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Komatsu PC240LC-10 Hydraulic Excavator Service Manual

1,654 pages · Publication SEN0S538-05

$169.91
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Models
PC240LC-10
Serial coverage
90001 and up
Manual type
Service Manual
Pages
1,654
Publication
SEN0S538-05
Condition
Brand new
Komatsu PC240LC-10 Hydraulic Excavator Service Manual, publication SEN0S538-05

What's inside

From the manual's own table of contents: 313 sections, 595 entries. See sample pages (PDF, 824 KB)

Index and foreword
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table
Specification
Specifications
Specification drawings
Working range drawings
Weight table
Table of fuel, coolant and lubricants
Structure and function
Engine and cooling system
Show all 313 sections
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Cooling system
Power train
Power train system
Swing circle
Swing machinery
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system
Hydraulic equipment layout drawing
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Swing motor
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve (for high pressure circuit)3 topics
  • Attachment circuit selector valve (for low pressure circuit)
  • Center swivel joint
  • Accumulator
Work equipment2 topics
  • Work equipment shim
  • Bucket play adjustment shim
Cab and its attachments2 topics
  • Cab mount and cab tipping stopper
  • ROPS cab
Electrical system4 topics
  • Electrical control system
  • Machine monitor system
  • KOMTRAX system
  • Sensor
Standard value table
Standard service value table3 topics
  • Standard value table for engine related parts
  • Standard value table for chassis related parts
  • Posture of machine for measuring performance and measurement procedure
Testing and adjusting
Related information on testing and adjusting31 topics
  • Tools for testing and adjusting
  • Sketch of tools for testing and adjusting
  • Testing engine speed
  • Testing boost pressure
  • Testing exhaust gas color
  • Testing and adjusting valve clearance
  • Testing compression pressure
  • Measuring blowby pressure
  • Measuring engine oil pressure
  • Measuring EGR valve and KVGT oil pressure
  • Measuring fuel pressure
  • Measuring fuel delivery, return and leakage
  • Bleeding air from fuel system
  • Testing fuel circuit for leakage
  • Handling cylinder cutout mode operation
  • Handling no-injection cranking operation
  • Testing and adjusting air conditioner compressor belt tension
  • Replacing fan belt
  • Testing swing circle bearing clearance
  • Testing and adjusting track tension
  • Releasing remaining pressure from hydraulic circuit
  • Measuring and adjusting oil pressure in work equipment, swing, and travel circuits
  • Testing oil pressure in control circuit
  • Testing and adjusting oil pressure in pump PC control circuit
  • Testing and adjusting oil pressure in pump LS control circuit
  • Testing output pressure of solenoid valve
  • Measuring PPC valve output pressure
  • Adjusting play of work equipment and swing PPC valves
  • Testing pump swash plate sensor
  • Isolating the parts causing hydraulic drift in work equipment
  • Testing oil leakage
Bleeding air from hydraulic circuit
Testing cab tipping stopper
Adjusting mirrors
Special functions of machine monitor
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm clinic service
Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Testing before troubleshooting
Inspection procedure before troubleshooting
Preparation work for troubleshooting of electrical system
Classification and procedure for troubleshooting
Symptom of probable failure and troubleshooting No
Information in troubleshooting table
Diagnostic procedure for wiring harness open curcuit of pressure sensor system
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse list and location
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Failure code [989L00] Engine Controller Lock Caution1
Failure code [989M00] Engine Controller Lock Caution2
Failure code [989N00] Engine Controller Lock Caution3
Failure code [A1U0N3] HC desorb request1
Failure code [A1U0N4] HC desorb request2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Engine Oil Pressure Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Engine Coolant Overheat
Failure code [B@BCZK] Radiator Coolant Level Low
Failure code [B@HANS] Hyd Oil Overheat
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error59 topics
  • Failure code [CA145] Coolant Temp Sens Low Error
