Komatsu Wheel Loader WA470-8E0 service & repair manual

Description Komatsu Wheel Loader WA470-8E0 service & repair manual

Komatsu Wheel Loader WA470-8E0 pdf workshop service repair manual

Serial numbers:
100439 and up

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

SERVICE MANUAL CONTENT:
Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions for Disposing of Waste Materials
Procedures for Exhaust Gas Regulations
Precautions for DEF
Store DEF
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect PushPull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table

Specifications
Abbreviation List
Specification Drawing
Weight Table
Table of Fuel, Coolant, and Lubricants

Structure and Function
Abbreviation List
Urea SCR System
Layout Drawing of Urea SCR System
Urea SCR System Diagram
Function of Urea SCR System
Component Parts of Urea SCR System
Bootup System
Layout Drawing of Bootup System (Machine with KOMTRAX Terminal)
Layout Drawing of Bootup System (Machine with Gateway Function Controller)
System Operating Lamp System
Battery Disconnect Switch
Preheating System
Engine System
Layout Drawing of Engine System
Engine Control System
Engine Power Mode Selector System
Automatic Idle Stop System
Component Parts of Engine System
Cooling System
Layout Drawing of Cooling System
Cooling Fan Control System
Component Parts of Cooling System
Control System
Layout Drawing of Control System (Machine with KOMTRAX Terminal)
Layout Drawing of Control System (Machine with Gateway Function Controller)
Machine Monitor System
Rearview Monitor System
KOMTRAX System
RDS Load Meter System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Work Equipment Pump and Steering Pump Control System
Component Parts of Hydraulic System
Power Train System
Layout Drawing of Power Train System
Operation of Power Train System
Transmission Control System
Transmission Gear Shift Control System
Transmission Protection Function
Directional Selector Switch Control Function
Transmission Cutoff Function
Component Parts of Power Train System
Work Equipment System
Layout Drawing of Work Equipment System
Work Equipment System Diagram (Applicable Machine: 100439 to 101011)
Work Equipment System Diagram (Applicable Machine: 101012 and Up)
Work Equipment Control System
Work Equipment Neutral Lock System
Remote Positioner System
Bucket Positioner and Boom Positioner
AutoDigging System
SemiAuto Digging System
ECSS
Component Parts of Work Equipment System
Steering System
Layout Drawing of Steering System
Secondary Steering System
Joystick Steering System
Steering Column
Component Parts of Steering System
Brake System
Layout Drawing of Brake System
Parking Brake Control System
Brake Cooling Control System
Component Parts of Brake System
AutoGreasing System
Layout Drawing of AutoGreasing System
Specifications of AutoGreasing System
Function of AutoGreasing System
AutoGreasing System
Undercarriage and Frame
Frame, Axle Mount and Center Hinge Pin
Tires
Work Equipment
Structure of Work Equipment
Structure of Bucket
CAB Related Parts
ROPS CAB

Standard Value Table
Abbreviation List
Standard Value Table for Engine
Standard Value Table for Engine: WA470-8E0
Standard Value Table for Machine
Standard Value Table for Machine: WA470-8E0
Machine Posture and Procedures to Measure Performance
Standard Value Table for Electricity
Standard Value Table for Electricity

