Komatsu WA120-3MC Avance Plus Wheel Loader Shop Manual SN A31001 and up – PDF DOWNLOAD

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Komatsu WA120-3MC Avance Plus Wheel Loader Shop Manual

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Komatsu WA120-3MC Avance Plus Wheel Loader Shop Manual

Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA120-3MC Avance Plus
Serial Number: A31001 and up
Book Code: CEBM005101
Language: English
Pages: 737
File Format: Portable Document Format (PDF)

KOMATSU WA120-3MC AVANCE PLUS WHEEL LOADER SHOP MANUAL SN A31001 AND UP – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu WA120-3MC Avance Plus Wheel Loader Shop Manual

FOREWORD
GENERAL :

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.

GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu WA120-3MC Avance Plus Wheel Loader Shop Manual

MAIN MENU.......................................................................................................  0
COVER...........................................................................................................  1
CONTENTS........................................................................................................  2
FOREWORD........................................................................................................ 11
	SAFETY...................................................................................................... 11
		SAFETY NOTICE........................................................................................... 11
			IMPORTANT SAFETY NOTICE............................................................................. 11
			GENERAL PRECAUTIONS................................................................................. 11
			PREPARATIONS FOR WORK............................................................................... 11
			PRECAUTIONS DURING WORK............................................................................. 11
	GENERAL..................................................................................................... 13
	HOW TO READ THE SHOP MANUAL................................................................................. 14
		VOLUMES................................................................................................. 14
		DISTRIBUTION AND UPDATING............................................................................... 14
		FILING METHOD........................................................................................... 14
		REVISED EDITION MARK.................................................................................... 14
		REVISIONS............................................................................................... 14
		SYMBOLS................................................................................................. 14
	HOISTING INSTRUCTIONS....................................................................................... 15
		HOISTING................................................................................................ 15
		WIRE ROPES.............................................................................................. 15
	COATING MATERIALS........................................................................................... 16
	STANDARD TIGHTENING TORQUE.................................................................................. 18
		STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS............................................................ 18
		TIGHTENING TORQUE OF HOSE NUTS.......................................................................... 19
		TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................................. 19
		TIGHTENING TORQUE FOR FLARED NUTS....................................................................... 19
	ELECTRIC WIRE CODE.......................................................................................... 20
		CLASSIFICATION BY THICKNESS............................................................................. 20
		CLASSIFICATION BY COLOR AND CODE........................................................................ 20
	CONVERSION TABLES........................................................................................... 21
		METHOD OF USING THE CONVERSION TABLE.................................................................... 21
01 GENERAL...................................................................................................... 27
	SPECIFICATION DRAWING....................................................................................... 28
	SPECIFICATIONS.............................................................................................. 29
	WEIGHT TABLE................................................................................................ 32
	LIST OF LUBRICANT AND WATER................................................................................. 34
	ENGINE OIL SPECIFICATIONS................................................................................... 35
		NORMAL OPERATION........................................................................................ 35
		ARCTIC OPERATION........................................................................................ 35
	DIESEL FUEL SPECIFICATIONS.................................................................................. 36
	COOLANT SPECIFICATIONS...................................................................................... 36
		GENERAL................................................................................................. 36
		WATER................................................................................................... 36
		ANTIFREEZE.............................................................................................. 37
		INHIBITORS/CONDITIONERS................................................................................. 39
10 STRUCTURE AND FUNCTION....................................................................................... 43
	POWER TRAIN................................................................................................. 47
	POWER TRAIN SYSTEM.......................................................................................... 48
	TORQUE CONVERTER, TRANSMISSION PIPING....................................................................... 50
	TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....................................................................... 52
		ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND..................................... 52
	TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...................................................................... 53
		ENGINE STOPPED.......................................................................................... 53
	TORQUE CONVERTER............................................................................................ 54
	TORQUE CONVERTER OIL FILTER................................................................................. 56
	TRANSMISSION................................................................................................ 58
		CLUTCH.................................................................................................. 60
			REVERSE 1ST CLUTCH.................................................................................. 60
			FORWARD, 2ND CLUTCH................................................................................. 61
			3RD, 4TH CLUTCH..................................................................................... 61
			FORWARD 1ST......................................................................................... 63
			FORWARD 2ND......................................................................................... 64
			FORWARD 3RD......................................................................................... 65
			FORWARD 4TH......................................................................................... 66
			REVERSE 1ST......................................................................................... 67
	TRANSMISSION CONTROL VALVE.................................................................................. 68
		UPPER VALVE............................................................................................. 69
		LOWER VALVE............................................................................................. 70
		TRANSMISSION SOLENOID VALVE............................................................................. 71
		TORQUE CONVERTER OUTLET PORT VALVE...................................................................... 72
		PILOT REDUCING VALVE.................................................................................... 73
