Komatsu Crawler Carrier Shop Manual CD110R-2 Shop Manual SEBM030003 PDF

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Komatsu Crawler Carrier Shop Manual CD110R-2 Shop Manual SEBM030003 – PDF DOWNLOAD

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Komatsu Crawler Carrier Shop Manual CD110R-2 Shop Manual SEBM030003 – PDF DOWNLOAD

Language : English
Pages :383
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Crawler Carrier Shop Manual CD110R-2 Shop Manual SEBM030003 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
CD110R-2 1501 and up

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 Crawler Carrier Shop Manual CD110R-2 Shop Manual SEBM030003 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
CD110R-2 1501 and up

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 EQUIPMENT102
AIR CONDITIONER PIPING103
ELECTRIC CONTROL SYSTEM104
SYSTEM COMPONENTS114
MONITOR SYSTEM120
SENSORS125
20 TESTING AND ADJUSTING130
STANDARD VALUE TABLE FOR ENGINE131
STANDARD VALUE TABLE FOR CHASSIS132
TESTING AND ADJUSTING137
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING138
TESTING ENGINE SPEED139
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)140
MEASURING EXHAUST GAS COLOR141
ADJUSTING VALVE CLEARANCE142
MEASURING COMPRESSION PRESSURE144
MEASURING BLOW-BY PRESSURE145
TESTING AND ADJUSTING FUEL INJECTION TIMING146
MEASURING ENGINE OIL PRESSURE148
ADJUSTING ENGINE STOP SOLENOID149
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE150
ADJUSTING OF ENGINE SPEED SENSOR151
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION151
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM152
BLEEDING AIR FROM FUEL CIRCUIT153
MEASURING CLEARANCE OF SWING CIRCLE BEARING154
TESTING AND ADJUSTING TRACK SHOE TENSION155
TESTING HST OIL PRESSURE156
TESTING AND ADJUSTING WORK EQUIPMENT AND SWING CIRCUIT PRESSURE159
TESTING CONTROL PUMP CIRCUIT PRESSURE160
TESTING SOLENOID VALVE OUTPUT PRESSURE162
ADJUSTING SWING PPC VALVE163
TESTING TRAVEL DEVIATION164
MEASURING OIL LEAKAGE165
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT166
BLEEDING AIR FROM EACH PART167
TROUBLESHOOTING169
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 TROUBLESHOOTING181
CONNECTOR ARRANGEMENT AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM184
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 199
T-ADAPTER-BOXES AND T-ADAPTER TABLE222
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM225
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL226
TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM” IS INDICATED239
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE240
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE243
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 TABLE294
E-1 ENGINE DOES NOT START295
E-2 ENGINE STOPS WHILE IN OPERATION300
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING301
E-4 ENGINE DOES NOT STOP303
E-5 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK305
E-6 PREHEATER DOES NOT WORK306
E-7 DUMP BODY, SWING AND TRAVEL DO NOT MOVE308
E-8 NO DISPLAY IN MONITOR PANEL AT ALL310
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING311
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL311
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING312
E-12 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY313
E-13 FUEL GAUGE DOES NOT DISPLAY CORRECTLY314
E-14 BATTERY ELECTROLYTE LEVEL MONITOR DOES NOT DISPLAY NORMALLY315
E-15 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY316
E-16 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS317
E-17 WINDSHIELD WIPER DOES NOT WORK318
E-18 ALARMING BUZZER CANNOT BE CANCELLED320
E-19 “SWING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION321
E-20 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION322
E-21 TRAVEL ALARM DOES NOT SOUND323
E-22 SWING FLASHER DOES NOT FLASH325
E-23 CENTER INDICATOR LAMP DOES NOT LIGHT UP327
E-24 REVERSE TRAVEL INDICATOR LAMP DOES NOT LIGHT UP329
E-25 HEADLAMP DOES NOT LIGHT UP331
E-26 HORN DOES NOT SOUND333
E-27 EMERGENCY STOP SWITCH DOES NOT FUNCTION334
E-28 AIR CONDITIONER DOES NOT WORK336
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE)338
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM339
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE341
H-1 SPEED OR POWER OF DUMP BODY OPERATION AND SWING OPERATION IS LOW342
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS342
H-3 SWING SYSTEM, DUMP BODY SYSTEM, AND TRAVEL SYSTEM DO NOT MOVE343
H-4 ABNORMAL SOUND COMES NOT (FROM AROUND PUMP)343
H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW343
H-6 SPEED OR POWER OF DUMP BODY SPEED IS LOW344
H-7 DUMP BODY DOES NOT MOVE344
H-8 HYDRAULIC DRIFT OF DUMP BODY IS LARGE344
H-9 MACHINE DEVIATES IN ONE DIRECTION DURING TRAVEL345
H-10 MACHINE DEVIATES LARGELY AT START347
H-11 TRAVEL SPEED OR POWER IS LOW347
H-12 MACHINE IS NOT STEERED SMOOTHLY348
H-13 TRAVEL SPEED DOES NOT CHANGE348
H-14 TRAVEL SYSTEM DOES NOT MOVE (ONLY ONE SIDE)349
H-15 UPPER STRUCTURE DOES NOT SWING350
H-16 SWING ACCELERATION IS LOW351
H-17 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING352
H-18 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING352
H-19 LARGE ABNORMAL SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING353
H-20 HYDRAULIC DRIFT OF SWING IS LARGE353
H-21 SWING SPEED IS LOWER THAN SPECIFICATION354
TROUBLESHOOTING OF ENGINE (S MODE)355
METHOD OF USING TROUBLESHOOTING CHARTS356
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)360
S-2 ENGINE DOES NOT START361
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)364
S-4 ENGINE STOPS DURING OPERATIONS365
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 QUICKLY370
S-10 FUEL CONSUMPTION IS EXCESSIVE371
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN372
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 MADE376
S-16 VIBRATION IS EXCESSIVE377
90 OTHERS378
HYDRAULIC CIRCUIT DIAGRAM379
ELECTRIC CIRCUIT DIAGRAM (1/4)380
ELECTRIC CIRCUIT DIAGRAM (2/4)381
ELECTRIC CIRCUIT DIAGRAM (3/4)382
ELECTRIC CIRCUIT DIAGRAM (4/4)383

IMAGES PREVIEW OF THE MANUAL:

S.M 24/12/24