Komatsu PC240LC-10 Hydraulic Excavator Shop Manual SEN05538-08 – PDF DOWNLOAD

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Komatsu PC240LC-10 Hydraulic Excavator Shop Manual SEN05538-08 – PDF DOWNLOAD

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Komatsu PC240LC-10 Hydraulic Excavator Shop Manual SEN05538-08 – PDF DOWNLOAD

Language : English
Pages : 1698
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-10 Hydraulic Excavator Shop Manual SEN05538-08 – PDF DOWNLOAD

• SERIAL NUMBERS 90001 and up

Cover 1
00 Index and foreword . 3
Index . 4
Foreword, safety and general information 16
Important safety notice . 16
How to read the shop manual . 23
Explanation of terms for maintenance standard . 25
Handling equipment of fuel system devices . 27
Handling of intake system parts . 28
Handling of hydraulic equipment . 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation . 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
01 Specification 67
Table of contents . 68
Specifications 69
Specification drawings 69
Working range drawings 70
Specifications 71
Weight table 74
Table of fuel, coolant and lubricants . 75
10 Structure and function . 77
Table of contents . 78
Engine and cooling system . 79
Engine related parts 79
KVGT 81
EGR system piping drawing . 88
EGR system circuit diagram 90
EGR valve . 92
EGR cooler 94
KCCV layout drawing . 96
KCCV ventilator . 98
KDPF 100
Cooling system 104
Power train . 106
Power train system 106
Swing circle 108
Swing machinery . 109
Final drive . 111
Undercarriage and frame . 113
Track frame and idler cushion . 113
Hydraulic system 115
Hydraulic equipment layout drawing 115
Valve control . 117
Hydraulic tank 119
CLSS 121
Main pump . 126
Control valve . 150
Swing motor . 204
Travel motor 215
PPC valve . 228
Solenoid valve 249
Attachment circuit selector valve (for high pressure circuit) . 252
Attachment circuit selector valve (for low pressure circuit) 254
Anti-drop valve 257
Center swivel joint . 265
Accumulator . 267
Work equipment 268
Work equipment 268
Work equipment shim . 269
Bucket play adjustment shim . 270
Cab and its attachments . 271
Cab mount and cab tipping stopper . 271
ROPS cab 272
Electrical system . 273
Electrical control system . 273
Machine monitor system 316
KOMTRAX system 336
Sensor 338
20 Standard value table . 357
Table of contents . 358
Standard service value table 359
Standard value table for engine related parts . 359
Standard value table for chassis related parts 360
Posture of machine for measuring performance and measurement procedure 369
30 Testing and adjusting 373
Table of contents . 374
Related information on testing and adjusting 375
Tools for testing and adjusting . 375
Sketch of tools for testing and adjusting . 379
Engine and cooling system . 381
Testing engine speed 381
Testing boost pressure 382
Testing exhaust gas color . 383
Testing and adjusting valve clearance . 387
Testing compression pressure 390
Measuring blowby pressure . 394
Measuring engine oil pressure . 395
Measuring EGR valve and KVGT oil pressure . 396
Measuring fuel pressure . 397
Measuring fuel delivery, return and leakage . 403
Bleeding air from fuel system . 408
Testing fuel circuit for leakage 410
Handling cylinder cutout mode operation . 411
Handling no-injection cranking operation 412
Testing and adjusting air conditioner compressor belt tension . 413
Replacing fan belt 414
Power train . 415
Testing swing circle bearing clearance 415
Undercarriage and frame . 416
Testing and adjusting track tension . 416
Hydraulic system 417
Releasing remaining pressure from hydraulic circuit . 417
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits 422
Testing oil pressure in control circuit . 426
Testing and adjusting oil pressure in pump PC control circuit . 427
Testing and adjusting oil pressure in pump LS control circuit . 430
Testing output pressure of solenoid valve . 435
Measuring PPC valve output pressure . 439
Adjusting play of work equipment and swing PPC valves . 441
Testing pump swash plate sensor . 442
Isolating the parts causing hydraulic drift in work equipment . 443
