Komatsu WA470-1 Wheel Loader Shop Manual SEBMU4210106 PDF

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Komatsu WA470-1 Wheel Loader Shop Manual SEBMU4210106 – PDF DOWNLOAD

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Komatsu WA470-1 Wheel Loader Shop Manual SEBMU4210106 – PDF DOWNLOAD

Language : English
Pages : 1120
Downloadable : Yes
File Type : PDF

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Komatsu WA470-1 Wheel Loader Shop Manual SEBMU4210106 – PDF DOWNLOAD

• MACHINE MODEL SERIAL No.
  WA470-1                  10001 and up

COVER 1
CONTENTS . 2
10 ENGINE 20
12 TESTING AND ADJUSTING . 20
STANDARD VALUE TABLE . 21
TOOL LIST FOR TESTING AND ADJUSTING . 23
ADJUSTING VALVE CLEARANCE 24
MEASURING COMPRESSION PRESSURE . 25
TESTING AND ADJUSTING FUEL INJECTION TIMING 26
MEASURING BLOW-BY PRESSURE . 28
TESTING AND ADJUSTING FAN BELT TENSION . 29
MEASURING EXHAUST GAS COLOR 30
MEASURING ACCELERATOR PEDAL OPERATING FORCE AND OPERATING ANGLE 31
TESTING AND ADJUSTING FUEL CUT SOLENOID 35
13 DISASSEMBLY AND ASSEMBLY 36
STARTING MOTOR ASSEMBLY 37
REMOVAL 37
INSTALLATION . 37
ALTERNATOR ASSEMBLY 38
REMOVAL 38
INSTALLATION . 38
FUEL INJECTION PUMP ASSEMBLY . 39
REMOVAL 39
INSTALLATION . 39
WATER PUMP ASSEMBLY 40
REMOVAL 40
INSTALLATION . 40
NOZZLE HOLDER ASSEMBLY . 41
REMOVAL 41
INSTALLATION . 42
TURBOCHARGER ASSEMBLY 43
REMOVAL 43
INSTALLATION . 43
CYLINDER HEAD ASSEMBLY . 44
REMOVAL 44
INSTALLATION . 50
RADIATOR ASSEMBLY 57
REMOVAL 57
INSTALLATION . 60
OIL COOLER ASSEMBLY 62
REMOVAL 62
INSTALLATION . 62
ENGINE . 63
REMOVAL 63
INSTALLATION . 69
FUEL TANK 75
REMOVAL 75
INSTALLATION . 75
14 MAINTENANCE STANDARD 76
ENGINE MOUNT . 77
20 POWER TRAIN . 78
21 STRUCTURE AND FUNCTION 78
GENERAL 79
・HYDRAULIC CIRCUIT FOR POWER TRAIN . 81
・HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN . 82
DAMPER . 84
TORQUE CONVERTER AND TRANSMISSION PIPING . 86
TORQUE CONVERTER CHARGING PUMP . 87
TORQUE CONVERTER . 88
TORQUE CONVERTER OIL FILTER 91
TORQUE CONVERTER OIL COOLER 92
TORQUE CONVERTER RELIEF VALVE 93
TRANSMISSION . 94
TRANSMISSION CONTROL VALVE . 102
UPPER VALVE 106
LOWER VALVE 107
TRANSMISSION SOLENOID VALVE 110
EMERGENCY MANUAL SPOOL . 111
PRIORITY VALVE . 114
MODULATING VALVE AND QUICK RETURN VALVE 115
ACCUMULATOR VALVE 118
PILOT REDUCING VALVE . 120
TRANSMISSION PILOT FILTER 121
TRANSFER . 122
DRIVE SHAFT 123
AXLE MOUNT . 124
AXLE AND DIFFERENTIAL 128
TORQUE PROPORTIONING DIFFERENTIAL 133
FINAL DRIVE 134
TIRE AND WHEEL . 136
22 TESTING AND ADJUSTING . 137
STANDARD VALUE TABLE . 138
TOOL LIST FOR TESTING AND ADJUSTING 139
MEASURING ENGINE STALL SPEED . 140
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION 142
MEASURING SHIFT LEVER 144
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL . 145
TIRE AND WHEEL . 147
TROUBLESHOOTING 148
PRECAUTIONS WHEN TROUBLESHOOTING . 149
METHOD OF READING TROUBLESHOOTING TABLE 151
PREVENTING RECURRENCE OF TROUBLE . 153
JUDGMENT ON POWER TRAIN 154
TROUBLESHOOTING TABLE 157
1. MACHINE DOES NOT MOVE . 157
2. MACHINE LACKS POWER OR SPEED 159
3. EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR . 160
4. TORQUE CONVERTER OIL TEMPERATURE TOO HIGH . 161
