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KOMATSU PC240LC-10 PC240NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05538-02 – PDF DOWNLOAD
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KOMATSU PC240LC-10 PC240NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05538-02 – PDF DOWNLOAD
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Description
KOMATSU PC240LC-10 PC240NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05538-02 – PDF DOWNLOAD
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KOMATSU PC240LC-10 PC240NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05538-02 – PDF DOWNLOAD
Language : English
Pages : 1660
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC240LC-10 PC240NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05538-02 – PDF DOWNLOAD
00 Index and foreword ..................................................................................................................... 0 Index ................................................................................................................................. 4 Foreword, safety and general information .............................................................................................. 16 Important safety notice ........................................................................................................... 16 How to read the shop manual ....................................................................................................... 21 Explanation of terms for maintenance standard ..................................................................................... 23 Handling of fuel system devices ................................................................................................... 25 Handling of intake system parts ................................................................................................... 26 Handling of hydraulic equipment ................................................................................................... 27 Method of disconnecting and connecting push-pull type coupler ..................................................................... 29 Handling of electrical equipment .................................................................................................. 32 How to read electric wire code .................................................................................................... 40 Precautions when performing operation ............................................................................................. 43 Standard tightening torque table .................................................................................................. 46 List of abbreviation .............................................................................................................. 50 Conversion table .................................................................................................................. 54 01 Specifications ......................................................................................................................... 59 Table of contents ..................................................................................................................... 60 Specifications ........................................................................................................................ 61 Specification drawings ............................................................................................................ 61 Working range drawings ............................................................................................................ 62 Specifications .................................................................................................................... 63 Weight table ...................................................................................................................... 66 Table of fuel, coolant and lubricants ............................................................................................. 67 10 Structure and function ................................................................................................................. 69 Table of contents ..................................................................................................................... 70 Engine and cooling system ............................................................................................................. 71 Engine related parts .............................................................................................................. 71 Cooling system .................................................................................................................... 73 Power train system .................................................................................................................... 75 Power train ....................................................................................................................... 75 Swing circle ...................................................................................................................... 77 Swing machinery ................................................................................................................... 78 Final drive ....................................................................................................................... 80 Undercarriage and frame ............................................................................................................... 82 Track frame and idler cushion ..................................................................................................... 82 Hydraulic system ...................................................................................................................... 84 Hydraulic equipment layout drawing ................................................................................................ 84 Valve control ..................................................................................................................... 86 Hydraulic tank .................................................................................................................... 87 CLSS .............................................................................................................................. 89 Main pump ......................................................................................................................... 94 Control valve ..................................................................................................................... 119 Swing motor ....................................................................................................................... 172 Travel motor ...................................................................................................................... 183 PPC valve ......................................................................................................................... 196 Solenoid valve .................................................................................................................... 217 Attachment circuit selector valve (for low pressure circuit) ...................................................................... 220 Center swivel joint ............................................................................................................... 223 Accumulator ....................................................................................................................... 225 ATT EPC valve assembly ............................................................................................................ 226 Return oil filter ................................................................................................................. 228 Quick coupler control valve ....................................................................................................... 229 Work equipment ........................................................................................................................ 232 Work equipment .................................................................................................................... 232 Work equipment shim ............................................................................................................... 233 Bucket play adjustment shim ....................................................................................................... 234 Cab and its attachments ............................................................................................................... 235 Cab mount and cab tipping stopper ................................................................................................. 235 ROPS cab .......................................................................................................................... 236 Electrical system ..................................................................................................................... 237 Electrical control system ......................................................................................................... 237 Machine monitor system ............................................................................................................ 281 KOMTRAX system .................................................................................................................... 300 Sensors ........................................................................................................................... 302 PPC levers ........................................................................................................................ 321 Auto grease system ................................................................................................................ 323 20 Standard value table ................................................................................................................... 335 Table of contents ..................................................................................................................... 336 Standard service value table .......................................................................................................... 337 Standard value table for engine related parts ..................................................................................... 337 Standard value table for chassis related parts .................................................................................... 338 30 Testing and adjusting .................................................................................................................. 351 Table of contents ..................................................................................................................... 