Komatsu PW150-1 Hydraulic Excavator Service Repair Shop Manual (1001 and up) - SEBM020E0104

This Complete Service Repair Workshop Manual PDF Download for the PW150-1 Komatsu Hydraulic Excavator (S/N: 1001 and up) 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 PW150-1 - S/N: 1001 and up


TABLE OF CONTENTS :

01 GENERAL
10 ENGINE
20 POWER TRAIN
40 STEERING SYSTEM
50 AIR SYSTEM
60 HYDRAULIC SYSTEM
70 WORK EQUIPMENT
80 ELECTRIC AND ELECTRONIC SYSTEM
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM020E0104
Total Pages : 516


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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CONTENTS

01 GENERAL
GENERAL VIEW
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
ENGINE ASSEMBLY DRAWING
ENGINE SPECIFICATIONS
WEIGHT TABLE
TABLE OF OIL AND COOLANT CAPACITIES

10 ENGINE
11 STRUCTURE AND FUNCTION
ENGINE MOUNT
RADIATOR AND HYDRAULIC OIL COOLER
PTO (POWER TAKE-OFF)
FUEL TANK AND PIPING
ENGINE CONTROL
12 TESTING AND ADJUSTING
STANDARDS FOR TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING BLOW-BY
MEASURING COMPRESSION PRESSURE
LUBRICATION SYSTEM
MEASURING EXHAUST GAS COLOR
MEASURING COOLANT TEMPERATURE
13 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR
DISMOUNTING
MOUNTING
ALTERNATOR
DISMOUNTING
MOUNTING
ENGINE OIL COOLER
DISMOUNTING
MOUNTING
NOZZLE HOLDER
DISMOUNTING
MOUNTING
FUEL INJECTION PUMP
DISMOUNTING
MOUNTING
AIR COMPRESSOR
DISMOUNTING
MOUNTING
WATER PUMP
DISMOUNTING
MOUNTING
CYLINDER HEAD
DISMOUNTING
MOUNTING
RADIATOR AND HYDRAULIC OIL COOLER
DISMOUNTING
MOUNTING
ENGINE
DISMOUNTING
MOUNTING
PTO
DISMOUNTING
MOUNTING

20 POWER TRAIN
21 STRUCTURE AND FUNCTION
POWER TRAIN
1. OUTLINE
2. SCHEMATIC OF POWER TRAIN
3. HYDRAULIC CIRCUIT DIAGRAM
TRAVEL SYSTEM
1. OUTLINE
2. SCHEMATIC OF TRAVEL SYSTEM
3. HYDRAULIC CIRCUIT DIAGRAM
4. CENTER SWIVEL JOINT
5. TRAVEL MOTOR AND BRAKE VALVE
6. TRAVEL SHUTTLE VALVE
7. TRAVEL SUCTION VALVE
8. TRANSMISSION
9. TRAVEL CONTROL SYSTEM
SWING SYSTEM
1. OUTLINE
2. SCHEMATIC OF SWING SYSTEM
3. HYDRAULIC CIRCUIT DIAGRAM
4. SWING MOTOR AND BRAKE VALVE
5. SWING MACHINERY
6. SWING CIRCLE
23 DISASSEMBLY AND ASSEMBLY
CENTER SWIVEL JOINT
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
TRAVEL MOTOR
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
TRAVEL BRAKE VALVE
DISMOUNTING
MOUNTING
TRANSMISSION
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
SWING MOTOR AND BRAKE VALVE
DISMOUNTING
MOUNTING
SWING MACHINERY
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
SWING CIRCLE
DISMOUNTING
MOUNTING
24 MAINTENANCE STANDARD
CENTER SWIVEL JOINT
TRAVEL BRAKE VALVE
TRAVEL SHUTTLE VALVE
TRAVEL SUCTION VALVE
TRANSMISSION
SWING MACHINERY
SWING CIRCLE

