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KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05538-12 – PDF
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KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05538-12 – PDF DOWNLOAD
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KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05538-12 – PDF DOWNLOAD
Language : English
Pages : 1716
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05538-12 – PDF DOWNLOAD
Cover.......................................................................................................................................... 3 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 mass air flow and temperature sensor....................................................................................... 386 Testing and adjusting valve clearance ............................................................................................. 389 Testing compression pressure ...................................................................................................... 392 Measuring blowby pressure ......................................................................................................... 396 Measuring engine oil pressure ..................................................................................................... 397 Measuring EGR valve and KVGT oil pressure ......................................................................................... 398 Measuring fuel pressure ........................................................................................................... 399 Measuring fuel delivery, return and leakage ....................................................................................... 405 Bleeding air from fuel system ..................................................................................................... 410 Testing fuel circuit for leakage .................................................................................................. 412 Handling cylinder cutout mode operation ........................................................................................... 413 Handling no-injection cranking operation .......................................................................................... 414 Testing and adjusting air conditioner compressor belt tension ..................................................................... 415 Replacing fan belt ................................................................................................................ 416 Power train ........................................................................................................................... 417 Testing swing circle bearing clearance ............................................................................................ 417 Undercarriage and frame ............................................................................................................... 418 Testing and adjusting track tension ............................................................................................... 418 Hydraulic system ...................................................................................................................... 419 Releasing remaining pressure from hydraulic circuit ............................................................................... 419 Measuring and adjusting oil pressure in work equipment, swing, and travel circuits ................................................ 424 Testing oil pressure in control circuit ........................................................................................... 428 Testing and adjusting oil pressure in pump PC control circuit ..................................................................... 429 Testing and adjusting oil pressure in pump LS control circuit ..................................................................... 432 Testing output pressure of solenoid valve ......................................................................................... 437 Measuring PPC valve output pressure ............................................................................................... 441 Adjusting play of work equipment and swing PPC valves ............................................................................. 443 Testing pump swash plate sensor ................................................................................................... 444 Isolating the parts causing hydraulic drift in work equipment ..................................................................... 445 Testing oil leakage ............................................................................................................... 447 Bleeding air from hydraulic circuit ............................................................................................... 450 Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side).................... 452 Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side)......................................... 454 Replacing accumulator bladder on high pressure side for accumulator piping......................................................... 456 Cab and its attachments ............................................................................................................... 462 Testing cab tipping stopper ....................................................................................................... 462 Adjusting mirrors ................................................................................................................. 463 Electrical system ..................................................................................................................... 465 Special functions of machine monitor .............................................................................................. 465 Adjusting rearview camera angle ................................................................................................... 531 Handling voltage circuit of engine controller ..................................................................................... 533 Handling battery disconnect switch ................................................................................................ 534 Testing diodes .................................................................................................................... 535 Pm clinic ............................................................................................................................. 536 Pm clinic service ................................................................................................................. 536 40 Troubleshooting ........................................................................................................................ 547 Table of contents ..................................................................................................................... 548 Related information on troubleshooting ................................................................................................ 555 Troubleshooting points ............................................................................................................ 555 Sequence of events in troubleshooting ............................................................................................. 557 Testing before troubleshooting .................................................................................................... 559 Inspection procedure before troubleshooting ....................................................................................... 561 Preparation work for troubleshooting of electrical system ......................................................................... 589 Classification and procedure for troubleshooting .................................................................................. 593 Symptom of probable failure and troubleshooting No. ............................................................................... 596 Information in troubleshooting table .............................................................................................. 599 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................... 601 Connector list and layout ......................................................................................................... 603 Connector contact identification .................................................................................................. 614 T-branch box and T-branch adapter table ........................................................................................... 653 Fuse list and location ............................................................................................................ 658 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ..................................................................... 660 Failure codes table ............................................................................................................... 663 Troubleshooting by failure code (Display of code) ..................................................................................... 