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Komatsu PW100-3 Shop Manual SEBM020D0304 – PDF DOWNLOAD
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Komatsu PW100-3 Shop Manual SEBM020D0304 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
PW100-3 1890 and up
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Description
Komatsu PW100-3 Shop Manual SEBM020D0304 – PDF DOWNLOAD
FILE DETAILS:
Komatsu PW100-3 Shop Manual SEBM020D0304 – PDF DOWNLOAD
Language : English
Pages :447
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu PW100-3 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.
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.
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.
DISASSEMBL V AND ASSEMBLV
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.
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.
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PW100-3 Shop Manual SEBM020D0304 – PDF DOWNLOAD
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 LEVER100
8 FORWARD-REVERSE SELECTOR SOLENOID VALVE101
9 TRANSMISSION SELECTOR VALVE102
10 TRAVLE PPC VALVE105
SWING SYSTEM106
1 OUTLINE106
2 SCHEMATIC OF TRAVEL SYSTEM107
3 HYDRAULIC CIRCUIT DIAGRAM108
4 SWING MOTOR AND BRAKE VALVE109
5 SWING MACHINERY115
6 SWING CIRCLE117
23 DISASSEMBLY AND ASSEMBLY118
CENTER SWIVEL JOINT119
REMOVAL119
INSTALLATION119
DISASSEMBLY121
ASSEMBLY121
SWING CIRCLE123
REMOVAL123
INSTALLATION125
SWING MACHINERY129
REMOVAL129
INSTALLATION129
DISASSEMBLY129
ASSEMBLY133
TRANSMISSION137
REMOVAL137
INSTALLATION137
DISASSEMBLY139
ASSEMBLY145
SWING MOTOR151
REMOVAL151
INSTALLATION151
TRAVEL MOTOR151
REMOVAL151
INSTALLATION151
TRAVEL BRAKE VALVE153
REMOVAL153
INSTALLATION153
24 MAINTENANCE STANDARD155
TRAVEL BRAKE VALVE156
TRAVEL SUCTION VALVE157
TRANSMISSION158
SWING MACHINERY159
SWING CIRCLE160
40 STEERING SYSTEM161
41 STRUCTURE AND FUNCTION161
STEERING SYSTEM162
1 OUTLINE162
2 SCHEMATIC OF STEERING SYSTEM163
3 HYDRAULIC CIRCUIT DIAGRAM164
4 STEERING PUMP165
5 STEERING VALVE AND MAIN RELIEF VALVE166
6 STEERING CYLINDER176
7 AXLE177
8 DRIVE SHAFT184
9 WHEEL185
BRAKE SYSTEM186
1 OUTLINE186
2 SCHEMATIC OF BRAKE SYSTEM187
3 PNEUMATIC CIRCUIT DIAGRAM188
4 BRAKE VALVE189
5 SHUTTLE VALVE (DOUBLE CHECK VALVE)191
6 AIR MASTER192
7 WHEEL BRAKE194
8 PARKING BRAKE196
9 PARKING BRAKE CHAMBER198
10 2-WAY CONTROL VALVE200
11 QUICK-RELEASE VALVE202
SUSPENSION SYSTEM203
1 OUTLINE203
2 SCHEMATIC OF SUSPENSION SYSTEM204
3 HYDRAULIC AND PNEUMATIC CIRCUIT DIAGRAM205
4 SUSPENSION LOCK VALVE206
5 SUSPENSION LOCK CYLINDER208
42 TESTING AND ADJUSTING209
TESTING AND ADJUSTING TOE-IN210
ADJUSTING MAXIMUM STEERING ANGLE OF FRONT AXLE211
ADJUSTING PARKING BRAKE212
ADJUSTING PARKING BRAKE ROD213
BLEEDING AIR FROM BRAKE CIRCUIT214
43 DISASSEMBLY AND ASSEMBLY215
STEERING CYLINDER216
REMOVAL216
INSTALLATION216
STEERING PUMP216
REMOVAL216
INSTALLATION216
FRONT AXLE218
REMOVAL218
INSTALLATION218
REAR AXLE220
REMOVAL220
INSTALLATION220
FINAL DRIVE222
REMOVAL222
INSTALLATION226
FRONT DIFFERENTIAL230
REMOVAL230
INSTALLATION230
REAR DIFFERENTIAL232
REMOVAL232
INSTALLATION232
DIFFERENTIAL234
DISASSEMBLY234
ASSEMBLY236
AIR MASTER241
REMOVAL241
INSTALLATION241
DISC PLATE243
REMOVAL243
INSTALLATION247
FRONT CALIPER251
REMOVAL251
INSTALLATION251
REAR CALIPER251
REMOVAL251
INSTALLATION251
CALIPER253
DISASSEMBLY253
ASSEMBLY253
PARKING BRAKE255
REMOVAL255
INSTALLATION255
SUSPENSION LOCK VALVE255
