Komatsu Hydraulic Excavator PW100-3 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PW100-3, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PW100-3 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 447 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM020D0304 - Hydraulic Excavator PW100-3 Shop Manual.pdf
MAIN SECTIONS
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
CONC 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
