Komatsu WA120-3CS Avance Loader Shop Manual SEBM012402 – PDF DOWNLOAD

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Komatsu WA120-3CS Avance Loader Shop Manual SEBM012402 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA120-3CS Avance Loader Shop Manual SEBM012402 – PDF DOWNLOAD

Language : English
Pages :421
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu WA120-3CS Avance Loader Shop Manual SEBM012402 – PDF DOWNLOAD

MACHINE MODEL
WA120-3CS
SERIAL NUMBER
10004 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.

TABLE OF CONTENTS:

Komatsu WA120-3CS Avance Loader Shop Manual SEBM012402 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 22
GENERAL ASSEMBLY DRAWING 23
SPECIFCATIONS 24
WEIGHT TABLE 27
LIST OF LUBRICANT AND WATER 28
10 STRUCTURE AND FUNCTION 30
OUTLINE 31
POWER TRAIN SYSTEM 32
DAMPER 34
HST PIPING 35
HYDRAULIC CIRCUIT DIAGRAM FOR HYDROSTATIC TRANSMISSION(HST) 36
MAIN PISTON PUMP 38
HIGH-PRESSURE RELIEF VALVE 40
LOW-PRESSURE RELIEF VALVE 42
HST CHARGE PUMP 43
CHARGE PUMP OIL FILTER 45
SPEED RELATED VALVE(DA VALVE) 46
HIGH-PRESSURE CUT-OFF VALVE 47
PISTON MOTOR 48
DIRECTIONAL SHUTTLE VALVE 50
SERVO VALVE 51
INTERMEDIATE FIXED CONTROL OF ANGLE 52
INCHING VALVE 53
TRANSFER 54
HST CONTROL 55
DRIVE SHAFT 56
AXLE 57
DIFFERENTIAL 59
FINAL DRIVE 62
AXLE MOUNT 64
CENTER HINGE PIN 65
STEERING PIPING 66
STEERING COLUMN 67
PRIORITY VALVE 68
STEERING VALVE(ORBIT-ROLL) 72
BRAKE PIPING 80
BRAKE CONTROL 81
BRAKE 82
BRAKE MASTER CYLINDER 84
PARKING BRAKE CONTROL 87
PARKING BRAKE 88
HYDRAULIC PIPING 89
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 91
WORK EQUIPMENT LEVER LINKAGE 93
HYDRAUIC TANK 94
HYDRAULIC FILTER 95
MAIN CONTROL VALVE 96
WORK EQUIPMENT LINKAGE104
BUCKET106
BUCKET POSITIONER107
PROXIMITY SWITCH108
CANOPY109
ELECTRIC CIRCUIT DIAGRAM110
CENTRAL PANEL(CLUSTER GAUGE)111
SENSOR112
ENGINE STARTING CIRCUIT113
ENGINE STOP CIRCUIT114
PARKING BRAKE CIRCUIT115
20 TESTING AND ADJUSTING117
STANDARD VALUE TABLE FOR ENGINE118
STANDARD VALUE TABLE FOR CHASSIS119
STANDARD VALUE TABLE FOR ELECTRICAL PARTS123
TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING127
MEASURING ENGINE SPEED129
MEASURING EXHAUST COLOR130
ADJUSTING VALVE CLEARANCE131
MEASURING COMPRESSION PRESSURE132
MEASURING BLOW-BY PRESSURE133
TESTING AND ADJUSTING FUEL INJECTION TIMING134
MEASURING ENGINE OIL PRESSURE135
TESTING AND ADJUSTING FAN BELT TENSION135
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE136
TESTING AND ADJUSTING HST OIL PRESSURE138
TESTING AND ADJUSTING STEERING OIL PRESSURE142
BLEEDING AIR FROM STEERING CIRCUIT144
MEASURING BRAKE PERFORMANCE145
