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KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-04 – PDF DOWNLOAD
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KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-04 – PDF DOWNLOAD
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KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-04 – PDF DOWNLOAD
Language : English
Pages : 1839
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-04 – PDF DOWNLOAD
Cover.................................................................................................................................................... 1 Notice of revision....................................................................................................................................... 3 00 Index and foreword.................................................................................................................................... 13 Table of contents.................................................................................................................................... 14 Foreword and general information..................................................................................................................... 27 Safety notice.................................................................................................................................... 27 How to read the shop manual...................................................................................................................... 32 Explanation of terms for maintenance standard.................................................................................................... 34 Handling of electric equipment and hydraulic component........................................................................................... 36 Handling of connectors newly used for engines.................................................................................................... 45 How to read electric wire code................................................................................................................... 48 Precautions when carrying out operation.......................................................................................................... 51 Method of disassembling and connecting push-pull type coupler.................................................................................... 54 Standard tightening torque table................................................................................................................. 57 Conversion table................................................................................................................................. 61 01 Specification......................................................................................................................................... 67 Specification and technical data..................................................................................................................... 69 Specification dimension drawing.................................................................................................................. 69 Specifications................................................................................................................................... 70 Weight table..................................................................................................................................... 74 Table of fuel, coolant and lubricants............................................................................................................ 76 10 Structure, function and maintenance standard.......................................................................................................... 79 Engine and cooling system............................................................................................................................ 82 Engine mount and transmission mount.............................................................................................................. 82 Cooling system................................................................................................................................... 83 Cooling fan pump................................................................................................................................. 84 Cooling fan motor................................................................................................................................ 92 Power train.......................................................................................................................................... 99 Power train...................................................................................................................................... 99 Power train system diagram....................................................................................................................... 100 Drive shaft...................................................................................................................................... 102 Power train piping diagram....................................................................................................................... 103 Torque converter................................................................................................................................. 104 Transmission..................................................................................................................................... 112 Transmission control valve....................................................................................................................... 130 ECMV............................................................................................................................................. 134 Main relief valve and torque converter relief valve.............................................................................................. 146 Axle............................................................................................................................................. 148 Differential..................................................................................................................................... 152 Limited slip differential........................................................................................................................ 157 Final drive...................................................................................................................................... 164 Steering system...................................................................................................................................... 170 Steering component layout drawing................................................................................................................ 170 Steering column.................................................................................................................................. 171 Steering pump.................................................................................................................................... 172 Steering valve................................................................................................................................... 185 Orbit-roll valve................................................................................................................................. 202 Stop valve....................................................................................................................................... 210 Steering relief valve............................................................................................................................ 211 Steering cylinder................................................................................................................................ 212 Emergency steering motor......................................................................................................................... 214 Emergency steering pump.......................................................................................................................... 215 Joystick steering lever linkage.................................................................................................................. 216 Electrical steering lever........................................................................................................................ 217 Joystick EPC valve............................................................................................................................... 218 Brake system......................................................................................................................................... 220 Brake component layout drawing................................................................................................................... 220 Charge valve..................................................................................................................................... 221 Brake valve...................................................................................................................................... 228 Accumulator (for brake).......................................................................................................................... 233 Slack adjuster................................................................................................................................... 234 Brake............................................................................................................................................ 236 Parking brake control............................................................................................................................ 241 Parking brake.................................................................................................................................... 242 Parking brake solenoid valve..................................................................................................................... 244 Emergency parking brake release valve............................................................................................................ 246 Undercarriage and frame.............................................................................................................................. 248 Axle mount and center hinge pin.................................................................................................................. 248 Tires............................................................................................................................................ 252 Hydraulic system..................................................................................................................................... 254 Hydraulic component layout drawing............................................................................................................... 254 Work equipment control lever linkage............................................................................................................. 