Komatsu JV100A-1 JV100WA-1 JV100WP-1 Road Machines Shop Manual SEBM02650103K – PDF DOWNLOAD

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Komatsu JV100A-1 JV100WA-1 JV100WP-1 Road Machines Shop Manual SEBM02650103K – PDF DOWNLOAD

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DESCRIPTION:

Komatsu JV100A-1 JV100WA-1 JV100WP-1 Road Machines Shop Manual SEBM02650103K – PDF DOWNLOAD

MACHINE M0DEL SERIAL No.
JV1 ООА-1 10011 and up
JV100WA-1 20003 and up
JV1 00WP-1 30003 and up

FOREWORD:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
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 ADJUSTMENTS
This sections 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.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu JV100A-1 JV100WA-1 JV100WP-1 Road Machines Shop Manual SEBM02650103K – PDF DOWNLOAD

COVER 1
CONTENTS 2
10 ENGINE 20
11 STRUCTURE AND FUNCTION 20
ACCEL,FUEL TANK AND PIPING 21
RADIATOR,ENGINE MOUNT AND AIR CLEANER 22
12 TESTING AND ADJUSTING 23
TESTING AND ADJUSTING TOOL LIST 24
TESTING AND ADJUSTING DATA 25
ADJUSTMENT OF VALVE CLEARANCE 26
MEASURING COMPRESSION PRESSURE 27
MEASURING BLOW-BY 28
TESTING AND ADJUSTING FUEL INJECTION TIMING 29
TESTING AND ADJUSTING FAN BELT TENSION 31
TROUBLESHOOTING 32
STARTING MOTOR DOES NOT ROTATE AT ALL WHEN STARTING SWITCH IS PLACED IN START(IN COLD WEATHER) 33
STARTING MOTOR DOES NOT ROTATE 34
ROTATION OF STARTING MOTOR IS TOO SLOW TO START THE ENGINE 36
WHEN THE STARTING SWITCH IS PUT IN START POSITION,THE SOUND OF THE PINION GOING IN AND OUT CAN BE HEARD,BUT THE STARTING MOTOR DOES NOT ROTATE 37
HEATER SIGNAL DOES NOT COME ON,EVEN WHEN THE STARTING SWITCH IS IN PREHEAT POSITION 38
BATTERY IS OFTEN INSUFFICIENTLY CHARGED 40
13 DISASSEMBLY AND ASSEMBLY 42
STARTING MOTOR 43
REMOVAL AND INSTALLATION 43
ALTERNATOR 44
REMOVAL AND INSTALLATION 44
FUEL INJECTION PUMP 45
REMOVAL AND INSTALLATION 45
WATER PUMP 46
REMOVAL INSTALLATION 46
NOZZLE HOLDER 47
REMOVAL AND INSTALLATION 47
TURBOCHARGER 48
REMOVAL AND INSTALLATION 48
RADIATOR AND OIL COOLER 49
REMOVAL 49
INSTALLATION 50
CYLINDER HEAD 51
REMOVAL 51
INSTALLATION 55
ENGINE 59
REMOVAL 59
INSTALLATION 64
20 POWER TRAIN 69
21 STRUCTURE AND FUNCTION 69
POWER TRAIN 70
PTO(POWER TAKE-OFF) 71
HYDROSTATIC TRANSMISSION(H S T ) 72
RANGE TRANSMISSION 77
TRANSMISSION CONTROL LEVERS 80
UNIVERSAL JOINT 81
DIFFERENTIAL 81
NON-SPIN DIFFERENTIAL 82
FINAL DRIVE 87
WHEEL 88
