Komatsu WA470-6 Shop Manual
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Komatsu WA470-6 Shop Manual

Wheel loader
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Manual
WA470-
WA480
WHEEL LOADER
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.
Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
May 2012
6
-6
WA470-6 A46001
WA480-6 A48001
6D125E-5
Copyright 2012 Komatsu
Printed in U.S.A.
Komatsu America Corp.
CEBM023002
and up
and up

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  • Page 1 6D125E-5 ENGINE This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 DIAGRAMS AND SCHEMATICS..........90-1 00-2 WA470-6, WA480-6 Find manuals at https://best-manuals.com...
  • Page 3 10-4 10-33 00-6 00-36 10-5 10-34 00-7 00-37 10-6 10-35 00-8 00-38 10-7 10-36 00-9 00-39 10-8 10-37 00-10 00-40 10-9 10-38 00-11 00-41 10-10 10-39 00-12 00-42 10-11 10-40 00-13 WA470-6, WA480-6 00-2-1 WA470-6, WA480-6 Find manuals at https://best-manuals.com...
  • Page 4 10-164 10-66 10-99 10-132 10-165 10-67 10-100 10-133 10-166 10-68 10-101 10-134 10-167 10-69 10-102 10-135 10-168 10-70 10-103 10-136 10-169 10-71 10-104 10-137 10-170 10-72 10-105 10-138 10-171 10-73 10-106 10-139 10-172 00-2-2 WA470-6, WA480-6 Find manuals at https://best-manuals.com...
  • Page 5 10-296 10-231 10-264 10-297 10-198 10-199 10-232 10-265 10-298 10-200 10-233 10-266 10-299 10-201 10-234 10-267 10-300 10-202 10-235 10-268 10-301 10-203 10-236 10-269 10-302 10-204 10-237 10-270 10-303 10-205 10-238 10-271 10-304 WA470-6, WA480-6 00-2-3 Find manuals at https://best-manuals.com...
  • Page 6 30-34 10-330 10-363 30-2 30-35 10-331 10-364 30-3 30-36 10-332 10-365 30-4 30-37 10-333 10-366 30-5 30-38 10-334 10-367 30-6 30-39 10-335 10-368 30-7 30-40 10-336 10-369 30-8 30-41 10-337 10-370 30-9 30-42 00-2-4 WA470-6, WA480-6 Find manuals at https://best-manuals.com...
  • Page 7 30-166 30-101 30-134 30-167 30-68 30-69 30-102 30-135 30-168 30-70 30-103 30-136 30-169 30-71 30-104 30-137 30-170 30-72 30-105 30-138 30-171 30-73 30-106 30-139 30-172 30-74 30-107 30-140 30-173 30-75 30-108 30-141 30-174 WA470-6, WA480-6 00-2-5 Find manuals at https://best-manuals.com...
  • Page 8 40-85 30-200 40-20 40-53 40-86 30-201 40-21 40-54 40-87 30-202 40-22 40-55 40-88 30-203 40-23 40-56 40-89 30-204 40-24 40-57 40-90 30-205 40-25 40-58 40-91 30-206 40-26 40-59 40-92 30-207 40-27 40-60 40-93 00-2-6 WA470-6, WA480-6 Find manuals at https://best-manuals.com...
  • Page 9 40-217 40-152 40-185 40-218 40-119 40-120 40-153 40-186 40-219 40-121 40-154 40-187 40-220 40-122 40-155 40-188 40-221 40-123 40-156 40-189 40-222 40-124 40-157 40-190 40-223 40-125 40-158 40-191 40-224 40-126 40-159 40-192 40-225 WA470-6, WA480-6 00-2-7 Find manuals at https://best-manuals.com...
  • Page 10 40-349 40-251 40-284 40-317 40-350 40-252 40-285 40-318 40-351 40-253 40-286 40-319 40-352 40-254 40-287 40-320 40-353 40-255 40-288 40-321 40-354 40-256 40-289 40-322 40-355 40-257 40-290 40-323 40-356 40-258 40-291 40-324 40-357 00-2-8 WA470-6, WA480-6 Find manuals at https://best-manuals.com...
  • Page 11 40-480 40-382 40-415 40-448 40-481 40-383 40-416 40-449 40-482 40-384 40-417 40-450 40-483 40-385 40-418 40-451 40-484 40-386 40-419 40-452 40-485 40-387 40-420 40-453 40-486 40-388 40-421 40-454 40-487 40-389 40-422 40-455 40-488 40-390 40-423 40-456 40-489 WA470-6, WA480-6 00-2-9...
