Komatsu WA120L-3MC Wheel Loader Shop Manual SEBM021800

Description

• Model List:
  • WA120L-3MC Wheel Loader

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. LIST OF LUBRICANT AND WATER
• 4. STRUCTURE AND FUNCTION
• 4.1. POWER TRAIN
• 4.2. POWER TRAIN SYSTEM
• 4.3. TORQUE CONVERTER, TRANSMISSION PIPING
• 4.4. TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
• 4.5. TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
• 4.6. TORQUE CONVERTER
• 4.7. TRANSMISSION
• 4.8. TRANSMISSION CONTROL VALVE
• 4.9. TRANSMISSION CONTROL
• 4.10. DRIVE SHAFT
• 4.11. AXLE
• 4.12. FINAL DRIVE
• 4.13. AXLE MOUNT
• 4.14. CENTER HINGE PIN
• 4.15. STEERING PIPING
• 4.16. STEERING COLUMN
• 4.17. PRIORITY VALVE
• 4.18. STEERING VALVE (DRBITROLL)
• 4.19. BRAKE PIPING
• 4.20. BRAKE CONTROL
• 4.21. BRAKE BOOSTER
• 4.22. BRAKE
• 4.23. PARKING BRAKE CONTROL
• 4.24. PARKING BRAKE
• 4.25. HYDRAULIC PIPING
• 4.26. WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
• 4.27. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 4.28. HYDRAULIC TANK
• 4.29. PPC VALVE
• 4.30. ACCUMULATOR
• 4.31. MAIN CONTROL VALVE
• 4.32. WORK EQUIPMENT LINKAGE
• 4.33. BUCKET
• 4.34. BUCKET POSITIONER AND BOOM KICKOUT
• 4.35. PROXIMITY SWITCH
• 4.36. ROPS CAB
• 4.37. AIR CONDITIONER
• 4.38. ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
• 4.39. ELECTRICAL WIRING DIAGRAM
• 4.40. AIR CONDITIONING AND HEATER ELECTRICAL DIAGRAM
• 4.41. CENTRAL PANEL
• 4.42. SENSOR
• 4.43. ENGINE STARTING CIRCUIT
• 4.44. ENGINE STOP CIRCUIT
• 4.45. FUEL CUTOFF SOLENOID
• 4.46. AUTOMATIC PREHEATING CIRCUIT (O.H.S. CONTROLLER)
• 4.47. TRANSMISSION AUTOSHIFT CONTROL SYSTEM
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.4. ADJUSTING VALVE CLEARANCE
• 5.5. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.6. MEASURING EXHAUST COLOR
• 5.7. MEASURING BLOWBY PRESSURE
• 5.8. MEASURING ENGINE OIL PRESSURE
• 5.9. MEASURING ENGINE SPEED
• 5.10. ADJUSTING ENGINE STOP SOLENOID
• 5.11. MEASURING ACCELERATOR PEDAL
• 5.12. MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
• 5.13. MEASURING STALL SPEED
• 5.14. MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE
• 5.15. METHOD OF OPERATING EMERGENCY MANUAL SOLENOID VALVE
• 5.16. TESTING AND ADJUSTING STEERING WHEEL
• 5.17. MEASURING STEERING OIL PRESWSURE
• 5.18. MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
• 5.19. TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
• 5.20. MEASURING BRAKE PERFORMANCE
• 5.21. MEASURING BRAKE OIL PRESSURE
• 5.22. TESTINMG FOR BRAKE DISC WEAR
• 5.23. BLEEDING AIR FROM BRAKE SYSTEM
• 5.24. MEASURING PARKING BRAKE PERFORMANCE
• 5.25. TESTING AND ADJUSTING PARKING BRAKE LINKAGE
• 5.26. TESTING PARKING BRAKE DISC WEAR
• 5.27. MEASURING PARKING BRAKE DISC WEAR
• 5.28. ADJUSTING WORK EQUIPMENT PPC VALVE
• 5.29. MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.30. MEASURING WORK EQUIPMENT
