Komatsu Avance Plus WA120-3MC Wheel Loader Shop Manual CEBM005101 – PDF DOWNLOAD

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Komatsu Avance Plus WA120-3MC Wheel Loader Shop Manual CEBM005101 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Avance Plus WA120-3MC Wheel Loader Shop Manual CEBM005101 – PDF DOWNLOAD

Language : English
Pages : 737
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Avance Plus WA120-3MC Wheel Loader Shop Manual CEBM005101 – PDF DOWNLOAD

• SERIAL NUMBERS
• WA120-3MC – A31001 and UP

MAIN MENU 0
COVER 1
CONTENTS 2
FOREWORD 11
SAFETY 11
SAFETY NOTICE 11
IMPORTANT SAFETY NOTICE 11
GENERAL PRECAUTIONS 11
PREPARATIONS FOR WORK 11
PRECAUTIONS DURING WORK 11
GENERAL 13
HOW TO READ THE SHOP MANUAL 14
VOLUMES 14
DISTRIBUTION AND UPDATING 14
FILING METHOD 14
REVISED EDITION MARK 14
REVISIONS 14
SYMBOLS 14
HOISTING INSTRUCTIONS 15
HOISTING 15
WIRE ROPES 15
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 18
TIGHTENING TORQUE OF HOSE NUTS 19
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 19
TIGHTENING TORQUE FOR FLARED NUTS 19
ELECTRIC WIRE CODE 20
CLASSIFICATION BY THICKNESS 20
CLASSIFICATION BY COLOR AND CODE 20
CONVERSION TABLES 21
METHOD OF USING THE CONVERSION TABLE 21
01 GENERAL 27
SPECIFICATION DRAWING 28
SPECIFICATIONS 29
WEIGHT TABLE 32
LIST OF LUBRICANT AND WATER 34
ENGINE OIL SPECIFICATIONS 35
NORMAL OPERATION 35
ARCTIC OPERATION 35
DIESEL FUEL SPECIFICATIONS 36
COOLANT SPECIFICATIONS 36
GENERAL 36
WATER 36
ANTIFREEZE 37
INHIBITORS/CONDITIONERS 39
10 STRUCTURE AND FUNCTION 43
POWER TRAIN 47
POWER TRAIN SYSTEM 48
TORQUE CONVERTER, TRANSMISSION PIPING 50
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 52
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND 52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 53
ENGINE STOPPED 53
TORQUE CONVERTER 54
TORQUE CONVERTER OIL FILTER 56
TRANSMISSION 58
CLUTCH 60
REVERSE 1ST CLUTCH 60
FORWARD, 2ND CLUTCH 61
3RD, 4TH CLUTCH 61
FORWARD 1ST 63
FORWARD 2ND 64
FORWARD 3RD 65
FORWARD 4TH 66
REVERSE 1ST 67
TRANSMISSION CONTROL VALVE 68
UPPER VALVE 69
LOWER VALVE 70
TRANSMISSION SOLENOID VALVE 71
TORQUE CONVERTER OUTLET PORT VALVE 72
PILOT REDUCING VALVE 73
TRANSMISSION SOLENOID VALVE 74
PRIORITY VALVE 75
MAIN REGULATOR VALVE 76
QUICK RETURN VALVE 77
MODULATION FILL VALVE 81
DIRECTIONAL SELECTOR SPOOL 83
EMERGENCY MANUAL SPOOL 84
OPERATION OF FORWARD 1ST 86
ACCUMULATOR VALVE 88
TRANSMISSION CONTROL 90
DRIVE SHAFT 91
AXLE 92
FRONT AXLE 92
FRONT DIFFERENTIAL 93
REAR AXLE 94
REAR DIFFERENTIAL 95
TORQUE PROPORTIONING DIFFERENTIAL 97
FINAL DRIVE 98
AXLE MOUNT 100
CENTER HINGE PIN 102
STEERING PIPING 103
STEERING COLUMN 104
PRIORITY VALVE 105
STEERING VALVE (ORBIT-ROLL) 108
CONNECTION BETWEEN HAND PUMP AND SLEEVE 114
BRAKE 116
BRAKE PIPING 116
BRAKE CONTROL 117
BRAKE BOOSTER 118
BRAKE 121
PARKING BRAKE CONTROL 123
PARKING BRAKE 124
HYDRAULIC 126
HYDRAULIC PIPING 126
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 128
ENGINE LOW IDLING, WORK EQUIPMENT IN “HOLD” 128
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 129
