Documente Academic
Documente Profesional
Documente Cultură
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN00802-07 00 Index and foreword
01 Specification SEN00787-02
Specification and technical data SEN00804-02
40 Troubleshooting SEN00799-02
Failure code table and fuse locations SEN01691-02 q
General information on troubleshooting SEN01692-02 q
Troubleshooting by failure code (Display of code), Part 1 SEN01693-02 q
Troubleshooting by failure code (Display of code), Part 2 SEN01694-02 q
Troubleshooting by failure code (Display of code), Part 3 SEN01695-02 q
Troubleshooting by failure code (Display of code), Part 4 SEN01696-02 q
2 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 3
SEN00802-07 00 Index and foreword
Table of contents 1
00 Index and foreword
Index SEN00802-07
Composition of shop manual ................................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information SEN00803-03
Safety notice ............................................................................................................................ 2
How to read the shop manual.................................................................................................. 7
Explanation of terms for maintenance standard ...................................................................... 9
Handling of electric equipment and hydraulic component ....................................................... 11
Handling of connectors newly used for engines ...................................................................... 20
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...................................................................................................................... 36
01 Specification
Specification and technical data SEN00804-02
Specification dimension drawing.............................................................................................. 3
Specifications........................................................................................................................... 4
Weight table ............................................................................................................................. 8
Table of fuel, coolant and lubricants ........................................................................................ 10
4 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 5
SEN00802-07 00 Index and foreword
6 WA470-6, WA480-6
00 Index and foreword SEN00802-07
40 Troubleshooting
Failure code table and fuse locations SEN01691-02
Failure code table .................................................................................................................... 2
Fuse locations ......................................................................................................................... 14
General information on troubleshooting SEN01692-02
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting ................................................................................... 3
Testing before troubleshooting ................................................................................................ 4
Classification and procedures of troubleshooting.................................................................... 5
Information contained in troubleshooting table ........................................................................ 9
Connection table for connector pin numbers ........................................................................... 11
T- branch box and T- branch adapter table ............................................................................. 47
Troubleshooting by failure code (Display of code), Part 1 SEN01693-02
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
WA470-6, WA480-6 7
SEN00802-07 00 Index and foreword
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 [44K0L4] (Bucket positioner: ON/OFF signals disagree)...................................... 32
Troubleshooting by failure code (Display of code), Part 2 SEN01694-02
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
Troubleshooting by failure code (Display of code), Part 3 SEN01695-02
Failure code [CA263] (Fuel temperature sensor high error) .................................................... 4
Failure code [CA265] (Fuel temperature sensor low error) ..................................................... 6
Failure code [CA271] (PCV1 Short circuit) .............................................................................. 8
Failure code [CA272] (PCV1 Disconnection)........................................................................... 10
