Komatsu Wheel Loader WA120, WA120L, WA120LC Repair Service Manuals
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loaders WA120, WA120L, WA120LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loaders WA120-3, WA120L-3, WA120-1LC workshop service repair manual includes:
* 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
PARKING BRAKE PILOT IAMP ...263
EMERGENCY STEERING NORMAL PILOT LAMP (OPT)...264
EMERGENCY STEERING PILOT LAMP (OPT) ...264
TURN SIGNAL PILOT LAMP ...264
SPEEDOMETER...264
WORKING PILOT LAMP...265
HIGH BEAM PILOT LAMP...265
SERVICE METER...265
SWITCHES ...266
PARKING LAMP AND TRANSMISSION CUT-OFF SELECTOR SWITCH ...266
WORKING LAMP AND CLUSTER GAUGE CHECK SWITCH ...267
LAMP SWITCH ...267
STARTING SWITCH...268
HORN BUTTON ...268
ETHER START SWITCH ...269
CAB DOME LAMP SWITCH ...269
FRONT WIPER SWITCH...269
REAR WIPER SWITCH ...269
PEDALS AND LEVERS ...270
DIRECTIONAL LEVER ...270
SPEED CONTROL LEVER...270
SAFETY LOCK (FOR DIRECTIONAL LEVER) ...271
SPEED CONTROL LEVER STOPPER ...271
TURN SIGNAL LEVER...271
ACCELERATOR PEDAL ...271
BRAKE PEDALS ...272
WORK EQUIPMENT CONTROL LEVER ...273
WORK EQUIPMENT CONTROL LEVER LOCK ...274
PARKING BRAKE LEVER ...274
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED...274
FUSE BOX ...275
FUSE BOX I...276
FUSE BOX II...276
OPERATOR'S SEAT ...277
RIGID TYPE...277
FORWARD-BACKWARD ADJUSTMENT ...277
SEAT HEIGHT ADJUSTMENT...277
BACKREST ADJUSTMENT...277
BUCKET TYPE SEAT (OPT)...277
FORWARD-BACKWARD ADJUSTMENT...277
SEAT ANGLE ADJUSTMENT...277
SEAT CUSHION ADJUSTMENT...277
BACKREST ADJUSTMENT...277
SEAT HEIGHT ADJUSTMENT...277
SEARS SEAT ...278
FORWARD-BACKWARD ADJUSTMENT ...278
SEAT ANGLE ADJUSTMENT ...278
WEIGHT ADJUSTMENT ...278
BACKREST TILT ADJUSTMENT ...278
HEIGHT ADJUSTMENT ...278
KAB SEAT...279
WEIGHT ADJUSTMENT...279
HEIGHT ADJUSTMENT...279
BACKREST ANGLE ADJUSTMENT...279
FORE AND AFT ADJUSTMENT...279
HEADREST ADJUSTMENT (IF EQUIPPED)...279
RIGHT SIDE ARMREST...279
SEAT BELT ...280
ClGARETTE LIGHTER...281
AIR CLEANER SERVICE INDICATOR...281
FRAME LOCKING BAR...281
DRAWBAR PIN...282
CAB HEATER AND DEFROSTER ...283
CONTROL PANEL...283
FAN SPEED SWITCH...283
FOOT / DEFROSTER SELECT LEVER...283
AIR INTAKE SELECTOR LEVER...283
CHECK BEFORE STARTING ...284
WALK-AROUND CHECK...284
CHECK AND REFILL COOLANT...284
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN...285
CHECK FUEL LEVEL AND REFILL FUEL...285
CHECK AIR CLEANER SERVICE INDICATOR...286
CHECK AND REFILL OF OIL IN BRAKE OIL TANK...286
ADDITIONAL CHECKS...287
CHECK ELECTRICAL WIRING...287
DRAIN THE WATER FROM PRIMARY FUEL FILTER/WATER SEPARATOR...287
OPERATING YOUR MACHINE ...288
BEFORE STARTING THE ENGINE ...288
STARTING ENGINE ...289
SPECIAL STARTING ...289
COLD WEATHER STARTING...290
CHECKS AFTER STARTING ...292
COLD WEATHER WARM-UP PROCEDURE ...292
