Komatsu CD110R-1 Crawler Carrier Shop Manual SEBM021902 PDF

Description

Komatsu CD110R-1 Crawler Carrier Shop Manual SEBM021902 – PDF DOWNLOAD

FILE DETAILS:

Komatsu CD110R-1 Crawler Carrier Shop Manual SEBM021902 – PDF DOWNLOAD 

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu CD110R-1 Crawler Carrier 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 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

DESCRIPTION:

Komatsu CD110R-1 Crawler Carrier Shop Manual SEBM021902 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
CD110R-1                   1317 and UP

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 26/12/24