352 General information on testing and adjusting .......................................................................................... 353 Tools for testing and adjusting ................................................................................................... 353 Sketch of tools for testing and adjusting ......................................................................................... 357 Engine and cooling system ............................................................................................................. 359 Checking engine speed ............................................................................................................. 359 Measuring boost pressure .......................................................................................................... 360 Measuring exhaust gas color ....................................................................................................... 361 Measuring and adjusting valve clearance ........................................................................................... 363 Measuring compression pressure .................................................................................................... 366 Measuring blowby pressure ......................................................................................................... 370 Measuring engine oil pressure ..................................................................................................... 371 Measuring EGR valve and KVGT oil pressure ......................................................................................... 372 Measuring fuel pressure ........................................................................................................... 373 Measuring fuel delivery, return and leakage ....................................................................................... 379 Bleeding air from fuel system ..................................................................................................... 384 Checking fuel circuit for leakage ................................................................................................. 386 Handling cylinder cutout mode operation ........................................................................................... 387 Handling no injection cranking operation .......................................................................................... 388 Checking and adjusting air conditioner compressor belt tension .................................................................... 389 Replacing fan belt ................................................................................................................ 390 Power train ........................................................................................................................... 391 Testing swing circle bearing clearance ............................................................................................ 391 Undercarriage and frame ............................................................................................................... 392 Testing and adjusting track shoe tension .......................................................................................... 392 Hydraulic system ...................................................................................................................... 393 Releasing remaining pressure from hydraulic circuit ............................................................................... 393 Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits ............................................. 394 Measuring oil pressure in control circuit ......................................................................................... 398 Measuring and adjusting oil pressure in pump PC control circuit ................................................................... 399 Measuring and adjusting oil pressure in pump LS control circuit ................................................................... 402 Measuring solenoid valve output pressure .......................................................................................... 407 Measuring PPC valve output pressure ............................................................................................... 410 Adjusting play of work equipment and swing PPC valves ............................................................................. 412 Measuring and adjusting quick coupler control valve output pressure ............................................................... 413 Testing pump swash plate sensor ................................................................................................... 414 Isolating the parts causing hydraulic drift in work equipment ..................................................................... 415 Measuring oil leakage ............................................................................................................. 416 Bleeding air from hydraulic circuit ............................................................................................... 419 Cab and its attachments ............................................................................................................... 421 Checking cab tipping stopper ...................................................................................................... 421 Adjusting mirrors ................................................................................................................. 422 Electrical system ..................................................................................................................... 424 Special functions of machine monitor .............................................................................................. 424 Angle adjustment of rear view camera .............................................................................................. 493 Handling voltage circuit of engine controller ..................................................................................... 495 Handling battery disconnect switch ................................................................................................ 496 Testing diodes .................................................................................................................... 497 Pm clinic ............................................................................................................................. 498 Pm clinic service ................................................................................................................. 498 40 Troubleshooting ........................................................................................................................ 509 Table of contents ..................................................................................................................... 510 General information on troubleshooting ................................................................................................ 517 Instruction on troubleshooting .................................................................................................... 517 How to proceed troubleshooting .................................................................................................... 519 Testing before troubleshooting .................................................................................................... 520 Testing procedure before troubleshooting .......................................................................................... 522 Preparation work for troubleshooting of electrical system ......................................................................... 550 Classification and procedure for troubleshooting .................................................................................. 554 Symptom of probable failure and troubleshooting No. ............................................................................... 557 Information mentioned in troubleshooting table .................................................................................... 560 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................... 562 Connector list and layout ......................................................................................................... 564 Connector contact identification .................................................................................................. 575 T-branch box and T-branch adapter table ........................................................................................... 611 Fuse list and location ............................................................................................................ 617 Precautions for cleaning and replacing KDPF (KCSF, KDOC) .......................................................................... 619 Failure codes table ............................................................................................................... 621 Troubleshooting by failure code (Display of code) ..................................................................................... 630 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................... 630 Failure code [879AKB] A/C Inner Sensor Short Circuit .............................................................................. 631 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................... 632 Failure code [879BKB] A/C Outer Sensor Short Circuit .............................................................................. 633 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................................. 634 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................ 635 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....................................................................... 636 Failure code [879EMC] Ventilation Damper Abnormality .............................................................................. 637 Failure code [879FMC] Air Mix Damper Abnormality .................................................................................. 638 Failure code [879GKX] Refrigerant Abnormality ..................................................................................... 639 Failure code [989L00] Engine Controller Lock Caution1 ............................................................................. 640 Failure code [989M00] Engine Controller Lock Caution2 ............................................................................. 641 Failure code [989N00] Engine Controller Lock Caution3 ............................................................................. 642 Failure code [A1U0N3] HC desorb request1 .......................................................................................... 643 Failure code [A1U0N4] HC desorb request2 .......................................................................................... 