Komatsu WA470-6 WA480-6 Wheel Loader Shop Manual VEBM946101

Description

Komatsu WA470-6 WA480-6 Wheel Loader Shop Manual VEBM946101- PDF DOWNLOAD

FILE DETAILS:

Komatsu WA470-6 WA480-6 Wheel Loader Shop Manual VEBM946101- PDF DOWNLOAD 

Language : English
Pages : 1554
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu WA470-6 WA480-6 Wheel Loader Shop Manual VEBM946101- PDF DOWNLOAD 

MACHINE MODEL  SERIAL NUMBER
WA470-6                  H50051 and up
WA480-6                  H60051 and up

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

DESCRIPTION:

Komatsu WA470-6 WA480-6 Wheel Loader Shop Manual VEBM946101- PDF DOWNLOAD 

MACHINE MODEL  SERIAL NUMBER
WA470-6                  H50051 and up
WA480-6                  H60051 and up

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.

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24