between
Resistance
ness) Min. 1 MΩ
value
ECMA (female) V – PMPR (female) C with

Short circuit of wiring harness between
Resistance
Min. 1 MΩ
value
★Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
4 Defective engine controller ECMA (female) Resistance value
Between 5 – H 4.75 – 5.25 V
Between V – H 0.42 – 0.58 V
20-410 PC1250-7
Circuit diagram related to fuel pump pressure sensor
PC1250-7 20-411
Error code C119 (Abnormally low level in fuel pump pressure sensor system)
User code Error code Failure Code Abnormally low level in fuel pump pressure sensor system
Trouble
Contents of
• Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.
trouble
controller • Opens and controls fuel pump.
Problem that
appears on
machine
Related
information

and standard
state
Error code C121 (Abnormality in engine speed sensor 1 systems)
User code Error code Failure Code Abnormality in engine speed sensor 1 systems
Trouble
E15 C121 C121LC (Engine controller system)
Contents of
• Signal is not input to both of engine speed sensor circuit 2 systems.
trouble
Action of
controller
Problem that
appears on
machine
• Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
Related
(Code 010: Engine speed)
information

and standard
state
20-412 PC1250-7
Error code C122 (Abnormally high level in boost pressure sensor system)
User code Error code Failure Code Abnormally high level in boost pressure sensor system
Trouble
Contents of
• Signal voltage of boost pressure sensor circuit is above 4.72 V.
trouble
Action of
controller
Problem that
• When machine is accelerated sharply, exhaust gas color is bad.
appears on
• Engine output rises.
machine
Related • Special cable (799-795-5480) is necessary for troubleshooting for boost pressure sensor.

Defective boost pressure
1 sensor IMPR (male) Voltage
Between C – B 0.42 – 0.58 V
IMPR (female) A
Resistance
ness Max. 10 Ω
value
Wiring harness between ECMA (female) G –
IMPR (female) B
Resistance
tor) value
Wiring harness between ECMA (female) Y –
IMPR (female) C
Resistance
Max. 10 Ω
state
(female) 6 – IMPR (female) A with wiring har-
Resistance
Min. 1 MΩ
ness around it
ness
3
(female) G – IMPR (female) B with wiring har-
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) Y – IMPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
Between 6 – G 4.75 – 5.25 V
Between Y – G 0.42 – 0.58 V
20-414 PC1250-7
Circuit diagram related to boost pressure sensor
Error code C123 (Abnormally low level in boost pressure sensor system)
User code Error code Failure Code Abnormally low level in boost pressure sensor system
Trouble
Contents of
• Signal voltage of boost pressure sensor circuit is below 0.30 V.
trouble
Action of
controller
Problem that
appears on • Engine output lowers.
machine
Related
information

and standard
state
PC1250-7 20-415
Error code C131 (Abnormally high level in throttle sensor system)
User code Error code Failure Code Abnormally high level in throttle sensor system
Trouble
Contents of
• Signal voltage of throttle sensor circuit is above 4.80 V.
trouble
controller • Keeps engine speed at constant level.
Problem that
appears on • Engine output and speed rise suddenly.
machine
• Input of the throttle sensor to the engine controller (Voltage) can be checked in the monitoring mode.
Related
(Code 030: Thorottle sensor voltage)
information

Defective thorottle sensor E06 (male) Resistance value

1
(Internal trouble) Between 1 – 3 4.0 – 6.0 kΩ
Between 1 – 2 0.25 – 7.0 kΩ
Between 2 – 3 0.25 – 7.0 kΩ
Disconnection in wiring har- Wiring harness between ECMB (female) P – Resistance
ness Max. 10 Ω
E06 (female) 1 value
Wiring harness between ECMB (female) A – Resistance
tor) E06 (female) 3 value
Possible causes Wiring harness between ECMB (female) S – Resistance
and standard Max. 10 Ω
E06 (female) 2 value
value in normal
state ★Prepare with starting switch OFF, then carry out troubleshooting without
Short circuit of wiring harness between ECMB
Resistance
(female) P – E06 (female) 1 with wiring har- Min. 1 MΩ
ness around it
ness
3 Short circuit of wiring harness between ECMB
(with another wiring har- Resistance
ness) (female) A – E06 (female) 3 with wiring har- Min. 1 MΩ
value
ness around it
Short circuit of wiring harness between ECMB
Resistance
(female) S – E06 (female) 2 with wiring har- Min. 1 MΩ
value
ness around it
ECMB Voltage
Between S – A 0.30 – 4.80 V
20-416 PC1250-7
Circuit diagram related to throttle sensor
Error code C132 (Abnormally low level in throttle sensor system)
User code Error code Failure Code Abnormally low level in throttle sensor system
Trouble
Contents of
• Signal voltage of throttle sensor circuit is below 0.30 V.
trouble
controller • Keeps engine speed at constant level.
Problem that
appears on • Engine speed and output lower suddenly.
machine
• Input of the throttle sensor to the engine controller (Voltage) can be checked in the monitoring mode.
Related
(Code 030: Thorottle sensor voltage)
information

and standard
state
PC1250-7 20-417
Error code C135 (Abnormally high level in engine oil pressure sensor system)
User code Error code Failure Code Abnormally high level in engine oil pressure sensor system
Trouble
Contents of
• Signal voltage of engine oil pressure sensor circuit is above 4.88 V.
trouble
Action of
controller
Problem that
appears on
machine
Related • Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.

Defective engine oil pres-
1 sure sensor OLPR Voltage
Between C – B 0.42 – 0.58 V
OLPR (female) A
Resistance
ness Max. 10 Ω
value
OLPR (female) B
Resistance
tor) value
Wiring harness between ECMA (female) N –
OLPR (female) C
Resistance
Max. 10 Ω
and standard ★Prepare with starting switch OFF, then carry out troubleshooting with-
value in normal out turning starting switch ON.
state
(female) 6 – OLPR (female) A with wiring har-
Resistance
Min. 1 MΩ
ness around it
ness
3
(female) G – OLPR (female) B with wiring har-
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) N – OLPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
Between 6 – G 4.75 – 5.25 V
Between N – G 0.42 – 0.58 V
20-418 PC1250-7
Circuit diagram related to engine oil pressure sensor
PC1250-7 20-419
Error code C141 (Abnormally low level in engine oil pressure sensor system)
User code Error code Failure Code Abnormally low level in engine oil pressure sensor system
Trouble
Contents of
• Signal voltage of engine oil pressure sensor circuit is below 0.31 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
Error code C143 (Lowering of engine oil pressure)
User code Error code Failure Code Lowering of engine oil pressure
Trouble
E15 C143 C143ZG (Engine controller system)
• Engine oil pressure sensor detected pressure lower than pressure set in controller.
• Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Contents of Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
trouble Max. 0.15 MPa {1.5 kg/cm2} at 1,500 rpm
Max. 0.18 MPa {1.85 kg/cm2} at 1,800 rpm
Max. 0.21 MPa {2.1 kg/cm2} at 2,000 rpm
Action of
• Limits fuel injection rate to 50% after 10 seconds.
controller
Problem that
appears on
machine
Related
information

Possible causes Check displayed error codes. If code related to engine controller is dis-
and standard played, carry out troubleshooting for it first.
value in normal Defective engine oil pres-
state 2 Carry out troubleshooting for error codes [C135] and [C141].
sure sensor system
3 Defective engine See Shop Manual for engine (170-3 Series).
20-420 PC1250-7
Error code C 144 (Abnormally high level in engine coolant temperature sensor sys-
tem)
User code Error code Failure Code Abnormally high level in engine coolant temperature sensor
Trouble system
Contents of
• Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.
trouble
Action of
controller
Problem that
appears on
machine
Related • Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor.

Defective engine coolant out turning starting switch ON.
1 temperature sensor
CLTP Resistance value
Between A – B
(Internal trouble)
36 – 600 Ω
Disconnection in wiring har- out turning starting switch ON.
ness
Wiring harness between ECMA (female) L –
CLTP (female) A
Resistance
value
CLTP (female) B
tor) Resistance
value
and standard
value in normal ★Prepare with starting switch OFF, then carry out troubleshooting with-
state out turning starting switch ON.
(female) L – CLTP (female) A with wiring har-

Resistance
ness Min. 1 MΩ
3 value
ness)
(female) G – CLTP (female) B with wiring har-
Resistance
Min. 1 MΩ
value
ness around it
Between L – G 36 – 600 Ω
PC1250-7 20-421
Circuit diagram related to engine coolant temperature sensor
20-422 PC1250-7
Error code C145 (Abnormally low level in engine coolant temperature sensor system)
User code Error code Failure Code Abnormally low level in engine coolant temperature sensor
Trouble system
Contents of
• Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
Error code C151 (Rise of engine coolant temperature)
User code Error code Failure Code Rise of engine coolant temperature
Trouble
E11 C151 C151NS (Engine controller system)
Contents of • Engine coolant temperature sensor detected temperature higher than temperature set in controller.
trouble • Criterion (for reference): Min. 105°C
Action of
• Limits fuel injection rate to 50% after 10 seconds.
controller
Problem that
appears on
machine
Related
information

value in normal Defective engine coolant
temperature sensor system
PC1250-7 20-423
Error code C153 (Abnormally high level in air intake temperature sensor system)
User code Error code Failure Code Abnormally high level in air intake temperature sensor
Trouble system
Contents of
• Signal voltage of air intake temperature sensor circuit is above 4.88 V.
trouble
Action of
controller
Problem that
appears on
machine
Related • Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.

