Komatsu WA120L-3MC Shop Manual SEBM021800 – PDF DOWNLOAD

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Komatsu Wheel Loader WA12L0-3MC Shop Manual – PDF DOWNLOAD

FILE DETAILS:

Komatsu Wheel Loader WA12L0-3MC Shop Manual – PDF DOWNLOAD

Language : English
Pages :650
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Wheel Loader WA12L0-3MC Shop Manual – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
WA120L-3MC 54104 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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling
each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together

TABLE OF CONTENTS:

Komatsu WA120L-3MC Shop Manual SEBM021800 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 23
GENERAL ASSEMBLY DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 28
LIST OF LUBRICANT AND WATER 30
10 STRUCTURE AND FUNCTION 32
POWER TRAIN 33
POWER TRAIN SYSTEM 34
TORQUE CONVERTER, TRANSMISSION PIPING 36
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 37
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 38
TORQUE CONVERTER 39
TRANSMISSION 41
TRANSMISSION CONTROL VALVE 51
TRANSMISSION CONTROL 72
DRIVE SHAFT 73
AXLE 74
FINAL DRIVE 80
AXLE MOUNT 81
CENTER HINGE PIN 83
STEERING PIPING 84
STEERING COLUMN 85
PRIORITY VALVE 86
STEERING VALVE (DRBIT-ROLL) 89
BRAKE PIPING 97
BRAKE CONTROL 98
BRAKE BOOSTER 99
BRAKE 103
PARKING BRAKE CONTROL105
PARKING BRAKE 106
HYDRAULIC PIPING 107
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM109
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM110
HYDRAULIC TANK112
PPC VALVE115
ACCUMULATOR122
MAIN CONTROL VALVE123
WORK EQUIPMENT LINKAGE136
BUCKET138
BUCKET POSITIONER AND BOOM KICK-OUT139
PROXIMITY SWITCH141
ROPS CAB143
AIR CONDITIONER144
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)145
ELECTRICAL WIRING DIAGRAM 148
AIR CONDITIONING AND HEATER ELECTRICAL DIAGRAM153
CENTRAL PANEL154
SENSOR155
ENGINE STARTING CIRCUIT156
ENGINE STOP CIRCUIT157
FUEL CUT-OFF SOLENOID158
AUTOMATIC PREHEATING CIRCUIT (OHS CONTROLLER)159
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM163
20 TESTING AND ADJUSTING182
STANDARD VALUE TABLE FOR ENGINE183
STANDARD VALUE TABLE FOR CHASSIS184
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING187
ADJUSTING VALVE CLEARANCE189
TESTING AND ADJUSTING FUEL INJECTION TIMING190
MEASURING EXHAUST COLOR191
MEASURING BLOW-BY PRESSURE192
MEASURING ENGINE OIL PRESSURE193
MEASURING ENGINE SPEED194
ADJUSTING ENGINE STOP SOLENOID195
MEASURING ACCELERATOR PEDAL196
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER198
MEASURING STALL SPEED199
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE201
METHOD OF OPERATING EMERGENCY MANUAL SOLENOID VALVE203
TESTING AND ADJUSTING STEERING WHEEL205
MEASURING STEERING OIL PRESWSURE 208
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL210
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE211
MEASURING BRAKE PERFORMANCE213
MEASURING BRAKE OIL PRESSURE214
TESTINMG FOR BRAKE DISC WEAR215
BLEEDING AIR FROM BRAKE SYSTEM 216
MEASURING PARKING BRAKE PERFORMANCE217
TESTING AND ADJUSTING PARKING BRAKE LINKAGE218
TESTING PARKING BRAKE DISC WEAR219
MEASURING PARKING BRAKE DISC WEAR220
ADJUSTING WORK EQUIPMENT PPC VALVE221
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE222
MEASURING WORK EQUIPMENT224
TESTING AND ADJUSTING BUCKET POSITIONER226
