Komatsu WA120-3 WA120L-3 WHEEL LOADER Shop Manual CEBM002002 – PDF

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Komatsu WA120-3 WA120L-3 WHEEL LOADER Shop Manual CEBM002002 – PDF DOWNLOAD

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Komatsu WA120-3 WA120L-3 WHEEL LOADER Shop Manual CEBM002002 – PDF DOWNLOAD

Language : English
Pages :585
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA120-3 WA120L-3 WHEEL LOADER Shop Manual CEBM002002 – PDF DOWNLOAD

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 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 WA120-3 WA120L-3 WHEEL LOADER Shop Manual CEBM002002 – PDF DOWNLOAD

MAIN MENU 0
CONTENTS 2
01 GENERAL 21
SPECIFICATION DRAWINGS 22
SPECIFICATIONS 23
WEIGHT TABLE 26
FUEL, COOLANT, AND LUBRICANTS 27
ENGINE OIL SPECIFICATIONS 28
DIESEL FUEL SPECIFICATIONS 29
COOLANT SPECIFICATIONS 30
10 STRUCTURE AND FUNCTION 35
POWER TRAIN 39
POWER TRAIN SYSTEM 40
TORQUE CONVERTER, TRANSMISSION PIPING 42
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 43
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 44
TORQUE CONVERTER 45
TORQUE CONVERTER OIL FILTER 47
TRANSMISSION 48
CLUTCH 50
REVERSE CLUTCH 50
FORWARD, 2ND CLUTCH 51
3RD, 4TH CLUTCH 51
Operation of clutch 52
FORWARD 1ST 53
FORWARD 2ND 54
FORWARD 3RD 55
FORWARD 4TH 56
REVERSE 1ST 57
TRANSMISSION CONTROL VALVE 58
UPPER VALVE 59
LOWER VALVE 60
TRANSMISSION SOLENOID VALVE 61
TORQUE CONVERTER OUTLET PORT VALVE 62
PILOT REDUCING VALVE 63
TRANSMISSION SOLENOID VALVE 64
PRIORITY VALVE 65
MAIN REGULATOR VALVE 66
QUICK RETURN VALVE 67
MODULATION FILL VALVE 71
DIRECTIONAL SELECTOR SPOOL 73
EMERGENCY MANUAL SPOOL 74
OPERATION OF FORWARD 1ST 75
ACCUMULATOR VALVE 77
TRANSMISSION CONTROL 79
DRIVE SHAFT 80
AXLE 81
FRONT AXLE 81
FRONT DIFFERENTIAL 82
REAR AXLE 83
REAR DIFFERENTIAL 84
Outline 85
TORQUE PROPORTIONING DIFFERENTIAL 86
FINAL DRIVE 87
AXLE MOUNT 88
CENTER HINGE PIN 90
STEERING PIPING 91
STEERING COLUMN 92
PRIORITY VALVE 93
STEERING VALVE (ORBIT-ROLL) 96
Operation 98
1 Steering wheel at neutral 98
2 Steering wheel turned (turning to left)100
CONNECTION BETWEEN HAND PUMP AND SLEEVE102
BRAKE PIPING104
BRAKE CONTROL105
BRAKE BOOSTER106
BRAKE110
PARKING BRAKE CONTROL112
PARKING BRAKE113
HYDRAULIC PIPING114
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM116
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM117
HYDRAULIC TANK118
OIL FILTER BYPASS VALVE119
BREATHER120
MAIN CONTROL VALVE122
2-SPOOL VALVE122
3-SPOOL VALVE124
RELIEF VALVE126
SAFETY VALVE (WITH SUCTION)127
SUCTION VALVE128
Boom and bucket spool at NEUTRAL position129
Boom spool at RAISE position130
Boom spool at LOWER position131
Boom spool at FLOAT position132
Bucket spool at TILT BACK position133
Bucket spool at DUMP position134
WORK EQUIPMENT LEVER LINKAGE135
WORK EQUIPMENT LINKAGE136
BUCKET138
BUCKET POSITIONER AND BOOM KICK-OUT140
BUCKET POSITIONER141
BOOM KICK-OUT141
PROXIMITY SWITCH142
OPERATION OF THE PROXIMITY SWITCH143
Bucket TILT BACK switch143
Boom RAISE switch143
Action of the proximity switch143
ROPS CAB144
AIR CONDITIONER146
AIR CONDITIONER AND HEATER PIPING146
ELECTRIC CIRCUIT DIAGRAM147
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)148