Defective air intake temper- turning starting switch ON.
1 ature sensor
IMTP (female) Resistance value
Between A – B
(Internal trouble)
36 – 600 Ω
ness
Wiring harness between ECMA (female) M –
IMTP (female) A
Resistance
value
IMTP (female) B
tor) Resistance
value
and standard
value in normal ★Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
(female) M – IMTP (female) A with wiring har-

Resistance
ness Min. 1 MΩ
3 value
ness)
(female) G – IMTP (female) B with wiring har-
Resistance
Min. 1 MΩ
value
ness around it
Between M – G 36 – 600 Ω
Circuit diagram related to air intake temperature sensor
20-424 PC1250-7
Error code C154 (Abnormally low level in air intake temperature sensor system)
User code Error code Failure Code Abnormally low level in air intake temperature sensor system
Trouble
Contents of
• Signal voltage of air intake temperature sensor circuit is below 0.08 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
PC1250-7 20-425
Error code C221 (Abnormally high level in atmospheric pressure sensor system)
User code Error code Failure Code Abnormally high level in atmospheric pressure sensor
Trouble system
Contents of
• Signal voltage of atmospheric pressure sensor circuit is above 4.78 V.
trouble
Action of
controller
Problem that
appears on
machine
Related • Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
information • Method of reproducing error code: Turn starting switch ON.

Defective atmospheric pres-
1 sure sensor AAPR Voltage
Between C – B 0.42 – 0.58 V
AAPR (female) A
Resistance
ness Max. 10 Ω
value
AAPR (female) B
Resistance
tor) value
Wiring harness between ECMA (female) X –
AAPR (female) C
Resistance
Max. 10 Ω
state
(female) 6 – AAPR (female) A with wiring har-
Resistance
Min. 1 MΩ
ness around it
ness
3
(female) G – AAPR (female) B with wiring har-
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) X – AAPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
Between 6 – G 4.75 – 5.25 V
Between X – G 0.42 – 0.58 V
20-426 PC1250-7
Circuit diagram related to atmospheric pressure sensor
PC1250-7 20-427
Error code C222 (Abnormally low level in atmospheric pressure sensor system)
User code Error code Failure Code Abnormally low level in atmospheric pressure sensor system
Trouble
Contents of
• Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
Error code C234 (Over-speed)
User code Error code Failure Code Over-speed

Trouble
E11 C234 C234NI (Engine controller system)
Contents of • Engine speed sensor detected speed higher than speed set in controller.
trouble • Criterion (for reference): Min. 2,400 rpm
Action of
• Closes fuel rail actuator fully (Cuts out fuel).
controller
Problem that
appears on
machine
Related
information

and standard Check displayed error codes. If code related to engine controller is dis-
value in normal played, carry out troubleshooting for it first.
state 2 Defective engine See Shop Manual for engine (170-3 Series).
20-428 PC1250-7
Error code C254 (Abnormal voltage of fuel shut-off valve)
User code Error code Failure Code Abnormal voltage of fuel shut-off valve
Trouble
Contents of
• Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 Ω).
trouble
Action of
• Turns off power for fuel shut-off valve.
controller
Problem that
appears on • Engine stops.
machine
Related
information

Defective fuel shut-off valve FSO (Valve side) Resistance value
1
(Internal trouble)
Between (+) – (–) 23 – 40 Ω
Between (+) – chassis ground 100 kΩ
Disconnection in wiring har- out turning starting switch ON.
ness
Wiring harness between ECMA (female) T – Resistance
FSO (wiring harness side) (+) value
Possible causes tor) Wiring harness between FSO (wiring harness Resistance
and standard Max. 10 Ω
side) (–) – chassis ground value
value in normal
state
Resistance
ness (female) T – FSO (wiring harness side) (+) with Min. 1 MΩ
3 value
(with another wiring har- wiring harness around it
ness) Short circuit of wiring harness between FSO
Resistance
(wiring harness side) (–) – chassis ground with Min. 1 MΩ
value
ECMA Resistance value
Between T – chassis ground 23 – 40 Ω
Circuit diagram related to fuel shut-off valve
PC1250-7 20-429
Error code C259 (Abnormality in fuel shut-off valve)
User code Error code Failure Code Abnormality in fuel shut-off valve
Trouble
E11 C259 C259FS (Engine controller system)
Contents of
• Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).
trouble
controller • Turns off power for fuel shut-off valve.
Problem that
appears on • Engine cannot be stopped.
machine
Related
information

Check displayed error codes. If code related to engine controller is dis-
played, carry out troubleshooting for it first.
Possible causes 2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
and standard Clogging, looseness, break-
value in normal Check fuel filter/piping directly for clogging, looseness, breakage, and
3 age, or leakage of fuel filter/
state leakage.
piping
4 Trouble in injector Check inside of injector directly.
Error code C261 (Abnormal rise of fuel temperature)
User code Error code Failure Code Abnormal rise of fuel temperature
Trouble
E11 C261 C261NS (Engine controller system)
Contents of • Fuel temperature sensor detected temperature higher than temperature set in controller.
trouble • Criterion (for reference): Min. 76°C
Action of
• Limits engine speed to 800 rpm after 30 seconds.
controller
Problem that
appears on
machine
Related
information

value in normal Defective fuel temperature
sensor system
20-430 PC1250-7
Error code C263 (Abnormally high level in fuel temperature sensor system)
User code Error code Failure Code Abnormally high level in fuel temperature sensor system
Trouble
Contents of
• Signal voltage of fuel temperature sensor circuit is above 4.95 V.
trouble
Action of
controller
Problem that
appears on
machine
Related • Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.

Defective fuel temperature turning starting switch ON.
1 sensor
FLTP (female) Resistance value
Between A – B
(Internal trouble)
36 – 600 kΩ
ness
Wiring harness between ECMA (female) P –
FLTP (female) A
Resistance
value
FLTP (female) B
tor) Resistance
value
and standard
value in normal ★Prepare with starting switch OFF, then carry out troubleshooting without
state turning starting switch ON.
(female) P – FLTP (female) A with wiring har-

Resistance
ness Min. 1 MΩ
3 value
ness)
(female) G – FLTP (female) B with wiring har-
Resistance
Min. 1 MΩ
value
ness around it
Between P – G 36 – 600 kΩ
Circuit diagram related to fuel temperature sensor
PC1250-7 20-431
Error code C265 (Abnormally low level in fuel temperature sensor system)
User code Error code Failure Code Abnormally low level in fuel temperature sensor system
Trouble
Contents of
• Signal voltage of fuel temperature sensor circuit is below 0.21 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
20-432 PC1250-7
Error code C316 (Abnormal current of fuel pump actuator)
User code Error code Failure Code Abnormal current of fuel pump actuator
Trouble
Contents of • Current of fuel pump actuator circuit is out of normal range.
Action of
controller
Problem that
appears on
machine
Related • Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.

Defective fuel pump actua-
1 tor PUMP (male) Resistance value
(Internal trouble) Between A – C 7–9Ω
ness
Wiring harness between ECMA (female) A –
PUMP (female) A
Resistance
value
Wiring harness between ECMA (female) ^ –
PUMP (female) C
tor) Resistance
Max. 10 Ω
state
(female) A – PUMP (female) A with wiring har-

Resistance
ness Min. 1 MΩ
3 value
ness)
(female) ^ – PUMP (female) C with wiring har-
Resistance
Min. 1 MΩ
value
ness around it
Between A – ^ 7–9Ω
Between A, ^ – another wiring
Min. 1 MΩ
harness
Circuit diagram related to fuel pump actuator
PC1250-7 20-433
Error code C318 (Abnormality in fuel pump actuator)
User code Error code Failure Code Abnormality in fuel pump actuator
Trouble
Contents of • Displayed pressure of fuel pump is excessively different from actual value.
trouble • Criteria for difference (for reference): ±0.21 MPa {2.1 kg/cm2} (when water temperature is 38°C)
Action of
controller
Problem that
appears on • Engine speed is unstable.
machine
Related
information

Check displayed error codes. If code related to engine controller is
displayed, carry out troubleshooting for it first.
Check fuel filter/piping directly for clogging, looseness, breakage,
2 age, or leakage of fuel filter/
and leakage.
piping
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel
3
fuel level in tank level gauge is in red range, supply fuel.
Possible causes
and standard Suction resistance of fuel filter may be large. Check fuel filter directly.
Large suction resistance of
value in normal 4 Negative suction pressure
fuel filter –27 kPa {–203 mmHg}
state (Tank side)
Trouble in fuel pump actua-
5 Fuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of
6 Carry out troubleshooting for error codes [C118] and [C119].
fuel pump pressure sensor
7 Trouble in injector Inside of injector may be defective. Check it directly.
When the filter is new, this value is –13.6 kPa {–102 mmHg}.
20-434 PC1250-7
Error code C346 (Abnormality in power-down unit of engine controller)
User code Error code Failure Code Abnormality in power-down unit of engine controller
Trouble
E15 C346 C346KT (Engine controller system)
Contents of
• Data recorded in power-down unit of engine controller has error.
trouble
Action of
controller
Problem that
• Power-down data (maintenance information, current controller information, engine operating hours, etc.)
appears on
are lost.
machine
• Charge level of battery (Voltage) can be checked in monitoring mode.
Related
(Code 043: Battery voltage)
information

Defective circuit breaker If circuit breaker is disconnected, circuit probably has short circuit with
1
(N03, N09) chassis ground.
Disconnection in wiring har- Wiring harness between ECMB (female) 3 and Resistance
ness Max. 10 Ω
B29 or between B19 and B23 value
Wiring harness between ECMB (female) 4, 5 Resistance
tor) and J19 (female) 1 value
Wiring harness between circuit breaker No. 3 Resistance
Max. 10 Ω
(B13) and battery relay terminal B value
Possible causes
and standard
value in normal Between wiring harness between ECMB
Resistance
state (female) 3 and B29 or between B19 and B23 Min. 1 MΩ
and wiring harness around it
ness
3 Between wiring harness between ECMB
(with another wiring har- Resistance
ness) (female) 4, 5 and J19 (female) 1 and wiring Min. 1 MΩ
value
harness around it
Wiring harness between circuit breaker N03
Resistance
(B13) – battery relay terminal B with wiring har- Min. 1 MΩ
value
ness around it
4 Defective engine controller ECMA, ECMB Voltage
Between ECMB 3, 4, 5
17.3 – 34.7 V
– ECMA 7, 8
20-436 PC1250-7
Circuit diagram related to engine controller power supply
PC1250-7 20-437
Error code C423 (Abnormality in in-range of timing rail pressure sensor system)
User code Error code Failure Code Abnormality in in-range of timing rail pressure sensor system
Trouble
E11 C423 C423L6 (Engine controller system)
Contents of • Timing rail pressure sensor detected abnormal pressure.
trouble • Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
controller • Limits high idling speed to 1,500 rpm.
Problem that
appears on
machine
Related • Special cable (799-795-5460) is necessary for troubleshooting for timing rail pressure sensor.

