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KOMATSU PW100-3 SERVICE REPAIR MANUAL (SN:1890 & UP) KOMATSU PW100-3 – PDF DOWNLOAD
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- KOMATSU PW100-3 SERVICE REPAIR MANUAL
- SERIAL NUMBER:1890 & UP
- PUBLICATION NUMBER:SEBM02000304
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Description
KOMATSU PW100-3 SERVICE REPAIR MANUAL (SN:1890 & UP) KOMATSU PW100-3
KOMATSU PW100-3 SERVICE REPAIR MANUAL (SN:1890 & UP) KOMATSU PW100-3 – PDF DOWNLOAD:
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TABLE OF CONTENTS:
KOMATSU PW100-3 SERVICE REPAIR MANUAL (SN:1890 & UP) KOMATSU PW100-3
COVER...................................................................................................... 1 CONTENTS................................................................................................... 2 10 ENGINE.................................................................................................. 24 11 STRUCTURE AND FUNCTION.............................................................................. 24 RADIATOR,OIL COOLER................................................................................ 25 PTO................................................................................................ 27 ENGINE CONTROL..................................................................................... 28 12 TESTING AND ADJUSTING............................................................................... 35 TOOLS FOR TESTING AND ADJUSTING.................................................................... 36 ADJUSTING VALVE CLEARANCE.......................................................................... 37 TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................ 38 MEASURING COMPRESSION PRESSURE..................................................................... 40 13 DISASSEMBLY AND ASSEMBLY............................................................................ 41 STARTING MOTOR..................................................................................... 42 REMOVAL........................................................................................ 42 INSTALLATION................................................................................... 42 ALTERNATOR......................................................................................... 42 REMOVAL........................................................................................ 42 INSTALLATION................................................................................... 42 ENGINE OIL COOLER.................................................................................. 44 REMOVAL........................................................................................ 44 INSTALLATION................................................................................... 44 FUEL INJECTION PUMP................................................................................ 46 REMOVAL........................................................................................ 46 INSTALLATION................................................................................... 46 AIR COMPRESSOR..................................................................................... 48 REMOVAL........................................................................................ 48 INSTALLATION................................................................................... 48 WATER PUMP......................................................................................... 50 REMOVAL........................................................................................ 50 INSTALLATION................................................................................... 50 NOZZLE HOLDER...................................................................................... 50 REMOVAL........................................................................................ 50 INSTALLATION................................................................................... 50 TURBOCHARGER....................................................................................... 52 REMOVAL........................................................................................ 52 INSTALLATION................................................................................... 52 CYLINDER HEAD...................................................................................... 54 REMOVAL........................................................................................ 54 INSTALLATION................................................................................... 58 RADIATOR AND HYDRAULIC OIL COOLER.................................................................. 64 REMOVAL........................................................................................ 64 INSTALLATION................................................................................... 64 ENGINE ............................................................................................ 66 REMOVAL........................................................................................ 66 INSTALLATION................................................................................... 70 PTO................................................................................................ 74 REMOVAL........................................................................................ 74 INSTALLATION................................................................................... 74 20 POWER TRAIN............................................................................................. 76 21 STRUCTURE AND FUNCTION.............................................................................. 76 POWER TRAIN........................................................................................ 77 TRAVEL SYSTEM...................................................................................... 78 1. OUTLINE..................................................................................... 78 2. SCHENATIC OF TRAVEL SYSTEM.................................................................. 79 3. HYDRAULIC AND PNEUMATIC CIRCUIT DIAGRAM..................................................... 80 4. TRAVEL MOTOR AND BRAKE VALVE................................................................ 82 5. CENTER SWIVEL JOINT......................................................................... 93 6. TRANSMISSION................................................................................ 94 7. FORWARD-REVERSE SELECTOR LEVER..............................................................100 8. FORWARD-REVERSE SELECTOR SOLENOID VALVE.....................................................101 9. TRANSMISSION SELECTOR VALVE.................................................................102 10. TRAVLE PPC VALVE...........................................................................105 SWING SYSTEM.......................................................................................106 1. OUTLINE.....................................................................................106 2. SCHEMATIC OF TRAVEL SYSTEM..................................................................107 3. HYDRAULIC CIRCUIT DIAGRAM...................................................................108 4. SWING MOTOR AND BRAKE VALVE.................................................................109 5. SWING MACHINERY.............................................................................115 6. SWING CIRCLE................................................................................117 23 DISASSEMBLY AND ASSEMBLY............................................................................118 CENTER SWIVEL JOINT................................................................................119 REMOVAL........................................................................................119 INSTALLATION...................................................................................119 DISASSEMBLY....................................................................................121 ASSEMBLY.......................................................................................121 SWING