257 Hydraulic tank................................................................................................................................... 260 Power train pump................................................................................................................................. 262 Work equipment pump.............................................................................................................................. 264 Work equipment control valve..................................................................................................................... 284 CLSS............................................................................................................................................. 295 Each function and operation of each valve........................................................................................................ 300 PPC valve........................................................................................................................................ 314 Accumulator (for PPC circuit).................................................................................................................... 322 Accumulator (for power train circuit)............................................................................................................ 323 Accumulator (for ECSS)........................................................................................................................... 324 Work equipment PPC cut-off solenoid valve........................................................................................................ 325 Work equipment....................................................................................................................................... 328 Work equipment linkage........................................................................................................................... 328 Bucket........................................................................................................................................... 331 Bucket positioner and boom kick-out.............................................................................................................. 332 Work equipment cylinder.......................................................................................................................... 338 Cab and its attachments.............................................................................................................................. 339 Cab.............................................................................................................................................. 339 Air conditioner.................................................................................................................................. 340 Electrical system.................................................................................................................................... 358 Machine monitor system........................................................................................................................... 358 Machine monitor.................................................................................................................................. 362 Electrical system (Transmission controller system)............................................................................................... 394 Transmission controller.......................................................................................................................... 434 Electrical system (Work equipment controller system)............................................................................................. 436 Work equipment controller........................................................................................................................ 442 Electric transmission control.................................................................................................................... 444 Kickdown switch and hold switch.................................................................................................................. 448 Load meter cancel switch and load meter subtotal switch.......................................................................................... 448 Multi-function knob.............................................................................................................................. 449 Joystick steering knob........................................................................................................................... 450 KOMTRAX system................................................................................................................................... 452 Engine starting circuit.......................................................................................................................... 454 Engine stopping circuit.......................................................................................................................... 456 Preheating circuit............................................................................................................................... 457 Engine power mode selector circuit............................................................................................................... 458 Engine output derating function.................................................................................................................. 459 Automatic warm-up function....................................................................................................................... 459 Parking brake circuit............................................................................................................................ 460 Sensor........................................................................................................................................... 462 20 Standard value table.................................................................................................................................. 473 Standard service value table......................................................................................................................... 475 Standard value table for engine.................................................................................................................. 475 Standard value table for chassis................................................................................................................. 476 30 Testing and adjusting................................................................................................................................. 485 Related information on testing and adjusting......................................................................................................... 488 Tools for testing, adjusting, and troubleshooting................................................................................................ 488 Engine and cooling system............................................................................................................................ 493 Testing engine speed............................................................................................................................. 493 Testing exhaust gas color........................................................................................................................ 495 Testing exhaust temperature...................................................................................................................... 497 Adjusting valve clearance........................................................................................................................ 499 Testing compression pressure..................................................................................................................... 501 Testing blow-by pressure......................................................................................................................... 502 Testing engine oil pressure...................................................................................................................... 503 Testing intake air (boost) pressure.............................................................................................................. 504 Handling fuel system equipment................................................................................................................... 505 Releasing residual pressure in fuel system....................................................................................................... 505 Testing fuel pressure............................................................................................................................ 506 Testing fuel return and leak amount.............................................................................................................. 507 Bleeding air from fuel circuit................................................................................................................... 510 Testing fuel circuit for leakage................................................................................................................. 512 Handling of reduced cylinder mode operation...................................................................................................... 513 Handling of no injection cranking operation...................................................................................................... 513 Handling of controller voltage circuit........................................................................................................... 514 Check of muffler and muffler stack for looseness and damage...................................................................................... 515 Check of muffler function........................................................................................................................ 515 Check of installed condition of cylinder head and manifolds...................................................................................... 516 Check of engine piping for damage and looseness.................................................................................................. 516 Testing and adjusting air conditioner compressor belt tension.................................................................................... 517 Testing and adjusting alternator belt tension.................................................................................................... 518 Power train.......................................................................................................................................... 519 Adjusting transmission speed sensor.............................................................................................................. 519 Adjusting directional lever length............................................................................................................... 520 Adjusting gear shift lever length................................................................................................................ 520 Testing FNR lever and gear shift lever........................................................................................................... 521 Testing and adjusting power train oil pressure................................................................................................... 522 Procedure for flushing torque converter and transmission hydraulic circuit....................................................................... 536 Method of moving machine when transmission valve is broken....................................................................................... 