Defective timing rail pres-
1 sure sensor TPR (male) Voltage
Between C – B 0.42 – 0.58 V
TPR (female) A
Resistance
ness Max. 10 Ω
value
TPR (female) B
Resistance
tor) value
Wiring harness between ECMA (female) W –
TPR (female) C
Resistance
Max. 10 Ω
value
Possible causes
and standard
(female) 5 – TPR (female) A with wiring har-

value in normal Short circuit of wiring harness between ECMA
Resistance
state Min. 1 MΩ
ness around it
ness
3
(female) H – TPR (female) B with wiring har-
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) W – TPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
4 Negative suction pressure
fuel filter 27 kPa {203 mmHg}
(Tank side)
5 Defective engine controller ECMA (female) Resistance value
Between 5 – H 4.75 – 5.25 V
Between W – H 0.42 – 0.58 V
20-438 PC1250-7
Circuit diagram related to timing rail pressure sensor
PC1250-7 20-439
Error code C441 (Abnormally low level in battery voltage system)
User code Error code Failure Code Abnormally low level in battery voltage system
Trouble
E15 C441 C441KK (Engine controller system)
Contents of
• Voltage of controller power supply circuit is below 12 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
Error code C442 (Abnormally high level in battery voltage system)
User code Error code Failure Code Abnormally high level in battery voltage system
Trouble
E15 C442 C442KG (Engine controller system)
Contents of
• Voltage of controller power supply circuit is below 38 V.
trouble
Action of
controller
Problem that
appears on
machine
Related
information

and standard
state
20-440 PC1250-7
Error code C451 (Abnormally high level in fuel rail pressure sensor system)
User code Error code Failure Code Abnormally high level in fuel rail pressure sensor system
Trouble
Contents of
• Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.
trouble
controller • Opens and controls fuel rail.
Problem that
appears on
machine
Related • Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.

Defective fuel rail pressure
1 sensor RPR Voltage
Between C – B 0.42 – 0.58 V
RPR (female) A
Resistance
ness Max. 10 Ω
value
RPR (female) B
Resistance
tor) value
Wiring harness between ECMA (female) U –
RPR (female) C
Resistance
Max. 10 Ω
state
(female) 5 – RPR (female) A with wiring har-
Resistance
Min. 1 MΩ
ness around it
ness
3
(female) H – RPR (female) B with wiring har-
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) U – RPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
Between 5 – H 4.75 – 5.25 V
Between U – H 0.42 – 0.58 V
PC1250-7 20-441
Circuit diagram related to fuel rail pressure sensor
Error code C452 (Abnormally low level in fuel rail pressure sensor system)
User code Error code Failure Code Abnormally low level in fuel rail pressure sensor system
Trouble
Contents of
• Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.
trouble
controller • Reduces current for fuel rail actuator to 0 A.
Problem that
appears on
machine
Related
information

and standard
state
20-442 PC1250-7
Error code C455 (Abnormal current of fuel rail actuator)
User code Error code Failure Code Abnormal current of fuel rail actuator
Trouble
Contents of • Current of fuel rail actuator circuit is out of normal range.
Problem that
appears on
machine
Related • Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
information • Method of reproducing error code: Turn starting switch ON or start engine.

Defective fuel rail actuator RAIL (male) Resistance value
1
Between A – C
(Internal trouble)
7–9Ω
ness
Wiring harness between ECMA (female) 3 –
RAIL (female) A
Resistance
value
Wiring harness between ECMA (female) @ –
RAIL (female) C
tor) Resistance
Max. 10 Ω
state
(female) 3 – RAIL (female) A with wiring har-

Resistance
ness Min. 1 MΩ
3 value
ness)
(female) @ – RAIL (female) C with wiring har-
Resistance
Min. 1 MΩ
value
ness around it
Between 3 – @ 7–9Ω
Between 3, @ – another wiring
Min. 1 MΩ
harness
Circuit diagram related to fuel rail actuator
PC1250-7 20-443
Error code C467 (Abnormality in timing rail actuator control)
User code Error code Failure Code Abnormality in timing rail actuator control
Trouble
Contents of • Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot
trouble be obtained.
Problem that
appears on
machine
Related
information

and standard
state
Error code C468 (Abnormality in fuel rail actuator control)
User code Error code Failure Code Abnormality in fuel rail actuator control
Trouble
Contents of • Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
trouble obtained.
controller • Limits maximum injection rate to 217 mm3/st.
Problem that
appears on
machine
Related
information

Check displayed error codes. If code related to engine controller is dis-
played, carry out troubleshooting for it first.
Check fuel filter/piping directly for clogging, looseness, breakage, and
Possible causes 2 age, or leakage of fuel filter/
leakage.
and standard piping
value in normal 3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
state Clogging of fuel rail actuator
4 Fuel rail actuator screen may be clogged. Check it directly.
screen
5 Breakage of injector O-ring Injector O-ring may be broken. Check it directly.
20-444 PC1250-7
Error code C514 (Abnormality in fuel rail actuator)
User code Error code Failure Code Abnormality in fuel rail actuator
Trouble
Contents of • Displayed injection rate of fuel rail is excessively different from actual injection rate.
trouble • Criterion (for reference): Difference is ±600 mm3/st for ±50 msec or ±250 mm3/st for ±200 msec.
Problem that
appears on
machine
Related
information

and standard
state
PC1250-7 20-445
Error code C554 (Abnormality in in-range of fuel rail pressure sensor system)
User code Error code Failure Code Abnormality in in-range of fuel rail pressure sensor system
Trouble
E11 C554 C554L6 (Engine controller system)
Contents of • Fuel rail pressure sensor detected abnormal pressure.
trouble • Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
Problem that
appears on
machine
Related • Special cable (799-795-5460) is necessary for troubleshooting for fuel rail pressure sensor.

Defective fuel rail pressure
1 sensor RPR Voltage
Between C – B 0.42 – 0.58 V
RPR (female) A
Resistance
ness Max. 10 Ω
value
RPR (female) B
Resistance
tor) value
Wiring harness between ECMA (female) U –
RPR (female) C
Resistance
Max. 10 Ω
value
Possible causes
and standard
(female) 5 – RPR (female) A with wiring har-

value in normal Short circuit of wiring harness between ECMA
Resistance
state Min. 1 MΩ
ness around it
ness
3
(female) H – RPR (female) B with wiring har-
Resistance
ness) Min. 1 MΩ
value
ness around it
(female) U – RPR (female) C with wiring har-

Resistance
Min. 1 MΩ
value
ness around it
Suction resistance of fuel filter may be large. Check fuel filter directly.
4 Negative suction pressure
fuel filter –27 kPa {–203 mmHg}
(Tank side)
Between 5 – H 4.75 – 5.25 V
Between U – H 0.42 – 0.58 V
When the filter is new, this value is –13.6 kPa {–102 mmHg}.
20-446 PC1250-7
Circuit diagram related to fuel rail pressure sensor
PC1250-7 20-447
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-502

E-1 Engine does not start (Engine does not rotate) .................................................................................... 20-503
E-2 Auto-decelerator does not work ........................................................................................................... 20-506
E-3 Auto engine warm-up device does not work ........................................................................................ 20-507
E-4 Preheater does not work ...................................................................................................................... 20-508
E-5 All work equipment, swing and travel do not move .............................................................................. 20-510
E-6 Machine push-up circuit does not work ................................................................................................ 20-512
E-7 Boom shockless circuit cannot be reset ............................................................................................... 20-514
E-8 No display in monitor panel at all ......................................................................................................... 20-516
E-9 Part of display on monitor panel is missing .......................................................................................... 20-517
E-10 Monitor panel displays contents irrelevant to the model .................................................................... 20-517
E-11 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-518
E-12 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-519
E-13 Fuel gauge does not display correctly ................................................................................................ 20-520
E-14 Swing lock monitor does not display correctly.................................................................................... 20-521
E-15 When the monitor switch is operated, no display appears ................................................................. 20-522
E-16 Windshield wiper does not work ......................................................................................................... 20-523
E-17 Alarming buzzer cannot be cancelled ................................................................................................ 20-526
E-18 "Boom RAISE" is not correctly displayed in monitor function ............................................................. 20-527
E-19 "Boom LOWER" is not correctly displayed in monitor function........................................................... 20-528
E-20 "Arm DIGGING" is not correctly displayed in monitor function ........................................................... 20-529
E-21 "Arm DUMPING" is not correctly displayed in monitor function.......................................................... 20-530
E-22 "Bucket DIGGING" is not correctly displayed in monitor function....................................................... 20-531
E-23 "Bucket DUMPING" is not correctly displayed in monitor function ..................................................... 20-532
E-24 "SWING" is not correctly displayed in monitor function ...................................................................... 20-534
E-25 "TRAVEL" is not correctly displayed in monitor function .................................................................... 20-536
E-26 Air Conditioner does not work ............................................................................................................ 20-538
E-27 Travel alarm does not sound .............................................................................................................. 20-539
E-28 Any of panel lamp, head lamp, working lamp (including additional lamp) does not light up............... 20-540
PC1250-7 20-501
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

★ The following information are edited and contained in the "Information Contained in Troubleshooting Table".
You are required to proceed with troubleshooting after fully grasping the contents.
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
<Phenomena of wiring harness fault>

• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
2
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in contact
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V) is
(The attached No. for in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a connec-
4
tor and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a con-
nector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the follow-
5 ing manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.

