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Komatsu JV100-2 Dump Truck Shop Manual SEBM011404 – PDF DOWNLOAD
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Komatsu JV100-2 Dump Truck Shop Manual SEBM011404 – PDF DOWNLOAD
MACHINE MODEL
JV100A-2 JV100WA-2 JV100WP-2
SERIAL NUMBER
11001 and up
21001 and up
31001 and up
21001 and up
31001 and up
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Description
Komatsu JV100-2 Dump Truck Shop Manual SEBM011404 – PDF DOWNLOAD
FILE DETAILS:
Komatsu JV100-2 Dump Truck Shop Manual SEBM011404 – PDF DOWNLOAD
Language : English
Pages :293
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu JV100-2 Dump Truck Shop Manual SEBM011404 – PDF DOWNLOAD
MACHINE MODEL
JV100A-2 JV100WA-2 JV100WP-2
SERIAL NUMBER
11001 and up
21001 and up
31001 and up
21001 and up
31001 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.
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.
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 ASSEMBLV
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.
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.
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu JV100-2 Dump Truck Shop Manual SEBM011404 – PDF DOWNLOAD
MACHINE MODEL
JV100A-2 JV100WA-2 JV100WP-2
SERIAL NUMBER
11001 and up
21001 and up
31001 and up
21001 and up
31001 and up
COVER 1
CONTENTS 2
01 GENERAL 22
GENERAL ASSEMBLY DRAWING 23
SPECIFICATIONS 25
WEIGHT TABLE 31
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
ACCELERATOR CONTROL 35
WATER SEPARATOR 36
RADIATOR, OIL COOLER 37
POWER TRAIN 38
PTO 39
HYDRAULIC CIRCUIT DIAGRAM FOR HYDROSTANTIC TRANSMISSION (HST) 40
TRAVEL PUMP 44
FRONT WHEEL TRAVEL MOTOR 47
REAR WHEEL TRAVEL MOTOR 48
TRAVEL HI/LO SELECTOR 49
HI/LO SELECTOR SOLENOID VALVE (FOR FRONT WHEEL TRAVEL MOTOR) 50
NEUTRAL SELECTOR SOLENOID VALVE 51
TRAVEL MOTOR BYPASS VALVE 53
TRAVEL CONTROL 54
TRANSFER 55
DRIVE SHAFT 56
DIFFERENTIAL 57
FINAL DRIVE 60
STEERING PIPING 62
STEERING PUMP 64
STEERING VALVE (ORBIT-ROLL TYPE) 65
PARKING BRAKE 72
HYDRAULIC PIPING 73
HYDRAULIC CIRCUIT DIAGRAM 77
EXCITER CONTROL 79
HYDRAULIC CIRCUIT DIAGRAM FOR EXCITER SYSTEM 80
EXCITER PUMP 81
EXCITER MOTOR 82
EXCITER STOP SOLENOID VALVE 83
ROLLER 84
ELECTRICAL WIRING DIAGRAM 86
ELECTRICAL CIRCUIT DIAGRAM 88
SENSOR 89
ENGINE START CIRCUIT 91
ENGINE STOP CIRCUIT 92
EXCITER SYSTEM ELECTRICAL CIRCUIT 93
20 TESTING AND ADJUSTING 94
STANDARD VALUE TABLE FOR ENGINE 95
STANDARD VALUE TABLE FOR CHASSIS 96
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 97
ADJUSTING VALVE CLEARANCE 99
TESTING AND ADJUSTING FUEL INJECTION TIMING100
MEASURING EXHAUST COLOR101
MEASURING COMPRESSION PRESSURE102
MEASURING BLOW-BY PRESSURE103
MEASURING EXHAUST GAS TEMPERATURE104
MEASURING ENGINE OIL PRESSURE105
ADJUSTING ENGINE STOP SOLENOID106
ADJUSTING FUEL CONTROL LINKAGE107
MEASURING TRAVEL PUMP CHARGE PRESSURE109
MEASURING TRAVEL OIL PRESSURE RELIEF PRESSURE110
ADJUSTING TRAVEL CONTROL LINKAGE111
