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KOMATSU WA120-1LC WHEEL LOADER SERVICE REPAIR MANUAL (SN:20001 & up ) – PDF Download
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- KOMATSU WA120-1LC WHEEL LOADER SERVICE REPAIR MANUAL
- Serial Number:20001 & up
- Publication Number:CEBMW16040
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Description
KOMATSU WA120-1LC WHEEL LOADER SERVICE REPAIR MANUAL (SN:20001 & up )
KOMATSU WA120-1LC WHEEL LOADER SERVICE REPAIR MANUAL (SN:20001 & UP ) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA120-1LC WHEEL LOADER SERVICE REPAIR MANUAL (SN:20001 & up )
- This service 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 service manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
- 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 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. - 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
TABLE OF CONTENTS:
KOMATSU WA120-1LC WHEEL LOADER SERVICE REPAIR MANUAL (SN:20001 & up )
MAIN MENU....................................................................................................... 0 CONTENTS........................................................................................................ 5 10 ENGINE....................................................................................................... 23 11 STRUCTURE AND FUNCTION................................................................................... 23 ENGINE MOUNTING......................................................................................... 24 RADIATOR AND OIL COOLER................................................................................. 25 FUEL TANK AND PIPING.................................................................................... 26 ENGINE CONTROL.......................................................................................... 27 12 TESTING AND ADJUSTING.................................................................................... 29 STANDARD VALUE TABLE ................................................................................... 30 SERVICE TOOL LIST ...................................................................................... 32 SAFETY PRECAUTIONS ..................................................................................... 33 EXHAUST GAS COLOR ...................................................................................... 34 ACCELERATOR PEDAL OPERATING FORCE AND ANGLE ............................................................ 35 OPERATING FORCE..................................................................................... 35 OPERATING ANGLE..................................................................................... 36 13 DISASSEMBLY AND ASSEMBLY ................................................................................ 39 CRANKING MOTOR ......................................................................................... 40 REMOVAL............................................................................................. 40 INSTALLATION........................................................................................ 40 ALTERNATOR ............................................................................................. 41 REMOVAL............................................................................................. 41 INSTALLATION........................................................................................ 41 OIL COOLER ............................................................................................. 42 REMOVAL............................................................................................. 42 INSTALLATION........................................................................................ 43 WATER PUMP ............................................................................................. 44 REMOVAL............................................................................................. 44 INSTALLATION........................................................................................ 45 FUEL INJECTORS ......................................................................................... 46 REMOVAL............................................................................................. 46 INSTALLATION........................................................................................ 48 TURBOCHARGER ........................................................................................... 50 REMOVAL............................................................................................. 50 INSTALLATION........................................................................................ 52 CYLINDER HEAD .......................................................................................... 54 REMOVAL............................................................................................. 54 INSTALLATION........................................................................................ 57 RADIATOR ............................................................................................... 60 REMOVAL............................................................................................. 60 INSTALLATION........................................................................................ 63 ENGINE ................................................................................................. 67 REMOVAL............................................................................................. 67 INSTALLATION........................................................................................ 74 FUEL TANK .............................................................................................. 82 REMOVAL............................................................................................. 82 INSTALLATION........................................................................................ 83 20 POWER TRAIN.................................................................................................. 85 21 STRUCTURE AND FUNCTION .................................................................................. 85 GENERAL ................................................................................................ 88 HYDRAULIC CIRCUIT FOR POWER TRAIN ...................................................................... 90 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN........................................................... 91 FORWARD FIRST....................................................................................... 92 TORQUE CONVERTER AND TRANSMISSION PIPING ............................................................... 94 TORQUE CONVERTER CHARGING PUMP ......................................................................... 95 OUTLINE............................................................................................. 95 SPECIFICATIONS...................................................................................... 95 TORQUE CONVERTER ....................................................................................... 96 SPECIFICATIONS...................................................................................... 96 OUTLINE............................................................................................. 97 FLOW OF MOTIVE FORCE............................................................................ 97 FLOW OF OIL..................................................................................... 97 TORQUE CONVERTER OIL FILTER ............................................................................ 98 OPERATION........................................................................................... 