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Komatsu PC240LC-10 Shop Manual
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Komatsu PC240LC-10 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.
June 2013
PC240LC-10 A20001
6D107E-2
-10
and up
Copyright 2013 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM024902

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Summary of Contents for Komatsu PC240LC-10

  • Page 1 6D107E-2 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 DIAGRAMS AND SCHEMATICS..........90-1 00-2 c PC240LC-10 Find manuals at https://best-manuals.com...
  • Page 3 00-33 01-4 10-19 00-5 00-34 01-5 10-20 00-6 00-35 01-6 10-21 00-7 00-36 01-7 10-22 00-8 00-37 01-8 10-23 00-9 00-38 01-9 10-24 00-10 00-39 01-10 10-25 00-11 00-40 01-11 10-26 00-12 PC240LC-10 00-2-1  PC240LC-10 Find manuals at https://best-manuals.com...
  • Page 4 10-150 10-52 10-85 10-118 10-151 10-53 10-86 10-119 10-152 10-54 10-87 10-120 10-153 10-55 10-88 10-121 10-154 10-56 10-89 10-122 10-155 10-57 10-90 10-123 10-156 10-58 10-91 10-124 10-157 10-59 10-92 10-125 10-158 00-2-2  PC240LC-10 Find manuals at https://best-manuals.com...
  • Page 5 30-6 10-184 10-217 10-250 30-7 10-185 10-218 10-251 30-8 10-186 10-219 10-252 30-9 10-187 10-220 10-253 30-10 10-188 10-221 10-254 30-11 10-189 10-222 10-255 30-12 10-190 10-223 10-256 30-13 10-191 10-224 10-257 30-14 PC240LC-10 00-2-3  Find manuals at https://best-manuals.com...
  • Page 6 30-40 30-73 30-106 30-139 30-41 30-74 30-107 30-140 30-42 30-75 30-108 30-141 30-43 30-76 30-109 30-142 30-44 30-77 30-110 30-143 30-45 30-78 30-111 30-144 ● 30-46 30-79 30-112 30-145 30-47 30-80 30-113 30-146 00-2-4  PC240LC-10 Find manuals at https://best-manuals.com...
  • Page 7 40-32 40-65 40-33 40-66 30-172 30-173 40-1 40-34 40-67 30-174 40-2 40-35 40-68 30-175 40-3 40-36 40-69 30-176 40-4 40-37 40-70 30-177 40-5 40-38 40-71 30-178 40-6 40-39 40-72 30-179 40-7 40-40 40-73 PC240LC-10 00-2-5  Find manuals at https://best-manuals.com...
  • Page 8 40-197 40-99 40-132 40-165 40-198 40-100 40-133 40-166 40-199 40-101 40-134 40-167 40-200 40-102 40-135 40-168 40-201 40-103 40-136 40-169 40-202 40-104 40-137 40-170 40-203 40-105 40-138 40-171 40-204 40-106 40-139 40-172 40-205 00-2-6  PC240LC-10 Find manuals at https://best-manuals.com...
  • Page 9 40-329 40-231 40-264 40-297 40-330 40-232 40-265 40-298 40-331 40-233 40-266 40-299 40-332 40-234 40-267 40-300 40-333 40-235 40-268 40-301 40-334 40-236 40-269 40-302 40-335 40-237 40-270 40-303 40-336 40-238 40-271 40-304 40-337 PC240LC-10 00-2-7  Find manuals at https://best-manuals.com...
  • Page 10 40-461 40-363 40-396 40-429 40-462 40-364 40-397 40-430 40-463 40-365 40-398 40-431 40-464 40-366 40-399 40-432 40-465 40-367 40-400 40-433 40-466 40-368 40-401 40-434 40-467 40-369 40-402 40-435 40-468 40-370 40-403 40-436 40-469 00-2-8  PC240LC-10 Find manuals at https://best-manuals.com...
  • Page 11 40-592 40-494 40-527 40-560 40-593 40-495 40-528 40-561 40-594 40-496 40-529 40-562 40-595 40-497 40-530 40-563 40-596 40-498 40-531 40-564 40-597 40-499 40-532 40-565 40-598 40-500 40-533 40-566 40-599 40-501 40-534 40-567 40-600 40-502 40-535 40-568 40-601 PC240LC-10 00-2-9 ...
  • Page 12 40-724 40-626 40-659 40-692 40-725 40-627 40-660 40-693 40-726 40-628 40-661 40-694 40-727 40-629 40-662 40-695 40-728 40-630 40-663 40-696 40-729 40-631 40-664 40-697 40-730 40-632 40-665 40-698 40-731 40-633 40-666 40-699 40-732 40-634 40-667 40-700 40-733 00-2-10  PC240LC-10...
  • Page 13 50-64 50-97 40-758 50-32 50-65 50-98 50-33 50-66 50-99 50-1 50-34 50-67 50-100 50-2 50-35 50-68 50-101 50-3 50-36 50-69 50-102 50-4 50-37 50-70 50-103 50-5 50-38 50-71 50-104 50-6 50-39 50-72 50-105 50-7 50-40 50-73 50-106 PC240LC-10 00-2-11 ...
  • Page 14 50-229 50-131 50-164 50-197 50-230 50-132 50-165 50-198 50-231 50-133 50-166 50-199 50-232 50-134 50-167 50-200 50-233 50-135 50-168 50-201 50-234 50-136 50-169 50-202 50-235 50-137 50-170 50-203 50-236 50-138 50-171 50-204 50-237 50-139 50-172 50-205 50-238 00-2-12  PC240LC-10...
  • Page 15 60-24 50-263 50-296 50-329 60-25 ● 50-264 50-297 50-330 60-26 50-265 50-298 50-331 60-27 50-266 50-299 50-332 60-28 50-267 50-300 50-333 60-29 50-268 50-301 50-334 60-30 50-269 50-302 50-335 60-31 50-270 50-303 50-336 60-32 50-271 50-304 60-33 PC240LC-10 00-2-13 ...
  • Page 16 80-46 80-79 ● ● ● 60-62 80-14 80-47 80-80 ● ● ● 60-63 80-15 80-48 80-81 ● ● ● 60-64 80-16 80-49 80-82 ● ● ● 60-65 80-17 80-50 80-83 ● ● ● 60-66 80-18 80-51 80-84 00-2-14  PC240LC-10...
  • Page 17 Page Mark Page Mark Page ● 80-85 ● 80-86 90-1 90-2 90-3 90-4 90-5 90-6 90-7 90-8 90-9 90-10 90-11 90-12 90-13 90-14 90-15 90-16 90-17 90-18 90-19 90-20 90-21 90-22 90-23 90-24 90-25 90-27 90-29 90-31 PC240LC-10 00-2-15 ...
  • Page 18 FOREWORD 00-2-16  PC240LC-10...

