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KOMATSU CD30R-1 SHOP MANUAL SEBM015701 – PDF DOWNLOAD
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Description
KOMATSU CD30R-1 SHOP MANUAL SEBM015701 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU CD30R-1 SHOP MANUAL SEBM015701 – PDF DOWNLOAD
Language : English
Pages : 208
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU CD30R-1 SHOP MANUAL SEBM015701 – PDF DOWNLOAD
COVER.......................................................................................................................................................... 1 CONTENTS....................................................................................................................................................... 2 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 SYSTEM DIAGRAM................................................................................................................................. 37 SWING CIRCLE............................................................................................................................................... 38 SWING MACHINERY............................................................................................................................................ 39 TRACK FRAME................................................................................................................................................ 40 IDLER CUSHION.............................................................................................................................................. 41 TRACK ROLLER BOGIE......................................................................................................................................... 42 TRACK SHOE................................................................................................................................................. 43 HYDRAULIC PIPING DRAWING................................................................................................................................... 44 HYDRAULIC TANK............................................................................................................................................. 46 HYDRAULIC PUMP............................................................................................................................................. 47 CONTROL VALVE.............................................................................................................................................. 54 SWING MOTOR................................................................................................................................................ 59 TRAVEL MOTOR............................................................................................................................................... 64 CENTER SWIVEL JOINT........................................................................................................................................ 74 VALVE CONTROL ............................................................................................................................................. 75 SWING PPC VALVE............................................................................................................................................ 76 SOLENOID VALVE............................................................................................................................................. 80 WORK EQUIPMENT............................................................................................................................................. 82 MACHINE MONITOR SYSTEM..................................................................................................................................... 83 20 TESTING AND ADJUSTING ...................................................................................................................................... 89 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.............................................................................................................. 90 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS............................................................................................................. 91 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................. 96 TESTING AND ADJUSTING...................................................................................................................................... 99 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING......................................................................................................100 MEASURING ENGINE SPEED.................................................................................................................................101 MEASURING EXHAUST COLOR................................................................................................................................102 ADJUSTING VALVE CLEARANCE..............................................................................................................................103 MEASURING COMPRESSION PRESSURE.........................................................................................................................104 TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................................105 MEASURING ENGINE OIL PRESSURE..........................................................................................................................106 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................................107 ADJUSTING FUEL CONTROL LEVER AND PEDAL.................................................................................................................108 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN TRAVEL CIRCUIT.............................................................................................111 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING CIRCUIT..............................................................................113 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE................................................................................................115 TESTING SOLENOID VALVE OUTPUT PRESSURE.................................................................................................................116 MEASURING PPC VALVE OUTPUT PRESSURE (FOR SWING)........................................................................................................117 ADJUSTING PPC VALVE (FOR SWING)........................................................................................................................118 TESTING TRAVEL DEVIATION...............................................................................................................................119 MEASURING OIL LEAKAGE..................................................................................................................................120 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT......................................................................................................121 TESTING AND ADJUSTING TRACK SHOE TENSION...............................................................................................................122 BLEEDING AIR...........................................................................................................................................123 TROUBLESHOOTING............................................................................................................................................125 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................................126 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................................127 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................................................................128 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................................136 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................................137 CONNECTOR ARRANGEMENT DIAGRAM..........................................................................................................................139 CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS..............................................................................................................142 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................148 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..........................................................................................................150 E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................151 E-1 ENGINE DOES NOT START..........................................................................................................................152 a) WHEN STARTING MOTOR DOES NOT TURN (STARTING SYSTEM).........................................................................................152 b) WHEN STARTING MOTOR TURNS (ENGINE STOP SOLENOID SYSTEM).....................................................................................155 E-2 ENGINE DOES NOT STOP...........................................................................................................................157 E-3 TRAVEL SPEED DOES NOT INCREASE EVEN TRAVEL BOOST PEDAL IS DEPRESSED............................................................................158 a) DOES NOT HI.................................................................................................................................158 b) DOES NOT LO.................................................................................................................................159 E-4 DOES NOT SWING.................................................................................................................................160 E-5 SWING BRAKE HAS NO EFFECT (THERE IS EXCESSIVE HYDRAULIC DRIFT).................................................................................161 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...............................................................................................163 TABLE OF FAILURE MODES AND CAUSES..................................................................................................................164 H-1 SPEEDS OF SWING, TRAVEL, DUMP BODY ARE SLOW....................................................................................................166 a) SWING SPEED IS