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KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-10 – PDF DOWNLOAD
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KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-10 – PDF DOWNLOAD
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KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-10 – PDF DOWNLOAD
Language : English
Pages : 1864
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-10 – PDF DOWNLOAD
Cover......................................................................................................................................................... 1 00 Index and foreword..................................................................................................................................... 3 Table of contents..................................................................................................................................... 4 Foreword and general information...................................................................................................................... 19 Safety notice..................................................................................................................................... 19 How to read the shop manual....................................................................................................................... 24 Explanation of terms for maintenance standard..................................................................................................... 26 Handling of electric equipment and hydraulic component............................................................................................ 28 Handling of connectors newly used for engines..................................................................................................... 37 How to read electric wire code.................................................................................................................... 40 Precautions when carrying out operation........................................................................................................... 43 Method of disassembling and connecting push-pull type coupler..................................................................................... 46 Standard tightening torque table.................................................................................................................. 49 Conversion table.................................................................................................................................. 53 01 Specification.......................................................................................................................................... 59 Specification and technical data...................................................................................................................... 61 Specification dimension drawing................................................................................................................... 61 Specifications.................................................................................................................................... 62 Weight table...................................................................................................................................... 66 Table of fuel, coolant and lubricants............................................................................................................. 68 10 Structure, function and maintenance standard........................................................................................................... 71 Engine and cooling system............................................................................................................................. 74 Engine mount and transmission mount............................................................................................................... 74 Cooling system.................................................................................................................................... 75 Cooling fan pump.................................................................................................................................. 76 Cooling fan motor................................................................................................................................. 84 Power train........................................................................................................................................... 91 Power train....................................................................................................................................... 91 Power train system diagram........................................................................................................................ 92 Drive shaft....................................................................................................................................... 94 Power train piping diagram........................................................................................................................ 95 Torque converter.................................................................................................................................. 96 Transmission...................................................................................................................................... 104 Transmission control valve........................................................................................................................ 122 ECMV.............................................................................................................................................. 126 Main relief valve and torque converter relief valve............................................................................................... 138 Axle.............................................................................................................................................. 140 Differential...................................................................................................................................... 144 Limited slip differential......................................................................................................................... 149 Final drive....................................................................................................................................... 156 Steering system....................................................................................................................................... 162 Steering component layout drawing................................................................................................................. 162 Steering column................................................................................................................................... 163 Steering pump..................................................................................................................................... 164 Steering valve.................................................................................................................................... 177 Orbit-roll valve.................................................................................................................................. 194 Stop valve........................................................................................................................................ 202 Steering relief valve............................................................................................................................. 203 Steering cylinder................................................................................................................................. 204 Emergency steering motor.......................................................................................................................... 206 Emergency steering pump........................................................................................................................... 207 Joystick steering lever linkage................................................................................................................... 208 Electrical steering lever......................................................................................................................... 209 Joystick EPC valve................................................................................................................................ 210 Brake system.......................................................................................................................................... 212 Brake component layout drawing.................................................................................................................... 212 Component layout of brake cooling system.......................................................................................................... 213 Brake cooling control system...................................................................................................................... 214 Charge valve...................................................................................................................................... 215 Brake valve....................................................................................................................................... 222 Accumulator (for brake)........................................................................................................................... 227 Slack adjuster.................................................................................................................................... 228 Brake............................................................................................................................................. 230 Parking brake control............................................................................................................................. 235 Parking brake..................................................................................................................................... 236 Parking brake solenoid valve...................................................................................................................... 238 Emergency parking brake release valve............................................................................................................. 240 Brake cooling oil cooler ......................................................................................................................... 241 Brake cooling pump motor.......................................................................................................................... 242 Brake cooling fan................................................................................................................................. 243 Undercarriage and frame............................................................................................................................... 244 Axle mount and center hinge pin................................................................................................................... 244 Tires............................................................................................................................................. 