538 Check of axle final drive for oil leakage........................................................................................................ 541 Check of drive shafts for looseness, play and damage............................................................................................. 541 Steering system...................................................................................................................................... 542 Testing and adjusting steering stop valve........................................................................................................ 542 Testing and adjusting steering wheel............................................................................................................. 544 Testing steering oil pressure.................................................................................................................... 546 Bleeding air from steering circuit............................................................................................................... 549 Brake system......................................................................................................................................... 550 Testing brake pedal.............................................................................................................................. 550 Testing and adjusting brake pedal linkage........................................................................................................ 551 Testing brake performance........................................................................................................................ 552 Testing and adjusting accumulator charge pressure................................................................................................ 553 Testing wheel brake oil pressure................................................................................................................. 555 Testing wear of wheel brake disc................................................................................................................. 557 Bleeding air from wheel brake circuit............................................................................................................ 558 Releasing residual pressure in brake accumulator circuit......................................................................................... 559 Testing parking brake performance................................................................................................................ 559 Testing parking brake oil pressure............................................................................................................... 560 Testing wear of parking brake disc............................................................................................................... 562 Manual release method for parking brake.......................................................................................................... 563 Hydraulic system..................................................................................................................................... 564 Testing hydraulic drive fan...................................................................................................................... 564 Adjustment of hydraulic fan speed sensor......................................................................................................... 566 Bleeding air from hydraulic drive fan circuit.................................................................................................... 567 Testing and adjusting work equipment control lever............................................................................................... 569 Testing and adjusting work equipment PPC oil pressure............................................................................................ 570 Testing and adjusting work equipment oil pressure................................................................................................ 573 Bleeding air from work equipment circuit......................................................................................................... 577 Releasing residual pressure in work equipment circuit............................................................................................ 578 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator.... 579 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator................................................. 585 Work equipment....................................................................................................................................... 590 Testing and adjusting bucket positioner.......................................................................................................... 590 Testing and adjusting boom kick-out.............................................................................................................. 592 Checking proximity switch operation pilot lamp................................................................................................... 593 Electrical system.................................................................................................................................... 594 Procedure for testing diodes..................................................................................................................... 594 Preparation work for troubleshooting for electrical system....................................................................................... 595 How to start KOMTRAX terminal operations......................................................................................................... 600 Indicator lamps of KOMTRAX terminal.............................................................................................................. 605 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................................... 608 Special functions of machine monitor (EMMS)...................................................................................................... 611 Pm-clinic............................................................................................................................................ 674 Pm-clinic inspection table....................................................................................................................... 674 40 Troubleshooting....................................................................................................................................... 679 General information on troubleshooting............................................................................................................... 689 Points to remember when troubleshooting.......................................................................................................... 689 How to proceed in troubleshooting................................................................................................................ 690 Testing before troubleshooting................................................................................................................... 692 Classification and procedures of troubleshooting................................................................................................. 694 Information in troubleshooting table............................................................................................................. 709 Troubleshooting method for open circuit in wiring harness of pressure sensor system.............................................................. 711 Connection table for connector pin numbers....................................................................................................... 713 T- branch box and T- branch adapter table........................................................................................................ 749 Fuse locations................................................................................................................................... 752 Phenomena looking like troubles and troubleshooting Nos.......................................................................................... 755 Information contained in troubleshooting table................................................................................................... 758 Troubleshooting by failure code (Display of code).................................................................................................... 761 Failure code [1500L0] (TORQFLOW transmission: Double meshing).................................................................................... 761 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)............................................................ 762 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)............................................................ 764 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)............................................................ 766 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)............................................................ 768 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON).......................................................... 770 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF).......................................................... 772 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON).......................................................... 774 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF).......................................................... 776 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON).......................................................... 778 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF).......................................................... 780 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON).......................................................... 782 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF).......................................................... 784 Failure code [2F00MA] (Parking brake: Malfunction)............................................................................................... 786 Failure code [2G43ZG] (Accumulator: Low oil pressure)............................................................................................ 788 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)............................................................................... 790 Failure code [AA1ANX] (Air cleaner: Clogging).................................................................................................... 794 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine).............................................................. 796 Failure code [AB00MA] (Alternator: Malfunction).................................................................................................. 798 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)............................................................................. 800 Failure code [B@BAZK] (Engine oil: Low level).................................................................................................... 803 Failure code [B@BCNS] (Coolant: Overheating)..................................................................................................... 804 Failure code [B@BCZK] (Coolant: Low level)....................................................................................................... 