Komatsu WA120-3 Avance Wheel Loader Shop Manual SEBM005706 PDF

Description

Komatsu WA120-3 Avance Wheel Loader Shop Manual SEBM005706 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA120-3 Avance Wheel Loader Shop Manual SEBM005706 – PDF DOWNLOAD 

Language : English
Pages : 735
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA120-3 Avance Wheel Loader Shop Manual SEBM005706 – PDF DOWNLOAD 

MACHINE MODEL                                                        SERIAL NUMBER
WА120-З                                                                            50001 and up
(4-speed transmission specification)
WА120-ЗА                                                                        50001 and up
(3-speed transmission specification)

COVER 1
CONTENTS 2
01 GENERAL 26
GENERAL ASSEMBLY DRAWING 27
SPECIFICATIONS 28
WEIGHT TABLE 34
LIST OF LUBRICANT AND WATER 38
10 STRUCTURE AND FUNCTION 41
POWER TRAIN 42
POWER TRAIN SYSTEM 43
TORQUE CONVERTER,TRANSMISSION PIPING 47
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM (WA120-3) 49
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM (WA120-3) 50
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM (WA120-3A) 53
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM (WA120-3A) 54
TORQUE CONVERTER 55
TORQUE CONVERTER OIL FILTER 58
TRANSMISSION (WA120-3) 59
TRANSMISSION (WA120-3A) 70
TRANSMISSION CONTROL VALVE 79
TRANSMISSION CONTROL 120
DRIVE SHAFT 122
AXLE 123
FINAL DRIVE 129
AXLE MOUNT 130
CENTER HINGE PIN 132
STEERING PIPING 133
STEERING COLUMN 134
PRIORITY VALVE 135
STEERING VALVE (ORBIT-ROLL) 138
BRAKE PIPING 146
BRAKE CONTROL 148
BRAKE BOOSTER 149
BRAKE 153
PARKING BRAKE CONTROL 155
PARKING BRAKE 157
HYDRAULIC PIPING 160
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 162
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 163
HYDRAULIC TANK 164
MAIN CONTROL VALVE 167
WORK EQUIPMENT LEVER LINKAGE 180
WORK EQUIPMENT LINKAGE 181
BUCKET 183
BUCKET POSITIONER AND BOOM KICK-OUT 184
PROXIMITY SWITCH 186
CANOPY 188
ROPS CAB 189
AIR CONDITIONER 190
TRAVEL DAMPER SYSTEM 191
ELECTRICAL WIRING DIAGRAM 196
ELECTRICAL CIRCUIT DIAGRAM (WA120-3) 198
ELECTRICAL CIRCUIT DIAGRAM (WA120-3A) 202
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM 206
CENTRAL PANEL 208
SENSOR 209
ENGINE STARTING CIRCUIT 210
ENGINE STOP CIRCUIT 214
FUEL CUT-OFF SOLENOID 216
AUTOMATIC PREHEATING CIRCUIT 217
AUTOMATIC AIR BLEED MECHANISM 224
ELECTRICAL TRANSMISSION CONTROL 225
COMBINATION SWITCH 227
TRANSMISSION CUT-OFF FUNCTION (WA120-3) 228
TRANSMISSION CUT-OFF FUNCTION (WA120-3A) 230
PARKING BRAKE FUNCTION 231
KICK-DOWN SWITCH 233
20 TESTING AND ADJUSTING 239
STANDARD VALUE TABLE FOR ENGINE 240
STANDARD VALUE TABLE FOR CHASSIS (WA120-3) 242
STANDARD VALUE TABLE FOR CHASSIS (WA120-3A) 245
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 249
ADJUSTING VALVE CLEARANCE 251
MEASURING COMPRESSION PRESSURE 253
TESTING AND ADJUSTING FUEL INJECTION TIMING 254
MEASURING EXHAUST COLOR 256
MEASURING BLOW-BY PRESSURE 257
MEASURING ENGINE OIL PRESSURE 259
TESTING AND ADJUSTING FAN BELT TENSION 260
MEASURING ENGINE SPEED 261
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 263
ADJUSTING ENGINE STOP SOLENOID 265
MEASURING ACCELERATOR PEDAL 266
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 268
MEASURING OPERAITNG FORCE AND STROKE OF TRANSMISSION VALVE SPOOL 269
MEASURING STALL SPEED 270
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE(WA120-3) 272
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE(WA120-3A) 274
METHOD OF OPERATING EMERGENCY MANUAL SPOOL(WA120-3) 275
TESTING AND ADJUSTING STEERING WHEEL 277
MEASURING STEERING OIL PRESSURE 280
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 282
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 283
MEASURING BRAKE PERFORMANCE 285
MEASURING BRAKE OIL PRESSURE 286
TESTING FOR BRAKE DISC WEAR 287
BLEEDING AIR FROM BRAKE SYSTEM 288
MEASURING PARKING BRAKE PERFORMANCE 289
