Komatsu Wheel Loader WA120MC, WA120LMC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA120-3MC, WA120L-3MC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA120-3MC, WA120L-3MC 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.
CEAM007701 - Wheel Loader WA120-3MC Operation & Maintenance Manual.pdf
SEAM038301T - Wheel Loader WA120-3MC avance Operation & Maintenance Manual.pdf
SEBM021800 - Wheel Loader WA120L-3MC Shop Manual.pdf
CEBM005101 - Wheel Loader WA120-3MC avance plus Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,803 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM007701 - Wheel Loader WA120-3MC Operation & Maintenance Manual....1
COVER....1
INTRODUCTION....7
FOREWORD....8
SAFETY INFORMATION....9
INTRODUCTION....10
INTENDED USE....10
FEATURES....10
BREAKING IN A NEW MACHINE....10
LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....11
MACHINE SERIAL NO. PLATE POSITION....11
ENGINE SERIAL NO. PLATE POSITION....11
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....11
CONTENTS....12
SAFETY....21
GENERAL PRECAUTIONS....22
SAFETY RULES....22
SAFETY FEATURES....22
UNAUTHORIZED MODIFICATION....22
CLOTHING AND PERSONAL PROTECTIVE ITEMS....23
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT....23
MOUNTING AND DISMOUNTING....24
FIRE PREVENTION FOR FUEL AND OIL....24
PRECAUTIONS WHEN HANDLING AT HIGH TEMPERATURES....25
ASBESTOS DUST HAZARD PREVENTION....25
CRUSHING OR CUTTING PREVENTION....25
FIRE EXTINGUISHER AND FIRST AID KIT....26
PRECAUTIONS WHEN USING ROPS....26
PRECAUTIONS FOR ATTACHMENTS....26
PRECAUTION WHEN HANDLING ACCUMULATOR....27
PRECAUTIONS DURING OPERATION....28
BEFORE STARTING ENGINE....28
SAFETY AT WORKSITE....28
FIRE PREVENTION....28
WALK AROUND CHECK....28
IN OPERATOR'S CAB....29
VENTILATION FOR ENCLOSED AREAS....29
PRECAUTIONS FOR MIRRORS, WINDOWS, AND LIGHTS....29
WHEN STARTING ENGINE....30
AFTER STARTING ENGINE....31
CHECKS AFTER STARTING ENGINE....31
PRECAUTIONS WHEN STARTING OFF....31
CHECK WHEN CHANGING DIRECTION....32
PRECAUTIONS WHEN TRAVELING....33
TRAVELING ON SLOPES....34
PROHIBITED OPERATIONS....34
PRECAUTIONS WHEN TRAVELING....35
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES....36
ENSURE GOOD VISIBILITY....37
OPERATE CAREFULLY ON SNOW....37
DO NOT HIT WORK EQUIPMENT....37
WHEN USING THE BRAKE....37
WHEN TRAVELING DOWNHILL....37
WORKING ON LOOSE GROUND....38
PARKING THE MACHINE....38
PRECAUTIONS IN COLD AREAS....39
TRANSPORTATION....40
LOADING AND UNLOADING....40
SHIPPING....40
BATTERY....41
BATTERY HAZARD PREVENTION....41
STARTING WITH BOOSTER CABLES....42
CHARGING BATTERY....43
TOWING....44
WHEN TOWING....44
PRECAUTIONS FOR MAINTENANCE....45
BEFORE CARRYING OUT MAINTENANCE....45
NOTIFICATION OF FAILURE....45
WARNING TAGS....45
CLEAN BEFORE INSPECTION AND MAINTENANCE....45
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE....46
WORK EQUIPMENT SUPPORT....46
PROPER TOOLS....47
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....47
USE OF LIGHTING....47
KEEP WORK PLACE CLEAN AND TIDY....47
APPOINT A LEADER WHEN WORKING WITH OTHERS....48
RADIATOR WATER LEVEL....48
PREVENTION OF FIRE....48
TURN E.C.S.S. SWITCH OFF....48
DURING MAINTENANCE....49
PERSONNEL....49
ATTACHMENTS....49
WORK UNDER THE MACHINE....49
KEEP THE MACHINE CLEAN....49
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE....50
PRECAUTIONS WHEN USING HAMMER....50
REPAIR WELDING....50
PRECAUTIONS WITH BATTERY....50
WHEN ABNORMALITY IS LOCATED....50
RULES TO FOLLOW WHEN ADDING FUEL OR OIL....51
ROTATING FAN AND BELT....51
HANDLING HIGH-PRESSURE HOSES....51
PRECAUTION HIGH PRESSURE OIL....51
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE AT HIGH TEMPERATURE OR HIGH PRESSURE....52
TIRE MAINTENANCE....53
CHECKS AFTER INSPECTION AND MAINTENANCE....53
WASTE MATERIALS....53
WHEN PERFORMING MAINTENANCE WITH THE CHASSIS RAISED....53
TIRES....54
HANDLING TIRES....54
STORING TIRES AFTER REMOVAL....55
POSITION FOR ATTACHING SAFETY LABELS....56
LOCATIONS....56
LABEL TEXT....57
OPERATION....63
GENERAL VIEW....64
EXTERIOR VIEW OF MACHINE....64
VIEW OF CONTROLS AND GAUGES....65
EXPLANATION OF COMPONENTS....67
METERS AND LAMPS....67
SWITCHES (ALL MODELS)....72
SWITCHES (MODELS WITH CAB)....76
CONTROL LEVERS AND PEDALS....78
MISCELLANEOUS....85
SAFETY BAR....85
TOWING PIN....85
GREASE PUMP CLAMP AND RUBBER RING....85
BACKUP ALARM....85
FUSES....86
FUSE CAPACITY AND NAME OF CIRCUIT....86
SLOW-BLOW FUSES....87
STORING THIS MANUAL....88
AUXILIARY POWER SOURCE....88
MACHINE AND ENGINE CHECKS....89
CHECKS BEFORE STARTING ENGINE....89
WALK-AROUND CHECKS....89
CHECK BEFORE STARTING....92
CHECKING AND ADDING COOLANT....92
CHECKING THE DUST INDICATOR....92
CHECKING THE BRAKE OIL TANK....93
CHECKING AND ADDING ENGINE OIL....93
DRAINING THE FUEL-WATER SEPARATOR....94
DRAINING THE FUEL SEDIMENT STRAINER....94
CHECKING THE ELECTRICAL WIRING....95
CHECKING THE FUEL LEVEL....95
INSPECTING THE TIRES....96
INSPECTING THE RIMS....96
CHECKING THE TIRE PRESSURE....96
CHECKING THE MONITOR PANEL....97
CHECKING THE PARKING BRAKE....98
CHECKING THE WHEEL BRAKES....98
CHECK SOUND OF HORN AND BACKUP ALARM....98
CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE....98
CHECK ENGINE EXHAUST COLOR AND SOUND....98
CHECK OPERATION OF GAUGES....98
CHECK STEERING WHEEL PLAY, CHECK STEERING OPERATION....98
CHECK THE REAR VIEW MIRROR....98
CHECK LOCK OF CAB DOOR (MACHINES EQUIPPED WITH CAB)....98
PRE-WORK SHIFT MACHINE CHECKS....99
ADJUSTING THE OPERATOR'S SEAT (STANDARD VERSION)....99
ADJUSTING THE OPERATOR’S SEAT....100
(OPTIONAL AIR-RIDE SEAT)....100
ADJUSTING THE SEAT BELT....101
ADJUSTING THE REAR VIEW MIRRORS....101
OPERATIONS AND CHECKS BEFORE STARTING ENGINE....102
STARTING THE ENGINE....103
NORMAL STARTING PROCEDURES (IN COLD AND WARM CONDITIONS)....103
AFTER EXTENDED SHUTDOWN OR OIL CHANGE....104
AFTER CHANGING FUEL FILTERS....104
AFTER RUNNING OUT OF FUEL....105
OPERATIONS AND CHECKS AFTER STARTING ENGINE....105
OPERATING THE MACHINE....107
MOVING THE MACHINE....107
CHANGING THE GEAR SPEED....109
CHANGING DIRECTION (FORWARD-REVERSE)....110
AUTO-SHIFT TRANSMISSION....110
TURNING THE MACHINE....111
STOPPING THE MACHINE....112
OPERATING THE WORK EQUIPMENT....113
LIFT ARM (LEVER)....113
BUCKET (LEVER)....114
PARKING THE MACHINE....115
CHECKS AFTER COMPLETION OF OPERATION....117
STOPPING ENGINE....117
CHECKS AFTER STOPPING ENGINE....117
LOCKING THE MACHINE....118
TRANSPORTING THE MACHINE....119
LOADING AND UNLOADING....119
PRECAUTIONS FOR LOADING....120
PRECAUTIONS FOR LIFTING THE VEHICLE....120
LIFTING POINT DECALS....121
WEIGHT LIST....121
LIFTING PROCEDURE....122
TYPICAL WORK OPERATIONS....123
DIGGING OPERATIONS WITH ROCK PILES....123
DIGGING OPERATIONS ON LEVEL GROUND....125
LEVELING OPERATIONS....126
