Komatsu PC240LC-10 Install guide
HYDRAULIC
EXCAVATOR
SEN05538-05
PC240LC-10
SERIAL NUMBERS
90001
and up
00 Index and foreword
Index
Index
(ALL-0310-001-A-00-A)
00 Index and foreword .......................................................................................................................00-1
Index .........................................................................................................................................00-2
Foreword, safety and general information ................................................................................... 00-14
Important safety notice .......................................................................................................00-14
How to read the shop manual.............................................................................................. 00-21
Explanation of terms for maintenance standard .................................................................... 00-23
Handling equipment of fuel system devices .......................................................................... 00-25
Handling of intake system parts........................................................................................... 00-26
Handling of hydraulic equipment.......................................................................................... 00-27
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-29
Handling of electrical equipment.......................................................................................... 00-32
How to read electric wire code............................................................................................. 00-40
Precautions when performing operation ............................................................................... 00-43
Practical use of KOMTRAX................................................................................................. 00-48
Standard tightening torque table.......................................................................................... 00-49
List of abbreviation ............................................................................................................. 00-55
Conversion table................................................................................................................ 00-60
01 Specification.................................................................................................................................01-1
Table of contents ........................................................................................................................01-2
Specifications.............................................................................................................................01-3
Specification drawings..........................................................................................................01-3
Working range drawings .......................................................................................................01-4
Specifications ......................................................................................................................01-5
Weight table ........................................................................................................................01-8
Table of fuel, coolant and lubricants .......................................................................................01-9
10 Structure and function ...................................................................................................................10-1
Table of contents ........................................................................................................................10-2
Engine and cooling system..........................................................................................................10-3
Engine related parts .............................................................................................................10-3
KVGT..................................................................................................................................10-5
EGR system piping drawing................................................................................................10-12
EGR system circuit diagram................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-20
KCCV ventilator ................................................................................................................. 10-22
KDPF................................................................................................................................ 10-24
Cooling system .................................................................................................................. 10-28
Power train............................................................................................................................... 10-30
Power train system............................................................................................................. 10-30
Swing circle ....................................................................................................................... 10-32
Swing machinery ............................................................................................................... 10-33
Final drive ......................................................................................................................... 10-35
Undercarriage and frame........................................................................................................... 10-37
Track frame and idler cushion ............................................................................................. 10-37
Hydraulic system ...................................................................................................................... 10-39
Hydraulic equipment layout drawing .................................................................................... 10-39
Valve control...................................................................................................................... 10-41
Hydraulic tank.................................................................................................................... 10-43
CLSS................................................................................................................................ 10-45
Main pump ........................................................................................................................ 10-50
Control valve ..................................................................................................................... 10-74
Swing motor .................................................................................................................... 10-128
Travel motor .................................................................................................................... 10-139
PPC valve ....................................................................................................................... 10-152
Solenoid valve ................................................................................................................. 10-173
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-176
00-2 PC240LC–10
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00 Index and foreword
Index
Attachment circuit selector valve (for low pressure circuit).................................................... 10-178
Center swivel joint............................................................................................................ 10-181
Accumulator .................................................................................................................... 10-183
Work equipment ..................................................................................................................... 10-184
Work equipment............................................................................................................... 10-184
Work equipment shim....................................................................................................... 10-185
Bucket play adjustment shim............................................................................................. 10-186
Cab and its attachments.......................................................................................................... 10-187
Cab mount and cab tipping stopper ................................................................................... 10-187
ROPS cab....................................................................................................................... 10-188
Electrical system .................................................................................................................... 10-189
Electrical control system ................................................................................................... 10-189
Machine monitor system................................................................................................... 10-232
KOMTRAX system........................................................................................................... 10-252
Sensor ............................................................................................................................ 10-254
20 Standard value table .....................................................................................................................20-1
Table of contents ........................................................................................................................20-2
Standard service value table........................................................................................................20-3
Standard value table for engine related parts.......................................................................... 20-3
Standard value table for chassis related parts......................................................................... 20-4
Posture of machine for measuring performance and measurement procedure......................... 20-13
30 Testing and adjusting ....................................................................................................................30-1
Table of contents ........................................................................................................................30-2
Related information on testing and adjusting ................................................................................. 30-3
Tools for testing and adjusting ...............................................................................................30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Engine and cooling system..........................................................................................................30-9
Testing engine speed ...........................................................................................................30-9
Testing boost pressure ....................................................................................................... 30-10
Testing exhaust gas color ................................................................................................... 30-11
Testing and adjusting valve clearance.................................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Measuring blowby pressure ................................................................................................ 30-20
Measuring engine oil pressure............................................................................................. 30-21
Measuring EGR valve and KVGT oil pressure....................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage.......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Testing fuel circuit for leakage ............................................................................................. 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no-injection cranking operation.............................................................................. 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Replacing fan belt .............................................................................................................. 30-40
Power train............................................................................................................................... 30-41
Testing swing circle bearing clearance ................................................................................. 30-41
Undercarriage and frame........................................................................................................... 30-42
Testing and adjusting track tension ...................................................................................... 30-42
Hydraulic system ...................................................................................................................... 30-43
Releasing remaining pressure from hydraulic circuit.............................................................. 30-43
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits .................. 30-44
Testing oil pressure in control circuit..................................................................................... 30-48
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-49
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-52
Testing output pressure of solenoid valve ............................................................................. 30-57
Measuring PPC valve output pressure ................................................................................. 30-61
Adjusting play of work equipment and swing PPC valves....................................................... 30-63
Testing pump swash plate sensor........................................................................................ 30-64
Isolating the parts causing hydraulic drift in work equipment................................................... 30-65
Testing oil leakage ............................................................................................................. 30-67
PC240LC–10 00-3
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00 Index and foreword
Index
Bleeding air from hydraulic circuit ........................................................................................ 30-70
Cab and its attachments............................................................................................................ 30-72
Testing cab tipping stopper ................................................................................................. 30-72
Adjusting mirrors................................................................................................................ 30-73
Electrical system ...................................................................................................................... 30-75
Special functions of machine monitor................................................................................... 30-75
Adjusting rearview camera angle....................................................................................... 30-141
Handling voltage circuit of engine controller........................................................................ 30-143
Handling battery disconnect switch .................................................................................... 30-144
Testing diodes ................................................................................................................. 30-145
Pm clinic ................................................................................................................................ 30-146
Pm clinic service .............................................................................................................. 30-146
40 Troubleshooting............................................................................................................................40-1
Table of contents ........................................................................................................................40-2
Related information on troubleshooting......................................................................................... 40-9
Troubleshooting points .........................................................................................................40-9
Sequence of events in troubleshooting................................................................................. 40-11
Testing before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation work for troubleshooting of electrical system....................................................... 40-43
Classification and procedure for troubleshooting ................................................................... 40-47
Symptom of probable failure and troubleshooting No............................................................. 40-50
Information in troubleshooting table ..................................................................................... 40-53
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-55
Connector list and layout .................................................................................................... 40-57
Connector contact identification........................................................................................... 40-68
T-branch box and T-branch adapter table ........................................................................... 40-107
Fuse list and location........................................................................................................ 40-112
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-114
Failure codes table........................................................................................................... 40-117
Troubleshooting by failure code (Display of code) ...................................................................... 40-126
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-126
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-127
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-128
Failure code [879BKB] A/C Outer Sensor Short Circuit........................................................ 40-129
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-130
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-131
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-132
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-133
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-134
Failure code [879GKX] Refrigerant Abnormality.................................................................. 40-135
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-136
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-137
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-138
Failure code [A1U0N3] HC desorb request1 ....................................................................... 40-139
Failure code [A1U0N4] HC desorb request2 ....................................................................... 40-141
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-143
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-145
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-147
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-148
Failure code [B@BCNS] Engine Coolant Overheat ............................................................. 40-149
Failure code [B@BCZK] Radiator Coolant Level Low .......................................................... 40-150
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-152
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-153
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-154
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-156
Failure code [CA131] Throttle Sensor High Error................................................................. 40-158
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-160
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-162
00-4 PC240LC–10
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00 Index and foreword
Index
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-164
Failure code [CA153] Chg Air Temp Sensor High Error........................................................ 40-166
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-168
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-170
Failure code [CA221] Ambient Press Sensor High Error ...................................................... 40-172
Failure code [CA222] Ambient Press Sensor Low Error ....................................................... 40-174
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-176
Failure code [CA234] Eng Overspeed ................................................................................ 40-177
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-178
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-179
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-180
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-182
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-183
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-184
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-186
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-188
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-190
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-192
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-194
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-196
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-197
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-198
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-200
Failure code [CA357] Mass Air Flow Sensor Low Error........................................................ 40-202
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-204
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-205
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-207
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-209
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-210
Failure code [CA442] Battery Voltage High Error................................................................. 40-212
Failure code [CA449] Rail Press Very High Error................................................................. 40-213
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-214
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-216
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-217
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-218
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-220
Failure code [CA553] Rail Press High Error ........................................................................ 40-222
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-223
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-224
Failure code [CA559] Rail Press Low Error......................................................................... 40-225
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-227
Failure code [CA687] Turbo Speed Low Error..................................................................... 40-228
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-230
Failure code [CA691] Intake Air Temp Sens High Error........................................................ 40-232
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-234
Failure code [CA697] ECM Int Temp Sensor High Error ....................................................... 40-236
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-237
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-238
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-239
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-243
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-244
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-246
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-248
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-250
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-252
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-254
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-256
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-258
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-260
PC240LC–10 00-5
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00 Index and foreword
Index
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-263
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-265
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-270
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-271
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-272
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-273
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-274
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-275
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-277
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-280
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-281
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-282
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-284
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-286
Failure code [CA2373] Exh Manifold Press. Sens Volt ......................................................... 40-287
Failure code [CA2374] Exhaust Manifold Press Sens Low Error........................................... 40-289
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-291
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-293
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-295
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-297
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-299
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-301
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-303
Failure code [CA2554] Exh Manifold Press Sens In Range Error.......................................... 40-304
Failure code [CA2555] Grid Htr Relay Volt Low Error........................................................... 40-305
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-308
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-310
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-312
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-314
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-315
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-316
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-318
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-320
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-323
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-326
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-328
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-331
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-332
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-333
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-334
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-336
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-339
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-343
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-347
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-350
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error............................................. 40-354
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-358
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-362
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-365
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-369
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-370
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-372
Failure code [D110KB] Battery Relay Output Voltage .......................................................... 40-373
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-375
Failure code [D811MC] KOMTRAX Error............................................................................ 40-378
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-379
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
......................................................................................................................... 40-380
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...................................... 40-382
00-6 PC240LC–10
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00 Index and foreword
Index
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-383
Failure code [DA20MC] Pump Controller............................................................................ 40-384
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-385
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-387
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-390
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ....................................... 40-392
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ....................................... 40-394
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-395
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-397
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-398
Failure code [DAF0MC] Monitor Error ................................................................................ 40-399
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-400
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-402
Failure code [DAFGMC] GPS Module Error........................................................................ 40-403
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ........................................... 40-404
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)............................................ 40-406
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-407
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-408
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-409
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-413
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-418
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .......................................................... 40-422
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-424
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-425
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-428
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality........................................ 40-431
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-433
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-436
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality .................................. 40-439
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-442
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-445
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-448
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-451
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-454
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-457
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-460
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-463
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................... 40-466
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...................................... 40-469
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-472
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-474
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-476
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-478
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-480
Failure code [DW45KA] Swing Brake Sol Open Circuit ........................................................ 40-482
Failure code [DW45KB] Swing Brake Sol Short Circuit ........................................................ 40-485
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-488
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-490
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-492
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-494
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-496
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit...................................................... 40-498
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-500
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-502
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ................................................. 40-504
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ................................................. 40-506
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-508
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-510
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-512
PC240LC–10 00-7
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00 Index and foreword
Index
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-514
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-516
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-518
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-520
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-522
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-524
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-526
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-528
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-530
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-532
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-534
Failure code [DY2CKB] Washer Drive Short Circuit............................................................. 40-536
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-538
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-540
Troubleshooting of electrical system (E-mode) .......................................................................... 40-542
E-1 Engine does not start (Engine does not crank) .............................................................. 40-542
E-2 Manual preheating system does not work..................................................................... 40-548
E-3 Automatic preheating system does not work................................................................. 40-551
E-4 Preheating monitor does not light up when preheater is operated ................................... 40-553
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-555
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-558
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-559
E-8 Coolant temperature monitor lights up in white while engine is running ........................... 40-560
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-561
E-10 Charge level monitor lights up while engine is running ................................................. 40-562
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-563
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-564
E-13 Water separator monitor lights up while engine is running ............................................ 40-565
E-14 Coolant temperature monitor lights up in red while engine is running............................. 40-566
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-567
E-16 Engine oil pressure monitor lights up in red while engine is running .............................. 40-568
E-17 Fuel gauge indicates either full or empty and does not move........................................ 40-569
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-570
E-19 Coolant temperature gauge indicates either Min. or Max. and does not move ................ 40-571
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor
Max.) ................................................................................................................. 40-572
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not
move ................................................................................................................. 40-573
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min.
nor Max.) ........................................................................................................... 40-575
E-23 Content of display on machine monitor is different from that of actual machine .............. 40-576
E-24 Machine monitor does not display some items ............................................................ 40-577
E-25 Function switch does not work................................................................................... 40-578
E-26 Automatic preheating system does not work (In cold season)....................................... 40-579
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
switch is operated ............................................................................................... 40-580
E-28 Auto-deceleration is not actuated or canceled when lever is operated ........................... 40-581
E-29 Working mode selection screen is not diplayed when working mode switch is
operated ............................................................................................................ 40-582
E-30 Engine or hydraulic pump setting does not change when working mode is
changed............................................................................................................. 40-583
E-31 Travel speed monitor does not change when travel speed switch is operated ................ 40-584
E-32 Travel speed does not change when travel speed is shifted ......................................... 40-585
E-33 Alarm buzzer does not stop sounding......................................................................... 40-586
E-34 When starting switch is turned to OFF position, service meter is not displayed............... 40-587
E-35 Service mode cannot be selected .............................................................................. 40-588
E-36 Any of work equipment, swing and travel does not work............................................... 40-589
00-8 PC240LC–10
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00 Index and foreword
Index
E-37 Any of work equipment, swing and travel cannot be locked .......................................... 40-591
E-38 Machine cannot swing while swing brake cancel switch is canceled ............................. 40-592
E-39 Swing brake does not operate while swing brake cancel switch is locked ...................... 40-594
E-40 One-touch power maximizing function does not work or monitor is not displayed ........... 40-596
E-41 One-touch power maximizing function cannot be released........................................... 40-598
E-42 Travel alarm does not sound when machine travels..................................................... 40-599
E-43 Travel alarm does not stop sounding when machine stops........................................... 40-600
E-44 Horn does not sound ................................................................................................ 40-601
E-45 Horn does not stop sounding..................................................................................... 40-603
E-46 Wiper monitor does not light up or go out when wiper switch is operated ....................... 40-604
E-47 Wiper does not operate when wiper switch is operated ................................................ 40-605
E-48 Window washer does not operate when window washer switch is operated................... 40-607
E-49 BOOM LOWER indication is not displayed properly with monitoring function ................. 40-608
E-50 ARM DUMP indication is not displayed properly with monitoring function ...................... 40-609
E-51 ARM IN indication is not displayed properly with monitoring function............................. 40-610
E-52 BOOM RAISE indication is not displayed properly with monitoring function ................... 40-611
E-53 BUCKET CURL indication is not displayed properly with monitoring function ................. 40-612
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ................ 40-613
E-55 SWING indication is not displayed properly with monitoring function ............................. 40-614
E-56 TRAVEL indication is not displayed properly with monitoring function............................ 40-615
E-57 Service is not displayed properly with monitoring function ............................................ 40-616
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-619
E-59 KOMTRAX system does not work properly ................................................................. 40-620
Troubleshooting of hydraulic and mechanical system (H-mode).................................................. 40-621
Information described in troubleshooting table (H-mode) ..................................................... 40-621
System chart for hydraulic system ..................................................................................... 40-622
Failure mode and cause table ........................................................................................... 40-624
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-632
H-2 Engine speed lowers significantly or engine stalls ......................................................... 40-635
H-3 Any of work equipment, swing and travel does not work ................................................ 40-637
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-638
H-5 Fine control performance or response is poor ............................................................... 40-639
H-6 Boom operation lacks speed or power ......................................................................... 40-640
H-7 Arm operation lacks speed or power............................................................................ 40-642
H-8 Bucket operation lacks speed or power........................................................................ 40-644
H-9 Work equipment does not move in single operation....................................................... 40-645
H-10 Hydraulic drift of boom is large .................................................................................. 40-646
H-11 Hydraulic drift of arm is large ..................................................................................... 40-647
H-12 Hydraulic drift of bucket is large ................................................................................. 40-648
H-13 Time lag of work equipment is large ........................................................................... 40-649
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-651
H-15 One-touch power maximizing function does not work .................................................. 40-652
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-653
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-654
H-18 In combined operations of swing and travel, travel speed drops largely ......................... 40-655
H-19 Machine does not travel straight ................................................................................ 40-656
H-20 Travel speed is too low ............................................................................................. 40-657
H-21 Machine is hard to steer or travel power is low ............................................................ 40-659
H-22 Travel speed does not change, or travel speed is too low or high.................................. 40-661
H-23 One of tracks does not run ........................................................................................ 40-662
H-24 Upper structure does not swing to the right or left ........................................................ 40-663
H-25 Upper structure swings only to the right or left............................................................. 40-664
H-26 Swing acceleration is poor or swing speed is low (both right and left) ............................ 40-665
H-27 Swing acceleration is poor or swing speed is low (either right or left)............................. 40-666
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-667
PC240LC–10 00-9
00 Index and foreword
Index
H-30 Shock is large when upper structure stops swinging.................................................... 40-669
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-670
H-32 Swing drift on a slope is large while swing holding brake is applied............................... 40-671
H-33 Swing drift on a slope is large while swing holding brake is released............................. 40-672
H-34 Attachment circuit cannot be changed while attachment is installed.............................. 40-673
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-674
Troubleshooting of engine (S-mode)......................................................................................... 40-675
Information mentioned in troubleshooting table (S mode)..................................................... 40-675
S-1 When starting switch is turned to START position, engine does not crank ....................... 40-676
S-2 When engine cranks, smoke does not come out ........................................................... 40-677
S-3 Engine does not start while fuel is injected (Incomplete combustion)............................... 40-678
S-4 Startability is poor....................................................................................................... 40-679
S-5 Engine does not pick up smoothly ............................................................................... 40-681
S-6 Engine stops during operation ..................................................................................... 40-682
S-7 Engine runs rough or is unstable ................................................................................. 40-684
S-8 Engine lacks power .................................................................................................... 40-685
S-9 Exhaust smoke is black (KDPF clogs up early) ............................................................. 40-687
S-10 Engine oil consumption is too much ........................................................................... 40-689
S-11 Oil becomes contaminated early ................................................................................ 40-690
S-12 Fuel consumption is excessive .................................................................................. 40-691
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-692
S-14 Engine oil pressure drops ......................................................................................... 40-693
S-15 Fuel is contaminated in engine oil .............................................................................. 40-694
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)................................. 40-695
S-17 Coolant temperature rises too high (Overheating) ....................................................... 40-696
S-18 Unusual noise is heard ............................................................................................. 40-697
S-19 Vibration is excessive ............................................................................................... 40-698
S-20 Automatic regeneration is operated frequently ............................................................ 40-699
S-21 Active regeneration is operated for long ..................................................................... 40-700
S-22 White smoke comes out in the process of active regeneration ...................................... 40-701
50 Disassembly and assembly ...........................................................................................................50-1
Table of contents ........................................................................................................................50-2
Related information on disassembly and assembly ........................................................................ 50-4
How to read this manual .......................................................................................................50-4
Coating materials list ............................................................................................................50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-18
Engine and cooling system ........................................................................................................ 50-21
Removal and installation of supply pump assembly............................................................... 50-21
Removal and installation of injector assembly....................................................................... 50-26
Removal and installation of cylinder head assembly.............................................................. 50-35
Removal and installation of radiator assembly ...................................................................... 50-55
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-57
Removal and installation of aftercooler assembly.................................................................. 50-60
Removal and installation of engine and main pump assembly ................................................ 50-62
Removal and installation of engine front oil seal .................................................................... 50-74
Removal and installation of engine rear oil seal..................................................................... 50-78
Removal and installation of fuel cooler assembly .................................................................. 50-81
Removal and installation of fuel tank assembly ..................................................................... 50-82
Removal and installation of engine hood assembly ............................................................... 50-85
Removal and installation of KDPF assembly......................................................................... 50-88
Disassembly and assembly of KDPF assembly .................................................................... 50-96
Removal and installation of KCCV assembly ...................................................................... 50-104
Removal and installation of air cleaner assembly ................................................................ 50-108
Power train system ..................................................................................................................50-111
Removal and installation of travel motor and final drive assembly..........................................50-111
Disassembly and assembly of final drive ............................................................................ 50-112
Removal and installation of swing motor and swing machinery assembly .............................. 50-120
Disassembly and assembly of swing machinery.................................................................. 50-123
00-10 PC240LC–10
00 Index and foreword
Index
Removal and installation of swing circle assembly .............................................................. 50-131
Undercarriage and frame......................................................................................................... 50-132
Separation and connection of track shoe assembly............................................................. 50-132
Removal and installation of sprocket.................................................................................. 50-135
Removal and installation of idler and idler cushion assembly ............................................... 50-136
Disassembly and assembly of idler .................................................................................... 50-137
Disassembly and assembly of idler cushion........................................................................ 50-140
Disassembly and assembly of track roller........................................................................... 50-142
Disassembly and assembly of carrier roller......................................................................... 50-145
Removal and installation of revolving frame assembly ......................................................... 50-148
Removal and installation of counterweight assembly ........................................................... 50-150
Hydraulic system .................................................................................................................... 50-153
Removal and installation of center swivel joint assembly ..................................................... 50-153
Disassembly and assembly of center swivel joint ................................................................ 50-156
Removal and installation of hydraulic tank assembly ........................................................... 50-157
Removal and installation of main pump assembly ............................................................... 50-161
Removal and installation of control valve assembly ............................................................. 50-165
Disassembly and assembly of control valve........................................................................ 50-172
Disassembly and assembly of work equipment PPC valve................................................... 50-179
Disassembly and assembly of travel PPC valve.................................................................. 50-182
Work equipment ..................................................................................................................... 50-185
Removal and installation of work equipment assembly ........................................................ 50-185
Disassembly and assembly of work equipment cylinder....................................................... 50-188
Cab and its attachments.......................................................................................................... 50-194
Removal and installation of operator's cab assembly........................................................... 50-194
Removal and installation of operator cab glass (adhered glass) ........................................... 50-199
Removal and installation of front window assembly ............................................................. 50-209
Removal and installation of floor frame assembly................................................................ 50-215
Removal and installation of air conditioner unit assembly..................................................... 50-221
Removal and installation of operator's seat......................................................................... 50-225
Removal and installation of seat belt.................................................................................. 50-227
Removal and installation of front wiper assembly ................................................................ 50-229
Electrical system .................................................................................................................... 50-236
Removal and installation of air conditioner compressor assembly......................................... 50-236
Removal and installation of air conditioner condenser assembly .......................................... 50-239
Removal and installation of engine controller assembly ....................................................... 50-241
Removal and installation of pump controller assembly......................................................... 50-243
Removal and installation of machine monitor assembly ....................................................... 50-246
Removal and installation of pump swash plate sensor ......................................................... 50-248
Removal and installation of mass air flow and temperature sensor ....................................... 50-249
Removal and installation of KOMTRAX terminal assembly .................................................. 50-250
60 Maintenance standard...................................................................................................................60-1
Table of contents ........................................................................................................................60-2
Engine and cooling system..........................................................................................................60-3
Engine mount ......................................................................................................................60-3
Cooling system ....................................................................................................................60-4
Power train system .....................................................................................................................60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery .................................................................................................................60-6
Final drive ...........................................................................................................................60-8
Undercarriage and frame........................................................................................................... 60-10
Sprocket............................................................................................................................ 60-10
Track frame and idler cushion ............................................................................................. 60-12
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-17
Track shoe ........................................................................................................................ 60-18
Hydraulic system ...................................................................................................................... 60-22
Hydraulic tank.................................................................................................................... 60-22
PC240LC–10 00-11
00 Index and foreword
Index
Main pump ........................................................................................................................ 60-23
Control valve ..................................................................................................................... 60-24
Swing motor ...................................................................................................................... 60-34
Travel motor ...................................................................................................................... 60-36
PPC valve ......................................................................................................................... 60-39
Solenoid valve.......................................................................................................................... 60-48
Attachment circuit selector valve (for high-pressure circuit)........................................................... 60-49
Attachment circuit selector valve (for low-pressure circuit) ............................................................ 60-50
Center swivel joint..................................................................................................................... 60-51
Work equipment ....................................................................................................................... 60-52
Work equipment................................................................................................................. 60-52
Work equipment cylinder .................................................................................................... 60-61
80 Appendix......................................................................................................................................80-1
Table of contents ........................................................................................................................80-2
Air conditioner components .........................................................................................................80-3
Precautions for refrigerant.....................................................................................................80-3
Air conditioner component ....................................................................................................80-4
Configuration and function of refrigeration cycle...................................................................... 80-6
Outline of refrigeration cycle..................................................................................................80-7
Air conditioner unit ...............................................................................................................80-9
Dual pressure switch .......................................................................................................... 80-16
Air conditioner controller .....................................................................................................80-17
Compressor....................................................................................................................... 80-18
Air conditioner condenser ................................................................................................... 80-19
Sunlight sensor.................................................................................................................. 80-21
Outer temperature sensor (outside air temperature sensor) ................................................... 80-22
Procedure for testing and troubleshooting ............................................................................ 80-23
Circuit diagram and arrangement of connector pins............................................................... 80-25
System diagram................................................................................................................. 80-27
Input and output signals of the air conditioner controller......................................................... 80-28
Parts and connectors layout................................................................................................ 80-30
Layout of air conditioner related parts and connectors ........................................................... 80-31
Testing air leakage (duct) .................................................................................................... 80-34
Testing with self-diagnosis function ...................................................................................... 80-37
How to open the electrical system abnormality record screen in service mode of the machine
monitor ................................................................................................................ 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Testing sunlight sensor ....................................................................................................... 80-43
Testing (dual) pressure switch for refrigerant......................................................................... 80-44
Testing relays .................................................................................................................... 80-45
Troubleshooting chart 1 ...................................................................................................... 80-46
Troubleshooting chart 2 ...................................................................................................... 80-47
Information in troubleshooting table ..................................................................................... 80-50
Failure code list related to air conditioner.............................................................................. 80-51
Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-52
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-53
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-54
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-56
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-58
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-59
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-60
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-62
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-63
Failure code [879GKX] Refrigerant Abnormality.................................................................... 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)................................................ 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-70
00-12 PC240LC–10
00 Index and foreword
Index
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-72
Troubleshooting with gauge pressure................................................................................... 80-74
Testing refrigerant pressure................................................................................................. 80-77
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-80
Handling of compressor oil.................................................................................................. 80-82
Desiccant replacement ....................................................................................................... 80-84
90 Diagrams and drawings.................................................................................................................90-1
Table of contents ........................................................................................................................90-2
Hydraulic circuit diagram .............................................................................................................90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram.......................................................................................................90-7
Electric circuit diagram .............................................................................................................. 90-11
Symbols in electric circuit diagram....................................................................................... 90-11
Electric circuit diagram........................................................................................................ 90-15
Electric circuit diagram of air conditioner unit ........................................................................ 90-27
Adjustment (Pump calibration: Matching speed calibration) ...................................................................
Adjustment (Pump calibration: Restore default value) ...........................................................................
Index.................................................................................................................................................................... 1
PC240LC–10 00-13
00 Index and foreword
Foreword, safety and general information
Foreword, safety and general information
(ALL-0370-001-A-00-A)
Important safety notice
(ALL-1120-012-A-01-A)
(Rev. 2014/08)
•Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
•The symbol mark kis used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
Safety points
•Good arrangement
•Correct work clothes
•Observance of work standard
•Practice of making and checking signals
•Prohibition of operation and handling by
unlicensed workers
•Safety check before starting work
•Wearing protective goggles (for cleaning or
grinding work)
•Wearing shielding goggles and protectors (for
welding work)
•Good physical condition and preparation
•Precautions against work which you are not
used to or you are used to too much
General precautions
kk Inappropriate handling causes an extreme
danger. Read and understand what is
described in the operation and maintenance
manual before operating the machine. Read
and understand what is described in this
manual before starting the work.
•Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For
the locations of the safety labels and detailed
explanation of precautions, see the operation
and maintenance manual.
•Locate a place in the repair workshop to keep
the 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, water or oil on the floor. Smoke
only in the areas provided for smoking. Never
smoke while working.
•When performing any work, always wear the
safety shoes and helmet. Do not wear loose
work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when
hitting parts with a hammer.
2. Always wear the protective eyeglasses when
grinding parts with a grinder, etc.
•When performing any work with 2 or more
workers, always agree on the working procedure
before starting. While working, always keep
conversations of the work between your fellow
workers and your self on any step of the work.
During the work, hang the warning tag of
"UNDER WORKING" in the operator's
compartment.
•Only qualified workers must perform the work
and operation which require license or
qualification.
•Keep the tools in good condition. And learn the
correct way to use the tools, and use the proper
ones among them. Before starting the work,
thoroughly check the tools, lift truck, service
vehicle, etc.
•If welding repairs is required, always have a
trained and experienced welder with good
knowledge of welding perform the work. When
performing welding work, always wear welding
gloves, apron, shielding goggles, cap, etc.
•Before starting work, warm up your body
thoroughly to start work under good condition.
•Avoid continuing work for long hours and take
rests with proper intervals to keep your body in
good condition. Take a rest in a specified safe
place.
Preparation
•Before adding oil or making any repairs, place
the machine on a firm and level ground, and
apply the parking brake and chock the wheels or
tracks to prevent the machine from moving.
•Before starting work, lower the work equipment
(blade, ripper, bucket, etc.) to the ground. If it is
not possible to lower the equipment to the
ground, insert the lock pin or use blocks to
prevent the work equipment from falling. And be
sure to lock all the work equipment control levers
and hang a warning tag on them.
•When performing the disassembling or
assembling work, support the machine securely
with blocks, jacks, or stands before starting the
work.
•Remove all of mud and oil from the steps or
other places used to get on and off the machine
completely. Always use the handrails, ladders of
steps when getting on or off the machine. Never
00-14 PC240LC–10
00 Index and foreword
Foreword, safety and general information
jump on or off the machine. When the scaffold is
not provided, use steps or stepladder to secure
your footing.
Precautions during work
•For the machine equipped with the battery
disconnect switch, check that the system
operating lamp is turned off before starting the
work. Then, turn the battery disconnect switch to
OFF (Q) position and remove the switch key. For
the machine not equipped with the battery
disconnect switch, remove the cable from the
battery before starting the work. Be sure to
remove the negative end (-) of the battery cable
first.
•Release the remaining pressure in the circuits
completely before the work when the parts in the
circuits of oil, fuel, coolant and air are
disconnected or removed. When the cap of the
oil filter, drain plug or oil pressure pickup plug is
removed, loose them slowly to prevent the oil
from spurting out.
•When removing or installing the checking plug or
the piping in the fuel circuit, wait 30 seconds or
longer after the engine is shut down and start
the work after the remaining pressure is
released from the fuel circuit.
•Immediately after the engine is shut down, the
coolant and oil in the circuits are hot. Be careful
not to get scalded by the hot coolant and oil.
Start the work after checking that the coolant
and oil are cooled down sufficiently.
•Start the work after the engine is shut down. Be
sure to shut down the engine when working on
or around the rotating parts in particular. When
checking the machine without shutting down the
engine (measuring oil pressure, rotational speed,
oil or coolant temperature), take extreme care
not to get caught in the rotating parts or the
working equipment.
•The hoist or crane must be used to sling the
components weighing 25 kg or heavier. Check
the slings (wire rope, nylon sling, chain and
hook) for damage before the work. Use the
slings with ample capacity and install them to
the proper places. Operate the hoist or crane
slowly to prevent the component from hitting any
other part. Do not work with any part still raised
by the hoist or crane.
•When removing the part which is under internal
pressure or reaction force of the spring, always
leave 2 bolts in diagonal positions. Loosen those
2 bolts gradually and alternately and release the
pressure, then, remove the part.
•When removing the part, be careful not to break
or damage the electrical wiring. The damaged
wiring may cause electrical fires.
•When removing piping, prevent the fuel or oil
from spilling out. If any fuel or oil drips onto the
floor, wipe it off immediately. Fuel or oil on the
floor can cause you to slip and can even cause
fires.
•As a general rule, do not use gasoline to wash
parts. Do not use gasoline to clean the electrical
parts, in particular.
•Reinstall the parts removed to their original
places. Replace the damaged parts and the
parts which must not be used with new ones.
When installing the hoses and wiring harnesses,
be careful that they are not damaged by
contacting with other parts when the machine is
operated.
•When connecting the high pressure hoses and
tubes, make sure that they are not twisted. The
damaged high pressure hoses and tubes are
very dangerous when they are installed. So, be
extremely careful when connecting the high
pressure pipings. In addition, check that their
connections are correct.
•When assembling or installing the parts, be sure
to tighten the bolts to the specified torque. When
installing the protective parts such as guards, or
the parts which vibrate violently or rotate at high
speeds, be sure to check that they are installed
correctly.
•When aligning 2 holes, never insert your fingers
or hand into the holes. Align the holes with care
so that your fingers are not caught in the hole.
•When measuring hydraulic pressure, check that
the measuring tools are correctly installed.
•Pay attention to safety when removing and
installing the tracks of the track type machines.
When removing the track, it separates suddenly.
The workers should not stand at either end of
the track.
•If the engine is operated for a long time in a
closed place which is not ventilated well, you
may suffer from gas poisoning. Accordingly,
open the windows and doors to ventilate the
place well.
Precautions for slinging work and making
signals
•Only one appointed worker must make signals
and co-worker must communicate with each
other frequently. The appointed signaler must
make specified signals clearly at the place
where the signaler is well seen from the
operator's seat and where the signaler can see
the working condition easily. The signaler must
always stand in front of the load and guide the
operator safely.
1. Do not stand under the load.
2. Do not step on the load.
•Check the slings before starting sling work.
•Keep putting on the gloves during sling work.
(Put on the leather gloves, if available.)
PC240LC–10 00-15
00 Index and foreword
Foreword, safety and general information
•Measure the weight of the load by the eye and
check its center of gravity.
•Use the proper sling according to the weight of
the load and method of slinging. If too thick wire
ropes are used to sling a light load, the load may
slip and fall.
•Do not sling a load with 1 wire rope only. If do so,
the load may rotate or the sling gets loose and
the sling may slip off. Install 2 or more wire ropes
symmetrically.
kSlinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
•Hanging angle must be 60 deg. or smaller as a
rule.
•When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower
than that of the hook.
aWhen slinging a load with 2 ropes or more,
the larger the hanging angle is, the larger the
tension of each rope. The figure bellow
shows the variation of allowable load in kg
when hoisting is made with 2 ropes, each of
which is allowed to sling up to 9.8 kN
{1,000kg} a load vertically, at various
hanging angles. When the 2 ropes sling a
load vertically, up to 2,000 kg of total weight
can be suspended. This weight is reduced to
1,000 kg when the 2 ropes make a hanging
angle of 120 deg.. If the 2 ropes sling a 2,000
kg load at a hanging angle of 150 deg., each
rope is subjected to a force as large as 4,000
kg.
•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 eye bolts and fix wire ropes,
chains, etc. to them with shackles, etc.
•Apply wire ropes to the middle part of the hook.
aSlinging near the tip of the hook may cause
the rope to slip off the hook during hoisting.
The strength of the hook is maximum at its
central part.
•Do not use twisted or kinked wire ropes.
•When slinging up a load, observe the following.
1. Wind up the rope slowly until the wire rope
tensions. When putting your hands on the
wire ropes, do not grasp them but press them
down from above. If you grasp them, your
fingers may be caught.
2. After the wire ropes are stretched, stop the
crane and check the condition of the slung
load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
•When lowering a load, pay attention to the
following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
Precautions for using mobile crane
aRead the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
Precautions for using overhead traveling crane
kk The hoist or crane must be used to sling the
components weighing 25 kg or heavier. A
part weighing 25 kg or heavier in
"disassembly and assembly" section is
indicated with the symbol of 44.
•Before starting work, check the wire ropes,
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter
00-16 PC240LC–10
00 Index and foreword
Foreword, safety and general information
for electric shock prevention, crane collision
prevention device, and energizing warning lamp,
and check the following safety items.
•Observe the signals for sling work.
•Operate the hoist at a safe place.
•Be sure to check the directions of the direction
indication plate (north, south, east and west) and
the operating button.
•Do not sling a load at an angle. Do not move the
crane while the slung load is swinging.
•Do not raise or lower a load while the crane is
moving longitudinally or laterally.
•Do not drag a sling.
•When lifting up a load, stop it just after it leaves
the ground and check safety, and then lift it up.
•Consider the travel route in advance and lift up a
load to a safe height.
•Place the control switch in a position where it will
not be an obstacle to work and passage.
•After operating the hoist, do not swing the
control switch.
•Remember the position of the main switch so
that you can turn off the power immediately in an
emergency.
•Shut down the main switch when the hoist stops
because of a blackout. When turning on a switch
which is turned OFF by the ground fault circuit
interrupter for electric shock prevention, check
that the devices related to that switch are not in
operating condition.
•If you find an obstacle around the hoist, stop the
operation.
•After finishing the work, stop the hoist at the
specified position and raise the hook to at least 2
meters above the floor. Do not leave the sling
attached to the hook.
Selecting wire ropes
•Select adequate ropes depending on the weight
of the parts to be hoisted, referring to the table
below
Wire rope (JIS G3525, 6 x 37 - Type A)
(Standard Z twist wire ropes without galvanizing)
Nominal
diameter of rope Allowable load
mm kN ton
10 8.8 0.9
12 12.7 1.3
14 17.3 1.7
16 22.6 2.3
18 28.6 2.9
20 35.3 3.6
25 55.3 5.6
30 79.6 8.1
40 141.6 14.4
50 221.6 22.6
60 318.3 32.4
aThe allowable load is calculated as one sixth of
the breaking load of the rope to be used (safety
coefficient: 6).
Precautions for disconnecting and connecting
hoses and tubes in air conditioner circuit
Disconnection
kk When replacing the air conditioner unit, air
conditioner compressor, condenser or
receiver drier, etc., collect the refrigerant (air
conditioner gas: R134a) from the air
conditioner circuit before disconnecting the
air conditioner hoses.
aAsk a qualified person for collecting, adding and
filling operations of the refrigerant (air
conditioner gas: R134a). (Only registered
persons can work.)
aNever release the refrigerant (air conditioner
gas: R134a) to the atmosphere.
kk If refrigerant gas (air conditioner gas: R134a)
gets in your eyes, you may lose your sight.
And if it touches your skin, you may suffer
from frostbite. Put on protective eyeglasses,
gloves and working clothes with long
sleeves while collecting the refrigerant or
filling the air conditioner circuit with the
refrigerant.
•When loosening the nuts fixing air conditioner
hoses and tubes, be sure to use 2 wrenches;
use one wrench to fix and use the other one to
loosen the nut.
Connection
•When installing the hose for the air conditioner
circuit, take care not to allow invasion of dirt,
dusts and water into the hose.
•Check that the O-rings are fitted to the joints
when connecting the air conditioner piping.
•Once an O-ring is used, it is deformed and
deteriorated. Accordingly, do not reuse it.
•When removing the O-rings, use a soft tool so
that the piping is not damaged.
•Check that the O-ring is not damaged or
deteriorated.
•Apply compressor oil for refrigerant (R134a) to
the O-ring.
aHowever, do not apply oil to the threaded
part of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL
SYSTEMS
ZXL100PG (equivalent to
PAG46)
SANDEN SP-10
PC240LC–10 00-17
00 Index and foreword
Foreword, safety and general information
•When tightening nuts of the air conditioner
hoses and tubes, be sure to use 2 wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
aExample of fitting of O-ring
•An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",
"Precautions for disconnection and connection
of air conditioner piping".
00-18 PC240LC–10
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