806 Failure code [b@CENS] (Torque converter oil: Overheating)........................................................................................ 808 Failure code [B@CENS] (Torque converter oil: Overheating)........................................................................................ 810 Failure code [B@HANS] (Hydraulic oil: Overheating)............................................................................................... 812 Failure code [CA111] (Abnormality in engine controller).......................................................................................... 814 Failure code [CA115] (Engine Ne or Bkup speed sensor error)...................................................................................... 817 Failure code [CA122] Chg Air Press Sensor High Error............................................................................................. 818 Failure code [CA123] Chg Air Press Sensor Low Error.............................................................................................. 820 Failure code [CA131] Throttle sensor : High error................................................................................................ 822 Failure code [CA132] Throttle sensor : Low error................................................................................................. 824 Failure code [CA135] Eng Oil Press Sensor High Error............................................................................................. 826 Failure code [CA141] Eng Oil Press Sensor Low Error.............................................................................................. 828 Failure code [CA144] Coolant Temp Sens High Error................................................................................................ 830 Failure code [CA145] Coolant Temp Sens Low Error................................................................................................. 832 Failure code [CA153] Chg Air Temp Sensor High Error.............................................................................................. 834 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................................................... 836 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................................................ 838 Failure code [CA221] Ambient Press Sens High Error............................................................................................... 840 Failure code [CA222] Ambient Press Sens Low Error................................................................................................ 842 Failure code [CA227] Sens Supply 2 Volt High Error............................................................................................... 844 Failure code [CA234] Eng Overspeed............................................................................................................... 845 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................................. 846 Failure code [CA263] Fuel Temp Sensor High Error................................................................................................. 848 Failure code [CA265] Fuel Temp Sensor Low Error.................................................................................................. 850 Failure code [CA271] IMV/PCV1 Short Error........................................................................................................ 852 Failure code [CA272] IMV/PCV1 Open Error......................................................................................................... 854 Failure code [CA273] PCV2 Short Error............................................................................................................ 856 Failure code [CA274] PCV2 Open Error............................................................................................................. 858 Failure code [CA322] Inj #1(L#1) Open/Short Error................................................................................................ 860 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................................................... 862 Failure code [CA324] Inj #3(L#3) Open/Short Error................................................................................................ 864 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................................................... 866 Failure code [CA331] Inj #2(L#2) Open/Short Error................................................................................................ 868 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................................................... 870 Failure code [CA342] (Calibration code inconsistency)............................................................................................ 872 Failure code [CA351] Injectors Drive Circuit Error............................................................................................... 873 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................................................ 874 Failure code [CA386] Sens Supply 1 Volt High Error............................................................................................... 876 Failure code [CA431] Idle validation switch : Error.............................................................................................. 877 Failure code [CA432] Idle validation switch : Action error....................................................................................... 880 Failure code [CA441] (Battery voltage low error)................................................................................................. 882 Failure code [CA442] (Battery voltage high error)................................................................................................ 884 Failure code [CA449] Rail Press Very High Error.................................................................................................. 886 Failure code [CA451] Rail Press Sensor High Error................................................................................................ 888 Failure code [CA452] Rail Press Sensor Low Error................................................................................................. 890 Failure code [CA553] (Common rail pressure high error 1)......................................................................................... 892 Failure code [CA554] (Common rail pressure sensor in-range error)................................................................................ 893 Failure code [CA559] (Supply pump pressure very low error)....................................................................................... 894 Failure code [CA689] Eng Ne Speed Sensor Error................................................................................................... 898 Failure code [CA731] (Engine Bkup speed sensor phase error)...................................................................................... 900 Failure code [CA757] (All continuous data lost error)............................................................................................ 901 Failure code [CA778] Eng Bkup Speed Sensor Error................................................................................................. 902 Failure code [CA1633] KOMNET Datalink Timeout Error.............................................................................................. 904 Failure code [CA2185] Throttle sensor power supply voltage : High error.......................................................................... 906 Failure code [CA2186] Throttle sensor power supply voltage : Low error........................................................................... 908 Failure code [CA2249] (Supply pump pressure very low error 2).................................................................................... 910 Failure code [CA2555] Intake heater relay : Open circuit......................................................................................... 912 Failure code [CA2556] Intake heater relay : Short circuit........................................................................................ 914 Failure code [D150KA] (Emergency steering relay: Disconnection).................................................................................. 916 Failure code [D150KB] (Emergency steering relay: Short circuit).................................................................................. 918 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)........................................................... 920 Failure code [D160KA] (Backup lamp relay output: Disconnection).................................................................................. 922 Failure code [D160KB] (Backup lamp relay output: Short circuit).................................................................................. 924 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection).................................................................... 926 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit).................................................................... 928 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)............................................. 930 Failure code [D192KA] (ECSS solenoid: Disconnection)............................................................................................. 932 Failure code [D192KB] (ECSS solenoid: Short circuit)............................................................................................. 933 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)...................................................................... 934 Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection).................................................................. 936 Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit).................................................................. 938 Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line)........................................... 940 Failure code [D5ZHKA] (Terminal C signal: Disconnection)......................................................................................... 943 Failure code [D5ZHKB] (Terminal C signal: Short circuit)......................................................................................... 947 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)........................................................................ 950 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)................................................. 955 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree).......................................................................... 958 Failure code [DAF3KK] (Machine monitor: Low source voltage (input)).............................................................................. 960 Failure code [DAF5KP] (Machine monitor: Low output voltage)...................................................................................... 962 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system))................. 964 Failure code [DAQ0KK] (Transmission controller: Low source voltage).............................................................................. 966 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)....................................................................... 