Testing oil leakage . 445
Bleeding air from hydraulic circuit . 448
Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side) 450
Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side) . 452
Replacing accumulator bladder on high pressure side for accumulator piping . 454
Cab and its attachments . 460
Testing cab tipping stopper . 460
Adjusting mirrors . 461
Electrical system . 463
Special functions of machine monitor 463
Adjusting rearview camera angle . 529
Handling voltage circuit of engine controller . 531
Handling battery disconnect switch 532
Testing diodes 533
Pm clinic . 534
Pm clinic service . 534
40 Troubleshooting 545
Table of contents . 546
Related information on troubleshooting 553
Troubleshooting points 553
Sequence of events in troubleshooting . 555
Testing before troubleshooting 557
Inspection procedure before troubleshooting . 559
Preparation work for troubleshooting of electrical system . 587
Classification and procedure for troubleshooting 591
Symptom of probable failure and troubleshooting No. . 594
Information in troubleshooting table 597
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 599
Connector list and layout . 601
Connector contact identification 612
T-branch box and T-branch adapter table . 651
Fuse list and location 656
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement . 658
Failure codes table . 661
Troubleshooting by failure code (Display of code) . 670
Failure code [879AKA] A/C Inner Sensor Open Circuit . 670
Failure code [879AKB] A/C Inner Sensor Short Circuit 671
Failure code [879BKA] A/C Outer Sensor Open Circuit . 672
Failure code [879BKB] A/C Outer Sensor Short Circuit 673
Failure code [879CKA] Ventilating Sensor Open Circuit . 674
Failure code [879CKB] Ventilating Sensor Short Circuit 675
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit . 676
Failure code [879EMC] Ventilation Damper Abnormality 677
Failure code [879FMC] Air Mix Damper Abnormality 678
Failure code [879GKX] Refrigerant Abnormality . 679
Failure code [989L00] Engine Controller Lock Caution1 . 680
Failure code [989M00] Engine Controller Lock Caution2 . 681
Failure code [989N00] Engine Controller Lock Caution3 . 682
Failure code [A1U0N3] HC desorb request1 683
Failure code [A1U0N4] HC desorb request2 685
Failure code [AA10NX] Air Cleaner Clogging 687
Failure code [AB00KE] Charge Voltage Low 689
Failure code [B@BAZG] Engine Oil Pressure Low . 691
Failure code [B@BAZK] Eng Oil Level Low . 692
Failure code [B@BCNS] Engine Coolant Overheat . 693
Failure code [B@BCZK] Radiator Coolant Level Low 694
Failure code [B@HANS] Hyd Oil Overheat 696
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 697
Failure code [CA122] Chg Air Press Sensor High Error 698
Failure code [CA123] Chg Air Press Sensor Low Error . 700
Failure code [CA131] Throttle Sensor High Error . 702
Failure code [CA132] Throttle Sensor Low Error 704
Failure code [CA144] Coolant Temp Sens High Error . 706
Failure code [CA145] Coolant Temp Sens Low Error 708
Failure code [CA153] Chg Air Temp Sensor High Error . 710
Failure code [CA154] Chg Air Temp Sensor Low Error 712
Failure code [CA187] Sensor 2 Supply Volt Low Error . 714
Failure code [CA221] Ambient Press Sensor High Error 716
Failure code [CA222] Ambient Press Sensor Low Error . 718
Failure code [CA227] Sensor 2 Supply Volt High Error 720
Failure code [CA234] Eng Overspeed 721
Failure code [CA238] Ne Speed Sensor Supply Volt Error 722
Failure code [CA239] Ne Speed Sens Supply Volt High Error . 723
Failure code [CA271] IMV/PCV1 Short Error . 724
Failure code [CA272] IMV/PCV1 Open Error 726
Failure code [CA295] Ambient Press Sens In Range Error 727
Failure code [CA322] Inj #1(L#1) Open/Short Error . 728
Failure code [CA323] Inj #5(L#5) Open/Short Error . 730
Failure code [CA324] Inj #3(L#3) Open/Short Error . 732
Failure code [CA325] Inj #6(L#6) Open/Short Error . 734
Failure code [CA331] Inj #2(L#2) Open/Short Error . 736
Failure code [CA332] Inj #4(L#4) Open/Short Error . 738
Failure code [CA343] ECM Critical Internal Failure 740
Failure code [CA351] Injectors Drive Circuit Error 741
