Komatsu WA120 WA120L WA120LC (WA120-3, WA120L-3, WA120-1LC) Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA120LC.zip
A full workshop service and repair manual, complete with electrical wiring diagrams, for Komatsu Wheel Loaders WA120, WA120L, and WA120LC — containing every technical detail needed to service, troubleshoot, fix, and overhaul these machines the way professional technicians do.
Inside the Komatsu Wheel Loaders WA120-3, WA120L-3, WA120-1LC workshop service repair manual you will find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEBM002002 - Wheel Loader WA120-3, WA120L-3 Shop Manual.pdf
CEBMW16040 - Wheel Loader WA120-1LC Shop Manual.pdf
CEAM002302 - Wheel Loader WA120-3, WA120L-3 Operation & Maintenance Manual.pdf
CEAMW16041 - Wheel Loader WA120-1LC Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,503 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
CEAM002302 - Wheel Loader WA120-3, WA120L-3 Operation & Maintenance Manual...2
INTRODUCTION...5
1. FORWARD...6
2. SAFETY INFORMATION...7
3. INTRODUCTION...8
3.1 INTENDED USE...8
3.2 FEATURES...8
3.3 BREAKING IN A NEW MACHINE...8
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
4.1 MACHINE SERIAL NO. PLATE POSITION...9
4.2 ENGINE SERIAL NO. PLATE POSITION...9
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
5. CONTENTS...10
SAFETY...15
6. GENERAL PRECAUTIONS...16
7. PRECAUTIONS DURING OPERATION...22
7.1 BEFORE STARTING ENGINE...22
7.2 AFTER STARTING ENGINE...25
7.3 TRANSPORTATION...34
7.4 BATTERY...35
7.5 TOWING...38
8. PRECAUTIONS FOR MAINTENANCE...39
8.1 BEFORE CARRYING OUT MAINTENANCE...39
8.2 DURING MAINTENANCE...44
8.3 TIRES...50
9. POSITION FOR ATTACHING SAFETY LABELS...52
9.1 POSITION FOR ATTACHING SAFETY LABELS...52
OPERATION...57
10. GENERAL VIEW...58
10.1 GENERAL VIEW OF MACHINE...58
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...59
11. EXPLANATION OF COMPONENTS...61
11.1 METER, LAMPS...61
11.2 SWITCHES...65
11.3 CONTROL LEVERS, PEDAL...71
11.4 CAP WITH LOCK...75
11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...75
11.5 SAFETY BAR...75
11.6 TOWING PIN...76
11.7 GREASE PUMP CLAMP AND RUBBER RING...76
11.8 BACK-UP ALARM...76
11.9 FUSE...77
11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT...77
11.10 SLOW BLOW FUSE...78
11.11 STORAGE PLACE FOR THIS MANUAL...79
11.12 AUXILIARY POWER SOURCE...79
11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB...79
12. CHECK BEFORE STARTING ENGINE...80
12.1 WALK AROUND CHECK...80
12.2 CHECK BEFORE STARTING...83
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...83
12.2.2 CHECK FUEL LEVEL, ADD FUEL...83
12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...84
12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...84
12.2.5 CHECK DUST INDICATOR...85
12.2.6 CHECK ELECTRICAL WIRING...85
12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...86
12.2.8 CHECK EFFECT OF PARKING BRAKE...86
12.2.9 CHECK EFFECT OF WHEEL BRAKES...87
12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM...87
12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...87
12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND...87
12.2.13 CHECK OPERATIONS OF GAUGES...87
12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...87
12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...87
12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...87
12.3 ADJUSTMENT BEFORE OPERATION...88
12.3.1 OPERATOR'S SEAT...88
12.3.2 ADJUST SEAT BELT...90
12.3.3 ADJUST REAR VIEW MIRRORS...91
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...92
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...95
12.5 STARTING ENGINE...93
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...93
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...94
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...94
