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Komatsu PC240LC-10 Shop Manual

Hydraulic excavator
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SEN05538-05
HYDRAULIC
PC240LC
-10
EXCAVATOR
90001
SERIAL NUMBERS
and up

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Summary of Contents for Komatsu PC240LC-10

  • Page 1 SEN05538-05 HYDRAULIC PC240LC EXCAVATOR 90001 SERIAL NUMBERS and up...
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 SHOP MANUAL HYDRAULIC EXCAVATOR PC240LC–10 Model Serial Number PC240LC–10 90001 and up 00 Index and foreword 1 00 Index and foreword PC240LC–10 00-1 Find manuals at https://best-manuals.com...
  • Page 4 00 Index and foreword Index Index (ALL-0310-001-A-00-A) 00 Index and foreword ........................00-1 Index ............................00-2 Foreword, safety and general information ................... 00-14 Important safety notice ....................... 00-14 How to read the shop manual....................00-21 Explanation of terms for maintenance standard ..............00-23 Handling equipment of fuel system devices ................
  • Page 5 00 Index and foreword Index Attachment circuit selector valve (for low pressure circuit)............ 10-178 Center swivel joint ......................10-181 Accumulator ........................10-183 Work equipment ........................10-184 Work equipment....................... 10-184 Work equipment shim....................... 10-185 Bucket play adjustment shim..................... 10-186 Cab and its attachments ......................10-187 Cab mount and cab tipping stopper ...................
  • Page 6 00 Index and foreword Index Bleeding air from hydraulic circuit ..................30-70 Cab and its attachments ......................30-72 Testing cab tipping stopper ....................30-72 Adjusting mirrors ........................ 30-73 Electrical system ........................30-75 Special functions of machine monitor ................... 30-75 Adjusting rearview camera angle ..................30-141 Handling voltage circuit of engine controller................
  • Page 7 00 Index and foreword Index Failure code [CA145] Coolant Temp Sens Low Error ............40-164 Failure code [CA153] Chg Air Temp Sensor High Error ............40-166 Failure code [CA154] Chg Air Temp Sensor Low Error............40-168 Failure code [CA187] Sensor 2 Supply Volt Low Error ............40-170 Failure code [CA221] Ambient Press Sensor High Error ............
  • Page 8 00 Index and foreword Index Failure code [CA1921] KDPF Soot Load High Error 1............40-263 Failure code [CA1922] KDPF Soot Load High Error 2............40-265 Failure code [CA1942] Crankcase Press Sens In Range Error ..........40-270 Failure code [CA1993] KDPF Delta Pressure Low Error ............40-271 Failure code [CA2185] Throt Sensor Sup Volt High Error .............
  • Page 9 00 Index and foreword Index Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............40-383 Failure code [DA20MC] Pump Controller................40-384 Failure code [DA22KK] Pump Solenoid Power Low Error............. 40-385 Failure code [DA25KP] 5V Sensor 1 Power Abnormality............40-387 Failure code [DA29KQ] Model Selection Abnormality ............40-390 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ........
  • Page 10 00 Index and foreword Index Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ............40-514 Failure code [DXE0KA] LS-EPC Sol Open Circuit ............... 40-516 Failure code [DXE0KB] LS-EPC Sol Short Circuit ............... 40-518 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ..........40-520 Failure code [DXE4KB] Attachment Flow EPC Short Circuit..........
  • Page 11 00 Index and foreword Index E-37 Any of work equipment, swing and travel cannot be locked .......... 40-591 E-38 Machine cannot swing while swing brake cancel switch is canceled ......40-592 E-39 Swing brake does not operate while swing brake cancel switch is locked ...... 40-594 E-40 One-touch power maximizing function does not work or monitor is not displayed ...
  • Page 12 00 Index and foreword Index H-30 Shock is large when upper structure stops swinging............ 40-669 H-31 Large unusual noise is heard when upper structure stops swinging ......40-670 H-32 Swing drift on a slope is large while swing holding brake is applied....... 40-671 H-33 Swing drift on a slope is large while swing holding brake is released......
  • Page 13 00 Index and foreword Index Removal and installation of swing circle assembly .............. 50-131 Undercarriage and frame......................50-132 Separation and connection of track shoe assembly ............. 50-132 Removal and installation of sprocket.................. 50-135 Removal and installation of idler and idler cushion assembly ..........50-136 Disassembly and assembly of idler ..................