TRAVEL, OPERATING EFFORT OF TRAVEL LEVER112
TESTING STEERING OIL PRESSURE114
ADJUSTING PARKING BRAKE LINKAGE115
TESTING AND ADJUSTING PARKING BRAKE116
REPLACING PARKING BRAKE PAD117
ADJUSTING PARKING BRAKE CALIPER118
ADJUSTING EXCITER CONTROL LINKAGE119
TRAVEL, OPERATING EFFORT OF EXCITER LEVER120
TESTING EXCITER OIL PRESSURE122
TROUBLESHOOTING123
POINTS TO REMEMBER WHEN TROUBLESHOOTING 124
SEQUENCE OF EVENTS IN TROUBLESHOOTING125
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE126
CHECKS BEFORE TROUBLESHOOTING134
CONNECTOR TYPES AND MOUNTING LOCATIONS135
CONNECTOR PIN ARRANGEMENT DIAGRAM136
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS137
METHOD OF USING TROUBLESHOOTING CHARTS143
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)145
E-1 ENGINE DOES NOT START146
a) STARTING MOTOR DOES NOT TURN146
b) ENGINE STOP SOLENOID DOES NOT WORK147
E-2 ENGINE DOES NOT STOP148
E-3 WHEN STARTING SWITCH IS TURNED TO HEAT, HEATER SIGNAL NOT LIGHT UP149
E-4 ELECTRICAL COMPONENTS DO NOT WORK 151
E-5 HEAD LAMP DOES NOT LIGHT UP152
E-6 MACHINE DOES NOT TRAVEL 153
E-7 TRAVEL SPEED DOES NOT CHANGE WHEN TRAVELING154
E-8 EVEN WHEN EXCITER SWITCH IS TURNED ON THERE IS NO VIBRATION156
E-9 EVEN WHEN EXCITER SWITCH IS TURNED OFF THERE IS VIBRATION157
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)159
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)160
H-1 THERE IS ABNORMAL NOISE162
H-2 HYDRAULIC OIL TEMPERATURE IS HIGH164
H-3 MACHINE DOES NOT TRAVEL OR TRAVELS SLOWLY 165
H-4 THERE IS EXCESSIVE TIME LAG WHEN ACCELERATING OR DECELERATING170
H-5 TRAVEL LACKS POWER, GRADEABILITY IS LOW170
H-6 SPEED RANGE DOES NOT SHIFT WHEN SHIFT LEVER IS OPERATED171
H-7 MACHINE TRAVELS EVEN WHEN TRAVEL LEVER IS AT NEUTRAL 173
H-8 THERE IS NO EXCITATION174
H-9 EXCITING FORCE DROPS DURING OPERATION176
H-10 THERE IS EXCESSIVE TIME LAG WHEN STARTING OR STOPPING EXCITATION178
H-11 EXCITATION CONTINUES EVEN WHEN EXCITER IS TURNED OFF179
H-12 EXCITATION STOPS DURING OPERATION180
H-13 MACHINE CANNOT BE STEERED182
H-14 STEERING WHEEL IS HEAVY183
H-15 STEERING SPEED IS SLOW183
30 DISSEMBLY AND ASSEMBLY184
METHOD OF USING MANUAL185
PRECAUTIONS WHEN CARRYING OUT OPERATION186
SPECIAL TOOL LIST188
STARTING MOTOR189
REMOVAL AND INSTALLATION189
ALTERNATOR190
REMOVAL AND INSTALLATION190
ENGINE OIL COOLER CORE191
REMOVAL AND INSTALLATION191
FUEL INJECTION PUMP192
REMOVAL 192
INSTALLATION194
WATER PUMP197
REMOVAL AND INSTALLATION197
TURBOCHARGER198
REMOVAL AND INSTALLATION198
NOZZLE HOLDER199
REMOVAL 199
INSTALLATION200
THERMOSTAT201
REMOVAL AND INSTALLATION201
CYLINDER HEAD202
REMOVAL202
INSTALLATION207
RADIATOR, OIL COOLER210
REMOVAL210
INSTALLATION212
ENGINE213
REMOVAL213
INSTALLATION214
PTO215
DISASSEMBLY215
ASSEMBLY216
TRANSFER, TRAVEL MOTOR217
REMOVAL217
INSTALLATION218
TRANSFER219
DISASSEMBLY219
ASSEMBLY223
DIFFERENTIAL, FINAL DRIVE227
REMOVAL227
INSTALLATION228
DIFFERENTIAL229
DISASSEMBLY229
ASSEMBLY232
FINAL DRIVE237
DISASSEMBLY237
ASSEMBLY240
FLOOR FRAME244
REMOVAL244
