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Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual VEBM94610 – PDF DOWNLOAD
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Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual
MACHINE MODEL SERIAL NUMBER
WA470-6 H50051 and up
WA480-6 H60051 and up
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Description
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA470-6, WA480-6
Serial Number: H50051 and up, H60051 and up
Book Code: VEBM946101
Language: English
Pages: 1554
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual
How to read the shop manual:
1. 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):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA470-6, WA480-6 Wheel Loader Shop Manual
VEBM946101 WA470-6 and WA480-6....................................................................................................................... 1 00 Index and foreword................................................................................................................................ 0 Foreword and general information................................................................................................................. 19 Safety notice................................................................................................................................ 20 How to read the shop manual.................................................................................................................. 24 Explanation of terms for maintenance standard................................................................................................ 26 Handling electric equipment and hydraulic component.......................................................................................... 28 How to read electric wire code............................................................................................................... 36 Method of disassembling and connecting push-pull type coupler................................................................................ 39 Standard tightening torque table............................................................................................................. 42 Conversion table............................................................................................................................. 46 01 Specification..................................................................................................................................... 51 Specification and technical data................................................................................................................. 53 Specification dimension drawing.............................................................................................................. 53 Specifications............................................................................................................................... 54 Weight table................................................................................................................................. 58 Table of fuel, coolant and lubricants........................................................................................................ 60 10 Structure, function and maintenance standard...................................................................................................... 63 Engine and cooling system........................................................................................................................ 63 Engine mount and transmission mount.......................................................................................................... 64 Cooling system............................................................................................................................... 65 Cooling fan pump............................................................................................................................. 66 Cooling fan motor............................................................................................................................ 74 Power train...................................................................................................................................... 81 Power train.................................................................................................................................. 83 Power train system diagram................................................................................................................... 84 Drive shaft.................................................................................................................................. 86 Power train piping diagram................................................................................................................... 87 Torque converter............................................................................................................................. 88 Transmission................................................................................................................................. 96 Flow control valve........................................................................................................................... 113 Transmission control valve................................................................................................................... 114 ECMV......................................................................................................................................... 116 Main relief valve and torque converter relief valve.......................................................................................... 122 Axle......................................................................................................................................... 124 Differential................................................................................................................................. 128 Limited slip differential.................................................................................................................... 133 Final drive.................................................................................................................................. 140 Steering system.................................................................................................................................. 147 Steering piping diagram...................................................................................................................... 148 Steering column.............................................................................................................................. 149 Steering pump................................................................................................................................ 150 Steering valve............................................................................................................................... 163 Orbit-roll valve............................................................................................................................. 178 Stop valve................................................................................................................................... 182 Steering relief valve........................................................................................................................ 183 Steering cylinder............................................................................................................................ 184 Emergency steering motor..................................................................................................................... 186 Emergency steering pump...................................................................................................................... 187 Brake system..................................................................................................................................... 189 Brake piping diagram......................................................................................................................... 190 Charge valve................................................................................................................................. 191 Brake valve.................................................................................................................................. 198 Accumulator (for brake)...................................................................................................................... 203 Slack adjuster............................................................................................................................... 204 Brake........................................................................................................................................ 206 Parking brake control........................................................................................................................ 211 Parking brake................................................................................................................................ 212 Parking brake solenoid valve................................................................................................................. 214 Emergency parking brake release valve........................................................................................................ 216 Undercarriage and frame.......................................................................................................................... 217 Axle mount and center hinge pin.............................................................................................................. 218 Tires........................................................................................................................................ 222 Hydraulic system, Part 1......................................................................................................................... 