		TRANSMISSION SOLENOID VALVE............................................................................. 74
		PRIORITY VALVE.......................................................................................... 75
		MAIN REGULATOR VALVE.................................................................................... 76
		QUICK RETURN VALVE...................................................................................... 77
		MODULATION FILL VALVE................................................................................... 81
		DIRECTIONAL SELECTOR SPOOL.............................................................................. 83
		EMERGENCY MANUAL SPOOL.................................................................................. 84
		OPERATION OF FORWARD 1ST................................................................................ 86
		ACCUMULATOR VALVE....................................................................................... 88
	TRANSMISSION CONTROL........................................................................................ 90
	DRIVE SHAFT................................................................................................. 91
	AXLE........................................................................................................ 92
		FRONT AXLE.............................................................................................. 92
		FRONT DIFFERENTIAL...................................................................................... 93
		REAR AXLE............................................................................................... 94
		REAR DIFFERENTIAL....................................................................................... 95
		TORQUE PROPORTIONING DIFFERENTIAL....................................................................... 97
	FINAL DRIVE................................................................................................. 98
	AXLE MOUNT..................................................................................................100
	CENTER HINGE PIN............................................................................................102
	STEERING PIPING.............................................................................................103
	STEERING COLUMN.............................................................................................104
	PRIORITY VALVE..............................................................................................105
	STEERING VALVE (ORBIT-ROLL).................................................................................108
		CONNECTION BETWEEN HAND PUMP AND SLEEVE.................................................................114
	BRAKE.......................................................................................................116
		BRAKE PIPING............................................................................................116
		BRAKE CONTROL...........................................................................................117
		BRAKE BOOSTER...........................................................................................118
		BRAKE...................................................................................................121
		PARKING BRAKE CONTROL...................................................................................123
		PARKING BRAKE...........................................................................................124
	HYDRAULIC...................................................................................................126
		HYDRAULIC PIPING........................................................................................126
		WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.................................................................128
			ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD".........................................................128
		WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................129
		HYDRAULIC TANK..........................................................................................131
			OIL FILTER BYPASS VALVE.............................................................................132
			BREATHER............................................................................................133
		PPC VALVE...............................................................................................134
		PPC RELIEF VALVE........................................................................................140
		ACCUMULATOR.............................................................................................141
			FOR PPC VALVE.......................................................................................141
		MAIN CONTROL VALVE......................................................................................142
			2-SPOOL.............................................................................................142
			3-SPOOL.............................................................................................144
			RELIEF VALVE........................................................................................146
			SAFETY VALVE (WITH SUCTION).........................................................................147
			SUCTION VALVE.......................................................................................148
			BOOM AND BUCKET SPOOL AT NEUTRAL POSITION...........................................................149
			BOOM SPOOL AT RAISE POSITION........................................................................150
			BOOM SPOOL AT LOWER POSITION........................................................................151
			BOOM SPOOL AT FLOAT POSITION........................................................................152
			BUCKET SPOOL AT TILT BACK POSITION..................................................................153
			BUCKET SPOOL AT DUMP POSITION.......................................................................154
	WORK EQUIPMENT..............................................................................................155
		WORK EQUIPMENT LEVER LINKAGE............................................................................155
		WORK EQUIPMENT LINKAGE..................................................................................156
		BUCKET..................................................................................................158
		BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................159
			BUCKET POSITIONER...................................................................................160
			BOOM KICK-OUT.......................................................................................160
			PROXIMITY SWITCH....................................................................................161
	ROPS CAB....................................................................................................163
	AIR CONDITIONER.............................................................................................164
		AIR CONDITIONER AND HEATER PIPING.......................................................................164
		AIR CONDITIONER AND HEATER ELECTRICAL DIAGRAM...........................................................164
	ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)..............................................................165
		ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM...........................................................166
	CENTRAL PANEL...............................................................................................168
	SENSORS.....................................................................................................169
		ENGINE OIL PRESSURE.....................................................................................169
		BRAKE OIL LEVEL.........................................................................................169
		ENGINE SPEED SENSOR.....................................................................................170
	ENGINE......................................................................................................171
		ENGINE STARTING CIRCUIT.................................................................................171
		ENGINE STOP CIRCUIT.....................................................................................172
	AUTOMATIC PREHEATING CIRCUIT................................................................................173
		QUICK HEATING SYSTEM (QHS)..............................................................................173
		QHS CONTROLLER..........................................................................................175