248 Hydraulic system...................................................................................................................................... 250 Hydraulic component layout drawing................................................................................................................ 250 Work equipment control lever linkage.............................................................................................................. 253 Hydraulic tank.................................................................................................................................... 256 Power train pump.................................................................................................................................. 258 Work equipment pump............................................................................................................................... 260 Work equipment control valve...................................................................................................................... 280 CLSS.............................................................................................................................................. 291 Each function and operation of each valve......................................................................................................... 296 PPC valve......................................................................................................................................... 310 Accumulator (for PPC circuit)..................................................................................................................... 318 Accumulator (for power train circuit)............................................................................................................. 319 Accumulator (for ECSS)............................................................................................................................ 320 Work equipment PPC cut-off solenoid valve......................................................................................................... 321 Work equipment........................................................................................................................................ 324 Work equipment linkage............................................................................................................................ 324 Bucket............................................................................................................................................ 327 Bucket positioner and boom kick-out............................................................................................................... 328 Work equipment cylinder........................................................................................................................... 334 Cab and its attachments............................................................................................................................... 335 Cab............................................................................................................................................... 335 Air conditioner................................................................................................................................... 336 Electrical system..................................................................................................................................... 354 Machine monitor system............................................................................................................................ 354 Machine monitor................................................................................................................................... 358 Electrical system (Transmission controller system)................................................................................................ 390 Transmission controller........................................................................................................................... 430 Electrical system (Work equipment controller system).............................................................................................. 432 Work equipment controller......................................................................................................................... 438 Electric transmission control..................................................................................................................... 440 Kickdown switch and hold switch................................................................................................................... 444 Load meter cancel switch and load meter subtotal switch........................................................................................... 444 Multi-function knob............................................................................................................................... 445 Joystick steering knob............................................................................................................................ 446 KOMTRAX system.................................................................................................................................... 448 Engine starting circuit........................................................................................................................... 450 Engine stopping circuit........................................................................................................................... 452 Preheating circuit................................................................................................................................ 453 Engine power mode selector circuit................................................................................................................ 454 Engine output derating function................................................................................................................... 455 Automatic warm-up function........................................................................................................................ 455 Parking brake circuit............................................................................................................................. 456 Sensor............................................................................................................................................ 458 20 Standard value table................................................................................................................................... 469 Standard service value table.......................................................................................................................... 471 Standard value table for engine................................................................................................................... 471 Standard value table for chassis.................................................................................................................. 472 30 Testing and adjusting.................................................................................................................................. 481 Related information on testing and adjusting.......................................................................................................... 484 Tools for testing, adjusting, and troubleshooting................................................................................................. 484 Engine and cooling system............................................................................................................................. 489 Testing engine speed.............................................................................................................................. 489 Testing exhaust gas color......................................................................................................................... 491 Testing exhaust temperature....................................................................................................................... 493 Adjusting valve clearance......................................................................................................................... 495 Testing compression pressure...................................................................................................................... 497 Testing blow-by pressure.......................................................................................................................... 498 Testing engine oil pressure....................................................................................................................... 499 Testing intake air (boost) pressure............................................................................................................... 500 Handling fuel system equipment.................................................................................................................... 501 Releasing residual pressure in fuel system........................................................................................................ 501 Testing fuel pressure............................................................................................................................. 502 Testing fuel return and leak amount............................................................................................................... 503 Bleeding air from fuel circuit.................................................................................................................... 506 Testing fuel circuit for leakage.................................................................................................................. 508 Handling of reduced cylinder mode operation....................................................................................................... 509 Handling of no injection cranking operation....................................................................................................... 509 Handling of controller voltage circuit............................................................................................................ 510 Check of muffler and muffler stack for looseness and damage....................................................................................... 511 Check of muffler function......................................................................................................................... 511 Check of installed condition of cylinder head and manifolds....................................................................................... 512 Check of engine piping for damage and looseness................................................................................................... 512 Testing and adjusting air conditioner compressor belt tension..................................................................................... 513 Testing and adjusting alternator belt tension..................................................................................................... 514 Power train........................................................................................................................................... 515 Adjusting transmission speed sensor............................................................................................................... 