223 Hydraulic piping diagram..................................................................................................................... 224 Work equipment control lever linkage......................................................................................................... 227 Hydraulic tank............................................................................................................................... 228 Power train pump............................................................................................................................. 230 Work equipment pump.......................................................................................................................... 232 Work equipment control valve................................................................................................................. 252 CLSS......................................................................................................................................... 263 Each function and operation of each valve.................................................................................................... 268 Hydraulic system, Part 2......................................................................................................................... 283 PPC valve.................................................................................................................................... 284 Accumulator (for PPC circuit)................................................................................................................ 290 Accumulator (for ECSS)....................................................................................................................... 291 Work equipment................................................................................................................................... 293 Work equipment linkage....................................................................................................................... 294 Bucket....................................................................................................................................... 297 Bucket positioner and boom kick-out.......................................................................................................... 298 Work equipment cylinder...................................................................................................................... 304 Cab and its attachments.......................................................................................................................... 307 Cab.......................................................................................................................................... 307 Air conditioner.............................................................................................................................. 308 Electrical system, Part 1........................................................................................................................ 325 Machine monitor system....................................................................................................................... 326 Machine monitor.............................................................................................................................. 331 Electrical system, Part 2........................................................................................................................ 353 Electrical system (Transmission controller system)........................................................................................... 354 Transmission controller...................................................................................................................... 380 Electrical system, Part 3........................................................................................................................ 383 Electric transmission control................................................................................................................ 384 Combination switch........................................................................................................................... 386 Kickdown switch and hold switch.............................................................................................................. 388 KOMTRAX terminal system...................................................................................................................... 390 Engine starting circuit...................................................................................................................... 392 Engine stopping circuit...................................................................................................................... 394 Preheating circuit........................................................................................................................... 395 Engine power mode selector circuit........................................................................................................... 396 Engine output derating function.............................................................................................................. 397 Automatic warm-up function................................................................................................................... 397 Parking brake circuit........................................................................................................................ 398 Sensor....................................................................................................................................... 400 20 Standard value table.............................................................................................................................. 409 Standard service value table..................................................................................................................... 409 Standard value table for engine.............................................................................................................. 410 Standard value table for chassis............................................................................................................. 411 30 Testing and adjusting............................................................................................................................. 419 Testing and adjusting, Part 1.................................................................................................................... 419 Tools for testing, adjusting, and troubleshooting............................................................................................ 421 Measuring engine speed....................................................................................................................... 424 Measuring exhaust gas color.................................................................................................................. 426 Measuring exhaust temperature................................................................................................................ 427 Adjusting valve clearance.................................................................................................................... 429 Measuring compression pressure............................................................................................................... 431 Measuring blow-by pressure................................................................................................................... 433 Measuring engine oil pressure................................................................................................................ 434 Check of exhaust gas recirculation (EGR) system.............................................................................................. 435 Measuring intake air (boost) pressure........................................................................................................ 436 Handling fuel system equipment............................................................................................................... 437 Releasing residual pressure in fuel system................................................................................................... 437 Testing fuel pressure........................................................................................................................ 438 Testing fuel return and leak amount.......................................................................................................... 439 Bleeding air from fuel circuit............................................................................................................... 442 Testing fuel circuit for leakage............................................................................................................. 444 Handling of reduced cylinder mode operation.................................................................................................. 445 Handling of no injection cranking operation.................................................................................................. 445 Handling controller voltage circuit.......................................................................................................... 446 Check of muffler and muffler stack for looseness and damage.................................................................................. 447 Check of muffler function.................................................................................................................... 447 Check of installed condition of cylinder head and manifolds.................................................................................. 448 Check of engine piping for damage and looseness.............................................................................................. 448 Testing and adjusting air conditioner compressor belt tension................................................................................ 449 Testing and adjusting alternator belt tension................................................................................................ 