23 DISASSEMBLY AND ASSEMBLY . 162
DAMPER . 163
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999) . 163
REMOVAL AND INSTALLATION (SERIAL NO.20001 AND UP) 164
DISASSEMBLY (SERIAL NO.10001-19999) 165
ASSEMBLY (SERIAL NO.10001-19999) . 167
DISASSEMBLY (SERIAL NO.20001 AND UP) . 169
ASSEMBLY (SERIAL NO.20001 AND UP) 171
TORQUE CONVERTER CHARGING PUMP 175
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999) . 175
REMOVAL (SERIAL NO.20001 AND UP) . 176
INSTALLATION (SERIAL NO.20001 AND UP) 177
TORQUE CONVERTER AND TRANSMISSION 178
REMOVAL (SERIAL NO.10001-19999) 178
INSTALLATION (SERIAL NO.10001-19999) . 185
REMOVAL (SERIAL NO.20001 AND UP) . 193
INSTALLATION (SERIAL NO.20001 AND UP) 201
TORQUE CONVERTER ASSEMBLY 210
DISASSEMBLY 210
ASSEMBLY . 214
TRANSMISSION ASSEMBLY 220
DISASSEMBLY 220
ASSEMBLY . 233
TRANSFER ASSEMBLY 246
DISASSEMBLY 246
ASSEMBLY . 249
TRANSMISSION CONTROL VALVE . 254
REMOVAL 254
INSTALLATION . 257
DISASSEMBLY AND ASSEMBLY . 260
FRONT DIFFERENTIAL . 264
REMOVAL 264
INSTALLATION . 268
REAR DIFFERENTIAL 272
REMOVAL 272
INSTALLATION . 276
DIFFERENTIAL . 280
DISASSEMBLY 280
ASSEMBLY . 283
FRONT AXLE . 291
REMOVAL 291
INSTALLATION . 294
REAR AXLE 297
REMOVAL 297
INSTILLATION . 302
DRIVE SHAFT 307
DISASSEMBLY 307
ASSEMBLY . 309
FINAL DRIVE 311
DISASSEMBLY 311
ASSEMBLY . 315
24 MAINTENANCE STANDARD 320
TRANSMISSION MOUNT . 321
TORQUE CONVERTER CHARGING PUMP . 322
DAMPER . 323
TORQUE CONVERTER . 326
TORQFLOW TRANSMISSION 328
1. TRANSMISSION 328
2. TRANSMISSION CONTROL VALVE 331
3. SOLENOID VALVE 339
TRANSFER . 340
DIFFERENTIAL . 342
FINAL DRIVE 346
DRIVE SHAFT 348
AXLE MOUNT . 349
40 STEERING SYSTEM . 351
41 STRUCTURE AND FUNCTION 351
GENERAL 352
HYDRAULIC CIRCUIT FOR STEERING . 354
STEERING VALVE (SERIAL NO.10001-20000) . 361
STEERING VALVE (SERIAL NO.20001 AND UP) 368
TWO-WAY RESTRICTOR VALVE . 382
ORBIT-ROLL VALVE . 383
STOP VALVE . 387
STEERING PUMP 388
STEERING CYLINDER 389
STEERING COLUMN AND GEAR BOX . 390
STEERING LINKAGE . 391
STEERING COLUMN AND ORBIT-ROLL . 392
CENTER HINGE PIN . 393
42 TESTING AND ADJUSTING . 395
STANDARD VALUE TABLE . 396
TOOL LIST FOR TESTING AND ADJUSTING 396
MEASURING STEERING WHEEL PLAY 397
MEASURING OPERATING FORCE OF STEERING WHEEL . 398
OPERATING TIME OF STEERING WHEEL . 399
TESTING STEERING LINKAGE . 400
ADJUSTING STEERING LINKAGE . 401
STEERING OIL PRESSURE 402
TROUBLESHOOTING 404
TROUBLESHOOTING TABLE (SERIAL NO.10001-20000) 405
1. STEERING WHEEL DOES NOT TURN 405
2. STEERING WHEEL IS SLUGGISH 406
3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK 407
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING 407
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT 407
TROUBLESHOOTING TABLE (SERIAL NO.20001 AND UP) . 408
1. STEERING WHEEL DOES NOT TURN 408
2. STEERING WHEEL IS SLUGGISH 409
3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK 410
4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING 410
5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT 410
6. WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT,CHASSIS IS SUBJECTED TO LARGE SHOCK 410
43 DISASSEMBLY AND ASSEMBLY 411
STEERING GEAR 412
REMOVAL (SERIAL NO.10001-19999) 412
INSTALLATION (SERIAL NO.10001-19999) . 413