Failure code [CA352] Sensor 1 Supply Volt Low Error . 742
Failure code [CA356] Mass Air Flow Sensor High Error 744
Failure code [CA357] Mass Air Flow Sensor Low Error . 746
Failure code [CA386] Sensor 1 Supply Volt High Error 748
Failure code [CA428] Water in Fuel Sensor High Error 749
Failure code [CA429] Water in Fuel Sensor Low Error . 751
Failure code [CA435] Eng Oil Press Sw Error . 753
Failure code [CA441] Battery Voltage Low Error 754
Failure code [CA442] Battery Voltage High Error . 756
Failure code [CA449] Rail Press Very High Error . 757
Failure code [CA451] Rail Press Sensor High Error . 758
Failure code [CA452] Rail Press Sensor Low Error 760
Failure code [CA488] Chg Air Temp High Torque Derate 761
Failure code [CA515] Rail Press Sens Sup Volt High Error 762
Failure code [CA516] Rail Press Sens Sup Volt Low Error . 764
Failure code [CA553] Rail Press High Error 766
Failure code [CA555] Crankcase Press High Error 1 . 767
Failure code [CA556] Crankcase Press High Error 2 . 768
Failure code [CA559] Rail Press Low Error . 769
Failure code [CA595] Turbo Speed High Error 2 . 771
Failure code [CA687] Turbo Speed Low Error 772
Failure code [CA689] Eng Ne Speed Sensor Error 774
Failure code [CA691] Intake Air Temp Sens High Error 776
Failure code [CA692] Intake Air Temp Sens Low Error . 778
Failure code [CA697] ECM Int Temp Sensor High Error . 780
Failure code [CA698] ECM Int Temp Sensor Low Error 781
Failure code [CA731] Eng Bkup Speed Sens Phase Error 782
Failure code [CA778] Eng Bkup Speed Sensor Error 783
Failure code [CA1117] Persistent Data Lost Error 787
Failure code [CA1664] KDOC Malfunction 788
Failure code [CA1691] Regeneration Ineffective 790
Failure code [CA1695] Sensor 5 Supply Volt High Error . 792
Failure code [CA1696] Sensor 5 Supply Volt Low Error 794
Failure code [CA1843] Crankcase Press Sens High Error . 796
Failure code [CA1844] Crankcase Press Sens Low Error 798
Failure code [CA1879] KDPF Delta P Sensor High Error 800
Failure code [CA1881] KDPF Delta P Sensor Low Error . 802
Failure code [CA1883] KDPF Delta P Sens In Range Error 804
Failure code [CA1921] KDPF Soot Load High Error 1 . 807
Failure code [CA1922] KDPF Soot Load High Error 2 . 809
Failure code [CA1942] Crankcase Press Sens In Range Error . 814
Failure code [CA1993] KDPF Delta Pressure Low Error . 815
Failure code [CA2185] Throt Sensor Sup Volt High Error 816
Failure code [CA2186] Throt Sensor Sup Volt Low Error . 817
Failure code [CA2249] Rail Press Very Low Error . 818
Failure code [CA2271] EGR Valve Pos Sens High Error . 819
Failure code [CA2272] EGR Valve Pos Sens Low Error 821
Failure code [CA2288] Turbo Speed High Error 1 824
Failure code [CA2311] IMV Solenoid Error 825
Failure code [CA2349] EGR Valve Solenoid Open Error . 826
Failure code [CA2353] EGR Valve Solenoid Short Error 828
Failure code [CA2357] EGR Valve Servo Error . 830
Failure code [CA2373] Exh Manifold Press. Sens Volt . 831
Failure code [CA2374] Exhaust Manifold Press Sens Low Error . 833
Failure code [CA2375] EGR Orifice Temp Sens High Error 835
Failure code [CA2376] EGR Orifice Temp Sens Low Error . 837
Failure code [CA2381] KVGT Pos Sens High Error 839
Failure code [CA2382] KVGT Pos Sens Low Error . 841
Failure code [CA2383] KVGT Solenoid Open Error 843
Failure code [CA2386] KVGT Solenoid Short Error . 845
Failure code [CA2387] KVGT Servo Error 847
Failure code [CA2554] Exh Manifold Press Sens In Range Error 848
Failure code [CA2555] Grid Htr Relay Volt Low Error . 849
Failure code [CA2556] Grid Htr Relay Volt High Error 852
Failure code [CA2637] KDOC Face Plugging 854
Failure code [CA2639] Manual Stationary Regeneration Request 856
Failure code [CA2961] EGR Orifice Temp High Error 1 . 858
Failure code [CA2973] Chg Air Press Sensor In Range Error . 859
Failure code [CA3133] KDPF Outlet Press Sens High Error . 860
Failure code [CA3134] KDPF Outlet Press Sens Low Error 862
Failure code [CA3135] KDPF Outlet Press Sens In Range Error . 864
Failure code [CA3251] KDOC Inlet Temp High Error 867
Failure code [CA3253] KDOC Temp Error – Non Regeneration 870