PUSHING OPERATIONS....126
STANDARD LOADING OPERATIONS....127
LOAD-AND-CARRY OPERATIONS....128
PRECAUTIONS FOR OPERATION....128
PERMISSIBLE WATER DEPTH....128
IF WHEEL BRAKE DOES NOT WORK....128
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES....128
PRECAUTIONS WHEN DRIVING MACHINE....129
ADJUSTING THE WORK EQUIPMENT POSTURE....129
ADJUSTING THE BOOM KICKOUT....129
ADJUSTING THE BUCKET POSITIONER....130
BUCKET LEVEL INDICATOR....130
COLD WEATHER OPERATIONS....131
PRECAUTIONS DURING LOW AMBIENT TEMPERATURES....131
FUEL AND LUBRICANTS....131
COOLANT....131
BATTERY....132
AFTER COMPLETION OF WORK....132
AFTER COLD WEATHER HAS PASSED....132
LONG-TERM STORAGE....133
BEFORE STORAGE....133
DURING STORAGE....133
AFTER STORAGE....133
TROUBLESHOOTING....134
MACHINE RUNS OUT OF FUEL....134
TOWING THE MACHINE....134
ENGINE STARTS....135
ENGINE DOES NOT START....135
DISCHARGED BATTERY....136
BATTERY REMOVAL AND INSTALLATION....137
BATTERY CHARGING PRECAUTIONS....137
USING BOOSTER CABLES TO START THE ENGINE....138
OTHER TROUBLE....140
ELECTRICAL SYSTEM....140
CHASSIS....141
ENGINE....143
MAINTENANCE....145
GUIDES TO MAINTENANCE....146
OUTLINES OF SERVICE....148
OUTLINE OF OIL, FUEL, COOLANT....148
OIL....148
FUEL....149
COOLANT....149
GREASE....150
STORING OIL AND FUEL....150
FILTERS....150
FUEL INJECTION PUMP....150
OUTLINE OF ELECTRIC SYSTEM....151
WEAR PARTS LIST....152
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....153
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS....153
ENGINE OIL SPECIFICATIONS....154
NORMAL OPERATION....154
ARCTIC OPERATION....154
DIESEL FUEL SPECIFICATIONS....155
COOLANT SPECIFICATIONS....155
GENERAL....155
WATER....155
ANTIFREEZE....156
INHIBITORS/CONDITIONERS....157
MAINTENANCE OF COOLING SYSTEM INHIBITORS....157
COOLANT TESTING FOR CONDITIONER CONCENTRATION....157
REPLENISHING COOLANT CONDITIONER....157
DCA4 UNIT MAINTENANCE GUIDE....158
COOLING SYSTEM TEST KIT....160
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS....161
INTRODUCTION OF NECESSARY TOOLS....161
TORQUE LIST....162
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....163
SAFETY CRITICAL PARTS....164
MAINTENANCE SCHEDULE CHART....167
MAINTENANCE SCHEDULE CHART....167
SERVICE PROCEDURES....170
INITIAL 250 HOURS SERVICE....170
REPLACE FUEL FILTERS....170
REPLACE TRANSMISSION OIL FILTER ELEMENT....170
REPLACE HYDRAULIC TANK FILTER ELEMENT....170
WHEN REQUIRED....171
CHECKING, CLEANING OR REPLACING THE AIR CLEANER ELEMENT....171
CHECKING THE TRANSMISSION OIL LEVEL, ADDING OIL....173
CHECKING THE AXLE OIL LEVEL, ADDING OIL....174
CLEANING THE AXLE CASE BREATHER....175
CLEANING THE RADIATOR FINS....175
REPLACING THE BOLT-ON CUTTING EDGES....176
REPLACING THE BUCKET TEETH (IF EQUIPPED)....177
CHECKING THE AIR CONDITIONER (IF EQUIPPED)....178
CLEANING THE AIR CONDITIONER CONDENSER (IF EQUIPPED)....179
CHECKING THE WINDOW WASHING FLUID....179
CHECKING AND ADJUSTING THE PARKING BRAKE....180
REPLACING A SLOW-BLOW FUSE....181
CHECKING THE AIR INTAKE HEATER....181
CHECKS BEFORE STARTING....182
EVERY 50 HOURS SERVICE....182
DRAINING WATER AND SEDIMENT FROM THE FUEL TANK....182
EVERY 100 HOURS SERVICE....183
CHECKING THE OIL LEVEL IN THE HYDRAULIC TANK, ADDING OIL....183
CLEANING THE AIR CONDITIONER FRESH AIR FILTER ELEMENT....184
LUBRICATING....185
EVERY 250 HOURS SERVICE....186
CHANGING THE ENGINE OIL AND REPLACING THE ENGINE OIL FILTER....186
CHECKING FOR LOOSE WHEEL HUB BOLTS....188
CLEANING THE AIR CONDITIONER RECIRCULATION FILTER ELEMENT....188
CHECKING AND ADJUSTING THE AIR CONDITIONER COMPRESSOR BELT TENSION....189
CHECKING THE BATTERY ELECTROLYTE LEVEL....190
CHECKING THE AIR INTAKE SYSTEM....190
LUBRICATING....191
EVERY 500 HOURS SERVICE....192
REPLACING THE FUEL FILTERS....192
REPLACING THE TRANSMISSION OIL FILTER ELEMENT....194
LUBRICATING THE CENTER HINGE PIN....195
EVERY 1,000 HOURS SERVICE....196
CHANGING THE TRANSMISSION CASE OIL, CLEANING THE STRAINER....196
CLEANING THE TRANSMISSION CASE BREATHER....197
LUBRICATING THE FRONT, CENTER, AND REAR DRIVE SHAFTS....197
ADJUSTING THE ENGINE VALVE LASH CLEARANCE....198
CHANGING THE HYDRAULIC TANK OIL, REPLACING THE FILTER ELEMENT....199
CHECKING THE FAN BELT TENSION....201
CHECKING THE FAN BELT TENSIONER BEARING AND FAN HUB BEARING; INSPECTING THE FAN BELT....201
EVERY 2,000 HOURS SERVICE....203
REPLACING COOLANT, FLUSHING THE COOLING SYSTEM....203
REPLACING THE HYDRAULIC TANK BREATHER ELEMENT....206
CHANGING THE AXLE OIL....206
CHECK BRAKE DISC WEAR....207
CHECK THE ALTERNATOR....207
CHECK THE STARTER MOTOR....207
CHECKING THE VIBRATION DAMPER....207
REPLACING THE AIR CONDITIONER RECIRCULATION AND....207
FRESH AIR FILTER ELEMENTS....207
ADJUSTING THE ENGINE VALVE LASH CLEARANCE....208
CLEANING AND CHECKING THE TURBOCHARGER....210
CLEAN PPC CIRCUIT STRAINER....210
CHECK ACCUMULATOR GAS PRESSURE....210
EVERY 4,000 HOURS SERVICE....210
CHECK THE WATER PUMP....210
SPECIFICATIONS....211
WA120-3MC Specifications....212
OPTIONS, ATTACHMENTS....215
AVAILABLE ATTACHMENTS....216
BUCKETS AND TIRES SELECTION....217
AIR CONDITIONING....218
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL....218
FAN SWITCH....218
AIR CONDITIONER SWITCH....218
MODE SELECTOR SWITCH....219
FRESH/RECIRC SELECTOR SWITCH....219
TEMPERATURE CONTROL SWITCH....219
METHOD OF OPERATION....220
WHEN NOT USING THE AIR CONDITIONER REGU LARLY....220
COOL BOX....220
ECSS (Electronically-Controlled Suspension System)....221
STRUCTURE AND FUNCTION OF ECSS....221
METHOD OF OPERATING ECSS....222
PRECAUTIONS WHEN OPERATING ECSS SWITCH....222
ACCUMULATOR PRECAUTIONS....223
RADIO....224
OPERATING CONTROLS....224
OPERATION....225
SETTING THE CLOCK....227
REMOTE CONTROL UNIT....227
BATTERY REPLACEMENT....228
PRECAUTIONS WHEN USING....228
CEBM005101 - Wheel Loader WA120-3MC avance plus Shop Manual....231
COVER....231
CONTENTS....232
FOREWORD....241
SAFETY....241
SAFETY NOTICE....241
IMPORTANT SAFETY NOTICE....241
GENERAL PRECAUTIONS....241
PREPARATIONS FOR WORK....241
PRECAUTIONS DURING WORK....241
GENERAL....243
HOW TO READ THE SHOP MANUAL....244
VOLUMES....244
DISTRIBUTION AND UPDATING....244
FILING METHOD....244
REVISED EDITION MARK....244
REVISIONS....244
SYMBOLS....244
HOISTING INSTRUCTIONS....245
HOISTING....245
WIRE ROPES....245
COATING MATERIALS....246
STANDARD TIGHTENING TORQUE....248
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....248
TIGHTENING TORQUE OF HOSE NUTS....249
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....249
TIGHTENING TORQUE FOR FLARED NUTS....249
ELECTRIC WIRE CODE....250
CLASSIFICATION BY THICKNESS....250
CLASSIFICATION BY COLOR AND CODE....250
CONVERSION TABLES....251
METHOD OF USING THE CONVERSION TABLE....251
01 GENERAL....257
SPECIFICATION DRAWING....258
SPECIFICATIONS....259