INSTALLATION245
HYDRAULIC TANK246
REMOVAL246
INSTALLATION247
VIBRATORY ROLLER (JV100A)248
REMOVAL248
INSTALLATION250
DISASSEMBLY252
ASSEMBLY255
VIBRATORY ROLLER (JV100WA,WP)258
REMOVAL 258
INSTALLATION260
DISASSEMBLY262
ASSEMBLY266
FRONT AXLE (JV100A)270
DISASSEMBLY270
ASSEMBLY272
FRONT AXLE (JV100WA,WP)275
DISASSEMBLY275
ASSEMBLY277
40 MAINTENANCE STANDARD280
PTO281
TRANSFER282
DIFFERENTIAL283
FINAL DRIVE284
PARKING BRAKE CALIPER285
STEERING CYLINDER286
ROLLER287
ANTI-VIBRATION RUBBER288
90 OTHERS289
HYDRAULIC CIRCUIT DIAGRAM (JV100A-2)290
HYDRAULIC CIRCUIT DIAGRAM (JV100WA,WP-2)291
ELECTRIC CIRCUIT DIAGRAM292
CONNECTOR PIN ARRANGEMENT DIAGRAM293
CONTENTS 2
01 GENERAL 22
GENERAL ASSEMBLY DRAWING 23
SPECIFICATIONS 25
WEIGHT TABLE 31
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
ACCELERATOR CONTROL 35
WATER SEPARATOR 36
RADIATOR, OIL COOLER 37
POWER TRAIN 38
PTO 39
HYDRAULIC CIRCUIT DIAGRAM FOR HYDROSTANTIC TRANSMISSION (HST) 40
TRAVEL PUMP 44
FRONT WHEEL TRAVEL MOTOR 47
REAR WHEEL TRAVEL MOTOR 48
TRAVEL HI/LO SELECTOR 49
HI/LO SELECTOR SOLENOID VALVE (FOR FRONT WHEEL TRAVEL MOTOR) 50
NEUTRAL SELECTOR SOLENOID VALVE 51
TRAVEL MOTOR BYPASS VALVE 53
TRAVEL CONTROL 54
TRANSFER 55
DRIVE SHAFT 56
DIFFERENTIAL 57
FINAL DRIVE 60
STEERING PIPING 62
STEERING PUMP 64
STEERING VALVE (ORBIT-ROLL TYPE) 65
PARKING BRAKE 72
HYDRAULIC PIPING 73
HYDRAULIC CIRCUIT DIAGRAM 77
EXCITER CONTROL 79
HYDRAULIC CIRCUIT DIAGRAM FOR EXCITER SYSTEM 80
EXCITER PUMP 81
EXCITER MOTOR 82
EXCITER STOP SOLENOID VALVE 83
ROLLER 84
ELECTRICAL WIRING DIAGRAM 86
ELECTRICAL CIRCUIT DIAGRAM 88
SENSOR 89
ENGINE START CIRCUIT 91
ENGINE STOP CIRCUIT 92
EXCITER SYSTEM ELECTRICAL CIRCUIT 93
20 TESTING AND ADJUSTING 94
STANDARD VALUE TABLE FOR ENGINE 95
STANDARD VALUE TABLE FOR CHASSIS 96
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 97
ADJUSTING VALVE CLEARANCE 99
TESTING AND ADJUSTING FUEL INJECTION TIMING100
MEASURING EXHAUST COLOR101
MEASURING COMPRESSION PRESSURE102
MEASURING BLOW-BY PRESSURE103
MEASURING EXHAUST GAS TEMPERATURE104
MEASURING ENGINE OIL PRESSURE105
ADJUSTING ENGINE STOP SOLENOID106
ADJUSTING FUEL CONTROL LINKAGE107
MEASURING TRAVEL PUMP CHARGE PRESSURE109
MEASURING TRAVEL OIL PRESSURE RELIEF PRESSURE110
ADJUSTING TRAVEL CONTROL LINKAGE111
TRAVEL, OPERATING EFFORT OF TRAVEL LEVER112
TESTING STEERING OIL PRESSURE114
ADJUSTING PARKING BRAKE LINKAGE115
TESTING AND ADJUSTING PARKING BRAKE116
REPLACING PARKING BRAKE PAD117
ADJUSTING PARKING BRAKE CALIPER118
ADJUSTING EXCITER CONTROL LINKAGE119
TRAVEL, OPERATING EFFORT OF EXCITER LEVER120
TESTING EXCITER OIL PRESSURE122
TROUBLESHOOTING123
POINTS TO REMEMBER WHEN TROUBLESHOOTING 124
SEQUENCE OF EVENTS IN TROUBLESHOOTING125
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE126
CHECKS BEFORE TROUBLESHOOTING134
CONNECTOR TYPES AND MOUNTING LOCATIONS135
CONNECTOR PIN ARRANGEMENT DIAGRAM136
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS137
METHOD OF USING TROUBLESHOOTING CHARTS143