  • Page 14 00 Index and foreword Index Main pump ........................60-23 Control valve ........................60-24 Swing motor ........................60-34 Travel motor ........................60-36 PPC valve ......................... 60-39 Solenoid valve.......................... 60-48 Attachment circuit selector valve (for high-pressure circuit)............60-49 Attachment circuit selector valve (for low-pressure circuit) ............60-50 Center swivel joint........................
  • Page 15 00 Index and foreword Index A-4 Troubleshooting for FRESH/RECIRC air changeover ............80-72 Troubleshooting with gauge pressure................... 80-74 Testing refrigerant pressure....................80-77 Precautions for disconnecting and connecting air conditioner piping ........80-80 Handling of compressor oil....................80-82 Desiccant replacement ....................... 80-84 90 Diagrams and drawings.........................
  • Page 16 Komatsu. Some of these methods require the use of the special tools designed by Komatsu for the specific purpose. • The symbol mark k is used for such matters that require special cautions during the work. The work indicated by the caution mark should be performed according to the instructions with special attention to the cautions.
  • Page 17 00 Index and foreword Foreword, safety and general information jump on or off the machine. When the scaffold is floor, wipe it off immediately. Fuel or oil on the not provided, use steps or stepladder to secure floor can cause you to slip and can even cause your footing.
  • Page 18 00 Index and foreword Foreword, safety and general information • Measure the weight of the load by the eye and a Slinging near the tip of the hook may cause check its center of gravity. the rope to slip off the hook during hoisting. •...
  • Page 19 00 Index and foreword Foreword, safety and general information for electric shock prevention, crane collision a The allowable load is calculated as one sixth of prevention device, and energizing warning lamp, the breaking load of the rope to be used (safety and check the following safety items.
  • Page 20 00 Index and foreword Foreword, safety and general information • When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
  • Page 21 • Fire around the machine due to highly heated materials to a safe place before starting. exhaust gas Some machines are equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying soot in exhaust gas. Its exhaust...
  • Page 22 00 Index and foreword Foreword, safety and general information Actions if fire occurs (ALL-0000-17A-K-01-A) • Turn the starting switch to OFF position to stop the engine. • Use the handrails and steps to get off the machine. • Do not jump off the machine. You may fall or suffer serious injury.
  • Page 23 • Some attachments and optional parts described in this shop manual may not be arranged for certain areas. Contact your Komatsu distributor if one or some of them are required. • Materials and specifications are subject to change without notice.
  • Page 24 00 Index and foreword Foreword, safety and general information Symbol Important safety and quality portions are marked with the following symbols so that the shop manual is used practically. Symbol Item Remarks The special safety precautions required for performing work are Safety described.
  • Page 25 00 Index and foreword Foreword, safety and general information Explanation of terms for maintenance standard (ALL-0330-006-A-01-A) (Rev. 2012/10) • The chapter of maintenance standard shows judgement criteria to determine the products to be replaced or to be reused. The judgement criteria are described by using the following terms. Standard dimension and tolerance •...
  • Page 26 00 Index and foreword Foreword, safety and general information the parts can not be used any longer. This value is called "repair limit". • If a part is worn to the repair limit, it must be replaced or repaired. • The performance and function of the products lower while they are used.
  • Page 27 • If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel. Precautions for replacing fuel filter cartridge • Be sure to use the Komatsu genuine fuel filter cartridge. • The common rail fuel injection system (CRI)
  • Page 28 Foreword, safety and general information Handling of intake system parts (PC220-A900-2A4-K-00-A) (Rev.2013/10) • The Komatsu Variable Geometry Turbocharger consists of more precise parts (variable mechanism) than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the air intake system.
  • Page 29 00 Index and foreword Foreword, safety and general information Handling of hydraulic equipment (ALL-C000-2A4-P-01-A) (Rev. 2012/10) • With the increase in pressure and precision of the hydraulic components, the most common cause of a failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when adding hydraulic oil,or when disassembling or assembling the hydraulic components.
  • Page 30 00 Index and foreword Foreword, safety and general information Flushing operations • After disassembling the equipment or when changing the hydraulic oil with new one, flush the system to remove the contaminant and sludge left in the hydraulic circuit as well as the oil which includes them.
  • Page 31 00 Index and foreword Foreword, safety and general information Method of disconnecting and connecting of push-pull type coupler (ALL- C930-001-P-00-A) (Rev. 2012/01) Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
  • Page 32 00 Index and foreword Foreword, safety and general information Type 2 (ALL-C930-925-P-02-A) Disconnection Connection 1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male...
  • Page 33 00 Index and foreword Foreword, safety and general information Type 3 (ALL-C930-925-P-03-A) Disconnection Connection 1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male...