515 Adjusting directional lever length................................................................................................................ 516 Adjusting gear shift lever length................................................................................................................. 516 Testing FNR lever and gear shift lever............................................................................................................ 517 Testing and adjusting power train oil pressure.................................................................................................... 518 Procedure for flushing torque converter and transmission hydraulic circuit........................................................................ 532 Method of moving machine when transmission valve is broken........................................................................................ 534 Check of axle final drive for oil leakage......................................................................................................... 537 Check of drive shafts for looseness, play and damage.............................................................................................. 537 Steering system....................................................................................................................................... 538 Testing and adjusting steering stop valve......................................................................................................... 538 Testing and adjusting steering wheel.............................................................................................................. 540 Testing steering oil pressure..................................................................................................................... 542 Bleeding air from steering circuit................................................................................................................ 545 Brake system.......................................................................................................................................... 546 Testing brake pedal............................................................................................................................... 546 Testing and adjusting brake pedal linkage......................................................................................................... 547 Testing brake performance......................................................................................................................... 548 Testing and adjusting accumulator charge pressure................................................................................................. 549 Testing wheel brake oil pressure.................................................................................................................. 551 Testing wear of wheel brake disc.................................................................................................................. 553 Bleeding air from wheel brake circuit............................................................................................................. 554 Releasing residual pressure in brake accumulator circuit.......................................................................................... 555 Testing parking brake performance................................................................................................................. 555 Testing parking brake oil pressure................................................................................................................ 556 Testing wear of parking brake disc................................................................................................................ 558 Manual release method for parking brake........................................................................................................... 559 Hydraulic system...................................................................................................................................... 560 Testing hydraulic drive fan....................................................................................................................... 560 Adjustment of hydraulic fan speed sensor.......................................................................................................... 562 Bleeding air from hydraulic drive fan circuit..................................................................................................... 563 Testing and adjusting work equipment control lever................................................................................................ 565 Testing and adjusting work equipment PPC oil pressure............................................................................................. 566 Testing and adjusting work equipment oil pressure................................................................................................. 569 Bleeding air from work equipment circuit.......................................................................................................... 573 Releasing residual pressure in work equipment circuit............................................................................................. 574 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically Controlled Suspension System) accumulator..... 575 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator.................................................. 579 Work equipment........................................................................................................................................ 586 Testing and adjusting bucket positioner........................................................................................................... 586 Testing and adjusting boom kick-out............................................................................................................... 588 Checking proximity switch operation pilot lamp.................................................................................................... 589 Electrical system..................................................................................................................................... 590 Procedure for testing diodes...................................................................................................................... 590 Preparation work for troubleshooting for electrical system........................................................................................ 591 How to start KOMTRAX terminal operations.......................................................................................................... 596 Indicator lamps of KOMTRAX terminal............................................................................................................... 601 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor............................................................ 604 Special functions of machine monitor (EMMS)....................................................................................................... 607 Pm-clinic............................................................................................................................................. 670 Pm-clinic inspection table........................................................................................................................ 670 40 Troubleshooting........................................................................................................................................ 675 General information on troubleshooting................................................................................................................ 685 Points to remember when troubleshooting........................................................................................................... 685 How to proceed in troubleshooting................................................................................................................. 686 Testing before troubleshooting.................................................................................................................... 688 Classification and procedures of troubleshooting.................................................................................................. 690 Failure code table................................................................................................................................ 694 Information in troubleshooting table.............................................................................................................. 705 Troubleshooting method for open circuit in wiring harness of pressure sensor system............................................................... 707 Connection table for connector pin numbers........................................................................................................ 709 T- branch box and T- branch adapter table......................................................................................................... 745 Fuse locations.................................................................................................................................... 748 Phenomena looking like troubles and troubleshooting Nos........................................................................................... 751 Information contained in troubleshooting table.................................................................................................... 754 Troubleshooting by failure code (Display of code)..................................................................................................... 757 Failure code [1500L0] (TORQFLOW transmission: Double meshing)..................................................................................... 757 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)............................................................. 758 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)............................................................. 760 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)............................................................. 762 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)............................................................. 764 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)........................................................... 766 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)........................................................... 768 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)........................................................... 770 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)........................................................... 772 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)........................................................... 774 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)........................................................... 776 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)........................................................... 778 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)........................................................... 780 Failure code [2F00MA] (Parking brake: Malfunction)................................................................................................ 782 Failure code [2G43ZG] (Accumulator: Low oil pressure)............................................................................................. 