Komatsu Galeo WA450-6 WA480-6 (KA SPEC.) Wheel Loader Shop Manual SEN00809-04 PDF

Description

Komatsu Galeo WA450-6 WA480-6 (KA SPEC.) Wheel Loader Shop Manual SEN00809-04  – PDF DOWNLOAD

FILE DETAILS:

Komatsu Galeo WA450-6 WA480-6 (KA SPEC.) Wheel Loader Shop Manual SEN00809-04  – PDF DOWNLOAD

Language : English
Pages : 1596
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Galeo WA450-6 WA480-6 (KA SPEC.) Wheel Loader Shop Manual SEN00809-04  – PDF DOWNLOAD

SERIAL NUMBERS

• WA450-6 66001 and up
  WA480-6 85001 and up

MAIN MENU 0
COVER PAGE . 1
00 Index and foreword 3
Index 3
Composition of shop manual . 4
Table of contents 6
Foreword and general information . 21
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling electric equipment and hydraulic component 31
Precautions when carrying out operation 46
Method of disassembling and connecting push-pull type coupler 49
Standard tightening torque table . 52
Conversion table . 56
01 Specification . 63
Specification and technical data . 63
Specification and technical data . 65
Specification dimension drawing 65
Specifications . 66
Weight table . 70
Table of fuel, coolant and lubricants 72
10 Structure, function and maintenance standard 75
Engine and cooling system 75
Engine and cooling system 76
Engine mount and transmission mount 76
Cooling system . 77
Cooling fan pump . 78
Cooling fan motor 86
Power train 93
Power train 95
Power train 95
Power train system diagram . 96
Drive shaft 98
Power train piping diagram . 99
Torque converter . 100
Transmission . 108
Flow control valve . 125
Transmission control valve . 126
ECMV . 128
Main relief valve and torque converter relief valve 134
Axle . 136
Differential . 140
Limited slip differential 145
Final drive 152
Steering system 161
Steering system 162
Steering piping diagram 162
Steering column 163
Steering pump 164
Steering valve . 177
Orbit-roll valve . 192
Stop valve . 196
Steering relief valve 197
Steering cylinder 198
Emergency steering motor . 200
Emergency steering pump 201
Brake system . 203
Brake system . 204
Brake piping diagram . 204
Charge valve . 205
Brake valve 212
Accumulator (for brake) 217
Slack adjuster . 218
Brake 220
Parking brake control 225
Parking brake 226
Parking brake solenoid valve . 228
Emergency parking brake release valve 230
Undercarriage and frame 233
Undercarriage and frame 234
Tires 238
Hydraulic system, Part 1 . 241
Hydraulic system, Part 1 . 242
Hydraulic piping diagram . 242
Work equipment control lever linkage . 245
Hydraulic tank . 246
Power train pump . 248
Work equipment pump 250
Work equipment control valve . 270
CLSS . 281
Each function and operation of each valve 286
Hydraulic system, Part 2 . 301
Hydraulic system, Part 2 . 302
PPC valve 302
Accumulator (for PPC circuit) 308
Accumulator (for ECSS) . 309
Work equipment . 311
Work equipment . 312
Work equipment linkage . 312
Bucket . 315
Bucket positioner and boom kick-out 316
Work equipment cylinder 322
Cab and its attachments 325
Cab and its attachments 327
Cab 327
Air conditioner 328
Electrical system, Part 1 347
Electrical system, Part 1 348
Machine monitor system . 348
Machine monitor 353
Electrical system, Part 2 375
Electrical system, Part 2 376
Electrical system (Transmission controller system) . 376
Transmission controller 400
Electrical system, Part 3 403
Electrical system, Part 3 404
Electric transmission control 404
Combination switch . 406
Kickdown switch and hold switch 408
KOMTRAX terminal system 410
Engine starting circuit 412
Engine stopping circuit 414
Preheating circuit . 415
Engine power mode selector circuit . 416
Engine output derating function 417
Automatic warm-up function . 417
Parking brake circuit 418
Sensor . 420
20 Standard value table 429
Standard service value table . 430
Standard value table for engine 430
Standard value table for chassis . 431
30 Testing and adjusting . 441
Testing and adjusting, Part 1 441
Testing and adjusting, Part 1 443
Tools for testing, adjusting, and troubleshooting 443
Measuring engine speed . 446
Measuring exhaust gas color 448
Measuring exhaust temperature 449
Adjusting valve clearance 451
Measuring compression pressure . 453
Measuring blow-by pressure . 455
Measuring engine oil pressure 456
Measuring intake air (boost) pressure 458
Handling fuel system equipment . 459
Releasing residual pressure in fuel system . 459
Testing fuel pressure 460
Testing fuel return and leak amount 461
Bleeding air from fuel circuit . 464
Testing fuel circuit for leakage . 466
Handling of reduced cylinder mode operation 467
Handling of no injection cranking operation 467
Handling controller voltage circuit 468
Testing and adjusting air conditioner compressor belt tension 471
Testing and adjusting alternator belt tension 472
Adjusting transmission speed sensor 473
Measuring directional lever 475
Measuring and adjusting power train oil pressure . 476
Procedure for flushing torque converter and transmission hydraulic circuit . 491
Method of moving machine when transmission valve is broken . 492
Testing and adjusting steering stop valve 495
Testing and adjusting steering wheel . 497
Testing steering oil pressure 499
Bleeding air from steering circuit . 502
Testing and adjusting, Part 2 505
Testing and adjusting, Part 2 507
Testing hydraulic drive fan 507
Bleeding air from hydraulic drive fan circuit 509
Measuring brake pedal 511