22 TESTING AND ADJUSTING 92
TRAVEL AND OPERATING FORCE OF GEAR SHIFT LEVER 93
TRAVEL AND OPERATING FORCE OF TRAVEL LEVER 94
TESTING HYDRAULIC PRESSURE OF TRAVEL 95
23 DISASSEMBLY AND ASSEMBLY 96
PTO ASSEMBLY 97
REMOVAL 97
INSTALLATION 99
DISASSEMBLY 102
ASSEMBLY 104
TRAVEL PUMP ASSEMBLY 106
REMOVAL AND INSTALLATION 106
FRONT ROLLER TRAVEL MOTOR(JV100WA,WP) 107
REMOVAL 107
INSTALLATION 109
TRAVEL MOTOR ASSEMBLY 111
REMOVAL 111
INSTALLATION 112
RANGE TRANSMISSION ASSEMBLY 113
REMOVAL 113
INSTALLATION 114
DISASSEMBLY 116
ASSEMBLY 120
SHIFTER COVER ASSEMBLY 124
DISASSEMBLY 124
ASSEMBLY 125
REAR AXLE HOUSING ASSEMBLY 126
REMOVAL 126
INSTALLATION 127
BEVEL GEAR ASSEMBLY 129
DISASSEMBLY 129
ASSEMBLY 132
FINAL DRIVE ASSEMBLY 137
DISASSEMBLY 137
ASSEMBLY 139
PLANETARY GEAR 141
DISASSEMBLY AND ASSEMBLY 141
24 MAINTENANCE STANDARD 142
PTO 143
RANGE TRANSMISSION 144
DIFFERENTIAL 145
FINAL DRIVE 146
40 STEERING SYSTEM 147
41 STRUCTURE AND FUNCTION 147
STEERING PIPING 148
FLOW CONTROL VALVE 149
STEERING VALVE 151
STEERING PUMP 158
STEERING CYLINDER 158
42 TESTING AND ADJUSTING 159
CHECKING STEERING WHEEL PLAY 160
CHECKING STEERING WHEEL OPERATING FORCE 160
CHECKING RUN-OUT OF TIRES 161
TESTING TIRE INFLATION PRESSURE 161
43 DISASSEMBLY AND ASSEMBLY 162
STEERING PUMP ASSEMLBY 163
REMOVAL AND INSTALLATION 163
STEERING CYLINDER ASSEMBLY 164
REMOVAL 164
INSTALLATION 165
FLOW CONTROL VALVE ASSEMBLY 166
REMOVAL AND INSTALLATION 166
44 MAINTENANCE STANDARD 167
STEERING CYLINDER 168
50 BRAKE SYSTEM 169
51 STRUCTURE AND FUNCTION 169
BRAKE PIPING 170
BRAKE PIPING DIAGRAM 171
HYDROMASTER 172
MASTER CYLINDER 174
WHEEL BRAKE 174
PARKING BRAKE 175
52 TESTING AND ADJUSTING 176
CHECKING AND ADJUSTING BRAKE PEDAL HEIGHT 177
CHECKING AND ADJUSTING BRAKE PEDAL PLAY 177
CHECKING BRAKE PEDAL DEPRESSION HEIGHT 178
CHECKING BRAKE PEDAL OPERATING FORCE 178
CHECKING AND ADJUSTING WHEEL BRAKE 178
CHECKING AND ADJUSTING PARKING BRAKE 181
53 DISASSEMBLY AND ASSEMBLY 182
WHEEL BRAKE ASSEMBLY 183
REMOVAL AND INSTALLATION 183
BRAKE MASTER CYLINDER ASSEMBLY 184
REMOVAL AND INSTALLATION 184
HYDROMASTER 185
REMOVAL AND INSTALLATION 185
DISASSEMBLY 186
ASSEMBLY 188
PARKING BRAKE ASSEMBLY 190
REMOVAL(DISASSEMBLY) 190
INSTALLATION(ASSEMBLY) 191
54 MAINTENANCE STANDARD 192
WHEEL BRAKE 193
PARKING BRAKE 194
60 HYDRAULIC SYSTEM 195
61 STRUCTURE AND FUNCTION 195
HYDRAULIC PIPING 196
HYDRAULIC SYSTEM 198
HYDRAULIC CIRCUIT 202
