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

CEBM002002 - Wheel Loader WA120-3, WA120L-3 Shop Manual...2
CEBMW16040 - Wheel Loader WA120-1LC Shop Manual...587
  CONTENTS...591
  10 ENGINE...609
    11 STRUCTURE AND FUNCTION...609
      ENGINE MOUNTING...610
      RADIATOR AND OIL COOLER...611
      FUEL TANK AND PIPING...612
      ENGINE CONTROL...613
    12 TESTING AND ADJUSTING...615
      STANDARD VALUE TABLE ...616
      SERVICE TOOL LIST ...618
      SAFETY PRECAUTIONS ...619
      EXHAUST GAS COLOR ...620
      ACCELERATOR PEDAL OPERATING FORCE AND ANGLE ...621
        OPERATING FORCE...621
        OPERATING ANGLE...622
    13 DISASSEMBLY AND ASSEMBLY ...625
      CRANKING MOTOR ...626
        REMOVAL...626
        INSTALLATION...626
      ALTERNATOR ...627
        REMOVAL...627
        INSTALLATION...627
      OIL COOLER ...628
        REMOVAL...628
        INSTALLATION...629
      WATER PUMP ...630
        REMOVAL...630
        INSTALLATION...631
      FUEL INJECTORS ...632
        REMOVAL...632
        INSTALLATION...634
      TURBOCHARGER ...636
        REMOVAL...636
        INSTALLATION...638
      CYLINDER HEAD ...640
        REMOVAL...640
        INSTALLATION...643
      RADIATOR ...646
        REMOVAL...646
        INSTALLATION...649
      ENGINE ...653
        REMOVAL...653
        INSTALLATION...660
      FUEL TANK ...668
        REMOVAL...668
        INSTALLATION...669
  20 POWER TRAIN...671
    21 STRUCTURE AND FUNCTION ...671
      GENERAL ...674
      HYDRAULIC CIRCUIT FOR POWER TRAIN ...676
        HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...677
        FORWARD FIRST...678
      TORQUE CONVERTER AND TRANSMISSION PIPING ...680
      TORQUE CONVERTER CHARGING PUMP ...681
        OUTLINE...681
        SPECIFICATIONS...681
      TORQUE CONVERTER ...682
        SPECIFICATIONS...682
        OUTLINE...683
          FLOW OF MOTIVE FORCE...683
          FLOW OF OIL...683
      TORQUE CONVERTER OIL FILTER ...684
        OPERATION...684
      TORQUE CONVERTER OIL COOLER ...686
        OUTLINE...686
      TRANSMISSION ...687
        OUTLINE ...689
      CLUTCH SHAFTS ...689
        FORWARD AND REVERSE CLUTCHES ...689
        FIRST GEAR CLUTCH ...690
        SECOND AND THIRD GEAR CLUTCH ...690
        OPERATION OF CLUTCH ...691
          WHEN ENGAGED...691
          WHEN DISENGAGED...691
        FORWARD FIRST...692
          OPERATION...693
        REVERSE FIRST ...694
          OPERATION...695
      TRANSMISSION CONTROL VALVE ...696
        MAIN REGULATOR VALVE ...698
          FUNCTION ...698
          OPERATION...698
        TORQUE CONVERTER OIL OUTLET VALVE ...699
          FUNCTION...699
          OPERATION...699
        QUICK RETURN VALVE AND ACCUMULATOR...700
          FUNCTION...700
            Quick Return Valve...700
            Accumulator...700
          OPERATION...700
            When Clutch Is Engaged...700
            Immediately After Gear Shifting...700
        POWER MODULATING FUNCTION...702
          FUNCTION...702
        CLUTCH CUT-OFF VALVE...706
          OPERATION ...706
      DRIVE SHAFTS ...708
        OUTLINE ...708
      AXLES ...710
        FRONT ...710
        REAR ...711
      DIFFERENTIALS ...712
        FRONT...712
        REAR ...713
        TORQUE PROPORTIONING DIFFERENTIAL ...714
          OUTLINE...714
          FUNCTION ...715
          OPERATION ...715
      FINAL DRIVES ...716
        OUTLINE ...716
      AXLE MOUNTING ...718
        FRONT AXLE ...719
        REAR AXLE ...719
      TIRES AND WHEELS ...720
        THREE PIECE WHEEL...720
        ONE PIECE WHEEL ...721
        SPECIFICATIONS ...722
    22 TESTING AND ADJUSTING...723
      STANDARD VALUE TABLE ...724
      SERVICE TOOL LIST ...726
      SAFETY PRECAUTIONS ...726
      ENGINE STALL SPEEDS ...728