REMOVAL255
INSTALLATION255
SUSPENSION LOCK CYLINDER257
REMOVAL257
INSTALLATION257
DISASSEMBLY257
ASSEMBLY257
44 MAINTENANCE STANDARD259
STEERING GEAR PUMP260
STEERING CYLINDER261
DIFFERENTIAL262
FINAL DRIVE263
KING PIN,KNUCKLE AND TIE-ROD264
WHEEL BRAKE266
PARKING BRAKE267
SUSPENSION LOCK CYLINDER268
50 AIR SYSTEM269
51 STRUCTURE AND FUNCTION269
AIR SYSTEM270
1 OUTLINE270
2 SCHEMATIC OF AIR SYSTEM274
3 PNEUMATIC CIRCUIT DIAGRAM275
4 AIR GOVERNOR276
5 PARKING LAMP SWITCH278
6 LOW PRESSURE INDICATOR SWITCH279
7 STOP LAMP SWITCH280
60 HYDRAULIC SYSTEM281
61 STRUCTURE AND FUNCTION281
OUTLINE282
1 HYDRAULIC PIPING283
2 HYDRAULIC CIRCUIT SCHEMATIC285
3 HYDRAULIC CIRCUIT DIAGRAM289
HYDRAULIC TANK (WITH FUEL TANK)291
HYDRAULIC PUMP292
PC CONTROL SYSTEM302
OLSS (OPEN CENTER LOAD SENSING SYSTEM) (IF EQUIPPED)306
1 OUTLINE306
2 OLSS BASIC CIRCUIT308
3 SCHEMATIC OLSS309
4 SERVO VALVE,TVC VALVE,CO VALVE AND NC VALVE310
5 FUNCTION OF OLSS319
CONTROL VALVE328
1 LH 5-SPOOL CONTROL VALVE328
2 RH 4-SPOOL CONTROL VALVE330
HYDRAULIC CYLINDER338
WORK EQUIPMENT CONTROL343
1 OUTLINE343
2 BOOM CONTROL344
3 ARM CONTROL (ARM IN)346
4 BUCKET CONTROL348
62 TESTING AND ADJUSTING350
TOOLS FOR TESTING AND ADJUSTING351
TESTING AND ADJUSTING MAIN RELIEF PRESSURE352
TESTING AND ADJUSTING CHARGING CIRCUIT PRESSURE354
BLEEDING AIR355
TROUBLESHOOTING356
ELECTRICAL CIRCUIT DIAGRAM357
POSITION OF CONNECTOR358
CONNECTION TABLE FOR CONNECTOR PINS359
CHECKS BEFORE TROUBLESHOOTING361
TROUBLESHOOTING CHART366
E-1 CANNOT SWITCH BETWEEN FORWARD OR REVERSE366
E-2 TRAVEL SPEED IS SLOW,LACKS POWER WHEN TRAVELING UPHILL,ENGINE STALLS WHEN TRAVELING368
H-1 CANNOT SWITCH BETWEEN FORWARD OR REVERSE370
H-2 TRAVEL SPEED IS SLOW,LACKS POWER WHEN TRAVELING UPHILL372
H-3 WORK EQUIPMENT CONTROL LEVERS ARE HEAVY374
H-4 WORK EQUIPMENT,SWING SUDDENLY MOVES374
H-5 SPEED OF ALL WORK EQUIPMENT,SWING IS EXTREMELY SLOW OR LACKS POWER375
H-6 ENGINE STALLS DURING OPERATION,OR EXCESSIVE DROP IN ENGINE SPEED377
H-7 ABNORMAL NOISE FROM AROUND PUMP379
H-8 SWING SPEED IS SLOW380
H-9 EXCESSIVE HYDRAULIC DRIFT OF SWING381
H-10 DOES NOT SWING381
H-11 EXCESSIVE TIME LAG OF WORK EQUIPMENT382
63 DISASSEMBLY AND ASSEMBLY383
CHARGING PUMP384
REMOVAL384
INSTALLATION386
MAIN PUMP388
REMOVAL388
INSTALLATION388
MAIN PUMP INPUT SHAFT OIL SEAL390
REMOVAL390
INSTALLATION390
TVC VALVE (IF EQUIPPED)392
REMOVAL392
INSTALLATION392
CO・NC VALVE (IF EQUIPPED)392
REMOVAL392
INSTALLATION392
SERVO VALVE (IF EQUIPPED)392
REMOVAL392
INSTALLATION392
LH 5-SPOOL CONTROL VALVE394
REMOVAL394
INSTALLATION396
RH 4-SPOOL CONTROL VALVE398
REMOVAL398
INSTALLATION400
CONTROL VALVE402
DISASSEMBLY402
ASSEMBLY402
BOOM CYLINDER404
REMOVAL404
INSTALLATION404
ARM CYLINDER404
REMOVAL404
INSTALLATION404
BUCKET CYLINDER406
REMOVAL406
INSTALLATION406
HYDRAULIC CYLINDER408
DISASSEMBLY408
ASSEMBLY410
64 MAINTENANCE STANDARD414
CHARGING PUMP415
LH 5-SPOOL CONTROL VALVE416
RH 4-SPOOL CONTROL VALVE418
HYDRAULIC CYLINDER420
70 WORK EQUIPMENT SYSTEM422
71 STRUCTURE AND FUNCTION422
WORK EQUIPMENT423
1 BOOM,ARM AND BUCKET423
2 OUTRIGGER (IF EQUIPMENT)424
73 DISASSEMBLY AND ASSEMBLY425
WORK EQUIPMENT426
REMOVAL426
INSTALLATION426
DISASSEMBLY428
ASSEMBLY432
OPERATOR’S CAB436
REMOVAL436
INSTALLATION436
74 MAINTENANCE STANDARD438
WORK EQUIPMENT 439
80 ELECTRIC AND ELECTRONIC SYSTEM443
81 STRUCTURE AND FUNCTION443
ELECTRICAL CIRCUIT DIAGRAM444
IMAGES PREVIEW OF THE MANUAL:
S.M 13/12/24
