Komatsu WA120-3 WA120L-3 Wheel Loader Operation & Maintenance Manual - PDF

Komatsu WA120-3 WA120L-3 Wheel Loader Operation & Maintenance Manual

Description:

Komatsu WA120-3 WA120L-3 Wheel Loader Operation & Maintenance Manual

• This manual describes procedures for operation, handling, lubrication, maintenance, checking, and adjustment. It will help the operator and maintenance personnel realize peak performance through effective, economical and safe machine operation and maintenance.
• Keep this manual handy and have all personnel read it periodically. If this manual is lost or becomes dirty and can not be read, request a replacement manual from your local distributor.
• If you sell the machine, be sure to give this manual to the new owner.
• Continuing improvements in the design of this machine can lead to changes in detail, which may not be reflected in this manual. Consult your local distributor or Komatsu America International Company for the latest available information on your machine or for questions regarding information in this manual

Table Of Contents:

Komatsu WA120-3 WA120L-3 Wheel Loader Operation & Maintenance Manual

MAIN MENU........................................................................................  0
INTRODUCTION.....................................................................................  4
	1. FORWARD...................................................................................  5
	2. SAFETY INFORMATION........................................................................  6
	3. INTRODUCTION..............................................................................  7
		3.1 INTENDED USE.........................................................................  7
		3.2 FEATURES.............................................................................  7
		3.3 BREAKING IN A NEW MACHINE............................................................  7
	4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.............................  8
		4.1 MACHINE SERIAL NO. PLATE POSITION....................................................  8
		4.2 ENGINE SERIAL NO. PLATE POSITION.....................................................  8
		4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR............................................  8
	5. CONTENTS..................................................................................  9
SAFETY........................................................................................... 14
	6. GENERAL PRECAUTIONS....................................................................... 15
	7. PRECAUTIONS DURING OPERATION.............................................................. 21
		7.1 BEFORE STARTING ENGINE............................................................... 21
		7.2 AFTER STARTING ENGINE................................................................ 24
		7.3 TRANSPORTATION....................................................................... 33
		7.4 BATTERY.............................................................................. 34
		7.5 TOWING............................................................................... 37
	8. PRECAUTIONS FOR MAINTENANCE............................................................... 38
		8.1 BEFORE CARRYING OUT MAINTENANCE...................................................... 38
		8.2 DURING MAINTENANCE................................................................... 43
		8.3 TIRES................................................................................ 49
	9. POSITION FOR ATTACHING SAFETY LABELS...................................................... 51
		9.1 POSITION FOR ATTACHING SAFETY LABELS................................................. 51
OPERATION........................................................................................ 56
	10. GENERAL VIEW............................................................................. 57
		10.1 GENERAL VIEW OF MACHINE............................................................. 57
		10.2 GENERAL VIEW OF CONTROLS AND GAUGES................................................. 58
	11. EXPLANATION OF COMPONENTS................................................................ 60
		11.1 METER, LAMPS........................................................................ 60
		11.2 SWITCHES............................................................................ 64
		11.3 CONTROL LEVERS, PEDAL............................................................... 70
		11.4 CAP WITH LOCK....................................................................... 74
			11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK................................... 74
		11.5 SAFETY BAR.......................................................................... 74
		11.6 TOWING PIN.......................................................................... 75
		11.7 GREASE PUMP CLAMP AND RUBBER RING................................................... 75
		11.8 BACK-UP ALARM....................................................................... 75
		11.9 FUSE................................................................................ 76
			11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT............................................. 76
		11.10 SLOW BLOW FUSE..................................................................... 77
		11.11 STORAGE PLACE FOR THIS MANUAL...................................................... 78
		11.12 AUXILIARY POWER SOURCE............................................................. 78
			11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB.......................................... 78
	12. CHECK BEFORE STARTING ENGINE............................................................. 79
		12.1 WALK AROUND CHECK................................................................... 79
		12.2 CHECK BEFORE STARTING............................................................... 82
			12.2.1 CHECK COOLANT LEVEL, ADD COOLANT.............................................. 82
			12.2.2 CHECK FUEL LEVEL, ADD FUEL.................................................... 82
			12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.................................... 83
			12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK..................................... 83
			12.2.5 CHECK DUST INDICATOR.......................................................... 84
			12.2.6 CHECK ELECTRICAL WIRING....................................................... 84
			12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR................................. 85
			12.2.8 CHECK EFFECT OF PARKING BRAKE................................................. 85
			12.2.9 CHECK EFFECT OF WHEEL BRAKES.................................................. 86
			12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM......................................... 86
			12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE........................... 86
			12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND......................................... 86
			12.2.13 CHECK OPERATIONS OF GAUGES................................................... 86
			12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING.................... 86
			12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE................ 86
			12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB........................ 86
		12.3 ADJUSTMENT BEFORE OPERATION......................................................... 87
			12.3.1 OPERATOR'S SEAT............................................................... 87
			12.3.2 ADJUST SEAT BELT.............................................................. 89
			12.3.3 ADJUST REAR VIEW MIRRORS...................................................... 90