DISASSEMBLY (SERIAL NO.10001-19999) 414
ASSEMBLY (SERIAL NO.10001-19999) . 415
STEERING VALVE . 418
REMOVAL (SERIAL NO.20001 AND UP) . 418
INSTALLATION (SERIAL NO.20001 AND UP) 420
DISASSEMBLY (SERIAL NO.20001 AND UP) . 423
ASSEMBLY (SERIAL NO.20001 AND UP) 426
REMOVAL (SERIAL NO.10001-19999) 431
INSTALLATION (SERIAL NO.10001-19999) . 433
DISASSEMBLY (SERIAL NO.10001-19999) 435
ASSEMBLY (SERIAL NO.10001-19999) . 437
STEERING DEMAND VALVE 439
REMOVAL (SERIAL NO.20001 AND UP) . 439
INSTALLATION (SERIAL NO.20001 AND UP) 441
DISASSEMBLY (SERIAL NO.20001 AND UP) . 444
ASSEMBLY (SERIAL NO.20001 AND UP) 448
STEERING PUMP 452
REMOVAL (SERIAL NO.10001-19999) 452
INSTALLATION (SERIAL NO.10001-19999) . 453
REMOVAL (SERIAL NO.20001 AND UP) . 454
INSTALLATION (SERIAL NO.20001 AND UP) 455
STEERING CYLINDER . 456
REMOVAL (SERIAL NO.10001-19999) 456
INSTALLATION (SERIAL NO.10001-19999) . 457
REMOVAL (SERIAL NO.20001 AND UP) . 458
INSTALLATION (SERIAL NO.20001 AND UP) 459
DISASSEMBLY 460
ASSEMBLY . 462
CENTER HINGE PIN . 465
REMOVAL (SERIAL NO.10001-19999) 465
INSTALLATION (SERIAL NO.10001-19999) . 472
REMOVAL (SERIAL NO.20001 AND UP) . 481
INSTALLATION (SERIAL NO.20001 AND UP) 490
44 MAINTENANCE STANDARD 501
STEERING LINKAGE . 502
STEERING COLUMN AND GEAR BOX . 504
STEERING COLUMN AND ORBIT-ROLL . 505
STEERING VALVE . 506
STEERING PUMP 509
STEERING CYLINDER MOUNT 510
STEERING CYLINDER . 512
CENTER HINGE PIN . 513
50 BRAKE AND AIR SYSTEM 515
51 STRUCTURE AND FUNCTION 515
GENERAL 516
BRAKE AND AIR PIPING . 517
BRAKE AND AIR CIRCUIT SYSTEM . 519
AIR TANK . 521
SAFETY VALVE . 523
BRAKE VALVE 524
BRAKE ACTUATED . 525
OPERATING IN BALANCE . 526
BRAKE RELEASED . 527
AIR GOVERNOR . 528
TWO-WAY VALVE 530
BRAKE CHAMBER 531
SLACK ADJUSTER . 533
BRAKE 536
PARKING BRAKE 539
PARKING BRAKE SOLENOID VALVE . 541
SPRING CYLINDER 542
BRAKE CALIPER 543
52 TESTING AND ADJUSTING . 544
STANDARD VALUE TABLE . 545
TOOL LIST FOR TESTING AND ADJUSTING 546
MEASURING BRAKE PEDAL 547
MEASURING AIR 548
BRAKE PERFORMANCE 551
CHECKING BRAKE OIL PRESSURE 552
MEASURING WEAR OF BRAKE DISC . 553
AIR BLEEDING FROM BRAKE LINE . 555
PARKING BRAKE PERFORMANCE 556
CHECKING AND ADJUSTING PARKING BRAKE . 557
TROUBLESHOOTING 559
TROUBLESHOOTING TABLE 560
1. AIR PRESSURE DOES NOT RISES AT ALL 560
2. AIR PRESSURE DOES NOT RISE TO THE SPECIFIED RANGE . 561
3. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE 562
4. BRAKE DOES NOT RELEASE,OR DRAGS . 563
5. PARKING BRAKE DOES NOT RELEASE,OR DRAGS . 564
53 DISASSEMBLY AND ASSEMBLY 565
AIR GOVERNOR . 566
DISASSEMBL . 566
ASSEMBLY . 567
BRAKE VALVE 568
REMOVAL (SERIAL NO.10001-19999) 568
INSTALLATION (SERIAL NO.10001-19999) . 569
REMOVAL (SERIAL NO.20001 AND UP) . 570
INSTALLATION (SERIAL NO.20001 AND UP) 571
DISASSEMBLY 572
ASSEMBLY . 574
BRAKE CHAMBER 576
REMOVAL (SERIAL NO.10001-19999) 576
INSTALLATION (SERIAL NO.10001-19999) . 577
REMOVAL (SERIAL NO.20001 AND UP) . 578
INSTALLATION (SERIAL NO.20001 AND UP) 580
DISASSEMBLY 582
ASSEMBLY . 585
SLACK ADJUSTER . 588
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999) . 588
REMOVAL (SERIAL NO.20001 AND UP) . 589
INSTALLATION (SERIAL NO.20001 AND UP) 591
DISASSEMBLY 593