672 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................... 672 Failure code [879AKB] A/C Inner Sensor Short Circuit .............................................................................. 673 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................... 674 Failure code [879BKB] A/C Outer Sensor Short Circuit .............................................................................. 675 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................................. 676 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................ 677 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....................................................................... 678 Failure code [879EMC] Ventilation Damper Abnormality .............................................................................. 679 Failure code [879FMC] Air Mix Damper Abnormality .................................................................................. 680 Failure code [879GKX] Refrigerant Abnormality ..................................................................................... 681 Failure code [989L00] Engine Controller Lock Caution1 ............................................................................. 682 Failure code [989M00] Engine Controller Lock Caution2 ............................................................................. 683 Failure code [989N00] Engine Controller Lock Caution3 ............................................................................. 684 Failure code [A1U0N3] HC desorb request1 .......................................................................................... 685 Failure code [A1U0N4] HC desorb request2 .......................................................................................... 687 Failure code [AA10NX] Air Cleaner Clogging ........................................................................................ 689 Failure code [AB00KE] Charge Voltage Low .......................................................................................... 691 Failure code [B@BAZG] Engine Oil Pressure Low ..................................................................................... 693 Failure code [B@BAZK] Eng Oil Level Low ........................................................................................... 694 Failure code [B@BCNS] Engine Coolant Overheat ..................................................................................... 695 Failure code [B@BCZK] Radiator Coolant Level Low .................................................................................. 696 Failure code [B@HANS] Hyd Oil Overheat ............................................................................................ 698 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................. 699 Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. 700 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... 702 Failure code [CA131] Throttle Sensor High Error ................................................................................... 704 Failure code [CA132] Throttle Sensor Low Error .................................................................................... 706 Failure code [CA144] Coolant Temp Sens High Error ................................................................................. 708 Failure code [CA145] Coolant Temp Sens Low Error .................................................................................. 710 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 712 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 714 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................... 716 Failure code [CA221] Ambient Press Sensor High Error .............................................................................. 718 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................... 720 Failure code [CA227] Sensor 2 Supply Volt High Error .............................................................................. 722 Failure code [CA234] Eng Overspeed ................................................................................................ 723 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................ 724 Failure code [CA239] Ne Speed Sens Supply Volt High Error ......................................................................... 725 Failure code [CA271] IMV/PCV1 Short Error ......................................................................................... 726 Failure code [CA272] IMV/PCV1 Open Error .......................................................................................... 728 Failure code [CA295] Ambient Press Sens In Range Error ............................................................................ 729 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................................. 730 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................................. 732 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................................. 734 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................................. 736 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................................. 738 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................................. 740 Failure code [CA343] ECM Critical Internal Failure ................................................................................ 742 Failure code [CA351] Injectors Drive Circuit Error ................................................................................ 743 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................... 744 Failure code [CA356] Mass Air Flow Sensor High Error .............................................................................. 746 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................... 748 Failure code [CA386] Sensor 1 Supply Volt High Error .............................................................................. 750 Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 751 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 753 Failure code [CA435] Eng Oil Press Sw Error ....................................................................................... 755 Failure code [CA441] Battery Voltage Low Error .................................................................................... 756 Failure code [CA442] Battery Voltage High Error ................................................................................... 758 Failure code [CA449] Rail Press Very High Error ................................................................................... 759 Failure code [CA451] Rail Press Sensor High Error ................................................................................. 760 Failure code [CA452] Rail Press Sensor Low Error .................................................................................. 762 Failure code [CA488] Chg Air Temp High Torque Derate .............................................................................. 763 Failure code [CA515] Rail Press Sens Sup Volt High Error .......................................................................... 764 Failure code [CA516] Rail Press Sens Sup Volt Low Error ........................................................................... 766 Failure code [CA553] Rail Press High Error ........................................................................................ 768 Failure code [CA555] Crankcase Press High Error 1 ................................................................................. 769 Failure code [CA556] Crankcase Press High Error 2 ................................................................................. 770 Failure code [CA559] Rail Press Low Error ......................................................................................... 771 Failure code [CA595] Turbo Speed High Error 2 ..................................................................................... 773 Failure code [CA687] Turbo Speed Low Error ........................................................................................ 774 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 776 Failure code [CA691] Intake Air Temp Sens High Error .............................................................................. 778 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................... 780 Failure code [CA697] ECM Int Temp Sensor High Error ............................................................................... 782 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................ 783 Failure code [CA731] Eng Bkup Speed Sens Phase Error .............................................................................. 784 Failure code [CA778] Eng Bkup Speed Sensor Error .................................................................................. 785 Failure code [CA1117] Persistent Data Lost Error .................................................................................. 789 Failure code [CA1664] KDOC Malfunction ............................................................................................ 790 Failure code [CA1691] Regeneration Ineffective .................................................................................... 