450 Adjusting transmission speed sensor.......................................................................................................... 451 Adjusting directional lever length........................................................................................................... 452 Adjusting gear shift lever length............................................................................................................ 452 Measuring directional lever.................................................................................................................. 453 Measuring and adjusting power train oil pressure............................................................................................. 454 Procedure for flushing torque converter and transmission hydraulic circuit................................................................... 469 Method of moving machine when transmission valve is broken................................................................................... 470 Check of axle final drive for oil leakage.................................................................................................... 472 Check of drive shafts for looseness, play and damage......................................................................................... 472 Testing and adjusting steering stop valve.................................................................................................... 473 Testing and adjusting steering wheel......................................................................................................... 475 Testing steering oil pressure................................................................................................................ 477 Bleeding air from steering circuit........................................................................................................... 480 Testing and adjusting, Part 2.................................................................................................................... 481 Testing hydraulic drive fan.................................................................................................................. 483 Bleeding air from hydraulic drive fan circuit................................................................................................ 485 Measuring brake pedal........................................................................................................................ 487 Testing and adjusting brake pedal linkage.................................................................................................... 488 Measuring brake performance.................................................................................................................. 489 Testing and adjusting accumulator charge pressure............................................................................................ 490 Testing wheel brake oil pressure............................................................................................................. 491 Measuring wear of wheel brake disc........................................................................................................... 493 Bleeding air from wheel brake circuit........................................................................................................ 494 Releasing residual pressure in brake accumulator circuit..................................................................................... 495 Testing parking brake performance............................................................................................................ 495 Measuring parking brake oil pressure......................................................................................................... 496 Testing wear of parking brake disc........................................................................................................... 498 Manual release method for parking brake...................................................................................................... 499 Measuring and adjusting work equipment control lever......................................................................................... 500 Measuring and adjusting work equipment PPC oil pressure...................................................................................... 501 Measuring and adjusting work equipment oil pressure.......................................................................................... 504 Bleeding air from work equipment circuit..................................................................................................... 508 Releasing residual pressure in work equipment circuit........................................................................................ 509 Testing and adjusting bucket positioner...................................................................................................... 510 Testing and adjusting boom kick- out......................................................................................................... 512 Checking proximity switch operation pilot lamp............................................................................................... 513 Procedure for testing diodes................................................................................................................. 514 Preparation work for troubleshooting for electrical system................................................................................... 515 Starting KOMTRAX terminal operations......................................................................................................... 518 Indicator lamps of KOMTRAX terminal.......................................................................................................... 522 Adjusting machine monitor.................................................................................................................... 525 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....................................................... 526 Testing and adjusting, Part 3.................................................................................................................... 529 Special functions of machine monitor (EMMS).................................................................................................. 530 Pm-click inspection table.................................................................................................................... 591 Pm-click inspection table.................................................................................................................... 594 40 Troubleshooting................................................................................................................................... 597 Failure code table and fuse locations............................................................................................................ 597 Failure code table........................................................................................................................... 598 Fuse locations............................................................................................................................... 610 General information on troubleshooting........................................................................................................... 613 Points to remember when troubleshooting...................................................................................................... 614 Sequence of events in troubleshooting........................................................................................................ 615 Testing before troubleshooting............................................................................................................... 616 Classification and procedures of troubleshooting............................................................................................. 617 Information contained in troubleshooting table............................................................................................... 620 Connection table for connector pin numbers................................................................................................... 622 T-branch box and T-branch adapter table...................................................................................................... 645 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 649 Failure code [1500L0] (TORQFLOW transmission: Double meshing)................................................................................ 651 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)........................................................ 652 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)........................................................ 654 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)........................................................ 656 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)........................................................ 658 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)...................................................... 660 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)...................................................... 662 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)...................................................... 664 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)...................................................... 666 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)...................................................... 668 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)...................................................... 670 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)...................................................... 672 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)...................................................... 674 Failure code [2F00MA] (Parking brake: Malfunction)........................................................................................... 