Komatsu WA470-5H, WA480-5H Wheel Loader Service Repair Shop Manual - VEBM180101

This complete service repair workshop manual PDF download for the WA470-5H, WA480-5H Komatsu Wheel Loader has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WA470-5H - SN: WA470H50051 and up
Komatsu WA480-5H - SN: WA480H50051 and up
Engine : SAA6D125-3


TABLE OF CONTENTS :

00 SAFETY
01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
90 APPENDIX


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEBM180101
Total Pages : 1302


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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WA470-5H / WA480-5H
CONTENTS
SAFETY
Safety
Safety notice
General precautions
Preparations for work
Precautions during work
General
General
Structure and Function
Testing, Adjusting and Troubleshooting
Disassembly and Assembly
Maintenance Standard
How to read the shop manual
Volumes
Filing method
Revised edition mark
Revisions
Symbols
Hoisting instructions
Hoisting
Coating materials
Standard tightening torque
Standard tightening torque of bolts and nuts
Tightening torque of hose nuts
Tightening torque of split flange bolts
Tightening torque for flared nuts
Tightening torque for 102 engine series (bolts and nuts)
Tightening torque for 102 engine series (eye joints)
Tightening torque for 102 engine series (tapered screws)
Electric wire code
Classification by thickness
Classification by color and code
Conversion tables
Method of using the conversion table
Temperature
Units

GENERAL
General assembly drawing
Specifications
Weight table
List of lubricant and coolant

STRUCTURE AND FUNCTION, MAINTENANCE STANDARD
Radiator, oil cooler
Engine mount, transmission mount
Power train
Power train system diagram
Without torque converter lock-up clutch
With torque converter lock-up clutch
Drive shaft (propeller shaft)
Torque converter, transmission piping
Torque converter
Without lock-up clutch
Path of power transmission
With lock-up clutch
Path of power transmission
Transmission
F-R clutch (without lock-up clutch)
F-R clutch (with lock-up clutch)
1st-4th clutch
2nd-3rd clutch
Operation of clutch
Forward 1st
Forward 2nd
Forward 3rd
Forward 4th
Reverse 1st
Transmission control valve
Without lock-up clutch
With lock-up clutch
ECMV (Electronic Control Modulation Valve)
ECMV for speed clutch
ECMV for lock-up clutch
Main relief, torque converter relief valve
Flow valve
Axle
Front axle – WA470-5
Front axle – WA480-5
Rear axle – WA470-5
Rear axle – WA480-5
Differential
Anti-slip differential
Operation of anti-slip differential
Front differential
Rear differential
Final drive
WA470-5
WA480-5
Axle mounting, center hinge pin
Steering piping
Steering column, orbit-roll
Steering valve
Overload relief valve
Function
Operation
Steering relief valve
Function
Operation of steering relief valve
Operation of demand valve
Flow AMP
Operation of steering valve
Orbit-roll valve
Connection between hand pump and sleeve
Stop valve
Steering pump, switch pump
Emergency steering pump (op)
Emergency steering motor (op)
Steering cylinder
Joystick steering lever (op)
Steering lever (op)
(For joystick steering lever)
Steering switch valve (op)
(For joystick steering lever)
Brake piping
Brake valve
Brake valve (left)
Brake valve (right)
Outline
Operation
Charge valve
Accumulator (for brake)
Slack adjuster
Outline
Operation
Brake
Front
Outline
Rear
Outline
Outline
Parking brake control
Parking brake
Outline
Parking brake solenoid valve
Operation
Parking brake emergency release valve
Outline
Hydraulic piping
Outline
Work equipment control lever
For PPC valve
For EPC valve (op)
Hydraulic tank
Breather
Torque converter charging, work equipment, and PPC pumps
Outline
PPC relief valve
Outline
Operation
Travel damper valve (op)
Work equipment control valve
PPC valve
Work equipment control epc valve (op)
Shut off valve (op)
Cooling fan motor
Model: LMF28
Cooling fan motor drive pump
Model: LPV30
Servo valve
Safety valve
Work equipment linkage
Bucket
Bucket positioner, lift arm kick-out
Bucket positioner
Lift arm kick-out
Operation of proximity switch
Work equipment cylinder
Lift arm cylinder
Bucket cylinder
Cab (op)
Air conditioner (op)
Air conditioner piping
Machine monitoring system
Outline
Individual circuit diagrams of the machine monitor
Starting and lighting functions
Load meter
Sensing functions
Power supply and network
Machine monitor
Load meter specifications (option)
Table of monitor indication items
Setting of the machine monitor
Service mode functions
Items related to the fault history of electric ?system
Items related to the fault history of machine ?system
Items related to maintenance monitor
Engine cylinders cut-out function
Real-time monitoring function
Real-time monitoring items
Machine setting
Setting necessary for option mounting
Optional device setting for machine monitor
Transmission control system
System diagram
Control Function
Electric circuit diagram (std)
Electric circuit diagram (op)
Transmission controller
Work equipment control system (op)
System diagram
Electric circuit diagram (op)
Work equipment controller
Electric transmission control
Functions
Combination switch
Overview
Functions
Operation
Kick down, hold switch
Functions
Engine starting circuit
Function
Operation
Engine stop circuit
Operation
Parking brake circuit
Operation
Turn signal, hazard lamp circuit
Operation
Backup lamp, stop lamp circuit
Operation
Small lamp, head lamp circuit
Operation
Working lamp circuit
Operation
Horn circuit
Operation
Windshield wiper/window washer circuit (If equipped with cab)
Sensors
Engine speed sensor
Speed sensor
Engine oil pressure sensor
Engine oil level sensor
Engine water temperature sensor
Torque converter oil temperature sensor
Hydraulic oil temperature sensor
Transmission oil temperature sensor
Brake oil temperature sensor
Transmission cut-off pressure sensor
Radiator water level sensor
Fuel level sensor
Lift arm angle sensor (op)
Air cleaner clogging sensor
Pressure sensor for load meter (op)
Battery liquid sensor (op)
Relay
Standard value table for engine
Standard value table for chassis

