Komatsu WA120-3 (EU SPEC.) Wheel Loader Shop Manual SEBM018300 PDF

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Komatsu WA120-3 (EU SPEC.) Wheel Loader Shop Manual SEBM018300 – PDF DOWNLOAD

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Komatsu WA120-3 (EU SPEC.) Wheel Loader Shop Manual SEBM018300 – PDF DOWNLOAD 

Language : English
Pages : 533
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA120-3 (EU SPEC.) Wheel Loader Shop Manual SEBM018300 – PDF DOWNLOAD 

MACHINE MODEL         SERIAL NO.
WA120-3 (EU SPEC.)    53001 and up

COVER 1
CONTENTS 2
01 GENERAL 20
GENERAL ASSEMBLY DRAWING 21
SPECIFICATIONS 22
WEIGHT TABLE 25
LIST OF LUBRICANT AND WATER 26
10 STRUCTURE AND FUNCTION 28
POWER TRAIN 29
POWER TRAIN SYSTEM 30
TORQUE CONVERTER, TRANSMISSION PIPING 31
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 32
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 33
TORQUE CONVERTER 34
TRANSMISSION 36
TRANSMISSION CONTROL VALVE 46
TRANSMISSION CONTROL 67
DRIVE SHAFT 68
AXLE 69
FINAL DRIVE 75
AXLE MOUNT 76
CENTER HINGE PIN 78
STEERING PIPING 79
STEERING COLUMN 80
PRIORITY VALVE 81
STEERING VALVE (ORBIT-ROLL) 84
EMERGENCY STEERING PUMP 92
SECURITY VALVE 93
DIVERTER VALVE 94
OPERATION OF EMERGENCY STEERING CIRCUIT 95
BRAKE PIPING 99
BRAKE CONTROL 100
BRAKE BOOSTER 101
BRAKE 105
PARKING BRAKE CONTROL 107
PARKING BRAKE 108
HYDRAULIC PIPING 109
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 110
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 111
HYDRAULIC TANK 112
MAIN CONTROL VALVE 114
WORK EQUIPMENT LEVEL LINKAGE 127
WORK EQUIPMENT LINKAGE 128
BUCKET 129
BUCKET POSITIONER AND BOOM KICK-OUT 130
PROXIMITY SWITCH 132
CANOPY 134
ROPS CAB 135
AIR CONDITIONER 136
TRAVEL DAMPER SYSTEM (OPTION) 137
ELECTRICAL WIRING DIAGRAM 138
CENTRAL PANEL 140
ENGINE STARTING CIRCUIT 141
ENGINE STOP CIRCUIT 142
FUEL CUT-OFF SOLENOID 143
AUTOMATIC PREHEATING CIRCUIT 144
ELECTRICAL TRANSMISSION CONTROL 145
COMBINATION SWITCH 146
TRANSMISSION CUT-OFF FUNCTION 147
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 149
KICK-DOWN SWITCH, HOLD SWITCH 150
KICK-DOWN ELECTRICAL CIRCUIT 151
20 TESTING AND ADJUSTING 155
STANDARD VALUE TABLE FOR ENGINE 156
STANDARD VALUE TABLE FOR CHASSIS 157
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 160
ADJUSTING VALVE CLEARANCE 162
TESTING AND ADJUSTING FUEL INJECTION TIMING 163
MEASURING EXHAUST COLOR 164
MEASURING BLOW-BY PRESSURE 165
MEASURING ENGINE OIL PRESSURE 166
MEASURING ENGINE SPEED 167
ADJUSTING ENGINE STOP SOLENOID 168
MEASURING ACCELERATOR PEDAL 169
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 171
MEASURING STALL SPEED 172
MEASURING TORQUE CONVERTER, TRANSMISSION, OIL PRESSURE 174
METHOD OF OPERATING EMERGENCY MANUAL SOLENOID VALVE 176
TESTING AND ADJUSTING STEERING WHEEL 178
MEASURING STEERING OIL PRESSURE 181
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 183
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 184
MEASURING BRAKE PERFORMANCE 186
MEASURING BRAKE OIL PRESSURE 187
TESTING FOR BRAKE DISC WEAR 188
BLEEDING AIR FROM BRAKE SYSTEM 189
MEASURING PARKING BRAKE PERFORMANCE 190
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 191
TESTING PARKING BRAKE DISC WEAR 192
MEASURING PARKING BRAKE DISC WEAR 193
MEASURING WORK EQUIPMENT CONTROL LEVER 194
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 197
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 198
MEASURING WORK EQUIPMENT 200
TESTING AND ADJUSTING BUCKET POSITIONER 202
