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KOMATSU JV100A-1 JV100WA-1 JV100WP-1 SHOP MANUAL SEBM02660103K – PDF DOWNLOAD
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KOMATSU JV100A-1 JV100WA-1 JV100WP-1 SHOP MANUAL SEBM02660103K – PDF DOWNLOAD
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Description
KOMATSU JV100A-1 JV100WA-1 JV100WP-1 SHOP MANUAL SEBM02660103K – PDF DOWNLOAD
FILE DETAILS:
KOMATSU JV100A-1 JV100WA-1 JV100WP-1 SHOP MANUAL SEBM02660103K – PDF DOWNLOAD
Language : English
Pages : 303
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU JV100A-1 JV100WA-1 JV100WP-1 SHOP MANUAL SEBM02660103K – 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
DESCRIPTION:
KOMATSU JV100A-1 JV100WA-1 JV100WP-1 SHOP MANUAL SEBM02660103K – 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 diviced 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 check 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 25/12/24
