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KOMATSU WA120-1LC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A20001 and up) KOMATSU WA120-1LC – PDF DOWNLOAD
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- KOMATSU WA120-1LC WHEEL LOADER OPERATION & MAINTENANCE MANUAL
- SERIAL NUMBER:A20001 and up
- PUBLICATION NUMBER:CEAMW16041
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KOMATSU WA120-1LC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A20001 and up) KOMATSU WA120-1LC
KOMATSU WA120-1LC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A20001 AND UP) KOMATSU WA120-1LC – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA120-1LC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A20001 and up) KOMATSU WA120-1LC
- This manual provides rules and guidelines, which will help you use this machine safely and effectively. 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 are the owner or end user or from Komatsu Dresser Co. if you are a 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 if you are the owner or end user or consult Komatsu Dresser Co. if you are a distributor for the latest available information on your machine or for questions regarding information in this manual.
TABLE OF CONTENTS:
KOMATSU WA120-1LC WHEEL LOADER OPERATION & MAINTENANCE MANUAL (SN:A20001 and up) KOMATSU WA120-1LC
MAIN MENU................................................................. 0 FOREWORD.................................................................. 5 INTRODUCTION.............................................................. 6 SAFETY INFORMATION.................................................... 6 BREAKING IN THE NEW MACHINE........................................... 7 MACHINE AND ENGINE SERIAL NUMBERS..................................... 8 QUICK REFERENCE INFORMATION........................................... 9 CONTENTS.............................................................. 10 SAFETY PRECAUTIONS -- SECTION 1........................................... 17 GENERAL PRECAUTIONS .................................................. 18 PERSONNEL PRECAUTIONS ............................................ 18 MACHINE PRECAUTIONS .............................................. 18 OPERATION ............................................................ 19 BEFORE STARTING .................................................. 19 START-UP ......................................................... 20 GENERAL OPERATING PRECAUTIONS .................................... 20 DRIVING THE MACHINE .............................................. 21 OPERATING THE ATTACHMENTS ........................................ 22 PULLING/TOWING ................................................... 22 SHUTDOWN ......................................................... 23 MAINTENANCE .......................................................... 23 GENERAL MACHINE PRECAUTIONS ...................................... 23 GENERAL WORK PRECAUTIONS ......................................... 24 ATTACHMENTS ...................................................... 25 BRAKES ........................................................... 25 CAB/ROPS ......................................................... 25 COOLING .......................................................... 25 ELECTRICAL ....................................................... 26 ENGINE ........................................................... 26 FUEL SYSTEM ...................................................... 27 HYDRAULICS ....................................................... 27 TIRES AND RIMS ................................................... 27 TURBOCHARGER ..................................................... 27 SAFETY PRODUCT GRAPHICS AND LOCATIONS ................................ 28 OPERATION -- SECTION 2.................................................... 39 GENERAL VIEW ......................................................... 40 INSTRUMENTS AND CONTROLS ............................................. 41 CLUSTER GAUGE .................................................... 41 TORQUE CONVERTER OIL TEMPERATURE GAUGE........................ 41 ENGINE COOLING WATER TEMPERATURE GAUGE ...................... 42 FUEL GAUGE ................................................... 42 VOLTMETER .................................................... 42 PILOT LAMPS, METERS............................................... 43 BRAKE OIL LEVEL PILOT LAMP ................................... 43 PARKING BRAKE PILOT IAMP ..................................... 43 EMERGENCY STEERING NORMAL PILOT LAMP (OPT).................... 44 EMERGENCY STEERING PILOT LAMP (OPT) .......................... 44 TURN SIGNAL PILOT LAMP ....................................... 44 SPEEDOMETER................................................... 44 WORKING PILOT LAMP............................................ 45 HIGH BEAM PILOT LAMP.......................................... 45 SERVICE METER................................................. 45 SWITCHES ......................................................... 46 PARKING LAMP AND TRANSMISSION CUT-OFF SELECTOR SWITCH ........ 46 WORKING LAMP AND CLUSTER GAUGE CHECK SWITCH .................. 47 LAMP SWITCH .................................................. 47 STARTING SWITCH............................................... 48 HORN BUTTON .................................................. 48 ETHER START SWITCH ........................................... 49 CAB DOME LAMP SWITCH ......................................... 