Komatsu WA120-3CS Avance Wheel Loader Shop Manual SEBM012402

Description

• Model List:
  • WA120-3CS Avance Wheel Loader

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFCATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND WATER
• 4. STRUCTURE AND FUNCTION
• 4.1. OUTLINE
• 4.2. POWER TRAIN SYSTEM
• 4.3. DAMPER
• 4.4. HST PIPING
• 4.5. HYDRAULIC CIRCUIT DIAGRAM FOR HYDROSTATIC TRANSMISSION(HST)
• 4.6. MAIN PISTON PUMP
• 4.7. HIGHPRESSURE RELIEF VALVE
• 4.8. LOWPRESSURE RELIEF VALVE
• 4.9. HST CHARGE PUMP
• 4.10. CHARGE PUMP OIL FILTER
• 4.11. SPEED RELATED VALVE(DA VALVE)
• 4.12. HIGHPRESSURE CUTOFF VALVE
• 4.13. PISTON MOTOR
• 4.14. DIRECTIONAL SHUTTLE VALVE
• 4.15. SERVO VALVE
• 4.16. INTERMEDIATE FIXED CONTROL OF ANGLE
• 4.17. CENTER HINGE PIN
• 4.18. STEERING PIPING
• 4.19. STEERING COLUMN
• 4.20. PRIORITY VALVE
• 4.21. STEERING VALVE(ORBITROLL)
• 4.22. BRAKE PIPING
• 4.23. BRAKE CONTROL
• 4.24. BRAKE
• 4.25. BRAKE MASTER CYLINDER
• 4.26. PARKING BRAKE CONTROL
• 4.27. PARKING BRAKE
• 4.28. HYDRAULIC PIPING
• 4.29. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 4.30. WORK EQUIPMENT LEVER LINKAGE
• 4.31. HYDRAUIC TANK
• 4.32. HYDRAULIC FILTER
• 4.33. MAIN CONTROL VALVE
• 4.34. WORK EQUIPMENT LINKAGE
• 4.35. BUCKET
• 4.36. BUCKET POSITIONER
• 4.37. PROXIMITY SWITCH
• 4.38. CANOPY
• 4.39. ELECTRIC CIRCUIT DIAGRAM
• 4.40. CENTRAL PANEL(CLUSTER GAUGE)
• 4.41. SENSOR
• 4.42. ENGINE STARTING CIRCUIT
• 4.43. ENGINE STOP CIRCUIT
• 4.44. PARKING BRAKE CIRCUIT
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. STANDARD VALUE TABLE FOR ELECTRICAL PARTS
• 5.4. TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING
• 5.5. MEASURING ENGINE SPEED
• 5.6. MEASURING EXHAUST COLOR
• 5.7. ADJUSTING VALVE CLEARANCE
• 5.8. MEASURING COMPRESSION PRESSURE
• 5.9. MEASURING BLOWBY PRESSURE
• 5.10. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.11. MEASURING ENGINE OIL PRESSURE
• 5.12. TESTING AND ADJUSTING FAN BELT TENSION
• 5.13. METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
• 5.14. TESTING AND ADJUSTING HST OIL PRESSURE
• 5.15. TESTING AND ADJUSTING STEERING OIL PRESSURE
• 5.16. BLEEDING AIR FROM STEERING CIRCUIT
• 5.17. MEASURING BRAKE PERFORMANCE
• 5.18. TESTING DROP IN WHEEL BRAKE OIL PRESSURE
• 5.19. MEASURING WHEEL BRAKE DISC WEAR
• 5.20. BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
• 5.21. ADJUSTING WHEEL BRAKE LINKAGE
• 5.22. MEASURING PARKING BRAKE PERFORMANCE
• 5.23. TESTING AND ADJUSTING PARKING BRAKE LINKAGE
• 5.24. MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.25. BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
• 5.26. ADJUSTING WORK EQUIPMENT LEVER LINKAGE
• 5.27. TESTING AND ADJUSTING BUCKET POSITIONER
• 5.28. TROUBLESHOOTING
• 5.28.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.28.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.28.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.28.4. CHECKS BEFORE TROUBLESHOOTING