645 Failure code [AA10NX] Air Cleaner Clogging ........................................................................................ 647 Failure code [AB00KE] Charge Voltage Low .......................................................................................... 649 Failure code [B@BAZG] Engine Oil Pressure Low ..................................................................................... 651 Failure code [B@BAZK] Eng Oil Level Low ........................................................................................... 652 Failure code [B@BCNS] Engine Coolant Overheat ..................................................................................... 653 Failure code [B@BCZK] Radiator Coolant Level Low .................................................................................. 654 Failure code [B@HANS] Hyd Oil Overheat ............................................................................................ 656 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................. 657 Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. 658 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... 660 Failure code [CA131] Throttle Sensor High Error ................................................................................... 662 Failure code [CA132] Throttle Sensor Low Error .................................................................................... 664 Failure code [CA144] Coolant Temp Sens High Error ................................................................................. 666 Failure code [CA145] Coolant Temp Sens Low Error .................................................................................. 668 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 670 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 672 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................... 674 Failure code [CA221] Ambient Press Sensor High Error .............................................................................. 676 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................... 678 Failure code [CA227] Sensor 2 Supply Volt High Error .............................................................................. 680 Failure code [CA234] Eng Overspeed ................................................................................................ 681 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................ 682 Failure code [CA239] Ne Speed Sens Supply Volt High Error ......................................................................... 683 Failure code [CA271] IMV/PCV1 Short Error ......................................................................................... 684 Failure code [CA272] IMV/PCV1 Open Error .......................................................................................... 686 Failure code [CA295] Ambient Press Sens In Range Error ............................................................................ 687 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................................. 688 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................................. 690 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................................. 692 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................................. 694 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................................. 696 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................................. 698 Failure code [CA343] ECM Critical Internal Failure ................................................................................ 700 Failure code [CA351] Injectors Drive Circuit Error ................................................................................ 701 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................... 702 Failure code [CA356] Mass Air Flow Sensor High Error .............................................................................. 704 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................... 706 Failure code [CA386] Sensor 1 Supply Volt High Error .............................................................................. 708 Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 709 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 711 Failure code [CA435] Eng Oil Press Sw Error ....................................................................................... 713 Failure code [CA441] Battery Voltage Low Error .................................................................................... 714 Failure code [CA442] Battery Voltage High Error ................................................................................... 716 Failure code [CA449] Rail Press Very High Error ................................................................................... 717 Failure code [CA451] Rail Press Sensor High Error ................................................................................. 718 Failure code [CA452] Rail Press Sensor Low Error .................................................................................. 720 Failure code [CA488] Chg Air Temp High Torque Derate .............................................................................. 721 Failure code [CA515] Rail Press Sens Sup Volt High Error .......................................................................... 722 Failure code [CA516] Rail Press Sens Sup Volt Low Error ........................................................................... 724 Failure code [CA553] Rail Press High Error ........................................................................................ 726 Failure code [CA555] Crankcase Press High Error 1 ................................................................................. 727 Failure code [CA556] Crankcase Press High Error 2 ................................................................................. 728 Failure code [CA559] Rail Press Low Error ......................................................................................... 729 Failure code [CA595] Turbo Speed High Error 2 ..................................................................................... 731 Failure code [CA687] Turbo Speed Low Error ........................................................................................ 732 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 734 Failure code [CA691] Intake Air Temp Sens High Error .............................................................................. 736 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................... 738 Failure code [CA697] ECM Int Temp Sensor High Error ............................................................................... 740 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................ 741 Failure code [CA731] Eng Bkup Speed Sens Phase Error .............................................................................. 742 Failure code [CA778] Eng Bkup Speed Sensor Error .................................................................................. 743 Failure code [CA1117] Persistent Data Lost Error .................................................................................. 747 Failure code [CA1664] KDOC Malfunction ............................................................................................ 748 Failure code [CA1691] Regeneration Ineffective .................................................................................... 750 Failure code [CA1695] Sensor 5 Supply Volt Low Error .............................................................................. 752 Failure code [CA1696] Sensor 5 Supply Volt High Error ............................................................................. 754 Failure code [CA1843] Crankcase Press Sens High Error ............................................................................. 756 Failure code [CA1844] Crankcase Press Sens Low Error .............................................................................. 758 Failure code [CA1879] KDPF Delta P Sensor High Error .............................................................................. 760 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................... 762 Failure code [CA1883] KDPF Delta P Sens In Range Error ............................................................................ 764 Failure code [CA1921] KDPF Soot Load High Error 1 ................................................................................. 767 Failure code [CA1922] KDPF Soot Load High Error 2 ................................................................................. 769 Failure code [CA1942] Crankcase Press Sens In Range Error ......................................................................... 773 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................... 774 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................ 775 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................................. 776 Failure code [CA2249] Rail Press Very Low Error ................................................................................... 777 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................... 778 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................ 780 Failure code [CA2288] Turbo Speed High Error 1 .................................................................................... 783 Failure code [CA2311] IMV Solenoid Error .......................................................................................... 784 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................... 785 Failure code [CA2353] EGR Valve Solenoid Short Error .............................................................................. 787 Failure code [CA2357] EGR Differential Pressure ................................................................................... 789 Failure code [CA2373] Exh Manifold Press. Sens Volt ............................................................................... 790 Failure code [CA2374] Exhaust Manifold Press Sens Low Error ....................................................................... 792 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................ 794 Failure code [CA2376] EGR Orifice Temp Sens Low Error ............................................................................. 796 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................... 798 Failure code [CA2382] KVGT Pos Sens Low Error ..................................................................................... 800 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................... 802 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................... 804 Failure code [CA2387] KVGT Servo Error ............................................................................................ 