Failure code [CA3254] KDOC Outlet Temp High Error 1 . 872
Failure code [CA3255] KDPF Temp Error – Non Regeneration 875
Failure code [CA3256] KDPF Outlet Temp High Error 1 . 876
Failure code [CA3311] KDOC Outlet Temp High Error 2 . 877
Failure code [CA3312] KDPF Outlet Temp High Error 2 . 878
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 880
Failure code [CA3314] KDOC Inlet Temp Sens High Error . 883
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error . 887
Failure code [CA3316] KDOC Outlet Temp Sens Low Error . 891
Failure code [CA3317] KDOC Outlet Temp Sens High Error 894
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error . 898
Failure code [CA3319] KDPF Outlet Temp Sens High Error 902
Failure code [CA3321] KDPF Outlet Temp Sens Low Error . 906
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 909
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 913
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error . 914
Failure code [CA3741] Rail Press Valve Trip Error . 916
Failure code [D110KB] Battery Relay Output Voltage 917
Failure code [D19JKZ] Personal Code Relay Abnormality . 919
Failure code [D811MC] KOMTRAX Error . 922
Failure code [D862KA] GPS Antenna Open Circuit 923
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) . 924
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 926
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) . 927
Failure code [DA20MC] Pump Controller . 928
Failure code [DA22KK] Pump Solenoid Power Low Error . 929
Failure code [DA25KP] 5V Sensor 1 Power Abnormality . 931
Failure code [DA29KQ] Model Selection Abnormality . 934
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 936
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) . 938
Failure code [DA2QKR] CAN2 Discon (Pump Con) 939
Failure code [DA2RKR] CAN1 Discon (Pump Con) 941
Failure code [DAF0MB] Monitor ROM Abnormality . 942
Failure code [DAF0MC] Monitor Error . 943
Failure code [DAF8KB] Camera Power Supply Short Circuit . 944
Failure code [DAF9KQ] Model Selection Abnormality . 946
Failure code [DAFGMC] GPS Module Error 947
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) . 948
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 950
Failure code [DAFQKR] CAN2 Discon (Monitor) . 951
Failure code [DAZ9KQ] A/C Model Selection Abnormality . 952
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 953
Failure code [DB2QKR] CAN2 Discon (Engine Con) 957
Failure code [DB2RKR] CAN1 Discon (Engine Con) 962
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 966
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 968
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 969
Failure code [DHPBMA] R Pump Press Sensor Abnormality . 972
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality . 975
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 977
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality . 980
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality . 983
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality . 986
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality . 989
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality . 992
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 995
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 998
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 1001
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 1004
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 1007
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .1010
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .1013
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .1016
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .1018
Failure code [DV20KB] Travel Alarm Short Circuit 1020
Failure code [DW43KA] Travel Speed Sol Open Circuit .1022
Failure code [DW43KB] Travel Speed Sol Short Circuit 1024
Failure code [DW45KA] Swing Brake Sol Open Circuit 1026
Failure code [DW45KB] Swing Brake Sol Short Circuit .1029
Failure code [DW91KA] Travel Junction Sol Open Circuit 1032
Failure code [DW91KB] Travel Junction Sol Short Circuit .1034
