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Komatsu PC240LC-11 Shop Manual
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Komatsu PC240LC-11 Shop Manual

Hydraulic excavator
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Manual
PC240LC
HYDRAULIC EXCAVATOR
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
April 2015
PC240LC-11 A22001
6D107E-3
-11
and up
Copyright 2015 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM028602

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Summary of Contents for Komatsu PC240LC-11

  • Page 1 6D107E-3 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 Find manuals at https://best-manuals.com...
  • Page 3 00 INDEX AND FOREWORD PC240LC-11 00-1 Find manuals at https://best-manuals.com...
  • Page 4 LAYOUT DRAWING OF ENGINE SYSTEM ................... 10-39 ENGINE CONTROL SYSTEM ....................... 10-41 AUTO-DECELERATION SYSTEM ....................10-44 ENGINE AUTOMATIC WARM-UP SYSTEM .................. 10-46 OVERHEAT PREVENTION SYSTEM .................... 10-48 TURBOCHARGER PROTECTION SYSTEM ................. 10-51 AUTOMATIC IDLE STOP SYSTEM ....................10-53 00-2 PC240LC-11 Find manuals at https://best-manuals.com...
  • Page 5 20 STANDARD VALUE TABLE ........................20-1 CONTENTS ............................20-2 STANDARD VALUE TABLE FOR ENGINE ..................... 20-3 STANDARD VALUE TABLE FOR ENGINE: PC240LC-11 ..............20-3 STANDARD VALUE TABLE FOR MACHINE................... 20-7 STANDARD VALUE TABLE FOR MACHINE: PC240LC-11 ............. 20-7 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......20-20 STANDARD VALUE TABLE FOR ELECTRICAL ...................
  • Page 6 SEQUENCE OF EVENTS IN TROUBLESHOOTING..............40-25 CHECKS BEFORE TROUBLESHOOTING ..................40-27 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............. 40-29 TESTING IN ACCORDANCE WITH TESTING PROCEDURE............40-31 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION ..........40-53 PROCEDURE FOR TESTING AND TROUBLESHOOTING ............40-63 00-4 PC240LC-11 Find manuals at https://best-manuals.com...
  • Page 7 FAILURE CODE [CA144] Coolant Temperature Sensor High Error..........40-217 FAILURE CODE [CA145] Coolant Temperature Sensor Low Error..........40-219 FAILURE CODE [CA153] Charge Air Temperature Sensor High Error ..........40-221 FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...........40-224 PC240LC-11 00-5 Find manuals at https://best-manuals.com...
  • Page 8 FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error......40-321 FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error ......40-323 FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error........40-325 FAILURE CODE [CA1691] Defective Regeneration ..............40-326 00-6 PC240LC-11 Find manuals at https://best-manuals.com...
  • Page 9 FAILURE CODE [CA3229] SCR Temperature High Error..............40-451 FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration ......40-453 FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error .......40-455 FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration....40-459 PC240LC-11 00-7 Find manuals at https://best-manuals.com...
  • Page 10 FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error.......40-589 FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error............40-593 FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error ...........40-595 FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error ........40-599 00-8 PC240LC-11 Find manuals at https://best-manuals.com...
  • Page 11 FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)....40-722 FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) ....40-724 FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)................................40-726 FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)................................40-729 PC240LC-11 00-9...
  • Page 12 FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit ..40-859 FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit ..........40-861 FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit ..........40-863 FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .........40-865 00-10 PC240LC-11...
  • Page 13 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING......40-961 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ..40-962 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN- NING ............................40-963 PC240LC-11 00-11...
  • Page 14 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..............................40-1014 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION................................40-1015 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1016 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..............................40-1017 00-12 PC240LC-11...
  • Page 15 H-32 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW ..............................40-1086 H-33 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK.......40-1087 H-34 ATTACHMENT CIRCUIT CANNOT BE CHANGED............40-1088 H-35 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED .......40-1089 TROUBLESHOOTING OF ENGINE (S-MODE) .................40-1090 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).......40-1090 PC240LC-11 00-13...
  • Page 16 REMOVE AND INSTALL FUEL TANK ASSEMBLY ...............50-151 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............50-159 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY......50-170 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ..............50-181 REMOVE AND INSTALL AdBlue/DEF STRAINER................50-183 REMOVE AND INSTALL KDPF ASSEMBLY.................50-185 00-14 PC240LC-11...
  • Page 17 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ............50-510 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ......50-512 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........50-514 REMOVE AND INSTALL SCR TEMPERATURE SENSOR ............50-516 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY............50-520 PC240LC-11 00-15...
  • Page 18 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ..........80-8 OUTLINE OF REFRIGERATION CYCLE ..................80-9 COMPONENT PARTS OF AIR CONDITIONER SYSTEM ..............80-11 AIR CONDITIONER UNIT.......................80-11 COMPONENT PARTS OF AIR CONDITIONER UNIT..............80-15 AIR CONDITIONER CONTROLLER....................80-19 COMPRESSOR ..........................80-20 CONDENSER ..........................80-22 00-16 PC240LC-11...
  • Page 19 HYDRAULIC CIRCUIT DIAGRAM ......................90-3 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM ..............90-3 HYDRAULIC CIRCUIT DIAGRAM ....................90-7 ELECTRICAL CIRCUIT DIAGRAM ......................90-9 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM..............90-9 ELECTRICAL CIRCUIT DIAGRAM (1/7)..................90-13 ELECTRICAL CIRCUIT DIAGRAM (2/7)..................90-15 PC240LC-11 00-17...
  • Page 20 INDEX 00 INDEX AND FOREWORD ELECTRICAL CIRCUIT DIAGRAM (3/7)..................90-17 ELECTRICAL CIRCUIT DIAGRAM (4/7)..................90-19 ELECTRICAL CIRCUIT DIAGRAM (5/7)..................90-21 ELECTRICAL CIRCUIT DIAGRAM (6/7)..................90-23 ELECTRICAL CIRCUIT DIAGRAM (7/7)..................90-25 INDEX..................................1 00-18 PC240LC-11...