  • Failure code [CA153] Chg Air Temp Sensor High Error
  • Failure code [CA154] Chg Air Temp Sensor Low Error
  • Failure code [CA187] Sensor 2 Supply Volt Low Error
  • Failure code [CA221] Ambient Press Sensor High Error
  • Failure code [CA222] Ambient Press Sensor Low Error
  • Failure code [CA227] Sensor 2 Supply Volt High Error
  • Failure code [CA234] Eng Overspeed
  • Failure code [CA238] Ne Speed Sensor Supply Volt Error
  • Failure code [CA239] Ne Speed Sens Supply Volt High Error
  • Failure code [CA271] IMV/PCV1 Short Error
  • Failure code [CA272] IMV/PCV1 Open Error
  • Failure code [CA295] Ambient Press Sens In Range Error
  • Failure code [CA322] Inj #1(L#1) Open/Short Error
  • Failure code [CA323] Inj #5(L#5) Open/Short Error
  • Failure code [CA324] Inj #3(L#3) Open/Short Error
  • Failure code [CA325] Inj #6(L#6) Open/Short Error
  • Failure code [CA331] Inj #2(L#2) Open/Short Error
  • Failure code [CA332] Inj #4(L#4) Open/Short Error
  • Failure code [CA343] ECM Critical Internal Failure
  • Failure code [CA351] Injectors Drive Circuit Error
  • Failure code [CA352] Sensor 1 Supply Volt Low Error
  • Failure code [CA356] Mass Air Flow Sensor High Error
  • Failure code [CA357] Mass Air Flow Sensor Low Error
  • Failure code [CA386] Sensor 1 Supply Volt High Error
  • Failure code [CA428] Water in Fuel Sensor High Error
  • Failure code [CA429] Water in Fuel Sensor Low Error
  • Failure code [CA435] Eng Oil Press Sw Error
  • Failure code [CA441] Battery Voltage Low Error
  • Failure code [CA442] Battery Voltage High Error
  • Failure code [CA449] Rail Press Very High Error
  • Failure code [CA451] Rail Press Sensor High Error
  • Failure code [CA452] Rail Press Sensor Low Error
  • Failure code [CA488] Chg Air Temp High Torque Derate
  • Failure code [CA515] Rail Press Sens Sup Volt High Error
  • Failure code [CA516] Rail Press Sens Sup Volt Low Error
  • Failure code [CA553] Rail Press High Error
  • Failure code [CA555] Crankcase Press High Error 1
  • Failure code [CA556] Crankcase Press High Error 2
  • Failure code [CA559] Rail Press Low Error
  • Failure code [CA595] Turbo Speed High Error 2
  • Failure code [CA687] Turbo Speed Low Error
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA691] Intake Air Temp Sens High Error
  • Failure code [CA692] Intake Air Temp Sens Low Error
  • Failure code [CA697] ECM Int Temp Sensor High Error
  • Failure code [CA698] ECM Int Temp Sensor Low Error
  • Failure code [CA731] Eng Bkup Speed Sens Phase Error
  • Failure code [CA778] Eng Bkup Speed Sensor Error
  • Failure code [CA1117] Persistent Data Lost Error
  • Failure code [CA1664] KDOC Malfunction
  • Failure code [CA1691] Regeneration Ineffective
  • Failure code [CA1695] Sensor 5 Supply Volt High Error
  • Failure code [CA1696] Sensor 5 Supply Volt Low Error
  • Failure code [CA1843] Crankcase Press Sens High Error
  • Failure code [CA1844] Crankcase Press Sens Low Error
  • Failure code [CA1879] KDPF Delta P Sensor High Error
  • Failure code [CA1881] KDPF Delta P Sensor Low Error
  • Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2288] Turbo Speed High Error 1
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2373] Exh Manifold Press. Sens Volt
Failure code [CA2374] Exhaust Manifold Press Sens Low Error
Failure code [CA2375] EGR Orifice Temp Sens High Error
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2554] Exh Manifold Press Sens In Range Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2961] EGR Orifice Temp High Error 1
Failure code [CA2973] Chg Air Press Sensor In Range Error
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [CA3741] Rail Press Valve Trip Error
Failure code [D110KB] Battery Relay Output Voltage
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)59 topics
  • Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
  • Failure code [DA20MC] Pump Controller
  • Failure code [DA22KK] Pump Solenoid Power Low Error
  • Failure code [DA25KP] 5V Sensor 1 Power Abnormality
  • Failure code [DA29KQ] Model Selection Abnormality
  • Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
  • Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
  • Failure code [DA2QKR] CAN2 Discon (Pump Con)
  • Failure code [DA2RKR] CAN1 Discon (Pump Con)
  • Failure code [DAF0MB] Monitor ROM Abnormality
  • Failure code [DAF0MC] Monitor Error
  • Failure code [DAF8KB] Camera Power Supply Short Circuit
  • Failure code [DAF9KQ] Model Selection Abnormality
  • Failure code [DAFGMC] GPS Module Error
  • Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
  • Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
  • Failure code [DAFQKR] CAN2 Discon (Monitor)
  • Failure code [DAZ9KQ] A/C Model Selection Abnormality
  • Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
  • Failure code [DB2QKR] CAN2 Discon (Engine Con)
  • Failure code [DB2RKR] CAN1 Discon (Engine Con)
  • Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
  • Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
  • Failure code [DHPAMA] F Pump Press Sensor Abnormality
  • Failure code [DHPBMA] R Pump Press Sensor Abnormality
  • Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
  • Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
  • Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
  • Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
  • Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
  • Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
  • Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
  • Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
  • Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality
  • Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality
  • Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality
  • Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality
  • Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality
  • Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality
  • Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
  • Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
  • Failure code [DV20KB] Travel Alarm Short Circuit
  • Failure code [DW43KA] Travel Speed Sol Open Circuit
  • Failure code [DW43KB] Travel Speed Sol Short Circuit
  • Failure code [DW45KA] Swing Brake Sol Open Circuit
  • Failure code [DW45KB] Swing Brake Sol Short Circuit
  • Failure code [DW91KA] Travel Junction Sol Open Circuit
  • Failure code [DW91KB] Travel Junction Sol Short Circuit
  • Failure code [DWA2KA] Attachment Sol Open Circuit
  • Failure code [DWA2KB] Attachment Sol Short Circuit
  • Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit
  • Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit
  • Failure code [DWK2KA] Variable Back Press Sol Open Circuit
  • Failure code [DWK2KB] Variable Back Press Sol Short Circuit
  • Failure code [DWK8KA] Swing Press C/O Sol Open Circuit
  • Failure code [DWK8KB] Swing Press C/O Sol Short Circuit
  • Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
  • Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
  • Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE4KA] Attachment Flow EPC Open Circuit
Failure code [DXE4KB] Attachment Flow EPC Short Circuit
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Troubleshooting of electrical system (E-mode)
Engine does not start (Engine does not crank)
Manual preheating system does not work
Automatic preheating system does not work
Preheating monitor does not light up when preheater is operated
When starting switch is turned to ON position, machine monitor displays nothing2 topics
  • monitor lights up in yellow
    • level monitor lights up in yellow
Coolant temperature monitor lights up in white while engine is running
Hydraulic oil temperature monitor lights up in white while engine is running
Charge level monitor lights up while engine is running
Fuel level monitor lights up in red while engine is running
Air cleaner clogging monitor lights up in yellow while engine is running
Water separator monitor lights up while engine is running
Coolant temperature monitor lights up in red while engine is running
Hydraulic oil temperature monitor lights up in red while engine is running
Engine oil pressure monitor lights up in red while engine is running
Fuel gauge indicates either full or empty and does not move
Fuel gauge indicates incorrect amount (indicates neither full nor empty)
Coolant temperature gauge indicates either Min. or Max. and does not move2 topics
  • move
    • nor Max.)
Content of display on machine monitor is different from that of actual machine
Machine monitor does not display some items
Function switch does not work
Automatic preheating system does not work (In cold season)1 topic
  • switch is operated
Auto-deceleration is not actuated or canceled when lever is operated2 topics
  • operated
    • changed
Travel speed monitor does not change when travel speed switch is operated
Travel speed does not change when travel speed is shifted
Alarm buzzer does not stop sounding
When starting switch is turned to OFF position, service meter is not displayed
