Komatsu WA470-6 Shop Manual

Wheel loader

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Shop manual (52 pages)

Shop manual (51 pages)

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WHEEL LOADER

WA470

WA480

SERIAL NUMBERS

SEN04409-06

-6

WA470- 90001

and up

WA480- 90001

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Summary of Contents for Komatsu WA470-6

Page 1 SEN04409-06 WHEEL LOADER WA470 WA480 WA470- 90001 SERIAL NUMBERS and up WA480- 90001...
Page 2 SEN04418-06 WHEEL LOADER WA470-6 WA480-6 Machine model Serial number WA470-6 90001 and up WA480-6 90001 and up 00 Index and foreword 100 Index Composition of shop manual .......................... 2 Table of contents ............................. 4 WA470, 480-6 00-100...
Page 3 100 Index SEN04418-06 Composition of shop manual Composition of shop manual The contents of this shop manual are shown together with Form No. in a list. Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No.
Page 4 100 Index SEN04418-06 Composition of shop manual 304 Troubleshooting by failure code (Display of code), Part 4..........SEN04524-01 305 Troubleshooting by failure code (Display of code), Part 5..........SEN04525-02 306 Troubleshooting by failure code (Display of code), Part 6..........SEN04526-03 q 307 Troubleshooting by failure code (Display of code), Part 7..........SEN04527-02 308 Troubleshooting by failure code (Display of code), Part 8..........SEN04528-04 309 Troubleshooting by failure code (Display of code), Part 9..........SEN04529-01 310 Troubleshooting by failure code (Display of code), Part 10..........SEN04530-01...
Page 5 100 Index SEN04418-06 Table of contents Table of contents 00 Index and foreword 100 Index SEN04418-06 Composition of shop manual......................... Table of contents ............................200 Foreword and general information SEN04419-01 Safety notice ..............................How to read the shop manual ........................Explanation of terms for maintenance standard....................
Page 6 100 Index SEN04418-06 Table of contents Electrical steering lever ..........................49 Joystick EPC valve ............................50 400 Brake system SEN04424-01 Brake component layout drawing ........................Charge valve ..............................Brake valve..............................10 Accumulator (for brake) ..........................15 Slack adjuster ..............................16 Brake ................................
Page 7 100 Index SEN04418-06 Table of contents Engine power mode selector circuit ......................16 Engine output derating function ........................17 Automatic warm-up function.......................... 17 Parking brake circuit............................18 Sensor................................20 20 Standard value table 100 Standard service value table SEN04515-01 Standard value table for engine ........................Standard value table for chassis ........................
Page 8 100 Index SEN04418-06 Table of contents Testing brake performance ..........................10 Testing and adjusting accumulator charge pressure ..................11 Testing wheel brake oil pressure ........................13 Testing wear of wheel brake disc........................15 Bleeding air from wheel brake circuit......................16 Releasing residual pressure in brake accumulator circuit ................
Page 9 100 Index SEN04418-06 Table of contents Failure code [2G43ZG] (Accumulator: Low oil pressure) ................30 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ............32 302 Troubleshooting by failure code (Display of code), Part 2 SEN04522-03 Failure code [AA1ANX] (Air cleaner: Clogging) .................... Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) ........
Page 10 100 Index SEN04418-06 Table of contents Failure code [CA559] (Supply pump pressure very low error)............... 49 Failure code [CA689] (Engine Ne speed sensor error) ................. 53 Failure code [CA731] (Engine Bkup speed sensor phase error) ..............55 Failure code [CA757] (All continuous data lost error)..................55 Failure code [CA778] (Engine Bkup speed sensor error)................
Page 11 100 Index SEN04418-06 Table of contents Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals) ................36 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system) ........37 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ........42 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)..........
Page 12 100 Index SEN04418-06 Table of contents Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)........21 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) ..24 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ........27 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..
Page 13 100 Index SEN04418-06 Table of contents Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) ......38 Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection) ........... 40 Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)............42 Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection) ..........