TESTING AND ADJUSTING
Measuring engine speed
Measuring exhaust color
Measuring exhaust temperature
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring air supply pressure (boost pressure)
Measuring fuel pressure
Adjusting engine speed sensor
Handling equipment in fuel system
Releasing remaining pressure in fuel system
Bleeding air from fuel circuit
Reduced cylinder mode operation for engine
Checking for leakage in fuel system
Adjusting accelerator pedal potentiometer
Adjusting accelerator pedal microswitch
Adjusting transmission speed sensor
Testing and adjusting power train oil pressure
Flushing torque converter, transmission hydraulic circuit
Moving machine when transmission valve fails
Testing and adjusting steering control
Testing and adjusting steering oil pressure
Measuring brake oil pressure
Testing wear of wheel brake disc
Bleeding air from brake circuit
Testing wear of parking brake disc
Manual release method for parking brake
Testing and adjusting accumulator charge pressure
Testing and adjusting ppc oil pressure
Testing and adjusting work equipment hydraulic pressure
Testing and adjusting bucket positioner
Testing and adjusting lift arm kick-out
Checking proximity switch actuation pilot lamp
Adjusting machine monitor
Testing and adjusting load meter
Bleeding air
Releasing remaining pressure in hydraulic circuit.
Releasing remaining pressure in travel damper circuit
Handling controller high-voltage circuit
TESTING AND ADJUSTING
Points to remember when troubleshooting
Sequence of events in troubleshooting
Precautions when carrying out maintenance
Checks before troubleshooting
Equipment for troubleshooting electrical system
Special functions of machine monitor
Flow of modes and functions
Categories, procedure, and method of using ?troubleshooting charts
Connection table for connector pin numbers
TROUBLESHOOTING
Connector types and installation positions
Connectors layout drawing
Engine control system diagram
Error code [A000N1]
Error code [AD00L2]
Error code [AD00MA]
Error code [AD10L3]
Error code [AD10MA]
Error code [AD10MB]
Error code [AD11KA]
Error code [AD11KB]
Error code [AD51KA]
Error code [AD51KB]
Error code [ADA1KA]
Error code [ADAZKB]
Error code [ADB1KA]
Error code [ADC1KA]
Error code [ADD1KA]
Error code [ADDZKB]
Error code [ADE1KA]
Error code [ADF1KA]
Error code [D182KZ]
Error code [D1D0KB]
Error code [DB20KT]
Error code [AB20KT]
Error code [DB22KK]
Error code [DB29KQ]
Error code [DB2AMA]
Error code [DD11KB]
Error code [DGE3L6]
Error code [DGE4KX]
Error code [DH30KX]
Error code [DH40KX]
Error code [DK10KX]
Error code [DLE3LC]
Error code [DLH1LC]
Error code [ENG-1]
TROUBLESHOOTING OF ENGINE ?CONTROL SYSTEM (ENG MODE)
Connector types and installation positions
Connector layout drawing
Transmission control system diagram
Error code [1500L1]
Error code [15SAL1]
Error code [15SALH]
Error code [15SBL1]
Error code [15SBLH]
Error code [15SEL1]
Error code [15SELH]
Error code [15SFL1]
Error code [15SFLH]
Error code [15SGL1]
Error code [15SGLH]
Error code [15SHL1]
Error code [15SHLH]
Error code [15SJL1]
Error code [15SJLH]
Error code [989F00]
Error code [989G00]
Error code [B@C7NS]
Error code [D150KA]
Error code [D150KB]
Error code [D160KA]
Error code [D160KB]
Error code [D191KA]
Error code [D191KB]
Error code [D192KA]
Error code [D192KB]
Error code [DAQ0KK]
Error code [DAQ2KK]
Error code [DAQ9KQ]
Error code [DDK3KA]
Error code [DDK3KB]
Error code [DDK6KA]
Error code [DDK6KB]
