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Komatsu CD110R-2 Crawler Carrier Shop Manual 1501 and up – PDF DOWNLOAD
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Komatsu CD110R-2 Crawler Carrier Shop Manual
Book Code: SEBM030003
MACHINE MODEL SERIAL NUMBER
CD110R-2 1501 and up
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Description
Komatsu CD110R-2 Crawler Carrier Shop Manual
FILE DETAILS:
Komatsu CD110R-2 Crawler Carrier Shop Manual
Brands: Komatsu
Equipment Type: Crawler Carrier
Manuals Type: Shop Manual
Machine Model: CD110R-2
Serial Number: 1501 and up
Book Code: SEBM030003
Language: English
Pages: 383
File Format: Portable Document Format (PDF)
KOMATSU CD110R-2 CRAWLER CARRIER SHOP MANUAL 1501 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu CD110R-2 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-2 Crawler Carrier Shop Manual
COVER............................................................................................................................... 1 CONTENTS............................................................................................................................ 2 01 GENERAL.......................................................................................................................... 26 SPECIFICATION DRAWING........................................................................................................... 27 SPECIFICATIONS.................................................................................................................. 28 WEIGHT TABLE ................................................................................................................... 31 TABLE OF FUEL,COOLANT AND LUBRICANTS............................................................................................ 32 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD..................................................................................... 33 DAMPER.......................................................................................................................... 34 COOLING SYSTEM.................................................................................................................. 35 POWER TRAIN..................................................................................................................... 37 SWING CIRCLE.................................................................................................................... 38 SWING MACHINERY................................................................................................................. 39 TRACK FRAME..................................................................................................................... 41 IDLER CHSHION................................................................................................................... 42 IDLER........................................................................................................................... 43 TRACK ROLLER BOGIE.............................................................................................................. 44 TRACK ROLLER.................................................................................................................... 45 CARRIER ROLLER.................................................................................................................. 46 SPROCKET........................................................................................................................ 47 TRACK SHOE...................................................................................................................... 48 HYDRAULIC COMPONENT LAYOUT...................................................................................................... 49 HYDRAULIC TANK.................................................................................................................. 51 HYDRAULIC PUMP.................................................................................................................. 52 TRAVEL MOTOR.................................................................................................................... 62 DA VALVE........................................................................................................................ 68 TIMER VALVE..................................................................................................................... 70 FLOW COMPENSATION VALVE......................................................................................................... 73 SOLENOID VALVE.................................................................................................................. 74 EPC VALVE....................................................................................................................... 77 ACCUMULATOR..................................................................................................................... 80 CENTER SWIVEL JOINT............................................................................................................. 81 DUMP CYLINDER................................................................................................................... 82 CONTROL VALVE................................................................................................................... 83 SWING MOTOR..................................................................................................................... 85 SWING PPC VALVE................................................................................................................. 90 TRAVEL PPC VALVE................................................................................................................ 94 BODY PPC VALVE.................................................................................................................. 98 WORK EQUIPMENT..................................................................................................................102 AIR CONDITIONER PIPING..........................................................................................................103 ELECTRIC CONTROL SYSTEM.........................................................................................................104 SYSTEM COMPONENTS...............................................................................................................114 MONITOR SYSTEM..................................................................................................................120 SENSORS.........................................................................................................................125 20 TESTING AND ADJUSTING............................................................................................................130 STANDARD VALUE TABLE FOR ENGINE.................................................................................................131 STANDARD VALUE TABLE FOR CHASSIS................................................................................................132 TESTING AND ADJUSTING...........................................................................................................137 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING............................................................................138 TESTING ENGINE SPEED........................................................................................................139 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)..............................................................................140 MEASURING EXHAUST GAS COLOR.................................................................................................141 ADJUSTING VALVE CLEARANCE...................................................................................................142 MEASURING COMPRESSION PRESSURE..............................................................................................144 MEASURING BLOW-BY PRESSURE..................................................................................................145 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................................146 MEASURING ENGINE OIL PRESSURE...............................................................................................148 ADJUSTING