Measuring brake performance 513
Testing and adjusting accumulator charge pressure 514
Testing wheel brake oil pressure . 515
Measuring wear of wheel brake disc . 517
Bleeding air from wheel brake circuit 518
Releasing residual pressure in brake accumulator circuit . 519
Testing parking brake performance 519
Measuring parking brake oil pressure . 520
Manual release method for parking brake 523
Measuring and adjusting work equipment control lever . 524
Measuring and adjusting work equipment PPC oil pressure 525
Measuring and adjusting work equipment oil pressure 528
Bleeding air from work equipment circuit . 532
Releasing residual pressure in work equipment circuit 533
Testing and adjusting bucket positioner 534
Testing and adjusting boom kick out 536
Checking proximity switch operation pilot lamp . 537
Procedure for testing diodes . 538
Preparation work for troubleshooting for electrical system . 539
Starting KOMTRAX terminal operations . 542
Indicator lamps of KOMTRAX terminal 546
Adjusting machine monitor 549
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor . 550
Testing and adjusting, Part 3 553
Testing and adjusting, Part 3 554
Special functions of machine monitor (EMMS) 554
Pm-clinic inspection table . 617
40 Troubleshooting . 621
Failure code table and fuse locations 621
Failure code table and fuse locations 622
Failure code table . 622
Fuse locations . 634
General information on troubleshooting . 639
General information on troubleshooting . 640
Points to remember when troubleshooting 640
Sequence of events in troubleshooting 641
Testing before troubleshooting . 642
Classification and procedures of troubleshooting . 643
Information contained in troubleshooting table . 646
Connection table for connector pin numbers . 648
T-branch box and T-branch adapter table 671
Troubleshooting by failure code (Display of code), Part 1 675
Troubleshooting by failure code (Display of code), Part 1 677
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 677
Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 678
Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 680
Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 682
Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 684
Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 686
Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 688
Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 690
Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 692
Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 694
Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 696
Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 698
Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 700
Failure code [2F00MA] (Parking brake: Malfunction) . 702
Failure code [2G43ZG] (Accumulator: Low oil pressure) 704
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) . 706
Troubleshooting by failure code (Display of code), Part 2 709
Troubleshooting by failure code (Display of code), Part 2 712
Failure code [AA1ANX] (Air cleaner: Clogging) 712
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 714
Failure code [AB00MA] (Alternator: Malfunction) 716
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) . 718
Failure code [B@BAZK] (Engine oil: Low level) 721
Failure code [B@BCNS] (Coolant: Overheating) . 722
Failure code [B@BCZK] (Coolant: Low level) . 724
Failure code [B@C7NS] (Brake oil: Overheating) . 726
Failure code [b@CENS] (Torque converter oil: Overheating) 728
Failure code [B@CENS] (Torque converter oil: Overheating) 730
Failure code [B@HANS] (Hydraulic oil: Overheating) . 732
Failure code [CA111] (Abnormality in engine controller) 734
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 737
Failure code [CA122] (Charge pressure sensor high error) . 738
Failure code [CA123] (Charge pressure sensor low error) 740
Failure code [CA131] (Throttle sensor high error) 742
Failure code [CA132] (Throttle sensor low error) . 744
Failure code [CA135] (Engine oil pressure sensor high error) . 746
Failure code [CA141] (Engine oil pressure sensor low error) 748
Failure code [CA144] (Coolant sensor high error) . 750
Failure code [CA145] (Coolant sensor low error) 752
Failure code [CA153] (Charge temperature sensor high error) 754
Failure code [CA154] (Charge temperature sensor low error) . 756
Failure code [CA187] (Sensor power supply 2 low error) . 758
Failure code [CA221] (Atmospheric pressure sensor high error) 759
Failure code [CA222] (Atmospheric pressure sensor low error) . 761
Failure code [CA227] (Sensor power supply 2 high error) 762
Failure code [CA234] (Engine overspeed) 764
Failure code [CA238] (Ne speed sensor power supply error) 766
Troubleshooting by failure code (Display of code), Part 3 769
Troubleshooting by failure code (Display of code), Part 3 772
Failure code [CA263] (Fuel temperature sensor high error) 772
Failure code [CA265] (Fuel temperature sensor low error) . 774
Failure code [CA271] (PCV1 Short circuit) 776
Failure code [CA272] (PCV1 Disconnection) 778
Failure code [CA273] (PCV2 Short circuit) 780
Failure code [CA274] (PCV2 Disconnection) 782
Failure code [CA322] (Injector #1 (L/B #1) open/short error) . 784
Failure code [CA323] (Injector #5 (L/B #5) open/short error) . 786
Failure code [CA324] (Injector #3 (L/B #3) open/short error) . 788
Failure code [CA325] (Injector #6 (L/B #6) open/short error) . 790