• Arrow: Roughly indicates the location in the machine where it is installed.
20-502 PC1250-7
TROUBLESHOOTING E-1
E-1 Engine does not start (Engine does not rotate)
Failure
• The engine does not start (the engine does not rotate).
information
Relative • The following two engine start locking mechanisms are provided in the engine starting circuit.
information 1) Engine start locking by means of safety lock lever
: The multi-monitor specification machine only.
Shortage in battery Battery voltage Battery electrolyte specific gravity
1
capacity Min. 24 V Min. 1.26
Circuit breaker No. 1, If a circuit breaker is turned OFF or a fuse is broken, the circuit is probably short-circuited
2 No. 3 and No. 8, fuse with grounding.
3 defective If the monitor panel does not light up, perform troubleshooting of E-8 first.
Engine starting during the troubleshooting.
switch fault H15 (male) Position Resistance value
3
(Internal
disconnection) OFF Min. 1 MΩ
Between 1 and 4
Start Max. 1 Ω
Safety lock switch during the troubleshooting.
fault S14 (female) Lock lever Resistance value

4
(Internal
short-circuiting) Release Min. 1 MΩ
Between 1 and 3
LOCK Max. 1 Ω
Engine starting during the troubleshooting.
motor cut relay, R11
R11 (female) & R13 (male) Resistance value
and R13 defective
5
(Internal Between 1 and 2 100 – 500 Ω
disconnection or Between 3 and 5 Min. 1 MΩ
short-circuiting)
Between 3 and 6 Max. 1 Ω
★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
ing 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 start-
Engine starting ing motor relay is defective)
motor safety relay Engine start-
fault Safety relay Voltage
6 ing switch
(Internal
disconnection or Power source: Between B terminal and grounding 20 – 30 V
short-circuiting) Generation signal: Between terminal R and ST1 2, ST2 2 Max. 12 V
Start
Starting input: Between terminal S and ST1 1, ST2 1 20 – 30 V
Engine start output: Between C terminal and grounding 20 – 30 V
ing 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 start-
Engine starting
ing motor relay is defective)
motor fault
7 Engine start-
(Internal disconnec- Engine starting motor Voltage
tion or damage) ing switch
Power source: B terminal and grounding 20 – 30 V
Start
Engine start input: C terminal and grounding 20 – 30 V
PC1250-7 20-503
TROUBLESHOOTING E-1

★Turn the engine starting switch OFF for the preparations, and hold it in the ON position or
Alternator fault running during the troubleshooting.
8 (Internal
VHL (male) Voltage
Between C and grounding
short-circuit)
Max. 1 V
Resistance
Wiring harness between B28 and H15 (female) 1 Max. 1 Ω
value
Wiring harness from H15 (female) 4 to J01 to R11 (female) Resistance
Max. 1 Ω
5 value
Wiring harness between R11 (female) 3 and ST1, ST2 Resistance
Disconnection of wir- (female) 1 Max. 1 Ω
value
ing harness
Wiring harness between engine starting motor safety relay C Resistance
9 (Disconnection or Max. 1 Ω
defective contact terminal and engine starting motor C terminal value
Wiring harness between FB1-3 and S14 (female) 1 Max. 1 Ω
value
Resistance
Wiring harness between S14 (female) 3 and R11 (female) 1 Max. 1 Ω
value
Resistance
Wiring harness between R11 (female) 2 and R13 (female) 6 Max. 1 Ω
value
Resistance
Wiring harness from R13 (female) 3 to J04 to grounding Max. 1 Ω
value
Between wiring harness from battery relay B terminal to cir- Resistance
Min. 1 MΩ
cuit breaker No.3 and B18 value
Between wiring harness between B28 and H15 (female) 1 Resistance
Min. 1 MΩ
and grounding value
Between wiring harness from H15 (female) 4 to J01 to R11 Resistance
Min. 1 MΩ
(female) 5 and grounding value
Grounding fault of Between wiring harness between R11 (female) 3 and ST1, Resistance
wiring harness Min. 1 MΩ
10 ST2 (female) 1 and grounding value
(Contact with
grounding circuit) Between wiring harness between engine starting motor safety
Resistance
relay C terminal and engine starting motor C terminal and Min. 1 MΩ
value
grounding
Between wiring harness between FB1-3 and S14 (female) 1 Resistance
Min. 1 MΩ
and grounding value
Between wiring harness between S14 (female) 3 and R11 Resistance
Min. 1 MΩ
Between wiring harness from R13 (female) 2 to P02 Resistance
Min. 1 MΩ
(female) D and grounding value
★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
Short-circuiting of ing the troubleshooting.
wiring harness
Between wiring harness between ST1 (female) 2, ST2
(female) 2, E08 (female) C, J21, J02, D01 (female) 6, and
11
(Contact with 24 V
P02 (female) A and grounding
20-504 PC1250-7
TROUBLESHOOTING E-1
Electrical Circuit Diagram for Engine Start and Battery Charging
PC1250-7 20-505
TROUBLESHOOTING E-2
E-2 Auto-decelerator does not work
Failure
• The auto-decelerator does not work.
information
• Rotation of the auto-decelerator is set at 1,400 rpm. If the fuel dial is not set adjusting to this level, the
Relative
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 Monitoring code Item Normal display
1
fault Lever operation: ON
019 Boom RAISE
Lever NEUTRAL: OFF
Boom LOWER sig- Monitoring code Item Normal display
2
nal fault Lever operation: ON
019 Boom LOWER
Lever NEUTRAL: OFF
Arm DIGGING signal Monitoring code Item Normal display
3
019 Arm DIGGING
Lever NEUTRAL: OFF
Arm DUMPING Monitoring code Item Normal display
4
signal fault Lever operation: ON
019 Arm DUMPING
Lever NEUTRAL: OFF
Bucket DIGGING Monitoring code Item Normal display
5
021 Bucket DIGGING
Lever NEUTRAL: OFF
Bucket DUMPING Monitoring code Item Normal display
6
021 Bucket DUMPING
Lever NEUTRAL: OFF
Monitoring code Item Normal display
7 Swing signal fault
Lever operation: ON
019 Swing
Lever NEUTRAL: OFF
R.H. travel signal Monitoring code Item Normal display
8
019 R.H. travel
Lever NEUTRAL: OFF
L.H. travel signal Monitoring code Item Normal display
9
021 L.H. travel
Lever NEUTRAL: OFF
Pump controller As this is an internal failure, troubleshooting cannot be conducted. (If there is none of the
10
defective causes listed in Item 1 through 9, the controller is judged as defective.
20-506 PC1250-7
TROUBLESHOOTING E-3
E-3 Auto engine warm-up device does not work
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below 30°C,
Relative and raise the engine rotation up to 1,200 rpm.
information • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.

Presumed cause and standard
If the display on the monitor panel is not normal, proceed to No. C144 Troubleshooting.
value in normalcy
Engine cooling water Monitoring code Item Normal display

1 temperature signal Compare with the actual
fault Engine cooling water tem-
041 engine cooling water tem-
perature
perature.
As this is an internal failure, troubleshooting cannot be conducted.

Pump controller
2 (If the fault mentioned in the above item is not found, the pump controller is judged as
defective
defective)
PC1250-7 20-507
TROUBLESHOOTING E-4
E-4 Preheater does not work
Failure • Even if the preheater switch is turned to the PREHEAT position, the preheating monitor lamp does not
information (1) light up.
Relative • Input of the preheating signal (ON or OFF) can be confirmed in the monitor function.

Engine starting If preheating does not occur (the heater is not warmed up), refer to Failure Phenome-
1
switch fault non 2 below.
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
value in normalcy
ing harness tion during the troubleshooting.

2 (Disconnection or
Resistance
defective contact Wiring harness between P02 (female) H and J02 Max. 1 Ω
with connector) value
★Turn the engine starting switch OFF for the preparations.

P02 Engine starting switch Voltage
3 Monitor panel fault
OFF Max. 1 V
Between H and grounding
HEAT 20 – 30 V
Failure
• Even if the preheater switch is turned to the PREHEAT position, the preheater does not become warm.
information (2)
Relative • In low cooling water temperature (lower than 30°C), the pump controller drives the heater relay for 100
information seconds after the engine is started and automatically warms up the engine.