Service mode cannot be selected
Any of work equipment, swing and travel does not work23 topics
  • Any of work equipment, swing and travel cannot be locked
  • Machine cannot swing while swing brake cancel switch is canceled
  • Swing brake does not operate while swing brake cancel switch is locked
  • One-touch power maximizing function does not work or monitor is not displayed
  • One-touch power maximizing function cannot be released
  • Travel alarm does not sound when machine travels
  • Travel alarm does not stop sounding when machine stops
  • Horn does not sound
  • Horn does not stop sounding
  • Wiper monitor does not light up or go out when wiper switch is operated
  • Wiper does not operate when wiper switch is operated
  • Window washer does not operate when window washer switch is operated
  • BOOM LOWER indication is not displayed properly with monitoring function
  • ARM DUMP indication is not displayed properly with monitoring function
  • ARM IN indication is not displayed properly with monitoring function
  • BOOM RAISE indication is not displayed properly with monitoring function
  • BUCKET CURL indication is not displayed properly with monitoring function
  • BUCKET DUMP indication is not displayed properly with monitoring function
  • SWING indication is not displayed properly with monitoring function
  • TRAVEL indication is not displayed properly with monitoring function
  • Service is not displayed properly with monitoring function
  • Attachment hydraulic circuit cannot be changed
  • KOMTRAX system does not work properly
Troubleshooting of hydraulic and mechanical system (H-mode)28 topics
  • Information described in troubleshooting table (H-mode)
  • System chart for hydraulic system
  • Failure mode and cause table
  • All of work equipment, swing and travel operation lacks speed or power
  • Engine speed lowers significantly or engine stalls
  • Any of work equipment, swing and travel does not work
  • Unusual sound is heard from around hydraulic pump
  • Fine control performance or response is poor
  • Boom operation lacks speed or power
  • Arm operation lacks speed or power
  • Bucket operation lacks speed or power
  • Work equipment does not move in single operation
  • Hydraulic drift of boom is large
  • Hydraulic drift of arm is large
  • Hydraulic drift of bucket is large
  • Time lag of work equipment is large
  • One-touch power maximizing function does not work
  • In combined operations of swing and boom RAISE, boom rising speed is low
  • In combined operations of swing and travel, travel speed drops largely
  • Machine does not travel straight
  • Travel speed is too low
  • Machine is hard to steer or travel power is low
  • Travel speed does not change, or travel speed is too low or high
  • One of tracks does not run
  • Upper structure does not swing to the right or left
  • Upper structure swings only to the right or left
  • Swing acceleration is poor or swing speed is low (both right and left)
  • Swing acceleration is poor or swing speed is low (either right or left)
Shock is large when upper structure stops swinging
Large unusual noise is heard when upper structure stops swinging
Swing drift on a slope is large while swing holding brake is applied
Swing drift on a slope is large while swing holding brake is released
Attachment circuit cannot be changed while attachment is installed
Oil flow in attachment circuit cannot be controlled
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
When starting switch is turned to START position, engine does not crank
When engine cranks, smoke does not come out
Engine does not start while fuel is injected (Incomplete combustion)
Startability is poor
Engine does not pick up smoothly
Engine stops during operation
Engine runs rough or is unstable
Engine lacks power
Exhaust smoke is black (KDPF clogs up early)
Engine oil consumption is too much
Oil becomes contaminated early
Fuel consumption is excessive
Oil is in coolant (or coolant spurts or coolant level goes down)
Engine oil pressure drops
Fuel is contaminated in engine oil
Coolant is contaminated in engine oil (Oil becomes cloudy white)
Coolant temperature rises too high (Overheating)
Unusual noise is heard
Vibration is excessive
Automatic regeneration is operated frequently
Active regeneration is operated for long
White smoke comes out in the process of active regeneration
Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine and main pump assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of KDPF assembly