806 Failure code [CA2554] Exh Manifold Press Sens In Range Error ...................................................................... 807 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................... 808 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................................. 810 Failure code [CA2637] KDOC Face Plugging .......................................................................................... 812 Failure code [CA2639] Manual Stationary Regeneration Request ...................................................................... 814 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................... 816 Failure code [CA2973] Chg Air Press Sensor In Range Error ......................................................................... 817 Failure code [CA3133] KDPF Outlet Press Sens High Error ........................................................................... 818 Failure code [CA3134] KDPF Outlet Press Sens Low Error ............................................................................ 820 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....................................................................... 822 Failure code [CA3251] DOC Inlet Temp High Error ................................................................................... 825 Failure code [CA3253] KDOC Temp Error - Non Regeneration .......................................................................... 828 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................... 829 Failure code [CA3255] KDPF Temp Error - Non Regeneration .......................................................................... 832 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................... 833 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................... 834 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................... 835 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ............................................................................ 837 Failure code [CA3314] KDOC Inlet Temp Sens High Error ............................................................................. 840 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ......................................................................... 844 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ............................................................................. 848 Failure code [CA3317] KDOC Outlet Temp Sens High Error ............................................................................ 851 Failure code [CA3318] KDOC Inlet Temp Sens In Range Error ......................................................................... 855 Failure code [CA3319] KDPF Outlet Temp Sens High Error ............................................................................ 859 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ............................................................................. 863 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ........................................................................ 866 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................... 870 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..................................................................... 871 Failure code [CA3741] Rail Press Valve Trip Error ................................................................................. 873 Failure code [D110KB] Battery Relay Output Voltage ................................................................................ 874 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................................. 876 Failure code [D811MC] KOMTRAX Error ............................................................................................... 879 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................... 880 Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) ........................................................................ 881 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................................................... 883 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....................................................................................... 884 Failure code [DA20MC] Pump Controller ............................................................................................. 885 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................... 886 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................... 888 Failure code [DA29KQ] Model Selection Abnormality ................................................................................. 891 Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con) ....................................................................... 893 Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con) ...................................................................... 895 Failure code [DA2QKR] CAN2 Discon (Pump Con) ...................................................................................... 896 Failure code [DA2RKR] CAN1 Discon (Pump Con) ...................................................................................... 898 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................................................... 899 Failure code [DAF0MC] Monitor Error ............................................................................................... 900 Failure code [DAF8KB] Camera Power Supply Short Circuit ........................................................................... 901 Failure code [DAF9KQ] Model Selection Abnormality ................................................................................. 903 Failure code [DAFGMC] GPS Module Error ............................................................................................ 904 Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ........................................................................ 905 Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ....................................................................... 907 Failure code [DAFQKR] CAN2 Discon (Monitor) ....................................................................................... 908 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................................. 909 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................................... 910 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................... 914 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................... 919 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................ 923 Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality ........................................................................ 925 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality ........................................................................ 927 Failure code [DFB3L8] Service Lever 1 Potentio Error .............................................................................. 929 Failure code [DFB4L8] Service Lever 2 Potentio Error .............................................................................. 930 Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality .................................................................... 931 Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality .................................................................... 933 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ........................................................................ 935 Failure code [DHPAMA] F Pump Press Sensor Abnormality ............................................................................. 936 Failure code [DHPBMA] R Pump Press Sensor Abnormality ............................................................................. 939 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ....................................................................... 942 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................................................... 944 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ..................................................................... 947 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ..................................................................... 950 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ....................................................................... 953 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................................................... 956 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ....................................................................... 959 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality .................................................................... 962 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality .................................................................. 965 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .................................................................. 968 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality .................................................................. 971 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality .................................................................. 974 Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ........................................................................ 977 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality ....................................................................... 979 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ....................................................................... 982 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ..................................................................... 985 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ..................................................................... 987 Failure code [DV20KB] Travel Alarm Short Circuit .................................................................................. 989 Failure code [DW43KA] Travel Speed Sol Open Circuit ............................................................................... 991 Failure code [DW43KB] Travel Speed Sol Short Circuit .............................................................................. 993 Failure code [DW45KA] Swing Brake Sol Open Circuit ................................................................................ 995 Failure code [DW45KB] Swing Brake Sol Short Circuit ............................................................................... 