HYDRAULIC TANK 131
OIL FILTER BYPASS VALVE 132
BREATHER 133
PPC VALVE 134
PPC RELIEF VALVE 140
ACCUMULATOR 141
FOR PPC VALVE 141
MAIN CONTROL VALVE 142
2-SPOOL 142
3-SPOOL 144
RELIEF VALVE 146
SAFETY VALVE (WITH SUCTION) 147
SUCTION VALVE 148
BOOM AND BUCKET SPOOL AT NEUTRAL POSITION 149
BOOM SPOOL AT RAISE POSITION 150
BOOM SPOOL AT LOWER POSITION 151
BOOM SPOOL AT FLOAT POSITION 152
BUCKET SPOOL AT TILT BACK POSITION 153
BUCKET SPOOL AT DUMP POSITION 154
WORK EQUIPMENT 155
WORK EQUIPMENT LEVER LINKAGE 155
WORK EQUIPMENT LINKAGE 156
BUCKET 158
BUCKET POSITIONER AND BOOM KICK-OUT 159
BUCKET POSITIONER 160
BOOM KICK-OUT 160
PROXIMITY SWITCH 161
ROPS CAB 163
AIR CONDITIONER 164
AIR CONDITIONER AND HEATER PIPING 164
AIR CONDITIONER AND HEATER ELECTRICAL DIAGRAM 164
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) 165
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM 166
CENTRAL PANEL 168
SENSORS 169
ENGINE OIL PRESSURE 169
BRAKE OIL LEVEL 169
ENGINE SPEED SENSOR 170
ENGINE 171
ENGINE STARTING CIRCUIT 171
ENGINE STOP CIRCUIT 172
AUTOMATIC PREHEATING CIRCUIT 173
QUICK HEATING SYSTEM (QHS) 173
QHS CONTROLLER 175
HEATER RELAY 175
RIBBON HEATER 176
QHS WATER TEMPERATURE SENSOR 176
TRANSMISSION AUTO-SHIFT CONTROL 177
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 178
SHIFT CONTROL SYSTEM FUNCTION 179
INPUT SIGNALS 179
OUTPUT SIGNALS 180
SHIFT CHARACTERISTICS 181
SAFETY FUNCTION 185
TROUBLESHOOTING 185
TRANSMISSION CONTROLLER 186
CONNECTOR SIGNALS 186
COMBINATION SWITCH 187
TRANSMISSION CUT-OFF FUNCTION 188
PARKING BRAKE FUNCTION 190
KICK-DOWN SWITCH 191
KICK-DOWN ELECTRICAL CIRCUIT 192
KICK-DOWN SWITCH OPERATED 193
KICK-DOWN SWITCH ACTUATION – CANCELED (1) 194
KICK-DOWN SWITCH ACTUATION – CANCELED (2) 195
ELECTRICAL WIRING ILLUSTRATION 197
ELECTRICAL WIRING DIAGRAM (1/4) 199
ELECTRICAL WIRING DIAGRAM (2/4) 201
ELECTRICAL WIRING DIAGRAM (3/4) 203
ELECTRICAL WIRING DIAGRAM (4/4) 205
20 TESTING, ADJUSTING AND TROUBLESHOOTING 207
STANDARD VALUE TABLE 211
ENGINE TABLE – IN CHASSIS 211
CHASSIS TABLE 212
SERVICE TOOLS TABLE 218
ENGINE COMPONENTS 220
ADJUSTING ENGINE STOP MOTOR CABLE 220
ADJUSTING ENGINE STOP SOLENOID 220
MEASURING AND ADJUSTING VALVE CLEARANCE 220
MEASURING BLOW-BY PRESSURE 220
MEASURING COMPRESSION PRESSURE 220
MEASURING COOLANT TEMPERATURE 220
MEASURING ENGINE LUBRICATING OIL PRESSURE 220
MEASURING ENGINE SPEEDS 220
MEASURING EXHAUST COLOR 220
MEASURING EXHAUST GAS TEMPERATURE 220
MEASURING FUEL FILTER INLET RESTRICTION 220
TEST AND ADJUSTING FAN BELT TENSION 220
TEST AND ADJUSTING FUEL INJECTION TIMING 220
ACCELERATOR PEDAL 221
OPERATING FORCE 221
OPERATING ANGLE 222
SPEED LEVER 223
OPERATING FORCE 223
TRAVEL 223
STALL SPEEDS 224
TORQUE CONVERTER STALL SPEED 224
HYDRAULIC STALL SPEED 225
FULL STALL SPEED 225
TORQUE CONVERTER OIL PRESSURE 226
TRANSMISSION OIL PRESSURE 226
EMERGENCY MANUAL SPOOL 228
OPERATION 228
STEERING WHEEL 230
PLAY 230
OPERATING FORCE 230
OPERATING TIME 231
STEERING OIL PRESSURE 232
METHOD OF MEASURING MAIN RELIEF PRESSURE 232
METHOD OF ADJUSTING MAIN RELIEF PRESSURE 233
BRAKE 234
