Komatsu WA120-3MC WA120L-3MC Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA120LMC.zip
Full factory service and repair documentation, complete with electrical wiring schematics, for the Komatsu Wheel Loader models WA120-3MC and WA120L-3MC. Inside you'll find every technical detail needed to service, troubleshoot, fix, and rebuild these machines to the same standard as trained dealership technicians.
The workshop service and repair manual for the Komatsu Wheel Loader WA120-3MC and WA120L-3MC contains:
* 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.
CEAM007701 - Wheel Loader WA120-3MC Operation & Maintenance Manual.pdf
SEAM038301T - Wheel Loader WA120-3MC avance Operation & Maintenance Manual.pdf
SEBM021800 - Wheel Loader WA120L-3MC Shop Manual.pdf
CEBM005101 - Wheel Loader WA120-3MC avance plus Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,803 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM007701 - Wheel Loader WA120-3MC Operation & Maintenance Manual...1
COVER...1
INTRODUCTION...7
FOREWORD...8
SAFETY INFORMATION...9
INTRODUCTION...10
INTENDED USE...10
FEATURES...10
BREAKING IN A NEW MACHINE...10
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...11
MACHINE SERIAL NO. PLATE POSITION...11
ENGINE SERIAL NO. PLATE POSITION...11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...11
CONTENTS...12
SAFETY...21
GENERAL PRECAUTIONS...22
SAFETY RULES...22
SAFETY FEATURES...22
UNAUTHORIZED MODIFICATION...22
CLOTHING AND PERSONAL PROTECTIVE ITEMS...23
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT...23
MOUNTING AND DISMOUNTING...24
FIRE PREVENTION FOR FUEL AND OIL...24
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES...25
ASBESTOS DUST HAZARD PREVENTION...25
CRUSHING OR CUTTING PREVENTION...25
FIRE EXTINGUISHER AND FIRST AID KIT...26
PRECAUTIONS WHEN USING ROPS...26
PRECAUTIONS FOR ATTACHMENTS...26
PRECAUTION WHEN HANDLING ACCUMULATOR...27
PRECAUTIONS DURING OPERATION...28
BEFORE STARTING ENGINE...28
SAFETY AT WORKSITE...28
FIRE PREVENTION...28
WALK AROUND CHECK...28
IN OPERATOR'S CAB...29
VENTILATION FOR ENCLOSED AREAS...29
PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS...29
WHEN STARTING ENGINE...30
AFTER STARTING ENGINE...31
CHECKS AFTER STARTING ENGINE...31
PRECAUTIONS WHEN STARTING OFF...31
CHECK WHEN CHANGING DIRECTION...32
PRECAUTIONS WHEN TRAVELING...33
TRAVELING ON SLOPES...34
PROHIBITED OPERATIONS...34
PRECAUTIONS WHEN TRAVELING...35
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES...36
ENSURE GOOD VISIBILITY...37
OPERATE CAREFULLY ON SNOW...37
DO NOT HIT WORK EQUIPMENT...37
WHEN USING THE BRAKE...37
WHEN TRAVELING DOWNHILL...37
WORKING ON LOOSE GROUND...38
PARKING THE MACHINE...38
PRECAUTIONS IN COLD AREAS...39
TRANSPORTATION...40
LOADING AND UNLOADING...40
SHIPPING...40
BATTERY...41
BATTERY HAZARD PREVENTION...41
STARTING WITH BOOSTER CABLES...42
CHARGING BATTERY...43
TOWING...44
WHEN TOWING...44
PRECAUTIONS FOR MAINTENANCE...45
BEFORE CARRYING OUT MAINTENANCE...45
NOTIFICATION OF FAILURE...45
WARNING TAGS...45
CLEAN BEFORE INSPECTION AND MAINTENANCE...45
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE...46
WORK EQUIPMENT SUPPORT...46
PROPER TOOLS...47
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...47
USE OF LIGHTING...47
KEEP WORK PLACE CLEAN AND TIDY...47