997 Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................1000 Failure code [DW91KB] Travel Junction Sol Short Circuit ...........................................................................1002 Failure code [DWA2KA] Attachment Sol Open Circuit .................................................................................1004 Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................1006 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .............................................................................1008 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ............................................................................1010 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ........................................................................1012 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .......................................................................1014 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ............................................................................1016 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ...........................................................................1018 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .................................................................................1020 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ................................................................................1022 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .................................................................................1024 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ................................................................................1026 Failure code [DXE0KA] LS-EPC Sol Open Circuit .....................................................................................1028 Failure code [DXE0KB] LS-EPC Sol Short Circuit ....................................................................................1030 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ............................................................................1032 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...........................................................................1034 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........................................................................1036 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .........................................................................1038 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ............................................................................1040 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...........................................................................1042 Failure code [DXEAKA] Service Current EPC1 Discon .................................................................................1044 Failure code [DXEAKB] Service Current EPC1 Short ..................................................................................1046 Failure code [DXE7KA] Service Current EPC2 Discon .................................................................................1048 Failure code [DXE7KB] Service Current EPC2 Short ..................................................................................1050 Failure code [DXE8KA] Service Current EPC3 Discon .................................................................................1052 Failure code [DXE8KB] Service Current EPC3 Short ..................................................................................1054 Failure code [DXE9KA] Service Current EPC4 Discon .................................................................................1056 Failure code [DXE9KB] Service Current EPC4 Short ..................................................................................1058 Failure code [DY20KA] Wiper Working Abnormality ...................................................................................1060 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................................1062 Failure code [DY2CKB] Washer Drive Short Circuit ..................................................................................1064 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................1066 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .............................................................................1068 Troubleshooting of electrical system (E-mode) .........................................................................................1070 E-1 Engine does not start (Engine does not rotate) ................................................................................1070 E-2 Manual preheating system does not work ........................................................................................1076 E-3 Automatic preheating system does not work .....................................................................................1079 E-4 Preheating monitor does not light up when preheater is operated ...............................................................1081 E-5 When starting switch is turned to ON position, machine monitor displays nothing ...............................................1083 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ..........1086 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ....1087 E-8 Coolant temperature monitor lights up in white while engine is running ........................................................1088 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................................................1089 E-10 Charge level monitor lights up while engine is running .......................................................................1090 E-11 Fuel level monitor lights up in red while engine is running ..................................................................1091 E-12 Air cleaner clogging monitor lights up in yellow while engine is running .....................................................1092 E-13 Water separator monitor lights up while engine is running ....................................................................1093 E-14 Coolant temperature monitor lights up in red while engine is running .........................................................1094 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................................................1095 E-16 Engine oil pressure monitor lights up in red while engine is running .........................................................1096 E-17 Fuel gauge indicate either full or empty and does not move ...................................................................1097 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .....................................................1098 E-19 Coolant temperature gauge indicate either Min or Max and does not move .......................................................1099 E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max) ....................................1100 E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move .................................................1101 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max) ..............................1103 E-23 Content of display on machine monitor is different from that of actual machine ...............................................1104 E-24 Machine monitor does not display some items ..................................................................................1105 E-25 Function switch does not work ................................................................................................1106 E-26 Automatic preheating system does not work (In cold season) ...................................................................1107 E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .....................1108 E-28 Auto-deceleration is not actuated or canceled when lever is operated .........................................................1109 E-29 Working mode selector screen selection screen is not diplayed when working mode switch is operated ...........................1111 E-30 Engine or hydraulic pump setting does not change when working mode is changed ................................................1112 E-31 Travel speed monitor does not change when travel speed switch is operated ....................................................1113 E-32 Travel speed does not change when travel speed is shifted ....................................................................1114 E-33 Alarm buzzer does not stop sounding ..........................................................................................1115 E-34 When starting switch is turned to OFF position, service meter is not displayed ...............................................1116 E-35 Service mode cannot be selected ..............................................................................................1117 E-36 Any of work equipment, swing and travel does not work ........................................................................1118 E-37 Any of work equipment, swing and travel can not be locked ....................................................................1120 E-38 Machine can not swing while swing brake cancel switch is canceled ............................................................1121 E-39 Swing brake does not operate while swing brake cancel switch is locked .......................................................1123 E-40 One-touch power maximizing function does not work or monitor is not displayed ................................................1125 E-41 One-touch power maximizing function cannot be released .......................................................................1127 E-42 Travel alarm does not sound when machine travels .............................................................................1128 E-43 Travel alarm does not stop sounding when machine stops .......................................................................1129 E-44 Horn does not sound ..........................................................................................................1130 E-45 Horn does not stop sounding ..................................................................................................1132 E-46 Wiper monitor does not light up or go out when wipper switch is operated .....................................................1133 E-47 Wiper does not operate when wipper switch is operated ........................................................................1134 E-48 Window washer does not operate when window washer switch is operated .........................................................1136 E-49 BOOM LOWER indication is not displayed properly with monitoring function .....................................................1137 E-50 ARM DUMP indication is not displayed properly with monitoring function .......................................................1138 E-51 ARM IN indication is not displayed properly with monitoring function .........................................................1139 