TESTING DROP IN WHEEL BRAKE OIL PRESSURE146
MEASURING WHEEL BRAKE DISC WEAR147
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT148
ADJUSTING WHEEL BRAKE LINKAGE149
MEASURING PARKING BRAKE PERFORMANCE150
TESTING AND ADJUSTING PARKING BRAKE LINKAGE151
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE152
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT154
ADJUSTING WORK EQUIPMENT LEVER LINKAGE155
TESTING AND ADJUSTING BUCKET POSITIONER156
TROUBLESHOOTING157
POINTS TO REMEMBER WHEN TROUBLESHOOTING158
SEQUENCE OF EVENTS IN TROUBLESHOOTING159
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE160
CHECKS BEFORE TROUBLESHOOTING168
CONNECTOR TYPES AND MOUNTING LOCATIONS169
CONNECTOR PIN ARRANGEMENT DIAGRAM171
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS174
METHOD OF USING FAILURE MODE AND JUDGEMENT TABLE184
FAILURE MODES AND JUDGEMENT TABLE185
METHOD OF USING TROUBLESHOOTING CHARTS187
TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)189
USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE190
S- 1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)194
S- 2 ENGINE DOES NOT START195
(1) ENGINE DOES NOT TURN195
(2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT(FUEL IS NOT BEING INJECTED)196
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)197
S- 3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)198
S- 4 ENGINE STOPS DURING OPERATIONS199
S- 5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)200
S- 6 ENGINE LACKS OUTPUT(NO POWER)201
S- 7 EXHAUST GAS IS BLACK(INCOMPLETE COMBUSTION)202
S- 8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST GAS IS BLUE)203
S- 9 OIL BECOMES CONTAMINATED QUICKLY204
S-10 FUEL CONSUMPTION IS EXCESSIVE205
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN206
S-12 OIL PRESSURE LAMP LIGHTS UP(DROP IN OIL PRESSURE)207
S-13 OIL LEVEL RISES208
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)209
S-15 ABNORMAL NOISE IS MADE210
S-16 VIBRATION IS EXCESSIVE211
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)212
ELECTRICAL CIRCUIT SYSTEM DIAGRAM FOR ENGINE STARTING,STOP SYSTEM213
ELECTRICAL CIRCUIT SYSTEM DIAGRAM FOR HST SYSTEM214
ELECTRICAL CIRCUIT SYSTEM DIAGRAM FOR BUCKET POSITIONER SYSTEM215
E-1 ENGINE DOES NOT START216
a) ENGINE DOES NOT TURN(STARTING MOTOR SYSTEM)216
b) STARTING MOTOR TURN(ENGINE STOP MONITOR SYSTEM)219
E-2 ENGINE DOES NOT STOP221
E-3 DOES NOT TRAVEL IN ANY DIRECTION(FORWARD OR REVERSE)222
E-4 DOES NOT TRAVEL FORWARD(REVERSE IS NORMAL)224
E-5 DOES NOT TRAVEL IN REVERSE(FORWARD IS NORMAL)225
E-6 HI-LO MODE DOES NOT SWITCH226
a) STAYS IN HI AND DOES NOT SWITCH TO LO226
