Komatsu PC240LC-10 Install guide

CEBM024902
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Manual
PC240LC -10
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PC240LC-10 A20001 and up
ENGINE 6D107E-2
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.
Copyright 2013 Komatsu
Printed in U.S.A.
Komatsu America Corp.
June 2013

FOREWORD CONTENTS
00-2 cPC240LC-10
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
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10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
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20 STANDARD VALUE TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
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40 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
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60 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
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80 AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
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90 DIAGRAMS AND SCHEMATICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
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FOREWORD
PC240LC-10 00-2-1 
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PC240LC-10
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FOREWORD
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FOREWORD
PC240LC-10 00-2-3 
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FOREWORD
00-2-4 PC240LC-10
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FOREWORD
PC240LC-10 00-2-5 
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FOREWORD
00-2-6 PC240LC-10
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FOREWORD
PC240LC-10 00-2-7 
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FOREWORD
00-2-8 PC240LC-10
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FOREWORD
PC240LC-10 00-2-9 
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FOREWORD
00-2-10 PC240LC-10
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FOREWORD
00-2-16 PC240LC-10

FOREWORD SAFETY
PC240LC-10 00-3
12
SAFETY 00
Safety Notice 00
General Precautions 00
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine.
1. Before performing any greasing or repairs, read all the
precautions given on the decals which are fixed to the
machine.
2. When performing any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
•Always wear safety glasses when hitting parts with
a hammer.
•Always wear safety glasses when grinding parts
with a grinder, etc.
3. If welding repairs are needed, always have a trained,
experienced welder perform the work. When perform-
ing welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work.
4. When performing any operation with two or more 
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before starting
work, hang UNDER REPAIR signs on the controls in
the operator's compartment.
5. Only qualified workers must perform the work and
operation which require license or qualification.
6. Keep all tools in good condition and learn the correct
way to use them. Before starting work, thoroughly
check the tools, machine, forklift truck, service car, etc.
7. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
8. Before starting work, warm up your body thoroughly to
start work under good conditions. Avoid continuous
work for long hours and take rests at proper intervals to
keep your body in good condition. Take rests in 
specified safe places.
Safety Points
Important Safety Notice 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying
this symbol should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety,
and take the necessary actions to deal with the situation.
WARNING! Never modify, weld, cut, or
drill on any part of a ROPS
structure. Doing so may
weaken the structure which
could lead to possible failure
in a rollover situation.
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5Prohibition of operation and handling by
unlicensed workers
6 Safety check before starting work
7Wearing protective goggles 
(for cleaning or grinding work)
8Wearing shielding goggles and protectors
(for welding work)
9 Good physical condition and preparation
10 Precautions against work which you are not used to or work with which you are too
familiar

FOREWORD SAFETY
00-4 PC240LC-10
Preparations For Work 00
1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not 
possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the
control levers and hang warning signs on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad-
ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe footing.
Precautions During Work 00
1. When removing oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil
from spurting out. Before disconnecting or removing components of the oil, coolant or air circuits, first remove the pres-
sure completely from the circuit.
2. The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and
coolant to cool before performing any work on the oil or coolant circuits.
3. Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the
engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature,
etc.) take extreme care not to get rolled or caught in rotating or moving parts.
4. For the machine equipped with a battery disconnect switch, before starting the work, check that the system operating lamp
is turned OFF, and then turn the battery disconnect switch to the OFF (o) position and pull the switch key out. For
machines with a battery disconnect switch, before starting the work, remove the leads from the battery. ALWAYS remove
the lead from the negative (-) terminal first.
5. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
6. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in 
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
7. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
8. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
9. Never use flammable liquids to clean parts, use only non-flammable approved cleaning solutions to clean parts.
10. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
•When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
11. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
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.