★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 MΩ
tion) Between 1 and 3
HEAT Max. 1 Ω
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
tion during the troubleshooting.
Heater relay fault
value in normalcy
2 (Internal disconnec- Heater relay Continuity and resistance value

tion) Between coil terminal RLS and grounding Continued
Between contact terminals Min. 1 MΩ
Electrical intake air ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
heater tion during the troubleshooting.
3
tion) Between heater terminals Normal if continuity is established.
★Turn the engine starting switch OFF for the preparations, and hold it in the OFF posi-
Disconnection of wir- tion during the troubleshooting.
ing harness
Wiring harness from H15 (female) 3 to J02 to heater Resistance
relay terminal (RLS) value
defective contact
with connector) Wiring harness between battery relay M terminal and Resistance
Max. 1 Ω
heater relay terminal RLB value
20-508 PC1250-7
TROUBLESHOOTING E-4
Electrical Circuit Diagram for Engine Preheater
PC1250-7 20-509
TROUBLESHOOTING E-5
E-5 All work equipment, swing and travel do not move
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information

1 Fuse No. 3 fault If the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
Safety switch lock during the troubleshooting.
defective S14 (female) Safety control lever Resistance value
2
tion) Lock Min. 1 MΩ
Between 1 and 2
Release Max. 1 Ω
PPC lock solenoid during the troubleshooting.
fault
3 (Internal disconnec- V08 (male) Resistance value
tion or short-circuit- Between 2 and 1 20 – 60 Ω
ing)
Assembled-type ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
diode D01 fault during the troubleshooting.
4
(Internal short-cir- D01 (male) Resistance value
cuiting) Between 4 and 8 Min. 1 MΩ
Disconnection of wir- Resistance
ing harness Wiring harness between FB1-3 outlet and S14 (male) 1 Max. 1 Ω
value
5 (Disconnection or
Resistance
defective contact Wiring harness from S14 (male) 2 to J02 to V08 (female) 2 Max. 1 Ω
Resistance
value
Grounding fault of
wiring harness Between wiring harness between FB1-3 outlet and S14 Resistance
Min. 1 MΩ
6 (Contact with (male) 1 and grounding value
grounding (GND) Wiring harness from S14 (male) 2 to J02 to V02 (female) 2,
circuit) Resistance
or between wiring harness between D01 (female) 4 and J02 Min. 1 MΩ
value
(male) H and grounding
20-510 PC1250-7
TROUBLESHOOTING E-5
Electrical Circuit Diagram for Safety Lock Solenoid
PC1250-7 20-511
TROUBLESHOOTING E-6
E-6 Machine push-up circuit does not work
Failure
• Machine push-up circuit does not work
information
Relative
—
information

1 Fuse No. 2 defective If the fuse is broken, the circuit is probably short-circuited with grounding.
Machine push-up during the troubleshooting.
switch defective M38 (female) Machine push-up switch Resistance value
2
tion) OFF Min. 1 MΩ
Between 1 and 2
ON Max. 1 Ω
solenoid defective
3 (Internal short-cir- V05 (male) Resistance value
cuiting or grounding Between 1 and 2 20 – 60 Ω
fault)
Collected diode D04 ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
defective during the troubleshooting.
4
Wiring harness dis- Resistance
connected Wiring harness between FB1-2 outlet and M38 (male) 1 Max. 1 Ω
value
5 (Disconnection or
Wiring harness between M38 (male) 2, J06, and V05 Resistance
defective contact of Max. 1 Ω
connector) (female) 2 value
Resistance
value
Grounding fault of
wiring harness Between wiring harness between FB1-2 outlet and M38 Resistance
Max. 1 Ω
grounding (GND) Between wiring harness between M38 (male) 2, J06, V05
circuit) Resistance
(female) 2, or D04 (female) 1, J06 (male) F and ground- Max. 1 Ω
value
ing
20-512 PC1250-7
TROUBLESHOOTING E-6
Electric Circuit Diagram for Machine Push-Up
PC1250-7 20-513
TROUBLESHOOTING E-7
E-7 Boom shockless circuit cannot be reset
Failure
• Boom shockless circuit cannot be reset
information
Relative
—
information

1 Fuse No. 2 defective If the fuse is broken, the circuit is probably short-circuited with grounding.
Boom shockless during the troubleshooting.
switch defective M39 (female) Boom shockless switch Resistance value
2
tion) ON Min. 1 MΩ
Between 3 and 2
OFF Max. 1 Ω
solenoid defective
3 (Internal short-cir- V09•V10 (male) Resistance value
cuiting or grounding Between 1 and 2 20 – 60 Ω
fault)
Collected diode D05 ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
defective during the troubleshooting.
4
Wiring harness dis- Resistance
connected Wiring harness between FB1-2 outlet and M39 (male) 2 Max. 1 Ω
value
5 (Disconnection or
Wiring harness between M39 (male) 3, J01, J11, and Resistance
defective contact of Max. 1 Ω
connector) V09•V10 (female) 2 value
Resistance
Wiring harness between V09•V10 (female) 1 and grounding Max. 1 Ω
value
Grounding fault of
wiring harness Between wiring harness between FB1-2 outlet and M39 Resistance
Max. 1 Ω
grounding (GND) Between wiring harness between M39 (male) 3, J01, J11,
circuit) Resistance
V09•V10 (female) 2, or D05 (female) 1, and J01 (male) I Max. 1 Ω
value
and grounding
20-514 PC1250-7
TROUBLESHOOTING E-7
Electric Circuit Diagram for Boom shockless control
PC1250-7 20-515
TROUBLESHOOTING E-8
E-8 No display in monitor panel at all
Failure
• When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
information
Relative
—
information

Circuit breaker No. If the circuit breaker disconnected, there is a big possibility that grounding fault occurred in
1
2, No. 4 fault the circuit.

Disconnection of wir- during the troubleshooting.
ing harness
Resistance
2 (Disconnection or Wiring harness from P01 (female) 1 2 to B24, B14 to B22 Max. 1 Ω
value
defect contact with
connector) Resistance
Wiring harness between P01 (female) 6 7 and grounding Max. 1 Ω
value
Grounding fault of ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
wiring harness during the troubleshooting.
3 (Contact with
grounding (GND) Between wiring harness between P01 (female) 1, 2 and Resistance
Min. 1 MΩ
circuit) B24 or between B14 and B22 and grounding value
ing the troubleshooting.
Monitor panel P01 Voltage and resistance value
4
defective
Between 1 2 and grounding Voltage: 20 – 30 V
Between 6 7 and grounding Resistance value: Max. 1 Ω
Electrical Circuit Diagram for Power Source in Monitor Panel
20-516 PC1250-7
TROUBLESHOOTING E-9, E-10
E-9 Part of display on monitor panel is missing
Failure
• Part of the display in the monitor panel is missing.
information
Relative
—
information

standard value in normalcy
Presumed cause and
If all the LCD in the monitor panel light up (i.e. the screen becomes totally white) by the
Monitor panel LCD
1 following switching operation, then the monitor panel is normal.
fault
• Switching operation: [ ] + [ A ] (simultaneous switching operation)
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
E-10 Monitor panel displays contents irrelevant to the model
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information

standard value in normalcy
Presumed cause and
Model code signal If the display on the monitor panel is normal, proceed to Service Code [E217].
1 fault Monitoring code Item Normal display
(Internal failure) 002 Controller model code 1250
Monitor panel As this is an internal failure, troubleshooting cannot be conducted. (If there is no prob-
2
defective lem with the above switching operation, the monitor panel is judged as defective)
PC1250-7 20-517
TROUBLESHOOTING E-11
E-11 Fuel level monitor red lamp lights up while engine is running
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 monitor panel, the fuel level monitor lamp lights up red.
Relative
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
information
(Code No. 042: Fuel level sensor)

Fuel level lowered
★Refill fuel.
1 (system in normal
condition)
Fuel level sensor during the troubleshooting.
fault P06 (male) Fuel level Resistance value
2
(Internal
disconnection) FULL (Upper limit) Approx. 12 Ω
EMPTY (Lower limit) 85 – 110 Ω
3 (Contact with
Wiring harness between P02 (female) 2 and P06 (female) Resistance
grounding (GND) Max. 1 Ω
circuit) 1 value
Pump controller P02 (female) Fuel level Resistance value
4
defective
FULL (Upper limit) Approx. 12 Ω
Electrical Circuit Diagram for Fuel Level Sensor
20-518 PC1250-7
E-12 Hydraulic oil temperature gauge does not display correctly
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).
Relative • Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
information (Code No. 044: Hydraulic oil temperature)

Hydraulic oil temper- during the troubleshooting.
ature sensor fault Engine cooling water
1 (Internal disconnec- P10 Resistance value
temperature
tion or short-circuit-
ing) Between 1 and 2 90 – 3.5 kΩ
10 – 100 °C
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) B and P10 (female) 1 Max. 1 Ω
value
defective contact
Wiring harness between P02 (female) C and P10 (female) 2 Max. 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) B and P10 Resistance
Min. 1 MΩ
circuit) (female) 1 and grounding value
wiring harness ing the troubleshooting.
4
(Contact with 24 V Between wiring harness between P02 (female) B and P10
Pump controller Engine cooling water

5 P02 Resistance value
defective temperature
Between B and C 90 – 3.5 kΩ
10 – 100 °C
Between B and grounding Min. 1 MΩ
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
PC1250-7 20-519
E-13 Fuel gauge does not display correctly
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).
Relative • Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
information (Code No. 042: Fuel sensor voltage)

Fuel level sensor
fault
1 (Internal disconnec- P06 (male) Fuel level Resistance value
tion or short-circuit- FULL (Upper limit) Approx. 12 Ω
ing)
Disconnection of wir- ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
ing harness during the troubleshooting.
2 (Disconnection or
Resistance
defective contact Wiring harness between P02 (female) 2 and P06 (female) 1 Max. 1 Ω
3 (Contact with
grounding (GND) Between wiring harness between P02 (female) 2 and P06 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between P02 (female) 2 and P06
Pump controller P02 Fuel level Resistance value
5
defective
FULL (Upper limit) Approx. 12 Ω
Electrical Circuit Diagram for Fuel Level Sensor
20-520 PC1250-7
E-14 Swing lock monitor does not display correctly
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.
Relative • 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-circuit- OFF Min. 1 MΩ
ing) Between 1 and 2
ON Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness from P02 (female) G to J02 to X05 (male) 1 Max. 1 Ω
value
defective contact
Wiring harness from X05 (male) 2 to J05 to grounding Max. 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness from P02 (female) G to J02 to X05 Resistance
Min. 1 MΩ
circuit) (male) 1 and grounding value
4
(Contact with 24 V Between wiring harness from P02 (female) G to J02 to X05
Monitor panel P02 Swing lock switch Voltage
5
defective
OFF 20 – 30 V
Between G and grounding
ON Max. 1 V
Electrical Circuit Diagram for Swing Lock Switch
PC1250-7 20-521
E-15 When the monitor switch is operated, no display appears
Failure
• When operating the working mode changing switch, the working mode monitor does not appear.
information (1)
Relative
—
information
Presumed Cause Standard value in normalcy and references for troubleshooting

cause and
standard value Monitor panel
1 As this is an internal failure, troubleshooting cannot be conducted.
in normalcy defective
Failure
• When operating the auto-decelerator switch, the auto-deceleration monitor does not appear.
information (2)
Relative
★If the auto-decelerator itself does not work, either, carry out No. E-2 Troubleshooting.
information

cause and
Failure
• When operating the travel speed shifting switch, the travel speed monitor does not appear.
information (3)
Relative
★If the travel speed does not actually change, carry out No. E206, E216 Troubleshooting.
information

cause and
Failure
• When operating the windshield wiper switch, the windshield wiper monitor does not appear.
information (4)
Relative
★If the windshield wiper itself does not work, either, carry out No. E-16 Troubleshooting.
information

cause 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.
Relative
—
information

cause and
20-522 PC1250-7
E-16 Windshield wiper does not work
Failure
• The windshield wiper does not work.
information
Relative • Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.