Failure code [DWA2KA] Attachment Sol Open Circuit .1036
Failure code [DWA2KB] Attachment Sol Short Circuit 1038
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .1040
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 1042
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1044
Failure code [DWK2KB] Variable Back Press Sol Short Circuit .1046
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1048
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit .1050
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .1052
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1054
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .1056
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1058
Failure code [DXE0KA] LS-EPC Sol Open Circuit .1060
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1062
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1064
Failure code [DXE4KB] Attachment Flow EPC Short Circuit .1066
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1068
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .1070
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1072
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit .1074
Failure code [DY20KA] Wiper Working Abnormality .1076
Failure code [DY20MA] Wiper Parking Abnormality .1078
Failure code [DY2CKB] Washer Drive Short Circuit 1080
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .1082
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .1084
Troubleshooting of electrical system (E-mode) .1086
E-1 Engine does not start (Engine does not crank) .1086
E-2 Manual preheating system does not work 1092
E-3 Automatic preheating system does not work .1095
E-4 Preheating monitor does not light up when preheater is operated .1097
E-5 When starting switch is turned to ON position, machine monitor displays nothing .1099
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow 1102
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow 1103
E-8 Coolant temperature monitor lights up in white while engine is running 1104
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1105
E-10 Charge level monitor lights up while engine is running .1106
E-11 Fuel level monitor lights up in red while engine is running 1107
E-12 Air cleaner clogging monitor lights up in yellow while engine is running .1108
E-13 Water separator monitor lights up while engine is running 1109
E-14 Coolant temperature monitor lights up in red while engine is running .1110
E-15 Hydraulic oil temperature monitor lights up in red while engine is running .1111
E-16 Engine oil pressure monitor lights up in red while engine is running .1112
E-17 Fuel gauge indicates either full or empty and does not move 1113
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .1114
E-19 Coolant temperature gauge indicates either Min. or Max. and does not move 1115
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) 1116
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move 1117
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) 1119
E-23 Content of display on machine monitor is different from that of actual machine .1120
E-24 Machine monitor does not display some items 1121
E-25 Function switch does not work 1122
E-26 Automatic preheating system does not work (In cold season) .1123
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .1124
E-28 Auto-deceleration is not actuated or canceled when lever is operated .1125
E-29 Working mode selection screen is not diplayed when working mode switch is operated .1126
E-30 Engine or hydraulic pump setting does not change when working mode is changed 1127
E-31 Travel speed monitor does not change when travel speed switch is operated 1128
E-32 Travel speed does not change when travel speed is shifted 1129
E-33 Alarm buzzer does not stop sounding 1130
E-34 When starting switch is turned to OFF position, service meter is not displayed .1131
E-35 Service mode cannot be selected 1132
E-36 Any of work equipment, swing and travel does not work 1133
E-37 Any of work equipment, swing and travel cannot be locked .1135
E-38 Machine cannot swing while swing brake cancel switch is canceled .1136