MOVING MACHINE OFF ...293
CHANGING GEAR SPEED...294
CHANGING DIRECTION...294
TURNING ...295
TO STOP THE MACHINE...296
TO STOP THE ENGINE ...297
OPERATIONS AFTER STOPPING ENGINE ...297
OPERATIONAL PRECAUTIONS ...298
WORKING IN DUSTY LOCATIONS ...298
MAXIMUM DEPTH OF WATER ...298
IF WHEEL BRAKE DOES NOT WORK ...299
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES ...299
LOWER THE CENTER OF GRAVITY WHEN TURNING...299
BRAKING ON DOWNHILL SLOPES...299
IF ENGINE STOPS...299
POSSIBLE WORK USING LOADER ...300
EXCAVATION ...300
LEVELING...302
LOAD AND CARRY OPERATIONS ...303
LOADING ...303
Cross Drive Loading ...303
V-Shape Loading ...303
PARKING MACHINE...304
PRECAUTIONS WHEN TIRE CHAINS ARE FllTED...304
PROCEDURE FOR MOVING R.H. LADDER ...304
PROCEDURE FOR MOVING L.H. LADDER ...305
ADJUSTMENT OF WORK EQUIPMENT ...306
ADJUSTING BOOM KICKOUT ...306
ADJUSTING BUCKET POSITIONER...307
BUCKET LEVEL INDICATOR...307
HANDLING TIRES ...308
PRECAUTIONS WHEN HANDLING TIRES ...308
PRECAUTIONS WHEN DRIVING MACHINE ...308
TIRE PRESSURE ...308
TOWING ...310
TOWING THE MACHINE...310
WHEN ENGINE CANNOT BE USED ...310
WHEN ENGINE CAN BE USED ...310
TRANSPORTATION ...310
COLD WEATHER OPERATION ...311
PREPARATION FOR LOW TEMPERATURE...311
FUEL AND LUBRICANTS...311
COOLANT...311
BATTERY...311
CAUTIONS AFTER COMPLETION OF WORK...311
AFTER COLD WEATHER...312
LONG TERM STORAGE ...312
BEFORE STORAGE...312
DURING STORAGE...312
AFTER STORAGE...312
HANDLING OF BATTERY ...313
PRECAUTIONS FOR CHARGING BATTERY ...313
REMOVAL AND INSTALLATION OF BATTERY ...313
STARTING ENGINE WITH BOOSTER CABLES ...313
BEFORE CONNECTING BOOSTER CABLES...313
CONNECTING BOOSTER CABLES ...314
STARTING ENGINE ...314
DISCONNECTING BOOSTER CABLES ...314
TROUBLESHOOTING ...315
ELECTRICAL SYSTEM...315
ENGINE...315
CHASSIS ...316
TRANSMISSION...316
DRIVE AXLES ...316
WHEEL BRAKES...316
PARKING BRAKE...316
STEERING ...316
EQUIPMENT HYDRAULIC SYSTEM...316
MAINTENANCE -- SECTION 3...317
PERIODIC MAINTENANCE ...318
MAINTENANCE GUIDELINES ...318
OUTLINES OF SERVICE ...319
LUBRICATION WHEN SHIPPED...319
RELATING TO ENGINE...320
ENGINE OIL...320
COOLANT ...320
DIESEL FUEL ...320
RELATING TO HYDRAULIC SYSTEM...320
RELATING TO ELECTRICAL SYSTEM...320
RELATING TO LUBRICATION...321
BLEEDING AIR...321
BLEEDING AIR FROM HYDRAULIC TANK...321
BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT...322
BLEEDING AIR FROM FUEL SYSTEM...323
WEAR PARTS REPLACEMENT...325
PERIODICAL PART REPLACEMENT...325
LUBRICANTS, FUEL AND COOLANT...326
PROPER SELECTION TABLE...326
ENGINE OIL...327
Normal Operation...327
Arctic Operation...327
AXLE OIL...328
GREASE...328
DIESEL FUEL...328
COOLANT...328
SCHEDULED MAINTENANCE GUIDE...335
OIL FILLER AND LEVEL GAUGE POSITIONS...339
INITIAL 250 HOURS SERVICE ONLY...340
TRANSMISSION OIL FILTER ...340
WHEN REQUIRED ...340