TESTING AND ADJUSTING PARKING BRAKE LINKAGE(WA120-3) 290
TESTING AND ADJUSTING PARKING BRAKE LINKAGE(WA120-3A) 291
TESTING PARKING BRAKE DISC WEAR(WA120-3) 292
MEASURING PARKING BRAKE DISC WEAR(WA120-3) 293
TESTING AND ADJUSTING PARKING BRAKE CALIPER(WA120-3A) 294
MEASURING WORK EQUIPMENT CONTROL LEVER 296
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 299
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 300
MEASURING WORK EQUIPMENT 302
TESTING AND ADJUSTING BUCKET POSITIONER 304
TESTING AND ADJUSTING BOOM KICK-OUT 305
TROUBLESHOOTING 307
USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE 308
POINTS TO REMEMBER WHEN TROUBLESHOOTING 312
TROUBLESHOOTING OF ENGINE (S6D95L) SYSTEM (S MODE)[SERIAL NO 50001-52999] 313
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 314
S-2 ENGINE DOES NOT START 315
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 318
S-4 ENGINE STOPS DURING OPERATIONS 319
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 320
S-6 ENGINE LACKS OUTPUT (NO POWER) 321
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 322
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 323
S-9 OIL BECOMES CONTAMINATED QUICKLY 324
S-10 FUEL CONSUMPTION IS EXCESSIVE 325
S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 326
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 327
S-13 OIL LEVEL RISES 328
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 329
S-15 ABNORMAL NOISE IS MADE 330
S-16 VIBRATION IS EXCESSIVE 331
TROUBLESHOOTING OF ENGINE (S4D102E) SYSTEM (S MODE)[SERIAL NO 53001-UP] 332
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 333
S-2 ENGINE DOES NOT START 334
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 337
S-4 ENGINE STOPS DURING OPERATIONS 338
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 339
S-6 ENGINE LACKS OUTPUT (NO POWER) 340
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 341
S-8 OIL CONSUMPTION IS EXCESSIVE (FOR EXHAUST GAS IS BLUE) 342
S-9 OIL BECOMES CONTAMINATED QUICKLY 343
S-10 FUEL CONSUMPTION IS EXCESSIVE 344
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 345
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 346
S-13 OIL LEVEL RISES 347
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 348
S-15 ABNORMAL NOISE IS MADE 349
S-16 VIBRATION IS EXCESSIVE 350
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)(T,S,A,H MODE) 351
POWER TRAIN 352
T-1 MACHINE DOES NOT START 352
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 354
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 356
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHIEN OR SHIFGING GEAR 357
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 358
STEERING SYSTEM 359
S-1 STEERING WHEEL DOES NOT TURN 359
S-2 STEERING IS HEAVY 360
S-3 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 361
S-4 DEVIATES TO ONE SIDE WHEN TRAVELING 362
S-5 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT 362
S-6 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT 362
BRAKE SYSTEM 363
A-1 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 363
A-2 BRAKE IS NOT RELEASED, BRAKE DRAGS 364
WORK EQUIPMENT 365
H-1 BOOM DOES NOT RISE 365
H-2 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 366
H-3 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 367
H-4 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 367
H-5 EXCESSIVE HYDRAULIC DRIFT OF BOOM 367
H-6 BOOM SHAKES DURING OPERATION 367
H-7 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 368
H-8 BUCKET DOES NOT TILT BACK 369
H-9 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 370
H-10 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 371
H-11 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 371
H-12 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 371
H-13 BUCKET SHAKES DURING LOADING OPERATION 372
H-14 BUCKET DUMPS MOMETARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 372
H-15 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 373