W06 (Switch side)
Lower wiper switch Resistance value
Window wiper switch (When 2 wipers are set)
fault ON Max. 1 Ω
1 (Internal disconnec- Between 1 and 2
OFF Min. 1 MΩ
tion or short-circuit-
ing) W03 (Switch side)
Front window Resistance value
(When 1 wiper is set)
When installed at front Min. 1 MΩ
Between 1 and 2
When retracted at rear Max. 1 Ω
Windshield wiper during the troubleshooting.
motor fault W05, W04 (female) Continuity and resistance value
2 (Internal disconnec-
tion or short-circuit- Between 3 and 1 Continued
ing) Between W05 1 3, W04 1 3 and

Min. 1 MΩ
grounding
ing harness Wiring harness between P01 (female) 9 and W04 (male) 3 Resistance
or between P01 (female) 0 and W05 (male) 3 value
defective contact
with connector) Wiring harness between W04 (male) 1 or between W05 Resistance
Max. 1 Ω
(male) 1 and grounding value
4 (Contact with
grounding (GND) cir- Between wiring harness between P02 (female) E and W06 Resistance
Min. 1 MΩ
cuit) (male) 1 and grounding value
P02
Lower wiper switch Voltage
(When 2 wipers are set)
ON 20 – 30 V
Monitor panel fault Between E and grounding
OFF Max. 1 V
(Lower wiper switch
system) P02
Front window Voltage
(When 1 wiper is set)
When installed at front 20 – 30 V
Between E and grounding
When retracted at rear Max. 1 V
5 ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
P02 Wiper switch Voltage
Monitor panel fault OFF Max. 3 V
(Windshield wiper When 2 wipers are set :
motor system) Between 9 and grounding 20 – 30 V
Between 0 and grounding ON When 1 wiper is set
Max. 3 V ⇔ 20 – 30 V :
(Constant cycle)
PC1250-7 20-523
Electric circuit diagram related to wiper motor (Cab with fixed front window) (When 2 wipers are set)
20-524 PC1250-7
Electric circuit diagram related to wiper motor (Cab with pull-up front window) (When 1 wiper is set)
PC1250-7 20-525
E-17 Alarming buzzer cannot be cancelled
Failure
• The alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer cancellation switch (ON or OFF) can be confirmed in the monitor function.

Alarming buzzer
cancellation switch
fault Alarming buzzer
1 P03 (female) Resistance value
(Internal disconnec- cancellation switch
tion or short-circuit- Release Min. 1 MΩ

Depress Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between P02 (female) F and P03 (male) 1 Max. 1 Ω
value
defective contact
Wiring harness from P03 (male) 2 to J05 to grounding Max. 1 Ω
value
3
(Contact with 24 V Between wiring harness between P02 (female) F and P03
Alarming buzzer
4 Monitor panel fault P02 Voltage
cancellation switch
Release 20 – 30 V
Between F and grounding
Depress Max. 1 V
Electrical Circuit Diagram for Alarming Buzzer Cancellation Switch
20-526 PC1250-7
E-18 "Boom RAISE" is not correctly displayed in monitor function
Failure
• "Boom RAISE" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Boom RAISE PPC
hydraulic switch fault
1 (Internal disconnec- S02 (male) Boom control lever Resistance value
tion or short-circuit- NEUTRAL Min. 1 MΩ
RAISE Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) 0 and S02 (female) 2 Max. 1 Ω
value
defective contact
Wiring harness between S02 (female) 1 and grounding Max. 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) 0 and S02 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) 0 and S02
Pump controller C03 Boom control lever Voltage
5
defective
NEUTRAL 20 – 30 V
RAISE Max. 1 V
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
PC1250-7 20-527
E-19 "Boom LOWER" is not correctly displayed in monitor function
Failure
• "Boom LOWER" is not correctly displayed in the monitor function on the monitor panel.
information
Relative
—
information

Boom LOWER PPC
1 (Internal disconnec- S04 (male) Boom control lever Resistance value
LOWER Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) J and S04 (female) 2 Max. 1 Ω
value
defective contact
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) J and S04 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) J and S04
Pump controller C03 Boom control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between J and grounding
LOWER Max. 1 V
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
20-528 PC1250-7
E-20 "Arm DIGGING" is not correctly displayed in monitor function
Failure
• "Arm DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Arm DIGGING PPC
1 (Internal disconnec- S05 (male) Arm control lever Resistance value
DIGGING Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) T and S05 (female) 2 Max. 1 Ω
value
defective contact
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) T and S05 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) T and S05
Pump controller C03 Arm control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between T and grounding
DIGGING Max. 1 V
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
PC1250-7 20-529
E-21 "Arm DUMPING" is not correctly displayed in monitor function
Failure
• "Arm DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Arm DUMPING PPC ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
hydraulic switch ing the troubleshooting.
defect S03 (male) Arm control lever Resistance value
1
tion and short-circuit- NEUTRAL Min. 1 MΩ
Between 1 and 2
ing) DUMPING Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) ` and S03 (female) 2 Max. 1 Ω
value
defective contact
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) ` and S03 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) ` and S03
Pump controller C03 Arm control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between ` and grounding
DUMPING Max. 1 V
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
20-530 PC1250-7
E-22 "Bucket DIGGING" is not correctly displayed in monitor function
Failure
• "Bucket DIGGING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Bucket DIGGING ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
PPC hydraulic ing the troubleshooting.
switch fault S06 (male) Bucket control lever Resistance value
1
Between 1 and 2
ing) DIGGING Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) 9 and S06 (female) 2 Max. 1 Ω
value
defective contact
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) 9 and S06 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) 9 and S06
Pump controller C03 Bucket control lever Voltage
5
defective
NEUTRAL 20 – 30 V
DIGGING Max. 1 V
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
PC1250-7 20-531
E-23 "Bucket DUMPING" is not correctly displayed in monitor function
Failure
• "Bucket DUMPING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Bucket DUMPING ★Turn the engine starting switch OFF for the preparations, and keep the engine running dur-
PPC hydraulic ing the troubleshooting.
switch fault S07 (male) Bucket control lever Resistance value
1
Between 1 and 2
ing) DUMPING Max. 1 Ω
ing harness
Resistance
2 (Disconnection or Wiring harness between C03 (female) I and S07 (female) 2 Max. 1 Ω
value
defective contact
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) I and S07 Resistance
Min. 1 MΩ
4
(Contact with 24 V Between wiring harness between C03 (female) I and S07
Pump controller C03 Bucket control lever Voltage
5
defective
NEUTRAL 20 – 30 V
Between I and grounding
DUMPING Max. 1 V
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
20-532 PC1250-7
E-24 "SWING" is not correctly displayed in monitor function
Failure
• "SWING" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Swing PPC hydraulic
switch, left, fault
1 (Internal disconnec- S10 (male) Swing control lever Resistance value
Left Max. 1 Ω
Swing PPC hydraulic
switch, right, fault
2 (Internal disconnec- S08 (male) Swing control lever Resistance value
Right Max. 1 Ω
Disconnection of wir- Wiring harness between C03 (female) S and S10 (female)
Resistance
ing harness 2, or wiring harness between C03 (female) S and S08 Max. 1 Ω
value
3 (Disconnection or (female) 2
defective contact Resistance
with connector) Wiring harness between S10 (female) 1 and grounding Max. 1 Ω
value
Resistance
value
4 (Contact with Wiring harness between C03 (female) S and S10 (female)
grounding (GND) Resistance
2, or wiring harness between C03 (female) S and S08 Min. 1 MΩ
circuit) value
Short-circuiting of ing the troubleshooting.
wiring harness
5
(Contact with 24 V Wiring harness between C03 (female) S and S10 (female)
circuit) 2, or wiring harness between C03 (female) S and S08 Voltage Max. 1 V
Pump controller C03 Swing control lever Voltage
6
defective
NEUTRAL 20 – 30 V
Between S and grounding
Right or left Max. 1 V
20-534 PC1250-7
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
PC1250-7 20-535
E-25 "TRAVEL" is not correctly displayed in monitor function
Failure
• "TRAVEL" is not correctly displayed in the monitor function (special function) on the monitor panel.
information
Relative
—
information

Travel PPC hydraulic
switch fault
1 (Internal disconnec- S01, S11, S12, S13 (male) Travel control lever Resistance value
Forward or reverse Max. 1 Ω
ing harness
Wiring harness from C02 (female) C, R to J18 to S01, S11, Resistance
S12, S13 (female) 2 value
defective contact
with connector) Wiring harness from S01, S11, S12, S13 (female) 1 to Resistance
Max. 1 Ω
grounding value
3 (Contact with
grounding (GND) Wiring harness from C02 (female) C, R to J18 to S01, S11, Resistance
Min. 1 MΩ
circuit) S12, S13 (female) 2 and grounding value
4
(Contact with 24 V Wiring harness from C02 (female) C, R to J18 to S01, S11,
S12, S13 (female) 2 and grounding
Pump controller C02 Travel control lever Voltage
5
defective
Between C, R and NEUTRAL 20 – 30 V
grounding Forward or backward Max. 1 V
20-536 PC1250-7
Electric circuit diagram related to travel PPC pressure switch
PC1250-7 20-537
E-26 Air Conditioner does not work
Failure
• The air conditioner does not work.
information
Relative • For the electrical circuit diagram inside the air conditioner unit, refer to the section of STRUCTURE AND
information FUNCTION - Air Conditioner in this manual.