COOLANT ADDITIVE CONCENTRATION - DCA4 ...340
AIR CLEANER ELEMENT ...340
CHECKING...340
CLEANING OR REPLACING OUTER ELEMENT...341
REPLACING INNER ELEMENT...341
CLEANING OUTER ELEMENT...342
TRANSMISSION OIL ...343
RADIATOR CORE ...343
WINDSHIELD WASHER TANKS...344
DRIVE AXLE OIL...344
DRIVE AXLE HOUSING BREATHERS ...345
LUBRICATING ...345
BUCKET BOLT-ON CUTTlNG EDGE - IF EQUIPPED ...347
BUCKET TEETH - IF EQUIPPED ...347
BUCKET IS EQUIPPED WITH BOLT-ON TEETH...347
BUCKET IS EQUIPPED WITH WELDED ON OR REPLACEABLE TIP TEETH...348
PARKING BRAKE ...349
INSPECTION...349
ADJUSTMENT...349
CHECK BEFORE STARTING ...350
EVERY 50 HOURS SERVICE ...350
FUEL TANK...350
TIRES...350
EVERY 100 HOURS SERVICE ...350
HYDRAULIC TANK...350
LUBRICATING ...351
EVERY 250 HOURS SERVICE ...353
LUBRICATING ...353
WHEEL HUB BOLTS...355
ENGINE OIL PAN AND FILTER ...356
BATTERY ELECTROLYTE...357
AIR INTAKE SYSTEM...358
EVERY 500 HOURS SERVICE ...358
LUBRICATING...358
FUEL FILTERS...359
GENERAL...359
REPLACEMENT...359
TRANSMISSION OIL FILTER...361
ANTIFREEZE CONCENTRATION...361
EVERY 1000 HOURS SERVICE ...362
LUBRICATING ...362
HYDRAULIC TANK AND FILTER...364
TRANSMISSION CASE BREATHER...365
TRANSMISSION OIL AND STRAINER...365
ENGINE VALVES...366
DRIVE BELT...369
DRIVE BELT, TENSIONER BEARING AND FAN HUB...369
EVERY 2000 HOURS SERVICE ...370
DRIVE AXLES...370
HYDRAULIC TANK BREATHER...372
BRAKE DISC...372
VIBRATION DAMPER...372
COOLING SYSTEM ...373
SPECIFICATIONS -- SECTION 4...375
GENERAL SPECIFICATIONS ...376
STANDARD TIGHTENING TORQUES ...381
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS ...381
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS ...381
TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS...382
UNIT CONVERSIONS ...383
AREA ...384
DENSITY (Mass Density) ...384
FORCE ...385
FORCE PER LENGTH ...385
HEAT ...385
LENGTH ...386
MASS (WEIGHT) ...386
POWER ...387
PRESSURE ...387
TEMPERATURE ...387
TEMPERATURE INTERVAL OR TOLERANCE ...388
VOLUME...388
TORQUE ...389
VELOCITY...389
CEBM002002 - Wheel Loader WA120-3, WA120L-3 Shop Manual...392
CEBMW16040 - Wheel Loader WA120-1LC Shop Manual...977
CONTENTS...981
10 ENGINE...999
11 STRUCTURE AND FUNCTION...999
ENGINE MOUNTING...1000
RADIATOR AND OIL COOLER...1001
FUEL TANK AND PIPING...1002
ENGINE CONTROL...1003
12 TESTING AND ADJUSTING...1005
STANDARD VALUE TABLE ...1006
SERVICE TOOL LIST ...1008
SAFETY PRECAUTIONS ...1009
EXHAUST GAS COLOR ...1010
ACCELERATOR PEDAL OPERATING FORCE AND ANGLE ...1011
OPERATING FORCE...1011
OPERATING ANGLE...1012
13 DISASSEMBLY AND ASSEMBLY ...1015
CRANKING MOTOR ...1016
REMOVAL...1016
INSTALLATION...1016
ALTERNATOR ...1017
REMOVAL...1017
INSTALLATION...1017
OIL COOLER ...1018
REMOVAL...1018
INSTALLATION...1019
WATER PUMP ...1020
REMOVAL...1020
INSTALLATION...1021
FUEL INJECTORS ...1022
REMOVAL...1022
INSTALLATION...1024
TURBOCHARGER ...1026