792 Failure code [CA1695] Sensor 5 Supply Volt High Error ............................................................................. 794 Failure code [CA1696] Sensor 5 Supply Volt Low Error .............................................................................. 796 Failure code [CA1843] Crankcase Press Sens High Error ............................................................................. 798 Failure code [CA1844] Crankcase Press Sens Low Error .............................................................................. 800 Failure code [CA1879] KDPF Delta P Sensor High Error .............................................................................. 802 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................... 804 Failure code [CA1883] KDPF Delta P Sens In Range Error ............................................................................ 806 Failure code [CA1921] KDPF Soot Load High Error 1 ................................................................................. 809 Failure code [CA1922] KDPF Soot Load High Error 2 ................................................................................. 811 Failure code [CA1942] Crankcase Press Sens In Range Error ......................................................................... 816 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................... 817 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................ 818 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................................. 819 Failure code [CA2249] Rail Press Very Low Error ................................................................................... 820 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................... 821 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................ 823 Failure code [CA2288] Turbo Speed High Error 1 .................................................................................... 826 Failure code [CA2311] IMV Solenoid Error .......................................................................................... 827 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................... 828 Failure code [CA2353] EGR Valve Solenoid Short Error .............................................................................. 830 Failure code [CA2357] EGR Valve Servo Error ....................................................................................... 832 Failure code [CA2373] Exh Manifold Press. Sens Volt ............................................................................... 833 Failure code [CA2374] Exhaust Manifold Press Sens Low Error ....................................................................... 835 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................ 837 Failure code [CA2376] EGR Orifice Temp Sens Low Error ............................................................................. 839 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................... 841 Failure code [CA2382] KVGT Pos Sens Low Error ..................................................................................... 843 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................... 845 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................... 847 Failure code [CA2387] VGT Servo Error ............................................................................................. 849 Failure code [CA2554] Exh Manifold Press Sens In Range Error ...................................................................... 852 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................... 853 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................................. 856 Failure code [CA2637] KDOC Face Plugging .......................................................................................... 858 Failure code [CA2639] Manual Stationary Regeneration Request ...................................................................... 860 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................... 862 Failure code [CA2973] Chg Air Press Sensor In Range Error ......................................................................... 863 Failure code [CA3133] KDPF Outlet Press Sens High Error ........................................................................... 864 Failure code [CA3134] KDPF Outlet Press Sens Low Error ............................................................................ 866 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....................................................................... 868 Failure code [CA3251] KDOC Inlet Temp High Error .................................................................................. 871 Failure code [CA3253] KDOC Temp Error - Non Regeneration .......................................................................... 874 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................... 876 Failure code [CA3255] KDPF Temp Error - Non Regeneration .......................................................................... 879 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................... 880 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................... 881 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................... 882 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ............................................................................ 884 Failure code [CA3314] KDOC Inlet Temp Sens High Error ............................................................................. 887 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ......................................................................... 891 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ............................................................................. 895 Failure code [CA3317] KDOC Outlet Temp Sens High Error ............................................................................ 898 Failure code [CA3318] KDOC Inlet Temp Sens In Range Error ......................................................................... 902 Failure code [CA3319] KDPF Outlet Temp Sens High Error ............................................................................ 906 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ............................................................................. 910 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ........................................................................ 913 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................... 917 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..................................................................... 918 Failure code [CA3741] Rail Press Valve Trip Error ................................................................................. 920 Failure code [D110KB] Battery Relay Output Voltage ................................................................................ 921 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................................. 923 Failure code [D811MC] KOMTRAX Error ............................................................................................... 926 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................... 927 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ....................................................................... 928 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................................................... 930 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....................................................................................... 931 Failure code [DA20MC] Pump Controller ............................................................................................. 932 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................... 933 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................... 935 Failure code [DA29KQ] Model Selection Abnormality ................................................................................. 938 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ...................................................................... 940 Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ..................................................................... 942 Failure code [DA2QKR] CAN2 Discon (Pump Con) ...................................................................................... 943 Failure code [DA2RKR] CAN1 Discon (Pump Con) ...................................................................................... 945 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................................................... 946 Failure code [DAF0MC] Monitor Error ............................................................................................... 947 Failure code [DAF8KB] Camera Power Supply Short Circuit ........................................................................... 948 Failure code [DAF9KQ] Model Selection Abnormality ................................................................................. 