ECSS HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM149
OPERATION150
ELECTRICAL WIRING ILLUSTRATION153
ELECTRICAL WIRING DIAGRAM (1/3)154
CENTRAL PANEL (CLUSTER GAUGE)161
SENSOR162
ENGINE OIL PRESSURE162
BRAKE OIL LEVEL162
ENGINE STARTING CIRCUIT163
ENGINE STOP CIRCUIT164
AUTOMATIC PREHEATING CIRCUIT165
QUICK HEATING SYSTEM (QHS)165
QHS CONTROLLER167
HEATER RELAY167
RIBBON HEATER168
QHS WATER TEMPERATURE SENSOR168
ELECTRICAL TRANSMISSION CONTROL169
COMBINATION SWITCH170
TRANSMISSION CUT-OFF FUNCTION171
PARKING BRAKE FUNCTION173
KICK-DOWN SWITCH174
KICK-DOWN SWITCH174
KICK DOWN ELECTRIC CIRCUIT DIAGRAM175
KICK-DOWN SWITCH OPERATED176
KICK-DOWN SWITCH ACTUATION – CANCELED (1)177
KICK-DOWN SWITCH ACTUATION – CANCELED (2)178
KICK-DOWN SWITCH ACTUATION – CANCELED (3)179
20 TESTING, ADJUSTING AND TROUBLESHOOTING180
TESTING AND ADJUSTING183
STANDARD VALUE TABLE FOR ENGINE – In Chassis185
STANDARD VALUE TABLE FOR CHASSIS187
TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING191
MEASURING ENGINE SPEEDS193
MEASURING ENGINE LUBRICATING OIL PRESSURE194
MEASURING FUEL FILTER INLET RESTRICTION194
MEASURING BLOW-BY PRESSURE194
MEASURING COMPRESSION PRESSURE195
MEASURING EXHAUST COLOR196
MEASURING COOLANT TEMPERATURE197
MEASURING AND ADJUSTING VALVE CLEARANCE197
MEASURING ACCELERATOR PEDAL198
OPERATING FORCE OF ACCELERATOR PEDAL198
OPERATING ANGLE OF ACCELERATOR PEDAL199
MEASURING OPERATING FORCE, AND TRAVEL OF SPEED LEVER200
OPERATING FORCE OF SPEED LEVER200
TRAVEL OF SPEED LEVER200
MEASURING STALL SPEEDS201
TORQUE CONVERTER STALL SPEED201
HYDRAULIC STALL SPEED202
FULL STALL SPEED202
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE203
METHOD OF OPERATING EMERGENCY MANUAL SPOOL205
TESTING AND ADJUSTING STEERING WHEEL207
MEASURING PROCEDURE207
MEASURING OPERATING FORCE OF STEERING WHEEL208
MEASURING OPERATING TIME FOR STEERING WHEEL209
MEASURING STEERING OIL PRESSURE210
METHOD OF MEASURING MAIN RELIEF PRESSURE210
METHOD OF ADJUSTING MAIN RELIEF PRESSURE211
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL212
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE213
MEASURING BRAKE PERFORMANCE215
MEASURING BRAKE OIL PRESSURE216
TESTING FOR BRAKE DISC WEAR217
BLEEDING AIR FROM BRAKE SYSTEM218
MEASURING PARKING BRAKE PERFORMANCE219
TESTING AND ADJUSTING PARKING BRAKE LINKAGE220
TESTING PARKING BRAKE DISC WEAR221
MEASURING PARKING BRAKE DISC WEAR222
MEASURING WORK EQUIPMENT CONTROL LEVER223
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL226
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE227
MEASURING WORK EQUIPMENT229
TESTING AND ADJUSTING BUCKET POSITIONER232
TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED)233
TROUBLESHOOTING236
POINTS TO REMEMBER WHEN TROUBLESHOOTING237
SEQUENCE OF EVENTS IN TROUBLESHOOTING238
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE239
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT239
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS244
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT245
CHECKS BEFORE TROUBLESHOOTING247
HANDLING CONNECTORS248
PRECAUTIONS WHEN TROUBLESHOOTING249
PREVENTING RECURRENCE OF TROUBLE251
METHOD OF USING TROUBLESHOOTING CHARTS253
1 Category of troubleshooting code number253