TESTING AND ADJUSTING BOOM KICK-OUT227
TROUBLESHOOTING229
POINTS TO REMEMBER WHEN TROUBLESHOOTING 230
SEQUENCE OF EVENTS IN TROUBLESHOOTING231
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE232
CHECKS BEFORE TROUBLESHOOTING240
CONNECTOR TYPE AND INSTALLATION POSITION241
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS248
METHOD OF USING TROUBLESHOOTING CHARTS270
TROUBLESHOOTING OF ENGINE (S4D102E-1) SYSTEM (S MODE)278
S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)279
S-2 ENGINE DOES NOT START280
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)283
S-4 ENGINE STOPS DURING OPERATIONS284
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)285
S-6 ENGINE LACKS OUTPUT (NO POWER)286
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)287
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)288
S-9 OIL BECOMES CONTAMINATED QUICKLY289
S-10 FUEL CONSUMPTION IS EXCESSIVE290
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN291
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)292
S-13 OIL LEVEL RISES293
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)294
S-15 ABNORMAL NOISE IS MADE295
S-16 VIBRATION IS EXCESSIVE296
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)297
M MODE RELATED ELECTRICAL CIRCUIT DIAGRAM299
M-1 ABNORMALITY IN POWER SUPPLY SYSTEM OR GROUND SYSTEM OF MONITOR PANEL301
a) WHEN THE STARTING SWITCH IS TURNED ON, THE [ENGINE OIL PRESSURE], [PARKING BRAKE], [BRAKE OIL LEVEL] AND [PREHEATING] LAMPS DO NOT LIGHT UP AT THE SAME TIME (POWER SUPPLY SYSTEM)301
b) WHEN THE STARTING SWITCH IS TURNED ON, THE [BATTERY CHARGE LEVEL], [TURN SIGNAL], [HIGH BEAM] AND [SERVICE METER] LAMPS DO NOT LIGHT UP OR FLASH AT THE SAME TIME (GND SYSTEM)301
M-2 ABNORMALITY IN AUTOMATIC PREHEATING PILOT LAMP303
a) THE PREHEATING PILOT LAMP DOES NOT LIGHT UP WHILE THE AUTOMATIC PREHEATING SYSTEM (QHS) IS WORKING303
b) THOUGH THE AUTOMATIC PREHEATING SYSTEM (QHS) DOES NOT WORK, THE PREHEATING PILOT LAMP LIGHTS UP303
M-3 ABNORMALITY IN BRAKE OIL LEVEL CAUTION LAMP305
a) WHEN THE STARTING SWITCH IS TURNED ON, THE LAMP DOES NOT LIGHT UP 305
b) THOUGH THE OIL LEVEL IS NORMAL WHILE ENGINE IS RUNNING, THE LAMP LIGHTS UP 305
c) THOUGH THE OIL LEVEL IS ABNORMAL WHILE ENGINE IS RUNNING , THE LAMP DOES NOT LIGHT UP 306
M-4 ABNORMALITY IN PARKING BRAKE PILOT LAMP 307
a) THE LAMP DOES NOT LIGHT UP EVEN WHEN THE PARKING BRAKE PEDAL IS DEPRESSED307
B) THE LAMP DOES NOT GO OUT EVEN WHEN THE PARKING PEDAL IS RELEASED307
M-5 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP 309
a) THE LAMP DOES NOT LIGHT UP WHEN THE STARTING SWITCH IS TURNED ON 309
b) THE LAMP LIGHTS UP WHILE THE ENGINE IS RUNNING 309
M-6 ABNORMALITY IN BATTERY CHARGE LEVEL CAUTION LAMP 310
a) THE LAMP DOES NOT LIGHT UP WHEN THE STARTING SWITCH IS TURNED ON 310
b) THE LAMP LIGHTS UP WHILE THE ENGINE IS RUNNING 310
M-7 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE312
a) THE GAUGE DOES NOT MOVE UP FROM C (THE LOWEST POSITION)312
b) THE GAUGE DOES NOT MOVE DOWN FROM H (THE HIGHEST POSITION)312
c) TORQUE CONVERTER OIL TEMPERATURE INDICATED ON THE GAUGE IS DIFFERENT FROM THE REAL TEMPERATURE313
M-8 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE314
a) GAUGE DOES NOT MOVE UP FROM C (LOWEST LEVEL)314
b) GAUGE DOES NOT MOVE DOWN FROM H (HIGHEST LEVEL)314
c) READING ON GAUGE DIFFERS FROM THE ACTUAL ENGINE COOLANT TEMPERATURE315