WEIGHT TABLE....262
LIST OF LUBRICANT AND WATER....264
ENGINE OIL SPECIFICATIONS....265
NORMAL OPERATION....265
ARCTIC OPERATION....265
DIESEL FUEL SPECIFICATIONS....266
COOLANT SPECIFICATIONS....266
GENERAL....266
WATER....266
ANTIFREEZE....267
INHIBITORS/CONDITIONERS....269
10 STRUCTURE AND FUNCTION....273
POWER TRAIN....277
POWER TRAIN SYSTEM....278
TORQUE CONVERTER, TRANSMISSION PIPING....280
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....282
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND....282
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....283
ENGINE STOPPED....283
TORQUE CONVERTER....284
TORQUE CONVERTER OIL FILTER....286
TRANSMISSION....288
CLUTCH....290
REVERSE 1ST CLUTCH....290
FORWARD, 2ND CLUTCH....291
3RD, 4TH CLUTCH....291
FORWARD 1ST....293
FORWARD 2ND....294
FORWARD 3RD....295
FORWARD 4TH....296
REVERSE 1ST....297
TRANSMISSION CONTROL VALVE....298
UPPER VALVE....299
LOWER VALVE....300
TRANSMISSION SOLENOID VALVE....301
TORQUE CONVERTER OUTLET PORT VALVE....302
PILOT REDUCING VALVE....303
TRANSMISSION SOLENOID VALVE....304
PRIORITY VALVE....305
MAIN REGULATOR VALVE....306
QUICK RETURN VALVE....307
MODULATION FILL VALVE....311
DIRECTIONAL SELECTOR SPOOL....313
EMERGENCY MANUAL SPOOL....314
OPERATION OF FORWARD 1ST....316
ACCUMULATOR VALVE....318
TRANSMISSION CONTROL....320
DRIVE SHAFT....321
AXLE....322
FRONT AXLE....322
FRONT DIFFERENTIAL....323
REAR AXLE....324
REAR DIFFERENTIAL....325
TORQUE PROPORTIONING DIFFERENTIAL....327
FINAL DRIVE....328
AXLE MOUNT....330
CENTER HINGE PIN....332
STEERING PIPING....333
STEERING COLUMN....334
PRIORITY VALVE....335
STEERING VALVE (ORBIT-ROLL)....338
CONNECTION BETWEEN HAND PUMP AND SLEEVE....344
BRAKE....346
BRAKE PIPING....346
BRAKE CONTROL....347
BRAKE BOOSTER....348
BRAKE....351
PARKING BRAKE CONTROL....353
PARKING BRAKE....354
HYDRAULIC....356
HYDRAULIC PIPING....356
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....358
ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD"....358
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM....359
HYDRAULIC TANK....361
OIL FILTER BYPASS VALVE....362
BREATHER....363
PPC VALVE....364
PPC RELIEF VALVE....370
ACCUMULATOR....371
FOR PPC VALVE....371
MAIN CONTROL VALVE....372
2-SPOOL....372
3-SPOOL....374
RELIEF VALVE....376
SAFETY VALVE (WITH SUCTION)....377
SUCTION VALVE....378
BOOM AND BUCKET SPOOL AT NEUTRAL POSITION....379
BOOM SPOOL AT RAISE POSITION....380
BOOM SPOOL AT LOWER POSITION....381
BOOM SPOOL AT FLOAT POSITION....382
BUCKET SPOOL AT TILT BACK POSITION....383
BUCKET SPOOL AT DUMP POSITION....384
WORK EQUIPMENT....385
WORK EQUIPMENT LEVER LINKAGE....385
WORK EQUIPMENT LINKAGE....386
BUCKET....388
BUCKET POSITIONER AND BOOM KICK-OUT....389
BUCKET POSITIONER....390
BOOM KICK-OUT....390
PROXIMITY SWITCH....391
ROPS CAB....393
AIR CONDITIONER....394
AIR CONDITIONER AND HEATER PIPING....394
AIR CONDITIONER AND HEATER ELECTRICAL DIAGRAM....394
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)....395
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM....396
CENTRAL PANEL....398
SENSORS....399
ENGINE OIL PRESSURE....399
BRAKE OIL LEVEL....399
ENGINE SPEED SENSOR....400
ENGINE....401
ENGINE STARTING CIRCUIT....401
ENGINE STOP CIRCUIT....402
AUTOMATIC PREHEATING CIRCUIT....403
QUICK HEATING SYSTEM (QHS)....403
QHS CONTROLLER....405
HEATER RELAY....405
RIBBON HEATER....406
QHS WATER TEMPERATURE SENSOR....406
TRANSMISSION AUTO-SHIFT CONTROL....407
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM....408
SHIFT CONTROL SYSTEM FUNCTION....409
INPUT SIGNALS....409
OUTPUT SIGNALS....410
SHIFT CHARACTERISTICS....411
SAFETY FUNCTION....415
TROUBLESHOOTING....415
TRANSMISSION CONTROLLER....416
CONNECTOR SIGNALS....416
COMBINATION SWITCH....417
TRANSMISSION CUT-OFF FUNCTION....418
PARKING BRAKE FUNCTION....420
KICK-DOWN SWITCH....421
KICK-DOWN ELECTRICAL CIRCUIT....422
KICK-DOWN SWITCH OPERATED....423
KICK-DOWN SWITCH ACTUATION - CANCELED (1)....424
KICK-DOWN SWITCH ACTUATION - CANCELED (2)....425
ELECTRICAL WIRING ILLUSTRATION....427
ELECTRICAL WIRING DIAGRAM (1/4)....429
ELECTRICAL WIRING DIAGRAM (2/4)....431
ELECTRICAL WIRING DIAGRAM (3/4)....433
ELECTRICAL WIRING DIAGRAM (4/4)....435
20 TESTING, ADJUSTING AND TROUBLESHOOTING....437
STANDARD VALUE TABLE....441
ENGINE TABLE - IN CHASSIS....441
CHASSIS TABLE....442
SERVICE TOOLS TABLE....448
ENGINE COMPONENTS....450
ADJUSTING ENGINE STOP MOTOR CABLE....450
ADJUSTING ENGINE STOP SOLENOID....450
MEASURING AND ADJUSTING VALVE CLEARANCE....450
MEASURING BLOW-BY PRESSURE....450
MEASURING COMPRESSION PRESSURE....450
MEASURING COOLANT TEMPERATURE....450
MEASURING ENGINE LUBRICATING OIL PRESSURE....450
MEASURING ENGINE SPEEDS....450
MEASURING EXHAUST COLOR....450
MEASURING EXHAUST GAS TEMPERATURE....450
MEASURING FUEL FILTER INLET RESTRICTION....450
TEST AND ADJUSTING FAN BELT TENSION....450
TEST AND ADJUSTING FUEL INJECTION TIMING....450
ACCELERATOR PEDAL....451
OPERATING FORCE....451
OPERATING ANGLE....452
SPEED LEVER....453
OPERATING FORCE....453
TRAVEL....453
STALL SPEEDS....454
TORQUE CONVERTER STALL SPEED....454
HYDRAULIC STALL SPEED....455
FULL STALL SPEED....455
TORQUE CONVERTER OIL PRESSURE....456
TRANSMISSION OIL PRESSURE....456
EMERGENCY MANUAL SPOOL....458
OPERATION....458
STEERING WHEEL....460
PLAY....460
OPERATING FORCE....460
OPERATING TIME....461
STEERING OIL PRESSURE....462
METHOD OF MEASURING MAIN RELIEF PRESSURE....462
METHOD OF ADJUSTING MAIN RELIEF PRESSURE....463
BRAKE....464
BRAKE PEDAL....464
OPERATING FORCE....464
TRAVEL....464
BRAKE PEDAL LINKAGE....465
TESTING....465
ADJUSTING....465
BRAKE PERFORMANCE....467
BRAKE OIL PRESSURE....468
BRAKE DISC WEAR....469
BLEEDING AIR....470
PARKING BRAKE....471
PARKING BRAKE PERFORMANCE....471
PARKING BRAKE LINKAGE....472
DISC WEAR....473
TESTING....473
MEASURING....474
WORK EQUIPMENT....475
CONTROL LEVER....475
PPC VALVE....476
MEASURING PRESSURE....476
WORK EQUIPMENT HYDRAULIC PRESSURE....478
WORK EQUIPMENT MEASUREMENT....480
HYDRAULIC DRIFT WORK EQUIPMENT....481
BUCKET POSITIONER....482
TESTING....482
ADJUSTING....482
BOOM KICK-OUT....483
TESTING....483
ADJUSTING....483
PROXIMITY SWITCH ACTUATION PILOt LAMP (RED)....484
TROUBLESHOOTING GENERAL....485
POINTS TO REMEMBER WHEN TROUBLESHOOTING....487
SEQUENCE OF EVENTS IN TROUBLESHOOTING....489
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....490
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT....490
HANDLING CONTROL BOX....495
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT....496
CHECKS BEFORE TROUBLESHOOTING....498
JUDGEMENT OF POWER TRAIN....499
PRECAUTIONS WHEN TROUBLESHOOTING....500
SAFETY....500
METHODS FOR TROUBLESHOOTING....500
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING....502