APPOINT A LEADER WHEN WORKING WITH OTHERS...48
RADIATOR WATER LEVEL...48
PREVENTION OF FIRE...48
TURN E.C.S.S. SWITCH OFF...48
DURING MAINTENANCE...49
PERSONNEL...49
ATTACHMENTS...49
WORK UNDER THE MACHINE...49
KEEP THE MACHINE CLEAN...49
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE...50
PRECAUTIONS WHEN USING HAMMER...50
REPAIR WELDING...50
PRECAUTIONS WITH BATTERY...50
WHEN ABNORMALITY IS LOCATED...50
RULES TO FOLLOW WHEN ADDING FUEL OR OIL...51
ROTATING FAN AND BELT...51
HANDLING HIGH-PRESSURE HOSES...51
PRECAUTION HIGH PRESSURE OIL...51
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE...52
TIRE MAINTENANCE...53
CHECKS AFTER INSPECTION AND MAINTENANCE...53
WASTE MATERIALS...53
WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED...53
TIRES...54
HANDLING TIRES...54
STORING TIRES AFTER REMOVAL...55
POSITION FOR ATTACHING SAFETY LABELS...56
LOCATIONS...56
LABEL TEXT...57
OPERATION...63
GENERAL VIEW...64
EXTERIOR VIEW OF MACHINE...64
VIEW OF CONTROLS AND GAUGES...65
EXPLANATION OF COMPONENTS...67
METERS AND LAMPS...67
SWITCHES (ALL MODELS)...72
SWITCHES (MODELS WITH CAB)...76
CONTROL LEVERS AND PEDALS...78
MISCELLANEOUS...85
SAFETY BAR...85
TOWING PIN...85
GREASE PUMP CLAMP AND RUBBER RING...85
BACKUP ALARM...85
FUSES...86
FUSE CAPACITY AND NAME OF CIRCUIT...86
SLOW-BLOW FUSES...87
STORING THIS MANUAL...88
AUXILIARY POWER SOURCE...88
MACHINE AND ENGINE CHECKS...89
CHECKS BEFORE STARTING ENGINE...89
WALK-AROUND CHECKS...89
CHECK BEFORE STARTING...92
CHECKING AND ADDING COOLANT...92
CHECKING THE DUST INDICATOR...92
CHECKING THE BRAKE OIL TANK...93
CHECKING AND ADDING ENGINE OIL...93
DRAINING THE FUEL-WATER SEPARATOR...94
DRAINING THE FUEL SEDIMENT STRAINER...94
CHECKING THE ELECTRICAL WIRING...95
CHECKING THE FUEL LEVEL...95
INSPECTING THE TIRES...96
INSPECTING THE RIMS...96
CHECKING THE TIRE PRESSURE...96
CHECKING THE MONITOR PANEL...97
CHECKING THE PARKING BRAKE...98
CHECKING THE WHEEL BRAKES...98
CHECK SOUND OF HORN AND BACKUP ALARM...98
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...98
CHECK ENGINE EXHAUST COLOR AND SOUND...98
CHECK OPERATION OF GAUGES...98
CHECK STEERING WHEEL PLAY, CHECK STEERING OPERATION...98
CHECK THE REAR VIEW MIRROR...98
CHECK LOCK OF CAB DOOR (MACHINES EQUIPPED WITH CAB)...98
PRE-WORK SHIFT MACHINE CHECKS...99
ADJUSTING THE OPERATOR'S SEAT (STANDARD VERSION)...99
ADJUSTING THE OPERATOR’S SEAT...100
(OPTIONAL AIR-RIDE SEAT)...100
ADJUSTING THE SEAT BELT...101
ADJUSTING THE REAR VIEW MIRRORS...101
OPERATIONS AND CHECKS BEFORE STARTING ENGINE...102
STARTING THE ENGINE...103
NORMAL STARTING PROCEDURES (IN COLD AND WARM CONDITIONS)...103
AFTER EXTENDED SHUTDOWN OR OIL CHANGE...104
AFTER CHANGING FUEL FILTERS...104
AFTER RUNNING OUT OF FUEL...105
OPERATIONS AND CHECKS AFTER STARTING ENGINE...105
OPERATING THE MACHINE...107
MOVING THE MACHINE...107
CHANGING THE GEAR SPEED...109
CHANGING DIRECTION (FORWARD-REVERSE)...110
AUTO-SHIFT TRANSMISSION...110
TURNING THE MACHINE...111
STOPPING THE MACHINE...112
OPERATING THE WORK EQUIPMENT...113
LIFT ARM (LEVER)...113
BUCKET (LEVER)...114
PARKING THE MACHINE...115
CHECKS AFTER COMPLETION OF OPERATION...117
STOPPING ENGINE...117
CHECKS AFTER STOPPING ENGINE...117
LOCKING THE MACHINE...118
TRANSPORTING THE MACHINE...119