Page 14 100 Index SEN04418-06 Table of contents E-19 FNR switch mode cannot be set or reset....................66 E-20 Fan reverse function cannot be used or reset ..................68 E-21 Discharge from loader pump does not rise from minimum level............70 E-22 ECSS function cannot be used or reset....................72 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up ......
Page 15 100 Index SEN04418-06 Table of contents 600 Troubleshooting of engine (S-mode) SEN04533-02 Method of using troubleshooting chart ......................S-1 Starting performance is poor........................S-2 Engine does not start..........................S-3 Engine does not pick up smoothly......................12 S-4 Engine stops during operation........................ 13 S-5 Engine does not rotate smoothly ......................
Page 16 100 Index SEN04418-06 Table of contents Removal and installation of brake charge valve assembly................Removal and installation of hydraulic tank assembly ..................Removal and installation of steering and power train pump assembly............11 Removal and installation of work equipment and cooling fan pump assembly ..........12 Disassembly and assembly of hydraulic cylinder assembly ................
Page 17 100 Index SEN04418-06 Table of contents Electrical circuit diagram (6/10)........................13 Electrical circuit diagram (7/10)........................15 Electrical circuit diagram (8/10)........................17 Electrical circuit diagram (9/10)........................19 Electrical circuit diagram (10/10)........................21 Work equipment controller system electrical circuit diagram ................ 23 Connector list and stereogram ........................
Page 18 SEN04419-01 WHEEL LOADER WA470-6 WA480-6 Machine model Serial number WA470-6 90001 and up WA480-6 90001 and up 00 Index and foreword 200 Foreword and general information Safety notice ..............................2 How to read the shop manual ......................... 7 Explanation of terms for maintenance standard ..................... 9 Handling of electric equipment and hydraulic component ................11...
Page 19 Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose.
Page 20 200 Foreword and general information SEN04419-01 Safety notice Preparations for work When removing a cover which is under Before adding oil or making any repairs, internal pressure or under pressure from a park the machine on a hard and level spring, always leave 2 bolts in diagonal ground, and apply the parking brake and positions.
Page 21 200 Foreword and general information SEN04419-01 Safety notice Precautions for sling work and making signs Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily.
Page 22 200 Foreword and general information SEN04419-01 Safety notice If the load is unstable or the wire rope 13) If the hoist stops because of a power fail- or chains are twisted, lower the load ure, turn the power switch OFF. When and lift it up again.
Page 23 200 Foreword and general information SEN04419-01 Safety notice a Example of O-ring (Fitted to every joint of Precautions for disconnecting and con- necting hoses and tubes in air conditioner hoses and tubes) circuit Disconnection For the environment, the air condi- tioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of...
Page 24 This section explains the method of reproducing, repairing, and replacing parts. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. WA470, 480-6...
Page 25 200 Foreword and general information SEN04419-01 How to read the shop manual Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1.
Page 26 200 Foreword and general information SEN04419-01 Explanation of terms for maintenance standard Explanation of terms for maintenance standard The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance To be accurate, the finishing size of parts is a little different from one to another.
Page 27 200 Foreword and general information SEN04419-01 Explanation of terms for maintenance standard Standard clearance and standard value Clearance limit The clearance made when new parts are Parts can be used until the clearance assembled is called the “standard clear- between them is increased to a certain ance“, which is indicated by the range limit.
Page 28 200 Foreword and general information SEN04419-01 Handling of electric equipment and hydraulic component Handling of electric equipment and hydraulic component To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out.
Page 29 200 Foreword and general information SEN04419-01 Handling of electric equipment and hydraulic component Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the sol- dering may be damaged, or the wiring...
Page 30 200 Foreword and general information SEN04419-01 Handling of electric equipment and hydraulic component Removing, installing, and drying connec- tors and wiring harnesses Disconnecting connectors Hold the connectors when discon- necting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
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Wa480-6