b) STAYS IN LO AND DOES NOT SWITCH TO HI226
E-7 DEFECTIVE ACTUATION OF BUCKET POSITIONER227
a) BUCKET CONTROL LEVER IS NOT HELD AT TILT POSITION227
b) BUCKET CONTROL LEVER DOES NOT RETURN FROM TILT POSITION TO HOLD227
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE)229
FAILURE MODES AND CAUSES230
H- 1 DOES NOT TRAVEL IN ANY DIRECTION(FORWARD OR REVERSE)232
H- 2 DOES NOT TRAVEL FORWARD(REVERSE IS NORMAL)234
H- 3 DOES NOT TRAVEL IN REVERSE(FORWARD IS NORMAL)234
H- 4 TRAVEL SPEED IS SLOW IN BOTH DIRECTIONS(FORWARD AND REVERSE)235
H- 5 TRAVEL SPEED IS SLOW IN FORWARD(REVERSE IS NORMAL)236
H- 6 TRAVEL SPEED IS SLOW IN REVERSE(FORWARD IS NORMAL)236
H- 7 DRAWBAR PULL IS WEAK IN BOTH DIRCTIONS(FORWARD AND REVERSE)237
H- 8 DRAWBAR PULL IS WEAK IN FORWARD(REVERSE IS NORMAL)237
H- 9 DRAWBAR PULL IS WEAK IN REVERSE(FORWARD IS NORMAL)237
H-10 ENGINE STALLS WHEN TRAVELING,OR THERE IS EXCESSIVE DROP IN ENGINE SPEED238
H-11 HI-LO MODE DOES NOT SWITCH238
H-12 STEERING DOES NOT TURN239
H-13 STEERING EFFECT,RESPONSE IS POOR239
H-14 STEERING WHEEL IS HEAVY240
H-15 STEERING WOBBLES OR JERKS240
H-16 STEERING DEVIATES TO ONE SIDE WHEN TRAVELING240
H-17 WHEEL BRAKE HAS NO EFFECT OR EFFECT IS POOR241
H-18 WHEEL BRAKE CANNOT BE RELEASED OR BRAKE DRAGS241
H-19 BOOM AND BUCKET DO NOT MOVE AT SAME TIME242
H-20 BOOM AND BUCKET SPEED IS SLOW OR LACKS POWER WHEN OPERATED AT SAME TIME242
H-21 BOOM DOES NOT MOVE243
H-22 BOOM SPEED IS SLOW OR LACKS POWER243
H-23 BOOM DOES NOT MOVE TO FLOAT POSITION243
H-24 EXCESSIVE HYDRAULIC DRIFT OF BOOM244
H-25 BOOM CONTROL LEVER IS HEAVY244
H-26 BUCKET DOES NOT MOVE245
H-27 BUCKET SPEED IS SLOW OR LACKS POWER245
H-28 DEFECTIVE ACTUATION OF BUCKET POSITIONER245
H-29 EXCESSIVE HYDRAULIC DRIFT OF BUCKET246
H-30 BUCKET CONTROL LEVER IS HEAVY246
TROUBLESHOOTING OF MONITOR PANEL SYSTEM(M MODE)247
ELECTRICAL CIRCUIT SYSTEM249
M-1 ABNORMALITY IN MONITOR PANEL POWER SOURCE SYSTEM OR GND SYSTEM251
a) WHEN STARTING SWITCH IS TURNED ON,”FILTER CLOGGING”,”ENGINE OIL PRESSURE”,”PARKING BRAKE”,”BRAKE OIL LEVEL”,AND “PREHEATING”LAMPS DO NOT LIGHT UP AT THE SAME TIME(POWER SOURCE SYSTEM)251
b) WHEN STARTING SWITCH IS TURNED ON,”BATTERY CHARGE”,”HI BEAM”,AND “SERVICE METER” LAMPS DO NOT LIGHT UP AT THE SAME TIME(GND SYSTEM)251
M-2 ABNORMALITY IN BRAKE OIL LEVEL CAUTION LAMP253
a) WHEN STARTING SWITCH IS TURNED ON,LAMPS DO NOT LIGHT UP253
b) WHEN ENGINE IS RUNNING,ENGINE OIL PRESSURE IS NORMAL BUT LAMP LIGHTS UP253
c) WHEN THE ENGINE IS RUNNING,THE ENGINE OIL PRESSURE IS ABNORMAL BUT THE LAMP DOES NOT LIGHT UP254
M-3 ABNORMALITY IN PARKING BRAKE PILOT LAMP255