98 TORQUE CONVERTER OIL COOLER ............................................................................100 OUTLINE.............................................................................................100 TRANSMISSION ...........................................................................................101 OUTLINE ............................................................................................103 CLUTCH SHAFTS ..........................................................................................103 FORWARD AND REVERSE CLUTCHES .......................................................................103 FIRST GEAR CLUTCH ..................................................................................104 SECOND AND THIRD GEAR CLUTCH .......................................................................104 OPERATION OF CLUTCH ................................................................................105 WHEN ENGAGED....................................................................................105 WHEN DISENGAGED.................................................................................105 FORWARD FIRST.......................................................................................106 OPERATION.......................................................................................107 REVERSE FIRST ......................................................................................108 OPERATION.......................................................................................109 TRANSMISSION CONTROL VALVE .............................................................................110 MAIN REGULATOR VALVE ...............................................................................112 FUNCTION .......................................................................................112 OPERATION.......................................................................................112 TORQUE CONVERTER OIL OUTLET VALVE ..................................................................113 FUNCTION........................................................................................113 OPERATION.......................................................................................113 QUICK RETURN VALVE AND ACCUMULATOR..................................................................114 FUNCTION........................................................................................114 Quick Return Valve..........................................................................114 Accumulator.................................................................................114 OPERATION.......................................................................................114 When Clutch Is Engaged......................................................................114 Immediately After Gear Shifting.............................................................114 POWER MODULATING FUNCTION...........................................................................116 FUNCTION........................................................................................116 CLUTCH CUT-OFF VALVE................................................................................120 OPERATION ......................................................................................120 DRIVE SHAFTS ...........................................................................................122 OUTLINE ............................................................................................122 AXLES ..................................................................................................124 FRONT ..............................................................................................124 REAR ...............................................................................................125 DIFFERENTIALS ..........................................................................................126 FRONT...............................................................................................126 REAR ...............................................................................................127 TORQUE PROPORTIONING DIFFERENTIAL ..................................................................128 OUTLINE.........................................................................................128 FUNCTION .......................................................................................129 OPERATION ......................................................................................129 FINAL DRIVES ...........................................................................................130 OUTLINE ............................................................................................130 AXLE MOUNTING ..........................................................................................132 FRONT AXLE .........................................................................................133 REAR AXLE ..........................................................................................133 TIRES AND WHEELS .......................................................................................134 THREE PIECE WHEEL...................................................................................134 ONE PIECE WHEEL ....................................................................................135 SPECIFICATIONS .....................................................................................136 22 TESTING AND ADJUSTING....................................................................................137 STANDARD VALUE TABLE ...................................................................................138 SERVICE TOOL LIST ......................................................................................140 SAFETY PRECAUTIONS .....................................................................................140 ENGINE STALL SPEEDS ....................................................................................142 TORQUE CONVERTER AND TRANSMISSION OIL PRESSURES ........................................................144 TRANSMISSION SHIFT LEVERS...............................................................................146 TRANSMISSION CONTROL VALVE SPOOLS .....................................................................147 TROUBLESHOOTING.........................................................................................149 PRECAUTIONS.........................................................................................150 METHOD OF READING TROUBLESHOOTING TABLE.............................................................152 PREVENTING RECURRENCE OF TROUBLE....................................................................154 CHECKS BEFORE TROUBLESHOOTING.......................................................................155 TROUBLESHOOTING TABLE...............................................................................156 TORQUE CONVERTER AND TRANSMISSION...................................................................156 1. Machine does not move off....................................................................156 2. Machine speed is low, thrust is weak, gradeability falls off.................................158 3. Large shock when moving off or changing gear.................................................160 4. Large time lag when moving off or changing gear..............................................161 5. Oil temperature in torque converter is high..................................................162 23 DISASSEMBLY AND ASSEMBLY.................................................................................163 TORQUE CONVERTER CHARGING PUMP .........................................................................165 REMOVAL ............................................................................................165 INSTALLATION .......................................................................................165 TORQUE CONVERTER TRANSMISSION ..........................................................................166 REMOVAL ............................................................................................166 INSTALLATION .......................................................................................173 TORQUE CONVERTER .......................................................................................180 DISASSEMBLY ........................................................................................180 ASSEMBLY ...........................................................................................183 TRANSMISSION ...........................................................................................186 DISASSEMBLY ........................................................................................186 ASSEMBLY ...........................................................................................193 FORWARD REVERSE CLUTCH PACKS ...........................................................................204 DISASSEMBLY ........................................................................................204 ASSEMBLY ...........................................................................................207 FIRST SPEED CLUTCH PACK ................................................................................212 DISASSEMBLY ........................................................................................212 ASSEMBLY ...........................................................................................214 SECOND AND THIRD SPEED CLUTCH PACKS ....................................................................217 DISASSEMBLY ........................................................................................217 ASSEMBLY ...........................................................................................219 TRANSMISSION CONTROL VALVE .............................................................................224 REMOVAL ............................................................................................224 INSTALLATION .......................................................................................226 DISASSEMBLY ........................................................................................230 ASSEMBLY ...........................................................................................234 DRIVE SHAFT ............................................................................................240 DISASSEMBLY.........................................................................................240 ASSEMBLY............................................................................................242 FRONT AXLE..............................................................................................244 REMOVAL ............................................................................................244 INSTALLATION........................................................................................246 REAR AXLE ..............................................................................................248 REMOVAL.............................................................................................248 INSTALLATION........................................................................................252 DIFFERENTIAL ...........................................................................................257 DISASSEMBLY.........................................................................................257 ASSEMBLY............................................................................................261 AXLE HOUSING ...........................................................................................271 DISASSEMBLY.........................................................................................271 ASSEMBLY............................................................................................277 24 MAINTENANCE STANDARD.....................................................................................285 TRANSMISSION AND ENGINE MOUNT ..........................................................................286 TORQUE CONVERTER CHARGING PUMP .........................................................................288 TORQUE CONVERTER .......................................................................................289 TRANSMISSION............................................................................................290 TRANSMISSION CLUTCH ASSEMBLY............................................................................292 FORWARD-REVERSE CLUTCH ASSEMBLY.....................................................................292 1ST CLUTCH ASSEMBLY.................................................................................292 2ND, 3RD CLUTCH ASSEMBLY............................................................................292 TRANSMISSION CONTROL VALVE..............................................................................294 AXLE....................................................................................................296 DIFFERENTIAL ...........................................................................................298 FINAL DRIVE ............................................................................................300 DRIVE SHAFT.............................................................................................301 AXLE MOUNT..............................................................................................302 40 STEERING SYSTEM..............................................................................................305 41 STRUCTURE AND FUNCTION...................................................................................305 GENERAL ................................................................................................306 HYDRAULIC CIRCUIT FOR STEERING .........................................................................307 HYDRAULIC CIRCUIT DIAGRAM FOR STEERING .................................................................308 STEERING VALVE .........................................................................................309 CONNECTION OF HAND PUMP AND SLEEVE..................................................................315 FUNCTION OF CENTER PIN..........................................................................316 PRIORITY VALVE .........................................................................................317 STEERING CYLINDER ......................................................................................320 CENTER HINGE PIN .......................................................................................321 42 TESTING AND ADJUSTING....................................................................................323 STANDARD VALUE TABLE ...................................................................................324 SERVICE TOOL LIST ......................................................................................324 STEERING WHEEL PLAY ....................................................................................325 OPERATING FORCE OF STEERING WHEEL ......................................................................326 OPERATING TIME OF STEERING WHEEL .......................................................................327 STEERING OIL PRESSURE ..................................................................................328 TROUBLESHOOTING.........................................................................................329 TROUBLESHOOTING TABLE ..................................................................................330 STEERING CIRCUIT....................................................................................330 1. Steering wheel does not turn.................................................................330 2. Steering wheel is