Komatsu WA420-Series Wheel Loaders Repair Service Manual

Complete service repair manual with Electrical Wiring Diagrams for Komatsu WA420-Series Wheel Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu WA420-Series Wheel Loaders 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.

PRODUCT DETAILS:
Total Pages: 3,251 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

CEAM000600 - Wheel Loader WA420-3 Operation & Maintenance Manual.pdf
CEAM003700 - Wheel Loader WA420-3 avance plus Operation & Maintenance Manual.pdf
CEBM000200 - Wheel Loader WA420-3 Shop Manual.pdf
SEBM006204 - Wheel Loader WA420-3 avance Shop Manual.pdf
VEAM470400 - Wheel Loader WA420-3H Operation & Maintenance Manual.pdf
VEBM470104 - Wheel Loader WA420-3 Shop Manual.pdf

MAIN SECTIONS
CEAM000600 - Wheel Loader WA420-3 Operation & Maintenance Manual.....2
  1. FORWARD.....5
  2. SAFETY INFORMATION.....6
  3. INTRODUCTION.....7
  4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....8
  5. CONTENTS.....9
  SAFETY.....13
    6. GENERAL PRECAUTIONS.....14
    7. PRECAUTIONS DURING OPERATION.....19
      7.1 BEFORE STARTING ENGINE.....19
      7.2 OPERATING MACHINE.....21
      7.3 TRANSPORTATION.....26
      7.4 BATTERY.....27
      7.5 TOWING.....28
    8. PRECAUTIONS FOR MAINTENANCE.....29
      8.1 BEFORE CARRYING OUT MAINTENANCE.....29
      8.2 DURING MAINTENANCE.....31
      8.3 TIRES.....36
    9. POSITION FOR ATTACHING SAFETY LABELS.....38
  OPERATION.....42
    10. GENERAL VIEW.....43
      10.1 GENERAL VIEW OF MACHINE.....43
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....44
    11. EXPLANATION OF COMPONENTS.....45
      11.1 MACHINE MONITOR.....45
      11.2 SWITCHES.....55
      11.3 CONTROL LEVERS AND PEDALS.....61
      11.4 STEERING COLUMN TILT LEVER.....65
      11.5 CAP WITH LOCK.....66
      11.6 SAFETY BAR.....67
      11.7 TOWING PIN.....67
      11.8 GREASE PUMP.....68
      11.9 BACK UP ALARM.....68
      11.10 FUSE.....69
      11.11 SLOW-BLOW FUSE.....70
    12. OPERATION.....71
      12.1 CHECKS BEFORE STARTING.....71
      12.2 STARTING ENGINE.....84
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....85
      12.4 MOVING MACHINE OFF.....86
      12.5 CHANGING GEAR SPEED.....88
      12.6 CHANGING DIRECTION.....88
      12.7 TURNING.....89
      12.8 STOPPING MACHINE.....90
      12.9 OPERATION OF WORK EQUIPMENT.....91
      12.10 WORK POSSIBLE USING WHEEL LOADER.....92
      12.11 PRECAUTIONS FOR OPERATION.....97
      12.12 ADJUSTING WORK EQUIPMENT POSTURE.....99
      12.13 PARKING MACHINE.....101
      12.14 CHECKS AFTER COMPLETION OF OPERATION.....102
      12.15 STOPPING ENGINE.....102
      12.16 CHECK AFTER STOPPING ENGINE.....103
      12.17 LOCKING.....103
      12.18 HANDLING THE TIRES.....104
    13. TRANSPORTATION.....106
      13.1 LOADING, UNLOADING WORK.....106
      13.2 PRECAUTIONS FOR LOADING.....107
      13.3 PRECAUTIONS FOR TRANSPORTATION.....107
    14. COLD WEATHER OPERATION.....108
      14.1 PRECAUTIONS FOR LOW TEMPERATURE.....108
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....110
      14.3 AFTER COLD WEATHER.....110
    15. LONG-TERM STORAGE.....111
      15.1 BEFORE STORAGE.....111
      15.2 DURING STORAGE.....111
      15.3 AFTER STORAGE.....111
    16. TROUBLESHOOTING.....112
      16.1 WHEN MACHINE RUNS OUT OF FUEL.....112
      16.2 TOWING THE MACHINE.....113
      16.3 IF BATTERY IS DISCHARGED.....118
      16.4 OTHER TROUBLE.....122
  MAINTENANCE.....128
    17. GUIDES TO MAINTENANCE.....129
    18. OUTLINES OF SERVICE.....132
      18.1 OUTLINE OF OIL, FUEL, COOLANT.....132
      18.2 OUTLINE OF ELECTRIC SYSTEM.....135
    19. WEAR PARTS LIST.....136
    20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....137
      20.1 ENGINE OIL SPECIFICATIONS.....139
      20.2 DIESEL FUEL SPECIFICATIONS.....140
      20.3 COOLANT SPECIFICATIONS.....141
    21. STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.....147
      21.1 INTRODUCTION OF NECESSARY TOOLS.....147
      21.2 TORQUE LIST.....148
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....149
    23. MAINTENANCE SCHEDULE CHART.....153
      23.1 MAINTENANCE SCHEDULE CHART.....153
    24. SERVICE PROCEDURE.....157
      24.1 INITIAL 250 HOURS SERVICE.....157
      24.2 WHEN REQUIRED.....158
      24.3 CHECKS BEFORE STARTING.....167
      24.4 EVERY 50 HOURS SERVICE.....168
      24.5 EVERY 100 HOURS SERVICE.....169
      24.6 EVERY 250 HOURS SERVICE.....171
      24.7 EVERY 500 HOURS SERVICE.....177
      24.8 EVERY 1000 HOURS SERVICE.....181
      24.9 EVERY 2000 HOURS SERVICE.....190
  SPECIFICATIONS.....199
    25. SPECIFICATIONS.....200
  OPTIONAL ATTACHMENTS.....202
    26. OPTIONAL PARTS AND ATTACHMENTS.....203
    27. SELECTING BUCKETS AND TIRES.....204
    28. AIR CONDITIONING .....205
      28.1 GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL.....205
      28.2 COOL BOX COMPARTMENT.....206
    29. HANDLING E.C.S.S. (ELECTRONIC CONTROL SUSPENSION SYSTEM).....207
      29.1 STRUCTURE AND FUNCTION OF E.C.S.S.....207
      29.2 METHOD OF OPERATING E.C.S.S.....208
      29.3 PRECAUTIONS WHEN OPERATING E.C.S.S. SWITCH.....208
      29.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR.....209
    30. HANDLING AUTO-GREASING SYSTEM.....210
      30.1 METHOD OF OPERATING AUTO-GREASING SYSTEM.....210
      30.2 PRECAUTIONS WHEN HANDLING AUTO-GREASING SYSTEM.....218
      30.3 TROUBLESHOOTING.....219
      30.4 SPECIFICATIONS.....219
    31. OPTION DISPLAY.....220
CEAM003700 - Wheel Loader WA420-3 avance plus Operation & Maintenance Manual.....222
  COVER.....222
  INTRODUCTION.....225
    1. FOREWARD.....226
    2. SAFETY INFORMATION.....227
    3. INTRODUCTION.....228
      3.1 INTENDED USE.....228
      3.2 FEATURES.....228
      BREAKING IN A NEW MACHINE.....228
    4. LOCATION OF PLATES, TABLE FOR SERIAL NUMBER AND DISTRIBUTOR.....229
      4.1 MACHINE SERIAL NO. PLATE POSITION.....229
      4.2 ENGINE SERIAL NO. PLATE POSITION.....229
      4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR.....229
    5. TABLE OF CONTENTS.....230
  SAFETY.....236
    6. GENERAL PRECAUTIONS.....237
    7. PRECAUTIONS DURING OPERATION.....243
      7.1 BEFORE STARTING ENGINE.....243
      7.2 OPERATING MACHINE.....244
      7.3 TRANSPORTATION.....253
      7.4 BATTERY.....254
      7.5 TOWING.....256
    8. PRECAUTIONS FOR MAINTENANCE.....257
      8.1 BEFORE CARRYING OUT MAINTENANCE.....257
      8.2 DURING MAINTENACE.....262
      8.3 TIRES.....266
    9. SAFETY LABELS.....268
  OPERATION.....273
    10. GENERAL VIEW.....274
      10.1 GENERAL VIEW OF MACHINE.....274
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES.....275
    11. EXPLANATION OF COMPONENTS.....276
      11.1 MACHINE MONITORS.....276
        11.1.1 WARNING DISPLAYS.....278
        11.1.2 METER DISPLAY PORTION.....282
      11.2 SWITCHES.....286
      11.3 CONTROL LEVERS, PEDALS.....293
      11.4 STEERING COLUMN TILT LEVER.....298
      11.5 CAP WITH LOCK.....299
        11.5.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK.....299
      11.6 SAFETY BAR.....301
      11.7 TOWING PIN.....301
      11.8 GREASE PUMP.....302
      11.9 BACK UP ALARM.....302
      11.10 FUSE.....303
        11.10.1 FUSE CAPACITY AND NAME OF CIRCUIT.....303
      11.11 SLOW-BLOW FUSE.....304
      11.12 STORAGE FOR THIS MANUAL.....305
      11.13 ELECTRIC POWER (with ROPS CAB.....305
    12. OPERATION.....306
      12.1 CHECKS BEFORE STARTING.....306
        12.1.1 WALK AROUND CHECK.....306
        12.1.2 CHECK BEFORE STARTING.....309
        12.1.3 ADJUSTMENT BEFORE OPERATION.....314
        12.1.4 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....317
      12.2 STARTING ENGINE.....319
        12.2.1 COLD WEATHER STARTING.....320
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE.....321
      12.4 MOVING MACHINE.....322
      12.5 CHANGING GEARS.....324
      12.6 CHANGING DIRECTION.....324
      12.7 TURNING.....325
      12.8 STOPPING MACHINE.....326
      12.9 OPERATION OF WORK EQUIPMENT.....327
        12.9.1 STANDARD WORK EQUIPMENT CONTROLS.....327
        12.9.2 MONO-LEVER WORK EQUIPMENT CONTROLS.....329
      12.10 WORK POSSIBLE USING WHEEL LOADER.....330
        12.10.1 DIGGING OPERATIONS.....330
        12.10.2 LEVELING OPERATION.....333
        12.10.3 PUSHING OPERATION.....333
        12.10.4 LOAD AND CARRY OPERATION.....333
        12.10.5 LOADING OPERATIONS.....334
      12.11 PRECAUTIONS FOR OPERATION.....335
        12.11.1 PERMISSIBLE WATER DEPTH.....335
        12.11.2 IF WHEEL BRAKE DOES NOT WORK.....335
        12.11.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES.....335
        12.11.4 PRECAUTIONS WHEN DRIVING MACHINE.....336
      12.12 ADJUSTING WORK EQUIPMENT POSTURE.....337
        12.12.1 ADJUSTING BOOM KICKOUT.....337
        12.12.2 ADJUSTING BUCKET POSITIONER.....338
        12.12.3 BUCKET LEVEL INDICATOR.....338
      12.13 PARKING MACHINE.....339
      12.14 CHECKS AFTER COMPLETION OF OPERATION.....340
      12.15 STOPPING ENGINE.....340
      12.16 CHECK AFTER STOPPING ENGINE.....341
      12.17 LOCKING.....341
      12.18 HANDLING THE TIRES.....342
        12.18.1 PRECAUTIONS WHEEN HANDLING TIRES.....342
        12.18.2 TIRE PRESSURE.....342
    13. TRANSPORTATION.....344
      13.1 LOADING AND UNLOADING.....344
      13.2 PRECAUTIONS FOR LOADING.....345
      13.3 PRECAUTIONS FOR TRANSPORTATION.....345
      13.4 LIFTING MACHINE.....345
        13.4.1 LOCATION FOR LIFTING POSISTION ECALS.....346
        13.4.2 WEIGHT TABLE.....346
        13.4.3 LIFTING PROCEDURE.....347
    14. COLD WEATHER OPERATION.....348
      14.1 PRECAUTIONS FOR LOW TEMPERATURE.....348
        14.1.1 FUEL AND LUBRICANTS.....348
        14.1.2 COOLANT.....348
        14.1.3 BATTERY.....348
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK.....349
      14.3 AFTER COLD WEATHER.....349
    15. LONG TERM STORAGE.....350
      15.1 BEFORE STORAGE.....350
      15.2 DURING STORAGE.....350
      15.3 AFTER STORAGE.....350
    16. TROUBLESHOOTING.....351
      16.1 WHEN MACHINE RUNS OUT OF FUEL.....351
      16.2 TOWING THE MACHINE.....352
        16.2.1 WITH THE ENGINE RUNING.....353