2 Method of using troubleshooting table for each troubleshooting mode253
3 Using troubleshooting chart for engine related failure255
TROUBLESHOOTING OF ENGINE SYSTEM262
S-1 STARTING PERFORMANCE IS POOR (Starting always takes time)263
S-2 Engine does not start264
S-3 Engine does not pick up smoothly (Follow up is poor)267
S-4 Engine stops during operations268
S-5 Engine does not rotate smoothly (hunting)269
S-6 Engine lacks output (no power)270
S-7 Exhaust gas is black (incomplete combustion)271
S-8 Oil consumption is excessive (or exhaust gas is blue)272
S-9 Oil becomes contaminated quickly273
S-10 Fuel consumption is excessive274
S-11 Oil is in cooling water, or water spurts back, or water level goes down275
S-12 Oil pressure lamp lights up (drop in oil pressure)276
S-13 Oil level rises277
S-14 Water temperature becomes too high278
S-15 Abnormal noise is made279
S-16 Vibration is excessive280
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM282
POWER TRAIN283
T-1 Machine does not start283
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes285
T-3 Excessive shock when starting machine or shifting gear287
T-4 Excessive time lag when starting machine or shifting gear288
T-5 Torque converter oil temperature is high289
STEERING SYSTEM290
S-1 Steering wheel does not turn290
S-2 Steering is heavy291
S-3 Steering wheel shakes or there is excessive shock292
S-4 Deviates to one side when traveling293
S-5 Turning radius is different between left and right293
S-6 Excessive shock to machine when steering wheel is turned fully to left or right293
BRAKE SYSTEM294
A-1 Brakes do not work or braking effect is poor294
A-2 Brake is not released, brake drags295
WORK EQUIPMENT296
H-1 Boom does not rise296
H-2 Boom movement is slow or boom lacks lifting power297
H-3 When boom is raised, it moves slowly at a certain height298
H-4 Bucket cannot be pushed with boom cylinder (bucket floats)298
H-5 Excessive hydraulic drift of boom298
H-6 Boom shakes during operation298
H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE299
H-8 Bucket does not tilt back300
H-9 Bucket movement is slow or tilt-back lacks power301
H-10 Bucket movement becomes slow during tilt-back operation302
H-11 Bucket cannot be pushed with bucket cylinder302
H-12 Excessive hydraulic drift of bucket302
H-13 Bucket shakes during loading operation (Main control valve at HOLD)303
H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT303
H-15 Boom, bucket control levers are heavy or do not move smoothly304
AIR CONDITIONER / HEATER (EAGLE)305
TROUBLESHOOTING306
WIRING DIAGRAM 310
30 DISASSEMBLY AND ASSEMBLY311
METHOD OF USING MANUAL315
1 When removing or installing unit assemblies315
2 General precautions315
3 Listing of special tools315
PRECAUTIONS WHEN CARRYING OUT OPERATION316
1 Precautions when carrying out removal work316
2 Precautions when carrying out installation work317
3 Precautions when completing the operations318
SPECIAL TOOL LIST319
STARTING MOTOR ASSEMBLY321
REMOVAL321
INSTALLATION321
ALTERNATOR ASSEMBLY322
REMOVAL322
INSTALLATION322
FUEL INJECTION PUMP323
REMOVAL323
INSTALLATION323
ENGINE OIL COOLER324
REMOVAL324
INSTALLATION324
WATER PUMP325
REMOVAL325
INSTALLATION325