sluggish...................................................................331 3. Steering wheel moves unsteadily or is subjected to large shock...............................332 4. Machine tends to turn naturally in one particular direction when traveling...................332 5. Left and right turning radii are different...................................................332 43 DISASSEMBLY AND ASSEMBLY.................................................................................333 STEERING VALVE .........................................................................................334 REMOVAL ............................................................................................334 INSTALLATION........................................................................................335 DISASSEMBLY ........................................................................................336 ASSEMBLY ...........................................................................................339 STEERING RELIEF VALVE ..................................................................................344 REMOVAL AND DISASSEMBLY ............................................................................344 ASSEMBLY AND INSTALLATION ..........................................................................345 PRIORITY VALVE .........................................................................................346 REMOVAL ............................................................................................346 INSTALLATION .......................................................................................347 STEERING CYLINDER ......................................................................................348 REMOVAL ............................................................................................348 INSTALLATION .......................................................................................348 DISASSEMBLY ........................................................................................349 ASSEMBLY ...........................................................................................351 CENTER HINGE PIN .......................................................................................354 REMOVAL ............................................................................................354 INSTALLATION .......................................................................................362 44 MAINTENANCE STANDARD.....................................................................................371 STEERING CYLINDER MOUNT.................................................................................372 STEERING CYLINDER ......................................................................................373 CENTER HINGE PIN .......................................................................................374 STEERING COLUMN ........................................................................................376 PRIORITY VALVE..........................................................................................377 50 BRAKES.......................................................................................................379 51 STRUCTURE AND FUNCTION...................................................................................379 GENERAL ................................................................................................380 BRAKE MASTER CYLINDER...................................................................................381 BRAKE...................................................................................................383 PARKING BRAKE...........................................................................................385 BRAKE CALIPER...........................................................................................386 52 TESTING AND ADJUSTING....................................................................................387 STANDARD VALUE TABLE .................................................................................388 TOOL LIST ..............................................................................................389 MEASURING BRAKE PEDAL...................................................................................390 BRAKE PEDAL LINKAGE ...................................................................................391 BRAKE PERFORMANCE.......................................................................................393 BRAKE PISTON LEAKAGE ..................................................................................394 BRAKE DISC WEAR.........................................................................................395 AIR BLEEDING FROM BRAKE CIRCUIT ......................................................................396 PARKING BRAKE PERFORMANCE...............................................................................397 PARKING BRAKE .........................................................................................398 CHECKING............................................................................................398 ADJUSTING...........................................................................................399 MEASURING CLEARANCE ...............................................................................400 TROUBLESHOOTING.........................................................................................401 TROUBLESHOOTING TABLES ............................................................................402 1. Brake is ineffective or not very effective.......................................................402 2. Brake cannot be released or drags................................................................403 53 DISASSEMBLY AND ASSEMBLY.................................................................................405 MASTER CYLINDER .......................................................................................406 REMOVAL.............................................................................................406 INSTALLATION........................................................................................407 DISASSEMBLY.........................................................................................408 ASSEMBLY............................................................................................409 PARKING BRAKE...........................................................................................410 REMOVAL.............................................................................................410 INSTALLATION........................................................................................412 PARKING BRAKE PAD.......................................................................................414 REMOVAL.............................................................................................414 INSTALLATION........................................................................................415 54 MAINTENANCE STANDARD.....................................................................................417 MASTER CYLINDER ........................................................................................418 BRAKE...................................................................................................419 60 WORK EQUIPMENT SYSTEM........................................................................................421 61 STRUCTURE AND FUNCTION...................................................................................421 GENERAL ................................................................................................422 HYDRAULIC CIRCUIT ......................................................................................424 HYDRAULIC CIRCUIT DIAGRAM ............................................................................425 DUMP AND LIFT CONTROL LEVER LINKAGE ..................................................................426 BUCKET LINKAGE ........................................................................................427 BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................429 HYDRAULIC TANK ........................................................................................430 OIL FILTER BYPASS VALVE.............................................................................431 BREATHER............................................................................................431 HYDRAULIC AND STEERING PUMP ............................................................................432 MAIN CONTROL VALVE......................................................................................433 RELIEF VALVE ......................................................................................435 SAFETY VALVE (WITH SUCTION VALVE)...................................................................436 SUCTION VALVE.......................................................................................437 LIFT AND DUMP SPOOLS AT “HOLD POSITION”.............................................................438 LIFT SPOOL AT “RAISE POSITION”......................................................................439 LIFT SPOOL AT “LOWER POSITION”......................................................................440 DUMP SPOOL AT “FLOAT POSITION”......................................................................441 DUMP SPOOL AT “TILT BACK POSITION”..................................................................442 DUMP SPOOL AT “DUMP POSITION”.......................................................................443 HYDRAULIC CYLINDER ....................................................................................444 LIFT CYLINDER.......................................................................................444 DUMP CYLINDER.......................................................................................444 62 TESTING AND ADJUSTING....................................................................................445 STANDARD VALUE TABLE ...................................................................................447 TOOL LIST ..............................................................................................448 DUMP AND LIFT CONTROL LEVERS............................................................................449 MEASURING PROCEDURE.................................................................................449 ADJUSTING PROCEDURE.................................................................................450 DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL................................................................451 MEASURING PROCEDURE.................................................................................451 HYDRAULIC CIRCUIT FLUSHING..............................................................................452 BEFORE FLUSHING.....................................................................................452 WORK STEPS FOR FLUSHING.............................................................................453 HYDRAULIC PRESSURE .....................................................................................455 MEASURING PROCEDURE (Main relief valve).............................................................455 ADJUSTING PROCEDURE (Main relief valve).............................................................456 LIFT ARM AND BUCKET ....................................................................................457 MEASURING PROCEDURE.................................................................................457 Lifting time of lift arm........................................................................457 Lowering time of lift arm.......................................................................457 Dumping time of bucket..........................................................................458 Tilt back time of bucket........................................................................458 HYDRAULIC DRIFT ....................................................................................459 Measuring procedure.............................................................................459 BUCKET POSITIONER.......................................................................................460 INSPECTION PROCEDURE................................................................................460 ADJUSTING PROCEDURE.................................................................................460 BOOM KICK-OUT...........................................................................................461 INSPECTION PROCEDURE................................................................................461 ADJUSTING PROCEDURE.................................................................................461 TROUBLESHOOTING.........................................................................................463 LOADER CIRCUIT......................................................................................464 1. Lift arm does not rise.......................................................................464 2. Lift arm moves slowly or does not have sufficient lifting power..............................465 3. Lift arm movement becomes slow after it reaches a certain height.............................466 4. Bucket cannot be held down with lift cylinder................................................466 5. Lift arm has large hydraulic drift...........................................................466 6. Lift arm movement is unsteady during work....................................................466 7. Lift arm descends momentarily when the control lever is shifted from "Hold" to "Raise".......466 8. Bucket does not tilt back....................................................................467 9. Bucket moves slowly or has insufficient tilt back power......................................468 10. Bucket movement becomes slow during tilt back...............................................469 11. Bucket cannot be held down by the dump cylinder.............................................469 12. Bucket has large hydraulic drift............................................................469 13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold").....469 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"...........469 15. Control levers of lift arm and bucket move stiffly and sluggishly...........................470 63 DISASSEMBLY AND ASSEMBLY.................................................................................471 HYDRAULIC TANK .........................................................................................473 REMOVAL.............................................................................................473 INSTALLATION........................................................................................474 HYDRAULIC FILTER........................................................................................475 REMOVAL.............................................................................................475 INSTALLATION........................................................................................475 HYDRAULIC-STEERING PUMP ................................................................................476 REMOVAL.............................................................................................476 INSTALLATlON........................................................................................476 MAIN CONTROL VALVE ....................................................................................477 REMOVAL ............................................................................................477 INSTALLATION........................................................................................479 