M-9 ABNORMALITY IN FUEL LEVEL GAUGE316
a) GAUGE DOES NOT MOVE UP FROM E (LOWEST LEVEL)316
b) GAUGE DOES NOT MOVE DOWN FROM F (HIGHEST LEVEL)316
c) READING ON GAUGE DIFFERS FROM THE ACTUAL FUEL LEVEL 317
M-10 ABNORMALITY IN SERVICE METER318
a) SERVICE METER WORKS WHEN ENGINE STOPS318
b) SERVICE METER DOES NOT WORK WHILE ENGINE IS RUNNING 318
c) INDICATOR LAMP DOES NOT FLASH WHEN SERVICE METER IS WORKING 318
M-11 HIGH BEAM PILOT LAMP, TURN SIGNAL PILOT LAMP DO NOT LIGHT UP OR FLASH320
a) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP 320
b) TURN SIGNAL PILOT LAMP DOES NOT FLASH321
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)322
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING, STOPPING AND BATTERY CHARGING323
E-1 ENGINE DOES NOT START324
a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START324
b) FUEL CUT OFF VALVE DOES NOT WORK327
E-2 ABNORMALITY IN PREHEATING SYSTEM (QHS)328
a) PREHEATING IS NOT CARRIED OUT328
b) PREHEATING IS CARRIED OUT, BUT MONITOR DISPLAY IS NOT TURNED ON 329
c) PREHEATING IS ALWAYS CARRIED OUT FOR 45 SEC329
d) PREHEATING STAYS ON 329
e) THE PREHEATING TIME REDUCES OR BECOMES UNCERTAIN330
E-3 TRANSMISSION DOES NOT COME TO NEUTRAL WHILE PARKING BRAKE IS APPLIED (BUT THE TRANSMISSION CUTOFF IS IN ORDER)332
E-4 BOOM KICKOUT CANNOT BE CARRIED OUT333
E-5 BUCKET POSITIONER FUNCTION IS ABNORMAL336
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (AUTO-SHIFT TRANSMISSION) (A MODE )339
OUTLINE340
1 FUNCTION340
2 WHEN CARRYING OUT TROUBLESHOOTING340
3 FAILURE CODE TABLE340
4 TABLE OF FAILURE MODES AND CAUSES341
5 RELATED ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL342
A-1 FAILURE CODE [12] ABNORMALITY IN F SOLENOID SIGNAL SYSTEM344
A-2 FAILURE CODE [13] ABNORMALITY IN R SOLENOID SIGNAL SYSTEM344
A-3 FAILURE CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM345
A-4 FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM346
A-5 FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM347
A-6 FAILURE CODE [21] ABNORMALITY IN GEAR SHIFT LEVER SIGNAL SYSTEM348
A-7 FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM349
A-8 FAILURE CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL 350
A-9 ABNORMALITY IN KICK-DOWN SWITCH SYSTEM351
A-10 ABNORMALITY IN TRANSMISSION CUT-OFF SIGNAL SYSTEM352
A-11 ABNORMALITY IN NEUTRALIZER RELAY SIGNAL SYSTEM353
A-12 ABNORMALITY IN ALARM BUZZER SIGNAL SYSTEM354
A-13 ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM355
A-14 ABNORMALITY IN MODEL SELECTION HARNESS356
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (H MODE)357
H-1 MACHINE DOES NOT TRAVEL358
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES360
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR362
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR363
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 364
H-6 STEERING WHEEL DOES NOT TURN365
H-7 STEERING IS HEAVY366
H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK367
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING367
H-10 BRAKES DO NOT WORK BRAKING EFFECT IS POOR368
H-11 BRAKE IS NOT RELEASED, BRAKE DRAGS369
H-12 BOOM DOES NOT MOVE UP370
H-13 BOOM MOVES TOO SLOWLY OR LACKS LIFTING FORCE371
H-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT372
H-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)372