BRAKE PEDAL 234
OPERATING FORCE 234
TRAVEL 234
BRAKE PEDAL LINKAGE 235
TESTING 235
ADJUSTING 235
BRAKE PERFORMANCE 237
BRAKE OIL PRESSURE 238
BRAKE DISC WEAR 239
BLEEDING AIR 240
PARKING BRAKE 241
PARKING BRAKE PERFORMANCE 241
PARKING BRAKE LINKAGE 242
DISC WEAR 243
TESTING 243
MEASURING 244
WORK EQUIPMENT 245
CONTROL LEVER 245
PPC VALVE 246
MEASURING PRESSURE 246
WORK EQUIPMENT HYDRAULIC PRESSURE 248
WORK EQUIPMENT MEASUREMENT 250
HYDRAULIC DRIFT WORK EQUIPMENT 251
BUCKET POSITIONER 252
TESTING 252
ADJUSTING 252
BOOM KICK-OUT 253
TESTING 253
ADJUSTING 253
PROXIMITY SWITCH ACTUATION PILOt LAMP (RED) 254
TROUBLESHOOTING GENERAL 255
POINTS TO REMEMBER WHEN TROUBLESHOOTING 257
SEQUENCE OF EVENTS IN TROUBLESHOOTING 259
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 260
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 260
HANDLING CONTROL BOX 265
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 266
CHECKS BEFORE TROUBLESHOOTING 268
JUDGEMENT OF POWER TRAIN 269
PRECAUTIONS WHEN TROUBLESHOOTING 270
SAFETY 270
METHODS FOR TROUBLESHOOTING 270
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 272
PREVENTING RECURRENCE OF TROUBLE 273
HYDRAULIC EQUIPMENT 273
OIL CHECKS 273
CLEANING FRAGMENTS OF DAMAGED PARTS 273
METHOD OF USING TROUBLESHOOTING CHARTS 274
CATEGORY OF TROUBLESHOOTING CODE NUMBER 274
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 274
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 276
METHOD OF USING ENGINE RELATED CHARTS 278
TROUBLESHOOTING ELECTRICAL CONNECTORS 283
CONNECTOR TYPES 284
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 287
ELECTRICAL CIRCUIT DIAGRAMS 295
ENGINE START, STOP SYSTEM 295
PREHEATING SYSTEM 296
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE) 297
OUTLINE 298
FUNCTION 298
TROUBLESHOOTING 298
FAILURE CODE TABLE 298
TABLE OF TROUBLESHOOTING MODES AND CAUSES 299
A-1 TROUBLESHOOTING CODE [12] 300
F SOLENOID SIGNAL SYSTEM 300
A-2 TROUBLESHOOTING CODE [13] 301
R SOLENOID SIGNAL SYSTEM 301
A-3 TROUBLESHOOTING CODE [14] 302
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 302
A-4 TROUBLESHOOTING CODE [16] 303
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 303
A-5 TROUBLESHOOTING CODE [20] 304
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 304
A-6 TROUBLESHOOTING CODE [21] 305
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM 305
A-7 TROUBLESHOOTING CODE [22] 306
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 306
A-8 TROUBLESHOOTING CODE [23] 307
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM 307
A-10 KICK-DOWN SWITCH SYSTEM 308
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM 309
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM 310
A-13 BUZZER SIGNAL SYSTEM 311
A-15 CONTROLLER POWER SOURCE SYSTEM 312
TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM D-MODE – (ECSS) 313
ECSS – ELECTRICAL / HYDRAULIC SCHEMATIC 314
ECSS – WORKING CHART 314
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 315
INSPECTION / ADJUSTMENT 315
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 317
E-1 ENGINE DOES NOT START 318
A STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START 318
B CHECK FUEL SHUT-OFF SOLENOID 320
E-2 ENGINE DOES NOT STOP 321
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR 322
E-10 PREHEATING IS NOT CARRIED OUT 324
E-11 PREHEATING REMAINS ACTUATED 326
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 329
S-1 STARTING PERFORMANCE IS POOR 331
S-2 ENGINE DOES NOT START 332
A ENGINE DOES NOT TURN 332
B ENGINE TURNS BUT NO EXHAUST GAS COMES OUT 333
C EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START 334
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 335
S-4 ENGINE STOPS DURING OPERATIONS 336
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 337
S-6 ENGINE LACKS OUTPUT (NO POWER) 338
S-7 EXHAUST GAS IS BLACK 339
S-8 OIL CONSUMPTION IS EXCESSIVE 340
S-9 OIL BECOMES CONTAMINATED QUICKLY 341
S-10 FUEL CONSUMPTION IS EXCESSIVE 342
S-11 OIL IN COOLING WATER 343
S-12 OIL PRESSURE LAMP LIGHTS UP 344
S-13 OIL LEVEL RISES 345
S-14 WATER TEMPERATURE BECOMES TOO HIGH 346
S-15 ABNORMAL NOISE IS MADE 347
S-16 VIBRATION IS EXCESSIVE 348
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE) 349
POWER TRAIN 351
T-1 MACHINE DOES NOT START 351
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 352
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 354
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 355
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 356
STEERING SYSTEM 357
T-6 STEERING WHEEL DOES NOT TURN 357
T-7 STEERING IS HEAVY 358
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 359
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 360
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT 360
T-11 ECESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT 360
BRAKE SYSTEM 361
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 361
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS 362
WORK EQUIPMENT 363
T-14 BOOM DOES NOT RISE 363
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 364
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 365
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 365
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM 365
T-19 BOOM SHAKES DURING OPERATION 366
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 366
T-21 BUCKET DOES NOT TILT BACK 367
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 368
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 369
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 369
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 369
T-26 BUCKET SHAKES DURING LOADING OPERATION 370
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 370
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 371
TROUBLESHOOTING OF AIRCONDITIONER 373
SERVICE TOOLS 375
GAUGE MANIFOLD 375
STRUCTURE AND HANDLING OF GAUGE MANIFOLD 376
CHARGING HOSES 378
GAS LEAK DETECTOR 379
HALIDE TORCH LEAK DETECTOR 379
ELECTRIC LEAK TESTER 381
VALVE FOR SERVICE CANS 383
MAINTENANCE PROCEDURE 384
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING 384
PROHIBITED WORK 384
OTHER PRECAUTIONS 384