784 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)................................................................................ 786 Failure code [AA1ANX] (Air cleaner: Clogging)..................................................................................................... 790 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)............................................................... 792 Failure code [AB00MA] (Alternator: Malfunction)................................................................................................... 794 Failure code [B@BAZG] (Rotation derating by low engine oil pressure).............................................................................. 796 Failure code [B@BAZK] (Engine oil: Low level)..................................................................................................... 799 Failure code [B@BCNS] (Coolant: Overheating)...................................................................................................... 800 Failure code [B@BCZK] (Coolant: Low level)........................................................................................................ 802 Failure code [B@C7NS] (Brake oil: Overheating).................................................................................................... 804 Failure code [b@CENS] (Torque converter oil: Overheating)......................................................................................... 806 Failure code [B@CENS] (Torque converter oil: Overheating)......................................................................................... 808 Failure code [B@HANS] (Hydraulic oil: Overheating)................................................................................................ 810 Failure code [CA111] (Abnormality in engine controller)........................................................................................... 812 Failure code [CA115] (Engine Ne or Bkup speed sensor error)....................................................................................... 815 Failure code [CA122] Chg Air Press Sensor High Error.............................................................................................. 816 Failure code [CA123] Chg Air Press Sensor Low Error............................................................................................... 818 Failure code [CA131] Throttle sensor : High error................................................................................................. 820 Failure code [CA132] Throttle sensor : Low error.................................................................................................. 822 Failure code [CA135] Eng Oil Press Sensor High Error.............................................................................................. 824 Failure code [CA141] Eng Oil Press Sensor Low Error............................................................................................... 826 Failure code [CA144] Coolant Temp Sens High Error................................................................................................. 828 Failure code [CA145] Coolant Temp Sens Low Error.................................................................................................. 830 Failure code [CA153] Chg Air Temp Sensor High Error............................................................................................... 832 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................................ 834 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................................................. 836 Failure code [CA221] Ambient Press Sens High Error................................................................................................ 838 Failure code [CA222] Ambient Press Sens Low Error................................................................................................. 840 Failure code [CA227] Sens Supply 2 Volt High Error................................................................................................ 842 Failure code [CA234] Eng Overspeed................................................................................................................ 843 Failure code [CA238] Ne Speed Sens Supply Volt Error.............................................................................................. 844 Failure code [CA263] Fuel Temp Sensor High Error.................................................................................................. 846 Failure code [CA265] Fuel Temp Sensor Low Error................................................................................................... 848 Failure code [CA271] IMV/PCV1 Short Error......................................................................................................... 850 Failure code [CA272] IMV/PCV1 Open Error.......................................................................................................... 852 Failure code [CA273] PCV2 Short Error............................................................................................................. 854 Failure code [CA274] PCV2 Open Error.............................................................................................................. 856 Failure code [CA322] Inj #1(L#1) Open/Short Error................................................................................................. 858 Failure code [CA323] Inj #5 (L#5) Open/Short Error................................................................................................ 860 Failure code [CA324] Inj #3(L#3) Open/Short Error................................................................................................. 862 Failure code [CA325] Inj #6 (L#6) Open/Short Error................................................................................................ 864 Failure code [CA331] Inj #2(L#2) Open/Short Error................................................................................................. 866 Failure code [CA332] Inj #4 (L#4) Open/Short Error................................................................................................ 868 Failure code [CA342] (Calibration code inconsistency)............................................................................................. 870 Failure code [CA351] Injectors Drive Circuit Error................................................................................................ 871 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................................................. 872 Failure code [CA386] Sens Supply 1 Volt High Error................................................................................................ 874 Failure code [CA431] Idle validation switch : Error............................................................................................... 875 Failure code [CA432] Idle validation switch : Action error........................................................................................ 878 Failure code [CA441] (Battery voltage low error).................................................................................................. 880 Failure code [CA442] (Battery voltage high error)................................................................................................. 882 Failure code [CA449] Rail Press Very High Error................................................................................................... 884 Failure code [CA451] Rail Press Sensor High Error................................................................................................. 886 Failure code [CA452] Rail Press Sensor Low Error.................................................................................................. 888 Failure code [CA553] (Common rail pressure high error 1).......................................................................................... 890 Failure code [CA554] (Common rail pressure sensor in-range error)................................................................................. 891 Failure code [CA559] (Supply pump pressure very low error)........................................................................................ 892 Failure code [CA689] Eng Ne Speed Sensor Error.................................................................................................... 896 Failure code [CA731] (Engine Bkup speed sensor phase error)....................................................................................... 898 Failure code [CA757] (All continuous data lost error)............................................................................................. 899 Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................................................. 900 Failure code [CA1633] KOMNET Datalink Timeout Error............................................................................................... 902 Failure code [CA2185] Throttle sensor power supply voltage : High error........................................................................... 904 Failure code [CA2186] Throttle sensor power supply voltage : Low error............................................................................ 906 Failure code [CA2249] (Supply pump pressure very low error 2)..................................................................................... 908 Failure code [CA2555] Intake heater relay : Open circuit.......................................................................................... 910 Failure code [CA2556] Intake heater relay : Short circuit......................................................................................... 912 Failure code [D150KA] (Emergency steering relay: Disconnection)................................................................................... 914 Failure code [D150KB] (Emergency steering relay: Short circuit)................................................................................... 916 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)............................................................ 918 Failure code [D160KA] (Backup lamp relay output: Disconnection)................................................................................... 920 Failure code [D160KB] (Backup lamp relay output: Short circuit)................................................................................... 922 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)..................................................................... 924 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)..................................................................... 926 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line).............................................. 928 Failure code [D192KA] (ECSS solenoid: Disconnection).............................................................................................. 930 Failure code [D192KB] (ECSS solenoid: Short circuit).............................................................................................. 931 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)....................................................................... 932 Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection)................................................................... 934 Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit)................................................................... 