676 Failure code [2G43ZG] (Accumulator: Low oil pressure)........................................................................................ 678 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)........................................................................... 680 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 683 Failure code [AA1ANX] (Air cleaner: Clogging)................................................................................................ 686 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).......................................................... 688 Failure code [AB00MA] (Alternator: Malfunction).............................................................................................. 690 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)......................................................................... 692 Failure code [B@BAZK] (Engine oil: Low level)................................................................................................ 695 Failure code [B@BCNS] (Coolant: Overheating)................................................................................................. 696 Failure code [B@BCZK] (Coolant: Low level)................................................................................................... 698 Failure code [B@C7NS] (Brake oil: Overheating)............................................................................................... 700 Failure code [b@CENS] (Torque converter oil: Overheating).................................................................................... 702 Failure code [B@CENS] (Torque converter oil: Overheating).................................................................................... 704 Failure code [B@HANS] (Hydraulic oil: Overheating)........................................................................................... 706 Failure code [CA111] (Abnormality in engine controller)...................................................................................... 708 Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................................. 711 Failure code [CA122] (Charge pressure sensor high error)..................................................................................... 712 Failure code [CA123] (Charge pressure sensor low error)...................................................................................... 714 Failure code [CA131] (Throttle sensor high error)............................................................................................ 716 Failure code [CA132] (Throttle sensor low error)............................................................................................. 718 Failure code [CA135] (Engine oil pressure sensor high error)................................................................................. 720 Failure code [CA141] (Engine oil pressure sensor low error).................................................................................. 722 Failure code [CA144] (Coolant sensor high error)............................................................................................. 724 Failure code [CA145] (Coolant sensor low error).............................................................................................. 726 Failure code [CA153] (Charge temperature sensor high error).................................................................................. 728 Failure code [CA154] (Charge temperature sensor low error)................................................................................... 730 Failure code [CA187] (Sensor power supply 2 low error)....................................................................................... 732 Failure code [CA221] (Atmospheric pressure sensor high error)................................................................................ 733 Failure code [CA222] (Atmospheric pressure sensor low error)................................................................................. 735 Failure code [CA227] (Sensor power supply 2 high error)...................................................................................... 736 Failure code [CA234] (Engine overspeed)...................................................................................................... 738 Failure code [CA238] (Ne speed sensor power supply error).................................................................................... 740 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 743 Failure code [CA263] (Fuel temperature sensor high error).................................................................................... 746 Failure code [CA265] (Fuel temperature sensor low error)..................................................................................... 748 Failure code [CA271] (PCV1 Short circuit).................................................................................................... 750 Failure code [CA272] (PCV1 Disconnection).................................................................................................... 752 Failure code [CA273] (PCV2 Short circuit).................................................................................................... 754 Failure code [CA274] (PCV2 Disconnection).................................................................................................... 756 Failure code [CA322] (Injector #1 (L/B #1) open/short error)................................................................................. 758 Failure code [CA323] (Injector #5 (L/B #5) open/short error)................................................................................. 760 Failure code [CA324] (Injector #3 (L/B #3) open/short error)................................................................................. 762 Failure code [CA325] (Injector #6 (L/B #6) open/short error)................................................................................. 764 Failure code [CA331] (Injector #2 (L/B #2) open/short error)................................................................................. 766 Failure code [CA332] (Injector #4 (L/B #4) open/short error)................................................................................. 768 Failure code [CA342] (Calibration code inconsistency)........................................................................................ 770 Failure code [CA351] (Injectors drive circuit error)......................................................................................... 771 Failure code [CA352] (Sensor power supply 1 low error)....................................................................................... 773 Failure code [CA386] (Sensor power supply 1 high error)...................................................................................... 774 Failure code [CA431] (Idle validation switch error).......................................................................................... 776 Failure code [CA432] (Idle validation action error).......................................................................................... 778 Failure code [CA441] (Battery voltage low error)............................................................................................. 780 Failure code [CA442] (Battery voltage high error)............................................................................................ 783 Failure code [CA449] Common rail pressure high error 2....................................................................................... 785 Failure code [CA451] (Common rail pressure sensor high error)................................................................................ 786 Failure code [CA452] (Common rail pressure sensor low error)................................................................................. 788 Failure code [CA553] (Common rail pressure high error 1)..................................................................................... 789 Failure code [CA554] (Common rail pressure sensor in-range error)............................................................................ 790 Failure code [CA559] (Supply pump pressure very low error)................................................................................... 791 Failure code [CA689] (Engine Ne speed sensor error).......................................................................................... 795 Failure code [CA731] (Engine Bkup speed sensor phase error).................................................................................. 797 Failure code [CA757] (All continuous data lost error)........................................................................................ 797 Failure code [CA778] (Engine Bkup speed sensor error)........................................................................................ 798 Failure code [CA1228] (EGR valve servo error 1).............................................................................................. 800 Failure code [CA1625] (EGR valve servo error 2).............................................................................................. 801 Failure code [CA1633] (KOMNET datalink timeout error)........................................................................................ 802 Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................................ 804 Failure code [CA2186] (Throttle sensor power supply low error)............................................................................... 805 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 807 Failure code [CA2249] (Supply pump pressure very low error 2)................................................................................ 809 Failure code [CA2271] (EGR valve lift sensor high error)..................................................................................... 810 Failure code [CA2272] (EGR valve lift sensor low error)...................................................................................... 812 Failure code [CA2351] (EGR valve solenoid operation short circuit)........................................................................... 