Komatsu JV100A-1 JV100WA-1 & JV100WP-1 Vibratory Roller Shop Manual SEBM02650103K – PDF DOWNLOAD
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Komatsu JV100A-1 JV100WA-1 & JV100WP-1 Vibratory Roller Shop Manual SEBM02650103K – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
JV1 00A-1 10011 and up
JV100WA-1 20003 and up
JV1 00WP-1 30003 and up
Description
Komatsu JV100A-1 JV100WA-1 & JV100WP-1 Vibratory Roller Shop Manual SEBM02650103K – PDF DOWNLOAD
FILE DETAILS:
Komatsu JV100A-1 JV100WA-1 & JV100WP-1 Vibratory Roller Shop Manual SEBM02650103K – PDF DOWNLOAD
Language : English
Pages : 303
Downloadable : Yes
File Type : PDF
Size: 30.6 MB
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DESCRIPTION:
Komatsu JV100A-1 JV100WA-1 & JV100WP-1 Vibratory Roller Shop Manual SEBM02650103K – PDF DOWNLOAD
MACHINE MODEL SERIAL No.
JV1 00A-1 10011 and up
JV100WA-1 20003 and up
JV1 00WP-1 30003 and up
GENERAL PRECAUTIONS:
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
- Always wear safety glasses when hitting parts with a hammer.
- Always wear safety glasses when grinding parts with a grinder, etc.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
7. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine.Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
TABLE OF CONTENTS:
Komatsu JV100A-1 JV100WA-1 & JV100WP-1 Vibratory Roller 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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