  • Page 12 40-612 40-514 40-547 40-580 40-613 40-515 40-548 40-581 40-614 40-516 40-549 40-582 40-615 40-517 40-550 40-583 40-616 40-518 40-551 40-584 40-617 40-519 40-552 40-585 40-618 40-520 40-553 40-586 40-619 40-521 40-554 40-587 40-620 40-522 40-555 40-588 40-621 00-2-10 WA470-6, WA480-6...
  • Page 13 40-744 40-646 40-679 40-712 40-745 40-647 40-680 40-713 40-746 40-648 40-681 40-714 40-747 40-649 40-682 40-715 40-748 40-650 40-683 40-716 40-749 40-651 40-684 40-717 40-750 40-652 40-685 40-718 40-751 40-653 40-686 40-719 40-752 40-654 40-687 40-720 40-753 WA470-6, WA480-6 00-2-11...
  • Page 14 50-63 50-96 ❍ 40-779 50-31 50-64 50-97 ❍ 40-780 50-32 50-65 50-98 50-33 50-66 50-99 50-1 50-34 50-67 50-100 50-2 50-35 50-68 50-101 ● 50-3 50-36 50-69 50-102 ● 50-4 50-37 50-70 50-103 50-5 50-38 50-71 50-104 00-2-12 WA470-6, WA480-6...
  • Page 15 50-227 50-129 50-162 50-195 50-228 50-130 50-163 50-196 50-229 50-131 50-164 50-197 50-230 50-132 50-165 50-198 50-231 50-133 50-166 50-199 50-232 50-134 50-167 50-200 50-233 50-135 50-168 50-201 50-234 50-136 50-169 50-202 50-235 50-137 50-170 50-203 50-236 WA470-6, WA480-6 00-2-13...
  • Page 16 50-359 50-261 50-294 50-327 50-360 50-262 50-295 50-328 50-361 50-263 50-296 50-329 50-362 50-264 50-297 50-330 50-363 50-265 50-298 50-331 50-364 50-266 50-299 50-332 50-365 50-267 50-300 50-333 50-366 50-268 50-301 50-334 50-367 50-269 50-302 50-335 50-368 00-2-14 WA470-6, WA480-6...
  • Page 17 90-11 60-11 60-44 90-12 60-12 60-45 90-13 60-13 60-46 90-14 60-14 60-47 90-15 60-15 60-48 90-16 60-16 60-49 90-17 60-17 60-50 90-18 60-18 60-51 90-19 60-19 60-52 90-20 60-20 60-53 90-21 60-21 60-54 90-22 60-22 60-55 90-23 WA470-6, WA480-6 00-2-15...
  • Page 18 FOREWORD MEMORANDA 00-2-16 WA470-6, WA480-6...
  • Page 19 Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their WA470-6, WA480-6 00-3...
  • Page 20 15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the machine. 00-4 WA470-6, WA480-6...
  • Page 21 DIAGRAMS AND SCHEMATICS This section has the foldout drawings for the machine. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information. WA470-6, WA480-6 00-5...
  • Page 22 (-) and numbered after the page number. File as drained. in the example. Example: 10-4 10-4-1 Added pages 10-4-2 10-5 REVISED EDITION MARK When a manual is revised, an edition mark (bcd…) is recorded on the bottom outside corner of the pages. 00-6 WA470-6, WA480-6...
  • Page 23 Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident WA470-6, WA480-6 00-7...
  • Page 24 The tightness of fit is decided by the tolerance. • Indication of size of rotating shaft and hole and relationship drawing of them. • Example: Tolerance Standard size Shaft Hole –0.030 +0.046 –0.076 00-8 WA470-6, WA480-6...
  • Page 25 The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. • The interference limit shows the repair limit of the part of smaller tolerance. • If the interference between the parts exceeds the interference limit, they must be replaced or repaired. WA470-6, WA480-6 00-9...
  • Page 26 The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. 00-10 WA470-6, WA480-6...
  • Page 27 ★ If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with com- pressed air. WA470-6, WA480-6 00-11...
  • Page 28 ★ If the machine is left disassembled for a long time, it is particu- larly easy for improper contact to occur, so always cover the connector. 00-12 WA470-6, WA480-6...
  • Page 29 ★ If the connector cannot be plugged in easily, remove the clamp and adjust the position. ★ If the connector clamp has been removed, be sure to return it to its original position. Check that there are no loose clamps. WA470-6, WA480-6 00-13...
  • Page 30 (2) while moving it up and down until the locks are set normally. Arrows: 1), 2), 3) ★ Right figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks 00-14 WA470-6, WA480-6...