		HEATER RELAY............................................................................................175
		RIBBON HEATER...........................................................................................176
		QHS WATER TEMPERATURE SENSOR............................................................................176
	TRANSMISSION AUTO-SHIFT CONTROL.............................................................................177
	TRANSMISSION AUTO-SHIFT CONTROL SYSTEM......................................................................178
		SHIFT CONTROL SYSTEM FUNCTION...........................................................................179
			INPUT SIGNALS.......................................................................................179
			OUTPUT SIGNALS......................................................................................180
			SHIFT CHARACTERISTICS...............................................................................181
			SAFETY FUNCTION.....................................................................................185
		TROUBLESHOOTING.........................................................................................185
		TRANSMISSION CONTROLLER.................................................................................186
			CONNECTOR SIGNALS...................................................................................186
		COMBINATION SWITCH......................................................................................187
		TRANSMISSION CUT-OFF FUNCTION...........................................................................188
		PARKING BRAKE FUNCTION..................................................................................190
		KICK-DOWN SWITCH........................................................................................191
			KICK-DOWN ELECTRICAL CIRCUIT........................................................................192
			KICK-DOWN SWITCH OPERATED...........................................................................193
			KICK-DOWN SWITCH ACTUATION - CANCELED (1)...........................................................194
			KICK-DOWN SWITCH ACTUATION - CANCELED (2)...........................................................195
	ELECTRICAL WIRING ILLUSTRATION..............................................................................197
	ELECTRICAL WIRING DIAGRAM (1/4).............................................................................199
	ELECTRICAL WIRING DIAGRAM (2/4).............................................................................201
	ELECTRICAL WIRING DIAGRAM (3/4).............................................................................203
	ELECTRICAL WIRING DIAGRAM (4/4).............................................................................205
20 TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................207
	STANDARD VALUE TABLE........................................................................................211
		ENGINE TABLE - IN CHASSIS...............................................................................211
		CHASSIS TABLE...........................................................................................212
	SERVICE TOOLS TABLE.........................................................................................218
	ENGINE COMPONENTS...........................................................................................220
		ADJUSTING ENGINE STOP MOTOR CABLE.......................................................................220
		ADJUSTING ENGINE STOP SOLENOID..........................................................................220
		MEASURING AND ADJUSTING VALVE CLEARANCE.................................................................220
		MEASURING BLOW-BY PRESSURE..............................................................................220
		MEASURING COMPRESSION PRESSURE..........................................................................220
		MEASURING COOLANT TEMPERATURE...........................................................................220
		MEASURING ENGINE LUBRICATING OIL PRESSURE...............................................................220
		MEASURING ENGINE SPEEDS.................................................................................220
		MEASURING EXHAUST COLOR.................................................................................220
		MEASURING EXHAUST GAS TEMPERATURE.......................................................................220
		MEASURING FUEL FILTER INLET RESTRICTION.................................................................220
		TEST AND ADJUSTING FAN BELT TENSION.....................................................................220
		TEST AND ADJUSTING FUEL INJECTION TIMING................................................................220
	ACCELERATOR PEDAL...........................................................................................221
		OPERATING FORCE.........................................................................................221
		OPERATING ANGLE.........................................................................................222
	SPEED LEVER.................................................................................................223
		OPERATING FORCE.........................................................................................223
		TRAVEL..................................................................................................223
	STALL SPEEDS................................................................................................224
		TORQUE CONVERTER STALL SPEED............................................................................224
		HYDRAULIC STALL SPEED...................................................................................225
		FULL STALL SPEED........................................................................................225
	TORQUE CONVERTER OIL PRESSURE...............................................................................226
	TRANSMISSION OIL PRESSURE...................................................................................226
	EMERGENCY MANUAL SPOOL......................................................................................228
		OPERATION...............................................................................................228
	STEERING WHEEL..............................................................................................230
		PLAY....................................................................................................230
		OPERATING FORCE.........................................................................................230
		OPERATING TIME..........................................................................................231
	STEERING OIL PRESSURE.......................................................................................232
		METHOD OF MEASURING MAIN RELIEF PRESSURE................................................................232
		METHOD OF ADJUSTING MAIN RELIEF PRESSURE................................................................233
	BRAKE.......................................................................................................234
		BRAKE PEDAL.............................................................................................234
			OPERATING FORCE.....................................................................................234
			TRAVEL..............................................................................................234
		BRAKE PEDAL LINKAGE.....................................................................................235
			TESTING.............................................................................................235
			ADJUSTING...........................................................................................235
		BRAKE PERFORMANCE.......................................................................................237
		BRAKE OIL PRESSURE......................................................................................238
		BRAKE DISC WEAR.........................................................................................239
		BLEEDING AIR............................................................................................240
	PARKING BRAKE...............................................................................................241
		PARKING BRAKE PERFORMANCE...............................................................................241
		PARKING BRAKE LINKAGE...................................................................................242
		DISC WEAR...............................................................................................243
			TESTING.............................................................................................243