BLEEDING AIR FROM REFRIGERATION CIRCUIT 386
PURPOSE 386
CONNECTING GAUGE MANIFOLD 386
EVACUATION 387
AIR-TIGHTNESS CHECK 387
GAS-LEAK CHECK 388
EVACUATION (REPEATING) 388
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT 389
CHARGING FROM THE HIGH-PRESSURE SIDE 389
CHARGING FROM THE LOW PRESSURE SIDE 390
WHEN THE AMBIENT TEMPERATURE IS LOW 391
WHEN THE AMBIENT TEMPERATURE IS HIGH 391
REPLACING SERVICE CANS 392
CHECKING THE AMOUNT OF REFRIGERANT 392
REMOVAL OF GAUGE MANIFOLD 394
DISCHARGING THE REFRIGERANT 394
DAILY CHECKS 395
CHECK REFRIGERANT LEVEL 395
CLEANING THE CONDENSER 395
CHECKING THE V-BELT 395
CHECKING OIL LEVEL 396
PROCEDURE FOR CHECKING 396
PROCEDURE FOR CHECKING OIL LEVEL 396
ADDING AND REMOVING OIL 397
ADDING OIL BY EVACUATION 397
TROUBLESHOOTING 398
VISUAL AND ACOUSTICAL CHECKS 398
DEFECTIVE COOLING 399
TROUBLESHOOTING TABLE 401
DEFECTIVE HEATING 403
TROUBLESHOOTING USING GAUGE MANIFOLD 404
PREPARATIONS BEFORE MEASURING 404
INSUFFICIENT REFRIGERANT 404
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER 405
AIR INSIDE REFRIGERATION SYSTEM 406
MOISTURE IN REFRIGERATING SYSTEM 407
REFRIGERANT DOES NOT CIRCULATE 408
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE 409
DEFECTIVE COMPRESSION BY COMPRESSOR 410
30 DISASSEMBLY AND ASSEMBLY 411
METHOD OF USING MANUAL 415
PRECAUTIONS DURING OPERATION 416
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 416
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 417
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 418
OTHER PRECAUTIONS 418
SPECIAL TOOL LIST 419
ENGINE COMPONENTS 421
ALTERNATOR ASSEMBLY 421
CYLINDER HEAD ASSEMBLY 421
ENGINE OIL COOLER ASSEMBLY 421
FUEL INJECTION PUMP ASSEMBLY 421
NOZZLE HOLDER ASSEMBLY 421
STARTING MOTOR ASSEMBLY 421
THERMOSTAT ASSEMBLY 421
TURBOCHARGER ASSEMBLY 421
WATER PUMP ASSEMBLY 421
COVERS AND LADDER 422
REMOVAL 422
INSTALLATION 423
ENGINE HOOD 424
REMOVAL 424
INSTALLATION 425
RADIATOR 426
REMOVAL 426
INSTALLATION 429
ENGINE 430
REMOVAL 430
INSTALLATION 437
EXHAUST MUFFLER 438
REMOVAL 438
INSTALLATION 438
AIR CLEANER 439
REMOVAL 439
INSTALLATION 439
TORQUE CONVERTER CHARGING PUMP 440
REMOVAL 440
INSTALLATION 440
TORQUE CONVERTER, TRANSMISSION 441
REMOVAL 441
INSTALLATION 448
TORQUE CONVERTER 450
DISASSEMBLY 450
ASSEMBLY 452
TRANSMISSION 454
DISASSEMBLY 454
DISASSEMBLY OF PARKING BRAKE 463
ASSEMBLY OF PARKING BRAKE 465
ASSEMBLY 468
TRANSMISSION CLUTCH PACK 480
DISASSEMBLY 480
1ST, REVERSE CLUTCH 480
FORWARD, 2ND CLUTCH PACK 482
3RD, 4TH CLUTCH PACK 484
ASSEMBLY 486
1ST, REVERSE CLUTCH 486
FORWARD, 2ND CLUTCH 491
3RD, 4TH CLUTCH 495
TRANSMISSION CONTROL VALVE 500
REMOVAL 500
INSTALLATION 501
DISASSEMBLY 502
ASSEMBLY 504
TRANSMISSION SOLENOID VALVE 507
DISASSEMBLY 507
ASSEMBLY 508
TRANSMISSION ACCUMULATOR VALVE 509
DISASSEMBLY 509
ASSEMBLY 510
DRIVE SHAFT 511
DISASSEMBLY 511
ASSEMBLY 512
FRONT AXLE 513
REMOVAL 513
INSTALLATION 514
REAR AXLE 515
REMOVAL 515
INSTALLATION 519
DIFFERENTIAL 524
DISASSEMBLY 524
ASSEMBLY 528
AXLE HOUSING 538
DISASSEMBLY 538
ASSEMBLY 543
CENTER HINGE PIN 551
REMOVAL 551
INSTALLATION 559