Disassembly and assembly of KDPF assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery36 topics
  • Removal and installation of swing circle assembly
  • Separation and connection of track shoe assembly
  • Removal and installation of sprocket
  • Removal and installation of idler and idler cushion assembly
  • Disassembly and assembly of idler
  • Disassembly and assembly of idler cushion
  • Disassembly and assembly of track roller
  • Disassembly and assembly of carrier roller
  • Removal and installation of revolving frame assembly
  • Removal and installation of counterweight assembly
  • Removal and installation of center swivel joint assembly
  • Disassembly and assembly of center swivel joint
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of main pump assembly
  • Removal and installation of control valve assembly
  • Disassembly and assembly of control valve
  • Disassembly and assembly of work equipment PPC valve
  • Disassembly and assembly of travel PPC valve
  • Removal and installation of work equipment assembly
  • Disassembly and assembly of work equipment cylinder
  • Removal and installation of operator's cab assembly
  • Removal and installation of operator cab glass (adhered glass)
  • Removal and installation of front window assembly
  • Removal and installation of floor frame assembly
  • Removal and installation of air conditioner unit assembly
  • Removal and installation of operator's seat
  • Removal and installation of seat belt
  • Removal and installation of front wiper assembly
  • Removal and installation of air conditioner compressor assembly
  • Removal and installation of air conditioner condenser assembly
  • Removal and installation of engine controller assembly
  • Removal and installation of pump controller assembly
  • Removal and installation of machine monitor assembly
  • Removal and installation of pump swash plate sensor
  • Removal and installation of mass air flow and temperature sensor
  • Removal and installation of KOMTRAX terminal assembly
Maintenance standard12 topics
  • Engine mount
  • Cooling system
  • Swing circle
  • Swing machinery
  • Final drive
  • Sprocket
  • Track frame and idler cushion
  • Idler
  • Track roller
  • Carrier roller
  • Track shoe
  • Hydraulic tank
Attachment circuit selector valve (for high-pressure circuit)
Attachment circuit selector valve (for low-pressure circuit)
Center swivel joint
Work equipment cylinder
Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Air conditioner condenser
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Parts and connectors layout
Layout of air conditioner related parts and connectors
Testing air leakage (duct)
Testing with self-diagnosis function1 topic
  • monitor
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Failure code list related to air conditioner
Failure code [879EMC] Ventilating Damper Abnormality
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting of compressor system (Air is not cooled)7 topics
  • abnormal)
  • Troubleshooting for FRESH/RECIRC air changeover
  • Troubleshooting with gauge pressure
  • Testing refrigerant pressure
  • Precautions for disconnecting and connecting air conditioner piping
  • Handling of compressor oil
  • Desiccant replacement
Diagrams and drawings
Hydraulic circuit diagram2 topics
  • Symbols in hydraulic circuit diagram
  • Hydraulic circuit diagram
Electric circuit diagram3 topics
  • Symbols in electric circuit diagram
  • Electric circuit diagram
  • Electric circuit diagram of air conditioner unit

Inside this manual

Real pages from this service manual (1,654 pages). Open the sample pages (PDF, 823 KB)

Sample pages from the Komatsu PC240LC-10 Hydraulic Excavator Service Manual: Troubleshooting, Specifications, Diagram, Foldout diagram
  • Troubleshooting, page 844: Failure code [CA3251] KDOC Inlet Temp High Error
  • Specifications, page 1,494: 60 Maintenance standard
  • Diagram, page 1,594: 80 Appendix
  • Foldout diagram, page 1,638: Electrical circuit diagram (1/6)

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the PC240LC-10 are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Service Manual SEN0S538-05$169.91
Other manuals for the PC240LC-10

Operator's manuals

Details
Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,654 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu PC240LC-10 with 6D107E-2 EngineService Manual · CEBM024902 · $189.59

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).