REMOVAL...1026
INSTALLATION...1028
CYLINDER HEAD ...1030
REMOVAL...1030
INSTALLATION...1033
RADIATOR ...1036
REMOVAL...1036
INSTALLATION...1039
ENGINE ...1043
REMOVAL...1043
INSTALLATION...1050
FUEL TANK ...1058
REMOVAL...1058
INSTALLATION...1059
20 POWER TRAIN...1061
21 STRUCTURE AND FUNCTION ...1061
GENERAL ...1064
HYDRAULIC CIRCUIT FOR POWER TRAIN ...1066
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...1067
FORWARD FIRST...1068
TORQUE CONVERTER AND TRANSMISSION PIPING ...1070
TORQUE CONVERTER CHARGING PUMP ...1071
OUTLINE...1071
SPECIFICATIONS...1071
TORQUE CONVERTER ...1072
SPECIFICATIONS...1072
OUTLINE...1073
FLOW OF MOTIVE FORCE...1073
FLOW OF OIL...1073
TORQUE CONVERTER OIL FILTER ...1074
OPERATION...1074
TORQUE CONVERTER OIL COOLER ...1076
OUTLINE...1076
TRANSMISSION ...1077
OUTLINE ...1079
CLUTCH SHAFTS ...1079
FORWARD AND REVERSE CLUTCHES ...1079
FIRST GEAR CLUTCH ...1080
SECOND AND THIRD GEAR CLUTCH ...1080
OPERATION OF CLUTCH ...1081
WHEN ENGAGED...1081
WHEN DISENGAGED...1081
FORWARD FIRST...1082
OPERATION...1083
REVERSE FIRST ...1084
OPERATION...1085
TRANSMISSION CONTROL VALVE ...1086
MAIN REGULATOR VALVE ...1088
FUNCTION ...1088
OPERATION...1088
TORQUE CONVERTER OIL OUTLET VALVE ...1089
FUNCTION...1089
OPERATION...1089
QUICK RETURN VALVE AND ACCUMULATOR...1090
FUNCTION...1090
Quick Return Valve...1090
Accumulator...1090
OPERATION...1090
When Clutch Is Engaged...1090
Immediately After Gear Shifting...1090
POWER MODULATING FUNCTION...1092
FUNCTION...1092
CLUTCH CUT-OFF VALVE...1096
OPERATION ...1096
DRIVE SHAFTS ...1098
OUTLINE ...1098
AXLES ...1100
FRONT ...1100
REAR ...1101
DIFFERENTIALS ...1102
FRONT...1102
REAR ...1103
TORQUE PROPORTIONING DIFFERENTIAL ...1104
OUTLINE...1104
FUNCTION ...1105
OPERATION ...1105
FINAL DRIVES ...1106
OUTLINE ...1106
AXLE MOUNTING ...1108
FRONT AXLE ...1109
REAR AXLE ...1109
TIRES AND WHEELS ...1110
THREE PIECE WHEEL...1110
ONE PIECE WHEEL ...1111
SPECIFICATIONS ...1112
22 TESTING AND ADJUSTING...1113
STANDARD VALUE TABLE ...1114
SERVICE TOOL LIST ...1116
SAFETY PRECAUTIONS ...1116
ENGINE STALL SPEEDS ...1118
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURES ...1120
TRANSMISSION SHIFT LEVERS...1122
TRANSMISSION CONTROL VALVE SPOOLS ...1123
TROUBLESHOOTING...1125
PRECAUTIONS...1126
METHOD OF READING TROUBLESHOOTING TABLE...1128
PREVENTING RECURRENCE OF TROUBLE...1130
CHECKS BEFORE TROUBLESHOOTING...1131
TROUBLESHOOTING TABLE...1132
TORQUE CONVERTER AND TRANSMISSION...1132
1. Machine does not move off...1132
2. Machine speed is low, thrust is weak, gradeability falls off...1134
3. Large shock when moving off or changing gear...1136
4. Large time lag when moving off or changing gear...1137
5. Oil temperature in torque converter is high...1138
23 DISASSEMBLY AND ASSEMBLY...1139
TORQUE CONVERTER CHARGING PUMP ...1141