40 STEERING SYSTEM
41 STRUCTURE AND FUNCTION
STEERING SYSTEM
1. OUTLINE
2. SCHEMATIC OF STEERING SYSTEM
3. HYDRAULIC CIRCUIT DIAGRAM
4. STEERING PUMP
5. STEERING MAIN RELIEF VALVE
6. STEERING VALVE
7. STEERING CYLINDER
8. AXLE
9. DRIVE SHAFT
10.WHEEL
BRAKE SYSTEM
1. OUTLINE
2. SCHEMATIC OF BRAKE SYSTEM
3. PNEUMATIC CIRCUIT DIAGRAM
4. BRAKE VALVE
5. SHUTTLE VALVE (DOUBLE CHECK VALVE)
6. AIR MASTER
7. WHEEL BRAKE
8. PARKING BRAKE
9. PARKING BRAKE CHAMBER
10. 2-WAY CONTROL VALVE
11. QUICK-RELEASE VALVE
SUSPENSION SYSTEM
1. OUTLINE
2. SCHEMATIC OF SUSPENSION SYSTEM
3. HYDRAULIC AND PNEUMATIC CIRCUIT DIAGRAM
4. SUSPENSION LOCK VALVE
5. SUSPENSION LOCK CYLINDER
42 TESTING AND ADJUSTING
TESTING AND ADJUSTING TOE-IN
ADJUSTING MAXIMUM TURNING ANGLE OF FRONT WHEELS
ADJUSTING PARKING BRAKE
ADJUSTING PARKING BRAKE ROD
BLEEDING AIR FROM BRAKE CIRCUIT
43 DISASSEMBLY AND ASSEMBLY
STEERING PUMP
DISMOUNTING
MOUNTING
STEERING MAIN RELIEF VALVE
DISASSEMBLY
ASSEMBLY
STEERING CYLINDER
DISMOUNTING
MOUNTING
REAR AXLE
DISMOUNTING
MOUNTING
FRONT AXLE
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
DIFFERENTIAL (FRONT)
DISMOUNTING
MOUNTING
DIFFERENTIAL (REAR)
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
AIR MASTER ASSEMBLY
DISMOUNTING
MOUNTING
DISC PLATE (REAR)
DISMOUNTING
MOUNTING
REAR CALIPER
DISMOUNTING
MOUNTING
FRONT CALIPER
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
PARKING BRAKE
DISMOUNTING
MOUNTING
SUSPENSION LOCK VALVE
DISMOUNTING
MOUNTING
SUSPENSION LOCK CYLINDER
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
44 MAINTENANCE STANDARD
STEERING PUMP
STEERING CYLINDER
FINAL DRIVE AND DIFFERENTIAL
KING PIN AND KNUCKLE AND TIE-ROD
WHEEL BRAKE
PARKING BRAKE
SUSPENSION LOCK CYLINDER

50 AIR SYSTEM
51 STRUCTURE AND FUNCTION
AIR SYSTEM
1. OUTLINE
2. SCHEMATIC OF AIR SYSTEM
3. PNEUMATIC CIRCUIT DIAGRAM
4. AIR GOVERNOR
5. PARKING LAMP SWITCH
6. LOW PRESSURE INDICATOR SWITCH
7. PRESSURE REGULATOR VALVE
8. STOP LAMP SWITCH