950 Failure code [DAFGMC] GPS Module Error ............................................................................................ 951 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ....................................................................... 952 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ...................................................................... 954 Failure code [DAFQKR] CAN2 Discon (Monitor) ....................................................................................... 955 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................................. 956 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................................... 957 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................... 961 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................... 966 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................ 970 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ........................................................................ 972 Failure code [DHPAMA] F Pump Press Sensor Abnormality ............................................................................. 973 Failure code [DHPBMA] R Pump Press Sensor Abnormality ............................................................................. 976 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ....................................................................... 979 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................................................... 981 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ..................................................................... 984 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ..................................................................... 987 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ....................................................................... 990 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................................................... 993 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ....................................................................... 996 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................................... 999 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ..................................................................1002 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ..................................................................1005 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ..................................................................1008 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ..................................................................1011 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .......................................................................1014 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .......................................................................1017 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .....................................................................1020 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .....................................................................1022 Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................................1024 Failure code [DW43KA] Travel Speed Sol Open Circuit ...............................................................................1026 Failure code [DW43KB] Travel Speed Sol Short Circuit ..............................................................................1028 Failure code [DW45KA] Swing Brake Sol Open Circuit ................................................................................1030 Failure code [DW45KB] Swing Brake Sol Short Circuit ...............................................................................1033 Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................1036 Failure code [DW91KB] Travel Junction Sol Short Circuit ...........................................................................1038 Failure code [DWA2KA] Attachment Sol Open Circuit .................................................................................1040 Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................1042 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .............................................................................1044 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ............................................................................1046 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ........................................................................1048 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .......................................................................1050 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ............................................................................1052 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ...........................................................................1054 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .................................................................................1056 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ................................................................................1058 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .................................................................................1060 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ................................................................................1062 Failure code [DXE0KA] LS-EPC Sol Open Circuit .....................................................................................1064 Failure code [DXE0KB] LS-EPC Sol Short Circuit ....................................................................................1066 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ............................................................................1068 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...........................................................................1070 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........................................................................1072 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .........................................................................1074 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ............................................................................1076 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...........................................................................1078 Failure code [DY20KA] Wiper Working Abnormality ...................................................................................1080 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................................1082 Failure code [DY2CKB] Washer Drive Short Circuit ..................................................................................1084 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................1086 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .............................................................................1088 Troubleshooting of electrical system (E-mode) .........................................................................................1090 E-1 Engine does not start (Engine does not crank) .................................................................................1090 E-2 Manual preheating system does not work ........................................................................................1096 E-3 Automatic preheating system does not work .....................................................................................1099 E-4 Preheating monitor does not light up when preheater is operated ...............................................................1101 E-5 When starting switch is turned to ON position, machine monitor displays nothing ...............................................1103 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ..........1106 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ....1107 E-8 Coolant temperature monitor lights up in white while engine is running ........................................................1108 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................................................1109 E-10 Charge level monitor lights up while engine is running .......................................................................1110 E-11 Fuel level monitor lights up in red while engine is running ..................................................................1111 E-12 Air cleaner clogging monitor lights up in yellow while engine is running .....................................................1112 E-13 Water separator monitor lights up while engine is running ....................................................................1113 E-14 Coolant temperature monitor lights up in red while engine is running .........................................................1114 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................................................1115 E-16 Engine oil pressure monitor