813 Failure code [CA2352] (EGR valve solenoid operation disconnect).............................................................................. 815 Failure code [CA2555] (Intake heater relay disconnection error).............................................................................. 816 Failure code [CA2556] (Intake heater relay short circuit error).............................................................................. 818 Failure code [D150KA] (Emergency steering relay: Disconnection).............................................................................. 820 Failure code [D150KB] (Emergency steering relay: Short circuit).............................................................................. 822 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)....................................................... 824 Failure code [D160KA] (Backup lamp relay: Disconnection)..................................................................................... 826 Failure code [D160KB] (Backup lamp relay: Short circuit)..................................................................................... 828 Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit).................................................................... 830 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)................................................................ 832 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)................................................................ 834 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)......................................... 836 Failure code [D192KA] (ECSS solenoid: Disconnection)......................................................................................... 838 Failure code [D192KB] (ECSS solenoid: Short circuit)......................................................................................... 839 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line).................................................................. 840 Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection).................................................................. 841 Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit).................................................................. 843 Failure code [D193KY] (Joystick steering solenoid cut relay: Short circuit with power supply line)........................................... 845 Failure code [D5ZHKA] (Terminal C signal: Disconnection)..................................................................................... 847 Failure code [D5ZHKB] (Terminal C signal: Short circuit)..................................................................................... 851 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit).................................................................... 854 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)............................................. 859 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)...................................................................... 862 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).......................................................................... 864 Failure code [DAF5KP] (Machine monitor: Low output voltage).................................................................................. 866 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))............. 870 Troubleshooting by failure code (Display of code), Part 5........................................................................................ 873 Failure code [DAQ0KK] (Transmission controller: Low source voltage).......................................................................... 875 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)................................................................... 877 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))........................................... 878 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)..................................... 880 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))..... 881 Failure code [DAQRMA] (Transmission controller option setting: Malfunction).................................................................. 883 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)............ 884 Failure code [DB90KK] Work equipment controller: Low source voltage (input).................................................................. 886 Failure code [DB90KT] Work equipment controller: Abnormality in controller................................................................... 888 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)........................................... 889 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range............................................... 891 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)................................... 894 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)).... 895 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)................................................................ 897 Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation).................................................. 898 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time........................................................ 902 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time........................................................ 904 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time........................................................ 906 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time........................................................ 908 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time................................. 910 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time................................. 912 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time....................................................... 914 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time............................................ 916 Failure code [DD1GLD] Load meter mode selector switch (+/-): Switch is kept pressed for long time............................................ 918 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)............................................. 920 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)............................................................. 922 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)................................................... 924 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).......................................................... 926 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)...................................... 930 Troubleshooting by failure code (Display of code), Part 6........................................................................................ 933 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)......................................................................... 936 Failure code [DDK3KA] (Right FNR switch: Disconnection)...................................................................................... 938 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection).......................................................................... 941 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...................................................... 944 Failure code [DDK6KA] (FNR lever switch: Disconnection)...................................................................................... 946 Failure code [DDK6KB] (FNR lever switch: Short circuit)...................................................................................... 950 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).................................................................. 952 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)................................................ 955 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)............................................................... 958 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).................................................................... 960 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)....................................................... 962 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)........................................................................ 964 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)....................................................................... 968 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected).................................................................... 970 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)................................................................... 972 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range).......................................................... 974 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...................................................................... 976 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)......................................................... 978 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)................................................... 980 Troubleshooting by failure code (Display of code), Part 7........................................................................................ 983 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range).................................................. 986 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range).................................................... 988 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...................................................... 990 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)......................................................................... 992 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)......................................................................... 994 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)............................................................... 