Failure code [CA273] (PCV2 Short circuit) .............................................................................. 12
Failure code [CA274] (PCV2 Disconnection)........................................................................... 14
Failure code [CA322] (Injector #1 open/short error) ................................................................ 16
Failure code [CA323] (Injector #5 open/short error) ................................................................ 18
Failure code [CA324] (Injector #3 open/short error) ................................................................ 20
Failure code [CA325] (Injector #6 open/short error) ................................................................ 22
Failure code [CA331] (Injector #2 open/short error) ................................................................ 24
Failure code [CA332] (Injector #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
8 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 9
SEN00802-07 00 Index and foreword
10 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 11
SEN00802-07 00 Index and foreword
12 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 13
SEN00802-07 00 Index and foreword
14 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 15
SEN00802-07 00 Index and foreword
16 WA470-6, WA480-6
00 Index and foreword SEN00802-07
WA470-6, WA480-6 17
SEN00802-07
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
18
SEN00803-03
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN00803-03 00 Index and foreword
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
2 WA470-6, WA480-6
00 Index and foreword SEN00803-03
WA470-6, WA480-6 3
SEN00803-03 00 Index and foreword
4 WA470-6, WA480-6
00 Index and foreword SEN00803-03
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
WA470-6, WA480-6 5
SEN00803-03 00 Index and foreword
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 WA470-6, WA480-6
00 Index and foreword SEN00803-03
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
01. Specification
This section explains the specifications of the machine.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
WA470-6, WA480-6 7
SEN00803-03 00 Index and foreword
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 WA470-6, WA480-6
00 Index and foreword SEN00803-03
Example:
Standard size Tolerance
–0.022
120
–0.126
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WA470-6, WA480-6 9
SEN00803-03 00 Index and foreword
10 WA470-6, WA480-6
00 Index and foreword SEN00803-03
WA470-6, WA480-6 11
SEN00803-03 00 Index and foreword
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
12 WA470-6, WA480-6
00 Index and foreword SEN00803-03
WA470-6, WA480-6 13
SEN00803-03 00 Index and foreword
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
14 WA470-6, WA480-6
00 Index and foreword SEN00803-03
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WA470-6, WA480-6 15
SEN00803-03 00 Index and foreword
16 WA470-6, WA480-6
00 Index and foreword SEN00803-03
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
WA470-6, WA480-6 17
SEN00803-03 00 Index and foreword
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
18 WA470-6, WA480-6
00 Index and foreword SEN00803-03
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA470-6, WA480-6 19
SEN00803-03 00 Index and foreword
20 WA470-6, WA480-6
00 Index and foreword SEN00803-03
q 114 engine
q 107 engine
WA470-6, WA480-6 21
SEN00803-03 00 Index and foreword
q 95, 125 – 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
22 WA470-6, WA480-6
00 Index and foreword SEN00803-03
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (°C)
Low-voltage Conduc- Annealed copper for elec-
General wiring
wire for AV tor tric appliance
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- –30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
automobile Insulator Soft polyvinyl chloride
Heat-resis- Conduc- Annealed copper for elec-
General wiring in extremely
tant low-volt- tor tric appliance
AEX –50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WA470-6, WA480-6 23
SEN00803-03 00 Index and foreword
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
24 WA470-6, WA480-6
00 Index and foreword SEN00803-03
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: “GW” means that the background is Green and marking is White.
(Table 4)
Type of wire AVS or AV AEX
Charge R WG – – – – R –
Ground B – – – – – B –
Start R – – – – – R –
Light RW RB RY RG RL – D –
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB – L –