CIRCLE.......................................................................................123 REMOVAL........................................................................................123 INSTALLATION...................................................................................125 SWING MACHINERY....................................................................................129 REMOVAL........................................................................................129 INSTALLATION...................................................................................129 DISASSEMBLY....................................................................................129 ASSEMBLY.......................................................................................133 TRANSMISSION.......................................................................................137 REMOVAL........................................................................................137 INSTALLATION...................................................................................137 DISASSEMBLY....................................................................................139 ASSEMBLY.......................................................................................145 SWING MOTOR........................................................................................151 REMOVAL........................................................................................151 INSTALLATION...................................................................................151 TRAVEL MOTOR.......................................................................................151 REMOVAL........................................................................................151 INSTALLATION...................................................................................151 TRAVEL BRAKE VALVE.................................................................................153 REMOVAL........................................................................................153 INSTALLATION...................................................................................153 24 MAINTENANCE STANDARD................................................................................155 TRAVEL BRAKE VALVE.................................................................................156 TRAVEL SUCTION VALVE...............................................................................157 TRANSMISSION.......................................................................................158 SWING MACHINERY....................................................................................159 SWING CIRCLE.......................................................................................160 40 STEERING SYSTEM.........................................................................................161 41 STRUCTURE AND FUNCTION..............................................................................161 STEERING SYSTEM....................................................................................162 1. OUTLINE.....................................................................................162 2. SCHEMATIC OF STEERING SYSTEM................................................................163 3. HYDRAULIC CIRCUIT DIAGRAM...................................................................164 4. STEERING PUMP...............................................................................165 5. STEERING VALVE AND MAIN RELIEF VALVE........................................................166 6. STEERING CYLINDER...........................................................................176 7. AXLE........................................................................................177 8. DRIVE SHAFT.................................................................................184 9. WHEEL.......................................................................................185 BRAKE SYSTEM.......................................................................................186 1. OUTLINE.....................................................................................186 2. SCHEMATIC OF BRAKE SYSTEM...................................................................187 3. PNEUMATIC CIRCUIT DIAGRAM...................................................................188 4. BRAKE VALVE.................................................................................189 5. SHUTTLE VALVE (DOUBLE CHECK VALVE)..........................................................191 6. AIR MASTER..................................................................................192 7. WHEEL BRAKE.................................................................................194 8. PARKING BRAKE...............................................................................196 9. PARKING BRAKE CHAMBER.......................................................................198 10. 2-WAY CONTROL VALVE........................................................................200 11. QUICK-RELEASE VALVE........................................................................202 SUSPENSION SYSTEM..................................................................................203 1. OUTLINE.....................................................................................203 2. SCHEMATIC OF SUSPENSION SYSTEM..............................................................204 3. HYDRAULIC AND PNEUMATIC CIRCUIT DIAGRAM.....................................................205 4. SUSPENSION LOCK VALVE.......................................................................206 5. SUSPENSION LOCK CYLINDER....................................................................208 42 TESTING AND ADJUSTING...............................................................................209 TESTING AND ADJUSTING TOE-IN.......................................................................210 ADJUSTING MAXIMUM STEERING ANGLE OF FRONT AXLE.....................................................211 ADJUSTING PARKING BRAKE............................................................................212 ADJUSTING PARKING BRAKE ROD........................................................................213 BLEEDING AIR FROM BRAKE CIRCUIT....................................................................214 43 DISASSEMBLY AND ASSEMBLY............................................................................215 STEERING CYLINDER..................................................................................216 REMOVAL........................................................................................216 INSTALLATION...................................................................................216 STEERING PUMP......................................................................................216 REMOVAL........................................................................................216 INSTALLATION...................................................................................216 FRONT AXLE.........................................................................................218 REMOVAL........................................................................................218 INSTALLATION...................................................................................218 REAR AXLE..........................................................................................220 REMOVAL........................................................................................220 INSTALLATION...................................................................................220 FINAL DRIVE........................................................................................222 REMOVAL........................................................................................222 INSTALLATION...................................................................................226 FRONT DIFFERENTIAL.................................................................................230 REMOVAL........................................................................................230 INSTALLATION...................................................................................230 REAR