936 Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line)............................................ 938 Failure code [D5ZHKA] (Terminal C signal: Disconnection).......................................................................................... 941 Failure code [D5ZHKB] (Terminal C signal: Short circuit).......................................................................................... 945 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)......................................................................... 948 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state).................................................. 953 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)........................................................................... 956 Failure code [DAF3KK] (Machine monitor: Low source voltage (input))............................................................................... 958 Failure code [DAF5KP] (Machine monitor: Low output voltage)....................................................................................... 960 Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication (Abnormality in target component system)).................. 962 Failure code [DAQ0KK] (Transmission controller: Low source voltage)............................................................................... 964 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)........................................................................ 966 Failure code [DAQ1KA] (Terminal ACC input: Disconnection)......................................................................................... 967 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))................................................ 970 Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection signals).......................................... 972 Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication (Abnormality in target component system)).......... 973 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)....................................................................... 978 Failure code [DB2RKR] (CAN communication with engine controller: Defective communication (Abnormality in target component system)................. 979 Failure code [DB90KK] Work equipment controller: Low source voltage (input)....................................................................... 986 Failure code [DB90KT] Work equipment controller: Abnormality in controller........................................................................ 988 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)................................................ 990 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range.................................................... 993 Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model selection signals)........................................ 996 Failure code [DB9RKR] CAN communication with work equipment controller: Defective communication (Abnormality in target component system).......... 997 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction).....................................................................1002 Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and machine monitor: Defective operation)................1003 Failure code [DD15LD] ■ switch (Panel switch 1): Switch is kept pressed for long time.............................................................1004 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time.............................................................1006 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time.............................................................1008 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time.............................................................1010 Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time......................................1012 Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time......................................1014 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time............................................................1016 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time.................................................1018 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time.................................................1020 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)..................................................1022 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)..................................................................1024 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)........................................................1026 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)...............................................................1028 Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long time)...........................................1032 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)..............................................................................1034 Failure code [DDK3KA] (Right FNR switch: Disconnection)...........................................................................................1036 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)...............................................................................1039 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)...........................................................1042 Failure code [DDK6KA] (FNR lever switch: Disconnection)...........................................................................................1044 Failure code [DDK6KB] (FNR lever switch: Short circuit)...........................................................................................1048 Failure code [DDS5KA] (Steering pressure switch signal: Disconnected).............................................................................1050 Failure code [DDS5KB] (Steering pressure switch signal: Short circuit)............................................................................1052 Failure code [DDS5L6] (Steering: Low oil pressure)................................................................................................1054 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree).......................................................................1056 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time).....................................................1058 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)....................................................................1060 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time).........................................................................1062 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)............................................................1064 Failure code [DF10KA] (Transmission shift lever switch: Disconnected).............................................................................1066 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)............................................................................1070 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected).........................................................................1074 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)........................................................................1076 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)...............................................................1078 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)...........................................................................1080 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)..............................................................1082 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)........................................................1084 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)................................................................................1086 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)......................................................................1088 Failure code [DHPCKX] (Boom cylinder bottom pressure sensor: Out of input signal range)...........................................................1090 Failure code [DHPDKX] (Boom cylinder head pressure sensor: Out of input signal range).............................................................1092 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)...........................................................1094 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)..............................................................................1096 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)..............................................................................1098 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)....................................................................1100 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line).............................................1103 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)..........................................................1106 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection).....................................................................1109 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)..............................................1112 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)......................................................................1115 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)...............................................1118 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)............................................................1121 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection).......................................................................1124 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)................................................1127 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)...........................................................1130 Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)....................................1134 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree).................................................1136 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)............................................................1139 Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line).....................................1142 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)......................................................................................1144 Failure code [DKA0KX] (Lift arm angle sensor: Out of input signal range)..........................................................................1146 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)...............................................................1148 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing).....................................................................................1150 Failure code [DLF1KA] (Transmission input speed sensor: Disconnection)............................................................................1152 Failure code [DLF1LC] (Transmission input speed sensor: Short circuit)............................................................................1153 Failure code [DLM3KA] (Fan