      TORQUE CONVERTER AND TRANSMISSION OIL PRESSURES ...730
      TRANSMISSION SHIFT LEVERS...732
      TRANSMISSION CONTROL VALVE  SPOOLS ...733
      TROUBLESHOOTING...735
        PRECAUTIONS...736
        METHOD OF READING TROUBLESHOOTING TABLE...738
        PREVENTING RECURRENCE OF TROUBLE...740
        CHECKS BEFORE TROUBLESHOOTING...741
        TROUBLESHOOTING TABLE...742
        TORQUE CONVERTER AND TRANSMISSION...742
          1. Machine does not move off...742
          2. Machine speed is low, thrust is weak, gradeability falls off...744
          3. Large shock when moving off or changing gear...746
          4. Large time lag when moving off or changing gear...747
          5. Oil temperature in torque converter is high...748
    23 DISASSEMBLY AND ASSEMBLY...749
      TORQUE CONVERTER CHARGING PUMP ...751
        REMOVAL ...751
        INSTALLATION ...751
      TORQUE CONVERTER TRANSMISSION ...752
        REMOVAL ...752
        INSTALLATION ...759
      TORQUE CONVERTER ...766
        DISASSEMBLY ...766
        ASSEMBLY ...769
      TRANSMISSION ...772
        DISASSEMBLY ...772
        ASSEMBLY ...779
      FORWARD REVERSE CLUTCH PACKS ...790
        DISASSEMBLY ...790
        ASSEMBLY ...793
      FIRST SPEED CLUTCH PACK ...798
        DISASSEMBLY ...798
        ASSEMBLY ...800
      SECOND AND THIRD SPEED CLUTCH PACKS ...803
        DISASSEMBLY ...803
        ASSEMBLY ...805
      TRANSMISSION CONTROL VALVE ...810
        REMOVAL ...810
        INSTALLATION ...812
        DISASSEMBLY ...816
        ASSEMBLY ...820
      DRIVE SHAFT ...826
        DISASSEMBLY...826
        ASSEMBLY...828
      FRONT AXLE...830
        REMOVAL ...830
        INSTALLATION...832
      REAR AXLE ...834
        REMOVAL...834
        INSTALLATION...838
      DIFFERENTIAL ...843
        DISASSEMBLY...843
        ASSEMBLY...847
      AXLE HOUSING ...857
        DISASSEMBLY...857
        ASSEMBLY...863
    24 MAINTENANCE STANDARD...871
      TRANSMISSION AND ENGINE MOUNT ...872
      TORQUE CONVERTER CHARGING PUMP ...874
      TORQUE CONVERTER ...875
      TRANSMISSION...876
      TRANSMISSION CLUTCH ASSEMBLY...878
        FORWARD-REVERSE CLUTCH ASSEMBLY...878
        1ST CLUTCH ASSEMBLY...878
        2ND, 3RD CLUTCH ASSEMBLY...878
      TRANSMISSION CONTROL VALVE...880
      AXLE...882
      DIFFERENTIAL ...884
      FINAL DRIVE ...886
      DRIVE SHAFT...887
      AXLE MOUNT...888
  40 STEERING SYSTEM...891
    41 STRUCTURE AND FUNCTION...891
      GENERAL ...892
      HYDRAULIC CIRCUIT FOR STEERING ...893
      HYDRAULIC CIRCUIT DIAGRAM FOR STEERING ...894
      STEERING VALVE ...895
        CONNECTION OF HAND PUMP AND SLEEVE...901
          FUNCTION OF CENTER PIN...902
      PRIORITY VALVE ...903
      STEERING CYLINDER ...906
      CENTER HINGE PIN ...907
    42 TESTING AND ADJUSTING...909
      STANDARD VALUE TABLE ...910
      SERVICE TOOL LIST ...910
      STEERING WHEEL PLAY ...911
      OPERATING FORCE OF STEERING WHEEL ...912
      OPERATING TIME OF STEERING WHEEL ...913
      STEERING OIL PRESSURE ...914
      TROUBLESHOOTING...915
      TROUBLESHOOTING TABLE ...916
        STEERING CIRCUIT...916
          1. Steering wheel does not turn...916
          2. Steering wheel is sluggish...917
          3. Steering wheel moves unsteadily or is subjected to large shock...918
          4. Machine tends to turn naturally in one particular direction when traveling...918
          5. Left and right turning radii are different...918
    43 DISASSEMBLY AND ASSEMBLY...919
      STEERING VALVE ...920
        REMOVAL ...920
        INSTALLATION...921
        DISASSEMBLY ...922
        ASSEMBLY ...925
      STEERING RELIEF VALVE ...930
        REMOVAL AND DISASSEMBLY ...930
        ASSEMBLY AND INSTALLATION ...931
      PRIORITY VALVE ...932