30 DISASSEMBLY AND ASSEMBLY 374
METHOD OF USING MANUAL 376
PRECAUTIONS WHEN CARRYING OUT OPERATION 377
SPECIAL TOOL LIST 379
STARTING MOTOR 381
REMOVAL AND INSTALLATION 381
ALTERNATOR 382
REMOVAL AND INSTALLATION 382
FUEL INJECTION PUMP 384
REMOVAL 384
INSTALLATION 385
ENGINE OIL COOLER 391
REMOVAL AND INSTALLATION 391
WATER PUMP 393
REMOVAL AND INSTALLATION 393
NOZZLE HOLDER 395
REMOVAL AND INSTALLATION 395
THERMOSTAT 398
REMOVAL AND INSTALLATION 398
TURBOCHARGER 400
REMOVAL AND INSTALLATION 400
CYLINDER HEAD 401
REMOVAL 401
INSTALLAITON 404
RADIATOR 414
REMOVAL 414
INSTALLATION 417
ENGINE 420
REMOVAL 420
INSTALLATION 423
TORQUE CONVERTER CHARGING PUMP 428
REMOVAL AND INSTALLATION 428
TORQUE CONVERTER, TRANSMISSION 429
REMOVAL 429
INSTALLATION 437
TORQUE CONVERTER 438
DISASSEMBLY (WA120-3) 438
DISASSEMBLY (WA120-3A) 440
ASSEMBLY (WA120-3) 442
ASSEMBLY (WA120-3A) 444
TRANSMISSION 446
DISASSEMBLY (WA120-3) 446
DISASSEMBLY (WA120-3A) 457
ASSEMBLY (WA120-3) 464
ASSEMBLY (WA120-3A) 479
CLUTCH PACK 489
DISASSEMBLY (WA120-3) 489
DISASSEMBLY (WA120-3A) 495
ASSEMBLY (WA120-3) 501
ASSEMBLY (WA120-3A) 515
TRANSMISSION CONTROL VALVE 527
REMOVAL (WA120-3) 527
INSTALLATION (WA120-3) 528
REMOVAL (WA120-3A) 529
INSTALLATION (WA120-3A) 531
DISASSEMBLY (WA120-3) 532
DISASSEMBLY (WA120-3A) 534
ASSEMBLY (WA120-3) 537
ASSEMBLY (WA120-3A) 539
TRANSMISSION SOLENOID VALVE 544
DISASSEMBLY AND ASSEMBLY (WA120-3) 544
TRANSMISSION ACCUMULATOR VALVE 545
DISASSEMBLY (WA120-3) 545
ASSEMBLY (WA120-3) 546
DRIVE SHAFT 547
DISASSEMBLY 547
ASSEMBLY 549
FRONT AXLE 551
REMOVAL 551
INSTALLATION 552
REAR AXLE 553
REMOVAL 553
INSTALLATION 557
DIFFERENTIAL 562
DISASSEMBLY 562
ASSEMBLY 566
AXLE HOUSING 576
DISASSEMBLY 576
ASSEMBLY 581
CENTER HINGE PIN 589
REMOVAL 589
INSTALLATION 598
PRIORITY VALVE 607
REMOVAL 607
INSTALLATION 608
STEERING VALVE 609
REMOVAL 609
INSTALLATION 611
DISASSEMBLY 612
ASSEMBLY 615
STEERING CYLINDER 620
REMOVAL 620
INSTALLATION 621
BRAKE BOOSTER 622
REMOVAL 622
INSTALLATION 624
DISASSEMBLY 625
ASSEMBLY 628
PARKING BRAKE 633
REMOVAL (WA120-3) 633
INSTALLATION (WA120-3) 635
REMOVAL (WA120-3A) 636
INSTALLATION (WA120-3A) 638
PARKING BRAKE PAD 639
REMOVAL AND INSTALLATION 639
HYDRAULIC TANK 640
REMOVAL 640
INSTALLATION 641
HYDRAULIC FILTER 642
REMOVAL AND INSTALLATION 642
HYDRAULIC, STEERING PUMP 643
REMOVAL 643
INSTALLATION 644
MAIN CONTROL VALVE 645
REMOVAL 645
INSTALLATION 647
DISASSEMBLY 648
ASSEMBLY 650
BUCKET CYLINDER 652
REMOVAL 652
INSTALLATION 653
BOOM CYLINDER 654
REMOVAL 654
INSTALLATION 655
HYDRAULIC CYLINDER 656
DISASSEMBLY 656
ASSEMBLY 658
WORK EQUIPMENT 660
REMOVAL 660
INSTALLATION 663
FUEL TANK 666
REMOVAL 666
INSTALLATION 667
COUNTERWEIGHT 670
REMOVAL AND INSTALLATION 670
INSTRUMENT PANEL 671
REMOVAL AND INSTALLATION 671
ENGINE HOOD 672
REMOVAL AND INSTALLATION 672
40 MAINTENANCE STANDARD 673
ENGINE MOUNT, TRANSMISSION MOUNT 674
TORQUE CONVERTER CHARGING PUMP 676
TORQUE CONVERTER 678
TRANSMISSION (WA120-3) 680
TRANSMISSION (WA120-3A) 694
TRANSMISSION CONTROL VALVE (WA120-3) 700
TRANSMISSION CONTROL VALVE (WA120-3A) 706
ACCUMULATOR VALVE 709
DRIVE SHAFT 710
DIFFERENTIAL 711
FINAL DRIVE 714
AXLE MOUNT 716
CENTER HINGE PIN 717
STEERING COLUMN 719
PRIORITY VALVE 720
STEERING CYLINDER MOUNT 721
BRAKE BOOSTER 722
BRAKE 723
PARKING BRAKE 724
HYDRAULIC AND STEERING PUMP 726
MAIN CONTROL VALVE 727
HYDRAULIC CYLINDER 731
WORK EQUIPMENT LINKAGE 732
BUCKET 734
BUCKET POSITIONER AND BOOM KICK-OUT 735

DESCRIPTION:

Komatsu WA120-3 Avance Wheel Loader Shop Manual SEBM005706 – PDF DOWNLOAD 

MACHINE MODEL                                                        SERIAL NUMBER
WА120-З                                                                            50001 and up
(4-speed transmission specification)
WА120-ЗА                                                                        50001 and up
(3-speed transmission specification)

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

S.V 24/12/24