E-52 BOOM RAISE indication is not displayed properly with monitoring function .....................................................1140 E-53 BUCKET CURL indication is not displayed properly with monitoring function ....................................................1141 E-54 BUCKET DUMP indication is not displayed properly with monitoring function ....................................................1142 E-55 SWING indication is not displayed properly with monitoring function ..........................................................1143 E-56 TRAVEL indication is not displayed properly with monitoring function .........................................................1144 E-57 Service is not displayed properly with monitoring function ...................................................................1145 E-58 Attachment hydraulic circuit cannot be changed ...............................................................................1148 E-59 KOMTRAX system does not work properly ........................................................................................1149 Troubleshooting of hydraulic and mechanical system (H-mode) ...........................................................................1150 Information mentioned in troubleshooting table (H mode) ...........................................................................1150 System chart for hydraulic system .................................................................................................1151 Failure mode and cause table ......................................................................................................1153 H-1 All of work equipment, swing and travel operation lacks speed or power ........................................................1161 H-2 Engine speed lowers significantly or engine stalls ............................................................................1164 H-3 Any of work equipment, swing and travel does not work .........................................................................1166 H-4 Unusual sound is heard from around hydraulic pump .............................................................................1167 H-5 Fine control performance or response is poor ..................................................................................1168 H-6 Boom operation lacks speed or power ...........................................................................................1169 H-7 Arm operation lacks speed or power ............................................................................................1171 H-8 Bucket operation lacks speed or power .........................................................................................1173 H-9 Work equipment does not move in single operation ..............................................................................1174 H-10 Hydraulic drift of boom is large .............................................................................................1175 H-11 Hydraulic drift of arm is large ..............................................................................................1176 H-12 Hydraulic drift of bucket is large ...........................................................................................1177 H-13 Time lag of work equipment is large ..........................................................................................1178 H-14 When part of work equipment is relieved singly, other parts of work equipment move ...........................................1180 H-15 One-touch power maximizing function does not work ............................................................................1181 H-16 In combined operation of work equipment, equipment having heavier load moves slower ..........................................1182 H-17 In combined operations of swing and boom RAISE, boom rising speed is low .....................................................1183 H-18 In combined operations of swing and travel, travel speed drops largely .......................................................1184 H-19 Machine does not travel straight .............................................................................................1185 H-20 Travel speed is too low ......................................................................................................1186 H-21 Machine is hard to steer or travel power is low ..............................................................................1188 H-22 Travel speed does not change, or travel speed is too low or high .............................................................1190 H-23 One of tracks dose not run ...................................................................................................1191 H-24 Upper structure does not swing to the right or left ..........................................................................1192 H-25 Upper structure swing only to the right or left ..............................................................................1193 H-26 Swing acceleration is poor or swing speed is low (both right and left) .......................................................1194 H-27 Swing acceleration is poor or swing speed is low (either right or left) ......................................................1195 H-28 Upper structure overruns excessively when it stops swinging (both right and left) ............................................1196 H-29 Upper structure overruns excessively when it stops swinging (either right or left) ...........................................1197 H-30 Shock is large when upper structure stops swinging ...........................................................................1198 H-31 Large unusual noise is heard when upper structure stops swinging .............................................................1199 H-32 Swing drift on a slope is large while swing holding brake is applied .........................................................1200 H-33 Swing drift on a slope is large while swing holding brake is released ........................................................1201 H-34 Attachment circuit cannot be changed while attachment is installed ...........................................................1202 H-35 Oil flow in attachment circuit cannot be controlled ..........................................................................1203 H-36 Quick coupler cylinder will not extend .......................................................................................1204 H-37 Quick coupler cylinder will not extend (but buzzer does not sound) ...........................................................1206 H-38 Buzzer does not sound (but quick coupler cylinder does retract) ..............................................................1208 H-39 Quick coupler cylinder extends and retracts slowly ...........................................................................1210 Troubleshooting of engine (S-mode) ....................................................................................................1211 Information mentioned in troubleshooting table (S mode) ...........................................................................1211 S-1 When starting switch is turned to START position, engine does not crank .......................................................1212 S-2 When engine cranks, smoke does not come out ...................................................................................1213 S-3 Engine does not start while fuel is injected (Incomplete combustion) ..........................................................1214 S-4 Startability is poor ..........................................................................................................1215 S-5 Engine does not pick up smoothly ..............................................................................................1217 S-6 Engine stops during operation .................................................................................................1218 S-7 Engine runs rough or is unstable ..............................................................................................1220 S-8 Engine lacks power ............................................................................................................1221 S-9 Exhaust smoke is black (KDPF clogs up early) ..................................................................................1223 S-10 Engine oil consumption is too much ...........................................................................................1225 S-11 Oil becomes contaminated early ...............................................................................................1226 S-12 Fuel consumption is excessive ................................................................................................1227 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .............................................................1228 S-14 Engine oil pressure drops ....................................................................................................1229 S-15 Fuel is contaminated in engine oil ...........................................................................................1230 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .............................................................1231 S-17 Coolant temperature rises too high (Overheating) .............................................................................1232 S-18 Unusual noise is heard .......................................................................................................1233 S-19 Vibration is excessive .......................................................................................................1234 S-20 Automatic regeneration is operated frequently ................................................................................1235 S-21 Active regeneration is operated for long .....................................................................................1236 S-22 White smoke comes out in the process of active regeneration ..................................................................1237 Auto grease system ....................................................................................................................1238 Finding malfunctions ..............................................................................................................1238 Malfunction finding procedures ....................................................................................................1241 50 Disassembly and assembly ...............................................................................................................1243 Table of contents .....................................................................................................................1244 General information on disassembly and assembly .......................................................................................1246 How to read this manual ...........................................................................................................1246 Coating materials list ............................................................................................................1248 Special tools list ................................................................................................................1252 Sketches of special tools .........................................................................................................1258 Engine and cooling system .............................................................................................................1261 Removal and installation of supply pump assembly ..................................................................................1261 Removal and installation of injector assembly .....................................................................................1266 Removal and installation of cylinder head assembly ................................................................................1275 Removal and installation of radiator assembly .....................................................................................1295 Removal and installation of hydraulic oil cooler assembly .........................................................................1297 Removal and installation of aftercooler assembly ..................................................................................1300 Removal and installation of engine and main pump assembly .........................................................................1302 Removal and installation of engine front oil seal .................................................................................1314 Removal and installation of engine rear oil seal ..................................................................................1318 Removal and installation of fuel cooler assembly ..................................................................................1321 Removal and installation of fuel tank assembly ....................................................................................1322 Removal and installation of engine hood assembly ..................................................................................1325 Removal and installation of KDPF assembly .........................................................................................1328 Disassembly and assembly of KDPF ..................................................................................................1336 Removal and installation of KCCV assembly .........................................................................................1344 Removal and installation of air cleaner assembly ..................................................................................1346 Power train ...........................................................................................................................1349 Removal and installation of travel motor and final drive assembly .................................................................1349 Disassembly and assembly of final drive ...........................................................................................1350 Removal and installation of swing motor and swing machinery assembly ..............................................................1358 Disassembly and assembly of swing machinery .......................................................................................1361 Removal and installation of swing circle assembly .................................................................................1369 Undercarriage and frame ...............................................................................................................1370 Separation and connection of track shoe assembly ..................................................................................1370 Removal and installation of sprocket ..............................................................................................1372 Removal and installation of idler and idler cushion assembly ......................................................................1373 Disassembly and assembly of idler .................................................................................................1374 Disassembly and assembly of idler cushion .........................................................................................1377 Disassembly and assembly of track roller ..........................................................................................1379 Disassembly and assembly of carrier roller ........................................................................................1381 Removal and installation of revolving frame assembly ..............................................................................1384 Removal and installation of counterweight assembly ................................................................................1386 Hydraulic system ......................................................................................................................1389 Removal and installation of center swivel joint assembly ..........................................................................1389 Disassembly and assembly of center swivel joint ...................................................................................1391 Removal and installation of hydraulic tank assembly ...............................................................................1392 Removal and installation of main pump assembly ....................................................................................1396 Removal and installation of control valve assembly ................................................................................1400 Disassembly and assembly of control valve .........................................................................................1407 Disassembly and assembly of work equipment PPC valve ..............................................................................1412 Disassembly and assembly of travel PPC valve ......................................................................................1414 Removal and installation of quick coupler valve ...................................................................................1417 Work equipment ........................................................................................................................1418 Removal and installation of work equipment assembly ...............................................................................1418 Disassembly and assembly of work equipment cylinder ...............................................................................1421 Cab and its attachments ...............................................................................................................1427 Removal and installation of operator's cab assembly ...............................................................................1427 Removal and installation of operator cab glass (adhered glass) ....................................................................1432 Removal and installation of front window assembly .................................................................................1442 Removal and installation of floor frame assembly ..................................................................................1448 Removal and installation of air conditioner unit assembly .........................................................................1454 Removal and installation of operator's seat .......................................................................................1458 Removal and installation of seat belt .............................................................................................1460 Removal and installation of front wiper assembly ..................................................................................1461 Electric system .......................................................................................................................1467 Removal and installation of air conditioner compressor assembly ...................................................................1467 Removal and installation of air conditioner condenser assembly ....................................................................1470 Removal and installation of engine controller assembly ............................................................................1472 Removal and installation of pump controller assembly ..............................................................................1474 Removal and installation of machine monitor assembly ..............................................................................1477 Removal and installation of pump swash plate sensor ...............................................................................1479 Removal and installation of Mass air flow and temperature sensor ..................................................................1480 Removal and installation of KOMTRAX terminal assembly .............................................................................1481 60 Maintenance standard ...................................................................................................................1483 Table of contents .....................................................................................................................1484 Engine and cooling system .............................................................................................................1485 Engine mount ......................................................................................................................1485 Cooling system ....................................................................................................................1486 Power train ...........................................................................................................................1487 Swing circle ......................................................................................................................1487 Swing machinery ...................................................................................................................1488 Final drive .......................................................................................................................1490 Sprocket ..........................................................................................................................1492 Undercarriage and frame ...............................................................................................................1494 Truck frame and idler cushion .....................................................................................................1494 