DISASSEMBLY.........................................................................................483 ASSEMBLY............................................................................................485 DUMP CYLINDER ..........................................................................................486 REMOVAL.............................................................................................486 INSTALLATION........................................................................................488 LIFT CYLINDER .........................................................................................489 REMOVAL.............................................................................................489 INSTALIATION........................................................................................490 LIFT AND DUMP CYLINDER ................................................................................491 DISASSEMBLY.........................................................................................491 ASSEMBLY............................................................................................493 WORK EQUIPMENT..........................................................................................496 REMOVAL.............................................................................................496 INSTALLATION........................................................................................499 COUNTERWEIGHT...........................................................................................502 REMOVAL.............................................................................................502 INSTALLATION........................................................................................502 64 STRUCTURE AND FUNCTION...................................................................................503 MAIN CONTROL VALVE......................................................................................504 PARKING BRAKE...........................................................................................506 DUMP CYLINDER ..........................................................................................507 LIFT CYLINDER .........................................................................................508 WORK EQUIPMENT .........................................................................................510 BUCKET POSITIONER AND BOOM KICK-OUT ..................................................................512 BUCKET..................................................................................................513 HYDRAULIC AND STEERING PUMP.............................................................................514 80 ELECTRIC AND ELECTRONIC SYSTEM...............................................................................515 81 STRUCTURE AND FUNCTION...................................................................................515 CLUSTER GUAGE...........................................................................................516 PROXIMITY SWITCH........................................................................................517 OPERATION...........................................................................................518 ENGINE STARTING CIRCUIT.................................................................................519 ENGINE STOP CIRCUIT.....................................................................................520 ELECTRICAL WIRING DIAGRAM...............................................................................521 ELECTRICAL WIRING SCHEMATIC.............................................................................521 SENSOR..................................................................................................522 BRAKE OIL LEVEL SENSOR..............................................................................523 TORQUE CONVERTER OIL TEMPERATURE SENSOR.............................................................523 FUEL GAUGE SENSOR...................................................................................524 COOLANT TEMPERATURE SENSOR..........................................................................525 ENGINE OIL PRESSURE SENSOR..........................................................................525 83 DISASSEMBLY AND ASSEMBLY.................................................................................527 INSTRUMENT PANEL........................................................................................528 REMOVAL.............................................................................................528 INSTALLATION........................................................................................529 90 MISCELLANEOUS................................................................................................531 97 GEAR PUMP................................................................................................531 GENERAL ................................................................................................532 PRINCIPLE OF OPERATION .................................................................................533 MECHANISM FOR DELIVERING OIL........................................................................533 INTERNAL OIL LEAKAGE................................................................................534 FORCES ACTING ON THE GEAR...........................................................................534 "TRAPPING” PHENOMENON OF THE OIL....................................................................535 PRESSURE LOADED TYPE GEAR PUMP..........................................................................536 GENERAL DESCRIPTION.................................................................................536 STRUCTURE AND OPERATION.................................................................................537 FIXED SIDE PLATE TYPE GEAR PUMP.........................................................................538 SA SERIES ..............................................................................................539 STRUCTURE ..........................................................................................539 FEATURES........................................................................................539 SA-1............................................................................................540 SA-2............................................................................................540 SA-3............................................................................................541 SA-4............................................................................................542 TESTING AND ADJUSTING...............................................................................543 DISASSEMBLY ........................................................................................546 Single pump.....................................................................................546 Tandem pump.....................................................................................549 Triple pump.....................................................................................549 ASSEMBLY............................................................................................550 Single pump.....................................................................................550 Tandem pump.....................................................................................553 Triple pump.....................................................................................554 MAINTENANCE STANDARD ...............................................................................555 99 METRIC CONVERSIONS.......................................................................................557
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