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Komatsu CD110R-1 Crawler Carrier Shop Manual 1317 and up – PDF DOWNLOAD
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Komatsu CD110R-1 Crawler Carrier Shop Manual
MACHINE MODEL SERIAL NUMBER
CD110R-1 1317 and UP
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Description
Komatsu CD110R-1 Crawler Carrier Shop Manual 1317 and up
FILE DETAILS:
Komatsu CD110R-1 Crawler Carrier Shop Manual
Brands: Komatsu
Equipment Type: Crawler Carrier
Manuals Type: Shop Manual
Machine Model: CD110R-1
Serial Number: 1317 and up
Book Code: SEBM021902
Language: English
Pages: 384
File Format: Portable Document Format (PDF)
KOMATSU CD110R-1 CRAWLER CARRIER SHOP MANUAL 1317 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu CD110R-1 Crawler Carrier Shop Manual
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 Crawler Carrier Shop Manual
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 MOTOR.............................................................................................................105 CENTER SWIVEL JOINT.....................................................................................................111 TRAVEL MOTOR............................................................................................................113 CONTROL PUMP............................................................................................................123 VALVE CONTROL...........................................................................................................124 BODY PPC VALVE..........................................................................................................125 SWING PPC VALVE.........................................................................................................129 TRAVEL PPC VALVE........................................................................................................134 SOLENOID VALVE..........................................................................................................139 VARIABLE BACK PRESSURE VALVE............................................................................................142 DUMP CYLINDER...........................................................................................................144 WORK EQUIPMENT..........................................................................................................145 MACHINE MONITOR SYSTEM..................................................................................................146 20 TESTING AND ADJUSTING....................................................................................................151 STANDARD VALUE TABLES...................................................................................................152 STANDARD VALUE TABLE FOR ENGINE.....................................................................................152 STANDARD VALUE TABLE FOR CHASSIS....................................................................................153 STANDARD VALUE TABLE FOR ELECTRIC PARTS.............................................................................160 TESTING AND ADJUSTING...................................................................................................163 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................164 MEASURING ENGINE SPEED..............................................................................................165 MEASURING EXHAUST COLOR.............................................................................................166 ADJUSTING VALVE CLEARANCE...........................................................................................167 MEASURING COMPRESSION PRESSURE......................................................................................168 MEASURING BLOW-BY PRESSURE..........................................................................................169 TESTING AND ADJUSTING FUEL INJECTION TIMING.........................................................................170 MEASURING ENGINE OIL PRESSURE.......................................................................................173 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.......................................................................174 TESTING AND ADJUSTING WATER PUMP TENSION............................................................................175 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...................................................175 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)......................................................................176 ADJUSTING FUEL CONTROL CABLE........................................................................................177 ADJUSTING ENGINE STOP MOTOR CABLE...................................................................................178 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN TRAVEL CIRCUIT..........................................................179 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN BODY AND SWING CIRCUIT..................................................181 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 PRESSURE..........184 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN CONTROL PUMP CICUIT.....................................................187 TESTING OUTPUT PRESSURE OF SOLENOID VALVE...........................................................................188 MEASURING PPC VALVE OUTPUT PRESSURE.................................................................................189 ADJUSTING SWING PPC VALVE...........................................................................................190 TESTING TRAVEL DEVIATION............................................................................................191 MEASURING OIL LEAKAGE...............................................................................................192 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...................................................................194 TESTING CLEARANCE OF SWING CIRCLE BEARING...........................................................................195 TESTING AND ADJUSTING TRACK SHOE TENSION............................................................................196 BLEEDING AIR........................................................................................................197 TROUBLESHOOTING.........................................................................................................199 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................200 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................201 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................202 CHECKS BEFORE TROUBLESHOOTING.......................................................................................210 CONNECTOR TYPES AND MOUNTING LOCATIONS..............................................................................211 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................217 METHOD OF USING JUDGMENT TABLE......................................................................................225 METHOD OF USING TROUBLESHOOTING CHARTS..............................................................................226 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 MODE...........................................................................232 E-1 TROUBLE IN TVC SOLENOID SYSTEM..............................................................................234 A)ENGINE STALLS BELOW MEDIUM SPEED..........................................................................234 B) TRAVEL SPEED IS SLOW OR LACKS POWER WHEN FUEL CONTROL DIAL IS AT FULL....................................235 E-2 TROUBLE IN PPC LOCK SOLENOID SYSTEM.........................................................................236 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 SYSTEM..............................................................238 A) MACHINE DOES NOT SWING...................................................................................238 B) SWING BRAKE DOES NOT WORK (EXCESSIVE SWING HYDRAULIC DRIFT)..............................................240 E-4 TROUBLE IN TRAVEL SPEED SOLENOID SYSTEM.....................................................................243 A) TRAVEL SPEED DOES NOT CHANGE TO HI.......................................................................243 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 OPERATE..........................................................................246 B) STARTING MOTOR WORKS BUT ENGINE DOES NOT START (FAILURE IN ENGINE STOP MOTOR SYSTEM).....................248 E-6 ENGINE DOES NOT STOP........................................................................................250 