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Komatsu WHEEL LOADER Galeo WA470-6 WA480-6 SERIAL NUMBERS WA470- 85001 and up WA480- 85001 shop repair manual download

Komatsu WHEEL LOADER WA470-6 WA480-6 shop manual

Machine model   Serial number

WA470-6             85001 and up
WA480-6             85001 and up

Engine and cooling system

Engine and cooling system

This is Manual TABLE OF CONTENTS:

00 Index and foreword

  • Composition of shop manual
  • Table of contents

Foreword and general information

  • Safety notice 2
  • How to read the shop manual 7
  • Explanation of terms for maintenance standard 9
  • Handling electric equipment and hydraulic component 11
  • How to read electric wire code 23
  • Precautions when carrying out operation 26
  • Method of disassembling and connecting push-pull type coupler 29
  • Standard tightening torque table 32
  • Conversion table

01 Specification
Specification and technical data

  • Specification dimension drawing 3
  • Specifications 4
  • Weight table 8
  • Table of fuel, coolant and lubricants

10 Structure, function and maintenance standard
Engine and cooling system

  • Engine mount and transmission mount 2
  • Cooling system 3
  • Cooling fan pump 4
  • Cooling fan motor 12

Power train

  • Power train system diagram 4
  • Drive shaft 6
  • Power train piping diagram 7
  • Torque converter 8
  • Transmission 16
  • Flow control valve 33
  • Transmission control valve 34
  • ECMV 36
  • Main relief valve and torque converter relief valve 42
  • Axle 44
  • Differential 48
  • Limited slip differential 53
  • Final drive 60

Steering system

  • Steering piping diagram 2
  • Steering column 3
  • Steering pump 4
  • Steering valve 17
  • Orbit-roll valve
  • Stop valve 36
  • Steering relief valve 37
  • Steering cylinder 38
  • Emergency steering motor 40
  • Emergency steering pump 41

Brake system

  • Brake piping diagram 2
  • Charge valve 3
  • Brake valve 10
  • Accumulator (for brake) 15
  • Slack adjuster 16
  • Brake 18
  • Parking brake control 23
  • Parking brake 24
  • Parking brake solenoid valve 26
  • Emergency parking brake release valve 28

Undercarriage and frame

Hydraulic system, Part 1

  • Hydraulic system, Part 1 2
  • Hydraulic piping diagram 2
  • Work equipment control lever linkage 5
  • Hydraulic tank 6
  • Power train pump 8
  • Work equipment pump 10
  • Work equipment control valve 30
  • CLSS 41
  • Each function and operation of each valve 46

Hydraulic system, Part 2

  • PPC valve 2
  • Accumulator (for PPC circuit) 8
  • Accumulator (for ECSS) 9

Work equipment
Cab and its attachments
Electrical system, Part 1
Electrical system, Part 2
Electrical system, Part 3 2

  • Electric transmission control 2
  • Combination switch 4
  • Kickdown switch and hold switch 6
  • Loadmeter cancel switch and loadmeter subtotal switch 6
  • KOMTRAX terminal system 8
  • Engine starting circuit 10
  • Engine stopping circuit 12
  • Preheating circuit 13
  • Engine power mode selector circuit 14
  • Engine output derating function 15
  • Automatic warm-up function 15
  • Parking brake circuit 16
  • Sensor 18

20 Standard value table

30 Testing and adjusting

  • Tools for testing, adjusting, and troubleshooting 3
  • Measuring engine speed 6
  • Measuring exhaust gas color 8
  • Measuring exhaust temperature 9
  • Adjusting valve clearance 11
  • Measuring compression pressure 13
  • Measuring blow-by pressure 15
  • Measuring engine oil pressure 16
  • Check of exhaust gas recirculation (EGR) system 17
  • Measuring intake air (boost) pressure 18
  • Handling fuel system equipment 19
  • Releasing residual pressure in fuel system 19
  • Testing fuel pressure 20
  • Testing fuel return and leak amount 21
  • Bleeding air from fuel circuit 24
  • Testing fuel circuit for leakage 26
  • Handling of reduced cylinder mode operation 27
  • Handling of no injection cranking operation 27
  • Handling controller voltage circuit 28
  • Check of muffler and muffler stack for looseness and damage 29
  • Check of muffler function 29
  • Check of installed condition of cylinder head and manifolds 30
  • Check of engine piping for damage and looseness 30
  • Testing and adjusting air conditioner compressor belt tension 31
  • Testing and adjusting alternator belt tension 32
  • Adjusting transmission speed sensor 33
  • Measuring directional lever 35
  • Measuring and adjusting power train oil pressure 36
  • Procedure for flushing torque converter and transmission hydraulic circuit 51
  • Method of moving machine when transmission valve is broken 52
  • Check of axle final drive for oil leakage 54
  • Testing and adjusting steering stop valve 55