		12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE........................................ 91
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE......................................... 94
		12.5 STARTING ENGINE..................................................................... 92
			12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS........................ 92
			12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE..................... 93
			12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS............................... 93
			12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL................................. 93
		12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE......................................... 94
		12.7 MOVING MACHINE OFF.................................................................. 95
		12.8 CHANGING GEAR SPEED................................................................. 97
		12.9 CHANGING DIRECTION.................................................................. 97
		12.10 TURNING............................................................................ 98
		12.11 STOPPING MACHINE................................................................... 99
		12.12 OPERATION OF WORK EQUIPMENT........................................................100
			12.12.1 BOOM OPERATION (LEVER).......................................................100
			12.12.2 BUCKET OPERATION (LEVER).....................................................100
		12.13 WORK POSSIBLE USING WHEEL LOADER...................................................101
			12.13.1 DIGGING OPERATIONS WITH ROCK PILES...........................................101
			12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...........................................102
			12.13.3 LEVELING OPERATION...........................................................103
			12.13.4 PUSHING OPERATIONS...........................................................103
			12.13.5 LOAD AND CARRY OPERATIONS....................................................103
			12.13.6 LOADING OPERATIONS...........................................................104
		12.14 PRECAUTIONS FOR OPERATION..........................................................105
			12.14.1 PERMISSIBLE WATER DEPTH......................................................105
			12.14.2 IF WHEEL BRAKE DOES NOT WORK.................................................105
			12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...................................105
			12.14.4 PRECAUTIONS WHEN DRIVING MACHINE.............................................106
		12.15 ADJUSTING WORK EQUIPMENT POSTURE...................................................107
			12.15.1 ADJUSTING BOOM KICKOUT.......................................................107
			12.15.2 ADJUSTING BUCKET POSITIONER..................................................108
			12.15.3 BUCKET LEVEL INDICATOR.......................................................108
		12.16 PARKING MACHINE....................................................................109
		12.17 CHECKS AFTER COMPLETION OF OPERATION...............................................110
		12.18 STOPPING ENGINE....................................................................110
		12.19 CHECKS AFTER STOPPING ENGINE.......................................................111
		12.20 LOCKING............................................................................111
		12.21 HANDLING THE TIRES.................................................................112
			12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES..........................................112
			12.21.2 TIRE PRESSURE................................................................112
	13. TRANSPORTATION...........................................................................114
		13.1 LOADING, UNLOADING WORK.............................................................114
		13.2 PRECAUTION FOR LOADING..............................................................115
		13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...............................................115
			13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS.........................116
			13.3.2 WEIGHT LIST...................................................................116
			13.3.3 LIFTING PROCEDURE.............................................................117
	14. COLD WEATHER OPERATIONS..................................................................118
		14.1 PRECAUTIONS FOR LOW TEMPERATURE.....................................................118
			14.1.1 FUEL AND LUBRICANTS...........................................................118
			14.1.2 COOLANT.......................................................................118
			14.1.3 BATTERY.......................................................................119
		14.2 PRECAUTIONS AFTER COMPLETION OF WORK................................................120
		14.3 AFTER COLD WEATHER..................................................................120
	15. LONG TERM STORAGE........................................................................121
		15.1 BEFORE STORAGE......................................................................121
		15.2 DURING STORAGE......................................................................121
		15.3 AFTER STORAGE.......................................................................121
	16. TROUBLESHOOTING..........................................................................122
		16.1 WHEN MACHINE RUNS OUT OF FUEL.......................................................122
		16.2 TOWING THE MACHINE..................................................................123
			16.2.1 WHEN ENGINE CAN BE USED.......................................................125
			16.2.2 WHEN ENGINE CANNOT BE USED....................................................125
		16.3 IF BATTERY IS DISCHARGED............................................................126
			16.3.1 REMOVAL AND INSTALLATION OF BATTERY...........................................126
			16.3.2 PRECAUTIONS FOR CHARGING BATTERY..............................................127
			16.3.3 STARTING ENGINE WITH BOOSTER CABLE............................................128
		16.4 OTHER TROUBLE.......................................................................130
			16.4.1 ELECTRICAL SYSTEM.............................................................130
			16.4.2 CHASSIS.......................................................................131
			16.4.3 ENGINE........................................................................134
MAINTENANCE......................................................................................136
	17. GUIDES TO MAINTENANCE....................................................................137
	18. OUTLINES OF SERVICE......................................................................140
		18.1 OUTLINE OF OIL, FUEL, COOLANT.......................................................140
			18.1.1 OIL...........................................................................140
			18.1.2 FUEL..........................................................................141
			18.1.3 COOLANT.......................................................................141
			18.1.4 GREASE........................................................................142
			18.1.5 STORING OIL AND FUEL..........................................................142
			18.1.6 FILTERS.......................................................................142
		18.2 OUTLINE OF ELECTRIC SYSTEM..........................................................143
	19. WEAR PARTS LIST..........................................................................144
	20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....................145