			MEASURING...........................................................................................244
	WORK EQUIPMENT..............................................................................................245
		CONTROL LEVER...........................................................................................245
		PPC VALVE...............................................................................................246
			MEASURING PRESSURE..................................................................................246
		WORK EQUIPMENT HYDRAULIC PRESSURE.......................................................................248
		WORK EQUIPMENT MEASUREMENT..............................................................................250
			HYDRAULIC DRIFT WORK EQUIPMENT......................................................................251
		BUCKET POSITIONER.......................................................................................252
			TESTING.............................................................................................252
			ADJUSTING...........................................................................................252
		BOOM KICK-OUT...........................................................................................253
			TESTING.............................................................................................253
			ADJUSTING...........................................................................................253
		PROXIMITY SWITCH ACTUATION PILOt LAMP (RED).............................................................254
	TROUBLESHOOTING GENERAL.....................................................................................255
		POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................257
		SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................259
		PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...............................................................260
			PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT........................................................260
			HANDLING CONTROL BOX................................................................................265
			POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT................................................266
		CHECKS BEFORE TROUBLESHOOTING...........................................................................268
		JUDGEMENT OF POWER TRAIN................................................................................269
		PRECAUTIONS WHEN TROUBLESHOOTING........................................................................270
			SAFETY..............................................................................................270
			METHODS FOR TROUBLESHOOTING.........................................................................270
			PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.....272
		PREVENTING RECURRENCE OF TROUBLE........................................................................273
			HYDRAULIC EQUIPMENT.................................................................................273
				OIL CHECKS......................................................................................273
				CLEANING FRAGMENTS OF DAMAGED PARTS.............................................................273
		METHOD OF USING TROUBLESHOOTING CHARTS..................................................................274
			CATEGORY OF TROUBLESHOOTING CODE NUMBER.............................................................274
			METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.................................274
		METHOD OF USING MATRIX TROUBLESHOOTING TABLES...........................................................276
		METHOD OF USING ENGINE RELATED CHARTS...................................................................278
	TROUBLESHOOTING ELECTRICAL CONNECTORS.......................................................................283
		CONNECTOR TYPES.........................................................................................284
		CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..............................................................287
		ELECTRICAL CIRCUIT DIAGRAMS.............................................................................295
			ENGINE START, STOP SYSTEM...........................................................................295
			PREHEATING SYSTEM...................................................................................296
	TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE)..................................................297
		OUTLINE.................................................................................................298
			FUNCTION............................................................................................298
			TROUBLESHOOTING.....................................................................................298
			FAILURE CODE TABLE..................................................................................298
			TABLE OF TROUBLESHOOTING MODES AND CAUSES...........................................................299
		A-1 TROUBLESHOOTING CODE [12]...........................................................................300
			F SOLENOID SIGNAL SYSTEM............................................................................300
		A-2 TROUBLESHOOTING CODE [13]...........................................................................301
			R SOLENOID SIGNAL SYSTEM............................................................................301
		A-3 TROUBLESHOOTING CODE [14]...........................................................................302
			ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...........................................................302
		A-4 TROUBLESHOOTING CODE [16]...........................................................................303
			ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.........................................................303
		A-5 TROUBLESHOOTING CODE [20]...........................................................................304
			ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM......................................................304
		A-6 TROUBLESHOOTING CODE [21]...........................................................................305
			ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM............................................................305
		A-7 TROUBLESHOOTING CODE [22]...........................................................................306
			ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...........................................................306
		A-8 TROUBLESHOOTING CODE [23]...........................................................................307
			ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM...........................................................307
		A-10 KICK-DOWN SWITCH SYSTEM............................................................................308
		A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM.................................................................309
		A-12 NEUTRALIZER RELAY SIGNAL SYSTEM....................................................................310
		A-13 BUZZER SIGNAL SYSTEM...............................................................................311
		A-15 CONTROLLER POWER SOURCE SYSTEM.....................................................................312
	TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM D-MODE - (ECSS).................................313
		ECSS - ELECTRICAL / HYDRAULIC SCHEMATIC.................................................................314
		ECSS - WORKING CHART....................................................................................314
		ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...............................................................315
			INSPECTION / ADJUSTMENT.............................................................................315
	TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...............................................................317
		E-1 ENGINE DOES NOT START...............................................................................318
			A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START.............................318
			B. CHECK FUEL SHUT-OFF SOLENOID.....................................................................320
		E-2 ENGINE DOES NOT STOP................................................................................321
		E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR.......322
		E-10 PREHEATING IS NOT CARRIED OUT......................................................................324