  • Page 21: Troubleshooting

    REMARK • Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor. • The materials and specifications are subject to change without notice. • Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.

  • Page 22: How To Read The Shop Manual

    REMARK Remarks This signal word contains useful information to know. Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }. 00-20 PC240LC-11...

  • Page 23: Safety Matters

    Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purpos- •...

  • Page 24: Precautions During Work

    When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel cir- cuit. 00-22 PC240LC-11...
  • Page 25 When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed. PC240LC-11 00-23...
  • Page 26 • Hanging angle must be 60 ° or smaller as a rule. • When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook. 00-24 PC240LC-11...
  • Page 27 Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. PC240LC-11 00-25...
  • Page 28 Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing) Nominal diameter of rope ( mm) Allowable load ( kN { t} ) 8.8 {0.9} 12.7 {1.3} 17.3 {1.7} 22.6 {2.3} 28.6 {2.9} 35.3 {3.6} 55.3 {5.6} 79.6 {8.1} 141.6 {14.4} 221.6 {22.6} 00-26 PC240LC-11...
  • Page 29 When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening). PC240LC-11 00-27...
  • Page 30 • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Pre- cautions for disconnection and connection of air conditioner piping". 00-28 PC240LC-11...
  • Page 31 Fire around the machine due to highly heated exhaust gas This machine is equipped with KDPF (Komatsu Diesel Particulate Filter). KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re- generation), the temperature of discharged exhaust gas may be higher than that of conventional models.
  • Page 32 • When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications. • When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual. 00-30 PC240LC-11...