Error code [DDS5KA]
Error code [DDS5KB]
Error code [DDT0L4]
Error code [DDT4LD]
Error code [DDW9LD]
Error code [DDWLLD]
Error code [DF10KA]
Error code [DF10KB]
Error code [DGF1KX]
Error code [DGR2KA]
Error code [DGR2KB]
Error code [DHT1KX]
Error code [DLE2KA]
Error code [DLE2LC]
Error code [DLT3KA]
Error code [DT20KB]
Error code [DW7BKA]
Error code [DW7BKB]
Error code [DW7CKA]
Error code [DW7CKB]
Error code [DX16KA]
Error code [DX16KB]
Error code [DXH1KA]
Error code [DXH1KB]
Error code [DXH4KA]
Error code [DXH4KB]
Error code [DXH5KA]
Error code [DXH5KB]
Error code [DXH6KA]
Error code [DXH6KB]
Error code [DXH7KA]
Error code [DXH7KB]
Error code [DXH8KA]
Error code [DXH8KB]
Error code [DXHHKA]
Error code [DXHHKB]
Error code [DY30MA]
Error code [DY30MC]
Action code [TM-1]
Action code [TM-2]
Action code [TM-3]
Action code [TM-4]
Action code [TM-5]
Action code [TM-6]
Action code [TM-7]
Action code [TM-8]
Action code [TM-9]
Action code [TM-10-A]
Action code [TM-10-B]
Action code [TM-11]
Action code [TM-12]
Action code [TM-13]
Action code [TM-14]
Action code [TM-15]
Action code [TM-16]
Action code [TM-17]
Action code [TM-18]
Action code [TM-19]
Action code [TM-20]
Action code [TM-21]
Action code [TM-22]
Action code [TM-23]
Action code [TM-24]
Action code [TM-25]
Action code [TM-26]
Action code [TM-27]
Action code [TM-28]
Action code [TM-29]
TROUBLESHOOTING OF TRANSMISSION ?CONTROL SYSTEM (TM MODE)
Connector types and installation positions
Connector layout drawing
Work equipment control system diagram
Error code [D193KA]
Error code [D193KB]
Error code [DB90KK]
Error code [DB92KK]
Error code [DB95KX]
Error code [DD1ALD]
Error code [DD1BLD]
Error code [DFAOKM]
Error code [DK59KA]
Error code [DK59KY]
Error code [DK59L8]
Error code [DK5AKA]
Error code [DK5AKY]
Error code [DK5BKA]
Error code [DK5BKY]
Error code [DK5BL8]
Error code [DK5CKA]
Error code [DK5CKY]
Error code [DK5DKA]
Error code [DK5DKY]
Error code [DK5DL8]
Error code [DK5EKA]
Error code [DK5EKY]
Error code [DK5FKA]
Error code [DK5FKY]
Error code [DK5FKM]
Error code [DK5FL8]
Error code [DK5GKA]
Error code [DK5GKY]
Error code [DKAOKA]
Error code [DKAOKY]
Error code [DLE2LC]
Error code [DLT3LC]
Error code [DUM1KA]
Error code [DUM1KB]
Error code [DW4PKA]
Error code [DW4PKB]
Error code [DW4QKA]
Error code [DW4QKB]
Error code [DW4RKA]
Error code [DW4RKB]
Error code [DW4SKA]
Error code [DW4SKB]
Error code [DWM1KA]
Error code [DWM1KB]
Error code [DWN6KA]
Error code [DWN6KB]
Error code [DWN7KA]
Error code [DWN7KB]
Error code [DWN8KA]
Error code [DWN8KB]
Error code [DXHJKA]
Error code [DXHJKB]
Error code [DXHKKA]
Error code [DXHKKB]
Error code [DXHLKA]
Error code [DXHLKB]
Error code [DXHMKA]
Error code [DXHMKB]
Action code [WRK-1]
Action code [WRK-2]
Action code [WRK-3]
Action code [WRK-4]
Action code [WRK-5]
Action code [WRK-6]
Action code [WRK-7]
Action code [WRK-8]
Action code [WRK-9]
Action code [WRK-10]
Action code [WRK-11]
Action code [WRK-12]
Action code [WRK-13]
Action code [WRK-14]
Action code [WRK-15]
Action code [WRK-16]
Action code [WRK-17]
Action code [WRK-18]
Action code [WRK-19]
Action code [WRK-20]
Action code [WRK-21]
Action code [WRK-22]
Action code [WRK-23]
Action code [WRK-24]
Action code [WRK-25]
Action code [WRK-26]
Action code [WRK-27]
Action code [WRK-28]
TROUBLESHOOTING OF WORK ?EQUIPMENT ?CONTROL SYSTEM (WORK MODE)
Connector types and installation positions
Connector layout drawing
Monitor system diagram
Error code [2F00KM]