Testing and Adjusting
Precautions Before Work
Abbreviation List
Related Information on Testing and Adjusting
Differences In Machine Monitor Symbols
Tools for Testing and Adjusting
Sketch of Tools for Testing and Adjusting
Engine and Cooling System
Examine Engine Speed
Examine Boost Pressure
Examine Exhaust Gas Temperature
Examine Exhaust Gas Color
Examine Mass Air Flow and Temperature Sensor
Examine and Adjust Valve Clearance
Examine Compression Pressure
Examine Blowby Pressure
Examine Engine Oil Pressure
Examine EGR Valve and VGT Oil Pressure
Examine Fuel Pressure
Examine Fuel Return Rate and Leakage
Bleed Air from Fuel System
Examine Fuel Circuit for Leakage
Handle Cylinder Cutout Mode Operation
Handle No-Injection Cranking Operation
Examine KDPF, SCR and Muffler Stack for Looseness and Damage
Examine Installed Condition of Cylinder Heads and Manifolds
Examine Engine Piping for Damage and Looseness
Examine and Adjust Air Conditioner Compressor Belt Tension
Examine Alternator Belt
Examine Automatic Tensioner
Clean Fuel Doser
Write Injector Compensation Value to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
Examine SCR Related Functions
Clean DEF Tank
Clean DEF Pump
Power Train
Examine and Adjust Power Train Oil Pressure
Adjust Transmission Input Shaft Speed Sensor
Adjust Transmission Output Shaft Speed Sensor
Flush Torque Converter and Transmission Hydraulic Circuit
Precautions Before Work
Abbreviation List
Related Information to Troubleshooting
General Troubleshooting Points
Troubleshooting Points for Urea SCR System
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
Test in Accordance with Testing Procedure
Preparation for Troubleshooting of Electrical System
Procedure for Troubleshooting
Symptom and Troubleshooting Numbers
Information Shown in Troubleshooting Table
Connector List and Layout (Machine with KOMTRAX Terminal)
Connector List and Layout (Machine with Gateway Function Controller)
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location Table (Machine with KOMTRAX Terminal)
Fuse Location Table (Machine with Gateway Function Controller)
Precautions When You Clean and Replace KDPF (KCSF and KDOC)
Prepare Troubleshoot Machine Monitor
Procedure to Make Harness Checker on Machine Monitor LCD Unit
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])
Troubleshooting of Electrical System (E-Mode)
Troubleshooting for Hydraulic and Mechanical Systems (H-Mode)
Troubleshooting of Engine (S-Mode)
Troubleshooting for Auto-Greasing System
Outline of Failure Display
Troubleshooting for FCS
Troubleshooting for Auto-Greasing Pump
Replacement of Pump Element
Troubleshooting for Grease Supply System
Replace AutoGreasing Controller
Assembly procedure when disassembled in troubleshooting
Troubleshooting for RDS Load Meter System
Outline of Failure Display
How to Show Diagnostics Screen
Troubleshooting for RDS Load Meter

Disassembly and Assembly
Precautions Before Work
Abbreviation List
Related Information on Disassembly and Assembly
How to Read This Manual
Coating Materials List
Special Tool List
Sketches of Special Tools
Engine and Cooling System
Remove and Install Supply Pump Assembly
Remove and Install Injector Assembly
Remove and Install Fuel Doser Assembly
Remove and Install Cylinder Head Assembly
Remove and Install EGR Valve Assembly
Remove and Install EGR Cooler Assembly
Remove and Install Starter Assembly
Remove and Install Air Conditioner Compressor Belt
Remove and Install Alternator Belt
Remove and Install Automatic Tensioner
Remove and Install Radiator Assembly
Remove and Install Cooling Fan and Fan Motor Assembly
Remove and Install Hydraulic Oil Cooler Assembly
Remove and Install Aftercooler Assembly
Remove and Install Power Train Oil Cooler Assembly
Remove and Install Engine, Torque Converter, and Transmission Assembly
Disconnect and Connect Engine, Torque Converter, and Transmission Assembly
Remove and Install Engine Front Oil Seal
Remove and Install Engine Rear Oil Seal
Remove and Install Engine Hood Assembly
Remove and Install Fuel Tank Assembly
Remove and Install DEF Tank Assembly
Remove and Install DEF Tank Sensor Flange Assembly
Remove and Install DEF Tank Sensor
Remove and Install KDPF Assembly
Disassemble and Assemble KDPF Assembly
Remove and Install SCR Assembly
Remove and Install KDPF and SCR Assembly
Remove and Install Bellows Pipe Assembly
Remove and Install KCCV Assembly
Remove and Install VGT Assembly
Remove and Install DEF Mixing Tube
Remove and Install DEF Injector
Remove and Install DEF Pump
Remove and Install DEF Hose
Remove and Install Air Cleaner Assembly
Remove and Install Air Conditioner Compressor Assembly
Remove and Install Air Conditioner Condenser Assembly
Power Train
Disassemble and Assemble Torque Converter Assembly
Disassemble and Assemble Transmission Assembly
Disassemble and Assemble Transmission Clutch Pack Assembly
Remove and Install Front Axle Assembly
Remove and Install Rear Axle Assembly
Disassemble and Assemble Axle Housing Assembly
Disassemble and Assemble Differential Assembly
Steering System
Remove and Install Steering Valve Assembly
Brake System
Remove and Install Parking Brake Disc and Plate
Undercarriage and Frame
Remove and Install Center Hinge Pin
Remove and Install Counterweight Assembly
Remove and Install FullLength Fender Assembly
Hydraulic System
Remove and Install Hydraulic Tank Assembly
Remove and Install Work Equipment Pump and Cooling Fan Pump Assembly
Remove and Install Steering Pump and Power Train Pump Assembly
Remove and Install Control Valve Assembly
Work Equipment
Remove and Install Work Equipment Assembly
Disassemble and Assemble Hydraulic Cylinder Assembly
CAB Related Parts
Remove and Install Operator Cab Assembly
Remove and Install Operator Cab Glass (Adhered Glass)
Remove and Install Air Conditioner Unit Assembly
Remove and Install Operator Seat Assembly
How to Remove and Install Seat Belt
Electrical System
Remove and Install Engine Controller Assembly
Remove and Install Work Equipment Controller Assembly
Remove and Install Transmission Controller Assembly
Remove and Install Monitor Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Mass Air Flow and Temperature Sensor
Remove and Install KCCV Crankcase Pressure Sensor
Remove and Install KDPF Temperature Sensor
Remove and Install KDPF Differential Pressure Sensor
Remove and Install SCR Temperature Sensor
Remove and Install Ammonia Sensor
Remove and Install SCR Outlet NOx Sensor
Remove and Install KOMTRAX Terminal Assembly
Remove and Install Gateway Function Controller Assembly
Remove and Install Communication Terminal