996 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)........................................ 999 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).....................................................1002 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)................................................................1005 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).........................................1008 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).................................................................1011 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..........................................1014 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree).......................................................1017 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)..................................................................1020 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...........................................1023 Failure code [DK5DKA] (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection).............................................1026 Failure code [DK5DKY] (3-spool valve (attachment) EPC lever potentiometer (Main): Short circuit with power supply line)......................1029 Failure code [DK5DL8] (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)...................................1031 Failure code [DK5EKA] (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)..............................................1034 Failure code [DK5EKY] (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1038 Troubleshooting by failure code (Display of code), Part 8........................................................................................1041 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)......................................................1043 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...............................1046 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection).......................................................1048 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)................................1051 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)............................................1053 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).................................................................................1056 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..........................................................1058 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)................................................................................1060 Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)................................................................1062 Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range)....................................................1064 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)...................................................................1066 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)............................................................1068 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)............................................................1070 Failure code [DV00KB] (Alarm buzzer: Short circuit)..........................................................................................1072 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...........................................................................1074 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...........................................................................1076 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)....................................................1078 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...........................................................................1080 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...........................................................................1081 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)....................................................1082 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..............................................................................1084 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..............................................................................1085 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line).......................................................1086 Troubleshooting by failure code (Display of code), Part 9........................................................................................1089 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..............................................................................1091 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..............................................................................1092 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line).......................................................1093 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)..................................................................................1095 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)..................................................................................1096 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...........................................................1097 Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)..................................................................1099 Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)..................................................................1100 Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)...........................................1101 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)..................................................................1102 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)..................................................................1104 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...........................................1106 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).................................................................1108 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).................................................................1110 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..........................................1112 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).................................................................1114 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).................................................................1116 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..........................................1118 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)....................................................................1120 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)....................................................................1122 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)....................................................1124 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).................................................................................1126 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).................................................................................1127 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..........................................................1128 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)..................................................................................1130 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)..................................................................................1132 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...........................................................1134 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..............................................................................1136 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..............................................................................1138 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line).......................................................1140 Troubleshooting by failure code (Display of code), Part 10.......................................................................................1143 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..............................................................................1146 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..............................................................................1148 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line).......................................................1150 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..............................................................................1152 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..............................................................................1154 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line).......................................................1156 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)................................................................................1158 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)................................................................................1160 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).........................................................1162 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)................................................................................1164 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)................................................................................1166 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).........................................................1168 