LOADING AND UNLOADING...119
PRECAUTIONS FOR LOADING...120
PRECAUTIONS FOR LIFTING THE VEHICLE...120
LIFTING POINT DECALS...121
WEIGHT LIST...121
LIFTING PROCEDURE...122
TYPICAL WORK OPERATIONS...123
DIGGING OPERATIONS WITH ROCK PILES...123
DIGGING OPERATIONS ON LEVEL GROUND...125
LEVELING OPERATIONS...126
PUSHING OPERATIONS...126
STANDARD LOADING OPERATIONS...127
LOAD-AND-CARRY OPERATIONS...128
PRECAUTIONS FOR OPERATION...128
PERMISSIBLE WATER DEPTH...128
IF WHEEL BRAKE DOES NOT WORK...128
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...128
PRECAUTIONS WHEN DRIVING MACHINE...129
ADJUSTING THE WORK EQUIPMENT POSTURE...129
ADJUSTING THE BOOM KICKOUT...129
ADJUSTING THE BUCKET POSITIONER...130
BUCKET LEVEL INDICATOR...130
COLD WEATHER OPERATIONS...131
PRECAUTIONS DURING LOW AMBIENT TEMPERATURES...131
FUEL AND LUBRICANTS...131
COOLANT...131
BATTERY...132
AFTER COMPLETION OF WORK...132
AFTER COLD WEATHER HAS PASSED...132
LONG-TERM STORAGE...133
BEFORE STORAGE...133
DURING STORAGE...133
AFTER STORAGE...133
TROUBLESHOOTING...134
MACHINE RUNS OUT OF FUEL...134
TOWING THE MACHINE...134
ENGINE STARTS...135
ENGINE DOES NOT START...135
DISCHARGED BATTERY...136
BATTERY REMOVAL AND INSTALLATION...137
BATTERY CHARGING PRECAUTIONS...137
USING BOOSTER CABLES TO START THE ENGINE...138
OTHER TROUBLE...140
ELECTRICAL SYSTEM...140
CHASSIS...141
ENGINE...143
MAINTENANCE...145
GUIDES TO MAINTENANCE...146
OUTLINES OF SERVICE...148
OUTLINE OF OIL, FUEL, COOLANT...148
OIL...148
FUEL...149
COOLANT...149
GREASE...150
STORING OIL AND FUEL...150
FILTERS...150
FUEL INJECTION PUMP...150
OUTLINE OF ELECTRIC SYSTEM...151
WEAR PARTS LIST...152
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...153
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...153
ENGINE OIL SPECIFICATIONS...154
NORMAL OPERATION...154
ARCTIC OPERATION...154
DIESEL FUEL SPECIFICATIONS...155
COOLANT SPECIFICATIONS...155
GENERAL...155
WATER...155
ANTIFREEZE...156
INHIBITORS/CONDITIONERS...157
MAINTENANCE OF COOLING SYSTEM INHIBITORS...157
COOLANT TESTING FOR CONDITIONER CONCENTRATION...157
REPLENISHING COOLANT CONDITIONER...157
DCA4 UNIT MAINTENANCE GUIDE...158
COOLING SYSTEM TEST KIT...160
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...161
INTRODUCTION OF NECESSARY TOOLS...161
TORQUE LIST...162
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...163
SAFETY CRITICAL PARTS...164
MAINTENANCE SCHEDULE CHART...167
MAINTENANCE SCHEDULE CHART...167
SERVICE PROCEDURES...170
INITIAL 250 HOURS SERVICE...170
REPLACE FUEL FILTERS...170
REPLACE TRANSMISSION OIL FILTER ELEMENT...170
REPLACE HYDRAULIC TANK FILTER ELEMENT...170
WHEN REQUIRED...171
CHECKING, CLEANING OR REPLACING THE AIR CLEANER ELEMENT...171
CHECKING THE TRANSMISSION OIL LEVEL, ADDING OIL...173
CHECKING THE AXLE OIL LEVEL, ADDING OIL...174
CLEANING THE AXLE CASE BREATHER...175
CLEANING THE RADIATOR FINS...175
REPLACING THE BOLT-ON CUTTING EDGES...176
REPLACING THE BUCKET TEETH (IF EQUIPPED)...177
CHECKING THE AIR CONDITIONER (IF EQUIPPED)...178
CLEANING THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...179
CHECKING THE WINDOW WASHING FLUID...179
CHECKING AND ADJUSTING THE PARKING BRAKE...180
REPLACING A SLOW-BLOW FUSE...181
CHECKING THE AIR INTAKE HEATER...181
CHECKS BEFORE STARTING...182
EVERY 50 HOURS SERVICE...182