  • Page 33: Action If Fire Occurs

    Be sure to wear rubber gloves when handle the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton-work-gloves, wear rubber gloves under them. PC240LC-11 00-31...
  • Page 34 Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people. • When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products. 00-32 PC240LC-11...
  • Page 35 This machine is equipped with the following two exhaust gas treatment systems: • Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu- rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
  • Page 36 If it gets on your skin, thoroughly wash it off with water. Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws. 00-34 PC240LC-11...
  • Page 37 If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper- ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze. Drain AdBlue/DEF to prevent it from freezing. PC240LC-11 00-35...
  • Page 38 • Clean the oil filler port and its around, refilling pump, oil jug, or etc. • Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage. 00-36 PC240LC-11...

  • Page 39: Cleaning Operation

    (pump, or control valve) or during operation of the machine. REMARK The oil cleaning equipment can remove the ultra fine (approxi- mately 3 μm) particles that the filter built in the hydraulic equip- ment cannot remove. So, it is very effective device. PC240LC-11 00-37...
  • Page 40 Introduction of parts for the disassembly of the face seal type hoses and tubes Hose side Pipe joint side Nominal No. O-ring (3) Plug (1) Nut (2) 07376-70210 02789-00210 02896-11008 07376-70315 02789-00315 02896-11009 07376-70422 02789-00422 02896-11012 07376-70522 02789-00522 02896-11015 07376-70628 02789-00628 02896-11018 00-38 PC240LC-11...
  • Page 41 Split flange Sleeve head Flange (1) 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032 PC240LC-11 00-39...
  • Page 42 Introduction of parts for the removal of O-ring boss type joint Nominal No. Plug (1) O-ring (2) 07040-10807 07002-10823 07040-11007 07002-11023 07040-11209 07002-11223 07040-11409 07002-11423 07040-11612 07002-11623 07040-11812 07002-11823 07040-12012 07002-12034 07040-12412 07002-12434 07041-13012 07002-13034 07040-13316 07002-13334 07041-13612 07002-13634 07040-14220 07002-14234 07040-15223 07002-15234 00-40 PC240LC-11...
  • Page 43 When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening. • As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. PC240LC-11 00-41...
  • Page 44 When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser- voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
  • Page 45 • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair the parts referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY". PC240LC-11 00-43...
  • Page 46 The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion may become loose, and it may re- sult in a defective connection or breakage. 00-44 PC240LC-11...
  • Page 47 • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from. PC240LC-11 00-45...
  • Page 48 If a filter oth- er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
  • Page 49 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure.
  • Page 50 Propose the periodic inspection (Pm clinic, etc.) according to the service meter reading. How to operate KOMTRAX For the operating method of each screen of KOMTRAX, see “Global KOMTRAX Web Reference Manual (For Key Person)”. 00-48 PC240LC-11...
  • Page 51 Provide an oil container to receive a quantity of hydraulic oil which may flow out. Connection Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4). PC240LC-11 00-49...
  • Page 52 While keeping the condition of step 1, turn lever (3) to the right (clockwise). While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. 00-50 PC240LC-11...
  • Page 53 While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out. PC240LC-11 00-51...
  • Page 54 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD Connection Hold the tightening adapter part, and push body (2) straight un- til sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end. 00-52 PC240LC-11...

  • Page 55: Connecting Connectors

    Connecting connectors Check the connector visually. • Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion). PC240LC-11 00-53...
  • Page 56 If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 00-54 PC240LC-11...
  • Page 57 After the connector is completely dried, blow the contact restorer, and reassemble them. Handling controller When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point. PC240LC-11 00-55...
  • Page 58 When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read- ing does not change. NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit. 00-56 PC240LC-11...
  • Page 59 In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely. PC240LC-11 00-57...
  • Page 60 (L2), and then pull out connector (1) to- ward you. Method for connecting slide lock type connector (FRAMATOME-3, FRAMA- TOME-2) Insert it straight until it clicks. Method for disconnecting slide lock type connector (FRAMATOME-24) Slide down lock (red) (L1). 00-58 PC240LC-11...
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A22001