Error code [2G42ZG]
Error code [2G43ZG]
Error code [AA1ANX]
Error code [AB00L6]
Error code [AB00MA]
Error code [B@BAZG]
Error code [B@BAZK]
Error code [B@BCNS]
Error code [B@BCZK]
Error code [B@HANS]
Error code [B@CENS]
Error code [D5ZHL6]
Error code [DA80L4]
Error code [DAF3KK]
Error code [DAF5KP]
Error code [DAF6KP]
Error code [DAFBKM]
Error code [DAFSKQ]
Error code [DAQSKR]
Error code [DBQSKR]
Error code [DB9SKR]
Error code [DD15LD]
Error code [DD16LD]
Error code [DD17LD]
Error code [DD18LD]
Error code [DD1CLD]
Error code [DDK3KM]
Error code [DDK4KM]
Error code [DDK6KM]
Error code [DDS5L6]
Error code [DDY0LD]
Error code [DGE2KX]
Error code [DGH2KX]
Error code [DGT1KX]
Error code [DHE4L6]
Error code [DHPCKX]
Error code [DHPDKX]
Error Code [DKA0KX]
Error code [DV00KB]
Error code [DY30ME]
Action code [MON-1]
Action code [MON-2]
Action code [MON-3]
Action code [MON-4]
Action code [MON-5]
Action code [MON-6]
Action code [MON-7]
Action code [MON-8]
Action code [MON-9]
Action code [MON-10]
Action code [MON-11]
Action code [MON-12]
Action code [MON-13]
Action code [MON-14]
Action code [MON-15]
Action code [MON-16]
Action code [MON-17]
Action code [MON-18]
Action code [MON-19]
Action code [MON-20]
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)
H-1 The machine does not start
H-2 The lock-up clutch is not released (The engine stops) (When the lock-up clutch is provided)
H-3 – a The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and th...
H-3 – b The torque converter lock-up clutch is not let in (When the lock-up clutch is provided)
H-4 Shocks are large at the times of starting and shifting gear
H-5 Time lag is large at the times of starting and shifting gear
H-6 The torque converter oil temperature is high
H-7 The steering wheel does not turn
H-8 The steering wheel is heavy
H-9 The steering wheel fluctuates or is strongly shocked
H-10 The steering wheel fluctuates or is strongly shocked
H-11 The right and left swing radii are different
H-12 The brake does not work or does not work well
H-13 The brake is not released or is dragged
H-14 The brake is not released or dragged
H-15 The boom does not rise
H-16 The boom moves slowly or the boom rising force is insufficient
H-17 When rising, the boom comes to move slowly at specific height
H-18 The boom cylinder cannot hold down the bucket (The bucket rises in the air)
H-19 Hydraulic drifts of the boom occur often
H-20 The boom wobbles during operation
H-21 When the control lever is switched from "HOLD" to "RAISE," the boom falls temporarily
H-22 The bucket does not tilt back
H-23 The bucket moves slowly or the tilting-back force is insufficient
H-24 The bucket comes to operate slowly in he midst of tilting-back
H-25 The bucket cylinder cannot hold down the bucket
H-26 Hydraulic drifts of the bucket occur often
H-27 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD")
H-28 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily
H-29 The control levers of boom and bucket do not move smoothly and heavy
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
Connector types and installation positions
Connector layout drawing
Monitor system diagram
Action code [E-1]
Action code [E-2]
Action code [E-3]
Action code [E-4]
Action code [E-5-A]
Action code [E-5-B]
Action code [E-5-C]
Action code [E-6]
Action code [E-7-A]
Action code [E-7-B]
Action code [E-7-C]
Action code [E-7-D]
Action code [E-8]
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)

