Komatsu PW100-3 Service Repair Manual SEBM020D0304 PDF Download

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Komatsu PW100-3 Wheeled Excavator Shop Manual SEBM020D0304 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PW100-3 Wheeled Excavator Shop Manual SEBM020D0304 – PDF DOWNLOAD

Language : English
Pages : 447
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PW100-3 Wheeled Excavator Shop Manual SEBM020D0304 – PDF DOWNLOAD

MACHINE MODEL   Serial Number
PW100-3                     1890 And Up

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 Wheeled Excavator Shop Manual SEBM020D0304 – PDF DOWNLOAD

MACHINE MODEL   Serial Number
PW100-3                     1890 And Up

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
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.

G.B  14/12/24