49 FRONT WIPER SWITCH............................................ 49 REAR WIPER SWITCH ............................................ 49 PEDALS AND LEVERS ................................................ 50 DIRECTIONAL LEVER ............................................ 50 SPEED CONTROL LEVER........................................... 50 SAFETY LOCK (FOR DIRECTIONAL LEVER) .......................... 51 SPEED CONTROL LEVER STOPPER .................................. 51 TURN SIGNAL LEVER............................................. 51 ACCELERATOR PEDAL ............................................ 51 BRAKE PEDALS ................................................. 52 WORK EQUIPMENT CONTROL LEVER ................................. 53 WORK EQUIPMENT CONTROL LEVER LOCK ............................ 54 PARKING BRAKE LEVER .......................................... 54 CAB DOOR HOLD OPEN LOCK - IF EQUIPPED............................. 54 FUSE BOX ......................................................... 55 FUSE BOX I.................................................... 56 FUSE BOX II................................................... 56 OPERATOR'S SEAT .................................................. 57 RIGID TYPE.................................................... 57 FORWARD-BACKWARD ADJUSTMENT .............................. 57 SEAT HEIGHT ADJUSTMENT.................................... 57 BACKREST ADJUSTMENT....................................... 57 BUCKET TYPE SEAT (OPT)........................................ 57 FORWARD-BACKWARD ADJUSTMENT............................... 57 SEAT ANGLE ADJUSTMENT..................................... 57 SEAT CUSHION ADJUSTMENT................................... 57 BACKREST ADJUSTMENT....................................... 57 SEAT HEIGHT ADJUSTMENT.................................... 57 SEARS SEAT ................................................... 58 FORWARD-BACKWARD ADJUSTMENT .............................. 58 SEAT ANGLE ADJUSTMENT .................................... 58 WEIGHT ADJUSTMENT ........................................ 58 BACKREST TILT ADJUSTMENT ................................. 58 HEIGHT ADJUSTMENT ........................................ 58 KAB SEAT...................................................... 59 WEIGHT ADJUSTMENT......................................... 59 HEIGHT ADJUSTMENT......................................... 59 BACKREST ANGLE ADJUSTMENT................................. 59 FORE AND AFT ADJUSTMENT................................... 59 HEADREST ADJUSTMENT (IF EQUIPPED)......................... 59 RIGHT SIDE ARMREST................................................ 59 SEAT BELT ........................................................ 60 ClGARETTE LIGHTER..................................................... 61 AIR CLEANER SERVICE INDICATOR......................................... 61 FRAME LOCKING BAR..................................................... 61 DRAWBAR PIN........................................................... 62 CAB HEATER AND DEFROSTER ............................................. 63 CONTROL PANEL..................................................... 63 FAN SPEED SWITCH.............................................. 63 FOOT / DEFROSTER SELECT LEVER................................. 63 AIR INTAKE SELECTOR LEVER..................................... 63 CHECK BEFORE STARTING ................................................ 64 WALK-AROUND CHECK................................................. 64 CHECK AND REFILL COOLANT.......................................... 64 CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN...................... 65 CHECK FUEL LEVEL AND REFILL FUEL.................................. 65 CHECK AIR CLEANER SERVICE INDICATOR............................... 66 CHECK AND REFILL OF OIL IN BRAKE OIL TANK......................... 66 ADDITIONAL CHECKS................................................. 67 CHECK ELECTRICAL WIRING........................................... 67 DRAIN THE WATER FROM PRIMARY FUEL FILTER/WATER SEPARATOR.......... 67 OPERATING YOUR MACHINE ............................................... 68 BEFORE STARTING THE ENGINE ....................................... 68 STARTING ENGINE .................................................. 69 SPECIAL STARTING ............................................. 69 COLD WEATHER STARTING............................................. 70 CHECKS AFTER STARTING ............................................ 72 COLD WEATHER WARM-UP PROCEDURE ................................... 72 MOVING MACHINE OFF ............................................... 73 CHANGING GEAR SPEED............................................... 74 CHANGING DIRECTION................................................ 74 TURNING .......................................................... 75 TO STOP THE MACHINE............................................... 76 TO STOP THE ENGINE ............................................... 77 OPERATIONS AFTER STOPPING ENGINE ................................. 77 OPERATIONAL PRECAUTIONS .......................................... 78 WORKING IN DUSTY LOCATIONS ................................... 78 MAXIMUM DEPTH OF WATER ....................................... 78 IF WHEEL BRAKE DOES NOT WORK ................................. 79 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES ....................... 79 LOWER THE CENTER OF GRAVITY WHEN TURNING...................... 79 BRAKING ON DOWNHILL SLOPES.................................... 79 IF ENGINE STOPS............................................... 