40 Troubleshooting

Failure code table and fuse locations

General information on troubleshooting

Troubleshooting by failure code (Display of code)

  • Failure code [1500L0] (TORQFLOW transmission: Double meshing) 3
  • Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 4
  • Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 6
  • Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 8
  • Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 10
  • Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 12
  • Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 14
  • Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 16
  • Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 18
  • Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) 20
  • Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) 22
  • Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) 24
  • Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) 26
  • Failure code [2F00MA] (Parking brake: Malfunction) 28
  • Failure code [2G43ZG] (Accumulator: Low oil pressure) 30
  • Failure code [AA1ANX] (Air cleaner: Clogging) 4
  • Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) 6
  • Failure code [AB00MA] (Alternator: Malfunction) 8
  • Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 10
  • Failure code [B@BAZK] (Engine oil: Low level) 13
  • Failure code [B@BCNS] (Coolant: Overheating) 14
  • Failure code [B@BCZK] (Coolant: Low level) 16
  • Failure code [B@C7NS] (Brake oil: Overheating) 18
  • Failure code [b@CENS] (Torque converter oil: Overheating) 20
  • Failure code [B@CENS] (Torque converter oil: Overheating) 22
  • Failure code [B@HANS] (Hydraulic oil: Overheating) 24
  • Failure code [CA111] (Abnormality in engine controller) 26
  • Failure code [CA115] (Engine Ne or Bkup speed sensor error) 29
  • Failure code [CA122] (Charge pressure sensor high error) 30
  • Failure code [CA123] (Charge pressure sensor low error) 32
  • Failure code [CA131] (Throttle sensor high error) 34
  • Failure code [CA132] (Throttle sensor low error) 36
  • Failure code [CA135] (Engine oil pressure sensor high error) 38
  • Failure code [CA141] (Engine oil pressure sensor low error) 40
  • Failure code [CA144] (Coolant sensor high error) 42
  • Failure code [CA145] (Coolant sensor low error) 44
  • Failure code [CA153] (Charge temperature sensor high error) 46
  • Failure code [CA154] (Charge temperature sensor low error) 48
  • Failure code [CA187] (Sensor power supply 2 low error) 50
  • Failure code [CA221] (Atmospheric pressure sensor high error) 51
  • Failure code [CA222] (Atmospheric pressure sensor low error) 53
  • Failure code [CA227] (Sensor power supply 2 high error) 54
  • Failure code [CA234] (Engine overspeed) 56
  • Failure code [CA238] (Ne speed sensor power supply error) 58
  • Failure code [CA331] (Injector #2 (L/B #2) open/short error) 24
  • Failure code [CA332] (Injector #4 (L/B #4) open/short error) 26
  • Failure code [CA342] (Calibration code inconsistency) 28
  • Failure code [CA351] (Injectors drive circuit error) 29
  • Failure code [CA352] (Sensor power supply 1 low error) 31
  • Failure code [CA386] (Sensor power supply 1 high error) 32
  • Failure code [CA431] (Idle validation switch error) 34
  • Failure code [CA432] (Idle validation action error) 36
  • Failure code [CA441] (Battery voltage low error) 38
  • Failure code [CA442] (Battery voltage high error) 41
  • Failure code [CA449] Common rail pressure high error 2 43
  • Failure code [CA451] (Common rail pressure sensor high error) 44
  • Failure code [CA452] (Common rail pressure sensor low error) 46
  • Failure code [CA553] (Common rail pressure high error 1) 47
  • Failure code [CA554] (Common rail pressure sensor in-range error) 48
  • Failure code [CA559] (Supply pump pressure very low error) 49
  • Failure code [CA689] (Engine Ne speed sensor error) 53
  • Failure code [CA731] (Engine Bkup speed sensor phase error) 55
  • Failure code [CA757] (All continuous data lost error) 55
  • Failure code [CA778] (Engine Bkup speed sensor error) 56
  • Failure code [CA1228] (EGR valve servo error 1) 58
  • Failure code [CA1625] (EGR valve servo error 2) 59
  • Failure code [CA1633] (KOMNET datalink timeout error) 60
  • Failure code [CA2185] (Throttle sensor supply voltage high error) 62
  • Failure code [CA2186] (Throttle sensor power supply low error) 63
  • Failure code [CA2249] (Supply pump pressure very low error 2) 3
  • Failure code [CA2271] (EGR valve lift sensor high error) 4
  • Failure code [CA2272] (EGR valve lift sensor low error) 6
  • Failure code [CA2351] (EGR valve solenoid operation short circuit) 7
  • Failure code [CA2352] (EGR valve solenoid operation disconnect) 9
  • Failure code [CA2555] (Intake heater relay disconnection error) 10
  • Failure code [CA2556] (Intake heater relay short circuit error) 12
  • Failure code [D150KA] (Emergency steering relay: Disconnection) 14
  • Failure code [D150KB] (Emergency steering relay: Short circuit) 16
  • Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) 18
  • Failure code [D160KA] (Backup lamp relay: Disconnection) 20
  • Failure code [D160KB] (Backup lamp relay: Short circuit) 22
  • Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit) 24
  • Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) 26
  • Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) 28
  • Failure code [D191KY]
  • (Joystick steering neutral safety relay: Short circuit with power supply line) 30
  • Failure code [D192KA] (ECSS solenoid: Disconnection) 32
  • Failure code [D192KB] (ECSS solenoid: Short circuit) 33
  • Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) 34
  • Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection) 35
  • Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit) 37
  • Failure code [D193KY]
  • (Joystick steering solenoid cut relay: Short circuit with power supply line) 39
  • Failure code [D5ZHKA] (Terminal C signal: Disconnection) 41
  • Failure code [D5ZHKB] (Terminal C signal: Short circuit) 45
  • Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) 48
  • Failure code [D5ZHL6]
  • (Terminal C signal: Signal does not match engine running or stopped state) 53
  • Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) 56
  • Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 58 and more

