Komatsu CD110R-1 Shop Manual SEBM021902 – PDF DOWNLOAD

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Komatsu CD110R-1 Shop Manual SEBM021902 – PDF DOWNLOAD

FILE DETAILS:

Komatsu CD110R-1 Shop Manual SEBM021902 – PDF DOWNLOAD

Language : English
Pages :384
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu CD110R-1 Shop Manual SEBM021902 – PDF DOWNLOAD

FOREWORD
GENERAL

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the
  serviceman an accurate understanding of the product and by showing him the correct way to perform
  repairs and make judgements. Make sure you understand the contents of this manual and use it to full
  effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a
  service workshop. For ease of understanding, the manual is divided into the following chapters; these
  chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling
each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together

TABLE OF CONTENTS:

Komatsu CD110R-1 Shop Manual SEBM021902 – PDF DOWNLOAD

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 5
SAFETY NOTICE 5
FOREWORD 7
GENERAL 7
HOW TO READ THE SHOP MANUAL 8
HOISTING INSTRUCTIONS 9
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 10
COATING MATERIALS 12
STANDARD TIGHTENING TORQUE 14
ELECTRIC WIRE CODE 17
CONVERSION TABLE 18
UNITS 24
01 GENERAL 25
GENERAL ASSEMBLY DRAWING 26
SPECIFICATIONS 27
WEIGHT TABLE 30
TABLE OF OIL AND COOLANT CAPACITIES 31
10 STRUCTURE AND FUNCTION 33
RADIATOR AND OIL COOLER 34
DAMPER COUPLING 35
ENGINE CONTROL 36
POWER TRAIN 43
SWING CIRCLE 44
SWING MACHINERY 46
TRACK FRAME 49
FINAL DRIVE 51
IDLER 53
IDLER CUSHION 54
CARRIER ROLLER 55
TRACK ROLLER 56
TRACK ROLLER BOGIE 58
SPROCKET 60
TRACK SHOE 61
HYDRAULIC COMPONENT LAYOUT 62
HYDRAULIC TANK 64
HYDRAULIC PUMP 66
HYDRAULIC CONTROL VALVE 87
CLSS 98
SWING MOTOR105
CENTER SWIVEL JOINT111
TRAVEL MOTOR113
CONTROL PUMP123
VALVE CONTROL124
BODY PPC VALVE125
SWING PPC VALVE129
TRAVEL PPC VALVE134
SOLENOID VALVE139
VARIABLE BACK PRESSURE VALVE142
DUMP CYLINDER144
WORK EQUIPMENT145
MACHINE MONITOR SYSTEM146
20 TESTING AND ADJUSTING151
STANDARD VALUE TABLES152
STANDARD VALUE TABLE FOR ENGINE152
STANDARD VALUE TABLE FOR CHASSIS153
STANDARD VALUE TABLE FOR ELECTRIC PARTS160
TESTING AND ADJUSTING163
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING164
MEASURING ENGINE SPEED165
MEASURING EXHAUST COLOR166
ADJUSTING VALVE CLEARANCE167
MEASURING COMPRESSION PRESSURE168
MEASURING BLOW-BY PRESSURE169
TESTING AND ADJUSTING FUEL INJECTION TIMING170
MEASURING ENGINE OIL PRESSURE173
TESTING AND ADJUSTING ALTERNATOR BELT TENSION174
TESTING AND ADJUSTING WATER PUMP TENSION175
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR175
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)176
ADJUSTING FUEL CONTROL CABLE177
ADJUSTING ENGINE STOP MOTOR CABLE178
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN TRAVEL CIRCUIT179
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN BODY AND SWING CIRCUIT181
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)182
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTION INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE184
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN CONTROL PUMP CICUIT187
TESTING OUTPUT PRESSURE OF SOLENOID VALVE188
MEASURING PPC VALVE OUTPUT PRESSURE189