ASSEMBLY . 594
BRAKE ASSEMBLY . 595
DISASSEMBLY 595
ASSEMBLY . 601
DISASSEMBLY (SERIAL NO.20001 AND UP) . 608
ASSEMBLY (SERIAL NO.20001 AND UP) 614
SPRING CYLINDER . 622
REMOVAL . 622
INSTALLATION . 623
DISASSEMBLY 624
ASSEMBLY . 626
PARKING BRAKE 628
REMOVAL 628
INSTALLATION . 630
PARKING BRAKE PAD 633
REMOVAL AND INSTALLATION 633
54 MAINTENANCE STANDARD 634
BRAKE VALVE 635
BRAKE CHAMBER 637
SLACK ADJUSTER . 638
BRAKE 639
PARKING BRAKE 643
SPRING CYLINDER 644
60 WORK EQUIPMENT SYSTEM . 645
61 STRUCTURE AND FUNCTION 645
GENERAL . 646
HYDRAULIC PIPING . 647
HYDRAULIC CIRCUIT SYSTEM . 649
HYDRAULIC CIRCUIT DIAGRAM 650
HYDRAULIC TANK . 654
OIL FILTER BYPASS VALVE 656
HYDRAULIC PUMPS 658
HYDRAULIC PUMP 658
SWITCH AND POC (PPC) PUMP 659
POC VALVE 660
PPC VALVE 662
POC (PPC) RELIEF VALVE . 664
FUNCTION OF POC VALVE 665
FUNCTION OF PPC VALVE 670
MAIN CONTROL VALVE . 672
RELIEF VALVE . 680
SAFETY VALVE (WITH SUCTION VALVE) 681
SUCTION VALVE 682
FLOAT SELECTOR VALVE AND UNLOADER VALVE 683
ACCUMULATOR 691
HYDRAULIC CYLINDER . 692
BUCKET LINKAGE . 694
BUCKET POSITIONER AND BOOM KICK-OUT 696
WORK EQUIPMENT LEVER LINKAGE . 699
62 TESTING AND ADJUSTING . 701
STANDARD VALUE TABLE . 702
TOOL LIST FOR TESTING AND ADJUSTING 705
MEASURING DUMP AND LIFT CONTROL LEVERS . 706
ADJUSTING DUMP AND LIFT CONTROL LEVERS . 707
MEASURING HYDRAULIC PRESSURE OF WORK EQUIPMENT . 709
MEASURING WORK EQUIPMENT . 712
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT 713
ADJUSTING BUCKET POSITIONER 714
ADJUSTING BOOM KICK-OUT 715
TROUBLESHOOTING 716
TROUBLESHOOTING TABLE 717
1. LIFT ARM DOES NOT RISE 717
2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER . 718
3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT 719
4. RUCKET CANNOT BE HELD DOWN WITH LIFT CYLINDER . 719
5. LIFT ARM HAS LARGE HYDRAULIC DRIFT 719
6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK . 719
7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “RAISE” 719
8. BUCKET DOES NOT TILT BACK . 720
9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER . 721
10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK 722
11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER 722
12. BUCKET HAS LARGE HYDRAULIC DRIFT . 722
13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD (MAIN CONTROL VALVE IN “HOLD”) . 722
14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM “HOLD” TO “TILT BACK” 722
15. CONTROL LEVERS OF LIFT ARM AND DUMP MOVE STIFFLY AND SLUGGISHLY 723
63 DISASSEMBLY AND ASSEMBLY 724
HYDRAULIC TANK . 725
REMOVAL (SERIAL NO.10001-19999) 725
INSTALLATION (SERIAL NO.10001-19999) . 726
REMOVAL (SERIAL NO.20001 AND UP) . 727
INSTALLATION (SERIAL NO.20001 AND UP) 731
HYDRAULIC PUMP . 734
REMOVAL (SERIAL NO.10001-19999) 734
INSTALLATION (SERIAL NO.10001-19999) . 735
REMOVAL (SERIAL NO.20001 AND UP) . 736
INSTALLATION (SERIAL NO.20001 AND UP) 737
HYDRAULIC FILTER . 738
REMOVAL AND INSTALLATION . 738
SWITCH,POC PUMP 739
REMOVAL AND INSTALLATION (SERIAL NO.10001-19999) . 739
SWITCH,PPC PUMP 740
REMOVAL (SERIAL NO.20001 AND UP) . 740
INSTALLATION (SERIAL NO.20001 AND UP) 741
POC VALVE 742
REMOVAL (SERIAL NO.10001-19999) 742
INSTALLATION (SERIAL NO.10001-19999) . 744
