Komatsu WA120L-3MC Wheel Loader Shop Manual SEBM021800 – PDF DOWNLOAD 

Description

Komatsu WA120L-3MC Wheel Loader Shop Manual SEBM021800 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA120L-3MC Wheel Loader Shop Manual SEBM021800 – PDF DOWNLOAD 

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

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA120L-3MC Wheel Loader Shop Manual SEBM021800 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
WA120L-3MC             54104 and up

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 CONTROL 105
PARKING BRAKE 106
HYDRAULIC PIPING 107
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 109
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 110
HYDRAULIC TANK 112
PPC VALVE 115
ACCUMULATOR 122
MAIN CONTROL VALVE 123
WORK EQUIPMENT LINKAGE 136
BUCKET 138
BUCKET POSITIONER AND BOOM KICK-OUT 139
PROXIMITY SWITCH 141
ROPS CAB 143
AIR CONDITIONER 144
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) 145
ELECTRICAL WIRING DIAGRAM 148
AIR CONDITIONING AND HEATER ELECTRICAL DIAGRAM 153
CENTRAL PANEL 154
SENSOR 155
ENGINE STARTING CIRCUIT 156
ENGINE STOP CIRCUIT 157
FUEL CUT-OFF SOLENOID 158
AUTOMATIC PREHEATING CIRCUIT (O H S CONTROLLER) 159
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 163
20 TESTING AND ADJUSTING 182
STANDARD VALUE TABLE FOR ENGINE 183
STANDARD VALUE TABLE FOR CHASSIS 184
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 187
ADJUSTING VALVE CLEARANCE 189
TESTING AND ADJUSTING FUEL INJECTION TIMING 190
MEASURING EXHAUST COLOR 191
MEASURING BLOW-BY PRESSURE 192
MEASURING ENGINE OIL PRESSURE 193
MEASURING ENGINE SPEED 194
ADJUSTING ENGINE STOP SOLENOID 195
MEASURING ACCELERATOR PEDAL 196
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 198
MEASURING STALL SPEED 199
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE 201
METHOD OF OPERATING EMERGENCY MANUAL SOLENOID VALVE 203
TESTING AND ADJUSTING STEERING WHEEL 205
MEASURING STEERING OIL PRESWSURE 208
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 210
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 211
MEASURING BRAKE PERFORMANCE 213
MEASURING BRAKE OIL PRESSURE 214
TESTINMG FOR BRAKE DISC WEAR 215
BLEEDING AIR FROM BRAKE SYSTEM 216
MEASURING PARKING BRAKE PERFORMANCE 217
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 218
TESTING PARKING BRAKE DISC WEAR 219
MEASURING PARKING BRAKE DISC WEAR 220
ADJUSTING WORK EQUIPMENT PPC VALVE 221
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 222
MEASURING WORK EQUIPMENT 224
TESTING AND ADJUSTING BUCKET POSITIONER 226
TESTING AND ADJUSTING BOOM KICK-OUT 227
TROUBLESHOOTING 229
POINTS TO REMEMBER WHEN TROUBLESHOOTING 230
SEQUENCE OF EVENTS IN TROUBLESHOOTING 231
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 232
CHECKS BEFORE TROUBLESHOOTING 240
CONNECTOR TYPE AND INSTALLATION POSITION 241
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 248
METHOD OF USING TROUBLESHOOTING CHARTS 270
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 START 280
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 283
S-4 ENGINE STOPS DURING OPERATIONS 284
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 QUICKLY 289
S-10 FUEL CONSUMPTION IS EXCESSIVE 290
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 291
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 292
S-13 OIL LEVEL RISES 293
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 294
S-15 ABNORMAL NOISE IS MADE 295
S-16 VIBRATION IS EXCESSIVE 296
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE) 297
M MODE RELATED ELECTRICAL CIRCUIT DIAGRAM 299