H-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM 372
H-17 BOOM SHAKES DURING OPERATION 373
H-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE373
H-19 BUCKET DOES NOT TILT BACK374
H-20 BUCKET MOVES TOO SLOWLY OR LACKS TILT-BACK FORCE375
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 376
H-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER376
H-23 EXCESSIVE HYDRAULIC DRIFT OR BUCKET376
H-24 BUCKET SHAKES DURING TRAVEL WITH LOAD (WORK EQUIPMENT VALVE AT HOLD)377
H-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT377
H-26 BOOM AND BUCKET CONTROL LEVERS ARE HEAVY AND DO NOT MOVE SMOOTH378
30 DISASSEMBLY AND ASSEMBLY379
METHOD OF USING MANUAL381
PRECAUTIONS WHEN CARRYING OUT OPERATION382
SPECIAL TOOL LIST384
STARTING MOTOR386
REMOVAL AND INSTALLATION386
ALTERNATOR387
REMOVAL AND INSTALLATION387
FUEL INJECTION PUMP388
REMOVAL 388
INSTALLATION390
ENGINE OIL COOLER393
REMOVAL AND INSTALLATION393
WATER PUMP394
REMOVAL AND INSTALLATION394
NOZZLE HOLDER395
REMOVAL395
INSTALLATION396
THERMOSTAT397
REMOVAL AND INSTALLATION397
TURBOCHARGER398
REMOVAL AND INSTALLATION398
CYLINDER HEAD399
REMOVAL399
INSTALLATION404
RADIATOR407
REMOVAL 407
INSTALLATION408
ENGINE409
REMOVAL409
INSTALLATION410
TORQUE CONVERTER CHARGING PUMP413
REMOVAL AND INSTALLATION413
TORQUE CONVERTER, TRANSMISSION414
REMOVAL 414
INSTALLATION422
TORQUE CONVERTER423
DISASSEMBLY423
ASSEMBLY425
TRANSMISSION427
DISASSEMBLY427
ASSEMBLY438
CLUTCH PACK453
DISASSEMBLY 453
ASSEMBLY459
TRANSMISSION CONTROL VALVE473
REMOVAL473
INSTALLATION474
DISASSEMBLY 475
ASSEMBLY477
TRANSMISSION SOLENOID VALVE479
DISASSEMBLY AND ASSEMBLY479
TRANSMISSION ACCUMULATOR VALVE480
DISASSEMBLY 480
ASSEMBLY481
DRIVE SHAFT482
DISASSEMBLY482
ASSEMBLY484
FRONT AXLE486
REMOVAL486
INSTALLATION487
REAR AXLE488
REMOVAL488
INSTALLATION492
DIFFERENTIAL497
DISASSEMBLY497
ASSEMBLY501
AXLE HOUSING511
DISASSEMBLY 511
ASSEMBLY516
CENTER HINGE PIN524
REMOVAL524
INSTALLATION533
PRIORITY VALVE542
REMOVAL542
INSTALLATION543
STEERING VALVE544
REMOVAL544
INSTALLATION546
DISASSEMBLY 547
ASSEMBLY550
STEERING CYLINDER555
REMOVAL555
INSTALLATION556
BRAKE BOOSTER557
REMOVAL557
INSTALLATION559
DISASSEMBLY560
ASSEMBLY563
PARKING BRAKE568
REMOVAL568
INSTALLATION570
HYDRAULIC TANK571
REMOVAL571
INSTALLATION572
HYDRAULIC, STEERING PPC PUMP573
REMOVAL 573
INSTALLATION574
MAIN CONTROL VALVE575
REMOVAL 575
INSTALLATION577
DISASSEMBLY578
ASSEMBLY580
BUCKET CYLINDER582
REMOVAL 582
INSTALLATION583
BOOM CYLINDER584
REMOVAL584
INSTALLATION585
HYDRAULIC CYLINDER586
DISASSEMBLY586
ASSEMBLY588
WORK EQUIPMENT590
REMOVAL 590
INSTALLATION593
FUEL TANK596
REMOVAL 596
INSTALLATION597
COUNTERWEIGHT598
REMOVAL AND INSTALLATION598
INSTRUMENT PANEL599
REMOVAL AND INSTALLATION599
ENGINE HOOD 600
REMOVAL AND INSTALLATION600
40 MAINTENANCE STANDARD601
ENGINE MOUNT, TRANSMISSION MOUNT602
TORQUE CONVERTER, CHARGING PUMP603
TORQUE CONVERTER604
TRANSMISSION605
TRANSMISSION CONTROL VALVE617
ACCUMULATOR VALVE621
DRIVE SHAFT622
DIFFERENTIAL623
FINAL DRIVE626
AXLE MOUNT628
CENTER HINGE PIN629
STEERING COLUMN631
PRIORITY VALVE632
STEERING CYLINDER MOUNT633
BRAKE BOOSTER634
BRAKE635
PARKING BRAKE636
HYDRAULIC PUMP AND PPC PUMP637
MAIN CONTROL VALVE638
PPC VALVE644
STEERING CYLINDER, HYDRAULIC CYLINDER646
WORK EQUIPMENT LINKAGE647
BUCKET 649
BUCKET POSITIONER AND BOOM KICK-OUT650

IMAGES PREVIEW OF THE MANUAL:

S.M 13/12/24