968 Failure code [DAQ1KA] (Terminal ACC input: Disconnection)........................................................................................ 969 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))............................................... 972 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals)......................................... 974 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system))......... 975 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)...................................................................... 980 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)................ 981 Failure code [DB90KK] Work equipment controller: Low source voltage (input)...................................................................... 988 Failure code [DB90KT] Work equipment controller: Abnormality in controller....................................................................... 990 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)............................................... 992 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range................................................... 995 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)....................................... 998 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system)......... 999 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)....................................................................1004 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)...............1005 Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time............................................................1006 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................................................1008 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time............................................................1010 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time............................................................1012 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time.....................................1014 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time.....................................1016 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time...........................................................1018 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time................................................1020 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time................................................1022 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time).................................................1024 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time).................................................................1026 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time).......................................................1028 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)..............................................................1030 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)..........................................1034 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction).............................................................................1036 Failure code [DDK3KA] (Right FNR switch: Disconnection)..........................................................................................1038 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)..............................................................................1041 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)..........................................................1044 Failure code [DDK6KA] (FNR lever switch: Disconnection)..........................................................................................1046 Failure code [DDK6KB] (FNR lever switch: Short circuit)..........................................................................................1050 Failure code [DDS5KA] (Steering pressure switch signal: Disconnected)............................................................................1052 Failure code [DDS5KB] (Steering pressure switch signal: Short circuit)...........................................................................1054 Failure code [DDS5L6] (Steering: Low oil pressure)...............................................................................................1056 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)......................................................................1058 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)....................................................1060 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)...................................................................1062 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)........................................................................1064 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)...........................................................1066 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)............................................................................1068 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)...........................................................................1072 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)........................................................................1076 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit).......................................................................1078 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)..............................................................1080 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)..........................................................................1082 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range).............................................................1084 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range).......................................................1086 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)...............................................................................1088 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short).....................................................................1090 Failure code [DHPCKX] (Boom cylinder bottom pressure sensor: Out of input signal range)..........................................................1092 Failure code [DHPDKX] (Boom cylinder head pressure sensor: Out of input signal range)............................................................1094 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)..........................................................1096 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection).............................................................................1098 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit).............................................................................1100 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)...................................................................1102 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)............................................1105 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree).........................................................1108 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)....................................................................1111 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line).............................................1114 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection).....................................................................1117 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)..............................................1120 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)...........................................................1123 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)......................................................................1126 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)...............................................1129 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)..........................................................1132 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)...................................1136 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)................................................1138 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)...........................................................1141 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)....................................1144 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection).....................................................................................1146 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range).........................................................................1148 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)..............................................................1150 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)....................................................................................1152 Failure code [DLF1KA] (Transmission input speed sensor: Disconnection)...........................................................................1154 Failure code [DLF1LC] (Transmission input speed sensor: Short circuit)...........................................................................1155 Failure code [DLM3KA] (Fan speed sensor: Disconnection)..........................................................................................1156 Failure code [DLM3LC] (Fan speed sensor: Short circuit)..........................................................................................1158 Failure code [DLT3KA] (Transmission output speed sensor: Disconnection)..........................................................................1160 Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range)..............................................................1162 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).......................................................................1164 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)................................................................1166 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)................................................................1168 Failure code [DV00KB] (Alarm buzzer: Short circuit)..............................................................................................1170 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)...............................................................................1172 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)...............................................................................1174 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)........................................................1176 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)...............................................................................1178 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)...............................................................................1179 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)........................................................1180 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)..................................................................................1182 