speed sensor: Disconnection)...........................................................................................1154 Failure code [DLM3LC] (Fan speed sensor: Short circuit)...........................................................................................1156 Failure code [DLT3KA] (Transmission output speed sensor: Disconnection)...........................................................................1158 Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range)...............................................................1160 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)........................................................................1162 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit).................................................................1164 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit).................................................................1166 Failure code [DV00KB] (Alarm buzzer: Short circuit)...............................................................................................1168 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)................................................................................1170 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)................................................................................1172 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line).........................................................1174 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)................................................................................1176 Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)................................................................................1177 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line).........................................................1178 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)...................................................................................1180 Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)...................................................................................1181 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)............................................................1182 Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)...................................................................................1184 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)...................................................................................1185 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)............................................................1186 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection).......................................................................................1188 Failure code [DW7BKB] (Fan reverse solenoid: Short circuit).......................................................................................1189 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)................................................................1190 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection).......................................................................1192 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit).......................................................................1194 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)................................................1196 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)......................................................................1198 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)......................................................................1200 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)...............................................1202 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)......................................................................1204 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)......................................................................1206 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)...............................................1208 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection).........................................................................1210 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit).........................................................................1212 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source).........................................................1214 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)......................................................................................1216 Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)......................................................................................1217 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)...............................................................1218 Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection)................................................................................1220 Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)................................................................................1222 Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection)..............................................................................1224 Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit)..............................................................................1226 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection).......................................................................................1228 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit).......................................................................................1230 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)................................................................1232 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)...................................................................................1234 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)...................................................................................1236 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)............................................................1238 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)...................................................................................1240 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)...................................................................................1242 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)............................................................1244 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)...................................................................................1246 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)...................................................................................1248 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)............................................................1250 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection).....................................................................................1252 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit).....................................................................................1254 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)..............................................................1256 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection).....................................................................................1258 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit).....................................................................................1260 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)..............................................................1262 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)...................................................................................1264 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)...................................................................................1266 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)............................................................1268 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection).......................................................................1270 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit).......................................................................1272 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)................................................1274 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)........................................................................1276 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)........................................................................1278 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line).................................................1280 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)..................................................1282 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)...................................................1285 Failure code [DY30ME] Emergency steering: Operating for more than 1 minute........................................................................1288 Troubleshooting of electrical system (E-mode).........................................................................................................1291 Installing positions of fuses.....................................................................................................................1291 Information in troubleshooting table..............................................................................................................1294 E-1 Engine does not start.........................................................................................................................1296 E-2 Wiper does not operate........................................................................................................................1302 E-3 Windshield washer does not operate............................................................................................................1306 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off...............................................................1309 E-5 Working lamp does not light up or go off......................................................................................................1317 E-6 Turn signal lamp and hazard lamp do not light up or go off....................................................................................1322 E-7 Brake lamp does not light or it keeps lighting up.............................................................................................1328 E-8 Backup lamp does not light or it keeps lighting up............................................................................................1330 E-9 Backup buzzer does not sound or it keeps sounding.............................................................................................1332 E-10 Horn does not sound or it keeps sounding.....................................................................................................1334 E-11 Alarm buzzer does not