Komatsu PC240LL-10 Shop Manual
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Komatsu PC240LL-10 Shop Manual

Komatsu PC240LL-10 Shop Manual

Log loader. road builder
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PC240LL
LOG LOADER
ROAD BUILDER
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.
July 2015
-10
PC240LL-10 A20601
6D107E-2
and up
Copyright 2015 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM028501

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  • 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 Find manuals at https://best-manuals.com...
  • Page 3 DIAGRAMS AND SCHEMATICS..........90-1 00-2 PC240LL-10 Find manuals at https://best-manuals.com...

  • Page 4: Safety Notice

    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. PC240LL-10 00-3 Find manuals at https://best-manuals.com...

  • Page 5: 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 PC240LL-10 Find manuals at https://best-manuals.com...
  • Page 6 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). PC240LL-10 00-5...
  • Page 7 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 PC240LL-10 Find manuals at https://best-manuals.com...
  • Page 8 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. PC240LL-10 00-7 Find manuals at https://best-manuals.com...
  • Page 9 10-4 drained. 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 PC240LL-10 Find manuals at https://best-manuals.com...

  • Page 10: Hoisting Instructions

    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. PC240LL-10 00-9 Find manuals at https://best-manuals.com...
  • Page 11 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 PC240LL-10...
  • Page 12 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 PC240LL-10 00-11...
  • Page 13 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 PC240LL-10...
  • Page 14 ★ 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. PC240LL-10 00-13...
  • Page 15 ★ 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 PC240LL-10...
  • Page 16 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 PC240LL-10 00-15...
  • Page 17 ★ 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 PC240LL-10...
  • Page 18 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). PC240LL-10 00-17...
  • Page 19 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 PC240LL-10...
  • Page 20 [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.” PC240LL-10 00-19...
  • Page 21 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 PC240LL-10...
  • Page 22 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.” PC240LL-10 00-21...
  • Page 23 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 PC240LL-10...
  • Page 24 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. PC240LL-10 00-23...
  • Page 25 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 PC240LL-10...
  • Page 26 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. PC240LL-10 00-25...
  • Page 27 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 PC240LL-10...
  • Page 28 (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. PC240LL-10 00-27...
  • Page 29 (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 PC240LL-10...
  • Page 30 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 31 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 32: 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 PC240LL-10 00-31...
  • Page 33 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 PC240LL-10...
  • Page 34 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) PC240LL-10 00-33...
  • Page 35 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 PC240LL-10...
  • Page 36 14.75 ±1.48 35 ±4 3.57 ±0.41 25.81 ±2.95 25 ±3 2.55 ±0.31 18.44 ±2.21 55 ±6 5.61 ±0.61 40.57 ±4.43 35 ±4 3.57 ±0.41 25.81 ±2.95 75 ±8 7.65 ±0.82 55.32 ±5.90 45 ±5 4.59 ±0.51 33.19 ±3.69 PC240LL-10 00-35...
  • Page 37 — White & Red & Yellow & Green & Blue & Color — — Green Green Blue Black Black Code — — — — Yellow & Green & Color — — — Red & Blue — White Blue 00-36 PC240LL-10...
  • Page 38 (nominal No. 125 and below) Insulator Soft polyvinyl chloride (type 2) Annealed copper for electric Heat-resistant Conductor General wiring in extremely cold appliance low-voltage –50 to +110 district, wiring at high-temperature wire for (-58 to +230) Heat-resistant crosslinked place Insulator automobile polyethylene PC240LL-10 00-37...
  • Page 39 11/Circular 16/Circular – – – Diameter of compressed compressed Compressed strand Conductor Cross-section – 0.56 – 0.88 – 1.29 area (mm d (approx.) – – – CAVS Standard – – – ★ “f” of nominal No. denotes flexible”. 00-38 PC240LL-10...
  • Page 40 – – Others – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – PC240LL-10 00-39...

  • Page 41: Precautions For Operations

    Sleeve Nut (elbow end) Number 07376-70210 02789-20210 07376-70315 02789-00315 07376-70422 02789-00422 07376-70522 02789-00522 07376-70628 02789-00628 • Split flange type hoses and tubes Nominal Flange (hose end) Sleeve Head (tube end) Split Flange Number 07379-00400 07378-10400 07371-30400 07379-00500 07378-10500 07371-30500 00-40 PC240LL-10...
  • Page 42 Next, operate the hydraulic cylinder three to four times to the end of its stroke. After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, do the same procedure. PC240LL-10 00-41...
  • Page 43 Check the KDPF or muffler for abnormal sound and sound different from that of a new one. • If any abnormal sound is heard, repair the KDPF or muffler. Refer to both the Troubleshooting and the Disassembly and Assembly sections. 00-42 PC240LL-10...

  • Page 44: Conversion Tables

    2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 PC240LL-10 00-43...
  • Page 45 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26 00-44 PC240LL-10...
  • Page 46 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777 PC240LL-10 00-45...
  • Page 47 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4 00-46 PC240LL-10...
  • Page 48 3015 3030 3044 3058 3072 3086 3101 3115 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542 PC240LL-10 00-47...
  • Page 49 167.0 65.6 302.0 -14.4 42.8 105.8 24.4 168.8 68.3 311.0 -13.9 44.6 107.6 25.0 170.6 71.1 320.0 -13.3 46.4 109.4 25.6 172.4 73.9 329.0 -12.8 48.2 111.2 26.1 174.2 76.7 338.0 -12.2 50.0 113.0 26.7 176.0 79.4 347.0 00-48 PC240LL-10...

  • Page 50: Coating Materials

    Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent  LG-3 790-129-9070 1 kg seizure. ● Used as sealant for heat resistant gasket for at high temperature locations such as engine  pre-combustion chamber, exhaust pipe. PC240LL-10 00-49...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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