		E-11 PREHEATING REMAINS ACTUATED........................................................................326
	TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...................................................................329
		S-1 STARTING PERFORMANCE IS POOR........................................................................331
		S-2 ENGINE DOES NOT START...............................................................................332
			A. ENGINE DOES NOT TURN.............................................................................332
			B. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT........................................................333
			C. EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START..................................................334
		S-3 ENGINE DOES NOT PICK UP SMOOTHLY....................................................................335
		S-4 ENGINE STOPS DURING OPERATIONS......................................................................336
		S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................337
		S-6 ENGINE LACKS OUTPUT (NO POWER)......................................................................338
		S-7 EXHAUST GAS IS BLACK................................................................................339
		S-8 OIL CONSUMPTION IS EXCESSIVE........................................................................340
		S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................341
		S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................342
		S-11 OIL IN COOLING WATER...............................................................................343
		S-12 OIL PRESSURE LAMP LIGHTS UP........................................................................344
		S-13 OIL LEVEL RISES....................................................................................345
		S-14 WATER TEMPERATURE BECOMES TOO HIGH.................................................................346
		S-15 ABNORMAL NOISE IS MADE.............................................................................347
		S-16 VIBRATION IS EXCESSIVE.............................................................................348
	TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE)..................................................349
		POWER TRAIN.............................................................................................351
			T-1 MACHINE DOES NOT START..........................................................................351
			T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES............................352
			T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR..........................................354
			T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.......................................355
			T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH........................................................356
		STEERING SYSTEM.........................................................................................357
			T-6 STEERING WHEEL DOES NOT TURN....................................................................357
			T-7 STEERING IS HEAVY...............................................................................358
			T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK...............................................359
			T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...........................................360
			T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT.............................................360
			T-11 ECESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT.................360
		BRAKE SYSTEM............................................................................................361
			T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...................................................361
			T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS.............................................................362
		WORK EQUIPMENT..........................................................................................363
			T-14 BOOM DOES NOT RISE.............................................................................363
			T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER..............................................364
			T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.......................................365
			T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).....................................365
			T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM..............................................................365
			T-19 BOOM SHAKES DURING OPERATION...................................................................366
			T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.......................366
			T-21 BUCKET DOES NOT TILT BACK......................................................................367
			T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER...............................................368
			T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION........................................369
			T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...................................................369
			T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET............................................................369
			T-26 BUCKET SHAKES DURING LOADING OPERATION.........................................................370
			T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT......................370
			T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY..................................371
	TROUBLESHOOTING OF AIRCONDITIONER...........................................................................373
		SERVICE TOOLS...........................................................................................375
			GAUGE MANIFOLD......................................................................................375
				STRUCTURE AND HANDLING OF GAUGE MANIFOLD........................................................376
				CHARGING HOSES..................................................................................378
			GAS LEAK DETECTOR...................................................................................379
				HALIDE TORCH LEAK DETECTOR......................................................................379
				ELECTRIC LEAK TESTER............................................................................381
			VALVE FOR SERVICE CANS..............................................................................383
		MAINTENANCE PROCEDURE...................................................................................384
			PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING......................................................384
				PROHIBITED WORK.................................................................................384
				OTHER PRECAUTIONS...............................................................................384
			BLEEDING AIR FROM REFRIGERATION CIRCUIT.............................................................386
				PURPOSE.........................................................................................386
				CONNECTING GAUGE MANIFOLD.......................................................................386
				EVACUATION......................................................................................387
				AIR-TIGHTNESS CHECK.............................................................................387
				GAS-LEAK CHECK..................................................................................388
				EVACUATION (REPEATING)..........................................................................388
			CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT.................................................389
				CHARGING FROM THE HIGH-PRESSURE SIDE............................................................389
				CHARGING FROM THE LOW PRESSURE SIDE.............................................................390
				WHEN THE AMBIENT TEMPERATURE IS LOW.............................................................391
				WHEN THE AMBIENT TEMPERATURE IS HIGH............................................................391
			REPLACING SERVICE CANS..............................................................................392
			CHECKING THE AMOUNT OF REFRIGERANT..................................................................392
			REMOVAL OF GAUGE MANIFOLD...........................................................................394
			DISCHARGING THE REFRIGERANT.........................................................................394