DIFFERENTIAL..................................................................................232 REMOVAL........................................................................................232 INSTALLATION...................................................................................232 DIFFERENTIAL.......................................................................................234 DISASSEMBLY....................................................................................234 ASSEMBLY.......................................................................................236 AIR MASTER.........................................................................................241 REMOVAL........................................................................................241 INSTALLATION...................................................................................241 DISC PLATE.........................................................................................243 REMOVAL........................................................................................243 INSTALLATION...................................................................................247 FRONT CALIPER......................................................................................251 REMOVAL........................................................................................251 INSTALLATION...................................................................................251 REAR CALIPER.......................................................................................251 REMOVAL........................................................................................251 INSTALLATION...................................................................................251 CALIPER............................................................................................253 DISASSEMBLY....................................................................................253 ASSEMBLY.......................................................................................253 PARKING BRAKE......................................................................................255 REMOVAL........................................................................................255 INSTALLATION...................................................................................255 SUSPENSION LOCK VALVE..............................................................................255 REMOVAL........................................................................................255 INSTALLATION...................................................................................255 SUSPENSION LOCK CYLINDER...........................................................................257 REMOVAL........................................................................................257 INSTALLATION...................................................................................257 DISASSEMBLY....................................................................................257 ASSEMBLY.......................................................................................257 44 MAINTENANCE STANDARD................................................................................259 STEERING GEAR PUMP.................................................................................260 STEERING CYLINDER..................................................................................261 DIFFERENTIAL.......................................................................................262 FINAL DRIVE........................................................................................263 KING PIN,KNUCKLE AND TIE-ROD.......................................................................264 WHEEL BRAKE........................................................................................266 PARKING BRAKE......................................................................................267 SUSPENSION LOCK CYLINDER...........................................................................268 50 AIR SYSTEM..............................................................................................269 51 STRUCTURE AND FUNCTION..............................................................................269 AIR SYSTEM.........................................................................................270 1. OUTLINE.....................................................................................270 2. SCHEMATIC OF AIR SYSTEM.....................................................................274 3. PNEUMATIC CIRCUIT DIAGRAM...................................................................275 4. AIR GOVERNOR................................................................................276 5. PARKING LAMP SWITCH.........................................................................278 6. LOW PRESSURE INDICATOR SWITCH...............................................................279 7. STOP LAMP SWITCH............................................................................280 60 HYDRAULIC SYSTEM........................................................................................281 61 STRUCTURE AND FUNCTION..............................................................................281 OUTLINE............................................................................................282 1. HYDRAULIC PIPING............................................................................283 2. HYDRAULIC CIRCUIT SCHEMATIC.................................................................285 3. HYDRAULIC CIRCUIT DIAGRAM...................................................................289 HYDRAULIC TANK (WITH FUEL TANK)....................................................................291 HYDRAULIC PUMP.....................................................................................292 PC CONTROL SYSTEM..................................................................................302 OLSS (OPEN CENTER LOAD SENSING SYSTEM) (IF EQUIPPED)...............................................306 1. OUTLINE.....................................................................................306 2. OLSS BASIC CIRCUIT..........................................................................308 3. SCHEMATIC OLSS..............................................................................309 4. SERVO VALVE,TVC VALVE,CO VALVE AND NC VALVE.................................................310 5. FUNCTION OF OLSS............................................................................319 CONTROL VALVE......................................................................................328 1. L.H. 5-SPOOL CONTROL VALVE..................................................................328 2. R.H. 4-SPOOL CONTROL VALVE..................................................................330 HYDRAULIC CYLINDER.................................................................................338 WORK EQUIPMENT CONTROL.............................................................................343 1. OUTLINE.....................................................................................343 2. BOOM CONTROL................................................................................344 3. ARM CONTROL (ARM IN)........................................................................346 4. BUCKET CONTROL..............................................................................348 62 TESTING AND ADJUSTING...............................................................................350 TOOLS FOR TESTING AND ADJUSTING....................................................................351 TESTING AND ADJUSTING MAIN RELIEF PRESSURE.........................................................352 TESTING AND ADJUSTING CHARGING CIRCUIT PRESSURE....................................................354 BLEEDING AIR.......................................................................................355 TROUBLESHOOTING....................................................................................356 ELECTRICAL CIRCUIT DIAGRAM.....................................................................357 POSITION OF CONNECTOR..........................................................................358 CONNECTION TABLE