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...94
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...95
12.7 MOVING MACHINE OFF...96
12.8 CHANGING GEAR SPEED...98
12.9 CHANGING DIRECTION...98
12.10 TURNING...99
12.11 STOPPING MACHINE...100
12.12 OPERATION OF WORK EQUIPMENT...101
12.12.1 BOOM OPERATION (LEVER)...101
12.12.2 BUCKET OPERATION (LEVER)...101
12.13 WORK POSSIBLE USING WHEEL LOADER...102
12.13.1 DIGGING OPERATIONS WITH ROCK PILES...102
12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...103
12.13.3 LEVELING OPERATION...104
12.13.4 PUSHING OPERATIONS...104
12.13.5 LOAD AND CARRY OPERATIONS...104
12.13.6 LOADING OPERATIONS...105
12.14 PRECAUTIONS FOR OPERATION...106
12.14.1 PERMISSIBLE WATER DEPTH...106
12.14.2 IF WHEEL BRAKE DOES NOT WORK...106
12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...106
12.14.4 PRECAUTIONS WHEN DRIVING MACHINE...107
12.15 ADJUSTING WORK EQUIPMENT POSTURE...108
12.15.1 ADJUSTING BOOM KICKOUT...108
12.15.2 ADJUSTING BUCKET POSITIONER...109
12.15.3 BUCKET LEVEL INDICATOR...109
12.16 PARKING MACHINE...110
12.17 CHECKS AFTER COMPLETION OF OPERATION...111
12.18 STOPPING ENGINE...111
12.19 CHECKS AFTER STOPPING ENGINE...112
12.20 LOCKING...112
12.21 HANDLING THE TIRES...113
12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES...113
12.21.2 TIRE PRESSURE...113
13. TRANSPORTATION...115
13.1 LOADING, UNLOADING WORK...115
13.2 PRECAUTION FOR LOADING...116
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...116
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...117
13.3.2 WEIGHT LIST...117
13.3.3 LIFTING PROCEDURE...118
14. COLD WEATHER OPERATIONS...119
14.1 PRECAUTIONS FOR LOW TEMPERATURE...119
14.1.1 FUEL AND LUBRICANTS...119
14.1.2 COOLANT...119
14.1.3 BATTERY...120
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...121
14.3 AFTER COLD WEATHER...121
15. LONG TERM STORAGE...122
15.1 BEFORE STORAGE...122
15.2 DURING STORAGE...122
15.3 AFTER STORAGE...122
16. TROUBLESHOOTING...123
16.1 WHEN MACHINE RUNS OUT OF FUEL...123
16.2 TOWING THE MACHINE...124
16.2.1 WHEN ENGINE CAN BE USED...126
16.2.2 WHEN ENGINE CANNOT BE USED...126
16.3 IF BATTERY IS DISCHARGED...127
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...127
16.3.2 PRECAUTIONS FOR CHARGING BATTERY...128
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...129
16.4 OTHER TROUBLE...131
16.4.1 ELECTRICAL SYSTEM...131
16.4.2 CHASSIS...132
16.4.3 ENGINE...135
MAINTENANCE...137
17. GUIDES TO MAINTENANCE...138
18. OUTLINES OF SERVICE...141
18.1 OUTLINE OF OIL, FUEL, COOLANT...141
18.1.1 OIL...141
18.1.2 FUEL...142
18.1.3 COOLANT...142
18.1.4 GREASE...143
18.1.5 STORING OIL AND FUEL...143
18.1.6 FILTERS...143
18.2 OUTLINE OF ELECTRIC SYSTEM...144
19. WEAR PARTS LIST...145
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...146
20.1 ENGINE OIL SPECIFICATIONS...147
20.2 DIESEL FUEL SPECIFICATIONS...148
20.3 COOLANT SPECIFICATIONS...149
21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...155
21.1 INTRODUCTION OF NECESSARY TOOLS...155
21.2 TORQUE LIST...156
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...158
23. MAINTENANCE SCHEDULE CHART...162
23.1 MAINTENANCE SCHEDULE CHART...162
24. SERVICE PROCEDURES...166
24.1 INITIAL 250 HOURS SERVICE...166
24.1.1 REPLACE FUEL FILTERS...166
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...166
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT...166
24.2 WHEN REQUIRED...167
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...167
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...169
24.2.3 CHECK AXLE OIL LEVEL , ADD OIL...170
24.2.4 CLEAN THE AXLE CASE BREATHER...171
24.2.5 CLEAN RADIATOR FINS...171
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...172
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...173
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...174