60 HYDRAULIC SYSTEM
61 STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
1. OUTLINE
2. SCHEMATIC OF HYDRAULIC SYSTEM
3. HYDRAULIC CIRCUIT DIAGRAM
4. HYDRAULIC TANK AND FUEL TANK
5. HYDRAULIC PUMP
6. CONTROL VALVE
WORK EQUIPMENT HYDRAULIC SYSTEM
BOOM, ARM AND BUCKET
1. OUTLINE
2. SCHEMATIC OF WORK EQUIPMENT SYSTEM
3. HYDRAULIC CIRCUIT DIAGRAM
4. SLOW RETURN VALVE
5. HYDRAULIC CYLINDER
OUTRIGGER
1. OUTLINE
2. SCHEMATIC OF OUTRIGGER SYSTEM
3. HYDRAULIC CIRCUIT DIAGRAM
4. DOUBLE CHECK VALVE
5. HYDRAULIC CYLINDER
LEFT AND RIGHT INDEPENDENT OUTRIGGERS
1. OUTLINE
2. SCHEMATIC OF LEFT AND RIGHT INDEPENDENT OUTRIGGERS
3. HYDRAULIC AND AIR CIRCUIT DIAGRAM
4. AIR DIRECTION SELECTOR VALVE
5. HYDRAULIC DIRECTION SELECTOR VALVE
FRONT OUTRIGGER AND REAR EQUIPMENT
1. OUTLINE
2. SCHEMATIC OF FRONT OUTRIGGER AND REAR EQUIPMENT
3. HYDRAULIC AND AIR CIRCUIT DIAGRAM
4. AIR DIRECTION SELECTOR VALVE
5. HYDRAULIC DIRECTION SELECTOR VALVE
DOZER BLADE (IF EQUIPPED)
1. OUTLINE
2. SCHEMATIC OF DOZER BLADE
3. HYDRAULIC CIRCUIT DIAGRAM
4. HYDRAULIC CYLINDER
PPC CONTROL SYSTEM
1. OUTLINE
2. SCHEMATIC OF PPC CONTROL SYSTEM
3. PPC VALVE
4. R.H. PPC SHUTTLE VALVE
5. SOLENOID VALVE
62 TESTING AND ADJUSTING
STANDARD FOR TESTING AND ADJUSTING
TESTING TRAVEL OF CONTROL LEVERS
TESTING OPERATING FORCE OF CONTROL LEVERS
MEASURING OIL TEMPERATURE
MEASURING LEAKAGE OF SWING AND TRAVEL MOTOR
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT
BLEEDING AIR
MEASURING PLACE OF OIL PRESSURE
ADJUSTING PLACE OF HYDRAULIC PRESSURE
TESTING AND ADJUSTING MAIN RELIEF VALVE
CHECKING HYDRAULIC ASSIST SYSTEM
TROUBLESHOOTING
1. FORWARD-REVERSE SELECTOR IS INOPERATED
2. WORK EQUIPMENT SPEED IS SLOW, OR THERE IS NO POWER
3. MACHINE SPEED IS SLOW
4. SWING SPEED IS SLOW
5. ENGINE STALLS OR SPEED DROPS EXCESSIVELY DURING OPERATIONS
6. UPPER STRUCTURE DOES NOT SWING
63 DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
DISMOUNTING
MOUNTING
SERVO VALVE
DISMOUNTING
MOUNTING
L .H . 7-SPOOL CONTROL VALVE
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
R .H . 5-SPOOL CONTROL VALVE
DISMOUNTING
MOUNTING
SAFETY VALVE AND SUCTION VALVE
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
DISASSEMBLY
ASSEMBLY
SLOW RETURN VALVE
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
BOOM CYLINDER
DISMOUNTING
MOUNTING
ARM CYLINDER
DISMOUNTING
MOUNTING
BUCKET CYLINDER
DISMOUNTING
MOUNTING
OUTRIGGER CYLINDER
DISMOUNTING
MOUNTING
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
HYDRAULIC CYLINDER PISTON RING AND WEAR RING
DISMOUNTING
MOUNTING
64 MAINTENANCE STANDARD
L .H . 7-SPOOL CONTROL VALVE
R .H . 5-SPOOL CONTROL VALVE
CONTROL PUMP
SLOW RETURN VALVE
HYDRAULIC CYLINDER

70 WORK EQUIPMENT
71 STRUCTURE AND FUNCTION
WORK EQUIPMENT
1. BOOM, ARM AND BUCKET
2. REAR OUTRIGGER
3. FRONT OUTRIGGER (IF EQUIPPED)
4. DOZER BLADE IF (IF EQUIPPED)
73 DISASSEMBLY AND ASSEMBLY
OPERATOR'S CAB
DISMOUNTING
MOUNTING
WORK EQUIPMENT
DISMOUNTING
MOUNTING
DISASSEMBLY
ASSEMBLY
74 MAINTENANCE STANDARD
WORK EQUIPMENT

80 ELECTRIC AND ELECTRONIC SYSTEM
81 STRUCTURE AND FUNCTION
ELECTRIC AND ELECTRONIC SYSTEM
1. OUTLINE
2. ELECTRIC CIRCUIT DIAGRAM

90 OTHERS
91 OTHERS
OPERATOR'S CAB HEATER
OVERLOAD WARNING DEVICE (IF EQUIPPED)

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