FOR CONNECTOR PINS............................................................359 CHECKS BEFORE TROUBLESHOOTING..................................................................361 TROUBLESHOOTING CHART..........................................................................366 E-1 CANNOT SWITCH BETWEEN FORWARD OR REVERSE...............................................366 E-2 TRAVEL SPEED IS SLOW,LACKS POWER WHEN TRAVELING UPHILL,ENGINE STALLS WHEN TRAVELING....368 H-1 CANNOT SWITCH BETWEEN FORWARD OR REVERSE...............................................370 H-2 TRAVEL SPEED IS SLOW,LACKS POWER WHEN TRAVELING UPHILL.................................372 H-3 WORK EQUIPMENT CONTROL LEVERS ARE HEAVY................................................374 H-4 WORK EQUIPMENT,SWING SUDDENLY MOVES....................................................374 H-5 SPEED OF ALL WORK EQUIPMENT,SWING IS EXTREMELY SLOW OR LACKS POWER.....................375 H-6 ENGINE STALLS DURING OPERATION,OR EXCESSIVE DROP IN ENGINE SPEED.......................377 H-7 ABNORMAL NOISE FROM AROUND PUMP........................................................379 H-8 SWING SPEED IS SLOW....................................................................380 H-9 EXCESSIVE HYDRAULIC DRIFT OF SWING.....................................................381 H-10 DOES NOT SWING........................................................................381 H-11 EXCESSIVE TIME LAG OF WORK EQUIPMENT..................................................382 63 DISASSEMBLY AND ASSEMBLY............................................................................383 CHARGING PUMP......................................................................................384 REMOVAL........................................................................................384 INSTALLATION...................................................................................386 MAIN PUMP..........................................................................................388 REMOVAL........................................................................................388 INSTALLATION...................................................................................388 MAIN PUMP INPUT SHAFT OIL SEAL.....................................................................390 REMOVAL........................................................................................390 INSTALLATION...................................................................................390 TVC VALVE (IF EQUIPPED)............................................................................392 REMOVAL........................................................................................392 INSTALLATION...................................................................................392 CO・NC VALVE (IF EQUIPPED)..........................................................................392 REMOVAL........................................................................................392 INSTALLATION...................................................................................392 SERVO VALVE (IF EQUIPPED)..........................................................................392 REMOVAL........................................................................................392 INSTALLATION...................................................................................392 L.H. 5-SPOOL CONTROL VALVE.........................................................................394 REMOVAL........................................................................................394 INSTALLATION...................................................................................396 R.H. 4-SPOOL CONTROL VALVE.........................................................................398 REMOVAL........................................................................................398 INSTALLATION...................................................................................400 CONTROL VALVE......................................................................................402 DISASSEMBLY....................................................................................402 ASSEMBLY.......................................................................................402 BOOM CYLINDER......................................................................................404 REMOVAL........................................................................................404 INSTALLATION...................................................................................404 ARM CYLINDER.......................................................................................404 REMOVAL........................................................................................404 INSTALLATION...................................................................................404 BUCKET CYLINDER....................................................................................406 REMOVAL........................................................................................406 INSTALLATION...................................................................................406 HYDRAULIC CYLINDER.................................................................................408 DISASSEMBLY....................................................................................408 ASSEMBLY.......................................................................................410 64 MAINTENANCE STANDARD................................................................................414 CHARGING PUMP......................................................................................415 L.H. 5-SPOOL CONTROL VALVE.........................................................................416 R.H. 4-SPOOL CONTROL VALVE.........................................................................418 HYDRAULIC CYLINDER.................................................................................420 70 WORK EQUIPMENT SYSTEM...................................................................................422 71 STRUCTURE AND FUNCTION..............................................................................422 WORK EQUIPMENT.....................................................................................423 1 .BOOM,ARM AND BUCKET.........................................................................423 2. OUTRIGGER (IF EQUIPMENT)....................................................................424 73 DISASSEMBLY AND ASSEMBLY............................................................................425 WORK EQUIPMENT.....................................................................................426 REMOVAL........................................................................................426 INSTALLATION...................................................................................426 DISASSEMBLY....................................................................................428 ASSEMBLY.......................................................................................432 OPERATOR'S CAB.....................................................................................436 REMOVAL........................................................................................436 INSTALLATION...................................................................................436 74 MAINTENANCE STANDARD................................................................................438 WORK EQUIPMENT ...................................................................................439 80 ELECTRIC AND ELECTRONIC SYSTEM..........................................................................443 81 STRUCTURE AND FUNCTION..............................................................................443 ELECTRICAL CIRCUIT DIAGRAM.........................................................................444
DESCRIPTION:
KOMATSU PW100-3 SERVICE REPAIR MANUAL (SN:1890 & UP) KOMATSU PW100-3
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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. - 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. - 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.
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.