        16.2.2 WITH THE ENGINE STOPPED.....353
        16.2.3 RELEASING PARKING BRAKE.....354
        16.2.4 EMERGENCY TRAVEL OPERATION.....355
      16.3 IF BATTERY IS DISCHARGED.....356
        16.3.1 REMOVAL AND INSTALLATION OF BATTERY.....356
        16.3.2 PRECAUTION FOR CHARGING BATTERY.....357
        16.3.3 STARTING ENGINE WITH BOOSTER CABLE.....358
      16.4 OTHER TROUBLE.....360
        16.4.1 ELECTICAL SYSTEM.....360
        16.4.2 CHASSIS.....361
        16.4.3 ENGINE.....364
  MAINTENANCE.....367
    17. GUIDES TO MAINTENANCE.....368
    18. OUTLINES OF SERVICE.....371
      18.1 OUTLINE OF OIL, FUEL, COOLANTS.....371
        18.1.1 OIL.....371
        18.1.2 FUEL.....372
        18.1.3 COOLANT.....372
        18.1.4 GREASE.....372
        18.1.5 STORING OIL AND FUEL.....373
        18.1.6 FILTERS.....373
        18.1.7 FUEL INJECTION PUMP.....373
      18.2 OUTLINE OF ELECTRIC SYSTEM.....374
    19. WEAR PARTS LIST.....375
    20. FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE.....376
      20.1 PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....376
      20.2 ENGINE OIL SPECIFICATION.....377
        20.2.1 NORMAL OPERATION.....377
        20.2.2 ARCTIC OPERATION.....377
      20.3 TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.....378
      20.4 FINAL DRIVE OIL SPECIFICATION.....378
      20.5 DRIVE AXLE OIL SPECIFICATIONS.....378
      20.6 DIESEL FUEL SPECIFICATIONS.....378
      20.7 COOLANT SPECIFICATIONS.....379
        20.7.1 GENERAL.....379
        20.7.2 WATER.....379
        20.7.3  ANTIFREEZE.....379
        20.7.4 SUPPLEMENTAL COOLANT ADDITIVES.....380
    21. STANDARD TIGHTENING TORQUE FOR NUTS AND BOLTS.....385
      21.1 INTRODUCTION OF NECESSARY TOLS.....385
      21.2 TORQUE LIST.....386
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS.....387
    23. MAINTENANCE SCHEDULE.....391
      23.1 SCHEDULED MAINTENANCE CHART.....391
    24.SERVICE PROCEDURE.....395
      24.1 INITIAL 250 HOURS SERVICE.....395
      24.2 WHEN REQUIRED.....396
        24.2.1 CLEAN OR REPLACE AIR CLEANER ELEMENT.....396
        24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL.....398
        24.2.3 CHECK AXLE OIL LEVEL, ADD OIL.....399
        24.2.4 CLEAN THE AXLE CASE BREATHER.....400
        24.2.5 CLEAN THE RADIATOR FINS.....400
        24.2.6 REPLACE THE BOLT-ON CUTTING EDGES.....401
        24.2.7 REPLACE BUCKET TEETH.....401
        24.2.8 CHECK AIR CONDITIONER.....403
        24.2.9 CLEAN THE AIR CONDITIONER CONDENSER.....404
        24.2.10 OPERATE THE AIR CONDITIONER OFF SEASON.....404
        24.2.11 CHECK WINDOW WASHING FLUID, ADD FLUID.....404
        24.2.12 LUBRICATE WORK EQUIPMENT CONTROL VALVE LINKAGE (2 PLACES).....404
        24.2.13 REPLACE SLOW BLOW FUSE.....405
      24.3 SELECTION AND INSPECTION OF RITES.....406
      24.4 CHECKS BEFORE STARTING.....407
        24.4.1 CHECK MONITOR PANEL.....407
        24.4.2 CHECK COOLANT LEVEL, ADD WATER.....407
        24.4.3 CHECK FUEL LEVEL, ADD FUEL.....407
        24.4.4 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.....408
        24.4.5 CHECK ELECTRIC WIRING.....409
        24.4.6 DRAIN WATER FROM FUEL WATER SEPARATOR.....409
        24.4.7 CHECK EFFECT OF PARKING BRAKE.....410
        24.4.8 CHECK EFFECT OF BRAKE.....410
        24.4.9 CHECK SOUND OF HORN AND BACKUP ALARM.....410
        24.4.10 CHECK FLASHING OF LAMPS, CHECK FOR DIRT OR DAMAGE.....410
        24.4.11 CHECK ENGINE EXHAUST COLOR AND SOUND.....410
        24.4.12 CHECK OPERATION OF GAUGES.....410
        24.4.13 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION STEERING.....410
        24.4.14 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE.....410
      24.5 EVERY 50 HOURS SERVICE.....411
        24.5.1 DRAIN WATER, SEDIMENT FROM FUEL TANK.....411
      24.6 EVERY 100 HOURS SERVICE.....411
        24.6.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....411
        24.6.2 CLEAN ELEMENT IN AIR CONDITIONER, FRESH AIR FILTER.....412
        24.6.3 LUBRICATE REAR AXLE PIVOT PIN (3 PLACES).....412
      24.7 EVERY 250 HOURS SERVICE.....413
        24.7.1 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE.....413
        24.7.2 CHECK FOR LOOSE WHEEL HUB BOLTS, TIGHTEN.....414
        24.7.3 CLEAN ELEMENT IN AIR CONDITIONER, RECIRCULATION FILTER.....414
        24.7.4 CHECK AIR CONDTIONER COMPRESSOR BELT TENSION, ADJUST.....415
        24.7.5 CHECK BATTERY ELECTROLYTE LEVEL.....416
        24.7.6 LUBRICATING.....417
      24.8 EVERY 500 HOURS SERVICE.....418
        24.8.1 REPLACE FUELFILTER CARTRIDGE.....418
        24.8.2 REPLACE TRANSMISSION OIL FILTER ELEMENT.....420
        24.8.3 CORROSION RESISTOR.....421
      24.9 EVERY 1000 HOURS SERVICE.....422
        24.9.1 CHANGE OIL IN TRANSMISSION, CLEAN STRAINER.....422
        24.9.2 CLEAN TRANSMISSION, CLEAN STRAINER.....423
        24.9.3 LUBRICATE.....423
        24.9.4 CHECK ENGINE VALVE CLEARANCE, ADJUST.....425
        24.9.5 CHECK TENSION OF DRIVE BELT.....428
        24.9.6 CHECK DRIVE BELT TENSIONER BEARING AND FAN HUB BEARING.....428
      24.10 EVERY 2000 HOURS SERVICE.....430
        24.10.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH HYDRAULIC FILTER ELEMENT.....430
        24.10.2 CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT.....434
        24.10.3 REPLACE HYDRAULIC TANK BREATHER ELEMENT.....436
        24.10.4 CHANGE AXLE OIL.....437
        24.10.5 CHECK BRAKE DISC WEAR.....437
        24.10.6 CHECK VIBRATION DAMPER.....437
        24.10.7 REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER AND FRESH FILTER.....438
        24.10.8 CLEAN PPC CIRCUIT STRAINER.....438
        24.10.9 CHECK ACCUMULATOR GAS PRESSURE.....438
  SPECIFICATIONS.....439
    25. DIMENSIONS.....440
      25.1 WITH SMALL TIRES.....440
      25.2 WITH LARGE TIRES.....441
      25.3 SPECIFICATIONS.....442
  OPTIONS, ATTACHMENTS.....443
    26. OPTIONAL PARTS AND ATTACHMENTS.....444
    27. SELECTING BUCKETS AND TIRES.....445
    28. AIR CONDITIONING.....446
      28.1 GENERAL LOCATIONS AND FUNCTION OFCONTROL PANEL.....446
        28.1.1 FAN SWITCH.....446
        28.1.2 AIR CONDITIONER SWITCH.....446
        28.1.3 MODE SELECTOR SWITCH.....447
        28.1.4 FRESH/RECIRC SELECTOR SWITCH.....447
        28.1.5 TEMPERATURE CONTROL SWITCH.....447
      28.2 METHOD OF OPERATION.....448
        28.2.1 WHEN NOT USING THE AIR CONDITIONER REGULARLY.....448
      28.3 COOL BOX.....448
    29. HANDLING ECSS.....449
      29.1 STRUCTURE AND FUNCTION OF ECSS.....449
      29.2 METHOD OF OPERATING ECSS.....450
      29.3 PRECAUTIONS WHEN OPERATING ECSS SWITCH.....450
      29.4 ACCUMULATOR PRECAUTIONS.....451
      29.5 DISCONNECTING THE ECSS PIPING.....452
    30 OPTION DISPLAY.....453
      30.1 EMERGENCY STEERING PILOT LAMP.....453
      30.2 RADIO.....454
        30.2.1 OPERATING CONTROLS.....454
        30.2.2 OPERATION.....455
        30.2.3 SETTING THE CLOCK.....457
        30.2.4 REMOTE CONTROL UNIT.....457
        30.2.5 BATTERY REPLACEMENT.....458
        30.2.6 PRECAUTIONS WHEN USING.....458
CEBM000200 - Wheel Loader WA420-3 Shop Manual.....460
  CONTENTS.....461
  01 GENERAL.....479
    SPECIFICATION DRAWINGS.....480
    SPECIFICATIONS .....481
    WEIGHT TABLE .....484
    FUEL, COOLANT AND LUBRICANTS .....485
    ENGINE OIL SPECIFICATIONS .....486
    DIESEL FUEL SPECIFICATIONS .....487
    COOLANT SPECIFICATIONS .....488
  10 STRUCTURE AND FUNCTION.....493
    POWER TRAIN.....494
    POWER TRAIN SYSTEM.....495
    TORQUE CONVERTER, TRANSMISSION  PIPING .....497
    TRANSMISSION HYDRAULIC SYSTEM DIAGRAM .....498
    TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM .....499
    TORQUE CONVERTER .....500
    TORQUE CONVERTER OIL FILTER .....503
    TRANSMISSION.....504
    TRANSMISSION CONTROL VALVE.....514
    MODULATION VALVE.....527
    TRANSMISSION SOLENOID VALVE.....527
    ELECTRONIC CONTROL MODULATION VALVE (ECMV).....528
    PILOT OIL FILTER .....531
    DRIVE SHAFT .....532
    AXLE .....533
    DIFFERENTIAL .....535
    FINAL DRIVE .....539
    AXLE MOUNT, CENTER HINGE PIN .....540
    STEERING PIPING .....541
    STEERING COLUMN .....542
    STEERING VALVE .....543
    STEERING VALVE (ORBIT-ROLL).....557
    STOP VALVE .....561
    EMERGENCY STEERING PUMP .....562
    DIVERTER VALVE .....563
    BRAKE PIPING.....566
    BRAKE CIRCUIT DIAGRAM .....567
    BRAKE VALVE .....568
    ACCUMLATOR CHARGE VALVE .....573
    ACCUMULATOR  (FOR BRAKE) .....577
    SLACK ADJUSTER .....578
    BRAKE.....581
    PARKING BRAKE CONTROL .....583
    PARKING BRAKE .....584
    PARKING BRAKE SOLENOID VALVE .....585
    PARKING BRAKE VALVE .....586
    PARKING EMERGENCY RELEASE SOLENOID VALVE .....587
    HYDRAULIC PIPING.....588
    WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....589
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....590
    WORK EQUIPMENT LEVER LINKAGE.....591
    HYDRAULIC TANK .....592
    PPC VALVE .....594
    PPC RELIEF VALVE .....599
    ACCUMULATOR  (FOR PPC VALVE) .....600
    MAIN CONTROL VALVE .....601
    WORK EQUIPMENT LINKAGE .....614
    BUCKET .....616
    BUCKET POSITIONER AND BOOM KICK-OUT .....617
    CAB .....623
    AIR CONDITIONER .....624
    ELECTRIC CIRCUIT DIAGRAM.....625
    WIRING DIAGRAM (EAGLE AIR CONDITIONER/HEATER).....629
    ELECTRIC CIRCUIT DIAGRAM (E.C.S.S.).....630
    ELECTRIC CIRCUIT DIAGRAM (AUTO-GREASING).....631
    MACHINE MONITOR SYSTEM.....632
    MAIN MONITOR.....633
    MAINTENANCE MONITOR.....637
    TRANSMISSION AUTO-SHIFT CONTROL SYSTEM.....639
    TRANSMISSION CONTROLLER.....644
    E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM).....645
    SENSORS.....649
    ENGINE STARTING CIRCUIT.....654
    ENGINE STARTING CIRCUIT (ETHER START).....655
    ELECTRIC TRANSMISSION CONTROL.....656
    KICK-DOWN, HOLD SWITCH.....659
    KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.....660
    TRANSMISSION CUT-OFF SWITCH.....664
    TRANSMISSION CUT-OFF FUNCTION.....665
    ELECTRIC PARKING BRAKE CONTROL .....667
  20 TESTING AND ADJUSTING.....679
    STANDARD VALUE TABLE FOR ENGINE .....680
    STANDARD VALUE TABLE FOR CHASSIS .....681