Failure code [CA331] (Injector #2 (L/B #2) open/short error) . 792
Failure code [CA332] (Injector #4 (L/B #4) open/short error) . 794
Failure code [CA342] (Calibration code inconsistency) 796
Failure code [CA351] (Injectors drive circuit error) . 797
Failure code [CA352] (Sensor power supply 1 low error) . 799
Failure code [CA386] (Sensor power supply 1 high error) 800
Failure code [CA431] (Idle validation switch error) 802
Failure code [CA432] (Idle validation action error) 804
Failure code [CA441] (Battery voltage low error) . 806
Failure code [CA442] (Battery voltage high error) 809
Failure code [CA449] Common rail pressure high error 2 . 811
Failure code [CA451] (Common rail pressure sensor high error) 812
Failure code [CA452] (Common rail pressure sensor low error) . 814
Failure code [CA553] (Common rail pressure high error 1) . 815
Failure code [CA554] (Common rail pressure sensor in-range error) 816
Failure code [CA559] (Supply pump pressure very low error) . 817
Failure code [CA689] (Engine Ne speed sensor error) 821
Failure code [CA731] (Engine Bkup speed sensor phase error) 823
Failure code [CA757] (All continuous data lost error) 823
Failure code [CA778] (Engine Bkup speed sensor error) 824
Failure code [CA1228] (EGR valve servo error 1) 826
Failure code [CA1625] (EGR valve servo error 2) 827
Failure code [CA1633] (KOMNET datalink timeout error) 828
Failure code [CA2185] (Throttle sensor supply voltage high error) 830
Failure code [CA2186] (Throttle sensor power supply low error) . 831
Troubleshooting by failure code (Display of code), Part 4 833
Troubleshooting by failure code (Display of code), Part 4 835
Failure code [CA2249] (Supply pump pressure very low error 2) 835
Failure code [CA2271] (EGR valve lift sensor high error) . 836
Failure code [CA2272] (EGR valve lift sensor low error) 838
Failure code [CA2351] (EGR valve solenoid operation short circuit) . 839
Failure code [CA2352] (EGR valve solenoid operation disconnect) 841
Failure code [CA2555] (Intake heater relay disconnection error) 842
Failure code [CA2556] (Intake heater relay short circuit error) 844
Failure code [D150KA] (Emergency steering relay: Disconnection) 846
Failure code [D150KB] (Emergency steering relay: Short circuit) 848
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) . 850
Failure code [D160KA] (Backup lamp relay: Disconnection) . 852
Failure code [D160KB] (Backup lamp relay: Short circuit) . 854
Failure code [D160KZ] (Backup lamp relay: Disconnection or shortcircuit) . 856
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) . 858
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 860
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) . 862
Failure code [D192KA] (ECSS solenoid: Disconnection) . 864
Failure code [D192KB] (ECSS solenoid: Short circuit) . 865
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 866
Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 867
Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 869
Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line) . 871
Failure code [D5ZHKA] (Terminal C signal: Disconnection) . 873
Failure code [D5ZHKB] (Terminal C signal: Short circuit) . 877
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 880
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) . 885
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 888
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 890
Failure code [DAF5KP] (Machine monitor: Low output voltage) 892
Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)) 896
Troubleshooting by failure code (Display of code), Part 5 899
Troubleshooting by failure code (Display of code), Part 5 901
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 901
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) . 903
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)) . 904
Failure code [DAQ9KQ] (Transmission controller model selection:Disagreement of model selection signals) 906
Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)) . 907
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) . 909
Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system) . 910
Failure code [DB90KK] Work equipment controller: Low source voltage (input) 912
Failure code [DB90KT] Work equipment controller: Abnormality in controller . 914
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) . 915
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range 917
Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals) 920
Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)) 921
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) . 923
Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation) 924
Failure code [DD15LD] __ switch (Panel switch 1): Switch is kept pressed for long time . 928
Failure code [DD16LD] __ switch (Panel switch 2): Switch is kept pressed for long time . 930
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time 932
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time 934
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time 936
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time . 938
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time . 940
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time 942
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time 944
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) . 946