M-1 ABNORMALITY IN POWER SUPPLY SYSTEM OR GROUND SYSTEM OF MONITOR PANEL 301
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 LAMP 303
a) THE PREHEATING PILOT LAMP DOES NOT LIGHT UP WHILE THE AUTOMATIC PREHEATING SYSTEM (QHS) IS WORKING 303
b) THOUGH THE AUTOMATIC PREHEATING SYSTEM (QHS) DOES NOT WORK, THE PREHEATING PILOT LAMP LIGHTS UP 303
M-3 ABNORMALITY IN BRAKE OIL LEVEL CAUTION LAMP 305
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 DEPRESSED 307
B) THE LAMP DOES NOT GO OUT EVEN WHEN THE PARKING PEDAL IS RELEASED 307
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 GAUGE 312
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 TEMPERATURE 313
M-8 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 314
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 TEMPERATURE 315
M-9 ABNORMALITY IN FUEL LEVEL GAUGE 316
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 METER 318
a) SERVICE METER WORKS WHEN ENGINE STOPS 318
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 FLASH 320
a) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP 320
b) TURN SIGNAL PILOT LAMP DOES NOT FLASH 321
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 322
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING, STOPPING AND BATTERY CHARGING 323
E-1 ENGINE DOES NOT START 324
a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START 324
b) FUEL CUT OFF VALVE DOES NOT WORK 327
E-2 ABNORMALITY IN PREHEATING SYSTEM (QHS) 328
a) PREHEATING IS NOT CARRIED OUT 328
b) PREHEATING IS CARRIED OUT, BUT MONITOR DISPLAY IS NOT TURNED ON 329
c) PREHEATING IS ALWAYS CARRIED OUT FOR 45 SEC 329
d) PREHEATING STAYS ON 329
e) THE PREHEATING TIME REDUCES OR BECOMES UNCERTAIN 330
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 OUT 333
E-5 BUCKET POSITIONER FUNCTION IS ABNORMAL 336
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (AUTO-SHIFT TRANSMISSION) (A MODE ) 339
OUTLINE 340
1 FUNCTION 340
2 WHEN CARRYING OUT TROUBLESHOOTING 340
3 FAILURE CODE TABLE 340
4 TABLE OF FAILURE MODES AND CAUSES 341
5 RELATED ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL 342
A-1 FAILURE CODE [12] ABNORMALITY IN F SOLENOID SIGNAL SYSTEM 344
A-2 FAILURE CODE [13] ABNORMALITY IN R SOLENOID SIGNAL SYSTEM 344
A-3 FAILURE CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 345
A-4 FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 346
A-5 FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 347
A-6 FAILURE CODE [21] ABNORMALITY IN GEAR SHIFT LEVER SIGNAL SYSTEM 348
A-7 FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 349
A-8 FAILURE CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL 350
A-9 ABNORMALITY IN KICK-DOWN SWITCH SYSTEM 351
A-10 ABNORMALITY IN TRANSMISSION CUT-OFF SIGNAL SYSTEM 352
A-11 ABNORMALITY IN NEUTRALIZER RELAY SIGNAL SYSTEM 353
A-12 ABNORMALITY IN ALARM BUZZER SIGNAL SYSTEM 354
A-13 ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM 355
A-14 ABNORMALITY IN MODEL SELECTION HARNESS 356
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (H MODE) 357
H-1 MACHINE DOES NOT TRAVEL 358
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 360
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 362
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 363
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 364
H-6 STEERING WHEEL DOES NOT TURN 365
H-7 STEERING IS HEAVY 366
H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 367
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 367
H-10 BRAKES DO NOT WORK BRAKING EFFECT IS POOR 368
H-11 BRAKE IS NOT RELEASED, BRAKE DRAGS 369
H-12 BOOM DOES NOT MOVE UP 370