lights up in red while engine is running .........................................................1116 E-17 Fuel gauge indicates either full or empty and does not move ..................................................................1117 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .....................................................1118 E-19 Coolant temperature gauge indicates either Min. or Max. and does not move ....................................................1119 E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) ..................................1120 E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move ..............................................1121 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) ............................1123 E-23 Content of display on machine monitor is different from that of actual machine ...............................................1124 E-24 Machine monitor does not display some items ..................................................................................1125 E-25 Function switch does not work ................................................................................................1126 E-26 Automatic preheating system does not work (In cold season) ...................................................................1127 E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .....................1128 E-28 Auto-deceleration is not actuated or canceled when lever is operated .........................................................1129 E-29 Working mode selection screen is not diplayed when working mode switch is operated ...........................................1130 E-30 Engine or hydraulic pump setting does not change when working mode is changed ................................................1131 E-31 Travel speed monitor does not change when travel speed switch is operated ....................................................1132 E-32 Travel speed does not change when travel speed is shifted ....................................................................1133 E-33 Alarm buzzer does not stop sounding ..........................................................................................1134 E-34 When starting switch is turned to OFF position, service meter is not displayed ...............................................1135 E-35 Service mode cannot be selected ..............................................................................................1136 E-36 Any of work equipment, swing and travel does not work ........................................................................1137 E-37 Any of work equipment, swing and travel cannot be locked .....................................................................1139 E-38 Machine cannot swing while swing brake cancel switch is canceled .............................................................1140 E-39 Swing brake does not operate while swing brake cancel switch is locked .......................................................1142 E-40 One-touch power maximizing function does not work or monitor is not displayed ................................................1144 E-41 One-touch power maximizing function cannot be released .......................................................................1146 E-42 Travel alarm does not sound when machine travels .............................................................................1147 E-43 Travel alarm does not stop sounding when machine stops .......................................................................1148 E-44 Horn does not sound ..........................................................................................................1149 E-45 Horn does not stop sounding ..................................................................................................1151 E-46 Wiper monitor does not light up or go out when wiper switch is operated ......................................................1152 E-47 Wiper does not operate when wiper switch is operated .........................................................................1153 E-48 Window washer does not operate when window washer switch is operated .........................................................1155 E-49 BOOM LOWER indication is not displayed properly with monitoring function .....................................................1156 E-50 ARM DUMP indication is not displayed properly with monitoring function .......................................................1157 E-51 ARM IN indication is not displayed properly with monitoring function .........................................................1158 E-52 BOOM RAISE indication is not displayed properly with monitoring function .....................................................1159 E-53 BUCKET CURL indication is not displayed properly with monitoring function ....................................................1160 E-54 BUCKET DUMP indication is not displayed properly with monitoring function ....................................................1161 E-55 SWING indication is not displayed properly with monitoring function ..........................................................1162 E-56 TRAVEL indication is not displayed properly with monitoring function .........................................................1163 E-57 Service is not displayed properly with monitoring function ...................................................................1164 E-58 Attachment hydraulic circuit cannot be changed ...............................................................................1167 E-59 KOMTRAX system does not work properly ........................................................................................1168 Troubleshooting of hydraulic and mechanical system (H-mode) ...........................................................................1169 Information described in troubleshooting table (H-mode) ...........................................................................1169 System chart for hydraulic system .................................................................................................1170 Failure mode and cause table ......................................................................................................1172 H-1 All of work equipment, swing and travel operation lacks speed or power ........................................................1180 H-2 Engine speed lowers significantly or engine stalls ............................................................................1183 H-3 Any of work equipment, swing and travel does not work .........................................................................1185 H-4 Unusual sound is heard from around hydraulic pump .............................................................................1186 H-5 Fine control performance or response is poor ..................................................................................1187 H-6 Boom operation lacks speed or power ...........................................................................................1188 H-7 Arm operation lacks speed or power ............................................................................................1190 H-8 Bucket operation lacks speed or power .........................................................................................1192 H-9 Work equipment does not move in single operation ..............................................................................1193 H-10 Hydraulic drift of boom is large .............................................................................................1194 H-11 Hydraulic drift of arm is large ..............................................................................................1195 H-12 Hydraulic drift of bucket is large ...........................................................................................1196 H-13 Time lag of work equipment is large ..........................................................................................1197 H-14 When part of work equipment is relieved singly, other parts of work equipment move ...........................................1199 H-15 One-touch power maximizing function does not work ............................................................................1200 H-16 In combined operation of work equipment, equipment having heavier load moves slower ..........................................1201 H-17 In combined operations of swing and boom RAISE, boom rising speed is low .....................................................1202 H-18 In combined operations of swing and travel, travel speed drops largely .......................................................1203 H-19 Machine does not travel straight .............................................................................................1204 H-20 Travel speed is too low ......................................................................................................1205 H-21 Machine is hard to steer or travel power is low ..............................................................................1207 H-22 Travel speed does not change, or travel speed is too low or high .............................................................1209 H-23 