ADJUSTING SWING PPC VALVE190
TESTING TRAVEL DEVIATION191
MEASURING OIL LEAKAGE192
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT194
TESTING CLEARANCE OF SWING CIRCLE BEARING195
TESTING AND ADJUSTING TRACK SHOE TENSION196
BLEEDING AIR197
TROUBLESHOOTING199
POINTS TO REMEMBER WHEN TROUBLESHOOTING200
SEQUENCE OF EVENTS IN TROUBLESHOOTING201
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE202
CHECKS BEFORE TROUBLESHOOTING210
CONNECTOR TYPES AND MOUNTING LOCATIONS211
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS217
METHOD OF USING JUDGMENT TABLE225
METHOD OF USING TROUBLESHOOTING CHARTS226
TABLE OF FAILURE MODES AND CAUSES (1/2)228
TABLE OF FAILURE MODES AND CAUSES (2/2)230
TROUBLESHOOTING FOR ELECTRIC SYSTEM (E MODE)231
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE232
E-1 TROUBLE IN TVC SOLENOID SYSTEM234
A)ENGINE STALLS BELOW MEDIUM SPEED234
B) TRAVEL SPEED IS SLOW OR LACKS POWER WHEN FUEL CONTROL DIAL IS AT FULL235
E-2 TROUBLE IN PPC LOCK SOLENOID SYSTEM236
A) SOLENOID DOES NOT WORK (SAFETY LOCK STAYS ON)236
B) SOLENOID STAYS WORKING (SAFETY LOCK DOES NOT WORK)237
E-3 TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM238
A) MACHINE DOES NOT SWING238
B) SWING BRAKE DOES NOT WORK (EXCESSIVE SWING HYDRAULIC DRIFT)240
E-4 TROUBLE IN TRAVEL SPEED SOLENOID SYSTEM243
A) TRAVEL SPEED DOES NOT CHANGE TO HI243
B) TRAVEL SPEED DOES NOT CHANGE TO HI (TRAVEL SPEED IS KEPT AT HI)244
E-5 FAILURE IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)246
A) STARTING MOTOR DOES NOT OPERATE246
B) STARTING MOTOR WORKS BUT ENGINE DOES NOT START (FAILURE IN ENGINE STOP MOTOR SYSTEM)248
E-6 ENGINE DOES NOT STOP250
E-7 PREHEATING DOES NOT WORK252
TROUBLESHOOTIGN OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)253
H-1 TRAVEL SPEED IS SLOW OR LACKS POWER254
H-2 SPEEDS OF DUMPING BODY AND SWING ARE SLOW OR LACK POWER256
H-3 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS257
H-4 MACHINE DOES NOT TRAVEL, DUMP, AND SWING AT ALL258
H-5 ABNORMAL NOISE GENERATER (AROUND PUMP)259
H-6 FINE CONTROL IS POOR, OR RESPONSE IS POOR259
H-7 DUMPING BODY SPEED OR POWER IS LOW260
H-8 DUMPING BODY DOES NOT MOVE (BUT TRABEL AND SWING ARE NORMAL)261
H-9 EXCESSIVE HYDRULIC DRIFT (DUMPING BODY)261
H-10 MACHINE TURNS BY ITSELF DURING TRAVEL262
H-11 MACHINE TURNS EXTREMELY AT START263
H-12 TRAVEL SPEED IS LOW264
H-13 STEERING IS POOR265
H-14 TRAVEL SPEED DOES NOT CHANGE266
H-15 TRAVEL SYSTEM DOES NOT MOVE (EITHER SIDE)266
H-16 DOES NOT SWING267
H-17 SWING ACCELERATION IS POOR268
H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING270
H-19 EXCESSIVE SHOCK WHEN STOPPING SWING (EITHER SIDE)271
H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING271
H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING272
H-22 SWING SPEED IS LOWER THAN SPECIFICATION273
TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)275
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE276
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (3-SECOND SELF CHECK IS ALSO NOT CARRIED OUT)277
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN 3-SECOND SELF CHECK IS COMPLETED, LAMPS DO NOT GO OU277
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS278
A) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP)278
B) SWING LOCK OR PREHEATING LAMPS DO NOT LIGHT UP (GAUGE LAMPS ALL LIGHT UP)278
C) BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP278
D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP278
M-4 WHEN POWER IS ON (ENGINE STOPPED), BATTERY CHARGE CAUTION LAMPS DO NOT LIGHT UP279
M-5 WHEN POWER IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP280
M-6 WHEN STARTING SWTICH IS TURNED TO HEAT, PREHEATING LAMP DOES NOT LIGHT UP281
M-7 WHEN SWITCH IS OPERATED, SWING LOCK PILOT LAMP DOES NOT LIGHT UP282
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHT UP (ENGINE OIL PRESSURE IS NORMAL)283
M-9 WHEN ENGINE IS RUNNING, BATTERY CHARGE CAUTION LAMP LIGHT UP284
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE285
A) AFTER ENGINE IS STARTED, ONLY LOWES LEVEL LAMP (WHITE RANGE) LIGHT UP AND LEVEL DOES NOT RISE285
B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES AND ENTERS RED RANGE (THERE IS NOT OVERHEATING)285
C) WATER TEMPERATURE GAUGE GOES OUT285
M-11 ABNORMALITY IN FUEL GAUGE287
A) ALL SEGMENTS OF FUEL GAUGE GO OUT287
B) FUEL LEVEL HAS GONE DOWN, BUT GAUGE ALWAYS DISPLAYS FULL287
C) EVEN WHEN FUEL TANK IS FILLED, GAUGE DOES NOT DISPLAY FULL287
M-12 DEFECTIVE OPERATION OF ALARM BUZZER289
A) BUZZER DOES NOT SOUND289
B) BUZZER CONTINUES TO SOUND289
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE290
A) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP WHILE ENGINE IS RUNNING290
B) WHEN BATTERY CHARGE CAUTION LAMP LIGHT UP, GO TO M-9290
M-14 NIGHT LIGHTING DOES NOT LIGHT UP291
A) GAUGE LIGHTING DOES NOT LIGHT UP291
B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER WORKS NORMALLY)291
30 DISASSEMBLY AND ASSEMBLY294
METHOD OF USING MANUAL296
PRECAUTIONS WHEN PERFORMING OPERATION297
SPECIAL TOOL LIST300
SKETCHES OF SPECIAL TOOLS302
AFTERCOOLER ASSEMBLY303
REMOVAL303
INSTALLATION303
HYDRAULIC OIL COOLER304
REMOVAL304
INSTALLATION304
RADIATOR ASSEMBLY305
REMOVAL305
INSTALLATION307
MAIN PUMP ASSEMBLY308
REMOVAL308
INSTALLATION310
ENGINE AND MAIN PUMP311
REMOVAL311
INSTALLATION313
DAMPER314
REMOVAL314
INSTALLATION314
HYDRAULIC TANK315
REMOVAL315
INSTALLATION317
SWING MACHINERY AND SWING MOTOR318
DISASSEMBLY318
ASSEMBLY318
SWING MACHINERY319
DISASSEMBLY319
ASSEMBLY322
CENTER SWIVEL JOINT326
REMOVAL326
INSTALLATION327
DISASSEMBLY328
ASSEMBLY328
WORK EQUIPMENT CONTROL VALVE329
REMOVAL329
INSTALLATION330
DISASSEMBLY332
ASSEMBLY332
TRAVEL CONTROL VALVE ASSEMBLY334
REMOVAL334
INSTALLATION335
DISASSEMBLY336
ASSEMBLY339
FINAL DRIVE AND TRAVEL MOTOR 343
REMOVAL343
INSTALLATION344
FINAL DRIVE ASSEMBLY345
DISASSEMBLY345
ASSEMBLY348
DUMP CONTROL PPC VALVE354
DISASSEMBLY354
ASSEMBLY354
TRAVEL PPC VALVE355
DISASSEMBLY355
ASSEMBLY356
SWING PPC VALVE357
DISASSEMBLY357
ASSEMBLY357
DUMP CYLINDER359
DISASSEMBLY359
ASSEMBLY359
FUEL TANK ASSEMBLY362
REMOVAL362
INSTALLATION362
AIR CONDITIONER UNIT ASSEMBLY363
REMOVAL363
INSTALLATION363
CAB ASSEMBLY364
REMOVAL364
INSTALLATION365
REVOLVING FRAME ASSEMBLY366
REMOVAL366
INSTALLATION367
SWING CIRCLE ASSEMBLY368
REMOVAL368
INSTALLATION368
RUBBER SHOE ASSEMBLY369
REMOVAL369
INSTALLATION370
IDLER ASSEMBLY371
DISASSEMBLY371
ASSEMBLY372
IDLER CUSHION SPRING ASSEMBLY373
DISASSEMBLY373
ASSEMBLY374
TRACK ROLLER ASSEMBLY375
DISASSEMBLY375
ASSEMBLY376
DUMP BODY ASSEMBLY378
REMOVAL378
INSTALLATION378
90 OTHERS379
HYDRAULIC CIRCUIT DIAGRAM381
ELECTRIC CIRCUIT DIAGRAM383

IMAGES PREVIEW OF THE MANUAL:

S.M 12/12/24