			DAILY CHECKS........................................................................................395
				CHECK REFRIGERANT LEVEL.........................................................................395
				CLEANING THE CONDENSER..........................................................................395
			CHECKING THE V-BELT.................................................................................395
			CHECKING OIL LEVEL..................................................................................396
				PROCEDURE FOR CHECKING..........................................................................396
				PROCEDURE FOR CHECKING OIL LEVEL................................................................396
				ADDING AND REMOVING OIL.........................................................................397
				ADDING OIL BY EVACUATION........................................................................397
		TROUBLESHOOTING.........................................................................................398
			VISUAL AND ACOUSTICAL CHECKS........................................................................398
			DEFECTIVE COOLING...................................................................................399
			TROUBLESHOOTING TABLE...............................................................................401
			DEFECTIVE HEATING...................................................................................403
			TROUBLESHOOTING USING GAUGE MANIFOLD................................................................404
				PREPARATIONS BEFORE MEASURING...................................................................404
				INSUFFICIENT REFRIGERANT........................................................................404
				EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER......................................405
				AIR INSIDE REFRIGERATION SYSTEM.................................................................406
				MOISTURE IN REFRIGERATING SYSTEM................................................................407
				REFRIGERANT DOES NOT CIRCULATE..................................................................408
				FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE...............409
				DEFECTIVE COMPRESSION BY COMPRESSOR.............................................................410
30 DISASSEMBLY AND ASSEMBLY.....................................................................................411
	METHOD OF USING MANUAL......................................................................................415
	PRECAUTIONS DURING OPERATION................................................................................416
		PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK..............................................................416
		PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.........................................................417
		PRECAUTIONS WHEN COMPLETING THE OPERATIONS..............................................................418
		OTHER PRECAUTIONS.......................................................................................418
	SPECIAL TOOL LIST...........................................................................................419
	ENGINE COMPONENTS...........................................................................................421
		ALTERNATOR ASSEMBLY.....................................................................................421
		CYLINDER HEAD ASSEMBLY..................................................................................421
		ENGINE OIL COOLER ASSEMBLY..............................................................................421
		FUEL INJECTION PUMP ASSEMBLY............................................................................421
		NOZZLE HOLDER ASSEMBLY..................................................................................421
		STARTING MOTOR ASSEMBLY.................................................................................421
		THERMOSTAT ASSEMBLY.....................................................................................421
		TURBOCHARGER ASSEMBLY...................................................................................421
		WATER PUMP ASSEMBLY.....................................................................................421
	COVERS AND LADDER...........................................................................................422
		REMOVAL.................................................................................................422
		INSTALLATION............................................................................................423
	ENGINE HOOD.................................................................................................424
		REMOVAL.................................................................................................424
		INSTALLATION............................................................................................425
	RADIATOR....................................................................................................426
		REMOVAL.................................................................................................426
		INSTALLATION............................................................................................429
	ENGINE......................................................................................................430
		REMOVAL.................................................................................................430
		INSTALLATION............................................................................................437
	EXHAUST MUFFLER.............................................................................................438
		REMOVAL.................................................................................................438
		INSTALLATION............................................................................................438
	AIR CLEANER.................................................................................................439
		REMOVAL.................................................................................................439
		INSTALLATION............................................................................................439
	TORQUE CONVERTER CHARGING PUMP..............................................................................440
		REMOVAL.................................................................................................440
		INSTALLATION............................................................................................440
	TORQUE CONVERTER, TRANSMISSION..............................................................................441
		REMOVAL.................................................................................................441
		INSTALLATION............................................................................................448
	TORQUE CONVERTER............................................................................................450
		DISASSEMBLY.............................................................................................450
		ASSEMBLY................................................................................................452
	TRANSMISSION................................................................................................454
		DISASSEMBLY.............................................................................................454
			DISASSEMBLY OF PARKING BRAKE........................................................................463
			ASSEMBLY OF PARKING BRAKE...........................................................................465
		ASSEMBLY................................................................................................468
	TRANSMISSION CLUTCH PACK....................................................................................480
		DISASSEMBLY.............................................................................................480
			1ST, REVERSE CLUTCH.................................................................................480
			FORWARD, 2ND CLUTCH PACK............................................................................482
			3RD, 4TH CLUTCH PACK................................................................................484
		ASSEMBLY................................................................................................486
			1ST, REVERSE CLUTCH.................................................................................486
			FORWARD, 2ND CLUTCH.................................................................................491
			3RD, 4TH CLUTCH.....................................................................................495