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS .....684
    TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING .....688
    MEASURING ENGINE SPEED .....691
    MEASURING INTAKE MANIFOLD PRESSURE .....692
    MEASURING INTAKE AIR RESTRICTION .....693
    MEASURING ENGINE LUBRICATING OIL PRESSURE .....694
    MEASURING FUEL FILTER INLET RESTRICTION.....695
    MEASURING BLOW-BY PRESSURE.....696
    MEASURING  EXHAUST BACK PRESSURE .....697
    MEASURING COOLANT TEMPERATURE.....698
    MEASURING AND ADJUSTING VALVE CLEARANCE .....699
    MEASURING WASTEGATE ACTUATOR CALIBRATION .....700
    MEASURING EXAUST COLOR .....701
    MEASURING ACCELERATOR  PEDAL .....702
    MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER .....704
    MEASURING STALL SPEEDS .....705
    MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE.....707
    METHOD OF OPERATING EMERGENCY MANUAL SPOOL .....709
    MEASURING CLEARANCE BETWEEN TIRE AND WHEEL .....711
    TESTING AND ADJUSTING  STEERING WHEEL .....712
    TESTING AND ADJUSTING STEERING CONTROL.....715
    MEASURING STEERING OIL PRESSURE .....716
    MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL .....718
    MEASURING BRAKE PERFORMANCE .....719
    TESTING BRAKE OIL PRESSURE .....720
    MEASURING BRAKE DISC WEAR .....721
    BLEEDING AIR FROM BRAKE SYSTEM .....722
    MEASURING PARKING BRAKE PERFORMANCE .....723
    MANUAL RELEASE METHOD FOR PARKING BRAKE .....724
    TESTING WEAR OF PARKING BRAKE DISC .....725
    MEASURING WORK EQUIPMENT CONTROL LEVER .....726
    MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE .....728
    MEASURING WORK EQUIPMENT .....732
    TESTING AND ADJUSTING BUCKET POSITIONER.....734
    TESTING AND ADJUSTING BOOM KICK-OUT .....735
    ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE).....737
    CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR .....738
    TROUBLESHOOTING.....739
      POINTS TO REMEMBER WHEN TROUBLESHOOTING .....740
      SEQUENCE OF EVENTS IN TROUBLESHOOTING .....741
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE .....742
      HANDLING CONNECTORS .....749
      CHECKS BEFORE TROUBLESHOOTING .....750
      METHOD OF USING TROUBLESHOOTING CHARTS .....751
      CONNECTOR TYPES AND MOUNTING LOCATIONS, CONNECTOR PIN ARRANGEMENT DIAGRAM .....759
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....763
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....770
        S-1 Starting performance is poor (Starting always takes time) .....771
        S-2 Engine does not start .....772
          (I) Engine does not turn.....772
          (2) Engine turns but no exhaust gas comes out (Fuel is not being injected).....773
          (3) Exhaust gas comes out but engine does not start (Fuel is being injected).....774
        S-3 Engine does not pick up smoothly (Follow-up is poor) .....775
        S-4 Engine stops during operations .....776
        S-5 Engine does not rotate smoothly (hunting) .....777
        S-6 Engine lacks output (no power) .....778
        S-7 Exhaust gas is black (incomplete combustion) .....779
        S-8 Oil consumption is excessive (or exhaust gas is blue).....780
        S-9 Oil becomes contaminated quickly .....781
        S-10 Fuel consumption is excessive .....782
        S-11 Oil is in cooling water, or water spurts back, or water level goes  down .....783
        S-12 Oil pressure lamp lights up (drop in oil pressure) .....784
        S-13 Oil level rises .....785
        S-14 Water temperature becomes too high  (overheating) .....786
        S-15 Abnormal noise is made .....787
        S-16 Vibration is excessive .....788
      TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).....789
        TROUBLE DATA DISPLAY .....791
        M-1 Main monitor does not work .....794
        M-2 When starting switch is turned ON and engine is started  immediately, all lamps stay lighted up .....795
        M-3 Speedometer display does not work properly .....796
        M-4 Abnormality in shift indicator .....797
          (a) Stays at N even when directional lever is at F.....797
          (b) Stays at N even when directional lever is at R.....797
          (c) Does not display N even when directional lever is at N and displays R when directional lever is at F.....797
          (d) Does not display N even when directional lever is at N and displays F when directional lever is at R.....798
          (e) Does not display 1st, 4th.....798
          (f) Does not display 3rd, 4th.....799
          (g) Does not display 2nd, 3rd.....799
          (h) Does not display 1st, 2nd.....800
        M-5 High beam does not light up .....801
        M-6 Turn signal display does not light up .....802
          (a) L.H. turn signal does not light up.....802
          (b) R.H. turn signal does not light up.....802
        M-7 Abnormality in parking display .....803
          (a) Parking lamp does not light up.....803
          (b) Parking lamp stays lighted up.....803
        M-8 Abnormality in preheating system (QGS) .....804
          (a) Does not carry out preheating.....804
          (b) Always carries out preheating for 1 minute.....805
          (c) Preheating stays on.....805
          (d) Preheating time becomes shorter, or there is variation.....806
        M-9 Night lighting does not light up .....807
        M-10 Abnormality in front working lamp .....808
          (a) Neither monitor display nor front working lamp light up.....808
          (b) Working lamp lights up but monitor display does not light up.....808
          (c) Monitor lights up but working lamp does not light up.....808
        M-11 Abnormality in rear working lamp .....809
          (a) Neither monitor display nor rear working lamp light up.....809
          (b) Working lamp lights up but monitor display does not light up.....809
          (c) Monitor lights up but working lamp does not light up.....809
        M-12 Abnormality in transmission cut-off .....811
          (a) When monitor switch is pressed, cut-off function is not switched and display is not given.....811
          (b) Monitor display goes out but cut-off function stays on.....811
          (c) Monitor display lights up but cut-off function is not actuated.....812
        M-13 Abnormality in parking brake dragging warning .....813
          (a) When parking brake is applied, buzzer sounds (intermittently) even when directional lever is at N, caution lamp flashes.....813
          (b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at.....813
        M-14 When parking brake dragging warning is given, buzzer and  caution lamp are actuated continuously, or they are not actuated .....814
          (a) Actuated continuously.....814
          (b) Not actuated.....814
        M-15 Abnormality in buzzer .....815
          (a) Buzzer does not sound when starting switch is turned ON (during self-check).....815
          (b) Buzzer always sounds.....815
        M-16 Condition of monitor switches is not stored in memory .....816
        M-17 Abnormality in failure display mode .....817
          (a) Does not enter failure display mode.....817
          (b) Time for time elapsed since failure on failure display mode does not advance.....817
        M-18 Abnormality in emergency steering normal display .....818
          (a) Emergency steering normal display does not light up.....818
          (b) Emergency steering normal display stays lighted up.....818
        M-19 Abnormality in emergency steering actuation display .....819
          (a) Emergency steering actuation display does not light up.....819
          (b) Emergency steering actuation display stays lighted up.....819
        M-20 Abnormality in auto-greasing system .....820
          (a) Forced greasing cannot be carried out.....820
          (b) Monitor display flashes rapidly (2 times/sec).....820
          (c) When no more grease remains, monitor display flashes rapidly (2 times/sec).....820
          (d) Monitor display flashes slowly (1 time/sec).....821
          (e) Monitor display goes out.....821
        M-21 Abnormality in ECSS system .....822
          (a) Display does not change when switch is pressed.....822
          (b) Monitor display lights up but ECSS function does not work.....822
        M-22 Buzzer does not sound when  auto-leveling switch is actuated .....822
        M-23 Failure code is not sent to main monitor  (abnormality in network) .....823
      TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).....824
        K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec, and does not work .....825
          (a) All lamps on maintenance monitor do not light up for 3 seconds.....825
          (b) Some lamps do not light up.....826
        K-2 When starting switch is turned ON, all lamps on maintenance  monitor light up but do not go out .....826
        K-3 When engine is started immediately after starting switch is turned  ON (within 3 seconds), all lamps on maintenance monitor do not  go out .....827
        K-4 When starting switch is turned ON (engine stopped), CHECK items  flash .....828
          (a) Engine oil level display flashes.....828
          (b) Engine water level display flashes.....829
        K-5 When starting switch is turned ON (engine started), CAUTION  items flash .....830
          (a) Engine oil pressure display flashes.....830
          (b) Battery charge level display flashes.....831
          (c) Brake oil pressure display flashes.....832
          (d) Air cleaner display flashes.....833
        K-6 CAUTION items are flashing but alarm buzzer does not sound .....834
        K-7 There is no abnormality in monitor display but alarm buzzer  sounds .....835
        K-8 CAUTION items are flashing but warning lamp (CHECK  CAUTION lamp) does not light up .....836
          (a) CHECK lamp.....836
          (b) CAUTION lamp.....836
        K-9 There is no abnormality in maintenance monitor display but  warning lamp (CHECK lamp, CAUTION lamp) lights up .....837
          (a) CHECK lamp.....837
          (b) CAUTION lamp.....837
        K-10 Night lighting does not light up when lamp switch is turned ON  (only lighting of maintenance monitor does not light up) .....838