PREVENTING RECURRENCE OF TROUBLE....503
HYDRAULIC EQUIPMENT....503
OIL CHECKS....503
CLEANING FRAGMENTS OF DAMAGED PARTS....503
METHOD OF USING TROUBLESHOOTING CHARTS....504
CATEGORY OF TROUBLESHOOTING CODE NUMBER....504
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE....504
METHOD OF USING MATRIX TROUBLESHOOTING TABLES....506
METHOD OF USING ENGINE RELATED CHARTS....508
TROUBLESHOOTING ELECTRICAL CONNECTORS....513
CONNECTOR TYPES....514
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....517
ELECTRICAL CIRCUIT DIAGRAMS....525
ENGINE START, STOP SYSTEM....525
PREHEATING SYSTEM....526
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE)....527
OUTLINE....528
FUNCTION....528
TROUBLESHOOTING....528
FAILURE CODE TABLE....528
TABLE OF TROUBLESHOOTING MODES AND CAUSES....529
A-1 TROUBLESHOOTING CODE [12]....530
F SOLENOID SIGNAL SYSTEM....530
A-2 TROUBLESHOOTING CODE [13]....531
R SOLENOID SIGNAL SYSTEM....531
A-3 TROUBLESHOOTING CODE [14]....532
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM....532
A-4 TROUBLESHOOTING CODE [16]....533
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM....533
A-5 TROUBLESHOOTING CODE [20]....534
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM....534
A-6 TROUBLESHOOTING CODE [21]....535
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM....535
A-7 TROUBLESHOOTING CODE [22]....536
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM....536
A-8 TROUBLESHOOTING CODE [23]....537
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM....537
A-10 KICK-DOWN SWITCH SYSTEM....538
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM....539
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM....540
A-13 BUZZER SIGNAL SYSTEM....541
A-15 CONTROLLER POWER SOURCE SYSTEM....542
TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM D-MODE - (ECSS)....543
ECSS - ELECTRICAL / HYDRAULIC SCHEMATIC....544
ECSS - WORKING CHART....544
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL....545
INSPECTION / ADJUSTMENT....545
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....547
E-1 ENGINE DOES NOT START....548
A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START....548
B. CHECK FUEL SHUT-OFF SOLENOID....550
E-2 ENGINE DOES NOT STOP....551
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR.....552
E-10 PREHEATING IS NOT CARRIED OUT....554
E-11 PREHEATING REMAINS ACTUATED....556
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)....559
S-1 STARTING PERFORMANCE IS POOR....561
S-2 ENGINE DOES NOT START....562
A. ENGINE DOES NOT TURN....562
B. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT....563
C. EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START....564
S-3 ENGINE DOES NOT PICK UP SMOOTHLY....565
S-4 ENGINE STOPS DURING OPERATIONS....566
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....567
S-6 ENGINE LACKS OUTPUT (NO POWER)....568
S-7 EXHAUST GAS IS BLACK....569
S-8 OIL CONSUMPTION IS EXCESSIVE....570
S-9 OIL BECOMES CONTAMINATED QUICKLY....571
S-10 FUEL CONSUMPTION IS EXCESSIVE....572
S-11 OIL IN COOLING WATER....573
S-12 OIL PRESSURE LAMP LIGHTS UP....574
S-13 OIL LEVEL RISES....575
S-14 WATER TEMPERATURE BECOMES TOO HIGH....576
S-15 ABNORMAL NOISE IS MADE....577
S-16 VIBRATION IS EXCESSIVE....578
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE)....579
POWER TRAIN....581
T-1 MACHINE DOES NOT START....581
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES....582
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR....584
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....585
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH....586
STEERING SYSTEM....587
T-6 STEERING WHEEL DOES NOT TURN....587
T-7 STEERING IS HEAVY....588
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK....589
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING....590
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT....590
T-11 ECESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT....590
BRAKE SYSTEM....591
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR....591
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS....592
WORK EQUIPMENT....593
T-14 BOOM DOES NOT RISE....593
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER....594
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT....595
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)....595
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM....595
T-19 BOOM SHAKES DURING OPERATION....596
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....596
T-21 BUCKET DOES NOT TILT BACK....597
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER....598
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION....599
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER....599
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET....599
T-26 BUCKET SHAKES DURING LOADING OPERATION....600
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT....600
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY....601
TROUBLESHOOTING OF AIRCONDITIONER....603
SERVICE TOOLS....605
GAUGE MANIFOLD....605
STRUCTURE AND HANDLING OF GAUGE MANIFOLD....606
CHARGING HOSES....608
GAS LEAK DETECTOR....609
HALIDE TORCH LEAK DETECTOR....609
ELECTRIC LEAK TESTER....611
VALVE FOR SERVICE CANS....613
MAINTENANCE PROCEDURE....614
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING....614
PROHIBITED WORK....614
OTHER PRECAUTIONS....614
BLEEDING AIR FROM REFRIGERATION CIRCUIT....616
PURPOSE....616
CONNECTING GAUGE MANIFOLD....616
EVACUATION....617
AIR-TIGHTNESS CHECK....617
GAS-LEAK CHECK....618
EVACUATION (REPEATING)....618
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT....619
CHARGING FROM THE HIGH-PRESSURE SIDE....619
CHARGING FROM THE LOW PRESSURE SIDE....620
WHEN THE AMBIENT TEMPERATURE IS LOW....621
WHEN THE AMBIENT TEMPERATURE IS HIGH....621
REPLACING SERVICE CANS....622
CHECKING THE AMOUNT OF REFRIGERANT....622
REMOVAL OF GAUGE MANIFOLD....624
DISCHARGING THE REFRIGERANT....624
DAILY CHECKS....625
CHECK REFRIGERANT LEVEL....625
CLEANING THE CONDENSER....625
CHECKING THE V-BELT....625
CHECKING OIL LEVEL....626
PROCEDURE FOR CHECKING....626
PROCEDURE FOR CHECKING OIL LEVEL....626
ADDING AND REMOVING OIL....627
ADDING OIL BY EVACUATION....627
TROUBLESHOOTING....628
VISUAL AND ACOUSTICAL CHECKS....628
DEFECTIVE COOLING....629
TROUBLESHOOTING TABLE....631
DEFECTIVE HEATING....633
TROUBLESHOOTING USING GAUGE MANIFOLD....634
PREPARATIONS BEFORE MEASURING....634
INSUFFICIENT REFRIGERANT....634
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER....635
AIR INSIDE REFRIGERATION SYSTEM....636
MOISTURE IN REFRIGERATING SYSTEM....637
REFRIGERANT DOES NOT CIRCULATE....638
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE....639
DEFECTIVE COMPRESSION BY COMPRESSOR....640