TESTING AND ADJUSTING BOOM KICK-OUT 203
TROUBLESHOOTING 205
USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE 206
POINTS TO REMEMBER WHEN TROUBLESHOOTING 210
TROUBLESHOOTING OF ENGINE (S4D102E) SYSTEM (S MODE) 211
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 212
S-2 ENGINE DOES NOT START 213
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 216
S-4 ENGINE STOPS DURING OPERATIONS 217
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 218
S-6 ENGINE LACKS OUTPUT (NO POWER) 219
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 220
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 221
S-9 OIL BECOMES CONTAMINATED QUICKLY 222
S-10 FUEL CONSUMPTION IS EXCESSIVE 223
S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 224
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 225
S-13 OIL LEVEL RISES 226
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 227
S-15 ABNORMAL NOISE IS MADE 228
S-16 VIBRATION IS EXCESSIVE 229
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (AUTO-SHIFT TRANSMISSION) (A-MODE) 230
OUTLINE 231
1 FUNCTION 231
2 WHEN CARRYING OUT TROUBLESHOOTING 231
3 FAILURE CODE TABLE 231
4 TABLE OF TROUBLESHOOTING MODES AND CAUSES 232
A-1 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM 233
A-2 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM 233
A-3 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 234
A-4 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 235
A-5 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 236
A-6 TROUBLESHOOTING CODE [21] ABNORMALITY IN GEAR SHIFT LEVER SIGNAL SYSTEM 237
A-7 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 238
A-8 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL 239
A-9 KICK-DOWN SWITCH SYSTEM 240
A-10 TRANSMISSION CUT-OFF SIGNAL SYSTEM 241
A-11 NEUTRALIZER RELAY SIGNAL SYSTEM 242
A-12 CAUTION BUZZER SIGNAL SYSTEM 243
A-13 CONTROLLER POWER SOURCE SYSTEM 244
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (T MODE) 245
POWER TRAIN 246
T-1 MACHINE DOES NOT START 246
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 248
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 250
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 251
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 252
STEERING SYSTEM 253
T-6 STEERING WHEEL DOES NOT TURN 253
T-7 STEERING IS HEAVY 254
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 255
T-9 DEVIATES TO ONE SIDE WHEN TRAVELING 256
T-10 TURING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT 256
T-11 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT 256
BRAKE SYSTEM 257
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 257
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS 258
WORK EQUIPMENT 259
T-14 BOOM DOES NOT RISE 259
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 260
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 261
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 261
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM 261
T-19 BOOM SHAKES DURING OPERATION 261
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 262
T-21 BUCKET DOES NOT TILT BACK 263
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 264
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 265
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 265
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 265
T-26 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD) 266