        K-11 Night lighting lights up even when lamp switch is OFF, night  lighting stays lighted up .....839
        K-12 Service meter does not work .....840
        K-13 Service meter is running even when engine is stopped.....840
        K-14 Abnormality in gauge items .....841
          (a) Abnormality in fuel gauge.....841
          (b) Abnormality in engine water temperature gauge.....842
          (c) Abnormality in torque converter oil temperature gauge.....843
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....844
        E-1 Engine does not start .....845
          (a) Starting motor does not turn.....845
          (b) Starting motor turns.....849
        E-2 Engine does not stop .....851
        E-3 Engine stops when machine is traveling .....851
        E-4 Parking brake does not work .....852
          (a) Parking brake has no effect when parking brake switch is turned ON (parking).....852
          (b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake).....852
        E-5 Parking brake is applied when machine is traveling .....853
        E-6 Parking brake is released when starting switch is turned ON .....855
        E-7 Transmission does not change to neutral  when parking brake is applied  (but parking brake works normally) .....855
        E-8 Transmission does not work normally .....856
          (a) Problem in common circuit for transmission (always stays in 2nd).....858
          (b) Problem in H-L circuit.....858
          (c) Problem in speed circuit.....859
          (d) Problem in 4th circuit (does not enter 4th).....859
          (e) Contact in H-L circuit.....860
          (f) Contact in speed circuit.....862
          (g) Contact in 4th circuit (always stays in 4th).....864
          (h) Problem in FORWARD circuit (REVERSE is normal).....865
          (i) Problem in REVERSE circuit (FORWARD is normal).....867
          (j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal).....869
          (k) Contact in FORWARD circuit.....871
          (l) Contact in REVERSE circuit.....873
          (m) Problem in common circuit for FORWARD and REVERSE.....875
        E-9 Kick-down switch does not work  (the regular Fl to F4 shifts normally).....876
        E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position.....878
        E-11 Kick-down operation cannot be canceled .....878
          (a) Not canceled even when directional lever is moved from F to N or R.....878
          (b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th).....879
        E-12 Kick-down switch is actuated by mistake when traveling in 2nd .....881
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE).....882
        POWER TRAIN .....883
          T-1 Machine does not start .....883
          T-2 Travel speed is slow, thrusting power is weak, lacks power on  slopes .....885
          T-3 Excessive shock when starting machine or shifting gear .....887
          T-4 Excessive time lag when starting machine or shifting gear .....888
          T-5 Torque converter oil temperature is high .....889
        STEERING SYSTEM .....890
          T-6 Steering does not turn .....890
          T-7 Steering wheel is heavy .....891
          T-8 Steering wheel wobbles or  there is excessive shock .....892
          T-9 Machine steers to one side  when traveling .....892
          T-10 Turning radius to left and  right is different .....892
        BRAKE SYSTEM .....893
          T-11 Brakes do not work or braking effect is poor .....893
          T-12 Brakes are not released or brakes drag .....894
          T-13 Parking brake is not released or brake drags .....895
        WORK EQUIPMENT .....896
          T-14 Boom does not rise .....896
          T-15 Boom movement is slow or boom lacks lifting power .....897
          T-16 When boom is raised, it moves slowly at a certain height .....898
          T-17 Bucket cannot be pushed with boom cylinder (bucket floats) .....898
          T-18 Excessive hydraulic drift of boom .....898
          T-19 Boom shakes during operation .....898
          T-20 Boom drops momentarily when control lever is operated from  HOLD to RAISE .....899
          T-21 Bucket does not tilt back .....900
          T-22 Bucket movement is slow or tilt-back lacks power .....901
          T-23 Bucket movement becomes slow during tilt-back operation .....902
          T-24 Bucket cannot be pushed with bucket cylinder .....902
          T-25 Excessive hydraulic drift of bucket .....902
          T-26 Bucket shakes during loading operation  (Main control valve at HOLD) .....903
          T-27 Bucket dumps momentarily when control lever is operated from  HOLD to TILT .....903
          T-28 Boom, bucket control levers are heavy or do not move smoothly .....904
      TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).....905
        JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM .....906
        D-1 ECSS does not work .....907
          (a) Error code [d0] is displayed.....908
          (b) Error code [d1] is displayed.....908
          (c) Error code [d2] is displayed.....909
          (d) Error code [d3] is displayed.....909
          (e) Error code [d4] is displayed.....910
          (f) No abnormality display is given.....910
        D-2 ECSS canceled .....914
        D-3 Output is turned ON (travel speed does not become 5 km/h)  (deviates around 5 km/h) .....915
        D-4 Output is turned ON when transmission  z  is in 1st  4 .....915
        D-5 Output is turned ON when transmission is in 4th .....916
        D-6 Controller LED code is not displayed .....917
        D-7 ECSS is abnormal but main monitor does not give abnormality  display .....917
      TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A MODE).....918
        OUTLINE.....919
        1. Function.....919
        2. When carrying out troubleshooting.....919
        3. Failure code table.....919
        4. Table of troubleshooting modes and causes.....920
        A-1 Troubleshooting code [10] Modulation valve solenoid system  (disconnection, short circuit) .....921
        A-2 Troubleshooting code [11] Short circuit in power source for modulation valve solenoid system .....922
        A-3 Troubleshooting code [12] F solenoid signal system .....923
        A-4 Troubleshooting code [13] R solenoid signal system .....923
        A-5 Troubleshooting code [14] Abnormality in H-L solenoid signal  system .....924
        A-6 Troubleshooting code [16] Abnormality in speed solenoid signal  system .....925
        A-7 Troubleshooting code [17] Brake output signal.....926
        A-8 Troubleshooting code [20] Abnormality in directional lever signal  system .....927
        A-9 Troubleshooting code [21] Abnormality in speed lever signal  system .....928
        A-10 Troubleshooting code [22] Abnormality in travel speed signal .....929
        A-11 Troubleshooting code [23] Abnormality in engine speed signal.....930
        A-12 Hold switch system.....931
        A-13 Kick-down switch.....931
        A-14 Kick-down output signal system .....932
        A-15 Transmission cut-off signal system .....933
        A-l 6 Neutralizer signal system .....934
        A-17 Buzzer signal system .....935
        A-18 Network signal system .....936
        A-19 Controller power source system .....937
        A-20 Abnormality in model selection wiring harness .....938
      TROUBLESHOOTING - EAGLE AIR CONDITIONER .....939
  30 DISASSEMBLY AND ASSEMBLY.....943
    METHOD OF USING MANUAL .....945
    PRECAUTIONS WHEN CARRYING OUT OPERATION .....946
    SPECIAL TOOL LIST .....948
    RADIATOR.....951
      REMOVAL .....951
      INSTALLATION .....953
    ENGINE.....954
      REMOVAL .....954
      INSTALLATION .....959
    TORQUE CONVERTER CHARGING PUMP.....960
      REMOVAL .....960
      INSTALLATION .....960
    TORQUE CONVERTER, TRANSMISSION.....961
      REMOVAL .....961
      INSTALLATION .....968
    TORQUE CONVERTER.....970
      DISASSEMBLY .....970
      ASSEMBLY .....972
    TRANSMISSION.....975
      DISASSEMBLY .....975
      ASSEMBLY .....980
    TRANSMISSION CLUTCH PACK.....986
      DISASSEMBLY.....986
      ASSEMBLY .....995
    PARKING BRAKE.....1007
      DISASSEMBLY .....1007
      ASSEMBLY .....1009
    TRANSMISSION CONTROL VALVE.....1012
      REMOVAL.....1012
      INSTALLATION.....1014
      DISASSEMBLY.....1015
      ASSEMBLY.....1022
    TRANSMISSION ACCUMULATOR VALVE.....1028
      DISASSEMBLY .....1028
      ASSEMBLY .....1029
    DRIVE SHAFT.....1030
      DISASSEMBLY .....1030
      ASSEMBLY .....1032
    FRONT AXLE.....1034
      REMOVAL.....1034
      INSTALLATION .....1036
    REAR AXLE.....1037
      REMOVAL.....1037
      INSTALLATION .....1040
    FRONT DIFFERENTIAL.....1042
      REMOVAL .....1042
      INSTALLATION .....1045
    REAR DIFFERENTIAL.....1047
      REMOVAL .....1047
      INSTALLATION.....1050
    DIFFERENTIAL.....1052
      DISASSEMBLY .....1052
      ASSEMBLY .....1055
    FINAL DRIVE.....1063
      DISASSEMBLY .....1063
      ASSEMBLY .....1066
    CENTER HINGE PIN.....1070
      REMOVAL .....1070
      INSTALLATION .....1078
    STEERING VALVE (ORBIT-ROLL).....1084
      REMOVAL .....1084
      INSTALLATION.....1085
    STEERING VALVE.....1086
      DISASSEMBLY.....1086
      ASSEMBLY.....1089
      REMOVAL.....1094
      INSTALLATION .....1095
    STEERING DEMAND VALVE.....1096
      DISASSEMBLY .....1096
      ASSEMBLY .....1100
    STEERING SWITCH PUMP.....1104
      REMOVAL .....1104
      INSTALLATION .....1107
    STEERING CYLINDER.....1108
      REMOVAL .....1108
      INSTALLATION.....1109
    BRAKE VALVE.....1110
      REMOVAL .....1110
      INSTALLATION .....1111
    RIGHT BRAKE VALVE (TANDEM).....1112
      DISASSEMBLY .....1112
      ASSEMBLY.....1113
    LEFT BRAKE VALVE (SINGLE).....1114
      DISASSEMBLY .....1114
      ASSEMBLY .....1115
    SLACK ADJUSTER.....1116
      REMOVAL .....1116
      INSTALLATION.....1117
      DISASSEMBLY .....1118
      ASSEMBLY.....1119
    BRAKE ASSEMBLY.....1120
      DISASSEMBLY .....1120
      ASSEMBLY.....1126
    PARKING BRAKE DISC.....1134