a) LAMP DOES NOT LIGHT UP WHEN PARKING BRAKE PEDAL IS OPERATED255
b) LAMP DOES NOT GO OUT WHEN PARKING BRAKE PEDAL IS RELEASED256
M-4 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP257
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON257
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNING257
M-5 ABNORMALITY IN CHARGE CAUTION LAMP258
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON258
b) LAMP LIGHTS UP WHEN ENGINE IS RUNNIG259
M-6 ABNORMALITY IN PARKING BRAKE NOT APPLIED CAUTION LAMP AND BUZZER260
a) ENGINE IS STOPPED AND PARKING BRAKE PEDAL IS DEPRESSED,BUT LAMP LIGHTS UP AND BUZZER SOUNDS260
b) ENGINE IS STOPPED AND PARKING BRAKE PEDAL IS RELEASED,BUT LAMP IS OUT AND BUZZER DOES NOT SOUND260
c) WHEN ENGINE IS RUNNING,LAMP LIGHTS UP AND BUZZER SOUNDS261
M-7 ABNORMALITY IN HST OIL FILTER CLOGGING CAUTION LAMP262
a) LAMP DOES NOT LIGHT UP WHEN STARTING SWITCH IS TURNED ON262
b) WHEN THE ENGINE IS RUNNING,THE LAMP LIGHTS UP EVEN WHEN THE FILTER IS NOT CLOGGED262
c) WHEN THE ENGINE IS RUNNING,THE LAMP DOES NOT LIGHT UP EVEN WHEN THE FILTER IS CLOGGED263
M-8 ABNORMALITY IN HST OIL TEMPERATURE GAUGE264
a) GAUGE DOES NOT RISE FROM C (LOWEST POSITION)264
b) GAUGE DOES NOT GO DOWN FROM H (HIGHEST POSITION)264
c) HST OIL TEMPERATURE AND GAUGE DISPLAY DO NOT MATCH265
M-9 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE266
a) GAUGE DOES NOT RISE FROM C (LOWEST POSITION)266
b) GAUGE DOES NOT GO DOWN FROM H (HIGHEST POSITION)266
c) ENGINE WATER TEMPERATURE AND GAUGE DISPLAY DO NOT MATCH267
M-10 ABNORMALITY IN FUEL GAUGE268
a) GAUGE DOES NOT RISE FROM E (LOWEST POSITION)268
b) GAUGE DOES NOT GO DOWN FROM F (HIGHEST POSITION)268
c) FUEL LEVEL AND GAUGE DISPLAY DO NOT MATCH269
M-11 ABNORMALITY IN SERVICE METER270
a) SERVICE METER ADVANCES EVEN WHEN ENGINE IS STOPPED270
b) SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING270
c) WHEN SERVICE METER IS ADVANCING,INDICATOR LAMP DOES NOT FLASH270
M-12 ABNORMALITY IN HEAD LAMP,SIDE LAMP,AND LICENSE LAMP272
a) WHEN LAMP SWITCH IS AT POSITION I,NONE OF HEAD LAMP,SIDE LAMP,AND LICENSE LAMP LIGHT UP272
b) WHEN LAMP SWITCH IS AT POSITION I,HEAD LAMP DOES NOT LIGHT UP(SIDE LAMP AND LICENSE LAMP ARE NORMAL)273
c) WHEN LAMP SWITCH IS AT POSITION I,SIDE LAMP AND LICENSE LAMP DO NOT LIGHT UP(HEAD LAMP IS NORMAL)274
d) WHEN LAMP SWITCH IS AT POSITION II,HEAD LAMP DOES NOT SWITCH TO HI BEAM275
e) WHEN LAMP SWITCH IS AT POSITION II,HI BEAM PILOT LAMP ON MONITOR PANEL DOES NOT LIGHT UP275
M-13 ABNORMALITY IN TURN SIGNAL LAMP(TURN SIGNAL INDICATOR)276
a) NEITHER LEFT OR RIGHT TURN SIGNAL LAMPS FLASH276