One of tracks does not run ...................................................................................................1210 H-24 Upper structure does not swing to the right or left ..........................................................................1211 H-25 Upper structure swings only to the right or left .............................................................................1212 H-26 Swing acceleration is poor or swing speed is low (both right and left) .......................................................1213 H-27 Swing acceleration is poor or swing speed is low (either right or left) ......................................................1214 H-28 Upper structure overruns excessively when it stops swinging (both right and left) ............................................1215 H-29 Upper structure overruns excessively when it stops swinging (either right or left) ...........................................1216 H-30 Shock is large when upper structure stops swinging ...........................................................................1217 H-31 Large unusual noise is heard when upper structure stops swinging .............................................................1218 H-32 Swing drift on a slope is large while swing holding brake is applied .........................................................1219 H-33 Swing drift on a slope is large while swing holding brake is released ........................................................1220 H-34 Attachment circuit cannot be changed while attachment is installed ...........................................................1221 H-35 Oil flow in attachment circuit cannot be controlled ..........................................................................1222 Troubleshooting of engine (S-mode) ....................................................................................................1223 Information mentioned in troubleshooting table (S mode) ...........................................................................1223 S-1 When starting switch is turned to START position, engine does not crank .......................................................1224 S-2 When engine cranks, smoke does not come out ...................................................................................1225 S-3 Engine does not start while fuel is injected (Incomplete combustion) ..........................................................1226 S-4 Startability is poor ..........................................................................................................1227 S-5 Engine does not pick up smoothly ..............................................................................................1229 S-6 Engine stops during operation .................................................................................................1230 S-7 Engine runs rough or is unstable ..............................................................................................1232 S-8 Engine lacks power ............................................................................................................1233 S-9 Exhaust smoke is black (KDPF clogs up early) ..................................................................................1235 S-10 Engine oil consumption is too much ...........................................................................................1237 S-11 Oil becomes contaminated early ...............................................................................................1238 S-12 Fuel consumption is excessive ................................................................................................1239 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .............................................................1240 S-14 Engine oil pressure drops ....................................................................................................1241 S-15 Fuel is contaminated in engine oil ...........................................................................................1242 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .............................................................1243 S-17 Coolant temperature rises too high (Overheating) .............................................................................1244 S-18 Unusual noise is heard .......................................................................................................1245 S-19 Vibration is excessive .......................................................................................................1246 S-20 Automatic regeneration is operated frequently ................................................................................1247 S-21 Active regeneration is operated for long .....................................................................................1248 S-22 White smoke comes out in the process of active regeneration ..................................................................1249 50 Disassembly and assembly ...............................................................................................................1251 Table of contents .....................................................................................................................1252 Related information on disassembly and assembly .......................................................................................1254 How to read this manual ...........................................................................................................1254 Coating materials list ............................................................................................................1256 Special tools list ................................................................................................................1260 Sketches of special tools .........................................................................................................1268 Engine and cooling system .............................................................................................................1271 Removal and installation of supply pump assembly ..................................................................................1271 Removal and installation of injector assembly .....................................................................................1276 Removal and installation of cylinder head assembly ................................................................................1285 Removal and installation of radiator assembly .....................................................................................1305 Removal and installation of hydraulic oil cooler assembly .........................................................................1307 Removal and installation of aftercooler assembly ..................................................................................1310 Removal and installation of engine and main pump assembly .........................................................................1312 Removal and installation of engine front oil seal .................................................................................1324 Removal and installation of engine rear oil seal ..................................................................................1328 Removal and installation of fuel cooler assembly ..................................................................................1331 Removal and installation of fuel tank assembly ....................................................................................1332 Removal and installation of engine hood assembly ..................................................................................1335 Removal and installation of KDPF assembly .........................................................................................1338 Disassembly and assembly of KDPF assembly .........................................................................................1346 Removal and installation of KCCV assembly .........................................................................................1354 Removal and installation of air cleaner assembly ..................................................................................1358 Power train system ....................................................................................................................1361 Removal and installation of travel motor and final drive assembly .................................................................1361 Disassembly and assembly of final drive ...........................................................................................1362 Removal and installation of swing motor and swing machinery assembly ..............................................................1370 Disassembly and assembly of swing machinery .......................................................................................1373 Removal and installation of swing circle assembly .................................................................................1381 Undercarriage and frame ...............................................................................................................1382 Separation and connection of track shoe assembly ..................................................................................1382 Removal and installation of sprocket ..............................................................................................1385 Removal and installation of idler and idler cushion assembly ......................................................................1386 Disassembly and assembly of idler .................................................................................................1387 Disassembly and assembly of idler cushion .........................................................................................1390 Disassembly and assembly of track roller ..........................................................................................1392 Disassembly and assembly of carrier roller ........................................................................................1395 Removal and installation of revolving frame assembly ..............................................................................1398 Removal and installation of counterweight assembly ................................................................................1400 Hydraulic system ......................................................................................................................1403 Removal and installation of center swivel joint assembly ..........................................................................1403 Disassembly and assembly of center swivel joint ...................................................................................1406 Removal and installation of hydraulic tank assembly ...............................................................................1407 Removal and installation of main pump assembly ....................................................................................1411 Removal and installation of control valve assembly ................................................................................1415 Disassembly and assembly of control valve .........................................................................................1422 Disassembly and assembly of work equipment PPC valve ..............................................................................1429 Disassembly and assembly of travel PPC valve ......................................................................................1432 Work equipment ........................................................................................................................1435 Removal and installation of work equipment assembly ...............................................................................1435 Disassembly and assembly of work equipment cylinder ...............................................................................1438 Remove and install anti-drop valve assembly for boom...............................................................................1444 Remove and install anti-drop valve assembly for arm................................................................................1446 Disassemble and assemble anti-drop valve assembly..................................................................................1448 Cab and its attachments ...............................................................................................................1450 Removal and installation of operator's cab assembly ...............................................................................1450 Removal and installation of operator cab glass (adhered glass) ....................................................................1455 Removal and installation of front window assembly .................................................................................1465 Removal and installation of floor frame assembly ..................................................................................1471 Removal and installation of air conditioner unit assembly .........................................................................1477 Removal and installation of operator's seat .......................................................................................1481 Removal and installation of seat belt .............................................................................................1483 REMOVE AND INSTALL WORK EQUIPMENT CONTROLLEVER ASSEMBLY............................................................................1485 Removal and installation of front wiper assembly ..................................................................................1499 Electrical system .....................................................................................................................1508 Removal and installation of air conditioner compressor assembly ...................................................................1508 Removal and installation of air conditioner condenser assembly ....................................................................1511 Removal and installation of engine controller assembly ............................................................................1513 Removal and installation of pump controller assembly ..............................................................................1515 Removal and installation of machine monitor assembly ..............................................................................1518 Removal and installation of pump swash plate sensor ...............................................................................1520 Removal and installation of mass air flow and temperature sensor ..................................................................1521 Removal and installation of KOMTRAX terminal assembly .............................................................................1522 60 Maintenance standard ...................................................................................................................1525 Table of contents .....................................................................................................................1526 Engine and cooling system .............................................................................................................1527 Engine mount ......................................................................................................................1527 Cooling system ....................................................................................................................1528 Power train system ....................................................................................................................1529 Swing circle ......................................................................................................................1529 Swing machinery ...................................................................................................................1530 Final drive .......................................................................................................................1532 Undercarriage and frame ...............................................................................................................1534 Sprocket ..........................................................................................................................1534 Track frame and idler cushion .....................................................................................................1536 Idler .............................................................................................................................1538 Track roller ......................................................................................................................1540 Carrier roller ....................................................................................................................1541 Track shoe ........................................................................................................................1542 Hydraulic system ......................................................................................................................1546 Hydraulic tank ....................................................................................................................1546 Main pump .........................................................................................................................1547 Control valve .....................................................................................................................1548 Swing motor .......................................................................................................................1558 Travel motor ......................................................................................................................1560 PPC valve .........................................................................................................................1563 Solenoid valve ........................................................................................................................1572 Attachment circuit selector valve (for high-pressure circuit) .........................................................................1573 Attachment circuit selector valve (for low-pressure