      REMOVAL.....1134
      INSTALLATION .....1136
    HYDRAULIC TANK.....1139
      REMOVAL .....1140
      INSTALLATION .....1139
    WORK EQUIPMENT, PPC PUMP.....1140
      REMOVAL.....1140
      INSTALLATION .....1143
    PPC VALVE.....1144
      REMOVAL .....1144
      INSTALLATION .....1145
      DISASSEMBLY .....1146
      ASSEMBLY.....1147
    MAIN CONTROL VALVE.....1148
      REMOVAL .....1148
      INSTALLATION .....1150
      DISASSEMBLY.....1151
      ASSEMBLY .....1153
    BUCKET CYLINDER.....1156
      REMOVAL .....1156
      INSTALLATION .....1157
    BOOM CYLINDER.....1158
      REMOVAL.....1158
      INSTALLATION .....1159
    HYDRAULIC CYLINDER.....1160
      DISASSEMBLY .....1160
      ASSEMBLY .....1163
    WORK EQUIPMENT.....1166
      REMOVAL .....1166
      INSTALLATION .....1169
    COUNTERWEIGHT.....1171
      REMOVAL .....1171
      INSTALLATION.....1171
    FUEL TANK.....1172
      REMOVAL .....1172
      INSTALLATION.....1173
    CAB.....1174
      REMOVAL .....1174
      INSTALLATION  .....1175
    MAIN MONITOR.....1176
      REMOVAL .....1176
      INSTALLATION .....1177
    MAINTENANCE MONITOR.....1178
      REMOVAL .....1178
      INSTALLATION .....1178
    AIR CONDITIONER UNIT.....1179
      REMOVAL.....1179
      INSTALLATION .....1184
    AIR CONDITIONER CONDENSER.....1185
      REMOVAL .....1185
      INSTALLATION.....1186
    DRY RECEIVER.....1187
      REMOVAL .....1187
      INSTALLATION .....1187
    AIR CONDITIONER COMPRESSOR.....1188
      REMOVAL .....1188
      INSTALLATION.....1189
  40 MAINTENANCE STANDARD.....1190
    ENGINE MOUNT, TRANSMISSION MOUNT .....1191
    TORQUE CONVERTER .....1192
    TRANSMISSION .....1193
    TRANSMISSION CONTROL VALVE .....1200
    DRIVE SHAFT .....1204
    DIFFERENTIAL .....1205
    FINAL DRIVE .....1207
    AXLE MOUNT .....1208
    STEERING COLUMN .....1209
    STEERING VALVE .....1210
    STEERING CYLINDER MOUNT .....1211
    SLACK ADJUSTER .....1212
    BRAKE VALVE.....1213
    BRAKE .....1216
    PARKING BRAKE .....1218
    TORQUE CONVERTER, TRANSMISSION PUMP .....1219
SEBM006204 - Wheel Loader WA420-3 avance Shop Manual.....1235
  COVER.....1235
  CONTENTS.....1236
  01 GENERAL.....1259
    GENERAL ASSEMBLY DRAWING.....1260
    SPECIFICATIONS.....1262
    WEIGHT TABLE.....1265
    LIST OF LUBRICANT AND WATER.....1267
  10 STRUCTURE AND FUNCTION.....1269
    POWER TRAIN.....1270
    POWER TRAIN SYSTEM.....1271
    TORQUE CONVERTER, TRANSMISSION PIPING.....1273
    TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.....1274
    TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM.....1275
    TORQUE CONVERTER.....1276
    TORQUE CONVERTER OIL FILTER.....1279
    TRANSMISSION.....1280
    TRANSMISSION CONTROL VALVE.....1290
    TRANSMISSION SOLENOID VALVE.....1311
    PILOT OIL FILTER.....1312
    DRIVE SHAFT.....1313
    AXLE.....1314
    DIFFERENTIAL.....1316
    FINAL DRIVE.....1320
    AXLE MOUNT, CENTER HINGE PIN.....1321
    STEERING PIPING.....1322
    STEERING COLUMN.....1323
    STEERING VALVE.....1324
    ORBIT-ROLL VALVE.....1338
    STOP VALVE.....1342
    EMERGENCY STEERING PUMP.....1343
    DIVERTER VALVE.....1344
    BRAKE PIPING .....1347
    BRAKE CIRCUIT DIAGRAM.....1348
    BRAKE VALVE.....1350
    CHARGE VALVE.....1355
    ACCUMULATOR (FOR BRAKE).....1361
    SLACK ADJUSTER.....1362
    BRAKE.....1365
    PARKING BRAKE CONTROL.....1367
    PARKING BRAKE.....1368
    PARKING BRAKE SOLENOID VALVE.....1369
    PARKING BRAKE VALVE.....1370
    PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE.....1371
    HYDRAULIC PIPING.....1372
    WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.....1373
    WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....1374
    WORK EQUIPMENT LEVER LINKAGE.....1376
    HYDRAULIC TANK.....1377
    PPC VALVE.....1379
    PPC RELIEF VALVE.....1384
    ACCUMULATOR (FOR PPC VALVE).....1385
    MAIN CONTROL VALVE.....1386
    WORK EQUIPMENT LINKAGE.....1399
    BUCKET.....1401
    BUCKET POSITIONED AND BOOM KICK-OUT.....1402
    CAB.....1408
    ROPS CAB.....1410
    AIR CONDITIONER.....1411
    ELECTRIC CIRCUIT DIAGRAM.....1412
    MACHINE MONITOR SYSTEM.....1423
    MAIN MONITOR .....1424
    MAINTENANCE MONITOR.....1429
    WORK EQUIPMENT CONTROL SYSTEM.....1432
    E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM).....1439
    SENSORS.....1443
    ENGINE STARTING CIRCUIT.....1448
    ENGINE STOP CIRCUIT.....1449
    PREHEATING CIRCUIT.....1450
    ELECTRIC TRANSMISSION CONTROL.....1451
    KICK-DOWN SWITCH.....1454
    KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.....1455
    TRANSMISSION CUT-OFF SWITCH.....1460
    TRANSMISSION CUT-OFF FUNCTION.....1461
    ELECTRIC PARKING BRAKE CONTROL.....1463
  20 TESTING AND ADJUSTING.....1475
    STANDARD VALUE TABLE FOR ENGINE.....1476
    STANDARD VALUE TABLE FOR CHASSIS.....1477
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....1480
    TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....1485
    ADJUSTING VALVE CLEARANCE.....1486
    MEASURING COMPRESSION PRESSURE.....1487
    TESTING AND ADJUSTING FUEL INJECTION TIMING.....1488
    MEASURING EXHAUST COLOR.....1490
    MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).....1491
    MEASURING BLOW-BY PRESSURE.....1492
    TESTING AND ADJUSTING FAN BELT TENSION.....1493
    MEASURING ENGINE SPEED.....1494
    METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE.....1495
    MEASURING ENGINE OIL PRESSURE.....1497
    MEASURING EXHAUST GAS TEMPERATURE.....1498
    MEASURING ACCELERATOR PEDAL.....1499
    MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER.....1501
    MEASURING STALL SPEED.....1502
    MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE.....1504
    METHOD OF OPERATING EMERGENCY MANUAL SPOOL.....1506
    MEASURING CLEARANCE BETWEEN TIRE AND WHEEL.....1508
    TESTING AND ADJUSTING STEERING WHEEL.....1509
    TESTING AND ADJUSTING STEERING CONTROL.....1512
    MEASURING STEERING OIL PRESSURE.....1513
    MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL.....1515
    MEASURING BRAKE PERFORMANCE.....1516
    TESTING BRAKE OIL PRESSURE.....1517
    TESTING FOR BRAKE DISC WEAR.....1518
    BLEEDING AIR FROM BRAKE SYSTEM.....1519
    TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE.....1520
    MEASURING PARKING BRAKE PERFORMANCE.....1521
    METHOD FOR MANUAL RELEASE OF PARKING BRAKE.....1522
    TESTING WEAR OF PARKING BRAKE DISC.....1523
    MEASURING WORK EQUIPMENT CONTROL LEVER.....1524
    MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE.....1526
    MEASURING WORK EQUIPMENT.....1530
    TESTING AND ADJUSTING BUCKET POSITIONER.....1532
    TESTING AND ADJUSTING BOOM KICK-OUT .....1533
    ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE).....1535
    CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR.....1536
    ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER.....1537
    TROUBLESHOOTING.....1538
      POINTS TO REMEMBER WHEN TROUBLESHOOTING.....1539
      SEQUENCE OF EVENTS IN TROUBLESHOOTING.....1540
      PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....1541
      HANDLING CONNECTORS.....1548
      CHECKS BEFORE TROUBLESHOOTING.....1549
      METHOD OF USING TROUBLESHOOTING CHARTS.....1550
      CONNECTOR TYPES AND MOUNTING LOCATIONS.....1558
      CONNECTOR PIN ARRANGEMENT DIAGRAM.....1559
      CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....1562
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).....1569
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).....1570
        S-2 ENGINE DOES NOT START.....1571
          (1) ENGINE DOES NOT TURN.....1571
          (2) ENGINE TURNS BUT TO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED).....1572
          (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).....1573
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).....1574
        S-4 ENGINE STOPS DURING OPERATIONS.....1575
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).....1576
        S-6 ENGINE LACKS OUTPUT (NO POWER).....1577
        S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION).....1578
        S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).....1579
        S-9 OIL BECOMES CONTAMINATED QUICKLY.....1580
        S-10 FUEL CONSUMPTION IS EXCESSIVE.....1581
        S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....1582
        S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE).....1583
        S-13 OIL LEVEL RISES.....1584
        S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....1585
        S-15 ABNORMAL NOISE IS MADE.....1586
        S-16 VIBRATION IS EXCESSIVE.....1587
      TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE).....1588
        TROUBLE DATA DISPLAY.....1590
        M-1 MAIN MONITOR DOES NOT WORK.....1593
        M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP.....1594
        M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY.....1595
        M-4 ABNORMALITY IN SHIFT INDICATOR.....1596
          (a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F.....1596
          (b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R.....1596
          (c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F.....1596
          (d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R.....1597
          (e) DOES NOT DISPLAY 1ST,4TH.....1597
          (f) DOES NOT DISPLAY 3RD,4TH.....1598
          (g) DOES NOT DISPLAY 2ND,3RD.....1598
          (h) DOES NOT DISPLAY 1ST,2ND.....1599
        M-5 HIGH BEAM DOES NOT LIGHT UP.....1600
        M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP.....1601
          (a) L.H. TURN SIGNAL DOES NOT LIGHT UP.....1601
          (b) R.H. TURN SIGNAL DOES NOT LIGHT UP.....1601
        M-7 ABNORMALITY IN PARKING DISPLAY.....1602
          (a) PARKING LAMP DOES NOT LIGHT UP.....1602
          (b) PARKING LAMP STAYS LIGHTED UP.....1602
        M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS).....1603
          (a) DOES NOT CARRY OUT PREHEATING.....1603
          (b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE.....1604
          (c) PREHEATING STAYS ON.....1604