Type of
Br BrW BrR BrY BrB – – –
circuit
Lg LgR LgY LgB LgW – – –
O – – – – – – –
Others Gr – – – – – – –
P – – – – – – –
Sb – – – – – – –
Dg – – – – – – –
Ch – – – – – – –
WA470-6, WA480-6 25
SEN00803-03 00 Index and foreword
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
26 WA470-6, WA480-6
00 Index and foreword SEN00803-03
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
WA470-6, WA480-6 27
SEN00803-03 00 Index and foreword
28 WA470-6, WA480-6
00 Index and foreword SEN00803-03
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA470-6, WA480-6 29
SEN00803-03 00 Index and foreword
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 9)
30 WA470-6, WA480-6
00 Index and foreword SEN00803-03
Type 3
1. Disconnection
1) Hold the tightening portion and push body
(9) straight until sliding prevention ring (8)
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
onal portion at the male end. (Fig. 13)
WA470-6, WA480-6 31
SEN00803-03 00 Index and foreword
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
32 WA470-6, WA480-6
00 Index and foreword SEN00803-03
WA470-6, WA480-6 33
SEN00803-03 00 Index and foreword
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
34 WA470-6, WA480-6
00 Index and foreword SEN00803-03
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
WA470-6, WA480-6 35
SEN00803-03 00 Index and foreword
Conversion table 1
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
36 WA470-6, WA480-6
00 Index and foreword SEN00803-03
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA470-6, WA480-6 37
SEN00803-03 00 Index and foreword
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
38 WA470-6, WA480-6
00 Index and foreword SEN00803-03
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA470-6, WA480-6 39
SEN00803-03 00 Index and foreword
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
40 WA470-6, WA480-6
00 Index and foreword SEN00803-03
WA470-6, WA480-6 41
SEN00803-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
42
SEN00804-02
WA470-6
WA480-6
01 Specification 1
Specification and technical data
Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
WA470-6, WA480-6 1
SEN00804-02 01 Specification
2 WA470-6, WA480-6
01 Specification SEN00804-02
WA470-6 WA480-6
Check item Unit
(In P-mode) (In P-mode)
Machine weight (With BOC) kg 21,795 24,245
Normal load kg 6,720 7,820
Bucket capacity (Heaped, with BOC) m3 4.2 4.6
Engine model name — Komatsu SAA6D125E-5 Diesel engine
Engine rated output
kW {HP}/
• Net [ISO 9249/SAE J1349] (*1) 203 {272}/2,000 223 {299}/2,000
rpm
• Gross [SAE J1995] (*2) 204 {273}/2,000 224 {300}/2,000
A Overall length (with BOC) mm 8,875 9,170
B Overall height mm 3,435 3,500
C Overall height with bucket lifted up mm 5,895 6,175
D Overall width mm 2,920 3,010
E Minimum ground clearance mm 460 525
F Bucket width mm 3,170 3,170
G Dumping clearance (*3) Bucket tip/BOC tip mm 3,205/3,120 3,300/3,205
H Dumping reach (*3) Bucket tip/BOC tip mm 1,260/1,305 1,370/1,410
I Bucket dump angle (Max. height) deg. 45 49
Bucket tip/BOC tip mm 7,630/7,665 7,670/7,700
Min. turning radius
Center of outside tire mm 6,630 6,630
Tolerable drawbar pull load kN{kg} 146 {14,910} 137 {13,930}
1st (Forward/reverse) 5.8/6.1 6.3/6.6
2nd (Forward/reverse) 11.2/11.9 12.2/12.9
Travel speed km/h
3rd (Forward/reverse) 20.2/21.4 21.7/22.9
4th (Forward/reverse) 33.1/34.7 34.5/35.6
*1: Indicates the value at the minimum speed of cooling fan.
*2: Indicates the value of the engine alone (without cooling fan).
*3: Indicates the value at the 45° bucket dump angle.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of
an independent engine. While, net denotes the value measured of an engine under the condition essentially the
same as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
WA470-6: 191 kW {256 HP}/2,000 rpm
WA480-6: 211 kW {283 HP}/2,000 rpm
a BOC: Abbreviation for Bolt-On Cutting edge
WA470-6, WA480-6 3
SEN00804-02 01 Specification
Specifications 1
kg 9,810 10,910
travel posture
Machine weight (Rear wheel) in SAE
kg 11,985 13,335
travel posture
Bucket capacity (Heaped) m3 4.2 4.6
Normal load kg 6,720 7,820
E-mode P-mode E-mode P-mode
Travel speed (Forward 1st) 5.0 5.8 5.7 6.3
(Forward 2nd) 9.4 11.2 11.0 12.2
km/h
(Forward 3rd) 17.1 20.2 19.5 21.7
(Forward 4th) 27.7 33.1 30.8 34.5
Performance
4 WA470-6, WA480-6
01 Specification SEN00804-02
WA470-6, WA480-6 5
SEN00804-02 01 Specification
Cylinder bore mm 90 90
Steering cylinder
6 WA470-6, WA480-6
01 Specification SEN00804-02
Steering valve
• Type Spool type Spool type
2