30 DISASSEMBLY AND ASSEMBLY....641
METHOD OF USING MANUAL....645
PRECAUTIONS DURING OPERATION....646
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK....646
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK....647
PRECAUTIONS WHEN COMPLETING THE OPERATIONS....648
OTHER PRECAUTIONS....648
SPECIAL TOOL LIST....649
ENGINE COMPONENTS....651
ALTERNATOR ASSEMBLY....651
CYLINDER HEAD ASSEMBLY....651
ENGINE OIL COOLER ASSEMBLY....651
FUEL INJECTION PUMP ASSEMBLY....651
NOZZLE HOLDER ASSEMBLY....651
STARTING MOTOR ASSEMBLY....651
THERMOSTAT ASSEMBLY....651
TURBOCHARGER ASSEMBLY....651
WATER PUMP ASSEMBLY....651
COVERS AND LADDER....652
REMOVAL....652
INSTALLATION....653
ENGINE HOOD....654
REMOVAL....654
INSTALLATION....655
RADIATOR....656
REMOVAL....656
INSTALLATION....659
ENGINE....660
REMOVAL....660
INSTALLATION....667
EXHAUST MUFFLER....668
REMOVAL....668
INSTALLATION....668
AIR CLEANER....669
REMOVAL....669
INSTALLATION....669
TORQUE CONVERTER CHARGING PUMP....670
REMOVAL....670
INSTALLATION....670
TORQUE CONVERTER, TRANSMISSION....671
REMOVAL....671
INSTALLATION....678
TORQUE CONVERTER....680
DISASSEMBLY....680
ASSEMBLY....682
TRANSMISSION....684
DISASSEMBLY....684
DISASSEMBLY OF PARKING BRAKE....693
ASSEMBLY OF PARKING BRAKE....695
ASSEMBLY....698
TRANSMISSION CLUTCH PACK....710
DISASSEMBLY....710
1ST, REVERSE CLUTCH....710
FORWARD, 2ND CLUTCH PACK....712
3RD, 4TH CLUTCH PACK....714
ASSEMBLY....716
1ST, REVERSE CLUTCH....716
FORWARD, 2ND CLUTCH....721
3RD, 4TH CLUTCH....725
TRANSMISSION CONTROL VALVE....730
REMOVAL....730
INSTALLATION....731
DISASSEMBLY....732
ASSEMBLY....734
TRANSMISSION SOLENOID VALVE....737
DISASSEMBLY....737
ASSEMBLY....738
TRANSMISSION ACCUMULATOR VALVE....739
DISASSEMBLY....739
ASSEMBLY....740
DRIVE SHAFT....741
DISASSEMBLY....741
ASSEMBLY....742
FRONT AXLE....743
REMOVAL....743
INSTALLATION....744
REAR AXLE....745
REMOVAL....745
INSTALLATION....749
DIFFERENTIAL....754
DISASSEMBLY....754
ASSEMBLY....758
AXLE HOUSING....768
DISASSEMBLY....768
ASSEMBLY....773
CENTER HINGE PIN....781
REMOVAL....781
INSTALLATION....789
PRIORITY VALVE....798
REMOVAL....798
INSTALLATION....799
STEERING VALVE....800
REMOVAL....800
INSTALLATION....802
DISASSEMBLY....803
DISASSEMBLY OF ROTOR....803
DISASSEMBLY OF CONTROL SIDE....804
ASSEMBLY....806
ASSEMBLY OF CONTROL SIDE....806
ASSEMBLY OF ROTOR....808
MAIN CONTROL VALVE....811
REMOVAL....811
INSTALLATION....813
DISASSEMBLY....814
ASSEMBLY....816
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES....818
PPC VALVE....820
REMOVAL....820
INSTALLATION....821
STEERING CYLINDER....822
REMOVAL....822
INSTALLATION....824
BRAKE BOOSTER....825
REMOVAL....825
INSTALLATION....827
DISASSEMBLY....828
ASSEMBLY....831
PARKING BRAKE....836
REMOVAL....836
INSTALLATION....838
HYDRAULIC TANK....840
REMOVAL....840
INSTALLATION....841
HYDRAULIC FILTER....842
REMOVAL....842
INSTALLATION....842
STEERING PUMP....843
REMOVAL....843
INSTALLATION....844
BUCKET CYLINDER....845
REMOVAL....845
INSTALLATION....846
BOOM CYLINDER....847
REMOVAL....847
INSTALLATION....848
HYDRAULIC CYLINDER....849
DISASSEMBLY....849
ASSEMBLY....851
ECSS SYSTEM....854
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL....854
ECSS SOLENOID VALVE....855
REMOVAL....855
INSTALLATION....855
ECSS CONTROL VALVE....856
REMOVAL....856
INSTALLATION....856
WORK EQUIPMENT....857
REMOVAL....857
INSTALLATION....860
FUEL TANK....863
REMOVAL....863
INSTALLATION....864
COUNTERWEIGHT....865
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS....865
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS....865
REMOVAL OF REAR COUNTERWEIGHT....865
INSTALLATION OF REAR COUNTERWEIGHT....866
INSTRUMENT PANEL....867
REMOVAL....867
INSTALLATION....867
AIR CONDITIONING....868
AIR CONDITIONER UNIT....868
REMOVAL....868
INSTALLATION....874
AIR CONDITIONER CONDENSER....875
REMOVAL....875
INSTALLATION....876
DRYER RECEIVER....878
REMOVAL....878
INSTALLATION....878
AIR CONDITIONER COMPRESSOR....880
REMOVAL....880
INSTALLATION....881
40 MAINTENANCE STANDARD....884
ENGINE MOUNT, TRANSMISSION MOUNT....885
TORQUE CONVERTER CHARGING PUMP....887
TORQUE CONVERTER....889
TRANSMISSION....891
TRANSMISSION (1/3)....891
TRANSMISSION (2/3)....895
TRANSMISSION (3/3)....899
REVERSE, 1ST CLUTCH....901
FORWARD, 2ND CLUTCH....903
3RD, 4TH CLUTCH....905
TRANSMISSION CONTROL VALVE....907
UPPER VALVE....907
LOWER VALVE....909
SOLENOID VALVE....911
ACCUMULATOR VALVE....913
DRIVE SHAFT....915
DIFFERENTIAL....917
DIFERENTIAL (1/2)....917
DIFFERENTIAL (2/2)....919
FINAL DRIVE....921
AXLE MOUNT....923
ADDITIONAL COUNTERWEIGHT....925
CENTER HINGE PIN....927
STEERING COLUMN....929
PRIORITY VALVE....931
STEERING CYLINDER MOUNT....932
BRAKE BOOSTER....933
BRAKE....935
PARKING BRAKE....936
HYDRAULIC PUMP, SAL45+SB(1)8....937
MAIN CONTROL VALVE....938
2-SPOOL VALVE....938
3-SPOOL VALVE....941
PPC VALVE....944
HYDRAULIC CYLINDER....946
WORK EQUIPMENT LINKAGE....947
BUCKET....949
BUCKET POSITIONER AND BOOM KICK-OUT....951
90 OTHERS....954
AIR CONDITIONING AND HEATER ELETRICAL DIAGRAM....956
ELECTRICAL WIRING DIAGRAM....958
DIAGRAM (1/4)....958
DIAGRAM (2/4)....960
DIAGRAM (3/4)....962
DIAGRAM (4/4)....964
SEAM038301T - Wheel Loader WA120-3MC avance Operation & Maintenance Manual....968
COVER....968
FOREWORD....969
1. FOREWORD....970
2. SAFETY INFORMATION....972
3. INTRODUCTION....973
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....974
5. CONTENTS....975
SAFETY....979
6. GENERAL PRECAUTIONS....980
7. PRECAUTIONS DURING OPERATION....985
7.1 Before Starting Engine....985
7.2 After Starting Engine....987
7.3 Transportation....995
7.4 Battery....996
7.5 Towing....998
8. PRECAUTIONS FOR MAINTENANCE....999
8.1 Before Carrying Out Maintenance....999
8.2 During Maintenance....1004
8.3 Tires....1010
9. POSITION FOR ATTACHING SAFETY LABLES....1012
OPERATION....1019
10. GENERAL VIEW....1020
10.1 General View of Machine....1020
10.2 General View of Controls and Gauges....1021
11. EXPLANATION OF COMPONENTS....1024
11.1 Meter, Lamps....1024
11.2 Switches....1028
11.3 Control Levers, Pedals....1034
11.4 Cap with Lock....1039
11.5 Safety Bar....1040
11.6 Towing Pin....1040
11.7 Grease Pump Clamp and Rubber Ring....1040
11.8 Backup Alarm....1041
11.9 Fuse....1042
11.10 Slow-blow Fuse....1043
11.11 Manual Pocket....1044
11.12 Power Supply Socket....1044
12. OPERATION....1045
12.1 Check Before Starting Engine....1045
12.2 Starting Engine....1061
12.3 Operations and Checks After Starting Engine....1062
12.4 Moving Machine Off....1063
12.5 Changing Gear Speed....1064
12.6 Changing Direction....1065
12.7 Turning....1066
12.8 Stopping Machine....1067
12.9 Operation of Work Equipment....1068
12.10 Work Possible Using Wheel Loader....1069
12.11 Precautions for Operation....1073