          (d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION.....1605
        M-9 NIGHT LIGHTING DOES NOT LIGHT UP.....1606
        M-10 ABNORMALITY IN FRONT WORKING LAMP.....1607
          (a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP.....1607
          (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.....1607
          (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP.....1607
        M-11 ABNORMALITY IN REAR WORKING LAMP.....1608
          (a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP.....1608
          (b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP.....1608
          (c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP.....1608
        M-12 ABNORMALITY IN TRANSMISSION CUT-OFF.....1610
          (a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN.....1610
          (b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON.....1610
          (c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED.....1611
        M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING.....1612
          (a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES.....1612
          (b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N.....1612
        M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED.....1613
          (a) ACTUATED CONTINUOUSLY.....1613
          (b) NOT ACTUATED.....1613
        M-15 ABNORMALITY IN BUZZER.....1614
          (a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK).....1614
          (b) BUZZER ALWAYS SOUNDS.....1614
        M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY.....1615
        M-17 ABNORMALITY IN FAILURE DISPLAY MODE.....1616
          (a) DOES NOT ENTER FAILURE DISPLAY MODE.....1616
          (b) TIME FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE.....1616
        M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY.....1617
          (a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP.....1617
          (b) EMERGENCY STEERING NORMAL DISPLAY STAYS LIGHTED UP.....1617
        M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY.....1618
          (a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP.....1618
          (b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP.....1618
        M-20 ABNORMALITY IN AUTO-GREASING SYSTEM.....1619
          (a) FORCED GREASING CANNOT BE CARRIED OUT.....1619
          (b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC).....1619
          (c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC).....1619
          (d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC).....1620
          (e) MONITOR DISPLAY GOES OUT.....1620
        M-21 ABNORMALITY IN ECSS SYSTEM.....1621
          (a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED.....1621
          (b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK.....1621
        M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED.....1621
        M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK).....1622
      TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE).....1623
        K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK.....1624
          (a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS.....1624
          (b) SOME LAMPS DO NOT LIGHT UP.....1625
        K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT.....1625
        K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT.....1626
        K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH.....1627
          (a) ENGINE OIL LEVEL DISPLAY FLASHES.....1627
          (b) ENGINE WATER LEVEL DISPLAY FLASHES.....1628
        K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH.....1629
          (a) ENGINE OIL PRESSURE DISPLAY FLASHES.....1629
          (b) BATTERY CHARGE LEVEL DISPLAY FLASHES.....1630
          (c) BRAKE OIL PRESSURE DISPLAY FLASHES.....1631
          (d) AIR CLEANER DISPLAY FLASHES.....1632
        K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND.....1633
        K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS.....1634
        K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP.....1635
          (a) CHECK LAMP.....1635
          (b) CAUTION LAMP.....1635
        K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP)LIGHTS UP.....1636
          (a) CHECK LAMP.....1636
          (b) CAUTION LAMP.....1636
        K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP).....1637
        K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP.....1638
        K-12 SERVICE METER DOES NOT WORK.....1639
        K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.....1639
        K-14 ABNORMALITY IN GAUGE ITEMS.....1640
          (a) ABNORMALITY IN FUEL GAUGE.....1640
          (b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.....1641
          (c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.....1642
      TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....1643
        E-1 ENGINE DOES NOT START.....1644
          (a) STARTING MOTOR DOES NOT TURN.....1644
          (b) STARTING MOTOR TURNS.....1648
        E-2 ENGINE DOES NOT STOP.....1650
        E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.....1650
        E-4 PARKING BRAKE DOES NOT WORK.....1651
          (a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON.....1651
          (b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS.....1651
        E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING.....1652
        E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON .....1654
        E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED.....1654
        E-8 TRANSMISSION DOES NOT WORK NORMALLY.....1655
          (a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND).....1657
          (b) PROBLEM IN H-L CIRCUIT.....1657
          (c) PROBLEM IN SPEED CIRCUIT.....1658
          (d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH).....1658
          (e) CONTACT IN H-L CIRCUIT.....1659
          (f) CONTACT IN SPEED CIRCUIT.....1661
          (g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH).....1663
          (h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL).....1664
          (i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL).....1666
          (j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL).....1668
          (k) CONTACT IN FORWARD CIRCUIT.....1670
          (l) CONTACT IN REVERSE CIRCUIT.....1672
          (m) PROBLEM IN COMMON CIRCUIT FOE FORWARD AND REVERSE.....1674
        E-9 KICK-DOWN SWITCH DOES NOT WORK.....1675
        E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION) (SELF-HOLDING FUNCTION)).....1677
        E-11 KICK-DOWN OPERATION CANNOT BE CANCELED.....1677
          (a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R.....1677
          (b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH).....1678
        E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND.....1680
      TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE).....1681
        POWER TRAIN.....1682
          T-1 MACHINE DOES NOT START.....1682
          T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES.....1684
          T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.....1686
          T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.....1687
          T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.....1688
        STEERING SYSTEM.....1689
          T-6 STEERING DOES NOT TURN.....1689
          T-7 STEERING WHEEL IS HEAVY.....1690
          T-8 STEERING WHEEL WOBBLES OR THERE IS EXCESSIVE SHOCK.....1691
          T-9 MACHINE STEERS TO ONE SIDE WHEN TRAVELING.....1691
          T-10 TURNING RADIUS TO LEFT AND RIGHT IS DIFFERENT.....1691
        BRAKE SYSTEM.....1692
          T-11 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR.....1692
          T-12 BRAKES ARE NOT RELEASED OR BRAKES DRAG.....1693
          T-13 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS.....1694
        WORK EQUIPMENT.....1695
          T-14 BOOM DOES NOT RISE.....1695
          T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.....1696
          T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.....1697
          T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).....1697
          T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM.....1697
          T-19 BOOM SHAKES DURING OPERATION.....1697
          T-20 BOOM DROPS MOMENTARILY  WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.....1698
          T-21 BUCKET DOES NOT TILT BACK.....1699
          T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER.....1700
          T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.....1701
          T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER.....1701
          T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET.....1701
          T-26 BUCKET SHAKES DURING LOADING OPERATION.....1702
          T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.....1702
          T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY.....1703
      TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).....1704
        JUDGMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.....1705
        D-1 ECSS DOES NOT WORK.....1706
          (a) ERROR CODE [d0] IS DISPLAYED.....1707
          (b) ERROR CODE [d1] IS DISPLAYED.....1707
          (c) ERROR CODE [d2] IS DISPLAYED.....1708
          (d) ERROR CODE [d3] IS DISPLAYED.....1708
          (e) ERROR CODE [d4] IS DISPLAYED.....1709
          (f) NO ABNORMALITY DISPLAY IS GIVEN.....1709
        D-2 ECSS CANNOT BE CANCELED.....1713
        D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 km/h) (DEVIATES AROUND 5 km/h).....1714
        D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST.....1714
        D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH.....1715
        D-6 CONTROLLER LED CODE IS NOT DISPLAYED.....1716
        D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY.....1716
      TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE).....1717
        OUTLINE.....1719
          1. FUNCTION.....1719
          2. WHEN CARRYING OUT TROUBLESHOOTING.....1719