PRIORITY VALVE 568
REMOVAL 568
INSTALLATION 569
STEERING VALVE 570
REMOVAL 570
INSTALLATION 572
DISASSEMBLY 573
DISASSEMBLY OF ROTOR 573
DISASSEMBLY OF CONTROL SIDE 574
ASSEMBLY 576
ASSEMBLY OF CONTROL SIDE 576
ASSEMBLY OF ROTOR 578
MAIN CONTROL VALVE 581
REMOVAL 581
INSTALLATION 583
DISASSEMBLY 584
ASSEMBLY 586
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES 588
PPC VALVE 590
REMOVAL 590
INSTALLATION 591
STEERING CYLINDER 592
REMOVAL 592
INSTALLATION 594
BRAKE BOOSTER 595
REMOVAL 595
INSTALLATION 597
DISASSEMBLY 598
ASSEMBLY 601
PARKING BRAKE 606
REMOVAL 606
INSTALLATION 608
HYDRAULIC TANK 610
REMOVAL 610
INSTALLATION 611
HYDRAULIC FILTER 612
REMOVAL 612
INSTALLATION 612
STEERING PUMP 613
REMOVAL 613
INSTALLATION 614
BUCKET CYLINDER 615
REMOVAL 615
INSTALLATION 616
BOOM CYLINDER 617
REMOVAL 617
INSTALLATION 618
HYDRAULIC CYLINDER 619
DISASSEMBLY 619
ASSEMBLY 621
ECSS SYSTEM 624
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 624
ECSS SOLENOID VALVE 625
REMOVAL 625
INSTALLATION 625
ECSS CONTROL VALVE 626
REMOVAL 626
INSTALLATION 626
WORK EQUIPMENT 627
REMOVAL 627
INSTALLATION 630
FUEL TANK 633
REMOVAL 633
INSTALLATION 634
COUNTERWEIGHT 635
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS 635
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS 635
REMOVAL OF REAR COUNTERWEIGHT 635
INSTALLATION OF REAR COUNTERWEIGHT 636
INSTRUMENT PANEL 637
REMOVAL 637
INSTALLATION 637
AIR CONDITIONING 638
AIR CONDITIONER UNIT 638
REMOVAL 638
INSTALLATION 644
AIR CONDITIONER CONDENSER 645
REMOVAL 645
INSTALLATION 646
DRYER RECEIVER 648
REMOVAL 648
INSTALLATION 648
AIR CONDITIONER COMPRESSOR 650
REMOVAL 650
INSTALLATION 651
40 MAINTENANCE STANDARD 654
ENGINE MOUNT, TRANSMISSION MOUNT 655
TORQUE CONVERTER CHARGING PUMP 657
TORQUE CONVERTER 659
TRANSMISSION 661
TRANSMISSION (1/3) 661
TRANSMISSION (2/3) 665
TRANSMISSION (3/3) 669
REVERSE, 1ST CLUTCH 671
FORWARD, 2ND CLUTCH 673
3RD, 4TH CLUTCH 675
TRANSMISSION CONTROL VALVE 677
UPPER VALVE 677
LOWER VALVE 679
SOLENOID VALVE 681
ACCUMULATOR VALVE 683
DRIVE SHAFT 685
DIFFERENTIAL 687
DIFERENTIAL (1/2) 687
DIFFERENTIAL (2/2) 689
FINAL DRIVE 691
AXLE MOUNT 693
ADDITIONAL COUNTERWEIGHT 695
CENTER HINGE PIN 697
STEERING COLUMN 699
PRIORITY VALVE 701
STEERING CYLINDER MOUNT 702
BRAKE BOOSTER 703
BRAKE 705
PARKING BRAKE 706
HYDRAULIC PUMP, SAL45+SB(1)8 707
MAIN CONTROL VALVE 708
2-SPOOL VALVE 708
3-SPOOL VALVE 711
PPC VALVE 714
HYDRAULIC CYLINDER 716
WORK EQUIPMENT LINKAGE 717
BUCKET 719
BUCKET POSITIONER AND BOOM KICK-OUT 721
90 OTHERS 724
AIR CONDITIONING AND HEATER ELETRICAL DIAGRAM 726
ELECTRICAL WIRING DIAGRAM 728
DIAGRAM (1/4) 728
DIAGRAM (2/4) 730
DIAGRAM (3/4) 732
DIAGRAM (4/4) 734

DESCRIPTION:

Komatsu Avance Plus WA120-3MC Wheel Loader Shop Manual CEBM005101 – PDF DOWNLOAD

• SERIAL NUMBERS
• WA120-3MC – A31001 and UP

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 sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
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, ADJUSTING AND TROUBLESHOOTING
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  16/12/24