Troubleshooting of engine (S-mode)

50 Disassembly and assembly

Engine and cooling system

Power train

Undercarriage and frame

Hydraulic system

Work equipment

Cab and its attachments

90 Diagrams and drawings

♦ Komatsu WA470-6 WA-480-6 shop manual.pdf

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The Manual related content

Electrical system (Transmission controller system)

Except where otherwise specified, the displayed travel speed in this document represents the one when 26.5 – 25 tire is worn.

Transmission controller gear shifting control function
Electronic modulation function

  • To reduce the shocks made when the gear speed is changed (when the clutch is engaged), the modulation control is applied. The clutch oil pressure is controlled optimally to suit for the condition of the hydraulic circuit, depending on the engine speed, transmission oil temperature, travel speed, and gear shifting pattern and according to the transmission modulation data table saved in the transmission controller memory so that the transmission will be set in any gear speed (including the lockup clutch) smoothly.The modulation control is continued even while the clutch is disengaged in order to reduce lowering of the torque. If an abnormal time lag is made in gear shifting, the learning function corrects the modulation automatically.

Gear shifting display function

  • The transmission controller displays the state of input signals related to gear shift by sending them to the machine monitor via network.

1. Directional indicators The shift lever position pilot lamps of the machine monitor indicate state of the directional lever based on the input data to the transmission controller. When the directional lever is at the neutral position and no input signal is sent to the transmission controller, all the shift lever position pilot lamps of the machine monitor go off. If two independent signals were sent to the transmission controller by accident, two shift lever position pilot lamps of the machine monitor may turn on. As the directional lever is set to “R (Reverse)”, the transmission controller activates the back-up lamp relay to light the reverse lamp and sound the back-up alarm.

2. Gear speed indicators The shift lever position pilot lamps of the machine monitor indicate state of the gear shift lever based on the input data to the transmission controller. When the gear shift lever is at the neutral position and no input signal is sent to the transmission controller, all the shift lever position pilot lamps of the machine monitor go off. If two independent signals were sent to the transmission controller by accident, precedence is given to the higher gear speed. Thus, the shift lever position pilot lamps of the machine monitor may indicate a gear shift lever position not identical with its actual position.

3. Display of actual gear speed The shift indicator of the machine monitor indicates state of the directional lever and gear shift lever being based on the output data from the transmission controller. When the directional lever is at “N (Neutral)”, the indicator displays “N”. And when the directional lever is at “F (Forward)” or “R (Reverse)”, the indicator displays gear speed along with “F” or “R”. When the parking brake is in operation, the gear speed signal is not usually output. Thus, the indicator constantly displays “N”. It also displays “N” if the transmission is set to the neutral while the transmission cut-off is activated.

and more

 

 

 

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