          3. FAILURE COED TABLE.....1719
          4. TABLE OF TROUBLESHOOTING MODES AND CAUSES.....1720
        W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM.....1722
        W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF.....1723
        W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM.....1724
        W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM.....1725
        W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID.....1726
        W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID.....1726
        W-7 FAILURE CODE [48] ABNORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM.....1727
        W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM.....1729
        W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM.....1730
        W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH.....1731
        W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIOMETER SYSTEM.....1732
        W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM.....1732
        W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS.....1734
        W-14 SENSOR CANNOT BE ADJUSTED.....1735
        W-15 DOES NOT CARRY OUT AUTO-LEVELING.....1736
          (a) AUTO-LEVELER SWITCH SYSTEM.....1736
          (b) AUTO-LEVELER LED SYSTEM.....1736
          (c) BUCKET LEVER NEUTRAL SWITCH SYSTEM.....1737
          (d) ENGINE SPEED SIGNAL SYSTEM.....1738
        W-16 AUTO-LEVELER CANNOT BE SET.....1739
          (a) AUTO-LEVELER SET SWITCH SYSTEM.....1739
          (b) AUTO-LEVELER SET LED SYSTEM.....1739
        W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP.....1740
          (a) REMOTE POSITIONED SWITCH SYSTEM.....1740
          (b) REMOTE POSITIONED LED SYSTEM.....1740
        W-18 REMOTE POSITIONED SET LEDS DO NOT FLASH.....1741
          (a) REMOTE POSITIONED SWITCH SYSTEM.....1741
          (b) REMOTE POSITIONED LED SYSTEM.....1741
        W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONED IS AT RAISE AND AUTO MODE IS ON .....1742
        W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND.....1743
        W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW.....1744
        W-22 BUCKET (LEVER) CONTROL.....1745
          (a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT.....1745
          (b) LEVER IS NOT HELD BY DETENT.....1746
        W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR.....1748
        W-24 MAINTENANCE MONITOR CHECK.....1749
  30 DISASSEMBLY AND ASSEMBLY.....1750
    METHOD OF USING MANUAL.....1752
    PRECAUTIONS WHEN CARRYING OUT OPERATION.....1753
    SPECIAL TOOL LIST.....1755
    STARTING MOTOR.....1757
      REMOVAL AND INSTALLATION.....1757
    ALTERNATOR.....1758
      REMOVAL AND INSTALLATION.....1758
    ENGINE OIL COOLER.....1759
      REMOVAL AND INSTALLATION.....1759
    AFTERCOOLER CORE.....1760
      REMOVAL AND INSTALLATION.....1760
    FUEL INJECTION PUMP.....1761
      REMOVAL.....1761
      INSTALLATION.....1762
    WATER PUMP.....1763
      REMOVAL AND INSTALLATION.....1763
    TURBOCHARGER.....1764
      REMOVAL AND INSTALLATION.....1764
    NOZZLE HOLDER.....1765
      REMOVAL AND INSTALLATION.....1765
    THERMOSTAT.....1766
      REMOVAL AND INSTALLATION.....1766
    CYLINDER HEAD.....1767
      REMOVAL.....1767
      INSTALLATION.....1773
    RADIATOR.....1775
      REMOVAL.....1775
      INSTALLATION.....1777
    ENGINE.....1778
      REMOVAL.....1778
      INSTALLATION.....1783
    TORQUE CONVERTER CHARGING PUMP.....1784
      REMOVAL.....1784
      INSTALLATION.....1784
    TORQUE CONVERTER, TRANSMISSION.....1785
      REMOVAL.....1785
      INSTALLATION.....1792
    TORQUE CONVERTER.....1794
      DISASSEMBLY.....1794
      ASSEMBLY.....1796
    TRANSMISSION.....1799
      DISASSEMBLY.....1799
      ASSEMBLY.....1804
    TRANSMISSION CLUTCH PACK.....1810
      DISASSEMBLY.....1810
      ASSEMBLY.....1819
    PARKING BRAKE.....1831
      DISASSEMBLY.....1831
      ASSEMBLY.....1833
    TRANSMISSION CONTROL VALVE.....1836
      REMOVAL.....1836
      INSTALLATION.....1838
      DISASSEMBLY.....1839
      ASSEMBLY.....1844
    TRANSMISSION ACCUMULATOR VALVE.....1850
      DISASSEMBLY.....1850
      ASSEMBLY.....1851
    DRIVE SHAFT.....1852
      DISASSEMBLY.....1852
      ASSEMBLY.....1854
    FRONT AXLE.....1856
      REMOVAL.....1856
      INSTALLATION.....1858
    REAR AXLE.....1859
      REMOVAL.....1859
      INSTALLATION.....1862
    FRONT DIFFERENTIAL.....1864
      REMOVAL.....1864
      INSTALLATION.....1867
    REAR DIFFERENTIAL.....1869
      REMOVAL.....1869
      INSTALLATION.....1872
    DIFFERENTIAL.....1874
      DISASSEMBLY.....1874
      ASSEMBLY.....1877
    FINAL DRIVE.....1885
      DISASSEMBLY.....1885
      ASSEMBLY.....1888
    CENTER HINGE PIN.....1892
      REMOVAL.....1892
      INSTALLATION.....1900
    STEERING VALVE.....1906
      REMOVAL.....1906
      INSTALLATION.....1907
      DISASSEMBLY.....1908
      ASSEMBLY.....1911
    STEERING VALVE.....1916
      REMOVAL.....1916
      INSTALLATION.....1917
    STEERING DEMAND VALVE.....1918
      DISASSEMBLY.....1918
      ASSEMBLY.....1922
    STEERING,SWITCH PUMP .....1926
      REMOVAL.....1926
      INSTALLATION.....1929
    STEERING CYLINDER.....1930
      REMOVAL.....1930
      INSTALLATION.....1931
    BRAKE VALVE.....1932
      REMOVAL.....1932
      INSTALLATION.....1933
    RIGHT BRAKE VALVE (TANDEM).....1934
      DISASSEMBLY.....1934
      ASSEMBLY.....1935
    LEFT BRAKE VALVE (SINGLE).....1936
      DISASSEMBLY.....1936
      ASSEMBLY.....1937
    SLACK ADJUSTER.....1938
      REMOVAL.....1938
      INSTALLATION.....1939
      DISASSEMBLY.....1940
      ASSEMBLY.....1941
    BRAKE.....1942
      DISASSEMBLY.....1942
      ASSEMBLY.....1948
    PARKING BRAKE DISC.....1956
      REMOVAL.....1956
      INSTALLATION.....1958
    ACCUMULATOR CHARGE VALVE.....1959
      REMOVAL AND INSTALLATION.....1959
      DISASSEMBLY.....1960
      ASSEMBLY.....1962
    HYDRAULIC TANK.....1964
      REMOVAL.....1964
      INSTALLATION.....1966
    WORK EQUIPMENT,PPC PUMP.....1967
      REMOVAL.....1967
      INSTALLATION.....1970
    PPC VALVE.....1971
      REMOVAL.....1971
      INSTALLATION.....1972
      DISASSEMBLY.....1973
      ASSEMBLY.....1974
    MAIN CONTROL VALVE.....1975
      REMOVAL.....1975
      INSTALLATION.....1977
      DISASSEMBLY.....1978
      ASSEMBLY.....1980
    BUCKET CYLINDER.....1983
      REMOVAL.....1983
      INSTALLATION.....1984
    BOOM CYLINDER.....1985
      REMOVAL.....1985
      INSTALLATION.....1986
      DISASSEMBLY.....1987
      ASSEMBLY.....1990
    WORK EQUIPMENT.....1993
      REMOVAL.....1993
      INSTALLATION.....1996
    COUNTERWEIGHT.....1998
      REMOVAL AND INSTALLATION.....1998
    FUEL TANK.....1999
      REMOVAL.....1999
      INSTALLATION.....2000
    CAB.....2001
      REMOVAL.....2001
      INSTALLATION.....2002
    MAIN MONITOR.....2003
      REMOVAL.....2003
      INSTALLATION.....2004
    MAINTENANCE MONITOR.....2005
      REMOVAL AND INSTALLATION.....2005
    AIR CONDITIONER UNIT.....2006
      REMOVAL.....2006
      INSTALLATION.....2011
    AIR CONDITIONER CONDENSER.....2012
      REMOVAL.....2012
      INSTALLATION.....2013
    DRY RECEIVER.....2014
      REMOVAL AND INSTALLATION.....2014
    AIR CONDITIONER CONDENSER COMPRESSOR.....2015
      REMOVAL.....2015
      INSTALLATION.....2016
  40 MAINTENANCE STANDARD.....2017
    ENGINE MOUNT, TRANSMISSION MOUNT.....2018
    TORQUE CONVERTER.....2019
    TRANSMISSION.....2020
    TRANSMISSION CONTROL VALVE.....2027
    DRIVE SHAFT.....2031
    DIFFERENTIAL.....2032
    FINAL DRIVE.....2034
    AXLE MOUNT.....2035
    STEERING COLUMN.....2036
    STEERING VALVE.....2037
    STEERING CYLINDER MOUNT.....2038
    SLACK ADJUSTER.....2039
    BRAKE VALVE (SINGLE).....2040
    BRAKE.....2043
    PARKING BRAKE.....2045
    TORQUE CONVERTER,TRANSMISSION PUMP.....2046
    STEERING,SWITCH PUMP.....2047
    HYDRAULIC,PPC PUMP.....2048
    PPC VALVE.....2049
    CUT-OFF VALVE.....2050
    MAIN CONTROL VALVE.....2051
    HYDRAULIC CYLINDER.....2055
    CENTER HINGE PIN.....2057
    WORK EQUIPMENT LINKAGE.....2059
    BUCKET.....2061
    BUCKET POSITIONER AND BOOM KICK-OUT.....2062
VEAM470400 - Wheel Loader WA420-3H Operation & Maintenance Manual.....2063
  COVER.....2063
  FOREWORD.....2065
    SAFETY INFORMATION.....2066
    INTRODUCTION.....2067
    POSITIONS OF THE PLATES, TABLES FOR ENTERING THE SERIES NUMBER AND DEALER ADDRESS.....2068
    CONTENTS.....2069
    DIMENSIONS, WEIGHTS AND OPERATING DATA.....2073
    CE-CONFORMING EQUIPMENT.....2075
    LOADING.....2080
  Safety.....2081
    General Safety Measures.....2082
    Safety Precautions During Operation.....2088
    Machine Operation.....2090
    Transport.....2095
    Safety Measures During Maintenance.....2096
    POSITION FOR ATTACHING SAFETY LABELS.....2105
  OPERATION.....2109
    GENERAL VIEW OF THE MACHINE.....2110
    GENERAL VIEW OF CONTROLS AND GAUGES.....2111
    Description of the Individual Elements.....2113
      Control Monitor.....2113
      WARNING DISPLAYS.....2115
      GAUGE DISPLAYS.....2119
      METERS.....2121
      SWITCHES.....2124
      CONTROL LEVERS, PEDALS.....2133
      STEERING COLUMN TILT LEVER.....2139
      FUSE.....2142
      AIR CONDITIONER.....2144
    OPERATION.....2147
      PRE-START CHECKS.....2147
      STARTING THE ENGINE.....2160
      Operation and checks after starting the engine.....2161
      MACHINE TRAVEL.....2163
      GEAR CHANGE.....2165
      CHANGING DIRECTION.....2167
      STOPPING THE MACHINE.....2168
      OPERATING THE WORK EQUIPMENT.....2169
      ACTIVATING THE WORK UNIT.....2171
      WHEEL LOADER FUNCTIONS.....2172
      PRECAUTIONS IN OPERATION.....2176
      ADJUSTING THE WORK EQUIPMENT POSITION.....2178
      PARKING THE MACHINE.....2180
      STOPPING THE ENGINE.....2182
      HANDLING THE TIRES.....2183
    TRANSPORT.....2185
    COLD WEATHER OPERATION.....2187
    LONG-TERM STORAGE.....2190
    TROUBLESHOOTING.....2191
      IF THE FUEL TANK IS EMPTY.....2191
      IF BATTERY IS DISCHARGED.....2197
      MALFUNKTION OF BRAKE.....2201
      OTHER MALFUNCTIONS.....2202
  MAINTENANCE.....2209