E-39 Swing brake does not operate while swing brake cancel switch is locked .1138
E-40 One-touch power maximizing function does not work or monitor is not displayed 1140
E-41 One-touch power maximizing function cannot be released .1142
E-42 Travel alarm does not sound when machine travels .1143
E-43 Travel alarm does not stop sounding when machine stops .1144
E-44 Horn does not sound 1145
E-45 Horn does not stop sounding 1147
E-46 Wiper monitor does not light up or go out when wiper switch is operated 1148
E-47 Wiper does not operate when wiper switch is operated .1149
E-48 Window washer does not operate when window washer switch is operated .1151
E-49 BOOM LOWER indication is not displayed properly with monitoring function .1152
E-50 ARM DUMP indication is not displayed properly with monitoring function .1153
E-51 ARM IN indication is not displayed properly with monitoring function .1154
E-52 BOOM RAISE indication is not displayed properly with monitoring function .1155
E-53 BUCKET CURL indication is not displayed properly with monitoring function 1156
E-54 BUCKET DUMP indication is not displayed properly with monitoring function 1157
E-55 SWING indication is not displayed properly with monitoring function 1158
E-56 TRAVEL indication is not displayed properly with monitoring function .1159
E-57 Service is not displayed properly with monitoring function .1160
E-58 Attachment hydraulic circuit cannot be changed .1163
E-59 KOMTRAX system does not work properly 1164
Troubleshooting of hydraulic and mechanical system (H-mode) .1165
Information described in troubleshooting table (H-mode) .1165
System chart for hydraulic system .1166
Failure mode and cause table 1168
H-1 All of work equipment, swing and travel operation lacks speed or power 1176
H-2 Engine speed lowers significantly or engine stalls 1179
H-3 Any of work equipment, swing and travel does not work .1181
H-4 Unusual sound is heard from around hydraulic pump .1182
H-5 Fine control performance or response is poor 1183
H-6 Boom operation lacks speed or power .1184
H-7 Arm operation lacks speed or power 1186
H-8 Bucket operation lacks speed or power .1188
H-9 Work equipment does not move in single operation 1189
H-10 Hydraulic drift of boom is large .1190
H-11 Hydraulic drift of arm is large 1191
H-12 Hydraulic drift of bucket is large .1192
H-13 Time lag of work equipment is large 1193
H-14 When part of work equipment is relieved singly, other parts of work equipment move .1195
H-15 One-touch power maximizing function does not work 1196
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1197
H-17 In combined operations of swing and boom RAISE, boom rising speed is low .1198
H-18 In combined operations of swing and travel, travel speed drops largely .1199
H-19 Machine does not travel straight .1200
H-20 Travel speed is too low 1201
H-21 Machine is hard to steer or travel power is low 1203
H-22 Travel speed does not change, or travel speed is too low or high .1205
H-23 One of tracks does not run .1206
H-24 Upper structure does not swing to the right or left 1207
H-25 Upper structure swings only to the right or left .1208
H-26 Swing acceleration is poor or swing speed is low (both right and left) .1209
H-27 Swing acceleration is poor or swing speed is low (either right or left) 1210
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1211
H-29 Upper structure overruns excessively when it stops swinging (either right or left) .1212
H-30 Shock is large when upper structure stops swinging .1213
H-31 Large unusual noise is heard when upper structure stops swinging .1214
H-32 Swing drift on a slope is large while swing holding brake is applied .1215
H-33 Swing drift on a slope is large while swing holding brake is released 1216
H-34 Attachment circuit cannot be changed while attachment is installed .1217
H-35 Oil flow in attachment circuit cannot be controlled 1218
Troubleshooting of engine (S-mode) 1219
Information mentioned in troubleshooting table (S mode) .1219
S-1 When starting switch is turned to START position, engine does not crank .1220
S-2 When engine cranks, smoke does not come out .1221