REMOVAL ...1141
INSTALLATION ...1141
TORQUE CONVERTER TRANSMISSION ...1142
REMOVAL ...1142
INSTALLATION ...1149
TORQUE CONVERTER ...1156
DISASSEMBLY ...1156
ASSEMBLY ...1159
TRANSMISSION ...1162
DISASSEMBLY ...1162
ASSEMBLY ...1169
FORWARD REVERSE CLUTCH PACKS ...1180
DISASSEMBLY ...1180
ASSEMBLY ...1183
FIRST SPEED CLUTCH PACK ...1188
DISASSEMBLY ...1188
ASSEMBLY ...1190
SECOND AND THIRD SPEED CLUTCH PACKS ...1193
DISASSEMBLY ...1193
ASSEMBLY ...1195
TRANSMISSION CONTROL VALVE ...1200
REMOVAL ...1200
INSTALLATION ...1202
DISASSEMBLY ...1206
ASSEMBLY ...1210
DRIVE SHAFT ...1216
DISASSEMBLY...1216
ASSEMBLY...1218
FRONT AXLE...1220
REMOVAL ...1220
INSTALLATION...1222
REAR AXLE ...1224
REMOVAL...1224
INSTALLATION...1228
DIFFERENTIAL ...1233
DISASSEMBLY...1233
ASSEMBLY...1237
AXLE HOUSING ...1247
DISASSEMBLY...1247
ASSEMBLY...1253
24 MAINTENANCE STANDARD...1261
TRANSMISSION AND ENGINE MOUNT ...1262
TORQUE CONVERTER CHARGING PUMP ...1264
TORQUE CONVERTER ...1265
TRANSMISSION...1266
TRANSMISSION CLUTCH ASSEMBLY...1268
FORWARD-REVERSE CLUTCH ASSEMBLY...1268
1ST CLUTCH ASSEMBLY...1268
2ND, 3RD CLUTCH ASSEMBLY...1268
TRANSMISSION CONTROL VALVE...1270
AXLE...1272
DIFFERENTIAL ...1274
FINAL DRIVE ...1276
DRIVE SHAFT...1277
AXLE MOUNT...1278
40 STEERING SYSTEM...1281
41 STRUCTURE AND FUNCTION...1281
GENERAL ...1282
HYDRAULIC CIRCUIT FOR STEERING ...1283
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING ...1284
STEERING VALVE ...1285
CONNECTION OF HAND PUMP AND SLEEVE...1291
FUNCTION OF CENTER PIN...1292
PRIORITY VALVE ...1293
STEERING CYLINDER ...1296
CENTER HINGE PIN ...1297
42 TESTING AND ADJUSTING...1299
STANDARD VALUE TABLE ...1300
SERVICE TOOL LIST ...1300
STEERING WHEEL PLAY ...1301
OPERATING FORCE OF STEERING WHEEL ...1302
OPERATING TIME OF STEERING WHEEL ...1303
STEERING OIL PRESSURE ...1304
TROUBLESHOOTING...1305
TROUBLESHOOTING TABLE ...1306
STEERING CIRCUIT...1306
1. Steering wheel does not turn...1306
2. Steering wheel is sluggish...1307
3. Steering wheel moves unsteadily or is subjected to large shock...1308
4. Machine tends to turn naturally in one particular direction when traveling...1308
5. Left and right turning radii are different...1308
43 DISASSEMBLY AND ASSEMBLY...1309
STEERING VALVE ...1310
REMOVAL ...1310
INSTALLATION...1311
DISASSEMBLY ...1312
ASSEMBLY ...1315
STEERING RELIEF VALVE ...1320
REMOVAL AND DISASSEMBLY ...1320
ASSEMBLY AND INSTALLATION ...1321
PRIORITY VALVE ...1322
REMOVAL ...1322
INSTALLATION ...1323
STEERING CYLINDER ...1324
REMOVAL ...1324
INSTALLATION ...1324
DISASSEMBLY ...1325
ASSEMBLY ...1327
CENTER HINGE PIN ...1330
REMOVAL ...1330
INSTALLATION ...1338
44 MAINTENANCE STANDARD...1347
STEERING CYLINDER MOUNT...1348
STEERING CYLINDER ...1349
CENTER HINGE PIN ...1350
STEERING COLUMN ...1352
PRIORITY VALVE...1353
50 BRAKES...1355
51 STRUCTURE AND FUNCTION...1355