12.12 Adjusting Work Equipment Posture....1075
12.13 Parking Machine....1077
12.14 Checks After Completion of Operation....1079
12.15 Stopping Engine....1079
12.16 Check After Stopping Engine....1080
12.17 Locking....1080
12.18 Handling the Tires....1081
13. TRANSPORTATION....1083
13.1 Loading, Unloading Work....1083
13.2 Precautions for Loading....1084
13.3 Lifting Machine....1084
13.4 Precautions for Transportation....1087
14. COLD WEATHER OPERATION....1088
14.1 Precautions for Low Temperature....1088
14.2 Precautions After Completion of Work....1090
14.3 After Cold Weather....1090
15. LONG-TERM STORAGE....1091
15.1 Before Storage....1091
15.2 During Storage....1091
15.3 After Storage....1091
16. TROUBLESHOOTING....1092
16.1 When Machine Runs Out of Fuel....1092
16.2 Towing the Machine....1093
16.3 If Battery is Discharged....1096
16.4 Other Trouble....1100
MAINTENANCE....1107
17. GUIDES TO MAINTENANCE....1108
18. OUTLINES OF SERVICE....1111
18.1 Outline of Oil, Fuel, Coolant....1111
18.2 Outline of Electric System....1114
19. WEAR PARTS LIST....1115
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....1116
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....1120
21.1 Introduction of Necessary Tools....1120
21.2 Torque List....1121
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....1122
23. MAINTENANCE SCHEDULE CHART....1124
23.1 Maintenance Schedule Chart....1124
24. SERVICE PROCEDURE....1127
24.1 Initial 250 Hours Service....1127
Replace Fuel Filter Cartrfidge....1127
Replace Transmission Oil Filter Element....1127
Replace Hydraulic Tank Filter Element....1127
Check Engine Valve Clearance, Adjust....1127
24.2 When Required....1128
24.2.1 Check Clean, or Replace Air Cleaner Element....1128
24.2.2 Clean Inside of Cooling System....1131
24.2.3 Check Transmission Oil Level, Add Oil....1135
24.2.4 Check Axle Oil Level, Add Oil....1136
24.2.5 Check Axle Case Breather....1137
24.2.6 Clean Radiator Fins....1137
24.2.7 Replace Bolt-on Cutting Edge....1138
24.2.8 Replace Bucket Teeth (If Equipped)....1139
24.2.9 Check Air Conditioner (If Equipped)....1140
24.2.10 Clean Condenser of Air Conditioner (If Equipped)....1141
24.2.11 Check Window Washing Fluid Level, Add Fluid....1141
24.2.12 Adjust Parking Brake....1142
24.2.13 Check Electrical Intake Air Heater....1143
24.2.14 Replace Slow Blow Fuse....1143
24.2.15 Selection and Inspection of Tires....1144
24.3 Check Before Starting....1146
See "12.1.2 Check Before Starting" in the Operation Section....1146
24.4 Every 50 Hours Service....1147
24.4.1 Drain Water, Sediment From Fuel Tank....1147
24.5 Every 100 Hours Service....1148
24.5.1 Check Oil Level In Hydraulic Tank, Add Oil....1148
24.5.2 Clean Element In Car Heater Air Conditioner (If Equipped) Fresh Air Filter....1149
24.5.3 Lubricating....1150
Bucket Pin (2 points)....1150
Bucket Link Pin (2 points)....1150
Rear Axle Pivot Pin (2 points)....1150
24.6 Every 250 Hours Service....1151
24.6.1 Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge....1151
24.6.2 Check Battery Electrolyte Level....1153
24.6.3 Check for Loose Wheel Hub Nuts, Tighten....1153
24.6.4 Clean Element in Car Heater and Air Conditioner (If Equipped) Recirculation Filter....1154
24.6.5 Check Air Conditioner Compressor Belt Tension, Adjust (If Equipped)....1154
24.6.6 Lubricating....1155
Dump Cylinder Pin (2 points)....1155
Lift Cylinder Pin (4 points)....1155
Lift Arm Pivot Pin (2 points)....1155
Tilt Lever Pin (1 point)....1155
Steering Cylinder Pin (4 points)....1155
24.7 Every 500 Hours Service....1156
24.7.1 Replace Fuel Filter Cartridge....1156
24.7.2 Lubricating....1158
Center Drive Shaft Spline (1 point)....1158
Center Hings Pin (2 points)....1158
24.8 Every 1000 Hours Service....1159
24.8.1 Change Oil in Transmission Case and Transmission Oil Filter Cartridge, Clean Strainer....1159
24.8.2 Clean Transmission Case Breather....1160
24.8.3 Lubricating....1161
Front Drive Shaft (2 points)....1161
Drive Shaft Center Support (1 point)....1161
Center Drive Shaft ( 2 points)....1161
Rear Drive Shaft (2 points)....1162
24.8.4 Change Oil in Hydraulic Tank, Replace Hydraulic Filter Element....1163
24.8.5 Check Tightening Parts of Turbocharger....1165
24.8.6 Check Play of Turbocharger Rotor....1165
24.8.7 Check Fan Belt Tension and Replace Fan Belt....1165
24.9 Every 2000 Hours Service....1166
24.9.1 Replace Hydraulic Tank Breather Element....1166
24.9.2 Change Axle Oil (*)....1167
24.9.3 Check Brake Disc Wear....1168
24.9.4 Check Alternator, Starting Motor....1168
24.9.5 Check Engine Valve Clearance, Adjust....1168
24.9.6 Replace Element in Car Heater and Air Conditioner (If Equipped) Recirculation Air Filter, Fresh Air Filter....1168
24.10 Every 4000 Hours Service....1169
24.10.1 Check Water Pump....1169
SPECIFICATIONS....1171
25. SPECIFICATIONS....1172
OPERATIONS, ATTACHMENTS....1173
26. OPTIONAL PARTS AND ATTACHMENTS....1174
27. SELECTING BUCKETS AND TIRES....1175
28. CAR RADIO....1176
28.1 Explanation of Components....1176
28.2 Method of Use....1178
28.3 Precautions When Using Radio....1179
29. CAR STEREO....1180
29.1 Explanation of Components....1180
29.2 When Receiving Radio Broadcasts....1182
29.3 When Playing A Cassette Tape....1184
29.4 Specifications....1185
30. AIR CONDITIONER....1186
30.1 General Locations and Function of Control Panel....1186
30.2 Method of Operation....1188
30.3 Cool Box....1188
31. HANDLING E.C.S.S. (Electronic Controlled Supsension System)....1189
31.1 Structure and Function of E.C.S.S....1189
31.2 Method of Operating E.C.S.S....1190
31.3 Precautions When Operating E.C.S.S. Switch....1190
31.4 Precautions When Handling Accumulator....1191
SEBM021800 - Wheel Loader WA120L-3MC Shop Manual....1193
COVER....1193
CONTENTS ....1194
01 GENERAL ....1215
GENERAL ASSEMBLY DRAWING....1216
SPECIFICATIONS....1217
WEIGHT TABLE ....1220
LIST OF LUBRICANT AND WATER....1222
10 STRUCTURE AND FUNCTION....1224
POWER TRAIN....1225
POWER TRAIN SYSTEM....1226
TORQUE CONVERTER, TRANSMISSION PIPING....1228
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....1229
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM....1230
TORQUE CONVERTER ....1231
TRANSMISSION....1233
TRANSMISSION CONTROL VALVE....1243
TRANSMISSION CONTROL ....1264
DRIVE SHAFT ....1265
AXLE....1266
FINAL DRIVE....1272
AXLE MOUNT....1273
CENTER HINGE PIN....1275
STEERING PIPING....1276
STEERING COLUMN....1277
PRIORITY VALVE....1278
STEERING VALVE (DRBIT-ROLL)....1281
BRAKE PIPING....1289
BRAKE CONTROL....1290
BRAKE BOOSTER....1291
BRAKE ....1295
PARKING BRAKE CONTROL....1297
PARKING BRAKE ....1298
HYDRAULIC PIPING ....1299
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....1301
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM....1302
HYDRAULIC TANK....1304
PPC VALVE....1307