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)..................................................................................1183 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)...........................................................1184 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)..................................................................................1186 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)..................................................................................1187 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)...........................................................1188 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)......................................................................................1190 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)......................................................................................1191 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)...............................................................1192 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)......................................................................1194 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)......................................................................1196 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)...............................................1198 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection).....................................................................1200 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit).....................................................................1202 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)..............................................1204 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).....................................................................1206 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit).....................................................................1208 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)..............................................1210 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)........................................................................1212 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)........................................................................1214 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)........................................................1216 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection).....................................................................................1218 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit).....................................................................................1219 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)..............................................................1220 Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection)...............................................................................1222 Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)...............................................................................1224 Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection).............................................................................1226 Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit).............................................................................1228 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)......................................................................................1230 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)......................................................................................1232 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)...............................................................1234 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)..................................................................................1236 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)..................................................................................1238 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)...........................................................1240 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)..................................................................................1242 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)..................................................................................1244 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1246 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)..................................................................................1248 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)..................................................................................1250 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)...........................................................1252 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)....................................................................................1254 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)....................................................................................1256 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line).............................................................1258 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)....................................................................................1260 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)....................................................................................1262 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line).............................................................1264 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)..................................................................................1266 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)..................................................................................1268 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)...........................................................1270 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)......................................................................1272 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)......................................................................1274 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)...............................................1276 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection).......................................................................1278 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit).......................................................................1280 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)................................................1282 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine).................................................1284 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)..................................................1287 Failure code [DY30ME] Emergency steering: Operating for more than 1 minute.......................................................................1290 Troubleshooting of electrical system (E-mode)........................................................................................................1293 Installing positions of fuses....................................................................................................................1293 Information in troubleshooting table.............................................................................................................1296 E-1 Engine does not start........................................................................................................................1298 E-2 Wiper does not operate.......................................................................................................................1304 E-3 Windshield washer does not operate...........................................................................................................1308 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off..............................................................1311 E-5 Working lamp does not light up or go off.....................................................................................................1319 E-6 Turn signal lamp and hazard lamp do not light up or go off...................................................................................1324 E-7 Brake lamp does not light or it keeps lighting up............................................................................................1330 E-8 Backup lamp does not light or it keeps lighting up...........................................................................................1332 E-9 Backup buzzer does not sound or it keeps sounding............................................................................................1334 E-10 Horn does not sound or it keeps sounding....................................................................................................1336 E-11 Alarm buzzer does not sound or it keeps sounding............................................................................................1338 E-12 Air conditioner does not operate or stop....................................................................................................1340 E-13 The KOMTRAX system does not work properly...................................................................................................1344 E-14 When kick-down switch is turned ON, kick-down operation does not start......................................................................1346 E-15 When hold switch is pressed, holding operation does not start...............................................................................1348 E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied...........................1350 E-17 Transmission cut-off mode cannot be set or reset............................................................................................1352 E-18 Transmission cut-off set cannot be reset....................................................................................................1354 E-19 FNR switch mode cannot be set or reset......................................................................................................1356 E-20 Fan reverse function cannot be used or reset................................................................................................1358 E-21 Discharge from loader pump does not rise from minimum level.................................................................................1360 E-22 ECSS function cannot be used or reset.......................................................................................................1362 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up.............................................................1364 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate.............................................................1368 E-25 Air cleaner clogging indicator lamp does not light up.......................................................................................1370 E-26 Radiator coolant level caution lamp does not light up.......................................................................................1372 