Komatsu WA120-1LC Wheel Loader Shop Manual CEBMW16040 PDF

Description

Komatsu WA120-1LC Wheel Loader Shop Manual CEBMW16040 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA120-1LC Wheel Loader Shop Manual CEBMW16040 – PDF DOWNLOAD 

Language : English
Pages : 569
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA120-1LC Wheel Loader Shop Manual CEBMW16040 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL NUMBERS
WA120-1 LC                20001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu WA120-1LC Wheel Loader Shop Manual CEBMW16040 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL NUMBERS
WA120-1 LC                20001 and 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

S.V 14/12/24