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) . 948
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) . 950
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) 952
Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time) . 956
Troubleshooting by failure code (Display of code), Part 6 959
Troubleshooting by failure code (Display of code), Part 6 962
Failure code [DDE5MA] (Emergency steering drive switch:Malfunction) 962
Failure code [DDK3KA] (Right FNR switch: Disconnection) 964
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 967
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) 970
Failure code [DDK6KA] (FNR lever switch: Disconnection) 972
Failure code [DDK6KB] (FNR lever switch: Short circuit) 976
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) 978
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) 980
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) . 982
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for longtime) . 984
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) . 986
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) 988
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) . 992
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) . 994
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) . 996
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) 998
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) .1000
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) .1002
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) .1004
Troubleshooting by failure code (Display of code), Part 7 1007
Troubleshooting by failure code (Display of code), Part 7 1010
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) 1010
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out ofinput signal range) .1012
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) 1014
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) 1016
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) .1018
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) 1020
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) 1023
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) .1026
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) 1029
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) .1032
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) 1035
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) 1038
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) .1041
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) .1044
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) .1047
Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection) .1050
Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line) 1053
Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree) .1055
Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection) 1058
Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line) .1062
Troubleshooting by failure code (Display of code), Part 8 1065
Troubleshooting by failure code (Display of code), Part 8 1067
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) 1067
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line) .1070
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) .1072
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line) 1075
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) 1077
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) .1080
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) 1082
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 1084
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) 1086
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range) 1088
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) .1090
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) .1092
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) 1094
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1096
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) .1098
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) .1100
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) 1102
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) .1104
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) .1105
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) 1106
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1108
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1109
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) .1110
Troubleshooting by failure code (Display of code), Part 9 1113
Troubleshooting by failure code (Display of code), Part 9 1115
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1115
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1116
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit withpower supply line) 1117
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1119
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1120
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) .1121
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection) 1123
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) 1124
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) .1125
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) 1126
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) 1128
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) .1130