GENERAL ...1356
BRAKE MASTER CYLINDER...1357
BRAKE...1359
PARKING BRAKE...1361
BRAKE CALIPER...1362
52 TESTING AND ADJUSTING...1363
STANDARD VALUE TABLE ...1364
TOOL LIST ...1365
MEASURING BRAKE PEDAL...1366
BRAKE PEDAL LINKAGE ...1367
BRAKE PERFORMANCE...1369
BRAKE PISTON LEAKAGE ...1370
BRAKE DISC WEAR...1371
AIR BLEEDING FROM BRAKE CIRCUIT ...1372
PARKING BRAKE PERFORMANCE...1373
PARKING BRAKE ...1374
CHECKING...1374
ADJUSTING...1375
MEASURING CLEARANCE ...1376
TROUBLESHOOTING...1377
TROUBLESHOOTING TABLES ...1378
1. Brake is ineffective or not very effective...1378
2. Brake cannot be released or drags...1379
53 DISASSEMBLY AND ASSEMBLY...1381
MASTER CYLINDER ...1382
REMOVAL...1382
INSTALLATION...1383
DISASSEMBLY...1384
ASSEMBLY...1385
PARKING BRAKE...1386
REMOVAL...1386
INSTALLATION...1388
PARKING BRAKE PAD...1390
REMOVAL...1390
INSTALLATION...1391
54 MAINTENANCE STANDARD...1393
MASTER CYLINDER ...1394
BRAKE...1395
60 WORK EQUIPMENT SYSTEM...1397
61 STRUCTURE AND FUNCTION...1397
GENERAL ...1398
HYDRAULIC CIRCUIT ...1400
HYDRAULIC CIRCUIT DIAGRAM ...1401
DUMP AND LIFT CONTROL LEVER LINKAGE ...1402
BUCKET LINKAGE ...1403
BUCKET POSITIONER AND BOOM KICK-OUT...1405
HYDRAULIC TANK ...1406
OIL FILTER BYPASS VALVE...1407
BREATHER...1407
HYDRAULIC AND STEERING PUMP ...1408
MAIN CONTROL VALVE...1409
RELIEF VALVE ...1411
SAFETY VALVE (WITH SUCTION VALVE)...1412
SUCTION VALVE...1413
LIFT AND DUMP SPOOLS AT “HOLD POSITION”...1414
LIFT SPOOL AT “RAISE POSITION”...1415
LIFT SPOOL AT “LOWER POSITION”...1416
DUMP SPOOL AT “FLOAT POSITION”...1417
DUMP SPOOL AT “TILT BACK POSITION”...1418
DUMP SPOOL AT “DUMP POSITION”...1419
HYDRAULIC CYLINDER ...1420
LIFT CYLINDER...1420
DUMP CYLINDER...1420
62 TESTING AND ADJUSTING...1421
STANDARD VALUE TABLE ...1423
TOOL LIST ...1424
DUMP AND LIFT CONTROL LEVERS...1425
MEASURING PROCEDURE...1425
ADJUSTING PROCEDURE...1426
DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL...1427
MEASURING PROCEDURE...1427
HYDRAULIC CIRCUIT FLUSHING...1428
BEFORE FLUSHING...1428
WORK STEPS FOR FLUSHING...1429
HYDRAULIC PRESSURE ...1431
MEASURING PROCEDURE (Main relief valve)...1431
ADJUSTING PROCEDURE (Main relief valve)...1432
LIFT ARM AND BUCKET ...1433
MEASURING PROCEDURE...1433
Lifting time of lift arm...1433
Lowering time of lift arm...1433
Dumping time of bucket...1434
Tilt back time of bucket...1434
HYDRAULIC DRIFT ...1435
Measuring procedure...1435
BUCKET POSITIONER...1436
INSPECTION PROCEDURE...1436
ADJUSTING PROCEDURE...1436
BOOM KICK-OUT...1437
INSPECTION PROCEDURE...1437
ADJUSTING PROCEDURE...1437
TROUBLESHOOTING...1439
LOADER CIRCUIT...1440
1. Lift arm does not rise...1440
2. Lift arm moves slowly or does not have sufficient lifting power...1441
3. Lift arm movement becomes slow after it reaches a certain height...1442
4. Bucket cannot be held down with lift cylinder...1442