  • Page 19: Important Safety Notice

    UNDER REPAIR signs on the controls in Precautions against work which you are not the operator's compartment. used to or work with which you are too familiar Only qualified workers must perform the work and operation which require license or qualification. PC240LC-10 00-3...

  • Page 20: Preparations For Work

    12. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed  correctly. 00-4 PC240LC-10...
  • Page 21 When tightening nuts of the air conditioner hoses and tubes, be sure to use two wrenches; one to fix the nut and the other to tighten the nut to the specified torque (Use a torque wrench for tightening). PC240LC-10 00-5...
  • Page 22 18. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine. 00-6 PC240LC-10...
  • Page 23 DIAGRAMS AND SCHEMATICS This section has the foldout drawings for the machine. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information. PC240LC-10 00-7...

  • Page 24: How To Read The Shop Manual

    Drain be drained, and quantity to be Example: drained. 10-4 10-4-1 Added pages 10-4-2 10-5 Revised Edition Mark When a manual is revised, an edition mark (…) is recorded on the bottom outside corner of the pages. 00-8 PC240LC-10...

  • Page 25: Hoisting Instructions

    When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. PC240LC-10 00-9...
  • Page 26 Precautions for Using Mobile Crane Remember the position of the main switch so that you can Read the Operation & Maintenance Manual provided with turn off the power immediately in an emergency. the crane in advance and operate the crane safely. 00-10 PC240LC-10...
  • Page 27 Do not leave the sling installed to the hook. 11.2 13.7 12.5 15.7 21.6 27.5 35.3 43.1 22.4 54.9 98.1 10.0 176.5 18.0 274.6 28.0 392.2 40.0 The allowable load value is 1/6 of the breaking strength of the rope used. Safety coefficient: 6 PC240LC-10 00-11...
  • Page 28 The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. 00-12 PC240LC-10...
  • Page 29 ★ If there is oil or water in the compressed air, the contacts will become even dirtier, so completely remove the oil and water from the compressed air before cleaning with compressed air. PC240LC-10 00-13...
  • Page 30 ★ If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. 00-14 PC240LC-10...
  • Page 31 Since the DT 8-pin and 12-pin heavy duty wire connectors have two latches respectively, push them in until they click two times. Male connector Female connector ★ Normal locking state (Horizontal):a, b, d ★ Incomplete locking state (Diagonal):c PC240LC-10 00-15...
  • Page 32 ★ Mainly, following engines are object for following connectors. • 95E-5 • 107E-1, 107E-2 • 114E-3, 114E-5 • 125E-5, 125E-6 • 140E-5, 140E-6 • 170E-5 • 12V140E-3 Slide, lock type (Type 1) (FRAMATOME-3, FRAMATOME-2) • 95/107/114/125/140/170/12V140 Series • Various pressure sensors and Ne speed sensor. Examples: 00-16 PC240LC-10...
  • Page 33 Insert the connector straight until it “clicks.” Slide, lock type (Type 2) (FRAMATOME-24) • 107/114/125 Series • Intermediate connector between machine wiring harness and engine wiring harness. Examples: Intermediate connector (engine wiring harness): OEM CONNECTION (107/114/125 series) A. Disconnection Slide down lock (red) (L1). PC240LC-10 00-17...
  • Page 34 Oil temperature sensor: TOIL iv. Coolant temperature sensor: TWTR and other. A. Disconnection Disconnect the connector by pulling lock (B) (on the  wiring harness side) of connector (2) outward. B. Connection Insert the connector straight in until it “clicks.” 00-18 PC240LC-10...
  • Page 35 [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with the flat- head screwdriver [1], pull out connector (3) in the direc- tion of the arrow. B. Connection Insert the connector straight until it “clicks.” PC240LC-10 00-19...
  • Page 36 While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. • Example: Fuel pressure sensor in common rail PFUEL etc. (AMP-3) • Example: Injection pressure control valve of supply pump: PCV (SUMITOMO-2)) 00-20 PC240LC-10...
  • Page 37 Pull out housing (H1) in the direction of the arrow. ★ Housing (H1) is left on the wiring harness. B. Connection Insert the connector to the end, while aligning its groove to the other. ii. Turn housing (H1) in the direction of the arrow until it “clicks.” PC240LC-10 00-21...
  • Page 38 D. When performing troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. • If there is any change, there is probably a defective contact in that circuit. 00-22 PC240LC-10...
  • Page 39 If any old oil is left,  contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. PC240LC-10 00-23...
  • Page 40 The oil cleaning equipment is used to remove the ultra fine {about 3 (10 ft)} particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device. 00-24 PC240LC-10...
  • Page 41 After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality. PC240LC-10 00-25...
  • Page 42 Hold in the condition in Steps 1 and 2, and pull out the whole body (2) to disconnect it. Connection Hold the connector of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it. 00-26 PC240LC-10...
  • Page 43 (2) to disconnect it. Connection Hold the connector of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface a of the hexagonal portion at the male end to connect it. PC240LC-10 00-27...
  • Page 44 (B) between the maximum size of the shaft and the minimum size of the hole is the “standard  interference.” • After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. 00-28 PC240LC-10...
  • Page 45 Wash the system carefully with clean fuel if dusts enter the system. Precautions for replacing fuel filter cartridge ● Be sure to use the Komatsu genuine fuel filter cartridge. ● Since the common rail fuel injection system (CRI) consists of more precise parts than the conventional fuel injection pump and nozzles, it employs a high-efficiency special filter to prevent foreign matter from entering it.
  • Page 46 HANDLING OF INTAKE SYSTEM PARTS ● The Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable mechanism) than the conventional turbocharger. If foreign matter enters this system, it can cause a problem. Use special care to prevent entry of foreign matter when servicing the air intake system.

  • Page 47: Standard Tightening Torque

    Thread diameter of bolt Width across flats Tightning torque N•m lbf-ft 5.9 - 9.8 4.35 - 7.22 13.7 - 23.5 10.10 - 17.33 34.3 - 46.1 25.29 - 34.00 74.5 - 90.2 54.94 - 66.52 Figure A Figure B PC240LC-10 00-31...
  • Page 48 36.1 ± 14.4 78.5 ± 19.6 57.8 ± 14.4 137.3 ± 29.4 101.2 ± 21.6 176.5 ± 29.4 130.1 ± 21.6 196.1 ± 49 144.6 ± 36.1 245.2 ± 49 180.8 ± 36.1 294.2 ± 49 216.9 ± 36.1 00-32 PC240LC-10...
  • Page 49 93.1 - 122.5 (68.66 - 90.35) 107.8 (79.50) – 107.8 - 147.0 (79.50 - 108.42) 124.4 (91.75) 127.4 - 176.4 (93.96 - 130.10) 151.9 (112.03) – 181.3 - 240.1 (133.72 - 177.08) 210.7 (155.40) – 274.4 - 367.5 (202.38 - 271.05) 323.4 (238.52) PC240LC-10 00-33...
  • Page 50 Tightening Torque Thread Size Bolts and Nuts N•m lbf in 10 ±2 1.02 ±0.20 88.51 ±17.70 24 ±4 2.45 ±0.41 17.70 ±2.95 43 ±6 4.38 ±0.61 31.72 ±4.43 77 ±12 7.85 ±1.22 56.79 ±8.85 — — — 00-34 PC240LC-10...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

A20001