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) .1132
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) .1134
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) 1136
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .1138
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) .1140
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) 1142
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) 1144
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) 1146
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) 1148
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) .1150
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) .1151
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) 1152
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1154
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1156
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) .1158
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1160
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1162
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit withpower supply line) 1164
Troubleshooting by failure code (Display of code), Part 10 .1167
Troubleshooting by failure code (Display of code), Part 10 .1170
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1170
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1172
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) .1174
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1176
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1178
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) .1180
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1182
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1184
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) .1186
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1188
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1190
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) .1192
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1194
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1196
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) .1198
Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection) .1200
Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit) .1202
Failure code [DXHJKY] (3-spool valve extend EPC solenoid: Short circuit with power supply line) 1204
Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection) 1206
Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit) 1208
Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line) .1210
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) 1212
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) 1214
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) .1216
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) .1218
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) .1220
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) 1222
Troubleshooting of electrical system (E-mode) 1225
Troubleshooting of electrical system (E-mode) 1227
Before carrying out troubleshooting for electrical system 1227
Information in troubleshooting table .1230
E-1 Engine does not start 1232
E-2 Wiper does not operate .1238
E-3 Windshield washer does not operate .1242
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not lightup or go off .1245
E-5 Working lamp does not light up or go off .1253
E-6 Turn signal lamp and hazard lamp do not light up or go off .1258
E-7 Brake lamp does not light or it keeps lighting up 1264
E-8 Backup lamp does not light or it keeps lighting up .1266
E-9 Backup buzzer does not sound or it keeps sounding 1268
E-10 Horn does not sound or it keeps sounding 1270
E-11 Alarm buzzer does not sound or it keeps sounding 1272
E-12 Air conditioner does not operate or stop 1274
E-13 The KOMTRAX system does not work properly .1277
Troubleshooting of hydraulic and mechanical system (H-mode) 1281
Troubleshooting of hydraulic and mechanical system (H-mode) 1283
Method of using troubleshooting chart 1283
Table of failure modes and causes 1286
H-1 The machine does not start .1290
H-2 Torque converter lockup is not switched off (engine stalls) [Machinewith lockup clutch (if equipped)] 1292
H-2 Torque converter lockup is not switched off (engine stalls) [Machinewith lockup clutch (if equipped)] 1292
H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)] .1292
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] 1293
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted .1294
H-5 Shocks are large at the times of starting and shifting gear 1296
H-6 Time lag is large at the times of starting and shifting gear .1298
H-7 The torque converter oil temperature is high .1300
H-8 Steering does not turn .1301
H-9 Steering does not turn [Machine with joystick steering (if equipped)] 1302
H-10 Steering response is low 1303
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)] 1304
H-12 Steering is heavy .1305
H-13 When machine turns, it shakes or makes large shocks .1306
H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)] 1307
H-15 The wheel brake does not work or does not work well .1308
H-16 The wheel brake is not released or it drags .1309
H-17 The parking brake does not work or does not work well .1310
H-18 The parking brake is not released or it drags (including emergency release system) 1311
H-19 Lift arm does not rise 1312
H-20 Lift arm speed is low or rising force of lift arm is insufficient .1313