79 POSSIBLE WORK USING LOADER ................................... 80 EXCAVATION ............................................... 80 LEVELING.................................................. 82 LOAD AND CARRY OPERATIONS ................................ 83 LOADING .................................................. 83 Cross Drive Loading .................................. 83 V-Shape Loading ...................................... 83 PARKING MACHINE................................................... 84 PRECAUTIONS WHEN TIRE CHAINS ARE FllTED........................... 84 PROCEDURE FOR MOVING R.H. LADDER ............................. 84 PROCEDURE FOR MOVING L.H. LADDER ............................. 85 ADJUSTMENT OF WORK EQUIPMENT ......................................... 86 ADJUSTING BOOM KICKOUT ........................................... 86 ADJUSTING BUCKET POSITIONER....................................... 87 BUCKET LEVEL INDICATOR............................................ 87 HANDLING TIRES ....................................................... 88 PRECAUTIONS WHEN HANDLING TIRES .................................. 88 PRECAUTIONS WHEN DRIVING MACHINE ................................. 88 TIRE PRESSURE .................................................... 88 TOWING ............................................................... 90 TOWING THE MACHINE................................................ 90 WHEN ENGINE CANNOT BE USED ................................... 90 WHEN ENGINE CAN BE USED ...................................... 90 TRANSPORTATION ....................................................... 90 COLD WEATHER OPERATION ............................................... 91 PREPARATION FOR LOW TEMPERATURE................................... 91 FUEL AND LUBRICANTS........................................... 91 COOLANT....................................................... 91 BATTERY....................................................... 91 CAUTIONS AFTER COMPLETION OF WORK................................. 91 AFTER COLD WEATHER.................................................... 92 LONG TERM STORAGE .................................................... 92 BEFORE STORAGE.................................................... 92 DURING STORAGE.................................................... 92 AFTER STORAGE..................................................... 92 HANDLING OF BATTERY .................................................. 93 PRECAUTIONS FOR CHARGING BATTERY ................................. 93 REMOVAL AND INSTALLATION OF BATTERY .............................. 93 STARTING ENGINE WITH BOOSTER CABLES .............................. 93 BEFORE CONNECTING BOOSTER CABLES.............................. 93 CONNECTING BOOSTER CABLES .................................... 94 STARTING ENGINE .............................................. 94 DISCONNECTING BOOSTER CABLES ................................. 94 TROUBLESHOOTING ...................................................... 95 ELECTRICAL SYSTEM................................................. 95 ENGINE............................................................ 95 CHASSIS .......................................................... 96 TRANSMISSION.................................................. 96 DRIVE AXLES .................................................. 96 WHEEL BRAKES.................................................. 96 PARKING BRAKE................................................. 96 STEERING ..................................................... 96 EQUIPMENT HYDRAULIC SYSTEM.................................... 96 MAINTENANCE -- SECTION 3.................................................. 97 PERIODIC MAINTENANCE ................................................. 98 MAINTENANCE GUIDELINES ............................................... 98 OUTLINES OF SERVICE .................................................. 99 LUBRICATION WHEN SHIPPED.......................................... 99 RELATING TO ENGINE................................................100 ENGINE OIL....................................................100 COOLANT ......................................................100 DIESEL FUEL ..................................................100 RELATING TO HYDRAULIC SYSTEM......................................100 RELATING TO ELECTRICAL SYSTEM.....................................100 RELATING TO LUBRICATION...........................................101 BLEEDING AIR......................................................101 BLEEDING AIR FROM HYDRAULIC TANK..............................101 BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT...........102 BLEEDING AIR FROM FUEL SYSTEM.................................103 WEAR PARTS REPLACEMENT................................................105 PERIODICAL PART REPLACEMENT...........................................105 LUBRICANTS, FUEL AND COOLANT..........................................106 PROPER SELECTION TABLE............................................106 ENGINE OIL....................................................107 Normal Operation..........................................107 Arctic Operation..........................................107 AXLE OIL......................................................108 GREASE........................................................108 DIESEL FUEL...................................................108 COOLANT.......................................................108 SCHEDULED MAINTENANCE GUIDE...........................................115 