E-7 PREHEATING DOES NOT WORK....................................................................................252 TROUBLESHOOTIGN OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).........................................................253 H-1 TRAVEL SPEED IS SLOW OR LACKS POWER.........................................................................254 H-2 SPEEDS OF DUMPING BODY AND SWING ARE SLOW OR LACK POWER.....................................................256 H-3 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS.............................................................257 H-4 MACHINE DOES NOT TRAVEL, DUMP, AND SWING AT ALL.............................................................258 H-5 ABNORMAL NOISE GENERATER (AROUND PUMP)......................................................................259 H-6 FINE CONTROL IS POOR, OR RESPONSE IS POOR...................................................................259 H-7 DUMPING BODY SPEED OR POWER IS LOW..........................................................................260 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 TRAVEL......................................................................262 H-11 MACHINE TURNS EXTREMELY AT START...........................................................................263 H-12 TRAVEL SPEED IS LOW........................................................................................264 H-13 STEERING IS POOR...........................................................................................265 H-14 TRAVEL SPEED DOES NOT CHANGE...............................................................................266 H-15 TRAVEL SYSTEM DOES NOT MOVE (EITHER SIDE)..................................................................266 H-16 DOES NOT SWING.............................................................................................267 H-17 SWING ACCELERATION IS POOR.................................................................................268 H-18 EXCESSIVE OVERRUN WHEN STOPPING SWING......................................................................270 H-19 EXCESSIVE SHOCK WHEN STOPPING SWING (EITHER SIDE)..........................................................271 H-20 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...............................................................271 H-21 EXCESSIVE HYDRAULIC DRIFT OF SWING.........................................................................272 H-22 SWING SPEED IS LOWER THAN SPECIFICATION....................................................................273 TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)..........................................................................275 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE...........................................................................276 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 OU..........277 M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS......................278 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 UP............................................................278 D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP.......................................................278 M-4 WHEN POWER IS ON (ENGINE STOPPED), BATTERY CHARGE CAUTION LAMPS DO NOT LIGHT UP.............................279 M-5 WHEN POWER IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP.......................280 M-6 WHEN STARTING SWTICH IS TURNED TO HEAT, PREHEATING LAMP DOES NOT LIGHT UP...................................281 M-7 WHEN SWITCH IS OPERATED, SWING LOCK PILOT LAMP DOES NOT LIGHT UP............................................282 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 UP................................................284 M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE..............................................................285 A) AFTER ENGINE IS STARTED, ONLY LOWES LEVEL LAMP (WHITE RANGE) LIGHT UP AND LEVEL DOES NOT RISE............285 B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES AND ENTERS RED RANGE (THERE IS NOT OVERHEATING).........285 C) WATER TEMPERATURE GAUGE GOES OUT.........................................................................285 M-11 ABNORMALITY IN FUEL GAUGE..................................................................................287 A) ALL SEGMENTS OF FUEL GAUGE GO OUT........................................................................287 B) FUEL LEVEL HAS GONE DOWN, BUT GAUGE ALWAYS DISPLAYS FULL.................................................287 C) EVEN WHEN FUEL TANK IS FILLED, GAUGE DOES NOT DISPLAY FULL...............................................287 M-12 DEFECTIVE OPERATION OF ALARM BUZZER........................................................................289 A) BUZZER DOES NOT SOUND....................................................................................289 B) BUZZER CONTINUES TO SOUND................................................................................289 M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE.....................................................290 A) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP WHILE ENGINE IS RUNNING...............................290 B) WHEN BATTERY CHARGE CAUTION LAMP LIGHT UP, GO TO M-9.....................................................290 M-14 NIGHT LIGHTING DOES NOT LIGHT UP...........................................................................291 A) GAUGE LIGHTING DOES NOT LIGHT UP.........................................................................291 B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER WORKS NORMALLY)..................................291 30 DISASSEMBLY AND ASSEMBLY.................................................................................................294 METHOD OF USING MANUAL..................................................................................................296 PRECAUTIONS WHEN PERFORMING OPERATION...................................................................................297 SPECIAL TOOL LIST.......................................................................................................300 SKETCHES OF SPECIAL TOOLS...............................................................................................302 AFTERCOOLER ASSEMBLY....................................................................................................303 REMOVAL.............................................................................................................303 INSTALLATION........................................................................................................303 HYDRAULIC OIL COOLER....................................................................................................304 REMOVAL.............................................................................................................304 INSTALLATION........................................................................................................304 RADIATOR ASSEMBLY.......................................................................................................305 REMOVAL.............................................................................................................305 INSTALLATION........................................................................................................307 MAIN PUMP ASSEMBLY......................................................................................................308 REMOVAL.............................................................................................................308 INSTALLATION........................................................................................................310 ENGINE AND MAIN PUMP....................................................................................................311 REMOVAL.............................................................................................................311 INSTALLATION........................................................................................................313 DAMPER..................................................................................................................314 REMOVAL.............................................................................................................314 INSTALLATION........................................................................................................314 HYDRAULIC TANK..........................................................................................................315 REMOVAL.............................................................................................................315 INSTALLATION........................................................................................................317 