H-13 BOOM MOVES TOO SLOWLY OR LACKS LIFTING FORCE 371
H-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 372
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 RAISE 373
H-19 BUCKET DOES NOT TILT BACK 374
H-20 BUCKET MOVES TOO SLOWLY OR LACKS TILT-BACK FORCE 375
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 376
H-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 376
H-23 EXCESSIVE HYDRAULIC DRIFT OR BUCKET 376
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 TILT 377
H-26 BOOM AND BUCKET CONTROL LEVERS ARE HEAVY AND DO NOT MOVE SMOOTH 378
30 DISASSEMBLY AND ASSEMBLY 379
METHOD OF USING MANUAL 381
PRECAUTIONS WHEN CARRYING OUT OPERATION 382
SPECIAL TOOL LIST 384
STARTING MOTOR 386
REMOVAL AND INSTALLATION 386
ALTERNATOR 387
REMOVAL AND INSTALLATION 387
FUEL INJECTION PUMP 388
REMOVAL 388
INSTALLATION 390
ENGINE OIL COOLER 393
REMOVAL AND INSTALLATION 393
WATER PUMP 394
REMOVAL AND INSTALLATION 394
NOZZLE HOLDER 395
REMOVAL 395
INSTALLATION 396
THERMOSTAT 397
REMOVAL AND INSTALLATION 397
TURBOCHARGER 398
REMOVAL AND INSTALLATION 398
CYLINDER HEAD 399
REMOVAL 399
INSTALLATION 404
RADIATOR 407
REMOVAL 407
INSTALLATION 408
ENGINE 409
REMOVAL 409
INSTALLATION 410
TORQUE CONVERTER CHARGING PUMP 413
REMOVAL AND INSTALLATION 413
TORQUE CONVERTER, TRANSMISSION 414
REMOVAL 414
INSTALLATION 422
TORQUE CONVERTER 423
DISASSEMBLY 423
ASSEMBLY 425
TRANSMISSION 427
DISASSEMBLY 427
ASSEMBLY 438
CLUTCH PACK 453
DISASSEMBLY 453
ASSEMBLY 459
TRANSMISSION CONTROL VALVE 473
REMOVAL 473
INSTALLATION 474
DISASSEMBLY 475
ASSEMBLY 477
TRANSMISSION SOLENOID VALVE 479
DISASSEMBLY AND ASSEMBLY 479
TRANSMISSION ACCUMULATOR VALVE 480
DISASSEMBLY 480
ASSEMBLY 481
DRIVE SHAFT 482
DISASSEMBLY 482
ASSEMBLY 484
FRONT AXLE 486
REMOVAL 486
INSTALLATION 487
REAR AXLE 488
REMOVAL 488
INSTALLATION 492
DIFFERENTIAL 497
DISASSEMBLY 497
ASSEMBLY 501
AXLE HOUSING 511
DISASSEMBLY 511
ASSEMBLY 516
CENTER HINGE PIN 524
REMOVAL 524
INSTALLATION 533
PRIORITY VALVE 542
REMOVAL 542
INSTALLATION 543
STEERING VALVE 544
REMOVAL 544
INSTALLATION 546
DISASSEMBLY 547
ASSEMBLY 550
STEERING CYLINDER 555
REMOVAL 555
INSTALLATION 556
BRAKE BOOSTER 557
REMOVAL 557
INSTALLATION 559
DISASSEMBLY 560
ASSEMBLY 563
PARKING BRAKE 568
REMOVAL 568
INSTALLATION 570
HYDRAULIC TANK 571
REMOVAL 571
INSTALLATION 572
HYDRAULIC, STEERING PPC PUMP 573
REMOVAL 573
INSTALLATION 574
MAIN CONTROL VALVE 575
REMOVAL 575
INSTALLATION 577
DISASSEMBLY 578
ASSEMBLY 580
BUCKET CYLINDER 582
REMOVAL 582
INSTALLATION 583
BOOM CYLINDER 584
REMOVAL 584
INSTALLATION 585
HYDRAULIC CYLINDER 586
DISASSEMBLY 586
ASSEMBLY 588
WORK EQUIPMENT 590
REMOVAL 590
INSTALLATION 593
FUEL TANK 596
REMOVAL 596
INSTALLATION 597
COUNTERWEIGHT 598
REMOVAL AND INSTALLATION 598
INSTRUMENT PANEL 599
REMOVAL AND INSTALLATION 599
ENGINE HOOD 600
REMOVAL AND INSTALLATION 600
40 MAINTENANCE STANDARD 601
ENGINE MOUNT, TRANSMISSION MOUNT 602
TORQUE CONVERTER, CHARGING PUMP 603
TORQUE CONVERTER 604
TRANSMISSION 605
TRANSMISSION CONTROL VALVE 617
ACCUMULATOR VALVE 621
DRIVE SHAFT 622
DIFFERENTIAL 623
FINAL DRIVE 626
AXLE MOUNT 628
CENTER HINGE PIN 629
STEERING COLUMN 631
PRIORITY VALVE 632
STEERING CYLINDER MOUNT 633
BRAKE BOOSTER 634
BRAKE 635
PARKING BRAKE 636
HYDRAULIC PUMP AND PPC PUMP 637
MAIN CONTROL VALVE 638
PPC VALVE 644
STEERING CYLINDER, HYDRAULIC CYLINDER 646
WORK EQUIPMENT LINKAGE 647
BUCKET 649
BUCKET POSITIONER AND BOOM KICK-OUT 650

DESCRIPTION:

Komatsu WA120L-3MC Wheel Loader Shop Manual SEBM021800 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
WA120L-3MC             54104 and up

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 24/12/24