• Set pressure MPa {kg/cm } 24.5 {250} 24.5 {250}
Cooling fan motor
Motor
WA470-6, WA480-6 7
SEN00804-02 01 Specification
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model name WA470-6 WA480-6
Serial No. 85001 and up 85001 and up
Engine (excluding coolant and oil) 1,280 1,280
Cooling assembly (excluding coolant and oil) 147 147
• Radiator (1 piece) 20 20
• Aftercooler 26 26
• Oil cooler 14 14
Torque converter oil cooler 25 25
Cooling fan pump 25 25
Cooling fan motor 14 14
Transmission (including torque converter)
Without lockup clutch 949 949
With lockup clutch 988 988
Center drive shaft 32 32
Front drive shaft 40 40
Rear drive shaft 22 21
Front axle
With conventional differential 1,250 1,285
With limited slip differential 1,260 1,301
Rear axle
With conventional differential 1,142 1,266
With limited slip differential 1,154 1,282
Axle pivot (Rear axle) 144 144
[WA470: 19.50-25WTB] (1 piece) 228 —
Wheel
[WA480: 22.00-25WTB] (1 piece) — 251
[WA470: 23.5-25-20PR] (1 piece) 335 —
Tire
[WA480: 26.5-25-20PR] (1 piece) — 421
Power train pump 20 20
Work equipment hydraulic pump 75 75
Steering pump 38 38
Work equipment control valve 108 108
Work equipment PPC valve 4 4
Brake valve 7 7
Steering valve 24 24
Emergency steering motor 13 13
Emergency steering pump 3 3
Steering cylinder assembly (1 piece) 37 37
Lift cylinder assembly (1 piece) 185 196
Bucket cylinder assembly 206 264
Front frame 1,840 1,960
Rear frame 1,745 1,745
Counterweight 2,050 3,135
Engine hood assembly 466 466
• Hood body 295 295
• • Side door (1 piece) 37 37
• Hydraulic tank (excluding hydraulic oil) 171 171
Fuel tank (excluding fuel) 211 211
8 WA470-6, WA480-6
01 Specification SEN00804-02
Unit: kg
Machine model name WA470-6 WA480-6
Serial No. 85001 and up 85001 and up
Lift arm (including bushing) 1,470 1,571
Bucket link 89 108
Bell crank 390 410
Bucket (3,170 mm wide, including BOC) 2,011 2,259
Operator's cab (including floor assembly) 945 945
Operator seat 35 35
Air conditioner unit 5 5
Battery (1 piece) 45 45
a BOC: Abbreviation for Bolt-On Cutting edge
WA470-6, WA480-6 9
SEN00804-02 01 Specification
10 WA470-6, WA480-6
01 Specification SEN00804-02
Unit: l
WA470-6 WA480-6
Supply point
Specified capacity Refill capacity Specified capacity Refill capacity
Engine oil pan 47 38 47 38
Transmission case 65 54 65 54
Hydraulic system 270 173 275 173
Axle (Front/Rear) 60/56 60/56 59/59 59/59
Cooling system 61 — 61 —
Fuel tank 413 — 413 —
WA470-6, WA480-6 11
SEN00804-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
12
SEN01301-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01301-01 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Clearance between transmis-
1 sion mount bracket and adjust- 1 – 1.5 Adjust
ment bolt
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
Cooling system 1
Specifications
Radiator Oil cooler Aftercooler Power train oil cooler
Model name of core AL WAVE-4 CF40-1 AL WAVE PTO-OL
*1
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
100 × 558 × 20-stage
Total heat dissipation
55.14 × 2 6.15 × 2 23.32 2.152
surface (m2)
Pressure valve
70 ± 15
cracking pressure — — —
{0.7 ± 0.15}
(kPa {kg/cm2})
Vacuum valve
0–5
cracking pressure — — —
{0 – 0.05}
(kPa {kg/cm2})
*1: Size of element
WA470-6, WA480-6 3
SEN01301-01 10 Structure, function and maintenance standard
1. Servo valve
2. Air bleeder
3. Command current input connector
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
WA470-6, WA480-6 5
SEN01301-01 10 Structure, function and maintenance standard
Function
q The rotation and torque of the engine are
transmitted to the shaft of this pump. Then, this
pump converts the rotation and torque into
hydraulic energy and discharges hydraulic oil
according to the load.
q It is possible to change the delivery by chang-
ing the swash plate angle.
Structure
q Cylinder block (7) is supported to shaft (1) by
spline (a), and shaft (1) is supported by the
front and rear bearings.
q The tip of piston (6) is a concave ball, and shoe
(5) is caulked to it to form one unit. Piston (6)
and shoe (5) form a spherical bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface as it
slides in a circle. Rocker cam (4) also slides
around ball (11) using it as fulcrum.
q Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
q Cylinder block (7) carries out rotation relative
to valve plate (8) while sealing the pressurized
oil, and this surface ensures that the hydraulic
balance is maintained correctly.
q And oil in each cylinder chamber of cylinder
block (7) is available for suction or discharge
through valve plate (8).