SWING MACHINERY AND SWING MOTOR.........................................................................................318 DISASSEMBLY.........................................................................................................318 ASSEMBLY............................................................................................................318 SWING MACHINERY.........................................................................................................319 DISASSEMBLY.........................................................................................................319 ASSEMBLY............................................................................................................322 CENTER SWIVEL JOINT.....................................................................................................326 REMOVAL.............................................................................................................326 INSTALLATION........................................................................................................327 DISASSEMBLY.........................................................................................................328 ASSEMBLY............................................................................................................328 WORK EQUIPMENT CONTROL VALVE............................................................................................329 REMOVAL.............................................................................................................329 INSTALLATION........................................................................................................330 DISASSEMBLY.........................................................................................................332 ASSEMBLY............................................................................................................332 TRAVEL CONTROL VALVE ASSEMBLY...........................................................................................334 REMOVAL.............................................................................................................334 INSTALLATION........................................................................................................335 DISASSEMBLY.........................................................................................................336 ASSEMBLY............................................................................................................339 FINAL DRIVE AND TRAVEL MOTOR ...........................................................................................343 REMOVAL.............................................................................................................343 INSTALLATION........................................................................................................344 FINAL DRIVE ASSEMBLY....................................................................................................345 DISASSEMBLY.........................................................................................................345 ASSEMBLY............................................................................................................348 DUMP CONTROL PPC VALVE..................................................................................................354 DISASSEMBLY.........................................................................................................354 ASSEMBLY...........................................................................................................354 TRAVEL PPC VALVE........................................................................................................355 DISASSEMBLY.........................................................................................................355 ASSEMBLY............................................................................................................356 SWING PPC VALVE.........................................................................................................357 DISASSEMBLY.........................................................................................................357 ASSEMBLY............................................................................................................357 DUMP CYLINDER...........................................................................................................359 DISASSEMBLY.........................................................................................................359 ASSEMBLY............................................................................................................359 FUEL TANK ASSEMBLY......................................................................................................362 REMOVAL.............................................................................................................362 INSTALLATION........................................................................................................362 AIR CONDITIONER UNIT ASSEMBLY...........................................................................................363 REMOVAL.............................................................................................................363 INSTALLATION........................................................................................................363 CAB ASSEMBLY............................................................................................................364 REMOVAL.............................................................................................................364 INSTALLATION........................................................................................................365 REVOLVING FRAME ASSEMBLY................................................................................................366 REMOVAL.............................................................................................................366 INSTALLATION........................................................................................................367 SWING CIRCLE ASSEMBLY...................................................................................................368 REMOVAL.............................................................................................................368 INSTALLATION........................................................................................................368 RUBBER SHOE ASSEMBLY....................................................................................................369 REMOVAL.............................................................................................................369 INSTALLATION........................................................................................................370 IDLER ASSEMBLY..........................................................................................................371 DISASSEMBLY.........................................................................................................371 ASSEMBLY............................................................................................................372 IDLER CUSHION SPRING ASSEMBLY...........................................................................................373 DISASSEMBLY.........................................................................................................373 ASSEMBLY............................................................................................................374 TRACK ROLLER ASSEMBLY...................................................................................................375 DISASSEMBLY.........................................................................................................375 ASSEMBLY............................................................................................................376 DUMP BODY ASSEMBLY......................................................................................................378 REMOVAL.............................................................................................................378 INSTALLATION........................................................................................................378 90 OTHERS...................................................................................................................379 HYDRAULIC CIRCUIT DIAGRAM...............................................................................................381 ELECTRIC CIRCUIT DIAGRAM................................................................................................383
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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