ENGINE STOP SOLENOID..............................................................................................149 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...........................................................................150 ADJUSTING OF ENGINE SPEED SENSOR............................................................................................151 INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION....................................................................151 EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM.......................................................................152 BLEEDING AIR FROM FUEL CIRCUIT..............................................................................................153 MEASURING CLEARANCE OF SWING CIRCLE BEARING.................................................................................154 TESTING AND ADJUSTING TRACK SHOE TENSION....................................................................................155 TESTING HST OIL PRESSURE....................................................................................................156 TESTING AND ADJUSTING WORK EQUIPMENT AND SWING CIRCUIT PRESSURE.............................................................159 TESTING CONTROL PUMP CIRCUIT PRESSURE.......................................................................................160 TESTING SOLENOID VALVE OUTPUT PRESSURE......................................................................................162 ADJUSTING SWING PPC VALVE...................................................................................................163 TESTING TRAVEL DEVIATION....................................................................................................164 MEASURING OIL LEAKAGE.......................................................................................................165 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...........................................................................166 BLEEDING AIR FROM EACH PART.................................................................................................167 TROUBLESHOOTING.................................................................................................................169 POINTS TO REMEMBER WHEN TROUBLESHOOTING ....................................................................................170 SEQUENCE OF EVENTS IN TROUBLESHOOTING ......................................................................................171 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ...........................................................................172 CHECKS BEFORE TROUBLESHOOTING ..............................................................................................180 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING................................................................................181 CONNECTOR ARRANGEMENT AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM...........................................................184 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .................................................................................199 T-ADAPTER-BOXES AND T-ADAPTER TABLE.........................................................................................222 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM......................................................................225 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.......................................................................226 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" IS INDICATED............................................................239 BEFORE TROUBLESHOOTING FOR DISPLAYED CODE...............................................................................240 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................243 ERROR CODE IN ELECTRICAL SYSTEM [E108] (ENGINE COOLANT OVERHEATING).....................................................245 ERROR CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....246 ERROR CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....248 ERROR CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................250 ERROR CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...............................................252 ERROR CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER).....................................254 ERROR CODE IN ELECTRICAL SYSTEM [E201] (ABNORMALITY IN TRAVEL ALARM RELAY COIL (SHORT CIRCUIT)).........................256 ERROR CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING PARKING BRAKE SOLENOID)...............................258 ERROR CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN OVERRUN PREVENTION SOLENOID)................................260 ERROR CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................261 ERROR CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING PARKING BRAKE SOLENOID)..................................262 ERROR CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION OF OVERRUN PREVENTION SOLENOID)...................................264 ERROR CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................265 ERROR CODE IN ELECTRICAL SYSTEM [E217] (ABNORMALITY IN INPUTTING MODEL CODE)............................................266 ERROR CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN OVERRUN PREVENTION EPC SOLENOID)............................268 ERROR CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN OVERRUN PREVENTION EPC SOLENOID SYSTEM)........................269 ERROR CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................270 ERROR CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN SWING FLASHER RELAY)........................................271 ERROR CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN SWING FLASHER RELAY)...........................................273 ERROR CODE IN ELECTRICAL SYSTEM [E301] (OUT-OF-RATE ENGINE ROTATION AT LOW IDLING)......................................275 ERROR CODE IN ELECTRICAL SYSTEM [E302] (OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING).....................................275 ERROR CODE IN ELECTRICAL SYSTEM [E304] (SHORT-CIRCUITING IN ENGINE STOP SOLENOID RELAY).................................276 ERROR CODE IN ELECTRICAL SYSTEM [E306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)..........................................278 ERROR CODE IN ELECTRICAL SYSTEM [E308] (ABNORMALITY IN FUEL DIAL).......................................................280 ERROR CODE IN ELECTRICAL SYSTEM [E311] (ABNORMALITY IN DECELERATOR PEDAL POTENTIOMETER).................................282 ERROR CODE IN ELECTRICAL SYSTEM [E314] (DISCONNECTION OF ENGINE STOP SOLENOID RELAY)....................................284 ERROR CODE IN ELECTRICAL SYSTEM [E315] (SHORT-CIRCUITING IN BATTERY RELAY)..............................................286 ERROR CODE IN ELECTRICAL SYSTEM [E316] (STEP-OUT IN GOVERNOR MOTOR).....................................................288 ERROR CODE IN ELECTRICAL SYSTEM [E317] (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)..................................289 ERROR CODE IN ELECTRICAL SYSTEM [E318] (SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND B)...............................291 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...............................................................................293 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................294 E-1 ENGINE DOES NOT START...............................................................................................295 E-2 ENGINE STOPS WHILE IN OPERATION.....................................................................................300 E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING......................................................................301 E-4 ENGINE DOES NOT STOP................................................................................................303 E-5 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK............................................................................305 E-6 PREHEATER DOES NOT WORK.............................................................................................306 