Maintenance Standard
Abbreviation List
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Brake and Cooling Fan Pump
Maintenance Standard for Cooling Fan Motor
Power Train
Maintenance Standard for Drive Shaft
Maintenance Standard for Torque Converter
Maintenance Standard for Lockup Clutch ECMV
Maintenance Standard for Transmission
Maintenance Standard for Transmission Control Valve
Maintenance Standard for Forward and Reverse Clutch ECMV and 1st, 2nd Clutch ECMV
Maintenance Standard for 3rd, 4th Clutch ECMV
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve
Maintenance Standard for Front Axle
Maintenance Standard for Rear Axle
Maintenance Standard for Front Conventional Differential
Maintenance Standard for Rear Conventional Differential
Maintenance Standard for Front Limited Slip Differential
Maintenance Standard for Rear Limited Slip Differential
Maintenance Standard for Final Drive
Steering System
Maintenance Standard for Steering Column
Maintenance Standard for Steering Pump
Maintenance Standard for Steering Valve
Maintenance Standard for Steering Cylinder
Maintenance Standard for Secondary Steering Pump
Brake System
Maintenance Standard for Charge Valve
Maintenance Standard for Brake Circuit Accumulator
Maintenance Standard for Slack Adjuster
Maintenance Standard for Front Brake
Maintenance Standard for Rear Brake
Maintenance Standard for Parking Brake
Maintenance Standard for Parking Brake Solenoid Valve
Maintenance Standard for Flow Priority Valve
Maintenance Standard for Brake Cooling Pump
Maintenance Standard for Brake Cooling Strainer
Undercarriage and Frame
Maintenance Standard for Frame, Axle Mount and Center Hinge Pin
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Work Equipment Pump
Maintenance Standard for Power Train Charge Pump and Power Train Lubrication Pump
Maintenance Standard for Control Valve
Maintenance Standard for Work Equipment Lock Solenoid Valve
Work Equipment
Maintenance Standard for Work Equipment Linkage
Maintenance Standard for Bucket
Maintenance Standard for Lift Cylinder
Maintenance Standard for Bucket Cylinder

Appendix
Precautions Before Work
Abbreviation List
Air Conditioner System
Precautions for Refrigerant
Air Conditioner Component
Specifications of Air Conditioner
Structure and Function of Refrigeration Cycle
Outline of Refrigeration Cycle
Component Parts of Air Conditioner System
Air Conditioner Unit
Component Parts of Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Receiver Drier
Air Conditioner Related Sensors
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
System Diagram of Air Conditioner
Input and Output Signals of Air Conditioner Controller
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Conditioner with SelfDiagnosis Function
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor
Examine Temperature Control Function
How to Examine Temperature Control Function
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Evaporator Temperature Sensor
Examine Relay
How to Examine Relay
Air Conditioner Troubleshooting Chart
Information Shown in Troubleshooting Table
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)
A-4 Troubleshooting for Fresh/Recirc Air Changeover
Troubleshooting by Gauge Pressure
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil

Circuit Diagrams
Abbreviation List
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram (For Steering Wheel Spec)
Hydraulic Circuit Diagram (For Joystick Steering Spec)
Power Train Hydraulic Circuit Diagram
Hydraulic Oil Pressure of Brake Cooling System
Hydraulic AutoGreasing Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram

Engine SAA6D125E-7 workshop service repair manual