• 5.28.5. CONNECTOR TYPES AND MOUNTING LOCATIONS
• 5.28.6. CONNECTOR PIN ARRANGEMENT DIAGRAM
• 5.28.7. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.28.8. METHOD OF USING FAILURE MODE AND JUDGEMENT TABLE
• 5.28.9. FAILURE MODES AND JUDGEMENT TABLE
• 5.28.10. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.28.11. TROUBLESHOOTING OF ENGINE SYSTEM(S MODE)
• 5.28.12. TROUBLESHOOTING OF ELECTRICAL SYSTEM(E MODE)
• 5.28.13. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H MODE)
• 5.28.14. TROUBLESHOOTING OF MONITOR PANEL SYSTEM(M MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. SKETCHES OF SPECIAL TOOLS
• 6.5. STARTING MOTOR
• 6.5.1. REMOVAL AND INSTALLATION
• 6.6. ALTERNATOR
• 6.6.1. REMOVAL AND INSTALLATION
• 6.7. FUEL INJECTION PUMP
• 6.7.1. REMOVAL
• 6.7.2. INSTALLATION
• 6.8. NOZZLE HOLDER
• 6.8.1. REMOVAL AND INSTALLATION
• 6.9. WATER PUMP
• 6.9.1. REMOVAL AND INSTALLATION
• 6.10. THERMOSTAT
• 6.10.1. REMOVAL AND INSTALLATION
• 6.11. ENGINE OIL COOLER
• 6.11.1. REMOVAL AND INSTALLATION
• 6.12. ENGINE,HYDRAULIC PUMP
• 6.12.1. REMOVAL
• 6.12.2. INSTALLATION
• 6.13. FUEL TANK
• 6.13.1. REMOVAL AND INSTALLATION
• 6.14. CENTER HINGE PIN
• 6.14.1. REMOVAL
• 6.14.2. INSTALLATION
• 6.15. STEERING,HYDRAULIC PUMP
• 6.15.1. REMOVAL AND INSTALLATION
• 6.16. STEERING VALVE
• 6.16.1. REMOVAL
• 6.16.2. INSTALLATION
• 6.17. STEERING CYLINDER
• 6.17.1. REMOVAL
• 6.17.2. INSTALLATION
• 6.17.3. DISASSEMBLY
• 6.17.4. ASSEMBLY
• 6.18. BRAKE MASTER CYLINDER
• 6.18.1. REMOVAL AND INSTALLATION
• 6.19. INCHING VALVE
• 6.19.1. REMOVAL AND INSTALLATION
• 6.20. HYDRAULIC TANK
• 6.20.1. REMOVAL AND INSTALLATION
• 6.21. MAIN CONTROL VALVE
• 6.21.1. REMOVAL AND INSTALLATION
• 6.22. BOOM CYLINDER
• 6.22.1. REMOVAL
• 6.22.2. INSTALLATION
• 6.23. BUCKET CYLINDER
• 6.23.1. REMOVAL
• 6.23.2. INSTALLATION
• 6.24. BOOM,BUCKET CYLINDER
• 6.24.1. DISASSEMBLY
• 6.24.2. ASSEMBLY
• 6.25. BUCKET
• 6.25.1. REMOVAL AND INSTALLATION
• 6.26. BOOM
• 6.26.1. REMOVAL
• 6.26.2. INSTALLATION
• 6.27. ENGINE HOOD
• 6.27.1. REMOVAL AND INSTALLATION
• 6.28. CANOPY
• 6.28.1. REMOVAL AND INSTALLATION
• 6.29. FLOOR FRAME
• 6.29.1. REMOVAL
• 6.29.2. INSTALLATION
• 6.30. COUNTERWEIGHT(REAR END)
• 6.30.1. REMOVAL AND INSTALLATION
• 6.31. COUNTERWEIGHT(LOWER PORTION)
• 6.31.1. REMOVAL AND INSTALLATION
• 6.32. MONITOR PANEL
• 6.32.1. REMOVAL AND INSTALLATION
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT
• 7.2. TRANSFER MOUNT
• 7.3. TRANSFER
• 7.4. HST INCHING VALVE
• 7.5. DRIVE SHAFT
• 7.6. DIFFERENTIAL
• 7.7. FINAL DRIVE
• 7.8. AXLE MOUNT
• 7.9. CENTER HINGE PIN
• 7.10. STEERING COLUMN
• 7.11. PRIORITY VALVE
• 7.12. STEERING CYLINDER MOUNT
• 7.13. PARKING BRAKE
• 7.14. HYDRAULIC AND STEERING PUMP
• 7.15. HYDRAULIC CYLINDER
• 7.16. WORK EQUIPMENT LINKAGE
• 7.17. BUCKET
• 7.18. BUCKET POSITIONER
• 8. OTHERS
• 8.1. ELECTRIC CIRCUIT DIAGRAM(1/2)
• 8.2. ELECTRIC CIRCUIT DIAGRAM(2/2)