OIL FILLER AND LEVEL GAUGE POSITIONS..................................119 INITIAL 250 HOURS SERVICE ONLY........................................120 TRANSMISSION OIL FILTER ..........................................120 WHEN REQUIRED ........................................................120 COOLANT ADDITIVE CONCENTRATION - DCA4 ............................120 AIR CLEANER ELEMENT ..............................................120 CHECKING......................................................120 CLEANING OR REPLACING OUTER ELEMENT...........................121 REPLACING INNER ELEMENT.......................................121 CLEANING OUTER ELEMENT........................................122 TRANSMISSION OIL .................................................123 RADIATOR CORE ....................................................123 WINDSHIELD WASHER TANKS...........................................124 DRIVE AXLE OIL....................................................124 DRIVE AXLE HOUSING BREATHERS .....................................125 LUBRICATING ......................................................125 BUCKET BOLT-ON CUTTlNG EDGE - IF EQUIPPED ........................127 BUCKET TEETH - IF EQUIPPED .......................................127 BUCKET IS EQUIPPED WITH BOLT-ON TEETH.........................127 BUCKET IS EQUIPPED WITH WELDED ON OR REPLACEABLE TIP TEETH....128 PARKING BRAKE ....................................................129 INSPECTION....................................................129 ADJUSTMENT....................................................129 CHECK BEFORE STARTING ................................................130 EVERY 50 HOURS SERVICE ...............................................130 FUEL TANK.........................................................130 TIRES.............................................................130 EVERY 100 HOURS SERVICE ..............................................130 HYDRAULIC TANK....................................................130 LUBRICATING ......................................................131 EVERY 250 HOURS SERVICE ..............................................133 LUBRICATING ......................................................133 WHEEL HUB BOLTS...................................................135 ENGINE OIL PAN AND FILTER ........................................136 BATTERY ELECTROLYTE...............................................137 AIR INTAKE SYSTEM.................................................138 EVERY 500 HOURS SERVICE ..............................................138 LUBRICATING.......................................................138 FUEL FILTERS......................................................139 GENERAL.......................................................139 REPLACEMENT...................................................139 TRANSMISSION OIL FILTER...........................................141 ANTIFREEZE CONCENTRATION..........................................141 EVERY 1000 HOURS SERVICE .............................................142 LUBRICATING ......................................................142 HYDRAULIC TANK AND FILTER.........................................144 TRANSMISSION CASE BREATHER........................................145 TRANSMISSION OIL AND STRAINER.....................................145 ENGINE VALVES.....................................................146 DRIVE BELT........................................................149 DRIVE BELT, TENSIONER BEARING AND FAN HUB.........................149 EVERY 2000 HOURS SERVICE .............................................150 DRIVE AXLES.......................................................150 HYDRAULIC TANK BREATHER...........................................152 BRAKE DISC........................................................152 VIBRATION DAMPER..................................................152 COOLING SYSTEM ...................................................153 SPECIFICATIONS -- SECTION 4...............................................155 GENERAL SPECIFICATIONS ...............................................156 STANDARD TIGHTENING TORQUES ..........................................161 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS .....................161 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS ..........................161 TIGHTENING TORQUE FOR NUTS OF FLARED FITTINGS.....................162 UNIT CONVERSIONS .....................................................163 AREA .............................................................164 DENSITY (Mass Density) ...........................................164 FORCE ............................................................165 FORCE PER LENGTH .................................................165 HEAT .............................................................165 LENGTH ...........................................................166 MASS (WEIGHT) ...................................................166 POWER ............................................................167 PRESSURE .........................................................167 TEMPERATURE ......................................................167 TEMPERATURE INTERVAL OR TOLERANCE ................................168 VOLUME............................................................168 TORQUE ...........................................................169 VELOCITY..........................................................169
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