        REMOVAL ...932
        INSTALLATION ...933
      STEERING CYLINDER ...934
        REMOVAL ...934
        INSTALLATION ...934
        DISASSEMBLY ...935
        ASSEMBLY ...937
      CENTER HINGE PIN ...940
        REMOVAL ...940
        INSTALLATION ...948
    44 MAINTENANCE STANDARD...957
      STEERING CYLINDER MOUNT...958
      STEERING CYLINDER ...959
      CENTER HINGE PIN ...960
      STEERING COLUMN ...962
      PRIORITY VALVE...963
  50 BRAKES...965
    51 STRUCTURE AND FUNCTION...965
      GENERAL ...966
      BRAKE MASTER CYLINDER...967
      BRAKE...969
      PARKING BRAKE...971
      BRAKE CALIPER...972
    52 TESTING AND ADJUSTING...973
      STANDARD  VALUE  TABLE ...974
      TOOL LIST ...975
      MEASURING BRAKE PEDAL...976
      BRAKE  PEDAL LINKAGE ...977
      BRAKE PERFORMANCE...979
      BRAKE PISTON  LEAKAGE ...980
      BRAKE DISC WEAR...981
      AIR BLEEDING FROM  BRAKE  CIRCUIT ...982
      PARKING BRAKE PERFORMANCE...983
      PARKING  BRAKE ...984
        CHECKING...984
        ADJUSTING...985
        MEASURING  CLEARANCE ...986
      TROUBLESHOOTING...987
        TROUBLESHOOTING  TABLES ...988
        1. Brake is ineffective or not very effective...988
        2. Brake cannot be released or drags...989
    53 DISASSEMBLY AND ASSEMBLY...991
      MASTER  CYLINDER ...992
        REMOVAL...992
        INSTALLATION...993
        DISASSEMBLY...994
        ASSEMBLY...995
      PARKING BRAKE...996
        REMOVAL...996
        INSTALLATION...998
      PARKING BRAKE PAD...1000
        REMOVAL...1000
        INSTALLATION...1001
    54 MAINTENANCE STANDARD...1003
      MASTER CYLINDER ...1004
      BRAKE...1005
  60 WORK EQUIPMENT SYSTEM...1007
    61 STRUCTURE AND FUNCTION...1007
      GENERAL ...1008
      HYDRAULIC CIRCUIT ...1010
      HYDRAULIC  CIRCUIT  DIAGRAM ...1011
      DUMP  AND LIFT  CONTROL LEVER LINKAGE ...1012
      BUCKET  LINKAGE ...1013
      BUCKET POSITIONER AND BOOM KICK-OUT...1015
      HYDRAULIC  TANK ...1016
        OIL FILTER BYPASS VALVE...1017
        BREATHER...1017
      HYDRAULIC AND STEERING PUMP ...1018
      MAIN CONTROL VALVE...1019
        RELIEF  VALVE ...1021
        SAFETY VALVE (WITH SUCTION VALVE)...1022
        SUCTION VALVE...1023
        LIFT AND DUMP SPOOLS AT “HOLD POSITION”...1024
        LIFT SPOOL AT “RAISE POSITION”...1025
        LIFT SPOOL AT “LOWER POSITION”...1026
        DUMP SPOOL AT “FLOAT POSITION”...1027
        DUMP SPOOL AT “TILT BACK POSITION”...1028
        DUMP SPOOL AT “DUMP POSITION”...1029
      HYDRAULIC  CYLINDER ...1030
        LIFT CYLINDER...1030
        DUMP CYLINDER...1030
    62 TESTING AND ADJUSTING...1031
      STANDARD VALUE TABLE ...1033
      TOOL LIST ...1034
      DUMP AND LIFT CONTROL LEVERS...1035
        MEASURING PROCEDURE...1035
        ADJUSTING PROCEDURE...1036
      DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL...1037
        MEASURING PROCEDURE...1037
      HYDRAULIC CIRCUIT FLUSHING...1038
        BEFORE FLUSHING...1038
        WORK STEPS FOR FLUSHING...1039
      HYDRAULIC PRESSURE ...1041
        MEASURING PROCEDURE (Main relief valve)...1041
        ADJUSTING PROCEDURE (Main relief valve)...1042
      LIFT ARM AND BUCKET ...1043
        MEASURING PROCEDURE...1043
          Lifting time of lift arm...1043
          Lowering time of lift arm...1043
          Dumping time of bucket...1044
          Tilt back time of bucket...1044
        HYDRAULIC DRIFT ...1045
          Measuring procedure...1045
      BUCKET POSITIONER...1046
        INSPECTION PROCEDURE...1046
        ADJUSTING PROCEDURE...1046
      BOOM KICK-OUT...1047
        INSPECTION PROCEDURE...1047
        ADJUSTING PROCEDURE...1047
      TROUBLESHOOTING...1049
        LOADER CIRCUIT...1050
          1. Lift arm does not rise...1050