DISASSEMBLY AND ASSEMBLY
Method of using manual
Precautions when carrying out operation
Fuel supply pump assembly
Special tools
Removal
Installation
Schematic drawings of special tools
A1 Remover
A1 Block
A1 Bolt
Nozzle holder assembly
Removal
Installation
Nozzle tip
Special tool
Removal
Installation
Schematic drawing of special tool
A3 Wrench
Cylinder head assembly
Special tool
Removal
Installation
Radiator assembly
Removal
Installation
Air aftercooler assembly
Removal
Installation
Cooling fan drive motor
Removal
Installation
Engine assembly
Removal
Installation
Steering, switch pump, ?cooling fan drive pump assembly
Removal
Installation
Torque converter charge, work equipment and PPC pump assembly
Removal
installation
Torque converter, ?transmission assembly
Removal
Installation
Torque converter assembly (standard specifications)
Special tools
Disassembly
Assembly
Torque converter assembly (lock-up specifications)
Special tools
Disassembly
Assembly
Transmission assembly
Special tools
Disassembly
Assembly
Schematics of special tools
C1 Bracket
C6, C7 Pushing tools
C7 Spacer
C11 Lifting tool
C11 Lifting tool
Transmission clutch pack assembly
Special tools
Disassembly
Disassembly of forward-reverse clutch packs
Disassembly of 1st • 4th speed clutch packs
Disassembly of 2nd • 3rd clutch packs
Assembly
Assembly of forward-reverse clutch packs
Assembly of 1st • 4th clutch packs
Assembly of 2nd • 3rd clutch packs
Schematic diagram of special tool
C2 Push tool
Parking brake assembly
Special tools
Disassembly
Assembly
Schematic drawing of special tools
C4, C5 Push tool
C5 Spacer
C8 Push tool
C9 Push tool
C10 Push tool
C13 Bracket
Front axle assembly
Disassembly
Assembly
Rear axle assembly
Removal
Installation
Axle housing assembly
Special tools
Disassembly
Assembly
Schematic drawing of special tools
D7 Pushing tool
D7 Spacer
D7 Pushing tool
D9 Support
D9 Support
Differential assembly
Special tools
Disassembly
Assembly
Schematic drawing of special tools
D1 Plate
D2, D3 Push tool
D3 Spacer
D4 Push tool
D5 Push tool
Center hinge pin
Special tools
Removal
Installation
Steering valve assembly
Removal
Installation
Travel damper assembly
Removal
Installation
Parking brake disc
Special tools
Removal
Installation
Schematic drawing of special tools
C13 Bracket
Hydraulic tank
Removal
Installation
Work equipment valve assembly
Removal
Installation
Hydraulic cylinder assembly (steering, lift, and bucket cylinder assemblies)
Special tools
Disassembly
Assembly
Work equipment assembly
Removal
Installation
Counterweight
Removal
Installation
Fuel tank assembly
Removal
Installation
Cab assembly
Removal
Installation
Cab, floor frame assembly
Removal
Installation
Air conditioner unit assembly
Removal
Installation
Air conditioner compressor assembly
Special tools
Removal
Installation

APPENDIX
Power train oil circuit diagram
Power train oil circuit diagram
Brake oil circuit diagram

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