Idler .............................................................................................................................1496 Truck roller ......................................................................................................................1498 Carrier roller ....................................................................................................................1499 Track shoe ........................................................................................................................1500 Hydraulic system ......................................................................................................................1504 Hydraulic tank ....................................................................................................................1504 Main pump .........................................................................................................................1505 Control valve .....................................................................................................................1506 Swing motor .......................................................................................................................1514 Travel motor ......................................................................................................................1516 PPC valve .........................................................................................................................1519 Solenoid valve ........................................................................................................................1528 Hydraulic drift prevention valve ......................................................................................................1529 Attachment circuit selector valve (for low-pressure circuit) ..........................................................................1531 Center swivel joint ...................................................................................................................1532 Work equipment ........................................................................................................................1533 Work equipment cylinder ...........................................................................................................1533 80 Appendix ...............................................................................................................................1545 Table of contents .....................................................................................................................1546 Air conditioner .......................................................................................................................1547 Precautions for refrigerant .......................................................................................................1547 Air conditioner component .........................................................................................................1548 Configuration and function of refrigeration cycle .................................................................................1550 Outline of refrigeration cycle ....................................................................................................1551 Air conditioner unit ..............................................................................................................1553 Dual pressure switch ..............................................................................................................1559 Air conditioner controller ........................................................................................................1560 Air conditioner compressor ........................................................................................................1561 Air conditioner condenser .........................................................................................................1562 Sunlight sensor ...................................................................................................................1564 Outside air temperature sensor ....................................................................................................1565 Procedure for testing and troubleshooting .........................................................................................1566 Circuit diagram and arrangement of connector pins .................................................................................1568 System diagram ....................................................................................................................1570 Input and output signals of the air conditioner controller ........................................................................1571 Parts and connectors layout .......................................................................................................1573 Layout of air conditioner related parts and connectors ............................................................................1574 Testing air leakage (duct) ........................................................................................................1577 Testing with self-diagnosis function ..............................................................................................1580 How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor. ..................................1581 Testing vent (mode) changeover ....................................................................................................1583 Testing FRESH/RECIRC air changeover ...............................................................................................1585 Testing sunlight sensor ...........................................................................................................1586 Testing (dual) pressure switch for refrigerant ....................................................................................1587 Testing relays ....................................................................................................................1589 Troubleshooting chart 1 ...........................................................................................................1590 Troubleshooting chart 2 ...........................................................................................................1591 Information mentioned in troubleshooting table ....................................................................................1594 Failure code list related to air conditioner ......................................................................................1595 Failure code [879AKA] A/C Inner sensor Open Circuit ...............................................................................1596 Failure code [879AKB] A/C Inner sensor Short Circuit ..............................................................................1597 Failure code [879BKA] A/C Outer sensor Open Circuit ...............................................................................1598 Failure code [879BKB] A/C Outer sensor Short Circuit ..............................................................................1600 Failure code [879CKA] Ventilating sensor Open Circuit .............................................................................1602 Failure code [879CKB] Ventilating sensor Short Circuit ............................................................................1603 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .......................................................................1604 Failure code [879EMC] Ventilating Damper Abnormality ..............................................................................1606 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................1607 Failure code [879GKX] Refrigerant Abnormality .....................................................................................1608 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....................................................1609 A-2 Troubleshooting of compressor system (Air is not cooled) ......................................................................1611 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............................................1614 A-4 Troubleshooting for FRESH/RECIRC air changeover ...............................................................................1616 Troubleshooting with gauge pressure ...............................................................................................1618 Testing refrigerant pressure ......................................................................................................1621 Precautions for disconnecting and connecting air conditioner piping ...............................................................1624 Handling of compressor oil ........................................................................................................1626 Desiccant replacement .............................................................................................................1628 90 Diagrams and drawings ..................................................................................................................1631 Table of contents .....................................................................................................................1632 Hydraulic circuit diagram .............................................................................................................1633 Symbols in hydraulic circuit diagram ..............................................................................................1633 Electric circuit diagram ..............................................................................................................1639 Symbols in electric circuit diagram ...............................................................................................1639
DESCRIPTION:
KOMATSU PC240LC-10 PC240NLC-10 HYDRAULIC EXCAVATOR SHOP MANUAL UEN05538-02 – PDF DOWNLOAD
Composition of shop manual
• This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
• This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of each component. It 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
• This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
• This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting
• This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes.
50. Disassembly and assembly
• This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
• This section gives maintenance standard values of each component. The maintenance standard subsection explains the criteria and remedies for disassembly and service.
80. Appendix
• The section contains the equipment which can not be class, field in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment.
90 Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
S.S 26/12/24