          2. Lift arm moves slowly or does not have sufficient lifting power...1051
          3. Lift arm movement becomes slow after it reaches a certain height...1052
          4. Bucket cannot be held down with lift cylinder...1052
          5. Lift arm has large hydraulic drift...1052
          6. Lift arm movement is unsteady during work...1052
          7. Lift arm descends momentarily when the control lever is shifted from "Hold" to "Raise"...1052
          8. Bucket does not tilt back...1053
          9. Bucket moves slowly or has insufficient tilt back power...1054
          10. Bucket movement becomes slow during tilt back...1055
          11. Bucket cannot be held down by the dump cylinder...1055
          12. Bucket has large hydraulic drift...1055
          13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")...1055
          14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"...1055
          15. Control levers of lift arm and bucket move stiffly and sluggishly...1056
    63 DISASSEMBLY AND ASSEMBLY...1057
      HYDRAULIC TANK ...1059
        REMOVAL...1059
        INSTALLATION...1060
      HYDRAULIC FILTER...1061
        REMOVAL...1061
        INSTALLATION...1061
      HYDRAULIC-STEERING PUMP ...1062
        REMOVAL...1062
        INSTALLATlON...1062
      MAIN  CONTROL VALVE ...1063
        REMOVAL ...1063
        INSTALLATION...1065
        DISASSEMBLY...1069
        ASSEMBLY...1071
      DUMP CYLINDER ...1072
        REMOVAL...1072
        INSTALLATION...1074
      LIFT  CYLINDER ...1075
        REMOVAL...1075
        INSTALIATION...1076
      LIFT  AND DUMP CYLINDER ...1077
        DISASSEMBLY...1077
        ASSEMBLY...1079
      WORK EQUIPMENT...1082
        REMOVAL...1082
        INSTALLATION...1085
      COUNTERWEIGHT...1088
        REMOVAL...1088
        INSTALLATION...1088
    64 STRUCTURE AND FUNCTION...1089
      MAIN CONTROL VALVE...1090
      PARKING BRAKE...1092
      DUMP CYLINDER ...1093
      LIFT  CYLINDER ...1094
      WORK EQUIPMENT ...1096
      BUCKET  POSITIONER  AND BOOM KICK-OUT ...1098
      BUCKET...1099
      HYDRAULIC AND STEERING PUMP...1100
  80 ELECTRIC AND ELECTRONIC SYSTEM...1101
    81 STRUCTURE AND FUNCTION...1101
      CLUSTER GUAGE...1102
      PROXIMITY SWITCH...1103
        OPERATION...1104
      ENGINE STARTING CIRCUIT...1105
      ENGINE STOP CIRCUIT...1106
      ELECTRICAL WIRING DIAGRAM...1107
      ELECTRICAL WIRING SCHEMATIC...1107
      SENSOR...1108
        BRAKE OIL LEVEL SENSOR...1109
        TORQUE CONVERTER OIL TEMPERATURE SENSOR...1109
        FUEL GAUGE SENSOR...1110
        COOLANT TEMPERATURE SENSOR...1111
        ENGINE OIL PRESSURE SENSOR...1111
    83 DISASSEMBLY AND ASSEMBLY...1113
      INSTRUMENT PANEL...1114
        REMOVAL...1114
        INSTALLATION...1115
  90 MISCELLANEOUS...1117
    97 GEAR PUMP...1117
      GENERAL ...1118
      PRINCIPLE OF OPERATION ...1119
        MECHANISM FOR DELIVERING OIL...1119
        INTERNAL OIL LEAKAGE...1120
        FORCES ACTING ON THE GEAR...1120
        "TRAPPING” PHENOMENON OF THE OIL...1121
      PRESSURE LOADED TYPE GEAR PUMP...1122
        GENERAL DESCRIPTION...1122
      STRUCTURE AND OPERATION...1123
      FIXED SIDE PLATE TYPE GEAR PUMP...1124
      SA SERIES ...1125
        STRUCTURE ...1125
          FEATURES...1125
          SA-1...1126
          SA-2...1126
          SA-3...1127
          SA-4...1128
        TESTING AND ADJUSTING...1129
        DISASSEMBLY ...1132
          Single pump...1132
          Tandem pump...1135
          Triple pump...1135
        ASSEMBLY...1136
          Single pump...1136
          Tandem pump...1139
          Triple pump...1140
        MAINTENANCE STANDARD ...1141
    99 METRIC CONVERSIONS...1143

Komatsu Wheel Loader WA120, WA120L, WA120LC Repair Service Manuals