DISASSEMBLY AND ASSEMBLY (SERIAL NO.10001-19999) . 746
PPC VALVE 747
REMOVAL (SERIAL NO.20001 AND UP) . 747
INSTALLATION (SERIAL NO.20001 AND UP) 749
DISASSEMBLY AND ASSEMBLY (SERIAL NO.20001 AND UP) 751
MAIN CONTROL VALVE . 752
REMOVAL (SERIAL NO.10001-19999) 752
INSTALLATION (SERIAL NO.10001-19999) . 754
DISASSEMBLY (SERIAL NO.10001-19999) 756
ASSEMBLY (SERIAL NO.10001-19999) . 758
REMOVAL (SERIAL NO.20001 AND UP) . 760
INSTALLATION (SERIAL NO.20001 AND UP) 763
DISASSEMBLY (SERIAL NO.20001 AND UP) . 765
ASSEMBLY (SERIAL NO.20001 AND UP) 767
DUMP CYLINDER 769
REMOVAL 769
INSTALLATION . 771
LIFT CYLINDER 773
REMOVAL 773
INSTALLATION . 774
LIFT AND DUMP CYLINDERS 775
DISASSEMBLY 775
ASSEMBLY . 777
WORK EQUIPMENT . 780
REMOVAL 780
INSTALLATION . 783
COUNTERWEIGHT 786
REMOVAL AND INSTALLATION . 786
64 MAINTENANCE STANDARD 787
MAIN CONTROL VALVE . 788
SWITCH AND POC (PPC) PUMP 796
HYDRAULIC PUMP . 798
POC VALVE 799
POC VALVE (RELIEF VALVE) . 800
PPC VALVE 801
DUMP CYLINDER 803
LIFT CYLINDER 804
BUCKET LINKAGE . 805
BUCKET POSITIONER AND BOOM KICK-OUT 807
BUCKET . 808
80 ELECTRIC AND ELECTRONIC SYSTEM 809
81 STRUCTURE AND FUNCTION 809
ELECTRICAL WIRING DIAGRAM 810
ELECTRICAL WIRING DIAGRAM CIRCUIT 811
ENGINE STARTING CIRCUIT 818
ENGINE STOP CIRCUIT 821
PREHEATING CIRCUIT . 824
PREHEATING AND AFTER-HEATING WITH HEATER SWITCH 824
PREHEATING WITH STARTING SWITCH 825
AUTOMATIC PREHEATING . 826
COMBINATION SWITCH . 827
ELECTRICAL TRANSMISSION CONTROL 828
TRANSMISSION CUT-OFF SWITCH 830
TRANSMISSION CUT-OFF SELECTOR SWITCH . 831
NEUTRALIZER RELAY 833
KICK-DOWN SWITCH . 835
KICK-DOWN ELECTRIC CIRCUIT . 836
ELECTRICAL PARKING BRAKE CONTROL 842
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) 854
INDICATION ON MONITOR PANEL 858
CONTROLLER . 860
SENSORS 861
WIRING HARNESS . 867
OPERATION OF PROXIMITY SWITCH 869
82 TESTING AND ADJUSTING . 873
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM . 874
ADJUSTING MACHINE MONITOR (SPEEDOMETER MODULE) . 876
TROUBLESHOOTING 878
CHECKS BEFORE TROUBLESHOOTING 879
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART 880
CONNECTOR TERMINAL NUMBERS . 882
PRECAUTION WHEN HANDLING CONNECTOR . 887
ELECTRICAL WIRING DIAGRAM 889
ELECTRICAL CIRCUIT SYSTEM 891
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.10001-20000) 901
E-1. ENGINE DOES NOT START . 902
E-1A. ENGINE DOES NOT START 904
E-2. ENGINE DOES NOT STOP 906
E-3. ENGINE STOPS WHEN TRAVELING . 908
E-4. PARKING BRAKE DOES NOT WORK . 910
E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING . 912
E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED TO ON . 914
E-7. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED . 915
E-8. MACHINE DOES NOT TRAVEL FORWARD . 916
E-9. MACHINE DOES NOT TRAVEL REVERSE . 918
E-10. TRANSMISSION DOES NOT SHIFT GEAR (F-R SWITCH NORMAL) . 920
E-11. MACHINE DOES NOT TRAVEL WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS ON (MACHINE TRAVELS ONLY WHEN TRANSMISSION CUT-OFF SELECTOR SWITCH IS OFF) 922
E-12. TRANSMISSION CANNOT BE CUT-OFF . 923
E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL 924
E-14. PREHEATING DISPLAY DOES NOT GO OUT . 926
E-15. PREHEATING DOES NOT WORK . 927
TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (SERIAL NO.20001 AND UP) . 928
POSITION OF CONNECTORS FOR TROUBLESHOOTING . 929
E-1. ENGINE DOES NOT START . 935
E-2. ENGINE DOES NOT STOP 939
E-3. ENGINE STOPS WHEN TRAVELING . 939
E-4. PARKING BRAKE DOES NOT WORK . 940
E-5. PARKING BRAKE IS APPLIED WHEN TRAVELING . 941
E-6. PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 943
E-7. WHEN PARKING BRAKE IS APPLIED,SHIFT LEVER DOES NOT ENTER NEUTRAL 943
E-8. TRANSMISSION DOES NOT WORK NORMALLY . 944
E-9. KICK-DOWN SWITCH DOES NOT WORK (NORMAL F1-F4 SWITCHES CORRECTLY) 964
E-10. KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION) . 967
E-11. KICK-DOWN OPERATION IS NOT CANCELED 968
E-12. KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2 970
E-13. MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED . 970
E-14. PREHEAT DISPLAY STAYS ON . 972
E-15. PREHEATING DOES NOT STOP . 972
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO.10001-10080 (M SPEC.), SERIAL NO.10001-10118 (P SPEC.), SERIAL NO.10001-10125 (D SPEC.) 973
M-1. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),AND THERE IS NO ABNORMALITY IN MACHINE,CHECK BEFORE STARTING ITEM FLASHES . 976
a) BRAKE OIL LEVEL . 976
b) ENGINE OIL LEVEL 977
c) COOLANT LEVEL . 978
M-2. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASHES 979
a) BATTERY CHARGE 979
b) FUEL LEVEL 980
M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),EMERGENCY ITEMS FLASHES 981
a) FAILURE IN BRAKE LINE . 981
b) ENGINE OIL PRESSURE . 982
c) COOLANT LEVEL . 983
d) DROP IN AIR PRESSURE 984
e) COOLANT TEMPERATURE . 985
f) TORQUE CONVERTER OIL TEMPERATURE 986
M-4. WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE),PILOT ITEMS LIGHT UP ABNORMALLY,OR DOES NOT LIGHT UP 987
a) PARKING BRAKE DISPLAY DOES NOT GO OUT . 987
b) PARKING BRAKE DISPLAY DOES NOT LIGHT UP . 988
c) WORKING LAMP DISPLAY DOES NOT GO OUT 989
d) WORKING LAMP DISPLAY DOES NOT LIGHT UP 990
e) PREHEAT DISPLAY LIGHTS UP . 991
f) PREHEAT DISPLAY DOES NOT LIGHT UP . 992
g) FAILURE IN MAIN STEERING DISPLAY LIGHT UP (IF EQUIPPED) . 993
h) FAILURE IN MAIN STEERING DISPLAY DOES NOT LIGHT UP (IF EQUIPPED) 994
i) EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP (IF EQUIPPED) . 995
j) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP (IF EQUIPPED) . 996
k) TRANSMISSION CUT-OFF DISPLAY LIGHTS UP 997
l) TRANSMISSION CUT-OFF DISPLAY DOES NOT LIGHT UP 998
M-5. TURN SIGNAL LAMPS,HIGH BEAM LIGHT UP ABNORMALLY,OR DO NOT LIGHT UP 999
a) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) LIGHTS UP . 999
b) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) LIGHTS UP 999
c) PILOT DISPLAY OF TURN SIGNAL LAMP (RIGHT) DOES NOT LIGHT UP .1000
d) PILOT DISPLAY OF TURN SIGNAL LAMP (LEFT) DOES NOT LIGHT UP 1001
e) HIGH BEAM PILOT LAMP DOES NOT LIGHT UP 1002
f) HIGE BEAM PILOT LAMP DOES NOT WORK NORMALLY .1003
M-6. SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY 1004
M-7. SERVICEMETER DOES NOT WORK NORMALLY .1005
M-8. ABNORMALITY IN MONITOR PANEL 1007
a) NONE OF MONITOR PANEL WORKS .1007
b) PART OF MONITOR PANEL DOES NOT WORK .1009
c) EVEN WHEN ENGINE IS STOPPED,ENGINE OIL PRESSURE FLASHES,CAUTION BUZZER SOUNDS AND WARNING LAMP ALSO LIGHTS UP .1010