SLOW.........................................................................................................................166 b) TRAVEL, DUMP BODY SPEED IS SLOW.............................................................................................................166 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS......................................................................................167 H-3 SWING, TRAVEL, DUMP BODY DO NOT MOVE, OR SPEED IS EXTREMELY SLOW...............................................................................167 a) SWING DOES NOT MOVE, OR SPEED IS EXTREMELY SLOW.............................................................................................167 b) TRAVEL, DUMP BODY DO NOT MOVE, OR SPEED IS EXTREMELY SLOW...................................................................................167 H-4 SWING, TRAVEL, DUMP BODY LACK POWER............................................................................................................168 H-5 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)....................................................................................................168 H-6 DUMP BODY SPEED IS SLOW, OR LACKS POWER........................................................................................................168 H-7 EXCESSIVE HYDRAULIC DRIFT (DUMP BODY)..........................................................................................................169 H-8 DEVIATES TO ONE SIDE WHEN TRAVELING............................................................................................................169 H-9 LACKS POWER WHEN TRAVELING (OR SPEED IS SLOW) .................................................................................................170 H-10 TRAVEL SPEED DOES NOT SWITCH..................................................................................................................170 H-11 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)..........................................................................................................171 H-12 TRAVEL LEVER IS HEAVY.........................................................................................................................171 H-13 DOES NOT SWING................................................................................................................................171 a) DOES NOT SWING IN EITHER DIRECTION .........................................................................................................171 b) DOES NOT SWING IN ONE DIRECTION (LEFT OR RIGHT).............................................................................................172 H-14 SWING SWING SPEED IS SLOW OR ACCELERATION IS POOR.............................................................................................172 H-15 EXCESSIVE SHOCK WHEN STOPPING SWING...........................................................................................................173 H-16 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..................................................................................................173 H-17 EXCESSIVE HYDRAULIC DRIFT OF SWING............................................................................................................173 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).....................................................................................................175 MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................176 M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN.........................................................................................177 M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECONDS), LAMPS DO NOT GO OUT...................177 M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS.........................................................178 a) NO GAUGE LAMPS LIGHT UP (FUEL, COOLANT TEMPERATURE).........................................................................................178 b) CAUTION LAMPS (ENGINE OIL PRESSURE, BATTERY CHARGE), PILOT LAMP (PREHEATING) DO NOT LIGHT UP................................................178 M-4 DURING SELF CHECK (ALL LAMPS LIGHT UP FOR 3 SECONDS), EVEN IF STARTING SWITCH IS TURNED TO START, SELF CHECK IS NOT COMPLETED FOR 3 SECONDS....178 M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP................................................179 M-6 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHARGE CAUTION LAMP DOES NOT LIGHT UP.............................................................179 M-7 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP................................................................180 M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP ............................................................................180 M-9 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP..........................................................................................181 M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE......................................................................................................182 a) LEVEL DOES NOT RISE FROM SEGMENT C..........................................................................................................182 b) LEVEL DOES NOT GO DOWN FROM SEGMENT H, OR ALL SEGMENT GO OUT................................................................................182 c) COOLANT TEMPERATURE DOES NOT MATCH GAUGE DISPLAY............................................................................................183 M-11 ABNORMALITY IN FUEL GAUGE.....................................................................................................................184 a) LEVEL DOES NOT RISE FROM SEGMENT E OR ALL SEGMENTS GO OUT...................................................................................184 b) LEVEL DOES NOT GO DOWN FROM SEGMENT F ......................................................................................................184 c) FUEL LEVEL DOES NOT MATCH GAUGE DISPLAY.....................................................................................................185 M-12 DEFECTIVE OPERATION OF ALARM BUZZER...........................................................................................................186 a) BUZZER DOES NOT SOUND.......................................................................................................................186 b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP.................................................................................................186 M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE........................................................................................187 a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP..................................................................................................187 b) WHEN CHARGE CAUTION LAMP LIGHTS UP..........................................................................................................187 c) PILOT LAMP DOES NOT FLASH (SERVICE METER IS ACTUATED).......................................................................................187 M-14 NIGHT LIGHTING DOES NOT LIGHT UP..............................................................................................................188 a) GAUGE LIGHTING DOES NOT LIGHT UP............................................................................................................188 b) SERVICE METER LIGHTING DOES NOT LIGHT UP....................................................................................................188 40 MAINTENANCE STANDARD .......................................................................................................................................189 SWING MACHINERY............................................................................................................................................190 SWING CIRCLE...............................................................................................................................................191 TRACK FRAME, RECOIL SPRING.................................................................................................................................192 IDLER......................................................................................................................................................193 CARRIER ROLLER.............................................................................................................................................194 TRACK ROLLER BOGIE.........................................................................................................................................195 TRACK ROLLER...............................................................................................................................................196 SPROCKET...................................................................................................................................................197 TRACK SHOE.................................................................................................................................................198 CONTROL VALVE..............................................................................................................................................200 TRAVEL VALVE...............................................................................................................................................202 SWING MOTOR................................................................................................................................................203 CENTER SWIVEL JOINT........................................................................................................................................204 SWING PPC VALVE............................................................................................................................................205 90 OTHERS .....................................................................................................................................................206 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................207 ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................................208
DESCRIPTION:
KOMATSU CD30R-1 SHOP MANUAL SEBM015701 – PDF DOWNLOAD
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.
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 18/12/24