5. Lift arm has large hydraulic drift...1442
6. Lift arm movement is unsteady during work...1442
7. Lift arm descends momentarily when the control lever is shifted from "Hold" to "Raise"...1442
8. Bucket does not tilt back...1443
9. Bucket moves slowly or has insufficient tilt back power...1444
10. Bucket movement becomes slow during tilt back...1445
11. Bucket cannot be held down by the dump cylinder...1445
12. Bucket has large hydraulic drift...1445
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")...1445
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"...1445
15. Control levers of lift arm and bucket move stiffly and sluggishly...1446
63 DISASSEMBLY AND ASSEMBLY...1447
HYDRAULIC TANK ...1449
REMOVAL...1449
INSTALLATION...1450
HYDRAULIC FILTER...1451
REMOVAL...1451
INSTALLATION...1451
HYDRAULIC-STEERING PUMP ...1452
REMOVAL...1452
INSTALLATlON...1452
MAIN CONTROL VALVE ...1453
REMOVAL ...1453
INSTALLATION...1455
DISASSEMBLY...1459
ASSEMBLY...1461
DUMP CYLINDER ...1462
REMOVAL...1462
INSTALLATION...1464
LIFT CYLINDER ...1465
REMOVAL...1465
INSTALIATION...1466
LIFT AND DUMP CYLINDER ...1467
DISASSEMBLY...1467
ASSEMBLY...1469
WORK EQUIPMENT...1472
REMOVAL...1472
INSTALLATION...1475
COUNTERWEIGHT...1478
REMOVAL...1478
INSTALLATION...1478
64 STRUCTURE AND FUNCTION...1479
MAIN CONTROL VALVE...1480
PARKING BRAKE...1482
DUMP CYLINDER ...1483
LIFT CYLINDER ...1484
WORK EQUIPMENT ...1486
BUCKET POSITIONER AND BOOM KICK-OUT ...1488
BUCKET...1489
HYDRAULIC AND STEERING PUMP...1490
80 ELECTRIC AND ELECTRONIC SYSTEM...1491
81 STRUCTURE AND FUNCTION...1491
CLUSTER GUAGE...1492
PROXIMITY SWITCH...1493
OPERATION...1494
ENGINE STARTING CIRCUIT...1495
ENGINE STOP CIRCUIT...1496
ELECTRICAL WIRING DIAGRAM...1497
ELECTRICAL WIRING SCHEMATIC...1497
SENSOR...1498
BRAKE OIL LEVEL SENSOR...1499
TORQUE CONVERTER OIL TEMPERATURE SENSOR...1499
FUEL GAUGE SENSOR...1500
COOLANT TEMPERATURE SENSOR...1501
ENGINE OIL PRESSURE SENSOR...1501
83 DISASSEMBLY AND ASSEMBLY...1503
INSTRUMENT PANEL...1504
REMOVAL...1504
INSTALLATION...1505
90 MISCELLANEOUS...1507
97 GEAR PUMP...1507
GENERAL ...1508
PRINCIPLE OF OPERATION ...1509
MECHANISM FOR DELIVERING OIL...1509
INTERNAL OIL LEAKAGE...1510
FORCES ACTING ON THE GEAR...1510
"TRAPPING” PHENOMENON OF THE OIL...1511
PRESSURE LOADED TYPE GEAR PUMP...1512
GENERAL DESCRIPTION...1512
STRUCTURE AND OPERATION...1513
FIXED SIDE PLATE TYPE GEAR PUMP...1514
SA SERIES ...1515
STRUCTURE ...1515
FEATURES...1515
SA-1...1516
SA-2...1516
SA-3...1517
SA-4...1518
TESTING AND ADJUSTING...1519
DISASSEMBLY ...1522
Single pump...1522
Tandem pump...1525
Triple pump...1525
ASSEMBLY...1526
Single pump...1526
Tandem pump...1529
Triple pump...1530
MAINTENANCE STANDARD ...1531
99 METRIC CONVERSIONS...1533
Komatsu Wheel Loader WA120, WA120L, WA120LC Repair Service Manuals