H-21 When rising, the lift arm comes to move slowly at specific height .1314
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) .1314
H-23 Hydraulic drifts of the lift arm is large .1314
H-24 The lift arm wobbles during operation .1314
H-25 Bucket does not tilt back .1315
H-26 Bucket speed is low or tilting back force is insufficient .1316
H-27 The bucket comes to operate slowly in the midst of tilting-back .1317
H-28 The bucket cylinder cannot hold down the bucket .1317
H-29 Hydraulic drifts of the bucket is large .1317
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) .1317
H-31 Lift arm and bucket control levers do not move smoothly and are heavy .1318
H-32 During operation of the machine, engine speed lowers remarkablyor engine stalls .1319
H-33 Large shock is made when work equipment starts and stops 1319
H-34 When work equipment circuit is relieved singly, other work equipment moves 1319
H-35 ECSS does not operate, and pitching, bouncing occur .1320
Troubleshooting of engine (S-mode) .1323
Troubleshooting of engine (S-mode) .1325
Method of using troubleshooting chart 1325
S-1 Starting performance is poor .1328
S-2 Engine does not start 1330
S-3 Engine does not pick up smoothly .1334
S-4 Engine stops during operation 1335
S-5 Engine does not rotate smoothly 1336
S-6 Engine lacks output (or lacks power) .1337
S-7 Exhaust smoke is black (Incomplete combustion) .1338
S-8 Oil is consumed much (or exhaust gas color is blue) 1340
S-9 Engine oil becomes contaminated quickly 1341
S-10 Fuel consumption is excessive .1342
S-11 Coolant contains oil (blows back or reduces) 1343
S-12 Oil pressure drops 1344
S-13 Oil level rises (Water, fuel in oil) 1345
S-14 Coolant temperature rises too high (Overheating) 1347
S-15 Abnormal noise is made 1348
S-16 Vibration is excessive 1349
50 Disassembly and assembly 1351
General information on disassembly andassembly .1351
General information on disassembly and assembly 1352
How to read this manual 1352
Coating materials list .1354
Special tools list .1357
Sketches of special tools 1361
Engine and cooling system 1373
Engine and cooling system 1374
Removal and installation of engine assembly 1374
Removal and installation of hood .1378
Removal and installation of radiator assembly 1381
Removal and installation of aftercooler assembly .1384
Removal and installation of oil cooler assembly 1386
Removal and installation of cooling fan and drive motor assembly .1388
Removal and installation of fuel supply pump assembly 1391
Removal and installation of fuel injector assembly .1396
Removal and installation of cylinder head assembly .1401
Removal and installation of fuel tank assembly .1412
Power train, Part 1 1417
Power train, Part 1 1418
Removal and installation of torque converter and transmission assembly .1418
Disassembly and assembly of torque converter assembly (Standard specification) .1424
Disassembly and assembly of torque converter assembly (Lockup specification) .1428
Disassembly and assembly of transmission assembly 1435
Disassembly and assembly of transmission clutch pack assembly 1449
Disassembly and assembly of parking brake assembly .1466
Power train, Part 2 1475
Power train, Part 2 1476
Removal and installation of front axle assembly 1476
Removal and installation of rear axle assembly .1478
Disassembly and assembly of axle housing assembly 1484
Disassembly and assembly of differential assembly 1493
Undercarriage and frame 1513
Undercarriage and frame 1514
Removal and installation of centerhinge pin 1514
Removal and installation of counterweight 1522
Hydraulic system .1525
Hydraulic system .1526
Removal and installation of steering demand valve assembly .1526
Removal and installation of work equipment valve assembly 1529
Removal and installation of brake charge valve assembly 1532
Removal and installation of hydraulic tank assembly 1533
Removal and installation ofsteering and power train pump assembly 1535
Removal and installation of workequipment and cooling fan pump assembly 1537
Work equipment .1541
Work equipment .1542
Removal and installation of work equipment assembly 1542
Cab and its attachments 1547
Cab and its attachments 1548
Removal and installation of operator’s cab and floor frame assembly 1548
Removal and installation of operator’s cab glass (stuck glass) .1552
Disassembly and assembly of operator’s seat assembly .1560
Electrical system 1571
Electrical system 1572
Removal and installation of air conditioner unit assembly 1572
Removal and installation of engine controller assembly .1576
Removal and installation of transmission controller assembly .1577
Removal and installation of KOMTRAX controller assembly 1578
90 Diagrams and drawings .1581
Hydraulic diagrams and drawings 1581
Hydraulic diagrams and drawings 1582
Power train hydraulic circuit diagram 1582
Hydraulic circuit diagram 1585
Electrical diagrams and drawings .1588
Electrical diagrams and drawings .1590
Electrical circuit diagram (1/2) .1590
Electrical circuit diagram (2/2) .1592
Connector arrangement diagram 1594

DESCRIPTION:

Komatsu Galeo WA450-6 WA480-6 (KA SPEC.) Wheel Loader Shop Manual SEN00809-04  – PDF DOWNLOAD

SERIAL NUMBERS

• WA450-6 66001 and up
  WA480-6 85001 and up

Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution
Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.

G.B 26/12/24