ACCUMULATOR....1314
MAIN CONTROL VALVE....1315
WORK EQUIPMENT LINKAGE....1328
BUCKET....1330
BUCKET POSITIONER AND BOOM KICK-OUT....1331
PROXIMITY SWITCH....1333
ROPS CAB....1335
AIR CONDITIONER....1336
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)....1337
ELECTRICAL WIRING DIAGRAM ....1340
AIR CONDITIONING AND HEATER ELECTRICAL DIAGRAM....1345
CENTRAL PANEL....1346
SENSOR....1347
ENGINE STARTING CIRCUIT....1348
ENGINE STOP CIRCUIT....1349
FUEL CUT-OFF SOLENOID....1350
AUTOMATIC PREHEATING CIRCUIT (O.H.S. CONTROLLER)....1351
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM....1355
20 TESTING AND ADJUSTING....1374
STANDARD VALUE TABLE FOR ENGINE....1375
STANDARD VALUE TABLE FOR CHASSIS....1376
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....1379
ADJUSTING VALVE CLEARANCE....1381
TESTING AND ADJUSTING FUEL INJECTION TIMING....1382
MEASURING EXHAUST COLOR....1383
MEASURING BLOW-BY PRESSURE....1384
MEASURING ENGINE OIL PRESSURE....1385
MEASURING ENGINE SPEED....1386
ADJUSTING ENGINE STOP SOLENOID....1387
MEASURING ACCELERATOR PEDAL....1388
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER....1390
MEASURING STALL SPEED....1391
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE....1393
METHOD OF OPERATING EMERGENCY MANUAL SOLENOID VALVE....1395
TESTING AND ADJUSTING STEERING WHEEL....1397
MEASURING STEERING OIL PRESWSURE ....1400
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL....1402
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE....1403
MEASURING BRAKE PERFORMANCE....1405
MEASURING BRAKE OIL PRESSURE....1406
TESTINMG FOR BRAKE DISC WEAR....1407
BLEEDING AIR FROM BRAKE SYSTEM ....1408
MEASURING PARKING BRAKE PERFORMANCE....1409
TESTING AND ADJUSTING PARKING BRAKE LINKAGE....1410
TESTING PARKING BRAKE DISC WEAR....1411
MEASURING PARKING BRAKE DISC WEAR....1412
ADJUSTING WORK EQUIPMENT PPC VALVE....1413
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....1414
MEASURING WORK EQUIPMENT....1416
TESTING AND ADJUSTING BUCKET POSITIONER....1418
TESTING AND ADJUSTING BOOM KICK-OUT....1419
TROUBLESHOOTING....1421
POINTS TO REMEMBER WHEN TROUBLESHOOTING ....1422
SEQUENCE OF EVENTS IN TROUBLESHOOTING....1423
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....1424
CHECKS BEFORE TROUBLESHOOTING....1432
CONNECTOR TYPE AND INSTALLATION POSITION....1433
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....1440
METHOD OF USING TROUBLESHOOTING CHARTS....1462
TROUBLESHOOTING OF ENGINE (S4D102E-1) SYSTEM (S MODE)....1470
S-1 STARTING PERFORMANCE IS POOR (STARING ALWAYS TAKES TIME)....1471
S-2 ENGINE DOES NOT START....1472
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....1475
S-4 ENGINE STOPS DURING OPERATIONS....1476
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....1477
S-6 ENGINE LACKS OUTPUT (NO POWER)....1478
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)....1479
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)....1480
S-9 OIL BECOMES CONTAMINATED QUICKLY....1481
S-10 FUEL CONSUMPTION IS EXCESSIVE....1482
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....1483
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)....1484
S-13 OIL LEVEL RISES....1485
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....1486
S-15 ABNORMAL NOISE IS MADE....1487
S-16 VIBRATION IS EXCESSIVE....1488
TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)....1489
M MODE RELATED ELECTRICAL CIRCUIT DIAGRAM....1491
M-1 ABNORMALITY IN POWER SUPPLY SYSTEM OR GROUND SYSTEM OF MONITOR PANEL....1493
a) WHEN THE STARTING SWITCH IS TURNED ON, THE [ENGINE OIL PRESSURE], [PARKING BRAKE], [BRAKE OIL LEVEL] AND [PREHEATING] LAMPS DO NOT LIGHT UP AT THE SAME TIME. (POWER SUPPLY SYSTEM)....1493
b) WHEN THE STARTING SWITCH IS TURNED ON, THE [BATTERY CHARGE LEVEL], [TURN SIGNAL], [HIGH BEAM] AND [SERVICE METER] LAMPS DO NOT LIGHT UP OR FLASH AT THE SAME TIME. (GND SYSTEM)....1493
M-2 ABNORMALITY IN AUTOMATIC PREHEATING PILOT LAMP....1495
a) THE PREHEATING PILOT LAMP DOES NOT LIGHT UP WHILE THE AUTOMATIC PREHEATING SYSTEM (QHS) IS WORKING....1495
b) THOUGH THE AUTOMATIC PREHEATING SYSTEM (QHS) DOES NOT WORK, THE PREHEATING PILOT LAMP LIGHTS UP....1495
M-3 ABNORMALITY IN BRAKE OIL LEVEL CAUTION LAMP....1497
a) WHEN THE STARTING SWITCH IS TURNED ON, THE LAMP DOES NOT LIGHT UP ....1497
b) THOUGH THE OIL LEVEL IS NORMAL WHILE ENGINE IS RUNNING, THE LAMP LIGHTS UP ....1497
c) THOUGH THE OIL LEVEL IS ABNORMAL WHILE ENGINE IS RUNNING , THE LAMP DOES NOT LIGHT UP ....1498
M-4 ABNORMALITY IN PARKING BRAKE PILOT LAMP ....1499
a) THE LAMP DOES NOT LIGHT UP EVEN WHEN THE PARKING BRAKE PEDAL IS DEPRESSED....1499
B) THE LAMP DOES NOT GO OUT EVEN WHEN THE PARKING PEDAL IS RELEASED....1499
M-5 ABNORMALITY IN ENGINE OIL PRESSURE CAUTION LAMP ....1501
a) THE LAMP DOES NOT LIGHT UP WHEN THE STARTING SWITCH IS TURNED ON ....1501
b) THE LAMP LIGHTS UP WHILE THE ENGINE IS RUNNING ....1501
M-6 ABNORMALITY IN BATTERY CHARGE LEVEL CAUTION LAMP ....1502
a) THE LAMP DOES NOT LIGHT UP WHEN THE STARTING SWITCH IS TURNED ON ....1502
b) THE LAMP LIGHTS UP WHILE THE ENGINE IS RUNNING ....1502
M-7 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE....1504
a) THE GAUGE DOES NOT MOVE UP FROM C (THE LOWEST POSITION)....1504
b) THE GAUGE DOES NOT MOVE DOWN FROM H (THE HIGHEST POSITION)....1504
c) TORQUE CONVERTER OIL TEMPERATURE INDICATED ON THE GAUGE IS DIFFERENT FROM THE REAL TEMPERATURE....1505
M-8 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE....1506
a) GAUGE DOES NOT MOVE UP FROM C (LOWEST LEVEL)....1506
b) GAUGE DOES NOT MOVE DOWN FROM H (HIGHEST LEVEL)....1506
c) READING ON GAUGE DIFFERS FROM THE ACTUAL ENGINE COOLANT TEMPERATURE....1507
M-9 ABNORMALITY IN FUEL LEVEL GAUGE....1508
a) GAUGE DOES NOT MOVE UP FROM E (LOWEST LEVEL)....1508
b) GAUGE DOES NOT MOVE DOWN FROM F (HIGHEST LEVEL)....1508
c) READING ON GAUGE DIFFERS FROM THE ACTUAL FUEL LEVEL ....1509
M-10 ABNORMALITY IN SERVICE METER....1510
a) SERVICE METER WORKS WHEN ENGINE STOPS....1510
b) SERVICE METER DOES NOT WORK WHILE ENGINE IS RUNNING ....1510
c) INDICATOR LAMP DOES NOT FLASH WHEN SERVICE METER IS WORKING ....1510
M-11 HIGH BEAM PILOT LAMP, TURN SIGNAL PILOT LAMP DO NOT LIGHT UP OR FLASH....1512
a) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP ....1512
b) TURN SIGNAL PILOT LAMP DOES NOT FLASH....1513
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....1514
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING, STOPPING AND BATTERY CHARGING....1515
E-1 ENGINE DOES NOT START....1516
a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START....1516
b) FUEL CUT OFF VALVE DOES NOT WORK....1519
E-2 ABNORMALITY IN PREHEATING SYSTEM (QHS)....1520
a) PREHEATING IS NOT CARRIED OUT....1520
b) PREHEATING IS CARRIED OUT, BUT MONITOR DISPLAY IS NOT TURNED ON ....1521