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...175
24.2.10 CHECK WINDOW WASHING FLUID...175
24.2.11 ADJUST PARKING BRAKE...176
24.2.12 REPLACE SLOW BLOW FUSE...177
24.2.13 CHECK AIR INTAKE HEATER...177
24.3 CHECK BEFORE STARTING...178
24.4 EVERY 50 HOURS SERVICE...179
24.4.1 CHECK THE TIRE INFLATION PRESSURE...179
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...179
24.4.3 CHECK ENGINE AIR INTAKE SYSTEM...179
24.5 EVERY 100 HOURS SERVICE...180
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...180
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...181
24.5.3 LUBRICATING...182
24.6 EVERY 250 HOURS SERVICE...183
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...183
24.6.2 CHECK FOR LOOSE WHEEL BOLTS. TIGHTEN...184
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...184
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...185
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...186
24.6.6 CHECK AIR INTAKE SYSTEM...186
24.6.7 LUBRICATING...187
24.7 EVERY 500 HOURS SERVICE...188
24.7.1 REPLACE FUEL FILTERS...188
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...190
24.7.3 LUBRICATE...191
24.8 EVERY 1000 HOURS SERVICE...192
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...192
24.8.2 CLEAN TRANSMISSION CASE BREATHER...193
24.8.3 LUBRICATE...194
24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...195
24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE...196
24.8.6 CHECK FAN BELT TENSION...197
24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...197
24.8.8 CHECK TIGHTENING PARTS OF TURBOCHARGER...198
24.8.9 CHECK PLAY OF TURBOCHARGER ROTOR...198
24.9 EVERY 2000 HOURS SERVICE...198
24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...198
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...201
24.9.4 CHECK BRAKE DISC WEAR...202
24.9.5 CHECK ALTERNATOR...202
24.9.6 CHECK STARTER MOTOR...202
24.9.7 CHECK VIBRATION DAMPER...202
24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...202
24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE...203
24.9.10 CLEAN AND CHECK TURBOCHARGER...205
24.10 EVERY 4000 HOURS SERVICE...205
24.10.1 CHECK WATER PUMP...205
SPECIFICATIONS...207
25. SPECIFICATIONS...208
OPTIONS, ATTACHMENTS...212
26. AVAILABLE ATTACHMENTS...213
27. HEATER AND AIR CONDITIONING (IF EQUIPPED)...215
27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...215
27.2 COOL BOX COMPARTMENT...216
28. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...217
28.1 STRUCTURE AND FUNCTION OF E.C.S.S...217
28.2 METHOD OF OPERATING E.C.S.S...218
28.3 PRECAUTIONS WHEN OPERATING E.C.S.S...218
28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...219
CEAMW16041 - Wheel Loader WA120-1LC Operation & Maintenance Manual...221
FOREWORD...225
INTRODUCTION...226
SAFETY INFORMATION...226
BREAKING IN THE NEW MACHINE...227
MACHINE AND ENGINE SERIAL NUMBERS...228
QUICK REFERENCE INFORMATION...229
CONTENTS...230
SAFETY PRECAUTIONS -- SECTION 1...237
GENERAL PRECAUTIONS ...238
PERSONNEL PRECAUTIONS ...238
MACHINE PRECAUTIONS ...238
OPERATION ...239
BEFORE STARTING ...239
START-UP ...240
GENERAL OPERATING PRECAUTIONS ...240
DRIVING THE MACHINE ...241
OPERATING THE ATTACHMENTS ...242
PULLING/TOWING ...242
SHUTDOWN ...243
MAINTENANCE ...243
GENERAL MACHINE PRECAUTIONS ...243
GENERAL WORK PRECAUTIONS ...244
ATTACHMENTS ...245
BRAKES ...245
CAB/ROPS ...245
COOLING ...245
ELECTRICAL ...246
ENGINE ...246
FUEL SYSTEM ...247
HYDRAULICS ...247
TIRES AND RIMS ...247
TURBOCHARGER ...247
SAFETY PRODUCT GRAPHICS AND LOCATIONS ...248
OPERATION -- SECTION 2...259
GENERAL VIEW ...260
INSTRUMENTS AND CONTROLS ...261
CLUSTER GAUGE ...261
TORQUE CONVERTER OIL TEMPERATURE GAUGE...261
ENGINE COOLING WATER TEMPERATURE GAUGE ...262
FUEL GAUGE ...262
VOLTMETER ...262
PILOT LAMPS, METERS...263
BRAKE OIL LEVEL PILOT LAMP ...263