circuit) ..........................................................................1574 Anti-drop valve for boom...............................................................................................................1575 Anti-drop valve for arm................................................................................................................1577 Center swivel joint ...................................................................................................................1579 Work equipment ........................................................................................................................1580 Work equipment ....................................................................................................................1580 Work equipment cylinder ...........................................................................................................1589 80 Appendix ...............................................................................................................................1593 Table of contents .....................................................................................................................1594 Air conditioner components ............................................................................................................1595 Precautions for refrigerant .......................................................................................................1595 Air conditioner component .........................................................................................................1596 Configuration and function of refrigeration cycle .................................................................................1598 Outline of refrigeration cycle ....................................................................................................1599 Air conditioner unit ..............................................................................................................1601 Dual pressure switch ..............................................................................................................1608 Air conditioner controller ........................................................................................................1609 Compressor ........................................................................................................................1610 Air conditioner condenser .........................................................................................................1611 Sunlight sensor ...................................................................................................................1613 Outer temperature sensor (outside air temperature sensor) .........................................................................1614 Procedure for testing and troubleshooting .........................................................................................1615 Circuit diagram and arrangement of connector pins .................................................................................1617 System diagram ....................................................................................................................1619 Input and output signals of the air conditioner controller ........................................................................1620 Parts and connectors layout .......................................................................................................1622 Layout of air conditioner related parts and connectors ............................................................................1623 Testing air leakage (duct) ........................................................................................................1626 Testing with self-diagnosis function ..............................................................................................1629 How to open the electrical system abnormality record screen in service mode of the machine monitor ................................1630 Testing vent (mode) changeover ....................................................................................................1632 Testing FRESH/RECIRC air changeover ...............................................................................................1634 Testing sunlight sensor ...........................................................................................................1635 Testing (dual) pressure switch for refrigerant ....................................................................................1636 Testing relays ....................................................................................................................1637 Troubleshooting chart 1 ...........................................................................................................1638 Troubleshooting chart 2 ...........................................................................................................1639 Information in troubleshooting table ..............................................................................................1642 Failure code list related to air conditioner ......................................................................................1643 Failure code [879AKA] A/C Inner sensor Open Circuit ...............................................................................1644 Failure code [879AKB] A/C Inner sensor Short Circuit ..............................................................................1645 Failure code [879BKA] A/C Outer sensor Open Circuit ...............................................................................1646 Failure code [879BKB] A/C Outer sensor Short Circuit ..............................................................................1648 Failure code [879CKA] Ventilating sensor Open Circuit .............................................................................1650 Failure code [879CKB] Ventilating sensor Short Circuit ............................................................................1651 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .......................................................................1652 Failure code [879EMC] Ventilating Damper Abnormality ..............................................................................1654 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................1655 Failure code [879GKX] Refrigerant Abnormality .....................................................................................1656 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....................................................1657 A-2 Troubleshooting of compressor system (Air is not cooled) ......................................................................1659 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............................................1662 A-4 Troubleshooting for FRESH/RECIRC air changeover ...............................................................................1664 Troubleshooting with gauge pressure ...............................................................................................1666 Testing refrigerant pressure ......................................................................................................1669 Precautions for disconnecting and connecting air conditioner piping ...............................................................1672 Handling of compressor oil ........................................................................................................1674 Desiccant replacement .............................................................................................................1676 90 Diagrams and drawings ..................................................................................................................1679 Table of contents .....................................................................................................................1680 Hydraulic circuit diagram .............................................................................................................1681 Symbols in hydraulic circuit diagram ..............................................................................................1681 Hydraulic circuit diagram .........................................................................................................1685 Electric circuit diagram ..............................................................................................................1689 Symbols in electric circuit diagram ...............................................................................................1689 Electric circuit diagram ..........................................................................................................1693 Electric circuit diagram for air conditioner unit .................................................................................1705 INDEX......................................................................................................................................1707
DESCRIPTION:
KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05538-12 – PDF DOWNLOAD
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
S.S 24/12/24