1 Fuse No. 11 fault When the fuse is blown, there is a big possibility that grounding fault occurred in the circuit.
ing harness
Resistance
2 (Disconnection or Wiring harness between FB1-11 outlet and M26 (male) 4 5 Max. 1 Ω
value
defective contact
Wiring harness between M26 (male) 8 and grounding Max. 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between FB1-11 outlet and M26
Voltage Min. 1 MΩ
circuit) (male) 4 5 and grounding
Air conditioner unit ing the troubleshooting.
4
defective M26 Voltage
Between 4 5 and 8 20 – 30 V
Electrical Circuit Diagram for Air Conditioner
20-538 PC1250-7
E-27 Travel alarm does not sound
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.
Relative
—
information

If the monitor display is not correct, proceed to No. E-25 Troubleshooting.
Monitoring code Item Normal display
1 Travel signal fault
019 R.H. travel Control lever operation: ON
021 L.H. travel Control lever NEUTRAL: OFF

ing harness
Wiring harness between C03 (female) 8 and F01 (female) Resistance
defective contact
1 value
Wiring harness between F01 (female) 2 and grounding Max. 1 Ω
value
3 (Contact with
grounding (GND) Between wiring harness between C03 (female) 8 to F01 Resistance
Min. 1 MΩ
As this is an internal failure, troubleshooting cannot be conducted. (If none of the causes
4 Travel alarm fault
listed in Item 1 through 3 above is found, the travel alarm is judged as defective)
C03 Travel control lever Voltage
Pump controller NEUTRAL Max. 1 V
5
defective Between 8 and grounding Left forward, left reverse, or
20 – 30 V
right forward, right reverse
Electrical Circuit Diagram for Travel Alarm
PC1250-7 20-539
E-28 Any of panel lamp, head lamp, working lamp (including additional lamp) does
not light up
Failure
• Any of panel lamp, head lamp, and working lamp (including additional lamp) does not light up
information (1)
Relative
—
information

1 If a circuit breaker is turned OFF, the circuit probably has a grounding fault.
or No. 5 turned OFF
Light switch defec- Between M07 (female) 1 and 2 Resistance value

2
tive
Light switch ON Max. 1 Ω
Light switch OFF Min. 1 MΩ
Wiring harness dis- Wiring harness between circuit breaker No. Voltage between B15 and
connected 20 – 30 V
2 B22 and No. 5 B15 grounding
3 (Disconnection or
defective contact of
Wiring harness between circuit breaker No. Voltage between M07 1 and
20 – 30 V
connector) 5 B25 and M07 (male) 1 grounding
Wiring harness between M07 (male) 2 and Voltage between J01 5 and
20 – 30 V
J01 (male) 5 grounding
Grounding fault of Between wiring harness between circuit breaker No. 2 B22 Resistance
and No. 5 B15 and grounding value
4 (Contact with
Between wiring harness between circuit breaker No. 5 B25 Resistance
grounding (GND) Min. 1 MΩ
circuit) and M07 (male) 1 and grounding value
Between wiring harness between M07 (male) 2 and J01 Resistance
Min. 1 MΩ
(male) 5 value
20-540 PC1250-7
Failure
• Head lamp and working lamp do not light up.
information (2)
Relative
• Monitor panel and additional lamp light up.
information

Head lamp or work-
1 ing lamp defective The head lamp or working lamp may be defective. Check their bulbs for breakage.
(Breakage of bulb)
Wiring harness between J01 (male) 9 and Voltage between J11 8 and
20 – 30 V
J11 (female) 8 grounding
Wiring harness between J11 (female) 1 and Voltage between M08, M09
20 – 30 V
Disconnection of wir- M08, M09 (female) 1 1 and grounding
ing harness
Wiring harness between J11 (female) 2 and Voltage between M42 1 and
2 (Disconnection or 20 – 30 V
defective contact M42 (female) 1 grounding
with connector) ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
Wiring harness between M08, M09 (female) 2 and chassis Resistance
Max. 1 Ω
ground (T02) value
Wiring harness between M42 (female) 2 and chassis Resistance
Max. 1 Ω
ground (T03) value
Grounding fault of Between wiring harness between J01 (male) 9 and J11 Resistance
3 (Contact with
grounding (GND) Between wiring harness between J11 (female) 1 and M08, Resistance
Min. 1 MΩ
circuit) M09 (female) 1 and grounding value
Between wiring harness between J11 (female) 2 and M42 Resistance
Min. 1 MΩ
(female) 1 value
Failure
• Panel lamp does not light up.
information (3)
Relative
• 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 dis- ★Turn the engine starting switch OFF for the preparations, and hold it in the ON position dur-
connected ing the troubleshooting.
2 (Disconnection or
defective contact of Wiring harness between J01 (male) 7 and Voltage between P02 I and
20 – 30 V
connector) P02 (female) I grounding
Wiring harness ★Turn the engine starting switch OFF for the preparations, and hold it in the OFF position
short-circuited to during the troubleshooting.
3 grounding
(Contact with GND Between wiring harness between J01 (male) 7 and P02 Resistance
Min. 1 MΩ
circuit) (female) I and grounding value
Monitor panel ing the troubleshooting.
4
defective Between P02 I and
Light switch ON Voltage 20 – 30 V
grounding
PC1250-7 20-541
Failure
• Additional lamp does not light up.
information (4)
Relative
• Head lamp and working lamp light up.
information

Additional lamp
1 defective (Breakage The additional lamp may be defective. Check its bulb for breakage.
of bulb)
turned OFF
Working lamp relay ing the troubleshooting.
3 defective (Internal Replace the relay with another one with the starting switch OFF, and then turn the starting
disconnection) switch and light switch ON. If the working lamp lights up at this time, the working lamp relay
(R10) is defective.
Wiring harness between circuit breaker No. Voltage between B17 and
20 – 30 V
2 B22 and No. 7 B17 grounding
Wiring harness between circuit breaker No. Voltage between R10 3 and
20 – 30 V
7 B27 and R10 (female) 3 grounding

Wiring harness between J01 (male) 6 and Voltage between R10 1 and
20 – 30 V
R10 (female) 1 grounding
Disconnection of wir- Wiring harness between R10 (female) 5 Voltage between J03 3 and
ing harness 20 – 30 V
and J03 (male) 3 grounding
4 (Disconnection or
defective contact Wiring harness between J03 (male) 1 and Voltage between M40 1 and
20 – 30 V
with connector) M40 (female) 1 grounding
Wiring harness between J03 (male) 2 and Voltage between M41 1 and
20 – 30 V
M41 (female) 1 grounding
Wiring harness between R10 (female) 2 and chassis ground Resistance
Max. 1 Ω
(T03) value
Wiring harness between M40, M41 (female) 2 and chassis Resistance
Max. 1 Ω
ground value
Min. 1 MΩ
and No. 7 B17 and grounding value
Min. 1 MΩ
Grounding fault of and R10 (female) 3 and grounding value
wiring harness Between wiring harness between J01 (male) 6 and R10 Resistance
5 (Contact with Min. 1 MΩ
grounding (GND)
circuit) Between wiring harness between R10 (female) 5 and J03 Resistance
Min. 1 MΩ
(male) 3 and grounding value
Between wiring harness between J03 (male) 1 and M40 Resistance
Min. 1 MΩ
Between wiring harness between J03 (male) 2 and M41 Resistance
Min. 1 MΩ
20-542 PC1250-7
Electric circuit diagram related to panel lamp, head lamp, and working lamp
PC1250-7 20-543
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES .............................................................................................20-552

BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE).......................20-554
PC1250-7 20-551
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES

Hydraulic pump Control valve
Parts causing failure
Swing compensation valve

Hydraulic oil tank strainer
Safety-suction valve
Straight-travel valve
Jet sensor orifice

Main relief valve
Jet sensor valve

CO • NC valve
Suction valve
Servo valve
TVC valve
Pump
Spool
Valve
Failure mode
●
All work equipment,
Speeds of all work equipment, swing, travel are slow or lack power
travel, swing
There is excessive drop in engine speed, or engine stalls ● ●
No work equipment, travel, swing move
Abnormal noise generated (from around pump) ● ●
In normal mode ● ● ●
Boom is slow or lacks power With heavy lift ON ●
With machine push-up ON ●
Arm is slow or lacks power ● ● ●
Work equipment
Bucket is slow or lacks power ● ● ●

Boom does not move ●
Arm does not move ●
Bucket does not move ●
Excessive hydraulic drift ● ● ●
Boom ●
Excessive time lag
Arm, bucket ●
Boom shockless function does not work or cannot be canceled
Deviates in same direction in FOR-
● ● ● ● ● ● ● ●
Machine deviates naturally to one WARD and REVERSE
side when traveling Deviates in opposite direction in FOR-
●
WARD and REVERSE
Only at full stroke ● ●
Deviation is excessive when start-
Travel system
ing Both during fine control operations