E-7 DUMP BODY, SWING AND TRAVEL DO NOT MOVE.............................................................................308 E-8 NO DISPLAY IN MONITOR PANEL AT ALL..................................................................................310 E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING.........................................................................311 E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL............................................................311 E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING......................................................312 E-12 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY.......................................................313 E-13 FUEL GAUGE DOES NOT DISPLAY CORRECTLY..............................................................................314 E-14 BATTERY ELECTROLYTE LEVEL MONITOR DOES NOT DISPLAY NORMALLY........................................................315 E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY......................................................................316 E-16 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS............................................................317 E-17 WINDSHIELD WIPER DOES NOT WORK.....................................................................................318 E-18 ALARMING BUZZER CANNOT BE CANCELLED................................................................................320 E-19 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.............................................................321 E-20 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION............................................................322 E-21 TRAVEL ALARM DOES NOT SOUND........................................................................................323 E-22 SWING FLASHER DOES NOT FLASH.......................................................................................325 E-23 CENTER INDICATOR LAMP DOES NOT LIGHT UP............................................................................327 E-24 REVERSE TRAVEL INDICATOR LAMP DOES NOT LIGHT UP....................................................................329 E-25 HEADLAMP DOES NOT LIGHT UP.........................................................................................331 E-26 HORN DOES NOT SOUND................................................................................................333 E-27 EMERGENCY STOP SWITCH DOES NOT FUNCTION............................................................................334 E-28 AIR CONDITIONER DOES NOT WORK......................................................................................336 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)....................................................................338 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM........................................................................339 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................................341 H-1 SPEED OR POWER OF DUMP BODY OPERATION AND SWING OPERATION IS LOW....................................................342 H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS......................................................................342 H-3 SWING SYSTEM, DUMP BODY SYSTEM, AND TRAVEL SYSTEM DO NOT MOVE.......................................................343 H-4 ABNORMAL SOUND COMES NOT (FROM AROUND PUMP).........................................................................343 H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW.............................................................................343 H-6 SPEED OR POWER OF DUMP BODY SPEED IS LOW............................................................................344 H-7 DUMP BODY DOES NOT MOVE.............................................................................................344 H-8 HYDRAULIC DRIFT OF DUMP BODY IS LARGE...............................................................................344 H-9 MACHINE DEVIATES IN ONE DIRECTION DURING TRAVEL.....................................................................345 H-10 MACHINE DEVIATES LARGELY AT START..................................................................................347 H-11 TRAVEL SPEED OR POWER IS LOW.......................................................................................347 H-12 MACHINE IS NOT STEERED SMOOTHLY....................................................................................348 H-13 TRAVEL SPEED DOES NOT CHANGE.......................................................................................348 H-14 TRAVEL SYSTEM DOES NOT MOVE (ONLY ONE SIDE)........................................................................349 H-15 UPPER STRUCTURE DOES NOT SWING.....................................................................................350 H-16 SWING ACCELERATION IS LOW..........................................................................................351 H-17 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING........................................................352 H-18 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING............................................................352 H-19 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING...................................................353 H-20 HYDRAULIC DRIFT OF SWING IS LARGE..................................................................................353 H-21 SWING SPEED IS LOWER THAN SPECIFICATION............................................................................354 TROUBLESHOOTING OF ENGINE (S MODE)..........................................................................................355 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................356 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...........................................................360 S-2 ENGINE DOES NOT START...............................................................................................361 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................364 S-4 ENGINE STOPS DURING OPERATIONS......................................................................................365 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................................366 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)................................................................................367 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................368 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................369 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................370 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................................371 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..............................................372 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).........................................................373 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) ..............................................................................374 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................375 S-15 ABNORMAL NOISE IS MADE.............................................................................................376 S-16 VIBRATION IS EXCESSIVE.............................................................................................377 90 OTHERS...........................................................................................................................378 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................379 ELECTRIC CIRCUIT DIAGRAM (1/4)..................................................................................................380 ELECTRIC CIRCUIT DIAGRAM (2/4)..................................................................................................381 ELECTRIC CIRCUIT DIAGRAM (3/4)..................................................................................................382 ELECTRIC CIRCUIT DIAGRAM (4/4)..................................................................................................383
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
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