		20.1 ENGINE OIL SPECIFICATIONS...........................................................146
		20.2 DIESEL FUEL SPECIFICATIONS..........................................................147
		20.3 COOLANT SPECIFICATIONS..............................................................148
	21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS............................................154
		21.1 INTRODUCTION OF NECESSARY TOOLS.....................................................154
		21.2 TORQUE LIST.........................................................................155
	22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS............................................157
	23. MAINTENANCE SCHEDULE CHART...............................................................161
		23.1 MAINTENANCE SCHEDULE CHART..........................................................161
	24. SERVICE PROCEDURES.......................................................................165
		24.1 INITIAL 250 HOURS SERVICE...........................................................165
			24.1.1 REPLACE FUEL FILTERS..........................................................165
			24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................165
			24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT.........................................165
		24.2 WHEN REQUIRED.......................................................................166
			24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...................................166
			24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.........................................168
			24.2.3 CHECK AXLE OIL LEVEL , ADD OIL................................................169
			24.2.4 CLEAN THE AXLE CASE BREATHER..................................................170
			24.2.5 CLEAN RADIATOR FINS...........................................................170
			24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.............................................171
			24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)............................................172
			24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...........................................173
			24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED).............................174
			24.2.10 CHECK WINDOW WASHING FLUID...................................................174
			24.2.11 ADJUST PARKING BRAKE.........................................................175
			24.2.12 REPLACE SLOW BLOW FUSE.......................................................176
			24.2.13 CHECK AIR INTAKE HEATER......................................................176
		24.3 CHECK BEFORE STARTING...............................................................177
		24.4 EVERY 50 HOURS SERVICE..............................................................178
			24.4.1 CHECK THE TIRE INFLATION PRESSURE.............................................178
			24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK..........................................178
			24.4.3 CHECK ENGINE AIR INTAKE SYSTEM................................................178
		24.5 EVERY 100 HOURS SERVICE.............................................................179
			24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....................................179
			24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER.............................180
			24.5.3 LUBRICATING...................................................................181
		24.6 EVERY 250 HOURS SERVICE.............................................................182
			24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER....................182
			24.6.2 CHECK FOR LOOSE WHEEL BOLTS. TIGHTEN..........................................183
			24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER.........................183
			24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST.........................184
			24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...............................................185
			24.6.6 CHECK AIR INTAKE SYSTEM.......................................................185
			24.6.7 LUBRICATING...................................................................186
		24.7 EVERY 500 HOURS SERVICE.............................................................187
			24.7.1 REPLACE FUEL FILTERS..........................................................187
			24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.......................................189
			24.7.3 LUBRICATE.....................................................................190
		24.8 EVERY 1000 HOURS SERVICE............................................................191
			24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...............................191
			24.8.2 CLEAN TRANSMISSION CASE BREATHER..............................................192
			24.8.3 LUBRICATE.....................................................................193
			24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT............194
			24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE............................................195
			24.8.6 CHECK FAN BELT TENSION........................................................196
			24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT.........196
			24.8.8 CHECK TIGHTENING PARTS OF TURBOCHARGER........................................197
			24.8.9 CHECK PLAY OF TURBOCHARGER ROTOR..............................................197
		24.9 EVERY 2000 HOURS SERVICE............................................................197
			24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM..........................197
			24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT.......................................200
			24.9.4 CHECK BRAKE DISC WEAR.........................................................201
			24.9.5 CHECK ALTERNATOR..............................................................201
			24.9.6 CHECK STARTER MOTOR...........................................................201
			24.9.7 CHECK VIBRATION DAMPER........................................................201
			24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER....201
			24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE............................................202
			24.9.10 CLEAN AND CHECK TURBOCHARGER.................................................204
		24.10 EVERY 4000 HOURS SERVICE...........................................................204
			24.10.1 CHECK WATER PUMP.............................................................204
SPECIFICATIONS...................................................................................206
	25. SPECIFICATIONS...........................................................................207
OPTIONS, ATTACHMENTS.............................................................................211
	26. AVAILABLE ATTACHMENTS....................................................................212
	27. HEATER AND AIR CONDITIONING (IF EQUIPPED)................................................214
		27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL......................................214
		27.2 COOL BOX COMPARTMENT................................................................215
	28. HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)..............................216
		28.1 STRUCTURE AND FUNCTION OF E.C.S.S...................................................216
		28.2 METHOD OF OPERATING E.C.S.S.........................................................217
		28.3 PRECAUTIONS WHEN OPERATING E.C.S.S..................................................217
		28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...............................................218

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