HYDROSTATIC TRANSMISSION(HST) 206
62 TESTING AND ADJUSTING 208
MEASURING HYDRAULIC OIL TEMPERATURE 209
TROUBLESHOOTING 210
TROUBLESHOOTING TOOL TABLE 211
METHOD OF READING TROUBLESHOOTING TABLE 212
EXCESSIVE TIME LAG WHEN MACHINE STARTS OFF 214
MACHINE DOES NOT START 216
TRAVEL SPEED IS TOO SLOW,OR MACHINE DOES NOT TRAVEL(IN ALL SPEED RANGES) 218
BRAKES DO NOT WORK,OR BRAKING EFFECT IS POOR 220
BRAKE CANNOT BE RELEASED,OR BRAKE DRAGS 221
STEERING IS HEAVY,OR WILL NOT TURN 222
ROLLER DOES NOT VIBRATE 223
VIBRATING FORCE IS TOO SMALL,OR THERE IS AN EXCESSIVE TIME LAG WHEN VIBRATING 225
MACHINE VIBRATES ABNORMALLY 227
AMPLITUDE CANNOT BE SWITCHED 229
VIBRATION FREQUENCY CANNOT BE ADJUSTED 231
63 DISASSEMBLY AND ASSEMBLY 233
VIBRATOR PUMP ASSEMBLY 234
REMOVAL 234
INSTALLATION 235
VIBRATOR MOTOR ASSEMBLY 236
REMOVAL AND INSTALLATION 236
HYDRAULIC TANK ASSEMBLY 237
REMOVAL 237
INSTALLATION 240
OPERATOR’S PLATFORM 243
REMOVAL 243
INSTALLATION 246
70 WORK EQUIPMENT 249
71 STRUCTURE AND FUNCTION 249
VIBRATION CONTROL 250
DRUM 251
72 TESTING AND ADJUSTING 254
TRAVEL AND OPERATING FORCE OF VIBRATION LEVER 255
TESTING HYDRAULIC PRESSURE OF VIBRATOR 256
73 DISASSEMBLY AND ASSEMBLY 257
ARTICULATING ASSEMBLY(DISASSEMBLY) 258
REMOVAL(DISASSEMBLY) 258
INSTALLATION(ASSEMBLY) 260
VIBRATORY ROLLER ASSEMBLY 262
REMOVAL 262
INSTALLATION 264
DISASSEMBLY(JV100A-1) 266
ASSEMBLY(JV100A-1) 269
DISASSEMBLY(JV100WA-1,JV100WP-1) 272
ASSEMBLY(JV100WA-1,JV100WP-1) 276
FRONT AXLE ASSEMBLY 280
DISASSEMBLY 280
ASSEMBLY 282
80 ELECTRICAL SYSTEM 284
81 STRUCTURE AND FUNCTION 284
VIBRATION SWITCH 285
ELECTRICAL WIRING DIAGRAM 286
ELECTRICAL CIRCUIT DIAGRAM 288
82 TESTING AND ADJUSTING 292
TROUBLESHOOTING 293
EVEN IF THE VACUUM PRESSURE IN THE VACUUM TANK DROPS,THE ALARM BUZZE DOES NOT BUZZ 293
ELECTRICAL EQUIPMENT DOES NOT WORK 294
THE TURN SIGNAL LAMP DOES NOT FLASH 295
LIGHTING DEVICES SUCH AS HEAD LAMPS AND GAUGE LAMPS DO NOT LIGHT 297
EVEN IF THE VIBRATORY SWITCH IS PUT IN OFF POSITION,THE MACHINE STILL VIBRATES 298
EVEN IF THE VIBRATORY SWITCH IS PUT IN ON POSITON,THE MACHINE DOES NOT VIBRATE 299
90 OTHERS 301
92 TESTING AND ADJUSTING 301
INSPECTION TABLE 302
1 POWER TRAIN 302
2 TRAVEL AND STEERING SYSTEM 303
3 HYDRAULIC SYSTEM,WORK EQUIPMENT 303

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PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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