E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up..................................1373 E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up....................1374 E-29 Steering oil pressure caution lamp does not light up........................................................................................1376 E-30 Abnormality in t switch (panel switch 1) input..............................................................................................1378 E-31 Abnormality in U switch (panel switch 1) input..............................................................................................1380 E-32 Abnormality in < switch (panel switch 2) input..............................................................................................1382 E-33 Abnormality in > switch (panel switch 2) input..............................................................................................1384 E-34 When starting switch is turned to ON position, machine monitor displays nothing.............................................................1386 Troubleshooting of hydraulic and mechanical system (H-mode)..........................................................................................1388 Method of using troubleshooting chart............................................................................................................1388 Table of failure and causes......................................................................................................................1390 H-1 The machine does not start...................................................................................................................1394 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)].......................................1396 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]........................................................1397 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted.......................1398 H-5 Shocks are large at the times of starting and shifting gear..................................................................................1400 H-6 Time lag is large at the times of starting and shifting gear.................................................................................1402 H-7 The torque converter oil temperature is high.................................................................................................1404 H-8 Steering does not turn.......................................................................................................................1405 H-9 Steering does not turn [Machine with joystick steering (if equipped)]........................................................................1406 H-10 Steering response is poor...................................................................................................................1407 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]........................................................1408 H-12 Steering is heavy...........................................................................................................................1409 H-13 When machine turns, it shakes or makes large shocks.........................................................................................1410 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]..........................................1411 H-15 The wheel brake does not work or does not work well.........................................................................................1412 H-16 The wheel brake is not released or it drags.................................................................................................1413 H-17 The parking brake does not work or does not work well.......................................................................................1414 H-18 The parking brake is not released or it drags (including emergency release system)..........................................................1415 H-19 Lift arm does not rise......................................................................................................................1416 H-20 Lift arm speed is low or rising force of lift arm is insufficient...........................................................................1417 H-21 When rising, the lift arm comes to move slowly at specific height...........................................................................1418 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)...........................................................................1418 H-23 Hydraulic drift of the lift arm is large....................................................................................................1418 H-24 The lift arm wobbles during operation.......................................................................................................1418 H-25 Bucket does not tilt back...................................................................................................................1419 H-26 Bucket speed is low or tilting back force is insufficient...................................................................................1420 H-27 The bucket comes to operate slowly in the midst of tilting-back.............................................................................1421 H-28 The bucket cylinder cannot hold down the bucket.............................................................................................1421 H-29 Hydraulic drift of the bucket is large......................................................................................................1421 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”).....................................................1421 H-31 Lift arm and bucket control levers do not move smoothly and are heavy.......................................................................1422 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls............................................................1423 H-33 Large shock is made when work equipment starts and stops....................................................................................1423 H-34 When work equipment circuit is relieved singly, other work equipment moves..................................................................1423 H-35 ECSS does not operate, and pitching, bouncing occur.........................................................................................1424 Troubleshooting of engine (S-mode)...................................................................................................................1425 Method of using troubleshooting chart............................................................................................................1425 S-1 Engine is hard to start......................................................................................................................1428 S-2 Engine does not start........................................................................................................................1429 S-3 Engine does not pick up smoothly.............................................................................................................1432 S-4 Engine stops during operation................................................................................................................1433 S-5 Engine does not rotate smoothly..............................................................................................................1434 S-6 Engine lacks output (or lacks power).........................................................................................................1435 S-7 Exhaust gas color is black (incomplete combustion)...........................................................................................1436 S-8 Oil consumption is excessive (or exhaust gas color is blue)..................................................................................1437 S-9 Oil gets contaminated prematurely............................................................................................................1438 S-10 Fuel consumption is excessive...............................................................................................................1439 S-11 Coolant contains oil (blows back or reduces)................................................................................................1440 S-12 Oil pressure drops..........................................................................................................................1441 S-13 Oil level rises (Water, fuel in oil)........................................................................................................1442 S-14 Coolant temperature rises too high (overheat)...............................................................................................1443 S-15 Abnormal noise comes out....................................................................................................................1444 S-16 Vibration is excessive......................................................................................................................1445 50 Disassembly and assembly..............................................................................................................................1447 General information on disassembly and assembly......................................................................................................1450 How to read this manual..........................................................................................................................1450 Coating materials list...........................................................................................................................1452 Special tools list...............................................................................................................................1455 Sketches of special tools........................................................................................................................1460 Engine and cooling system............................................................................................................................1481 Removal and installation of engine assembly......................................................................................................1481 Removal and installation of engine hood assembly.................................................................................................1485 Removal and installation of radiator assembly....................................................................................................1488 Removal and installation of aftercooler assembly.................................................................................................1491 Removal and installation of oil cooler assembly..................................................................................................1493 Removal and installation of cooling fan and drive motor assembly.................................................................................1495 Removal and installation of fuel supply pump assembly............................................................................................1499 Removal and installation of fuel injector assembly...............................................................................................1505 Removal and installation of cylinder head assembly...............................................................................................1511 