d) EVEN WHEN ENGINE IS STOPPED,BATTERY CHARGE FLASHES AND WARNING LAMP LIGHTS UP 1011
e) NO LAMPS ON MONITOR LIGHTS UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO “ON”,ENGINE STOPPED) 1011
f) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING LAMP LIGHTS UP INTERMITTENTLY .1012
g) CENTRAL WARNING LAMP LIGHTS UP CONTINUOUSLY .1013
h) MONITOR DISPLAYS NO ABNORMALITY,BUT CENTRAL WARNING BUZZER SOUNDS INTERMITTENTLY 1014
i) CENTRAL WARNING BUZZER SOUNDS CONTINUOUSLY 1015
M-9. ABNORMALITY IN PANEL LAMPS ON MONITOR .1016
a) NO PANEL LAMPS LIGHT UP EVEN WHEN ONLY SMALL LAMP IN COMBINATION LAMP IS USED .1016
b) NO PANEL LAMPS LIGHT UP EVEN WORKING LAMP IS SWITCHED ON 1018
c) PANEL LAMPS OF GAUGE MODULE DO NOT LIGHT UP .1019
d) PANEL LAMPS OF CHECKS,CAUTION 1 AND 2,SPEEDOMETER MODULE DO NOT LIGHT UP 1020
e) PANEL LAMPS OF SERVICE METER DO NOT LIGHT UP 1021
M-10. ABNORMALITY IN ALARM BUZZER OR WARNING LAMP 1022
a) EMERGENCY ITEM IS FLASHING,BUT ALARM BUZZER DOES NOT SOUND 1022
b) EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING,BUT WARNING LAMPS DOES NOT FLASH .1024
M-11. ABNORMALITY IN GAUGE .1026
a) FUEL GAUGE 1026
b) AIR PRESSURE GAUGE 1029
c) COOLANT TEMPERATURE GAUGE .1031
d) TORQUE CONVERTER OIL TEMPERATURE GAUGE 1033
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM [SERIAL NO.10081 AND UP (M SPEC.), SERIAL NO.10119 AND UP (P SPEC.), SERIAL NO.10126 AND UP (D SPEC.)] 1035
POSITION OF CONNECTORS FOR TROUBLESHOOTING .1037
SERIAL NO.10081-20000 (M SPEC.) 1037
SERIAL NO.10119-20000 (P SPEC.) 1037
SERIAL NO.10126-20000 (D SPEC.) 1037
(SERIAL NO.20001 AND UP) .1043
M-1. WHEN STARTING SWITCH IS TURNED TO ON POSITION,MONITOR PANEL DOES NOT LIGHT UP FOR 3 SECONDS .1049
a) NONE OF MONITOR PANEL LIGHTS UP .1049
b) EXCEPT FOR SPEEDOMETER MODULE,NONE OF MONITOR PANEL LIGHTS UP .1049
c) NONE OF CAUTION ITEMS LIGHT UP 1049
d) SOME OTHER PARTS DO NOT LIGHT UP 1049
M-2. WHEN STARTING SWITCH IS TURNED TO ON POSITION,ALL MONITOR PANEL LIGHTS UP AND DOES NOT GO OUT .1050
M-3. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CHECK ITEM FLASHES (LEVELS OF CHECK ITEMS ARE CORRECT) .1051
a) (ENGINE OIL LEVEL) FLASHES 1051
b) (RADIATOR WATER LEVEL) FLASHES 1052
c) (BRAKE OIL LEVEL) FLASHES .1052
M-4. NO OPERATION IS BEING CARRIED OUT,BUT PILOT DISPLAY LIGHTS UP ABNORMALLY 1054
a) (PREHEAT) LIGHT UP 1054
b) (TRANSMISSION CUT-OFF) LIGHTS UP 1054
c) (PARKING BRAKE) LIGHTS UP .1055
d) (WORKING LAMP) LIGHTS UP 1055
M-5. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CHECK ITEM FLASHES .1057
a) ENGINE OIL PRESSURE SYSTEM 1057
b) ALTERNATOR SYSTEM .1057
M-6. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),CAUTION ITEM FLASHES .1058
a) ENGINE OIL PRESSURE SYSTEM 1058
b) ALTERNATOR SYSTEM .1058
M-7. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE) .1060
a) (CHARGE LEVEL) FLASHES 1060
b) (FUEL LEVEL) FLASHES 1060
c) (BRAKE LINE FAILURE) FLASHES 1060
d) (ENGINE OIL PRESSURE) FLASHES .1060
e) (RADIATOR WATER LEVEL) FLASHES 1060
f) (AIR PRESSURE) FLASHES 1061
g) (ENGINE WATER TEMPERATURE) FLASHES 1061
h) (TORQUE CONVERTER OIL TEMPERATURE) FLASHES 1061
M-8. SPEED SENSOR DISPLAY STAYS AT “O” .1063