S-3 Engine does not start while fuel is injected (Incomplete combustion) 1222
S-4 Start ability is poor 1223
S-5 Engine does not pick up smoothly 1225
S-6 Engine stops during operation .1226
S-7 Engine runs rough or is unstable 1228
S-8 Engine lacks power 1229
S-9 Exhaust smoke is black (KDPF clogs up early) 1231
S-10 Engine oil consumption is too much .1233
S-11 Oil becomes contaminated early .1234
S-12 Fuel consumption is excessive 1235
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .1236
S-14 Engine oil pressure drops 1237
S-15 Fuel is contaminated in engine oil .1238
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .1239
S-17 Coolant temperature rises too high (Overheating) .1240
S-18 Unusual noise is heard .1241
S-19 Vibration is excessive .1242
S-20 Automatic regeneration is operated frequently 1243
S-21 Active regeneration is operated for long .1244
S-22 White smoke comes out in the process of active regeneration 1245
50 Disassembly and assembly .1247
Table of contents .1248
Related information on disassembly and assembly .1250
How to read this manual .1250
Coating materials list 1252
Special tools list 1256
Sketches of special tools .1264
Engine and cooling system .1267
Removal and installation of supply pump assembly 1267
Removal and installation of injector assembly .1272
Removal and installation of cylinder head assembly 1281
Removal and installation of radiator assembly .1301
Removal and installation of hydraulic oil cooler assembly .1303
Removal and installation of aftercooler assembly 1306
Removal and installation of engine and main pump assembly .1308
Removal and installation of engine front oil seal .1320
Removal and installation of engine rear oil seal 1324
Removal and installation of fuel cooler assembly 1327
Removal and installation of fuel tank assembly 1328
Removal and installation of engine hood assembly 1331
Removal and installation of KDPF assembly .1334
Disassembly and assembly of KDPF assembly .1342
Removal and installation of KCCV assembly .1350
Removal and installation of air cleaner assembly 1354
Power train system 1357
Removal and installation of travel motor and final drive assembly .1357
Disassembly and assembly of final drive .1358
Removal and installation of swing motor and swing machinery assembly 1366
Disassembly and assembly of swing machinery .1369
Removal and installation of swing circle assembly .1377
Undercarriage and frame .1378
Separation and connection of track shoe assembly 1378
Removal and installation of sprocket 1381
Removal and installation of idler and idler cushion assembly 1382
Disassembly and assembly of idler .1383
Disassembly and assembly of idler cushion .1386
Disassembly and assembly of track roller 1388
Disassembly and assembly of carrier roller 1391
Removal and installation of revolving frame assembly 1394
Removal and installation of counterweight assembly 1396
Hydraulic system 1399
Removal and installation of center swivel joint assembly 1399
Disassembly and assembly of center swivel joint .1402
Removal and installation of hydraulic tank assembly .1403
Removal and installation of main pump assembly 1407
Removal and installation of control valve assembly 1411
Disassembly and assembly of control valve .1418
Disassembly and assembly of work equipment PPC valve 1425
Disassembly and assembly of travel PPC valve 1428
Work equipment 1431
Removal and installation of work equipment assembly .1431
Disassembly and assembly of work equipment cylinder .1434
Remove and install anti-drop valve assembly for boom .1440
Remove and install anti-drop valve assembly for arm 1442
Disassemble and assemble anti-drop valve assembly 1444
Cab and its attachments .1446
Removal and installation of operator’s cab assembly .1446
Removal and installation of operator cab glass (adhered glass) 1451
Removal and installation of front window assembly .1461
Removal and installation of floor frame assembly 1467
Removal and installation of air conditioner unit assembly .1473
Removal and installation of operator’s seat .1477
Removal and installation of seat belt .1479