  • Page 34 00 Index and foreword Foreword, safety and general information Handling of electrical equipment (ALL-E000-2A4-P-01-A) (Rev. 2012/11) • To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed.
  • Page 35 00 Index and foreword Foreword, safety and general information blow it with compressed air and spray it with electrical contact restorer. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If there is oil or water in the compressed air, it causes the contacts to become dirtier.
  • Page 36 00 Index and foreword Foreword, safety and general information • Check that there is no oil, dirt or water stick to the connector pins (joint portion). • Check that the connector pins are free from deformation, defective contact, corrosion, or damage.
  • Page 37 00 Index and foreword Foreword, safety and general information • If the connector clamp is removed, be sure to Drying wiring harness return it to its original position. And check • If there is any oil or dirt on the wiring harness, that it is securely installed.
  • Page 38 00 Index and foreword Foreword, safety and general information 2. While pressing lock (L2), pull out connector (1). Handling of connectors used on engine Slide, lock type (FRAMATOME-3, FRAMATOME-2) Disconnection 1. Slide lock (L1) to the right. 2. While pressing lock (L2), pull out connector (1) toward you.
  • Page 39 00 Index and foreword Foreword, safety and general information Connection Connection 1. Insert the connector securely until a click is 1. Insert the connector securely until a click is heard. heard. (AMP-3) Push lock type Disconnection (BOSCH-3) 1. While pressing lock (E), pull out connector (5) in Disconnection the direction of the arrow.
  • Page 40 00 Index and foreword Foreword, safety and general information (SUMITOMO-3) Disconnection 1. While pressing lock (E), pull out connector (5) in the direction of the arrow. a Pull the connector straight up. Connection 1. Insert the connector to the end while aligning its grove to the other.
  • Page 41 00 Index and foreword Foreword, safety and general information temperature even for a short period of time. (Place it on a suitable dry stand.) • Precautions when performing arc welding When performing arc welding on the machine body, disconnect wiring harness connectors connected to the controller.
  • Page 42 00 Index and foreword Foreword, safety and general information How to read electric wire code (ALL-E500-030-P-00-A) (Rev. 2012/10) • In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by symbols. The wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
  • Page 43 00 Index and foreword Foreword, safety and general information Dimensions (Table 2) (0.5) 0.75f (0.85) 1.25f (1.25) Nominal No. 0.5f Number of strands/ 7/0.32 Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32 strand Conductor Cross- sectional 0.51 0.56 0.76...
  • Page 44 00 Index and foreword Foreword, safety and general information Color codes table (Table 3) Color Code Color of wire Color Code Color of wire Light green & White Black Light green & Yellow Brown Brown & Black Blue & Red Brown &...
  • Page 45 00 Index and foreword Foreword, safety and general information Precautions when performing operation (ALL-1160-927-A-00-A) (Rev. 2012/11) • When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following general cautions. Precautions for removal and disassembly work •...
  • Page 46 00 Index and foreword Foreword, safety and general information Disconnection of taper seal type hoses and tubes Pipe joint side Hose side Nominal No. Plug (1) Nut (2) 07376-50210 07222-00210 07376-50315 07222-00312 07376-50422 07222-00414 07376-50522 07222-00515 07376-50628 07222-00616 07376-51034 07222-01018 07376-51234 07222-01219 07376-51443...
  • Page 47 00 Index and foreword Foreword, safety and general information Bolt pitch (mm) Hose side Tube side O-ring (4) Bolt (5) Washer (6) minal Split flange Sleeve head Flange (1) 07379- 01010- 79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445 01470 81455 07379- 07372- 77.8 42.8...
  • Page 48 00 Index and foreword Foreword, safety and general information Plug (1) Nominal Nominal No. thread size Square head type (A) Hexagonal socket head (B) 07042-00108 07043-00108 07042-00211 07043-00211 07042-00312 07043-00312 07042-00415 07043-00415 07042-00617 07043-00617 07042-01019 07043-01019 07042-01222 07043-01222 07042-01422 07043-01422 07042-02026 07043-02026 Precautions for installation and assembly work...
  • Page 49 • When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 50 00 Index and foreword Foreword, safety and general information Practical use of KOMTRAX (ALL-Q210-13V-K-00-A) (Rev. 2012/10) KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX operator can refer this information in the office and provide various services to the customers. When KOMTRAX is installed on the machine, the machine information can be checked through the KOMTRAX system and the testing and troubleshooting can be performed efficiently.
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90001