• 5.31. TESTING AND ADJUSTING BUCKET POSITIONER
• 5.32. TESTING AND ADJUSTING BOOM KICKOUT
• 5.33. TROUBLESHOOTING
• 5.33.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.33.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.33.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.33.4. CHECKS BEFORE TROUBLESHOOTING
• 5.33.5. CONNECTOR TYPE AND INSTALLATION POSITION
• 5.33.6. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.33.7. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.33.8. TROUBLESHOOTING OF ENGINE (S4D102E1) SYSTEM (S MODE)
• 5.33.9. TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)
• 5.33.10. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.33.11. TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (AUTOSHIFT TRANSMISSION) (A MODE )
• 5.33.12. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (H 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. STARTING MOTOR
• 6.4.1. REMOVAL AND INSTALLATION
• 6.5. ALTERNATOR
• 6.5.1. REMOVAL AND INSTALLATION
• 6.6. FUEL INJECTION PUMP
• 6.6.1. REMOVAL
• 6.6.2. INSTALLATION
• 6.7. ENGINE OIL COOLER
• 6.7.1. REMOVAL AND INSTALLATION
• 6.8. WATER PUMP
• 6.8.1. REMOVAL AND INSTALLATION
• 6.9. NOZZLE HOLDER
• 6.9.1. REMOVAL
• 6.9.2. INSTALLATION
• 6.10. THERMOSTAT
• 6.10.1. REMOVAL AND INSTALLATION
• 6.11. TURBOCHARGER
• 6.11.1. REMOVAL AND INSTALLATION
• 6.12. TORQUE CONVERTER CHARGING PUMP
• 6.12.1. REMOVAL AND INSTALLATION
• 6.13. TORQUE CONVERTER, TRANSMISSION
• 6.13.1. REMOVAL
• 6.13.2. INSTALLATION
• 6.14. TORQUE CONVERTER
• 6.15. TRANSMISSION CONTROL VALVE
• 6.15.1. REMOVAL
• 6.15.2. INSTALLATION
• 6.15.3. DISASSEMBLY
• 6.15.4. ASSEMBLY
• 6.16. TRANSMISSION SOLENOID VALVE
• 6.16.1. DISASSEMBLY AND ASSEMBLY
• 6.17. TRANSMISSION ACCUMULATOR VALVE
• 6.18. CENTER HINGE PIN
• 6.19. STEERING CYLINDER
• 6.20. HYDRAULIC, STEERING PPC PUMP
• 6.20.1. REMOVAL
• 6.20.2. INSTALLATION
• 6.21. MAIN CONTROL VALVE
• 6.21.1. REMOVAL
• 6.21.2. INSTALLATION
• 6.21.3. DISASSEMBLY
• 6.21.4. ASSEMBLY
• 6.22. BUCKET CYLINDER
• 6.23. HYDRAULIC CYLINDER
• 6.23.1. REMOVAL AND INSTALLATION
• 6.24. INSTRUMENT PANEL
• 6.24.1. REMOVAL AND INSTALLATION
• 6.25. ENGINE HOOD
• 6.25.1. REMOVAL AND INSTALLATION
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT, TRANSMISSION MOUNT
• 7.2. TORQUE CONVERTER, CHARGING PUMP
• 7.3. TORQUE CONVERTER
• 7.4. TRANSMISSION
• 7.5. TRANSMISSION CONTROL VALVE
• 7.6. ACCUMULATOR VALVE
• 7.7. DRIVE SHAFT
• 7.8. DIFFERENTIAL
• 7.9. FINAL DRIVE
• 7.10. AXLE MOUNT
• 7.11. CENTER HINGE PIN
• 7.12. STEERING COLUMN
• 7.13. PRIORITY VALVE
• 7.14. STEERING CYLINDER MOUNT
• 7.15. BRAKE BOOSTER
• 7.16. BRAKE
• 7.17. PARKING BRAKE
• 7.18. HYDRAULIC PUMP AND PPC PUMP
• 7.19. MAIN CONTROL VALVE
• 7.20. PPC VALVE
• 7.21. STEERING CYLINDER, HYDRAULIC CYLINDER
• 7.22. WORK EQUIPMENT LINKAGE
• 7.23. BUCKET
• 7.24. BUCKET POSITIONER AND BOOM KICKOUT