sound or it keeps sounding.............................................................................................1336 E-12 Air conditioner does not operate or stop.....................................................................................................1338 E-13 The KOMTRAX system does not work properly....................................................................................................1342 E-14 When kick-down switch is turned ON, kick-down operation does not start.......................................................................1344 E-15 When hold switch is pressed, holding operation does not start................................................................................1346 E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake is applied............................1348 E-17 Transmission cut-off mode cannot be set or reset.............................................................................................1350 E-18 Transmission cut-off set cannot be reset.....................................................................................................1352 E-19 FNR switch mode cannot be set or reset.......................................................................................................1354 E-20 Fan reverse function cannot be used or reset.................................................................................................1356 E-21 Discharge from loader pump does not rise from minimum level..................................................................................1358 E-22 ECSS function cannot be used or reset........................................................................................................1360 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up..............................................................1362 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate..............................................................1366 E-25 Air cleaner clogging indicator lamp does not light up........................................................................................1368 E-26 Radiator coolant level caution lamp does not light up........................................................................................1370 E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not light up...................................1371 E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature caution lamp does not light up.....................1372 E-29 Steering oil pressure caution lamp does not light up.........................................................................................1374 E-30 Abnormality in t switch (panel switch 1) input...............................................................................................1376 E-31 Abnormality in U switch (panel switch 1) input...............................................................................................1378 E-32 Abnormality in < switch (panel switch 2) input...............................................................................................1380 E-33 Abnormality in > switch (panel switch 2) input...............................................................................................1382 E-34 When starting switch is turned to ON position, machine monitor displays nothing..............................................................1384 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................................................1386 Method of using troubleshooting chart.............................................................................................................1386 Table of failure and causes.......................................................................................................................1388 H-1 The machine does not start....................................................................................................................1392 H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if equipped)]........................................1394 H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)].........................................................1395 H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted........................1396 H-5 Shocks are large at the times of starting and shifting gear...................................................................................1398 H-6 Time lag is large at the times of starting and shifting gear..................................................................................1400 H-7 The torque converter oil temperature is high..................................................................................................1402 H-8 Steering does not turn........................................................................................................................1403 H-9 Steering does not turn [Machine with joystick steering (if equipped)].........................................................................1404 H-10 Steering response is poor....................................................................................................................1405 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)].........................................................1406 H-12 Steering is heavy............................................................................................................................1407 H-13 When machine turns, it shakes or makes large shocks..........................................................................................1408 H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if equipped)]...........................................1409 H-15 The wheel brake does not work or does not work well..........................................................................................1410 H-16 The wheel brake is not released or it drags..................................................................................................1411 H-17 The parking brake does not work or does not work well........................................................................................1412 H-18 The parking brake is not released or it drags (including emergency release system)...........................................................1413 H-19 Lift arm does not rise.......................................................................................................................1414 H-20 Lift arm speed is low or rising force of lift arm is insufficient............................................................................1415 H-21 When rising, the lift arm comes to move slowly at specific height............................................................................1416 H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats)............................................................................1416 H-23 Hydraulic drift of the lift arm is large.....................................................................................................1416 H-24 The lift arm wobbles during operation........................................................................................................1416 H-25 Bucket does not tilt back....................................................................................................................1417 H-26 Bucket speed is low or tilting back force is insufficient....................................................................................1418 H-27 The bucket comes to operate slowly in the midst of tilting-back..............................................................................1419 H-28 The bucket cylinder cannot hold down the bucket..............................................................................................1419 H-29 Hydraulic drift of the bucket is large.......................................................................................................1419 H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”)......................................................1419 H-31 Lift arm and bucket control levers do not move smoothly and are heavy........................................................................1420 H-32 During operation of the machine, engine speed lowers remarkably or engine stalls.............................................................1421 H-33 Large shock is made when work equipment starts and stops.....................................................................................1421 H-34 When work equipment circuit is relieved singly, other work equipment moves...................................................................1421 H-35 ECSS does not operate, and pitching, bouncing occur..........................................................................................1422 Troubleshooting of engine (S-mode)....................................................................................................................1423 Method of using troubleshooting chart.............................................................................................................1423 S-1 Engine is hard to start.......................................................................................................................1426 S-2 Engine does not start.........................................................................................................................1427 S-3 Engine does not pick up smoothly..............................................................................................................1430 S-4 Engine stops during operation.................................................................................................................1431 S-5 Engine does not rotate smoothly...............................................................................................................1432 S-6 Engine lacks output (or lacks power)..........................................................................................................1433 S-7 Exhaust gas color is black (incomplete combustion)............................................................................................1434 S-8 Oil consumption is excessive (or exhaust gas color is blue)...................................................................................1435 S-9 Oil gets contaminated prematurely.............................................................................................................1436 S-10 Fuel consumption is excessive................................................................................................................1437 S-11 Coolant contains oil (blows back or reduces).................................................................................................1438 S-12 Oil pressure drops...........................................................................................................................1439 S-13 Oil level rises (Water, fuel in oil).........................................................................................................1440 S-14 Coolant temperature rises too high (overheat)................................................................................................1441 S-15 Abnormal noise comes out.....................................................................................................................1442 S-16 Vibration is excessive.......................................................................................................................1443 