c) PREHEATING IS ALWAYS CARRIED OUT FOR 45 SEC....1521
d) PREHEATING STAYS ON ....1521
e) THE PREHEATING TIME REDUCES OR BECOMES UNCERTAIN....1522
E-3 TRANSMISSION DOES NOT COME TO NEUTRAL WHILE PARKING BRAKE IS APPLIED. (BUT THE TRANSMISSION CUTOFF IS IN ORDER)....1524
E-4 BOOM KICKOUT CANNOT BE CARRIED OUT....1525
E-5 BUCKET POSITIONER FUNCTION IS ABNORMAL....1528
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (AUTO-SHIFT TRANSMISSION) (A MODE )....1531
OUTLINE....1532
1. FUNCTION....1532
2. WHEN CARRYING OUT TROUBLESHOOTING....1532
3. FAILURE CODE TABLE....1532
4. TABLE OF FAILURE MODES AND CAUSES....1533
5. RELATED ELECTRIC CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL....1534
A-1 FAILURE CODE [12] ABNORMALITY IN F SOLENOID SIGNAL SYSTEM....1536
A-2 FAILURE CODE [13] ABNORMALITY IN R SOLENOID SIGNAL SYSTEM....1536
A-3 FAILURE CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM....1537
A-4 FAILURE CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM....1538
A-5 FAILURE CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM....1539
A-6 FAILURE CODE [21] ABNORMALITY IN GEAR SHIFT LEVER SIGNAL SYSTEM....1540
A-7 FAILURE CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM....1541
A-8 FAILURE CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL ....1542
A-9 ABNORMALITY IN KICK-DOWN SWITCH SYSTEM....1543
A-10 ABNORMALITY IN TRANSMISSION CUT-OFF SIGNAL SYSTEM....1544
A-11 ABNORMALITY IN NEUTRALIZER RELAY SIGNAL SYSTEM....1545
A-12 ABNORMALITY IN ALARM BUZZER SIGNAL SYSTEM....1546
A-13 ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM....1547
A-14 ABNORMALITY IN MODEL SELECTION HARNESS....1548
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (H MODE)....1549
H-1 MACHINE DOES NOT TRAVEL....1550
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES....1552
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR....1554
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR....1555
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH ....1556
H-6 STEERING WHEEL DOES NOT TURN....1557
H-7 STEERING IS HEAVY....1558
H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK....1559
H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING....1559
H-10 BRAKES DO NOT WORK BRAKING EFFECT IS POOR....1560
H-11 BRAKE IS NOT RELEASED, BRAKE DRAGS....1561
H-12 BOOM DOES NOT MOVE UP....1562
H-13 BOOM MOVES TOO SLOWLY OR LACKS LIFTING FORCE....1563
H-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT....1564
H-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)....1564
H-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM ....1564
H-17 BOOM SHAKES DURING OPERATION ....1565
H-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE....1565
H-19 BUCKET DOES NOT TILT BACK....1566
H-20 BUCKET MOVES TOO SLOWLY OR LACKS TILT-BACK FORCE....1567
H-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION ....1568
H-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER....1568
H-23 EXCESSIVE HYDRAULIC DRIFT OR BUCKET....1568
H-24 BUCKET SHAKES DURING TRAVEL WITH LOAD (WORK EQUIPMENT VALVE AT HOLD)....1569
H-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT....1569
H-26 BOOM AND BUCKET CONTROL LEVERS ARE HEAVY AND DO NOT MOVE SMOOTH....1570
30 DISASSEMBLY AND ASSEMBLY....1571
METHOD OF USING MANUAL....1573
PRECAUTIONS WHEN CARRYING OUT OPERATION....1574
SPECIAL TOOL LIST....1576
STARTING MOTOR....1578
REMOVAL AND INSTALLATION....1578
ALTERNATOR....1579
REMOVAL AND INSTALLATION....1579
FUEL INJECTION PUMP....1580
REMOVAL ....1580
INSTALLATION....1582
ENGINE OIL COOLER....1585
REMOVAL AND INSTALLATION....1585
WATER PUMP....1586
REMOVAL AND INSTALLATION....1586
NOZZLE HOLDER....1587
REMOVAL....1587
INSTALLATION....1588
THERMOSTAT....1589
REMOVAL AND INSTALLATION....1589
TURBOCHARGER....1590
REMOVAL AND INSTALLATION....1590
CYLINDER HEAD....1591
REMOVAL....1591
INSTALLATION....1596
RADIATOR....1599
REMOVAL ....1599
INSTALLATION....1600
ENGINE....1601
REMOVAL....1601
INSTALLATION....1602
TORQUE CONVERTER CHARGING PUMP....1605
REMOVAL AND INSTALLATION....1605
TORQUE CONVERTER, TRANSMISSION....1606
REMOVAL ....1606
INSTALLATION....1614
TORQUE CONVERTER....1615
DISASSEMBLY....1615
ASSEMBLY....1617
TRANSMISSION....1619
DISASSEMBLY....1619
ASSEMBLY....1630
CLUTCH PACK....1645
DISASSEMBLY ....1645
ASSEMBLY....1651
TRANSMISSION CONTROL VALVE....1665
REMOVAL....1665
INSTALLATION....1666
DISASSEMBLY ....1667
ASSEMBLY....1669
TRANSMISSION SOLENOID VALVE....1671
DISASSEMBLY AND ASSEMBLY....1671
TRANSMISSION ACCUMULATOR VALVE....1672
DISASSEMBLY ....1672
ASSEMBLY....1673
DRIVE SHAFT....1674
DISASSEMBLY....1674
ASSEMBLY....1676
FRONT AXLE....1678
REMOVAL....1678
INSTALLATION....1679
REAR AXLE....1680
REMOVAL....1680
INSTALLATION....1684
DIFFERENTIAL....1689
DISASSEMBLY....1689
ASSEMBLY....1693
AXLE HOUSING....1703
DISASSEMBLY ....1703
ASSEMBLY....1708
CENTER HINGE PIN....1716
REMOVAL....1716
INSTALLATION....1725
PRIORITY VALVE....1734
REMOVAL....1734
INSTALLATION....1735
STEERING VALVE....1736
REMOVAL....1736
INSTALLATION....1738
DISASSEMBLY ....1739
ASSEMBLY....1742
STEERING CYLINDER....1747
REMOVAL....1747
INSTALLATION....1748
BRAKE BOOSTER....1749
REMOVAL....1749
INSTALLATION....1751
DISASSEMBLY....1752
ASSEMBLY....1755
PARKING BRAKE....1760
REMOVAL....1760
INSTALLATION....1762
HYDRAULIC TANK....1763
REMOVAL....1763
INSTALLATION....1764
HYDRAULIC, STEERING PPC PUMP....1765
REMOVAL ....1765
INSTALLATION....1766
MAIN CONTROL VALVE....1767
REMOVAL ....1767
INSTALLATION....1769
DISASSEMBLY....1770
ASSEMBLY....1772
BUCKET CYLINDER....1774
REMOVAL ....1774
INSTALLATION....1775
BOOM CYLINDER....1776
REMOVAL....1776
INSTALLATION....1777
HYDRAULIC CYLINDER....1778
DISASSEMBLY....1778
ASSEMBLY....1780
WORK EQUIPMENT....1782
REMOVAL ....1782
INSTALLATION....1785
FUEL TANK....1788
REMOVAL ....1788
INSTALLATION....1789
COUNTERWEIGHT....1790
REMOVAL AND INSTALLATION....1790
INSTRUMENT PANEL....1791
REMOVAL AND INSTALLATION....1791
ENGINE HOOD ....1792
REMOVAL AND INSTALLATION....1792
40 MAINTENANCE STANDARD....1793
ENGINE MOUNT, TRANSMISSION MOUNT....1794
TORQUE CONVERTER, CHARGING PUMP....1795
TORQUE CONVERTER....1796
TRANSMISSION....1797
TRANSMISSION CONTROL VALVE....1809
ACCUMULATOR VALVE....1813
DRIVE SHAFT....1814
DIFFERENTIAL....1815
FINAL DRIVE....1818
AXLE MOUNT....1820
CENTER HINGE PIN....1821
STEERING COLUMN....1823
PRIORITY VALVE....1824
STEERING CYLINDER MOUNT....1825
BRAKE BOOSTER....1826
BRAKE....1827
PARKING BRAKE....1828
HYDRAULIC PUMP AND PPC PUMP....1829
MAIN CONTROL VALVE....1830
PPC VALVE....1836
STEERING CYLINDER, HYDRAULIC CYLINDER....1838
WORK EQUIPMENT LINKAGE....1839
BUCKET ....1841
BUCKET POSITIONER AND BOOM KICK-OUT....1842
Komatsu Wheel Loader WA120MC, WA120LMC Repair Service Manual