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)145
E-1 ENGINE DOES NOT START146
a) STARTING MOTOR DOES NOT TURN146
b) ENGINE STOP SOLENOID DOES NOT WORK147
E-2 ENGINE DOES NOT STOP148
E-3 WHEN STARTING SWITCH IS TURNED TO HEAT, HEATER SIGNAL NOT LIGHT UP149
E-4 ELECTRICAL COMPONENTS DO NOT WORK 151
E-5 HEAD LAMP DOES NOT LIGHT UP152
E-6 MACHINE DOES NOT TRAVEL 153
E-7 TRAVEL SPEED DOES NOT CHANGE WHEN TRAVELING154
E-8 EVEN WHEN EXCITER SWITCH IS TURNED ON THERE IS NO VIBRATION156
E-9 EVEN WHEN EXCITER SWITCH IS TURNED OFF THERE IS VIBRATION157
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)159
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)160
H-1 THERE IS ABNORMAL NOISE162
H-2 HYDRAULIC OIL TEMPERATURE IS HIGH164
H-3 MACHINE DOES NOT TRAVEL OR TRAVELS SLOWLY 165
H-4 THERE IS EXCESSIVE TIME LAG WHEN ACCELERATING OR DECELERATING170
H-5 TRAVEL LACKS POWER, GRADEABILITY IS LOW170
H-6 SPEED RANGE DOES NOT SHIFT WHEN SHIFT LEVER IS OPERATED171
H-7 MACHINE TRAVELS EVEN WHEN TRAVEL LEVER IS AT NEUTRAL 173
H-8 THERE IS NO EXCITATION174
H-9 EXCITING FORCE DROPS DURING OPERATION176
H-10 THERE IS EXCESSIVE TIME LAG WHEN STARTING OR STOPPING EXCITATION178
H-11 EXCITATION CONTINUES EVEN WHEN EXCITER IS TURNED OFF179
H-12 EXCITATION STOPS DURING OPERATION180
H-13 MACHINE CANNOT BE STEERED182
H-14 STEERING WHEEL IS HEAVY183
H-15 STEERING SPEED IS SLOW183
30 DISSEMBLY AND ASSEMBLY184
METHOD OF USING MANUAL185
PRECAUTIONS WHEN CARRYING OUT OPERATION186
SPECIAL TOOL LIST188
STARTING MOTOR189
REMOVAL AND INSTALLATION189
ALTERNATOR190
REMOVAL AND INSTALLATION190
ENGINE OIL COOLER CORE191
REMOVAL AND INSTALLATION191
FUEL INJECTION PUMP192
REMOVAL 192
INSTALLATION194
WATER PUMP197
REMOVAL AND INSTALLATION197
TURBOCHARGER198
REMOVAL AND INSTALLATION198
NOZZLE HOLDER199
REMOVAL 199
INSTALLATION200
THERMOSTAT201
REMOVAL AND INSTALLATION201
CYLINDER HEAD202
REMOVAL202
INSTALLATION207
RADIATOR, OIL COOLER210
REMOVAL210
INSTALLATION212
ENGINE213
REMOVAL213
INSTALLATION214
PTO215
DISASSEMBLY215
ASSEMBLY216
TRANSFER, TRAVEL MOTOR217
REMOVAL217
INSTALLATION218
TRANSFER219
DISASSEMBLY219
ASSEMBLY223
DIFFERENTIAL, FINAL DRIVE227
REMOVAL227
INSTALLATION228
DIFFERENTIAL229
DISASSEMBLY229
ASSEMBLY232
FINAL DRIVE237
DISASSEMBLY237
ASSEMBLY240
FLOOR FRAME244
REMOVAL244
INSTALLATION245
HYDRAULIC TANK246
REMOVAL246
INSTALLATION247
VIBRATORY ROLLER (JV100A)248
REMOVAL248
INSTALLATION250
DISASSEMBLY252
ASSEMBLY255
VIBRATORY ROLLER (JV100WA,WP)258
REMOVAL 258
INSTALLATION260
DISASSEMBLY262
ASSEMBLY266
FRONT AXLE (JV100A)270
DISASSEMBLY270
ASSEMBLY272
FRONT AXLE (JV100WA,WP)275
DISASSEMBLY275
ASSEMBLY277
40 MAINTENANCE STANDARD280
PTO281
TRANSFER282
DIFFERENTIAL283
FINAL DRIVE284
PARKING BRAKE CALIPER285
STEERING CYLINDER286
ROLLER287
ANTI-VIBRATION RUBBER288
90 OTHERS289
HYDRAULIC CIRCUIT DIAGRAM (JV100A-2)290
HYDRAULIC CIRCUIT DIAGRAM (JV100WA,WP-2)291
ELECTRIC CIRCUIT DIAGRAM292
CONNECTOR PIN ARRANGEMENT DIAGRAM293
IMAGES PREVIEW OF THE MANUAL:
S.M 19/12/24
