Komatsu Excavator PC240LC-11E0 PC240NLC-11E0 workshop service manual

Description Komatsu Excavator PC240LC-11E0 PC240NLC-11E0 workshop service manual

Komatsu Hydraulic Excavator PC240LC-11E0, PC240NLC-11E0 pdf workshop service repair manual

Serial numbers:
K75001 and up, K75001-K75273, K75274 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
INDEX AND FOREWORD
ABBREVIATION LIST
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR DEF
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

SPECIFICATIONS
ABBREVIATION LIST
SPECIFICATION DRAWING
WORKING RANGE DRAWINGS
WEIGHT TABLE
TABLE OF FUEL, COOLANT, AND LUBRICANTS

STRUCTURE AND FUNCTION
ABBREVIATION LIST
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
COMPONENT PARTS OF UREA SCR SYSTEM
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTO-DECELERATION SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM
OVERHEAT PREVENTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM
AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
MACHINE MONITOR SYSTEM
KomVision SYSTEM
KOMTRAX SYSTEM
PPC LEVERS
AUTOMATIC GREASE SYSTEM
OUTLINE OF AUTO GREASE SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
SENSOR
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
ENGINE AND PUMP COMBINED CONTROL SYSTEM
PUMP AND VALVE CONTROL SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
STRUCTURE OF VALVE CONTROL
ONE-TOUCH POWER MAXIMIZING SYSTEM
PPC LOCK SYSTEM
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
TOOL CONTROL SYSTEM
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
SWING CONTROL SYSTEM DIAGRAM
COMPONENT PARTS OF SWING SYSTEM
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
TRAVEL CONTROL SYSTEM DIAGRAM
COMPONENT PARTS OF TRAVEL SYSTEM
UNDERCARRIAGE AND FRAME
LAYOUT DRAWING OF UNDERCARRIAGE
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
BUCKET CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB MOUNT
CAB TIPPING STOPPER

STANDARD VALUE TABLE
ABBREVIATION LIST
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR MACHINE
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE
STANDARD VALUE TABLE FOR ELECTRICAL

TESTING AND ADJUSTING
ABBREVIATION LIST
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST BOOST PRESSURE
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST EGR VALVE AND VGT OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL DISCHARGE, RETURN AND LEAKAGE
BLEEDING AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
TEST FAN BELT AND ALTERNATOR BELT
TEST AUTO-TENSIONER
REPLACING FAN BELT
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
CLEAN AdBlue/DEF TANK
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TEST OIL PRESSURE OF CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TEST OUTLET PRESSURE OF SOLENOID VALVE
TEST PPC VALVE OUTLET PRESSURE
TEST ATTACHMENT CIRCUIT OIL PRESSURE
ADJUST WORK EQUIPMENT AND SWING PPC VALVES
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE
TEST PUMP SWASH PLATE SENSOR
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TEST OIL LEAKAGE
BLEED AIR FROM HYDRAULIC CIRCUIT
CAB AND ITS ATTACHMENTS
TEST CAB TIPPING STOPPER
METHOD FOR ADJUSTING MIRRORS
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
METHOD FOR STARTING UP KOMTRAX SYSTEM
ADJUST REARVIEW CAMERA ANGLE
ADJUST KomVision CAMERA ANGLE
ADJUST KomVision RELATED ITEMS
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE BATTERY DISCONNECT SWITCH
TEST DIODES
Pm CLINIC
Pm CLINIC SERVICE

TROUBLESHOOTING
ABBREVIATION LIST
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
AUTOMATIC GREASE SYSTEM
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTOR LIST AND LAYOUT
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
FUSE LOCATION TABLE
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
TROUBLESHOOTING OF ENGINE (S-MODE)

DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL EGR VALVE ASSEMBLY
REMOVE AND INSTALL EGR COOLER ASSEMBLY
REMOVE AND INSTALL STARTER ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER
REMOVE AND INSTALL KDPF ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY
REMOVE AND INSTALL SCR ASSEMBLY
REMOVE AND INSTALL KDPF, SCR ASSEMBLY
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET
REMOVE AND INSTALL KCCV ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE
REMOVE AND INSTALL AdBlue/DEF INJECTOR
REMOVE AND INSTALL AdBlue/DEF PUMP
REMOVE AND INSTALL AdBlue/DEF HOSE
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
UNDERCARRIAGE AND FRAME
SEPARATION AND CONNECTION OF TRACK ASSEMBLY
REMOVE AND INSTALL SPROCKET
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL MAIN PUMP ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY
REMOVE AND INSTALL QUICK COUPLER VALVE
WORK EQUIPMENT
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL OPERATOR'S SEAT
REMOVE AND INSTALL SEAT BELT
REMOVE AND INSTALL FRONT WIPER ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR
REMOVE AND INSTALL SCR TEMPERATURE SENSOR
REMOVE AND INSTALL KomVision CAMERA
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS
REMOVE AND INSTALL COMMUNICATION TERMINAL

MAINTENANCE STANDARD
ABBREVIATION LIST
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE
MAINTENANCE STANDARD OF SWING MACHINERY
MAINTENANCE STANDARD OF FINAL DRIVE
MAINTENANCE STANDARD OF SPROCKET
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER
MAINTENANCE STANDARD OF CARRIER ROLLER
MAINTENANCE STANDARD OF TRACK SHOE
MAINTENANCE STANDARD OF TRIPLE SHOE
MAINTENANCE STANDARD OF SWAMP SHOE
MAINTENANCE STANDARD OF ROAD LINER
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF LS-EPC VALVE
MAINTENANCE STANDARD OF PC-EPC VALVE
MAINTENANCE STANDARD OF SWING MOTOR
MAINTENANCE STANDARD OF TRAVEL MOTOR
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
MAINTENANCE STANDARD OF TRAVEL PPC VALVE
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)
MAINTENANCE STANDARD OF SOLENOID VALVE
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
MAINTENANCE STANDARD OF BOOM CYLINDER
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)
MAINTENANCE STANDARD OF ARM CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER

APPENDIX
ABBREVIATION LIST 
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
AIR CONDITIONER CONTROLLER
COMPRESSOR
CONDENSER
SENSORS FOR AIR CONDITIONER SYSTEM
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TESTING AIR LEAKAGE (DUCT)
METHOD FOR TESTING AIR LEAKAGE (DUCT)
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
TEST VENT (MODE) CHANGEOVER
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST SUNLIGHT SENSOR
METHOD FOR TESTING SUNLIGHT SENSOR
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING CHART
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS L)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
TROUBLESHOOTING USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL
METHOD FOR REPLACING DESICCANT

CIRCUIT DIAGRAMS
ABBREVIATION LIST
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

Engine SAA6D107E-3 workshop service manual