NOZZLE HOLDER326
REMOVAL326
INSTALLATION326
THERMOSTAT327
REMOVAL327
INSTALLATION327
TURBOCHARGER328
REMOVAL328
INSTALLATION328
CYLINDER HEAD329
REMOVAL329
INSTALLATION329
RADIATOR330
REMOVAL330
INSTALLATION333
ENGINE334
REMOVAL334
INSTALLATION341
ENGINE HOOD342
REMOVAL342
INSTALLATION343
EXHAUST MUFFLER344
REMOVAL344
INSTALLATION344
AIR CLEANER345
REMOVAL345
INSTALLATION345
TORQUE CONVERTER CHARGING PUMP347
REMOVAL347
INSTALLATION347
TORQUE CONVERTER, TRANSMISSION348
REMOVAL348
INSTALLATION355
TORQUE CONVERTER ASSEMBLY356
DISASSEMBLY356
ASSEMBLY358
TRANSMISSION360
DISASSEMBLY360
PARKING BRAKE369
DISASSEMBLY369
ASSEMBLY371
ASSEMBLY374
TRANSMISSION CLUTCH PACK386
I DISASSEMBLY OF 1ST, REVERSE CLUTCH386
II DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK388
Ill DISASSEMBLY OF 3RD, 4TH CLUTCH PACK390
ASSEMBLY OF CLUTCH PACK392
l ASSEMBLY OF 1ST, REVERSE CLUTCH PACK392
II ASSEMBLY OF FORWARD, 2ND CLUTCH PACK397
Ill ASSEMBLY OF 3RD, 4TH CLUTCH PACK401
TRANSMISSION CONTROL VALVE406
REMOVAL406
INSTALLATION407
DISASSEMBLY408
ASSEMBLY410
TRANSMISSION SOLENOID VALVE412
TRANSMISSION ACCUMULATOR VALVE413
DISASSEMBLY413
ASSEMBLY414
DRIVE SHAFT416
DISASSEMBLY416
ASSEMBLY418
FRONT AXLE419
REMOVAL419
INSTALLATION420
REAR AXLE421
REMOVAL421
INSTALLATION425
DIFFERENTIAL430
DISASSEMBLY430
ASSEMBLY434
AXLE HOUSING444
DISASSEMBLY444
ASSEMBLY449
CENTER HINGE PIN457
REMOVAL457
INSTALLATION465
STEERING VALVE474
REMOVAL474
INSTALLATION476
DISASSEMBLY 477
DISASSEMBLY OF ROTOR477
DISASSEMBLY OF CONTROL SIDE478
ASSEMBLY480
ASSEMBLY OF ROTOR482
STEERING CYLINDER485
REMOVAL485
INSTALLATION486
BRAKE BOOSTER487
REMOVAL487
INSTALLATION489
DISASSEMBLY490
ASSEMBLY493
PARKING BRAKE498
REMOVAL498
INSTALLATION500
HYDRAULIC TANK501
REMOVAL501
INSTALLATION502
HYDRAULIC FILTER503
REMOVAL503
INSTALLATION503
HYDRAULIC STEERING PUMP504
REMOVAL504
INSTALLATION505
MAIN CONTROL VALVE506
REMOVAL506
INSTALLATION508
DISASSEMBLY509
ASSEMBLY511
BUCKET CYLINDER514
REMOVAL514
INSTALLATION515
BOOM CYLINDER516
REMOVAL516
INSTALLATION517
HYDRAULIC CYLINDERS518
DISASSEMBLY518
ASSEMBLY520
WORK EQUIPMENT522
REMOVAL522
INSTALLATION525
FUEL TANK528
REMOVAL528
INSTALLATION 529
COUNTERWEIGHTS530
REMOVAL OF LEFT AND RIGHT SIDE COUNTERWEIGHTS530
INSTALLATION OF LEFT AND RIGHT SIDE COUNTERWEIGHTS530
REMOVAL OF REAR COUNTERWEIGHT530
INSTALLATION OF REAR COUNTERWEIGHT531
INSTRUMENT PANEL532
REMOVAL532
INSTALLATION532
40 MAINTENANCE STANDARD533
ENGINE MOUNT, TRANSMISSION MOUNT535
TORQUE CONVERTER CHARGING PUMP536
TORQUE CONVERTER 537
TRANSMISSION538
TRANSMISSION (1/3)538
TRANSMISSION (2/3)540
TRANSMISSION (3/3)542
REVERSE, 1ST CLUTCH544
FORWARD , 2ND CLUTCH546
3RD, 4TH CLUTCH548
TRANSMISSION CONTROL VALVE550
LOWER VALVE552
SOLENOID VALVE553
ACCUMULATOR VALVE554
DRIVE SHAFT555
DIFFERENTIAL557
DIFFERENTIAL (1/2)557
DIFFERENTIAL (2/2)558
FINAL DRIVE560
AXLE MOUNT562
CENTER HINGE PIN564
STEERING COLUMN566
STEERING CYLINDER MOUNT567
PRIORITY VALVE568
BRAKE BOOSTER569
BRAKE570
PARKING BRAKE571
HYDRAULIC PUMP572
MAIN CONTROL VALVE574
2-SPOOL VALVE574
3-SPOOL VALVE576
HYDRAULIC CYLINDER578
WORK EQUIPMENT LINKAGE580
BUCKET582
BUCKET POSITIONER AND BOOM KICK-OUT583

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24