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 266
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 267
30 DISASSEMBLY AND ASSEMBLY 268
METHOD OF USING MANUAL 270
PRECAUTIONS WHEN CARRYING OUT OPERATION 271
SPECIAL TOOL LIST 273
STARTING MOTOR 275
REMOVAL AND INSTALLATION 275
ALTERNATOR 276
REMOVAL AND INSTALLATION 276
FUEL INJECTION PUMP 277
REMOVAL 277
INSTALLATION 279
ENGINE OIL COOLER 282
REMOVAL AND INSTALLATION 282
WATER PUMP 283
REMOVAL AND INSTALLATION 283
NOZZLE HOLDER 284
REMOVAL 284
INSTALLATION 285
THERMOSTAT 286
REMOAVAL AND INSTALLATION 286
TURBOCHARGER 287
REMOVAL AND INSTALLATION 287
CYLINDER HEAD 288
REMOVAL 288
INSTALLATION 293
RADIATOR 296
REMOVAL 296
INSTALLATION 297
ENGINE 298
REMOVAL 298
INSTALLATION 301
TORQUE CONVERTER CHARGING PUMP 302
REMOVAL AND INTALLATION 302
TORQUE CONVERTER, TRANSMISSION 303
REMOVAL 303
INSTALLATION 311
TORQUE CONVERTER 312
DISASSEMBLY 312
ASSEMBLY 314
TRANSMISSION 316
DISASSEMBLY 316
ASSEMBLY 327
CLUTCH PACK 342
DISASSEMBLY 342
ASSEMBLY 348
TRANSMISSION CONTROL VALVE 362
REMOVAL 362
INSTALLATION 363
DISASSEMBLY 364
ASSEMBLY 366
TRANSMISSION SOLENOID VALVE 368
DISASSEMBLY AND ASSEMBLY 368
TRANSMISSION ACCUMULATOR VALVE 369
DISASSEMBLY 369
ASSEMBLY 370
DRIVE SHAFT 371
DISASSEMBLY 371
ASSEMBLY 373
FRONT AXLE 375
REMOVAL 375
INSTALLATION 376
REAR AXLE 377
REMOVAL 377
INSTALLATION 381
DIFFERENTIAL 386
DISASSEMBLY 386
ASSEMBLY 390
AXLE HOUSING 400
DISASSEMBLY 400
ASSEMBLY 405
CENTER HINGE PON 413
REMOVAL 413
INSTALLATION 422
PRIORITY VALVE 431
REMOVAL 431
INSTALLATION 432
STEERING VALVE 433
REMOVAL 433
INSTALLATION 435
DISASSEMBLY 436
ASSEMBLY 439
STEERING CYLINDER 444
REMOVAL 444
INSTALLATION 445
BRAKE BOOSTER 446
REMOVAL 446
INSTALLATION 448
DISASSEMBLY 449
ASSEMBLY 452
PARKING BRAKE 457
REMOVAL 457
INSTALLATION 459
HYDRAULIC TANK 460
REMOVAL 460
INSTALLATION 461
HYDRAULIC FILTER 462
REMOVAL AND INSTALLATION 462
HYDRAULIC, STEERING PUMP 463
REMOVAL 463
INSTALLATION 464
MAIN CONTROL VALVE 465
REMOVAL 465
INSTALLATION 467
DISASSEMBLY 468
ASSEMBLY 470
BUCKET CYLINDER 472
REMOVAL 472
INSTALLATION 473
BOOM CYLINDER 474
REMOVAL 474
INSTALLATION 475
HYDRAULIC CYLINDER 476
DISASSEMBLY 476
ASSEMBLY 478
WORK EQUIPMENT 480
REMOVAL 480
INSTALLATION 483
FUEL TANK 486
REMOVAL 486
INSTALLATION 487
COUNTERWEIGHT 488
REMOVAL AND INSTALLATION 488
INSTRUMENT PANEL 489
REMOVAL AND INSTALLATION 489
ENGINE HOOD 490
REMOVAL INSTALLATION 490
40 MAINTENANCE STANDARD 491
ENGINE MOUNT, TRANSMISSION MOUNT 492
TORQUE CONVERTER CHARGING PUMP 493
TORQUE CONVERTER 494
TRANSMISSION 495
TRANSMISSION CONTROL VALVE 501
ACCUMULATOR VALVE 504
DRIVE SHAFT 505
DIFFERENTIAL 506
FINAL DRIVE 509
AXLE MOUNT 511
CENTER HINGE PIN 512
STEERING COLUMN 514
PRIORITY VALVE 515
STEERING CYLINDER MOUNT 516
BRAKE BOOSTER 517
BRAKE 518
PARKING BRAKE 519
HYDRAULIC AND STEERRING PUMP 520
MAIN CONTROL VALVE 521
HYDAULIC CYLINDER 525
WORK EQUIPMENT LINKAGE 526
BUCKET 528
BUCKET POSITIONER AND BOOM KICK-OUT 529
90 OTHERS 530
ELECTRICAL CIRCUIT DIAGRAM (1/2) 531
ELECTRICAL CIRCUIT DIAGRAM (2/2) 532
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM 533

DESCRIPTION:

Komatsu WA120-3 (EU SPEC.) Wheel Loader Shop Manual SEBM018300 – PDF DOWNLOAD 

MACHINE MODEL         SERIAL NO.
WA120-3 (EU SPEC.)    53001 and up

FOREWORD:
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 chapters; these chapters are further divided into the each main group of components.

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.

S.V 26/12/24