● ● ● ●
and at full stroke
Deviation is excessive during compound operations ●
Travel speed is slow or lacks power
Both directions (FORWARD and
Does not travel REVERSE)
(one side only) One direction only (either FORWARD
● ●
or REVERSE)
Travel speed does not switch
Both left and right
Does not swing
One direction only ●
Swing speed is slow or swing accel- Both left and right
eration is poor One direction only ●
During compound operations with bucket, swing speed is slow or accelera-
●
tion is poor
Swing system
During compound operations with boom when swing priority is ON, swing
speed is slow or acceleration is poor
Excessive overrun when stopping Both left and right
swing One direction only ●
Excessive shock when stopping Both left and right
swing One direction only
Excessive abnormal noise when Both left and right
stopping swing One direction only
Excessive hydraulic drift of swing
20-552 PC1250-7
●
●
●
●
Hydraulic cylinder
●
●
●
Center swivel joint
Swing motor proper, internal leakage
●
●
●
●
PC1250-7
●
●
●
●
●
Safety valve
●
●
●
●
Suction valve
Swing motor
●
●
●
●
Swing holding brake
TROUBLESHOOTING
●
Back pressure compensation valve
Travel motor proper, internal leakage
●
●
●
●
Counterbalance valve
●
Safety valve
●
Speed selector servo valve
Travel motor
●
Parking brake
●
●
Pump
pump
●
●
Relief valve
Control
●
●
●
●
●
●
●
●
●
●
●
●
PPC valve
●
Boom shockless valve
●
Swing PPC shuttle valve
●
Swing compensation pilot valve
●
CO cancel
●
●
2-stage relief
●
●
Machine push-up
●
Boom shockless
●
Straight-travel
Solenoid valve
●
Travel speed
●
●
●
●
Swing holding brake
●
Swing priority
●
PTO
●
●
●
●
Swing machinery
●
●
Final drive
●
●
Engine
Troubleshooting code
20-553
TABLE OF FAILURE MODES AND CAUSES
BEFORE CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC

SYSTEM (H MODE)
20-554 PC1250-7
1. Actuation and combination of hydraulic 2. Judgement procedure if work equipment is

pumps slow and there is travel deviation to the left:
• Three tandem pumps (total of 6 pumps) are • The cause is probably one of the following:
used in the work equipment, travel, and 1) Defective main relief of L.H. 5-spool
swing circuits: No. 1 pump (HPV95+95), No. control valve
2 pump (HPV95+95), and No. 3 pump 2) Defective jet sensor of L.H. 5-spool con-
(HPV160+160). trol valve
• The oil from the No. 1 front pump and No. 2 3) Defective CO • NC valve of No. 1 rear
front pump merges and flows to the R.H. 4- pump
spool valve; the oil from the No. 1 rear pump 4) Defective servo valve of No. 1 rear
and No. 2 rear pump merges and flows to the pump
L.H. 5-spool valve; and the oil from the No. 3 5) Defective No. 1 rear pump
front pump and No. 3 rear pump merges and 6) Defective servo valve of No. 2 rear
flows to the swing 4-spool valve. pump
• 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 the • If the problem occurs, measure the following
same way by the TVC valve installed to the to judge if the related part is defective.
No. 1 rear pump. 1) Measure relief pressure to judge main
• The CO • NC control for the No. 1 front pump relief valve
and No. 2 front pump is carried out in the 2) Measure differential pressure to judge
same way by the CO • NC valve installed to jet sensor
the No. 1 front pump and by the jet sensor in- 3) Measure output pressure to judge CO •
stalled to the R.H. 4-spool control valve. NC valve
• The CO • NC control for the No. 1 rear pump • As mentioned above, the oil flow in the No. 1
and No. 2 rear pump is carried out in the pump and No. 2 pump merges, so to judge if
same way by the CO • NC valve installed to the problem is in the No. 1 pump servo valve
the No. 1 rear pump and by the jet sensor in- and pump proper or in the No. 2 pump servo
stalled to the L.H. 5-spool control valve. valve and pump proper, interchange the out-
• The CO • NC control for the No. 3 front pump let port hoses of the No. 2 pump between the
and No. 3 rear pump is carried out in the front and rear. It is then possible to judge as
same way by the CO • NC valve installed to follows which pump is defective.
the front pump and by the jet sensor installed 1) If deviation is to left (no change), No. 1
to the swing 4-spool control valve. rear pump is defective
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).
• 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.
★ For the actual procedure for judgement, fol-
low the "Troubleshooting chart for judge-
ment when work equipment is slow and
there is travel deviation to the left".
PC1250-7 20-555
3. Judgement procedure if work equipment is

slow and there is travel deviation to the
right:
★ For this problem, use the explanation given
"2. Judgement procedure if work equipment
is slow and there is travel deviation to the
left", but replace as follows.
Use R.H. 4-spool control valve instead of
L.H. 5-spool control valve; and use front
pump instead of rear pump.
For all other points, the judgement proce-
dure is the same.
4. Judgement procedure if work equipment is

slow and swing is also slow (but travel
speed is normal):
• The cause is probably one of the following:
1) Defective main relief valve of swing 4-
spool control valve
2) Defective jet sensor of swing 4-spool
control valve
3) Defective CO • NC valve of No. 3 pump
4) Defective servo valve of No. 3 front
pump
5) Defective No. 3 front pump
6) Defective servo valve of No. 3 rear
pump
7) Defective No. 3 rear pump
• If the problem occurs, measure the following
to judge if the related part is defective.
1) Measure relief pressure to judge main
relief valve
2) Measure differential pressure to judge
jet sensor
3) Measure output pressure to judge CO •
NC valve
• To judge if the problem is in the servo valve
or the pump proper of the No. 3 front pump,
or in the servo valve or the pump proper of
the No. 3 rear pump, remove the servo valve
and test the individual part, or judge from the
stroke of the servo piston.
★ It is impossible to judge if the problem is in
the front pump or the rear pump while the
pumps are mounted on the machine, so re-
move the No. 3 pump assembly and test in-
dividually.
20-556 PC1250-7
Causes
Troubleshooting chart for judgement when work
equipment is slow and there is travel deviation to a b c d e f g h i j k l m n
the left L.H. 5- R.H. 4-
spool spool
No. 1 pump No. 2 pump
control control
★ Use this troubleshooting chart to judge if the loca- valve valve
tion of the problem is in the No. 1 pump system or
Front Rear
in the No. 2 pump system. Front pump Rear pump
pump pump
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.
★ Carry out the individual test on the servo pis-
ton at the specified repair shop.
Defective main relief valve
Defective main relief valve

Defective CO • NC valve
Defective CO • NC valve
2. If there is a big drop in speed and it seems that
Defective servo valve

there is an abnormality in the pump, check the
Defective jet sensor
Defective jet sensor

line filter also.
Defective pump
Defective pump
Defective pump
Defective pump
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 is
1 ● ● ● ● ● ● ●
slow
2 Travel relief pressure of rear pump is low ●
Machine deviates to left (no
3 ● ●
change)
Travel deviates to left
Item 2 is normal, and when

No. 2 pump outlet hoses are Machine deviates to right
4 ● ●
interchanged between front (opposite direction)
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 con-
8 ●
trol valve is defective
Item 6 is normal, but No. 1 rear NC valve output pressure is
9 ●
defective
There is travel deviation to right, and work equipment speed is
10 ● ● ● ● ● ● ●
slow
11 Travel relief pressure of front pump is low ●
Machine deviates to right (no
12 ● ●
change)
Travel deviates to right
Item 11 is normal, and when

No. 2 pump outlet hoses are Machine deviates to left (oppo-
13 ● ●
interchanged between front site direction)
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. 4-spool con-
17 ●
trol valve is defective
Item 15 is normal, but No. 1 rear NC valve output pressure is
18 ●
defective
★ Start troubleshooting from the top, and judge that the item with the most ● marks is the cause of the failure.
★ Remedy A: Adjust X: Repair or replace
PC1250-7 20-557
Interchange method of No. 2 pump outlet hoses between front and rear
Hyrdraulic circuit after interchanging hoses
20-558 PC1250-7
90 OTHERS
Hydraulic circuit diagram ............................................................................ 90- 3

Electrical circuit diagram (1/5) .................................................................... 90- 5
Electrical circuit diagram (4/5) .................................................................... 90-11
Electrical circuit diagram (5/5) .................................................................... 90-13
PC1250-7 90-1
OTHERS HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
PC1250-7 90-3
OTHERS ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM (1/5)
PC1250-7 90-5
PC1250-7 90-7
PC1250-7 90-9
PC1250-7 90-11
PC1250-7 90-13

Shop Manual Komatsu PC1250-7

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Shop Manual Komatsu PC1250-7

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SEBM027301

MACHINE MODEL SERIAL No.

• PC1250-7 mounts the SAA6D170E-3 engine.

10 STRUCTURE, FUNCTION AND

20 TESTING AND ADJUSTING ........................................................................ 20-1

30 DISASSEMBLY AND ASSEMBLY ..................... Will be issued 7-30-2002

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

¤ Heavy parts (25 kg or more) must be lifted

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

¤ Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets,

• Used in places requiring an imme-

• Features: Resistance to heat and

Adhesive: • Used as adhesive or sealant for

Polyethylene • Used as sealant for machined

Holtz • Used as heat-resisting sealant for

• Quick hardening type adhesive

• Quick hardening type adhesive

Loctite Polyethylene • Resistance to heat, chemicals

• Used as adhesive or sealant for

• Used as sealant for various

• Features: Silicon based, resist-

• Ftures: Silicon based, quick hard-

Three bond • Used as heat-resisting sealant for

• Used as lubricant for sliding por-

SYG2-400LI • General purpose type

SYG2-400CA • Used for normal temperature,

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

Thread diameter Width across

6 10 13.2 0 1.4 1.35 0 0.15

27 41 1320 0 140 135 0 15

Thread diameter Width across

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS