Komatsu PC240LL-10 Log Loader / Road Builder Service Repair Shop Manual (A20601 and up) - CEBM028500

This complete service repair workshop manual PDF download for the PC240LL-10 Komatsu Log Loader / Road Builder (SN: A20601 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : PC240LL-10
Serial Numbers : A20601 and up
Engine : 6D107E-2


TABLE OF CONTENTS :

- Index and foreword
- Specification
- Structure and function
- Standard value table
- Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM028500
Total Pages : 345


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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00 - FOREWORD
SAFETY
Safety Notice
Important Safety Notice
General Precautions
Preparations For Work
Precautions During Work
GENERAL
HOW TO READ THE SHOP MANUAL
Volumes
Distribution And Updating
Filing Method
Revised Edition Mark
Revisions
Symbols
HOISTING INSTRUCTIONS
Hoisting
Making Signs
Precautions
Precautions for Sling Work
Precautions for Using Mobile Crane
Precautions for Using Overhead Hoist Crane
Selecting Wire Ropes
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
Points to Remember When Handling Electric Equipment
Points to Remember When Handling Hydraulic Equipment
PUSH PULL COUPLER
Type 1
Disconnection
Connection
Type 2
Disconnection
Connection
Type 3
Disconnection
Connection
EXPLANATION OF MAINTENANCE STANDARD TERMS
HANDLING OF FUEL SYSTEM DEVICES
HANDLING OF INTAKE SYSTEM PARTS
STANDARD TIGHTENING TORQUE
Bolts And Nuts
Tightening Torque Of Hose Nuts
Tightening Torque Of Split Flange Bolts
Tightening Torque For Flared Nuts
Tightening Torques for Split Flanged Bolts
Tightening Torques For O-ring Boss Piping Joints
Table Of Tightening Torques For O-ring Boss Plugs
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)
Tightening Torque For Face Seal Joints
For 102, 107, and 114 Engine Series (Bolts and Nuts)
For 102, 107, and 114 Engine Series (Eye Joints)
For 102, 107, and 114 Engine Series (Taper Screws)
ELECTRIC WIRE CODE
Classification By Thickness
Classification By Color And Code
How To Read Electric Wire Code
PRECAUTIONS FOR OPERATIONS
Precautions when Carrying Out Removal Work
Precautions when Carrying Out Installation Work
Precautions when Completing the Operation
CONVERSION TABLES
Method Of Using The Conversion Table
COATING MATERIALS
LIST OF ABBREVIATIONS
List of Abbreviations Used in the Shop Manual
List of Abbreviations Used in the Circuit Diagrams

01 - GENERAL
SPECIFICATIONS
Dimension Drawings
Road Builder
Log Loader
Dimensions
Working Ranges
Road Builder
Log Loader
Engine
Undercarriage
Hydraulic System
Road Builder
Log Loader
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
Lubrication Chart

10 - STRUCTURE AND FUNCTION
ENGINE AND COOLING SYSTEM
Engine Related Parts
Radiator, Oil Cooler, Aftercooler, and Fuel Cooler
POWER TRAIN
Power Train
Swing Machinery
Swing Circle
Final Drive
UNDERCARRIAGE AND FRAME
Track Frame and Idler Cushion
HYDRAULIC SYSTEM
Hydraulic Equipment Layout
Valve Control
Hydraulic Tank
Oil Filler Cap
CLSS
Structure of CLSS
Basic Principle
Main Pump
Operation
LS Valve
PC Valve
LS(PC)-EPC Valve
Control Valve
Functions and Operation by Valve
Hydraulic Circuit Diagram and Name of Valves
Unload Valve
Introduction of LS Pressure
LS By-Pass Plug
Pressure Compensation Valve
Shuttle Valve In Pressure Compensation Valve
Boom Regeneration Circuit
Arm Regeneration Circuit
Merge-Divider Valve
LS Selector Valve
Self-Pressure Reducing Valve
Travel Junction Valve
Travel PPC Shuttle Valve
Boom Hydraulic Drift Prevention Valve
Arm Hydraulic Drift Prevention Valve (Road Builder)
Arm Drift Prevention Valve (Log Loader)
Operation
Suction Safety Valve For Drift Prevention Valve
Arm Quick Return Valve
Variable Back Pressure Valve
Main Relief Valve
Swing Motor
Swing Holding Brake
Relief Valve
Swing 2-Stage Relief Valve
Swing Motor Reverse Prevention Valve
Travel Motor
Operation of Travel Motor
Operation of Parking Brake
Brake Valve
Counterbalance Valve
Suction Safety Valve
PPC Valve
Work Equipment and Swing PPC Valve
Travel PPC Valve
Solenoid Valve
Attachment Solenoid Valve
Center Swivel Joint
Accumulator
PPC Accumulator
WORK EQUIPMENT
Road Builder
Log Loader
Work Equipment Shim
Bucket Play Adjustment Shim (Road Builder)
CAB AND ITS ATTACHMENTS
ELECTRICAL SYSTEM
Electrical Control System
Machine Control System Diagram
Engine Control Function
Engine and Pump Combined Control Function
Pump and Valve Control Function
One-Touch Power Maximizing Function
Auto-Deceleration Function
Engine Automatic Warm-Up Function
Overheat Prevention Function
Turbocharger Protection Function
Swing Control Function
Quick Warm-Up Function
Swing 2-Stage Relief Function
Travel Control Function
PPC Lock Function
Attachment Flow Control Function
System Component Part
Engine Controller
Pump Controller
Fuel Control Dial
Resister for PC-EPC valve
CAN Terminating Resistor
Engine Oil Pressure Switch
PPC Oil Pressure Switch
MACHINE MONITOR SYSTEM
Machine Monitor
Input and Output Signals
Display
Gauges
Caution Monitor
Pilot Monitor
Switches
Guidance ICON and Function Switch
Operator Mode Function
Service Mode Function
KOMTRAX SYSTEM
KOMTRAX terminal
Input and Output Signals
SENSORS
Ambient Pressure Sensor
Charge (Boost) Pressure and Temperature Sensor
Coolant Temperature Sensor
Ne (Crankshaft) Speed Sensor
Bkup (Camshaft) Speed Sensor
Common Rail Pressure Sensor
Exhaust Manifold Pressure Sensor
EGR Orifice Temperature Sensor
EGR Valve Lift Sensor
Turbo Speed Sensor
KVGT Position Sensor
Mass Air Flow and Temperature Sensor
KDPF Differential Pressure and Outlet Pressure Sensor
KDOC Inlet Temperature Sensor
KDOC Outlet Temperature Sensor
KDPF Outlet Temperature Sensor
Crankcase Pressure Sensor
Engine Oil Level Sensor
Fuel Level Sensor
Coolant Level Sensor
Hydraulic Oil Temperature Sensor
Front Pump Oil Pressure Sensor
Rear Pump Oil Pressure Sensor
PPC Oil Pressure Sensor
Air Cleaner Clogging Sensor
Front Pump Swash Plate Sensor
Rear Pump Swash Plate Sensor
Water-In-Fuel Sensor

20 - STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLES
Standard Value Table for Engine Related Parts
Standard Value Table for Chassis Related Parts
Engine Speed
Control Valve Spool Stroke
Control Lever Stroke
Operating Effort of Control Lever and Pedal
Hydraulic Pressure
Swing
Travel
Work Equipment
Performance in Combined Operation
Pump Swash Plate Sensor
Hydraulic Pump
Posture of Machine for Measuring Performance and Measurement Procedure
Control Valve: Spool Stroke
Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing
Swing 2: Hydraulic Drift of Swing
Travel 1: Travel Speed, Idle Running (Without Load)
Travel 2: Travel Speed (Actual Run), Travel Deviation
Travel 3: Travel Deviation
Travel 4: Hydraulic Drift of Travel
Work Equipment 1: Hydraulic Drift of Work Equipment
Work Equipment 2: Boom Speed
Work Equipment 3: Arm Speed
Work Equipment 4: Bucket Speed/Heel Speed
Work Equipment 5: Boom Time Lag
Work Equipment 6: Arm Time Lag
Work Equipment 7: Bucket Time Lag

90 - DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM
Symbols in Hydraulic Circuit Diagrams
Hydraulic Circuit Diagram (1/2)
Hydraulic Circuit Diagram (2/2)
ELECTRICAL SYSTEM
Symbols in Electrical Circuit Diagrams
Air Conditioner Electrical Circuit
Electrical Control System Diagram
Electrical Diagram (1/5)
Electrical Diagram (2/5)
Electrical Diagram (3/5)
Electrical Diagram (4/5)
Electrical Diagram (5/5)
Electrical Circuit Diagram - Log Loader Unique
Connector List and Stereogram
Chassis
Operator's Compartment
Engine Compartment

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