Komatsu Wheel Loader WA120MC, WA120LMC Repair Service Manual

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Price: US$ 49.00

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

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