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..............................................................................1170 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..............................................................................1172 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line).......................................................1174 Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection).....................................................................1176 Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit).....................................................................1178 Failure code [DXHJKY] (3-spool valve extend EPC solenoid: Short circuit with power supply line)..............................................1180 Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)....................................................................1182 Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)....................................................................1184 Failure code [DXHKKY] (3-spool valve retract EPC solenoid: Short circuit with power supply line).............................................1186 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)..................................................................1188 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)..................................................................1190 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...........................................1192 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)...................................................................1194 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)...................................................................1196 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)............................................1198 Troubleshooting of electrical system (E-mode)....................................................................................................1201 Before carrying out troubleshooting for electrical system....................................................................................1203 Information in troubleshooting table.........................................................................................................1206 E-1 Engine does not start....................................................................................................................1208 E-2 Wiper does not operate...................................................................................................................1214 E-3 Windshield washer does not operate.......................................................................................................1218 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..........................................................1222 E-5 Working lamp does not light up or go off.................................................................................................1230 E-6 Turn signal lamp and hazard lamp do not light up or go off...............................................................................1235 E-7 Brake lamp does not light or it keeps lighting up........................................................................................1241 E-8 Backup lamp does not light or it keeps lighting up.......................................................................................1243 E-9 Backup buzzer does not sound or it keeps sounding........................................................................................1245 E-10 Horn does not sound or it keeps sounding................................................................................................1247 E-11 Alarm buzzer does not sound or it keeps sounding........................................................................................1250 E-12 Air conditioner does not operate or stop................................................................................................1252 E-13 The KOMTRAX system does not work properly...............................................................................................1255 Troubleshooting of hydraulic and mechanical system (H-mode)......................................................................................1257 Method of using troubleshooting chart........................................................................................................1259 Table of failure modes and causes............................................................................................................1262 H-1 The machine does not start...............................................................................................................1266 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]...................................1268 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]....................................................1269 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted...................1270 H-5 Shocks are large at the times of starting and shifting gear..............................................................................1272 H-6 Time lag is large at the times of starting and shifting gear.............................................................................1274 H-7 The torque converter oil temperature is high.............................................................................................1276 H-8 Steering does not turn...................................................................................................................1277 H-9 Steering does not turn [Machine with joystick steering (if equipped)]....................................................................1278 H-10 Steering response is low................................................................................................................1279 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]....................................................1280 H-12 Steering is heavy.......................................................................................................................1281 H-13 When machine turns, it shakes or makes large shocks.....................................................................................1282 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]......................................1283 H-15 The wheel brake does not work or does not work well.....................................................................................1284 H-16 The wheel brake is not released or it drags.............................................................................................1285 H-17 The parking brake does not work or does not work well...................................................................................1286 H-18 The parking brake is not released or it drags (including emergency release system)......................................................1287 H-19 Lift arm does not rise..................................................................................................................1288 H-20 Lift arm speed is low or rising force of lift arm is insufficient.......................................................................1289 H-21 When rising, the lift arm comes to move slowly at specific height.......................................................................1290 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats).......................................................................1290 H-23 Hydraulic drifts of the lift arm is large...............................................................................................1290 H-24 The lift arm wobbles during operation...................................................................................................1290 H-25 Bucket does not tilt back...............................................................................................................1291 H-26 Bucket speed is low or tilting back force is insufficient...............................................................................1292 H-27 The bucket comes to operate slowly in the midst of tilting-back.........................................................................1293 H-28 The bucket cylinder cannot hold down the bucket.........................................................................................1293 H-29 Hydraulic drifts of the bucket is large.................................................................................................1293 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).................................................1293 H-31 Lift arm and bucket control levers do not move smoothly and are heavy...................................................................1294 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls........................................................1295 H-33 Large shock is made when work equipment starts and stops................................................................................1295 H-34 When work equipment circuit is relieved singly, other work equipment moves..............................................................1295 H-35 ECSS does not operate, and pitching, bouncing occur.....................................................................................1296 Troubleshooting of engine (S-mode)...............................................................................................................1297 Method of using troubleshooting chart........................................................................................................1299 S-1 Starting performance is poor.............................................................................................................1302 S-2 Engine does not start....................................................................................................................1304 S-3 Engine does not pick up smoothly.........................................................................................................1308 S-4 Engine stops during