Komatsu JV100-2 Vibratory Smooth Drum Roller Shop Manual – SEBM011404

This Complete Service Repair Workshop Manual PDF Download for the Komatsu Vibratory Smooth Drum Roller JV100-2 has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu JV100A-2 Vibratory Smooth Drum Roller
Serial Numbers : 11001 and up

Komatsu JV100WA-2 Vibratory Smooth Drum Roller
Serial Numbers : 21001 and up

Komatsu JV100WP-2 Vibratory Smooth Drum Roller
Serial Numbers : 31001 and up

TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM011404
Total Pages : 293

This 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
ACCELERATOR CONTROL
WATER SEPARATOR
RADIATOR, OIL COOLER
POWER TRAIN
PTO
HYDRAULIC CIRCUIT DIAGRAM FOR HYDROSTANTIC TRANSMISSION (HST)
TRAVEL PUMP
FRONT WHEEL TRAVEL MOTOR
REAR WHEEL TRAVEL MOTOR
TRAVEL HI/LO SELECTOR
HI/LO SELECTOR SOLENOID VALVE (FOR FRONT WHEEL TRAVEL MOTOR)
NEUTRAL SELECTOR SOLENOID VALVE
TRAVEL MOTOR BYPASS VALVE
TRAVEL CONTROL
TRANSFER
DRIVE SHAFT
DIFFERENTIAL
FINAL DRIVE
STEERING PIPING
STEERING PUMP
STEERING VALVE (ORBIT-ROLL TYPE)
PARKING BRAKE
HYDRAULIC PIPING
HYDRAULIC CIRCUIT DIAGRAM
EXCITER CONTROL
HYDRAULIC CIRCUIT DIAGRAM FOR EXCITER SYSTEM
EXCITER PUMP
EXCITER MOTOR
EXCITER STOP SOLENOID VALVE
ROLLER
ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SENSOR
ENGINE START CIRCUIT
ENGINE STOP CIRCUIT
EXCITER SYSTEM ELECTRICAL CIRCUIT

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING EXHAUST COLOR
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING EXHAUST GAS TEMPERATURE
MEASURING ENGINE OIL PRESSURE
ADJUSTING ENGINE STOP SOLENOID
ADJUSTING FUEL CONTROL LINKAGE
MEASURING TRAVEL PUMP CHARGE PRESSURE
MEASURING TRAVEL OIL PRESSURE RELIEF PRESSURE
ADJUSTING TRAVEL CONTROL LINKAGE
TRAVEL, OPERATING EFFORT OF TRAVEL LEVER
TESTING STEERING OIL PRESSURE
ADJUSTING PARKING BRAKE LINKAGE
TESTING AND ADJUSTING PARKING BRAKE
REPLACING PARKING BRAKE PAD
ADJUSTING PARKING BRAKE CALIPER
ADJUSTING EXCITER CONTROL LINKAGE
TRAVEL, OPERATING EFFORT OF EXCITER LEVER
TESTING EXCITER OIL PRESSURE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR PIN ARRANGEMENT DIAGRAM
CONNECTOR TABLE FOR CONNECTOR PIN NUMBERS
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
E-1 ENGINE DOES NOT START
a) STARTING MOTOR DOES NOT TURN
b) ENGINE STOP SOLENOID DOES NOT WORK
E-2 ENGINE DOES NOT STOP
E-3 WHEN STARTING SWITCH IS TURNED TO HEAT, HEATER SIGNAL NOT LIGHT UP
E-4 ELECTRICAL COMPONENTS DO NOT WORK
E-5 HEAD LAMP DOES NOT LIGHT UP
E-6 MACHINE DOES NOT TRAVEL
E-7 TRAVEL SPEED DOES NOT CHANGE WHEN TRAVELING
E-8 EVEN WHEN EXCITER SWITCH IS TURNED ON THERE IS NO VIBRATION
E-9 EVEN WHEN EXCITER SWITCH IS TURNED OFF THERE IS VIBRATION
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)
H-1 THERE IS ABNORMAL NOISE
H-2 HYDRAULIC OIL TEMPERATURE IS HIGH
H-3 MACHINE DOES NOT TRAVEL OR TRAVELS SLOWLY
H-4 THERE IS EXCESSIVE TIME LAG WHEN ACCELERATING OR DECELERATING
H-5 TRAVEL LACKS POWER, GRADEABILITY IS LOW
H-6 SPEED RANGE DOES NOT SHIFT WHEN SHIFT LEVER IS OPERATED
H-7 MACHINE TRAVELS EVEN WHEN TRAVEL LEVER IS AT NEUTRAL
H-8 THERE IS NO EXCITATION
H-9 EXCITING FORCE DROPS DURING OPERATION
H-10 THERE IS EXCESSIVE TIME LAG WHEN STARTING OR STOPPING EXCITATION
H-11 EXCITATION CONTINUES EVEN WHEN EXCITER IS TURNED OFF
H-12 EXCITATION STOPS DURING OPERATION
H-13 MACHINE CANNOT BE STEERED
H-14 STEERING WHEEL IS HEAVY
H-15 STEERING SPEED IS SLOW

30 DISSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER CORE
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL AND INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR, OIL COOLER
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
PTO
DISASSEMBLY
ASSEMBLY
TRANSFER, TRAVEL MOTOR
REMOVAL
INSTALLATION
TRANSFER
DISASSEMBLY
ASSEMBLY
DIFFERENTIAL, FINAL DRIVE
REMOVAL
INSTALLATION
DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
DISASSEMBLY
ASSEMBLY
FLOOR FRAME
REMOVAL
INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
VIBRATORY ROLLER (JV100A)
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
VIBRATORY ROLLER (JV100WA,WP)
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
FRONT AXLE (JV100A)
DISASSEMBLY
ASSEMBLY
FRONT AXLE (JV100WA,WP)
DISASSEMBLY
ASSEMBLY

40 MAINTENANCE STANDARD
PTO
TRANSFER
DIFFERENTIAL
FINAL DRIVE
PARKING BRAKE CALIPER
STEERING CYLINDER
ROLLER
ANTI-VIBRATION RUBBER

90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (JV100A-2)
HYDRAULIC CIRCUIT DIAGRAM (JV100WA,WP-2)
ELECTRIC CIRCUIT DIAGRAM
CONNECTOR PIN ARRANGEMENT DIAGRAM

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