M-9. HIGH BEAM DOES NOT LIGHT UP,OR LIGHTS UP ABNORMALLY .1064
a) IF HIGH BEAM DOES NOT LIGHT UP 1064
b) IF HIGH BEAM LIGHTS UP WHEN HEAD LAMP SWITCH IS OFF .1064
c) IF HI BEAM DISPLAY LIGHTS UP WHEN HEAD LAMP DIMMER SWITCH IS AT LO BEAM POSITION 1065
M-10. TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING .1066
a) IF TURN SIGNAL LAMP DOES NOT FLASH 1066
b) IF TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING 1066
M-11. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND .1067
M-12. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT ALARM BUZZER SOUNDS .1068
M-13. WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES NOT FLASH 1069
M-14. NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY,BUT WARNING LAMP LIGHTS UP 1069
M-15. WHEN STARTING SWITCH IS TURNED TO ON POSITION,LAMPS DO NOT LIGHT UP FOR 4 SEC.WHEN LAMP SWITCH IS ON,LAMPS DO NOT LIGHT UP .1070
a) NONE OF PANEL LIGHTS UP .1070
b) SOME OF PANEL LAMPS DO NOT LIGHT UP .1070
M-16. LAMP SWITCH IS NOT BEING OPERATED,BUT NIGHT LIGHTING LIGHTS UP.NIGHT LIGHTING STAYS ON .1071
M-17. SERVICE METER DOES NOT WORK 1072
M-18. SERVICE METER MOVES WHEN ENGINE IS STOPPED .1072
M-19. ABNORMALITY IN AIR PRESSURE GAUGE 1073
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA .1073
b) IF INDICATOR REMAINS AT MAXIMUM LEVEL .1073
M-20. ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 1074
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA .1074
b) IF INDICATOR REMAINS AT MINIMUM LEVEL .1074
M-21. ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGA 1075
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA .1075
b) IF INDICATOR REMAINS AT MINIMUM LEVEL .1075
M-22. ABNORMALITY IN FUEL GAUGE 1076
a) IF NOTHING IS DISPLAYED IN DISPLAY AREA .1076
b) IF INDICATOR REMAINS AT FULL 1076
83 DISASSEMBLY AND ASSEMBLY 1077
MACHINE MONITOR 1078
REMOVAL AND INSTALLATION .1078
90 OTHERS 1079
91 LOGGING SPECIFICATIONS 1079
HYDRAULIC CIRCUIT DIAGRAM 1080
MAIN CONTROL VALVE .1081
ARM CYLINDER .1083
WORK EQUIPMENT .1084
DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY .1085
ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY 1087
MAIN CONTROL VALVE .1089
WORK EQUIPMENT .1091
ARM CYLINDER .1093
93 DISASSEMBLY AND ASSEMBLY 1094
CAB 1095
REMOVAL 1095
INSTALLATION .1095
97 GEAR PUMP .1096
GENERAL 1096
GENERAL 1097
PRINCIPLE OF OPERATION .1098
PRESSURE LOADED TYPE GEAR PUMP .1101
FIXED SIDE PLATE TYPE GEAR PUMP 1103
SA SERIES 1104
STRUCTURE 1105
TESTING AND ADJUSTING 1108
DISASSEMBLY 1111
ASSEMBLY .1115
MAINTENANCE STANDARD .1120

DESCRIPTION:

Komatsu WA470-1 Wheel Loader Shop Manual SEBMU4210106 – PDF DOWNLOAD

• MACHINE MODEL SERIAL No.
  WA470-1                  10001 and up

FORWORD

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 chapters for each main group of components; these chapters are further divided into the following sections.
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 AND ADJUSTING
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.

PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under in- ternal pressure or under pressure from at spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts.

G.B 27/12/24