Removal and installation of front wiper assembly 1481
Electrical system .1490
Removal and installation of air conditioner compressor assembly .1490
Removal and installation of air conditioner condenser assembly 1493
Removal and installation of engine controller assembly 1495
Removal and installation of pump controller assembly 1497
Removal and installation of machine monitor assembly 1500
Removal and installation of pump swash plate sensor .1502
Removal and installation of mass air flow and temperature sensor 1503
Removal and installation of KOMTRAX terminal assembly .1504
60 Maintenance standard .1507
Table of contents .1508
Engine and cooling system .1509
Engine mount 1509
Cooling system 1510
Power train system 1511
Swing circle 1511
Swing machinery .1512
Final drive .1514
Undercarriage and frame .1516
Sprocket 1516
Track frame and idler cushion .1518
Idler .1520
Track roller 1522
Carrier roller 1523
Track shoe 1524
Hydraulic system 1528
Hydraulic tank 1528
Main pump .1529
Control valve .1530
Swing motor .1540
Travel motor 1542
PPC valve .1545
Solenoid valve 1554
Attachment circuit selector valve (for high-pressure circuit) .1555
Attachment circuit selector valve (for low-pressure circuit) 1556
Anti-drop valve for boom .1557
Anti-drop valve for arm 1559
Center swivel joint .1561
Work equipment 1562
Work equipment 1562
Work equipment cylinder .1571
80 Appendix .1575
Table of contents .1576
Air conditioner components 1577
Precautions for refrigerant .1577
Air conditioner component .1578
Configuration and function of refrigeration cycle .1580
Outline of refrigeration cycle 1581
Air conditioner unit 1583
Dual pressure switch 1590
Air conditioner controller 1591
Compressor 1592
Air conditioner condenser .1593
Sunlight sensor .1595
Outer temperature sensor (outside air temperature sensor) .1596
Procedure for testing and troubleshooting .1597
Circuit diagram and arrangement of connector pins .1599
System diagram 1601
Input and output signals of the air conditioner controller 1602
Parts and connectors layout .1604
Layout of air conditioner related parts and connectors 1605
Testing air leakage (duct) 1608
Testing with self-diagnosis function 1611
How to open the electrical system abnormality record screen in service mode of the machine monitor 1612
Testing vent (mode) changeover 1614
Testing FRESH/RECIRC air changeover .1616
Testing sunlight sensor .1617
Testing (dual) pressure switch for refrigerant 1618
Testing relays 1619
Troubleshooting chart 1 .1620
Troubleshooting chart 2 .1621
Information in troubleshooting table 1624
Failure code list related to air conditioner 1625
Failure code [879AKA] A/C Inner sensor Open Circuit .1626
Failure code [879AKB] A/C Inner sensor Short Circuit 1627
Failure code [879BKA] A/C Outer sensor Open Circuit .1628
Failure code [879BKB] A/C Outer sensor Short Circuit 1630
Failure code [879CKA] Ventilating sensor Open Circuit .1632
Failure code [879CKB] Ventilating sensor Short Circuit 1633
Failure code [879DKZ] Sunlight sensor Open or Short Circuit .1634
Failure code [879EMC] Ventilating Damper Abnormality 1636
Failure code [879FMC] Air Mix Damper Abnormality 1637
Failure code [879GKX] Refrigerant Abnormality .1638
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1639
A-2 Troubleshooting of compressor system (Air is not cooled) 1641
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1644
A-4 Troubleshooting for FRESH/RECIRC air changeover .1646
Troubleshooting with gauge pressure .1648
Testing refrigerant pressure 1651
Precautions for disconnecting and connecting air conditioner piping .1654
Handling of compressor oil 1656
Desiccant replacement .1658
90 Diagrams and drawings 1661
Table of contents .1662
Hydraulic circuit diagram .1663
Symbols in hydraulic circuit diagram 1663
Hydraulic circuit diagram .1667
Electric circuit diagram 1671
Symbols in electric circuit diagram .1671
Electric circuit diagram 1675
Electric circuit diagram for air conditioner unit .1687
INDEX 1689

DESCRIPTION:

Komatsu PC240LC-10 Hydraulic Excavator Shop Manual SEN05538-08 – PDF DOWNLOAD

• SERIAL NUMBERS 90001 and up

G.B 26/12/24