Komatsu Wheel Loader WA470-6R WA480-6R service & repair manual

Description Komatsu Wheel Loader WA470-6R WA480-6R service & repair manual

Komatsu Wheel Loader WA470-6R, WA480-6R pdf workshop service manual

Serial numbers:
10001 and up

Technical documentation, specifications, testing, troubleshooting, maintenance, electrical diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification dimension drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train system diagram
Drive shaft
Power train piping diagram
Torque converter
Transmission
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Axle
Differential
Limited slip differential
Final drive
Steering system
Steering component layout drawing
Steering column
Steering pump
Steering valve
Orbitroll valve
Stop valve
Steering relief valve
Steering cylinder
Emergency steering motor
Emergency steering pump
Joystick steering lever linkage
Electrical steering lever
Joystick EPC valve
Brake system
Brake component layout drawing
Component layout of brake cooling system
Brake cooling control system
Charge valve
Brake valve
Accumulator (for brake)
Slack adjuster
Brake
Parking brake control
Parking brake
Parking brake solenoid valve
Emergency parking brake release valve
Brake cooling oil cooler
Brake cooling pump motor
Brake cooling fan
Undercarriage and frame
Axle mount and center hinge pin
Tires
Hydraulic system
Hydraulic component layout drawing
Work equipment control lever linkage
Hydraulic tank
Power train pump
Work equipment pump
Work equipment control valve
CLSS
Each function and operation of each valve
PPC valve
Accumulator (for PPC circuit)
Accumulator (for power train circuit)
Accumulator (for ECSS)
Work equipment PPC cutoff solenoid valve
Work equipment
Work equipment linkage
Bucket
Bucket positioner and boom kickout
Work equipment cylinder
Cab and its attachments
Cab
Air conditioner
Electrical system
Machine monitor system
Machine monitor
Electrical system (Transmission controller system)
Transmission controller
Electrical system (Work equipment controller system)
Work equipment controller
Electric transmission control
Kickdown switch and hold switch
Load meter cancel switch and load meter subtotal switch
Multifunction knob
Joystick steering knob
KOMTRAX system
Engine starting circuit
Engine stopping circuit
Preheating circuit
Engine power mode selector circuit
Engine output derating function
Automatic warmup function
Parking brake circuit
Sensor

Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis

Testing and adjusting
Related information on testing and adjusting
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Engine and cooling system
Testing exhaust gas color
Testing exhaust temperature
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Testing fuel pressure
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Handling of controller voltage circuit
Check of muffler and muffler stack for looseness and damage
Check of muffler function
Check of installed condition of cylinder head and manifolds
Check of engine piping for damage and looseness
Testing and adjusting air conditioner compressor belt tension
Testing and adjusting alternator belt tension
Power train
Adjusting transmission speed sensor
Adjusting directional lever length
Adjusting gear shift lever length
Testing FNR lever and gear shift lever
Testing and adjusting power train oil pressure
Procedure for flushing torque converter and transmission hydraulic circuit
Method of moving machine when transmission valve is broken
Check of axle final drive for oil leakage
Check of drive shafts for looseness, play and damage
Steering system
Testing and adjusting steering stop valve
Testing and adjusting steering wheel
Testing steering oil pressure
Bleeding air from steering circuit
Brake system
Testing brake pedal
Testing and adjusting brake pedal linkage
Testing brake performance
Testing and adjusting accumulator charge pressure
Testing wheel brake oil pressure
Testing wear of wheel brake disc
Bleeding air from wheel brake circuit
Releasing residual pressure in brake accumulator circuit
Testing parking brake performance
Testing parking brake oil pressure
Testing wear of parking brake disc
Manual release method for parking brake
Hydraulic system
Testing hydraulic drive fan
Adjustment of hydraulic fan speed sensor
Bleeding air from hydraulic drive fan circuit
Testing and adjusting work equipment control lever
Testing and adjusting work equipment PPC oil pressure
Testing and adjusting work equipment oil pressure
Bleeding air from work equipment circuit
Releasing residual pressure in work equipment circuit
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically
Controlled Suspension System) accumulator
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator
Work equipment
Testing and adjusting bucket positioner
Testing and adjusting boom kickout
Checking proximity switch operation pilot lamp
Electrical system
Procedure for testing diodes
Preparation work for troubleshooting for electrical system
How to start KOMTRAX terminal operations
Indicator lamps of KOMTRAX terminal
Adjusting replaced, reassembled or added sensor, controller, etc with machine monitor
Special functions of machine monitor (EMMS)
Pm-clinic
Pm-clinic inspection table

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
How to proceed in troubleshooting
Testing before troubleshooting
Classification and procedures of troubleshooting
Failure code table
Information in troubleshooting table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Fuse locations
Phenomena looking like troubles and troubleshooting Nos
Information contained in troubleshooting table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of engine assembly
Removal and installation of engine hood assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of oil cooler assembly
Removal and installation of cooling fan and drive motor assembly
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front oil seal
Removal and Installation of engine rear oil seal
Removal and installation of fuel tank assembly
Power train
Removal and installation of torque converter and transmission assembly
Disassembly and assembly of torque converter and transmission assembly
Disassembly and assembly of torque converter assembly (Standard specification)
Disassembly and assembly of torque converter assembly (Lockup specification)
Disassembly and assembly of clutch pack assembly
Removal and installation of front axle assembly
Removal and installation of rear axle assembly
Disassembly and assembly of axle housing assembly
Disassembly and assembly of differential assembly
Brake system
Removal and installation of parking brake disc and plate
Undercarriage and frame
Removal and installation of center hinge pin
Removal and installation of counterweight
Hydraulic system
Removal and installation of steering demand valve assembly
Removal and installation of work equipment valve assembly
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
Removal and installation of work equipment and cooling fan pump assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operators cab and floor frame assembly
Removal and installation of operators cab glass (stuck glass)
Disassembly and assembly of operators seat assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of KOMTRAX terminal assembly

Appendix
Air conditioner
Precautions for refrigerant
Troubleshooting procedure
Circuit diagram and arrangement of connector pins
System diagram
Detail of air conditioner unit
Parts and connectors layout
Testing with self-diagnosis function (indication on control panel)
Testing temperature control
Testing vent (mode) changeover
Testing Fresh/Recirc changeover
Testing inside air temp sensor and outside air temp sensor
Testing evaporator temperature sensor
Testing sunlight sensor
Testing relays
Troubleshooting chart
Information in troubleshooting table
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for vent (mode) changeover
Troubleshooting for Fresh/Recirc air changeover
Troubleshooting with gauge pressure
Connection of service tool
Handling of compressor oil

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Power train hydraulic circuit diagram
Automatic greasing circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Electrical circuit diagram (rear view camera)
Work equipment controller system electrical circuit diagram
Connector list and stereogram

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