b) TURN SIGNAL LAMP FLASHES ON ONE SIDE ONLY276
c) TURN SIGNAL PILOT LAMP ON MONITOR DOES NOT FLASH277
M-14 ABNORMALITY IN STOP LAMP278
a) STOP LAMP DOES NOT LIGHT UP WHEN BRAKE PEDAL IS DEPRESSED278
b) STOP LAMP LIGHTS UP EVEN WHEN BRAKE PEDAL IS NOT BEING DEPRESSED278
30 DISASSEMBLY AND ASSEMBLY279
METHOD OF USING MANUAL281
PRECAUTIONS WHEN CARRYING OUT OPERATION282
SPECIAL TOOL LIST284
SKETCHES OF SPECIAL TOOLS287
STARTING MOTOR289
REMOVAL AND INSTALLATION289
ALTERNATOR290
REMOVAL AND INSTALLATION290
FUEL INJECTION PUMP291
REMOVAL291
INSTALLATION292
NOZZLE HOLDER293
REMOVAL AND INSTALLATION293
WATER PUMP294
REMOVAL AND INSTALLATION294
THERMOSTAT295
REMOVAL AND INSTALLATION295
ENGINE OIL COOLER296
REMOVAL AND INSTALLATION296
CYLINDER HEAD297
REMOVAL297
INSTALLATION300
RADIATOR302
REMOVAL302
INSTALLATION305
ENGINE,HYDRAULIC PUMP306
REMOVAL306
INSTALLATION309
FUEL TANK310
REMOVAL AND INSTALLATION310
DAMPER311
REMOVAL311
INSTALLATION312
HST PUMP313
REMOVAL313
INSTALLATION314
HST MOTOR315
REMOVAL315
INSTALLATION316
TRANSFER317
REMOVAL317
INSTALLATION318
DISASSEMBLY319
ASSEMBLY325
FRONT AXLE331
REMOVAL331
INSTALLATION332
REAR AXLE333
REMOVAL333
INSTALLATION335
AXLE337
DISASSEMBLY337
ASSEMBLY343
CENTER HINGE PIN353
REMOVAL353
INSTALLATION357
STEERING,HYDRAULIC PUMP361
REMOVAL AND INSTALLATION361
STEERING VALVE362
REMOVAL362
INSTALLATION363
STEERING CYLINDER364
REMOVAL364
INSTALLATION365
DISASSEMBLY366
ASSEMBLY369
BRAKE MASTER CYLINDER372
REMOVAL AND INSTALLATION372
INCHING VALVE373
REMOVAL AND INSTALLATION373
HYDRAULIC TANK374
REMOVAL AND INSTALLATION374
MAIN CONTROL VALVE375
REMOVAL AND INSTALLATION375
BOOM CYLINDER376
REMOVAL376
INSTALLATION377
BUCKET CYLINDER378
REMOVAL378
INSTALLATION379
BOOM,BUCKET CYLINDER380
DISASSEMBLY380
ASSEMBLY382
BUCKET384
REMOVAL AND INSTALLATION384
BOOM385
REMOVAL385
INSTALLATION386
ENGINE HOOD387
REMOVAL AND INSTALLATION387
CANOPY388
REMOVAL AND INSTALLATION388
FLOOR FRAME389
REMOVAL389
INSTALLATION392
COUNTERWEIGHT(REAR END)393
REMOVAL AND INSTALLATION393
COUNTERWEIGHT(LOWER PORTION)394
REMOVAL AND INSTALLATION394
MONITOR PANEL395
REMOVAL AND INSTALLATION395
40 MAINTENANCE STANDARD396
ENGINE MOUNT397
TRANSFER MOUNT398
TRANSFER399
HST INCHING VALVE401
DRIVE SHAFT402
DIFFERENTIAL403
FINAL DRIVE406
AXLE MOUNT407
CENTER HINGE PIN408
STEERING COLUMN409
PRIORITY VALVE410
STEERING CYLINDER MOUNT411
PARKING BRAKE412
HYDRAULIC AND STEERING PUMP413
HYDRAULIC CYLINDER414
WORK EQUIPMENT LINKAGE415
BUCKET417
BUCKET POSITIONER418
90 OTHERS419
ELECTRIC CIRCUIT DIAGRAM(1/2)420
ELECTRIC CIRCUIT DIAGRAM(2/2)421

IMAGES PREVIEW OF THE MANUAL:

S.M 14/12/24