Removal and installation of engine front oil seal................................................................................................1517 Removal and Installation of engine rear oil seal.................................................................................................1520 Removal and installation of fuel tank assembly...................................................................................................1525 Power train..........................................................................................................................................1528 Removal and installation of torque converter and transmission assembly...........................................................................1528 Disassembly and assembly of torque converter and transmission assembly...........................................................................1533 Disassembly and assembly of torque converter assembly (Standard specification)...................................................................1566 Disassembly and assembly of torque converter assembly (Lockup specification).....................................................................1571 Disassembly and assembly of clutch pack assembly.................................................................................................1579 Removal and installation of front axle assembly..................................................................................................1605 Removal and installation of rear axle assembly...................................................................................................1607 Disassembly and assembly of axle housing assembly................................................................................................1613 Disassembly and assembly of differential assembly................................................................................................1622 Brake system.........................................................................................................................................1643 Removal and installation of parking brake disc and plate.........................................................................................1643 Undercarriage and frame..............................................................................................................................1646 Removal and installation of center hinge pin.....................................................................................................1646 Removal and installation of counterweight........................................................................................................1654 Hydraulic system.....................................................................................................................................1656 Removal and installation of steering demand valve assembly.......................................................................................1656 Removal and installation of work equipment valve assembly........................................................................................1659 Removal and installation of brake charge valve assembly..........................................................................................1662 Removal and installation of hydraulic tank assembly..............................................................................................1663 Removal and installation of steering and power train pump assembly...............................................................................1665 Removal and installation of work equipment and cooling fan pump assembly.........................................................................1666 Disassembly and assembly of hydraulic cylinder assembly..........................................................................................1668 Work equipment.......................................................................................................................................1676 Removal and installation of work equipment assembly..............................................................................................1676 Cab and its attachments..............................................................................................................................1680 Removal and installation of operator's cab and floor frame assembly..............................................................................1680 Removal and installation of operator's cab glass (stuck glass)...................................................................................1684 Disassembly and assembly of operator's seat assembly.............................................................................................1692 Removal and installation of air conditioner unit assembly........................................................................................1734 Electrical system....................................................................................................................................1738 Removal and installation of engine controller assembly...........................................................................................1738 Removal and installation of transmission controller assembly.....................................................................................1739 Removal and installation of KOMTRAX terminal assembly............................................................................................1740 80 Appendix..............................................................................................................................................1741 Air conditioner......................................................................................................................................1743 Precautions for refrigerant......................................................................................................................1743 Troubleshooting procedure........................................................................................................................1744 Circuit diagram and arrangement of connector pins................................................................................................1746 System diagram...................................................................................................................................1751 Detail of air conditioner unit...................................................................................................................1753 Parts and connectors layout......................................................................................................................1755 Testing with self-diagnosis function (indication on control panel)...............................................................................1759 Testing temperature control......................................................................................................................1762 Testing vent (mode) changeover...................................................................................................................1763 Testing Fresh/Recirc changeover..................................................................................................................1765 Testing inside air temp. sensor and outside air temp. sensor.....................................................................................1767 Testing evaporator temperature sensor............................................................................................................1769 Testing sunlight sensor..........................................................................................................................1770 Testing relays...................................................................................................................................1771 Troubleshooting chart 1..........................................................................................................................1772 Troubleshooting chart 2..........................................................................................................................1773 Information in troubleshooting table.............................................................................................................1776 Troubleshooting for power supply system (Air conditioner does not operate).......................................................................1777 Troubleshooting for compressor and refrigerant system (Air is not cooled)........................................................................1780 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)...............................................................1783 Troubleshooting for temperature control..........................................................................................................1789 Troubleshooting for vent (mode) changeover.......................................................................................................1792 Troubleshooting for Fresh/Recirc air changeover..................................................................................................1795 Troubleshooting with gauge pressure..............................................................................................................1797 Connection of service tool.......................................................................................................................1799 Handling of compressor oil.......................................................................................................................1800 90 Diagrams and drawings.................................................................................................................................1803 Hydraulic diagrams and drawings......................................................................................................................1805 Symbols used in hydraulic circuit diagrams.......................................................................................................1805 Power train hydraulic circuit diagram............................................................................................................1808 Automatic greasing circuit diagram...............................................................................................................1810 Hydraulic circuit diagram........................................................................................................................1813 Electrical diagrams and drawings.....................................................................................................................1814 Symbols used in electric circuit diagrams........................................................................................................1814 Electrical circuit diagram.......................................................................................................................1818 Connector list and stereogram....................................................................................................................1829 Index....................................................................................................................................................1830
DESCRIPTION:
KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-04 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
S.S 30/12/24