	TRANSMISSION CONTROL VALVE..................................................................................500
		REMOVAL.................................................................................................500
		INSTALLATION............................................................................................501
		DISASSEMBLY.............................................................................................502
		ASSEMBLY................................................................................................504
	TRANSMISSION SOLENOID VALVE.................................................................................507
		DISASSEMBLY.............................................................................................507
		ASSEMBLY................................................................................................508
	TRANSMISSION ACCUMULATOR VALVE..............................................................................509
		DISASSEMBLY.............................................................................................509
		ASSEMBLY................................................................................................510
	DRIVE SHAFT.................................................................................................511
		DISASSEMBLY.............................................................................................511
		ASSEMBLY................................................................................................512
	FRONT AXLE..................................................................................................513
		REMOVAL.................................................................................................513
		INSTALLATION............................................................................................514
	REAR AXLE...................................................................................................515
		REMOVAL.................................................................................................515
		INSTALLATION............................................................................................519
	DIFFERENTIAL................................................................................................524
		DISASSEMBLY.............................................................................................524
		ASSEMBLY................................................................................................528
	AXLE HOUSING................................................................................................538
		DISASSEMBLY.............................................................................................538
		ASSEMBLY................................................................................................543
	CENTER HINGE PIN............................................................................................551
		REMOVAL.................................................................................................551
		INSTALLATION............................................................................................559
	PRIORITY VALVE..............................................................................................568
		REMOVAL.................................................................................................568
		INSTALLATION............................................................................................569
	STEERING VALVE..............................................................................................570
		REMOVAL.................................................................................................570
		INSTALLATION............................................................................................572
		DISASSEMBLY.............................................................................................573
			DISASSEMBLY OF ROTOR................................................................................573
			DISASSEMBLY OF CONTROL SIDE.........................................................................574
		ASSEMBLY................................................................................................576
			ASSEMBLY OF CONTROL SIDE............................................................................576
			ASSEMBLY OF ROTOR...................................................................................578
	MAIN CONTROL VALVE..........................................................................................581
		REMOVAL.................................................................................................581
		INSTALLATION............................................................................................583
		DISASSEMBLY.............................................................................................584
		ASSEMBLY................................................................................................586
	PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES.............................................................588
	PPC VALVE...................................................................................................590
		REMOVAL.................................................................................................590
		INSTALLATION............................................................................................591
	STEERING CYLINDER...........................................................................................592
		REMOVAL.................................................................................................592
		INSTALLATION............................................................................................594
	BRAKE BOOSTER...............................................................................................595
		REMOVAL.................................................................................................595
		INSTALLATION............................................................................................597
		DISASSEMBLY.............................................................................................598
		ASSEMBLY................................................................................................601
	PARKING BRAKE...............................................................................................606
		REMOVAL.................................................................................................606
		INSTALLATION............................................................................................608
	HYDRAULIC TANK..............................................................................................610
		REMOVAL.................................................................................................610
		INSTALLATION............................................................................................611
	HYDRAULIC FILTER............................................................................................612
		REMOVAL.................................................................................................612
		INSTALLATION............................................................................................612
	STEERING PUMP...............................................................................................613
		REMOVAL.................................................................................................613
		INSTALLATION............................................................................................614
	BUCKET CYLINDER.............................................................................................615
		REMOVAL.................................................................................................615
		INSTALLATION............................................................................................616
	BOOM CYLINDER...............................................................................................617
		REMOVAL.................................................................................................617
		INSTALLATION............................................................................................618
	HYDRAULIC CYLINDER..........................................................................................619
		DISASSEMBLY.............................................................................................619
		ASSEMBLY................................................................................................621
	ECSS SYSTEM.................................................................................................624
		ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...............................................................624
		ECSS SOLENOID VALVE.....................................................................................625
			REMOVAL.............................................................................................625
			INSTALLATION........................................................................................625
		ECSS CONTROL VALVE......................................................................................626
			REMOVAL.............................................................................................626
			INSTALLATION........................................................................................626
	WORK EQUIPMENT..............................................................................................627
		REMOVAL.................................................................................................627
		INSTALLATION............................................................................................630
	FUEL TANK...................................................................................................633
		REMOVAL.................................................................................................633
		INSTALLATION............................................................................................634
	COUNTERWEIGHT...............................................................................................635
		REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS................................................................635
		INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS...........................................................635
		REMOVAL OF REAR COUNTERWEIGHT...........................................................................635
		INSTALLATION OF REAR COUNTERWEIGHT......................................................................636
	INSTRUMENT PANEL............................................................................................637
		REMOVAL.................................................................................................637
		INSTALLATION............................................................................................637
	AIR CONDITIONING............................................................................................638
		AIR CONDITIONER UNIT....................................................................................638
			REMOVAL.............................................................................................638
			INSTALLATION........................................................................................644
		AIR CONDITIONER CONDENSER...............................................................................645
			REMOVAL.............................................................................................645
			INSTALLATION........................................................................................646
		DRYER RECEIVER..........................................................................................648
			REMOVAL.............................................................................................648
			INSTALLATION........................................................................................648
		AIR CONDITIONER COMPRESSOR..............................................................................650
			REMOVAL.............................................................................................650
			INSTALLATION........................................................................................651
40 MAINTENANCE STANDARD.........................................................................................654
	ENGINE MOUNT, TRANSMISSION MOUNT............................................................................655
	TORQUE CONVERTER CHARGING PUMP..............................................................................657
	TORQUE CONVERTER............................................................................................659
	TRANSMISSION................................................................................................661
		TRANSMISSION (1/3)......................................................................................661
		TRANSMISSION (2/3)......................................................................................665
		TRANSMISSION (3/3)......................................................................................669
		REVERSE, 1ST CLUTCH.....................................................................................671
		FORWARD, 2ND CLUTCH.....................................................................................673
		3RD, 4TH CLUTCH.........................................................................................675
	TRANSMISSION CONTROL VALVE..................................................................................677
		UPPER VALVE.............................................................................................677
		LOWER VALVE.............................................................................................679
		SOLENOID VALVE..........................................................................................681
	ACCUMULATOR VALVE...........................................................................................683
	DRIVE SHAFT.................................................................................................685
	DIFFERENTIAL................................................................................................687
		DIFERENTIAL (1/2).......................................................................................687
		DIFFERENTIAL (2/2)......................................................................................689
	FINAL DRIVE.................................................................................................691
	AXLE MOUNT..................................................................................................693
	ADDITIONAL COUNTERWEIGHT....................................................................................695
	CENTER HINGE PIN............................................................................................697
	STEERING COLUMN.............................................................................................699
	PRIORITY VALVE..............................................................................................701
	STEERING CYLINDER MOUNT.....................................................................................702
	BRAKE BOOSTER...............................................................................................703
	BRAKE.......................................................................................................705
	PARKING BRAKE...............................................................................................706
	HYDRAULIC PUMP, SAL45+SB(1)8................................................................................707
	MAIN CONTROL VALVE..........................................................................................708
		2-SPOOL VALVE...........................................................................................708
		3-SPOOL VALVE...........................................................................................711
	PPC VALVE...................................................................................................714
	HYDRAULIC CYLINDER..........................................................................................716
	WORK EQUIPMENT LINKAGE......................................................................................717
	BUCKET......................................................................................................719
	BUCKET POSITIONER AND BOOM KICK-OUT.........................................................................721
90 OTHERS.......................................................................................................724
	AIR CONDITIONING AND HEATER ELETRICAL DIAGRAM...............................................................726
	ELECTRICAL WIRING DIAGRAM...................................................................................728
		DIAGRAM (1/4)...........................................................................................728
		DIAGRAM (2/4)...........................................................................................730
		DIAGRAM (3/4)...........................................................................................732
		DIAGRAM (4/4)...........................................................................................734

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