operation............................................................................................................1309 S-5 Engine does not rotate smoothly..........................................................................................................1310 S-6 Engine lacks output (or lacks power).....................................................................................................1311 S-7 Exhaust smoke is black (Incomplete combustion)...........................................................................................1312 S-8 Oil is consumed much (or exhaust gas color is blue)......................................................................................1314 S-9 Engine oil becomes contaminated quickly..................................................................................................1315 S-10 Fuel consumption is excessive...........................................................................................................1316 S-11 Coolant contains oil (blows back or reduces)............................................................................................1317 S-12 Oil pressure drops......................................................................................................................1318 S-13 Oil level rises (Water, fuel in oil)....................................................................................................1319 S-14 Coolant temperature rises too high (Overheating)........................................................................................1321 S-15 Abnormal noise is made..................................................................................................................1322 S-16 Vibration is excessive..................................................................................................................1323 50 Disassembly and assembly..........................................................................................................................1325 General information on disassembly and assembly..................................................................................................1325 How to read this manual......................................................................................................................1326 Coating materials list.......................................................................................................................1328 Special tools list...........................................................................................................................1331 Sketches of special tools....................................................................................................................1335 Engine and cooling system........................................................................................................................1347 Removal and installation of engine assembly..................................................................................................1348 Removal and installation of hood.............................................................................................................1352 Removal and installation of radiator assembly................................................................................................1355 Removal and installation of aftercooler assembly.............................................................................................1358 Removal and installation of oil cooler assembly..............................................................................................1360 Removal and installation of cooling fan and drive motor assembly.............................................................................1362 Removal and installation of fuel supply pump assembly........................................................................................1365 Removal and installation of fuel injector assembly...........................................................................................1370 Removal and installation of cylinder head assembly...........................................................................................1375 Removal and installation of fuel tank assembly...............................................................................................1386 Power train, Part 1..............................................................................................................................1389 Removal and installation of torque converter and transmission assembly.......................................................................1390 Disassembly and assembly of torque converter assembly (Standard specification)...............................................................1396 Disassembly and assembly of torque converter assembly (Lockup specification).................................................................1400 Disassembly and assembly of transmission assembly............................................................................................1407 Disassembly and assembly of transmission clutch pack assembly................................................................................1421 Disassembly and assembly of parking brake assembly...........................................................................................1438 Power train, Part 2..............................................................................................................................1445 Removal and installation of front axle assembly..............................................................................................1446 Removal and installation of rear axle assembly...............................................................................................1448 Disassembly and assembly of axle housing assembly............................................................................................1454 Disassembly and assembly of differential assembly............................................................................................1463 Undercarriage and frame..........................................................................................................................1483 Removal and installation of center hinge pin.................................................................................................1484 Removal and installation of counterweight....................................................................................................1492 Hydraulic system.................................................................................................................................1495 Removal and installation of steering demand valve assembly...................................................................................1496 Removal and installation of work equipment valve assembly....................................................................................1499 Removal and installation of brake charge valve assembly......................................................................................1502 Removal and installation of hydraulic tank assembly..........................................................................................1503 Removal and installation of steering and power train pump assembly...........................................................................1505 Removal and installation of work equipment and cooling fan pump assembly.....................................................................1507 Work equipment...................................................................................................................................1509 Removal and installation of work equipment assembly..........................................................................................1510 Cab and its attachments..........................................................................................................................1515 Removal and installation of operator's cab and floor frame assembly..........................................................................1516 Removal and installation of operator's cab glass (stuck glass)...............................................................................1520 Disassembly and assembly of operator's seat assembly.........................................................................................1528 Electrical system................................................................................................................................1537 Removal and installation of air conditioner unit assembly....................................................................................1538 Removal and installation of engine controller assembly.......................................................................................1542 Removal and installation of transmission controller assembly.................................................................................1543 Removal and installation of KOMTRAX controller assembly......................................................................................1544 90 Diagrams and drawings.............................................................................................................................1545 Hydraulic diagrams and drawings..................................................................................................................1546 Power train hydraulic circuit diagram........................................................................................................1546 Electrical diagrams and drawings.................................................................................................................1551 Electrical circuit diagram (1/2).............................................................................................................1553 Electrical circuit diagram (2/2).............................................................................................................1554
KOMATSU WA470-6, WA480-6 WHEEL LOADER SHOP MANUAL VEBM94610 – PDF DOWNLOAD:
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