50 Disassembly and assembly...............................................................................................................................1445 General information on disassembly and assembly.......................................................................................................1448 How to read this manual...........................................................................................................................1448 Coating materials list............................................................................................................................1450 Special tools list................................................................................................................................1453 Sketches of special tools.........................................................................................................................1458 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.................................................................................................1624 Brake system..........................................................................................................................................1645 Removal and installation of parking brake disc and plate..........................................................................................1645 Undercarriage and frame...............................................................................................................................1648 Removal and installation of center hinge pin......................................................................................................1648 Removal and installation of counterweight.........................................................................................................1656 Hydraulic system......................................................................................................................................1658 Removal and installation of steering demand valve assembly........................................................................................1658 Removal and installation of work equipment valve assembly.........................................................................................1661 Removal and installation of brake charge valve assembly...........................................................................................1664 Removal and installation of hydraulic tank assembly...............................................................................................1665 Removal and installation of steering and power train pump assembly................................................................................1667 Removal and installation of work equipment and cooling fan pump assembly..........................................................................1668 Disassembly and assembly of hydraulic cylinder assembly...........................................................................................1670 Work equipment........................................................................................................................................1678 Removal and installation of work equipment assembly...............................................................................................1678 Cab and its attachments...............................................................................................................................1682 Removal and installation of operator's cab and floor frame assembly...............................................................................1682 Removal and installation of operator's cab glass (stuck glass)....................................................................................1686 Disassembly and assembly of operator's seat assembly..............................................................................................1694 Removal and installation of air conditioner unit assembly.........................................................................................1736 Electrical system.....................................................................................................................................1740 Removal and installation of engine controller assembly............................................................................................1740 Removal and installation of transmission controller assembly......................................................................................1741 Removal and installation of KOMTRAX terminal assembly.............................................................................................1742 80 Appendix...............................................................................................................................................1743 Air conditioner.......................................................................................................................................1745 Precautions for refrigerant.......................................................................................................................1745 Troubleshooting procedure.........................................................................................................................1746 Circuit diagram and arrangement of connector pins.................................................................................................1748 System diagram....................................................................................................................................1753 Detail of air conditioner unit....................................................................................................................1755 Parts and connectors layout.......................................................................................................................1757 Testing with self-diagnosis function (indication on control panel)................................................................................1761 Testing temperature control.......................................................................................................................1764 Testing vent (mode) changeover....................................................................................................................1765 Testing Fresh/Recirc changeover...................................................................................................................1767 Testing inside air temp. sensor and outside air temp. sensor......................................................................................1769 Testing evaporator temperature sensor.............................................................................................................1771 Testing sunlight sensor...........................................................................................................................1772 Testing relays....................................................................................................................................1773 Troubleshooting chart 1...........................................................................................................................1774 Troubleshooting chart 2...........................................................................................................................1775 Information in troubleshooting table..............................................................................................................1778 Troubleshooting for power supply system (Air conditioner does not operate)........................................................................1779 Troubleshooting for compressor and refrigerant system (Air is not cooled).........................................................................1782 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)................................................................1785 Troubleshooting for temperature control...........................................................................................................1791 Troubleshooting for vent (mode) changeover........................................................................................................1794 Troubleshooting for Fresh/Recirc air changeover...................................................................................................1797 Troubleshooting with gauge pressure...............................................................................................................1799 Connection of service tool........................................................................................................................1801 Handling of compressor oil........................................................................................................................1802 90 Diagrams and drawings..................................................................................................................................1805 Hydraulic diagrams and drawings.......................................................................................................................1807 Symbols used in hydraulic circuit diagrams........................................................................................................1807 Power train hydraulic circuit diagram.............................................................................................................1810 Automatic greasing circuit diagram................................................................................................................1812 Hydraulic circuit diagram.........................................................................................................................1815 Hydraulic circuit diagram (brake cooling system)..................................................................................................1817 Electrical diagrams and drawings......................................................................................................................1818 Symbols used in electric circuit diagrams.........................................................................................................1818 Electrical circuit diagram........................................................................................................................1821 Electrical circuit diagram (brake cooling system) (WA470-6R: applicable machine: 10001 to 15435, WA480-6R: applicable machine: 10001 to 15263)....1843 Electrical circuit diagram (brake cooling system) (WA470-6R: applicable machine: 15436 and up, WA480-6R: applicable machine: 15264 and up)........1845 Electrical circuit diagram (rear view camera).....................................................................................................1847 Work equipment controller system electrical circuit diagram.......................................................................................1851 Connector list and stereogram.....................................................................................................................1853 Index.....................................................................................................................................................1855
DESCRIPTION:
KOMATSU WA470-6R WA480-6R WHEEL LOADER SHOP MANUAL SEN06594-10 – PDF DOWNLOAD
1. 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