    MAINTENANCE GUIDE.....2210
    OUTLINES OF SERVICE.....2213
    WEARING PARTS LIST.....2217
    LUBRICATING AND OPERATING MEANS.....2218
    TOOLS AND STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS.....2221
    STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS.....2222
    MAINTENANCE SCHEDULE.....2224
    SERVICE PROCEDURE.....2227
      MAINTENANCE AFTER THE FIRST 250 OPERATING HOURS.....2227
      MAINTENANCE UPON DEMAND.....2228
      CHECKS BEFORE STARTING.....2241
      EVERY 50 HOURS SERVICE.....2247
      EVERY 100 HOURS SERVICE.....2248
      EVERY 250 HOURS SERVICE.....2250
      EVERY 500 HOURS SERVICE.....2257
      EVERY 1000 HOURS SERVICE.....2260
      EVERY 2000 HOURS SERVICE.....2266
      EVERY 4000 HOURS SERVICE.....2272
  SPECIFICATIONS.....2273
  Special Equipment and Attachments.....2277
    ALS-Electronics.....2278
VEBM470104 - Wheel Loader WA420-3 Shop Manual.....2282
  COVER.....2282
  Contents.....2283
  01 General.....2290
    Up to SN WA420H30296.....2291
    Dimensions and weights.....2291
    Specifications.....2293
    Weight table.....2296
    SN WA420H30297 and up.....2298
    Dimensions and weights.....2298
    Specifications.....2299
    Weight table.....2302
    List of lubricant and water.....2304
    Outlines of service.....2306
    General view of controls and gauges.....2309
    Torque list.....2311
  10 Structure and function.....2312
    Power train.....2314
    Power train system.....2315
    Torque converter, transmission piping.....2317
    Transmission hydraulic system diagram.....2318
    Transmission hydraulic circuit diagram.....2319
    Torque converter.....2320
    Transmission.....2324
    Clutch.....2326
    Transmission control valve.....2334
    Transmission solenoid valve.....2337
    Pilot reducing valve.....2339
    Main relief valve.....2340
    Torque converter outlet port valve.....2341
    Priority valve.....2342
    Transmission oil pressure system diagram.....2343
    H-L selector valve and range selector valve.....2346
    Emergency manual spool.....2348
    Electronic control modulation valve.....2349
    Pilot oil filter.....2352
    Accumulator valve.....2353
    Flow valve.....2355
    Check valve.....2356
    Drive shaft.....2358
    Axle.....2359
    Differential.....2361
    Final drive.....2368
    Axle mount, center hinge pin.....2369
    Steering piping.....2370
    Steering column, orbit roll.....2371
    Hydraulic circuit diagram for steering.....2372
    Orbit-roll valve.....2373
    Steering demand valve.....2374
    Overload relief valve.....2375
    Steering relief valve.....2377
    Operation of demand valve.....2378
    Emergency steering.....2388
    Brake piping.....2398
    Brake circuit diagram.....2399
    Brake valve.....2400
    Charge valve.....2405
    Accumulator for system brake.....2409
    Slack adjuster.....2410
    Brake circuit diagram.....2413
    Brake valve (dual circuit).....2414
    Brake valve (single circuit).....2416
    Brake pressure regulating valve.....2421
    Accumulator (for brake).....2422
    Accumulator for PPC valve.....2423
    Brake accumulator unit.....2424
    Brake.....2426
    Parking brake control.....2428
    Parking brake.....2429
    Parking brake valve.....2430
    Hydraulic piping.....2432
    Work equipment hydraulic circuit diagram.....2433
    Work equipment lever linkage.....2439
    Hydraulic tank.....2440
    PPC valve.....2442
    PPC relief valve.....2450
    Accumulator for PPC valve.....2451
    Main control valve (up to H30296).....2452
    Relief valve (up to H30296.....2454
    Safety valve (with suction).....2455
    Suction valve.....2456
    Main control valve (H30297 and up).....2457
    Safety valve with suction (H30297 and up).....2459
    Anticavitation valve (H30297 and up).....2460
    Safety valve (H30297 and up).....2460
    Hydraulic safety system.....2467
    Hydraulic safety system location (up to H30431).....2468
    Hydraulic safety valve (up to H30431).....2469
    Work equipment linkage.....2470
    Bucket.....2472
    Bucket positioner and boom kick-out.....2473
    Machine monitor system.....2480
    Main monitor.....2481
    Maintenance monitor.....2485
    Transmission auto-shift control system.....2487
    Transmission controller.....2492
    E.C.S.S.....2494
    Sensors.....2504
    Engine start circuit.....2510
    Ether start.....2511
    Electric transmission control.....2516
    Combination switch.....2517
    Kick-down, hold switch.....2519
    Transmission electric circuit diagram.....2520
    Transmission cut-off switch.....2525
    Transmission cut-off function.....2526
    Electric parking brake control.....2527
    Air-conditioner.....2528
    Wiring diagrams.....2582
  20 Testing and adjusting.....2610
    Standard value table for engine.....2611
    Standard value table for chassis.....2613
    Test certificate.....2616
    Standard value table for electrical parts.....2620
    Tools for testing, adjusting and troubleshooting.....2632
    Adjusting valve clearance.....2634
    Measuring compression pressure.....2638
    Measuring blow-by pressure.....2640
    Testing and adjusting fuel injection timing.....2642
    Mesuring exhaust color.....2644
    Measuring intake air pressure (boost pressure).....2645
    Measuring engine oil pressure.....2646
    Testing the fan belt tension.....2647
    Measuring accelerator pedal.....2648
    Basic adjustment of accelerator pedal.....2650
    Measuring operating force, travel of speed lever.....2652
    Measuring stall speed.....2653
    Measuring torque converter, transmission, parking brake oil pressure.....2655
    Method of operating emergency manual spool.....2657
    Measuring clearance between tyre and wheel.....2659
    Measuring operating force of steering wheel.....2660
    Measuring steering oil pressure.....2662
    Measuring operating force, travel of brake pedal.....2664
    Measuring brake performance.....2665
    Testing brake oil pressure.....2666
    Measuring brake disc wear.....2667
    Bleeding air from brake system.....2668
    Measuring parking brake performance.....2669
    Method of manual release of parking brake.....2670
    Testing wear of parking brake disc.....2671
    Measuring work equipment control lever.....2672
    Measuring PPC valve pressure.....2674
    Measuring work equipment.....2680
    Testing and adjusting bucket positioner.....2682
    Testing and adjusting boom kick-out.....2683
    Adjusting main monitor (speedometer modul).....2685
    Checking for abnormality in fuel level sensor.....2686
    Troubleshooting.....2690
    Points to remember when troubleshooting.....2691
    Sequence of events in troubleshooting.....2692
    Precautions when carrying out maintenance.....2693
    Handling connectors.....2700
    Checks before troubleshooting.....2701
    Method of using troubleshooting charts.....2702
    Connector types and mounting locations, connector pin arrangement diagram.....2712
    Connection table for connector pin numbers.....2719
    Troubleshooting of engine system (S mode).....2726
    Troubleshooting of main monitor system (M mode).....2746
    Troubleshooting of maintenance monitor system (K mode).....2784
    Troubleshooting of electrical system (E mode).....2804
    Troubleshooting of transmission controller system (A mode).....2842
    Troubleshooting of hydraulic and mechanical system (Chassis related) (T mode).....2862
    Troubleshooting of ECSS (Electronically Controlled Suspension System) (D mode).....2886
  30 Disassembly and assembly.....2900
    Method of using manual.....2902
    Precautions when carrying out operation.....2903
    Special tool list.....2905
    Starting motor.....2907
    Alternator.....2908
    Engine oil cooler.....2909
    Fuel injection pump.....2912
    Water pump.....2918
    Turbocharger.....2919
    Thermostat.....2923
    Cylinder head.....2927
    Torque converter charging pump.....2945
    Torque converter, transmission.....2946
    Torque converter.....2955
    Tranmission.....2960
    Transmission clutch pack.....2971
    Parking brake.....2992
    Transmission control valve.....2997
    Transmission accumulator valve.....3015
    Drive shaft.....3018
    Front axle.....3022
    Rear axle.....3025
    Front differential.....3030
    Rear differential.....3035
    Differential.....3040
    Final drive.....3051
    Center hinge pin.....3058
    Steering, orbit roll.....3072
    Steering valve.....3074
    Steering, switch pump.....3089
    Steering cylinder.....3093
    Brake valve.....3095
    Right brake valve (tandem).....3097
    Left brake valve (single).....3099
    Slack adjuster.....3101
    Brake.....3105
    Parking brake disc.....3119
    Hydraulic tank.....3122
    Work equipment, PPC pump.....3125
    PPC valve.....3132
    Main control valve.....3134
    Bucket cylinder.....3142
    Boom cylinder.....3144
    Hydraulic cylinder.....3146
    Work equipment.....3152
    Counterweight.....3157
    Fuel tank.....3158
    Cab.....3160
    Main monitor.....3162
    Maintenance monitor.....3164
    Air conditioner unit.....3165
    Air conditioner condenser.....3171
    Dry receiver.....3173
    Air conditioner compressor.....3174
  40 Maintenance standard.....3176
    Engine mount, transmission mount.....3177
    Torque converter.....3178
    Transmission.....3179
    Transmission control valve.....3189
    Drive shaft.....3193
    Diffential.....3195
    Final drive.....3197
    Axle mount.....3198
    Steerig column, orbit roll.....3199
    Steering valve.....3201
    Steering cylinder mount.....3202
    Slack adjuster.....3203
    Brake valve.....3204
    Brake.....3207
    Parking brake.....3209
    Torque converter, transmission pump.....3210
    Steering, switch pump.....3211
    Hydraulic, PPC pump.....3212
    PPC valve.....3213
    Cut-off valve.....3214
    Main control valve.....3215
    Boom cylinder.....3219
    Bucket cylinder.....3220
    Center hinge pin.....3221
    Work equipment linkage.....3223
    Bucket.....3225
    Bucket positioner and boom kick-out.....3226

Komatsu WA420-Series Wheel Loaders Repair Service Manual