  • Page 31 After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble. WA470-6, WA480-6 00-15...
  • Page 32 D. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. ★ If there is any change, there is probably defective contact in that circuit. 00-16 WA470-6, WA480-6...
  • Page 33 Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method. WA470-6, WA480-6 00-17...
  • Page 34 The oil cleaning equipment is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device. 00-18 WA470-6, WA480-6...
  • Page 35 A does not float. In this case, float part A with a small screwdriver while pressing lock (L2), and then pull out connector (1) toward you. Pull Lock Type PACKARD-2 ★ 95 – 170, 12V140 engines WA470-6, WA480-6 00-19...
  • Page 36 ★ If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow. 00-20 WA470-6, WA480-6...
  • Page 37 Connector Sensor Fuel pressure sensor in common rail: AMP-3 PFUEL, etc. ★ Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2) ★ Speed sensor of fuel supply pump: G (SUMITOMO-3) ★ Pull the connector straight up. WA470-6, WA480-6 00-21...
  • Page 38 ★ Housing (H1) is left on the wiring harness side. Connect the connector according to the following procedure. A. Insert the connector to the end, while setting its groove. B. Turn housing (H1) in the direction of the arrow until it clicks. 00-22 WA470-6, WA480-6...
  • Page 39 02789-20210 07376-70315 02789-20315 07376-70422 02789-20422 07376-70522 02789-20522 07376-70628 02789-20628 07376-71034 07221-21034 07376-71234 07221-21234 • Split flange type hoses and tubes Nominal Flange (hose end) Sleeve Head (tube end) Split Flange Number 07379-00400 07378-10400 07371-30400 07379-00500 07378-10500 07371-30500 WA470-6, WA480-6 00-23...
  • Page 40 Next, operate the hydraulic cylinder three to four times to the end of its stroke. After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, do the same procedure. 00-24 WA470-6, WA480-6...
  • Page 41 • Check the muffler for abnormal sound and sound different from that of a new muffler. • If any abnormal sound is heard, repair the muffler. Refer to both the Troubleshooting and the Disassembly and Assembly sections. WA470-6, WA480-6 00-25...
  • Page 42 After inserting the hose in the mating adapter, pull it back to check its connecting condition. When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate an abnormality. 00-26 WA470-6, WA480-6...
  • Page 43 (2) to disconnect it. CONNECTION Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts surface (a) of the hexagonal portion at the male end to connect it. WA470-6, WA480-6 00-27...
  • Page 44 (2) to disconnect it. CONNECTION Hold the mouthpiece of the tightening portion and push the body (2) in straight until the slide prevention ring (1) contacts surface (a) of the hexagonal portion at the male end to connect it. 00-28 WA470-6, WA480-6...
  • Page 45 Used as sealant for flange surfaces and bolts Gasket at high temperature locations; used to sealant LG-3 790-129-9070 1 kg prevent seizure. ● Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe. WA470-6, WA480-6 00-29...
  • Page 46 Used for normal temperature, light load SYG2-400CA-A G2-CA Various Various bearing at places in contact with water or SYG2-160CA Grease steam. SYG2- 160CNCA 400 g (10 per ● SYG2-400M Belows type Used for places with heavy load. case) 00-30 WA470-6, WA480-6...
  • Page 47 2131.55 - 2677.35 Thread diameter of bolt Width across flats N•m lbf ft 5.9 - 9.8 4.35 - 7.22 13.7 - 23.5 10.10 - 17.33 34.3 - 46.1 25.29 - 34.00 74.5 - 90.2 54.94 - 66.52 WA470-6, WA480-6 00-31...
  • Page 48 36.1 ± 14.4 78.5 ± 19.6 57.8 ± 14.4 137.3 ± 29.4 101.2 ± 21.6 176.5 ± 29.4 130.1 ± 21.6 196.1 ± 49 144.6 ± 36.1 245.2 ± 49 180.8 ± 36.1 294.2 ± 49 216.9 ± 36.1 00-32 WA470-6, WA480-6...
  • Page 49 177 - 245 {130.5 - 180.7} 216 {159.3} 1 3/16 - 12UN 30.2 (10) 177 - 245 {130.5 - 180.7} 216 {159.3} (12) 197 - 294 {145.3 - 216.8} 245 {180.7} (14) 246 - 343 {181.4 - 252.9} 294 {216.8} WA470-6, WA480-6 00-33...
  • Page 50 White & Red & Yellow & Green & Blue & Color — — Green Green Blue Black Black Code — — — — Yellow & Green & Color — — — Red & Blue — White Blue 00-34 WA470-6, WA480-6...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

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