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
Operation
1. Operation of pump q When center line (X) of rocker cam (4) is the
q Cylinder block (7) rotates together with shaft same as the axial direction of cylinder block (7)
(1) and shoe (5) slides on plane (A). At this [s was h pl ate an gl e = 0], the d iffer e nc e
time, rocker cam (4) slants around ball (11), between volumes (E) and (F) inside cylinder
changing the angle of inclination (a) of the cen- block (7) is 0, so pump does not suck and dis-
ter line (X) of rocker cam (4) in the axial direc- charge, and no pumping is carried out. [The
tion of cylinder block (7). Angle (a) is called the swash plate angle is not set to 0 actually, how-
swash plate angle. ever.]
q If angle (a) is made between center line (X) of q In short, swash plate angle (a) is in proportion
rocker cam (4) and the axis of cylinder block to the pump delivery.
(7), plane (A) works as a cam for shoe (5).
q Accordingly, piston (6) slides inside cylinder
block (7) and a difference is made between
volumes (E) and (F) in cylinder block (7). As a
result, each piston (6) sucks and discharges oil
by (F) – (E).
q In other words, cylinder block (7) rotates, and
the volume of chamber (E) becomes smaller,
so pressurized oil is discharged during this
process. At the same time, the volume of
chamber (F) becomes larger and the oil is
sucked in this process. [In the figure, chamber
(F) is at the end of the suction stroke and
chamber (E) is at the end of the discharge
stroke.]
WA470-6, WA480-6 7
SEN01301-01 10 Structure, function and maintenance standard
2. Control of delivery
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or delivery (Q) is increased. Swash
plate angle (a) is changed with servo piston
(10).
q Servo piston (10) reciprocates straight accord-
ing to the signal pressure of the servo valve.
This straight line motion is transmitted to
rocker cam (4). Then, rocker cam (4) sup-
ported on ball (11) pivots around ball (11).
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
Servo valve
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
WA470-6, WA480-6 9
SEN01301-01 10 Structure, function and maintenance standard
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
WA470-6, WA480-6 11
SEN01301-01 10 Structure, function and maintenance standard
Specifications
Type: LMF28
Capacity: 28.0 cc/rev
Rated speed: 1,600 rpm
Rated flow rate: 44.8 l/min
Check valve cracking pressure: 44.1 kPa {0.45 kg/cm2}
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed
× Outside
13 Spool return spring length load length load If damaged or
diameter
deformed,
58.8 N 47.1 N replace spring
44.84 × 12 33 —
{6 kg} {4.8 kg}
1.96 N 1.57 N
14 Check valve spring 13.0 × 6.5 9.5 —
{0.2 kg} {0.16 kg}
WA470-6, WA480-6 13
SEN01301-01 10 Structure, function and maintenance standard
1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate-
type axial piston motor. It converts the energy
of the pressurized oil sent from the hydraulic
pump into rotary motion.
Principle of operation
q The oil sent from the hydraulic pump flows
through valve plate (7) into cylinder block (5).
This oil can flow on only one side of the (Y – Y)
line connecting the top dead center and bottom
dead center of the stroke of piston (4).
q The oil sent to one side of cylinder block (5)
presses piston (4) [2 or 3 pieces], and gener-
ates force (F1) [F1 = P × xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of (a°)
degrees to output shaft (1), the force is divided
into components (F2) and (F3).
q The radial component (F3) generates torque [T
= F3 × ri] against the (Y – Y) line connecting
the top dead center and bottom dead center.
q The result of this torque [T = s(F3 × ri)] rotates
cylinder block (5) through the piston.
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
2. Suction valve
WA470-6, WA480-6 15
SEN01301-01 10 Structure, function and maintenance standard
1) When the ON/OFF solenoid is de-energized. 2) When the ON/OFF solenoid is energized.
q If ON/OFF solenoid (1) is “de-energized”, the q If ON/OFF solenoid (1) is “energized”, ON/OFF
pressurized oil from the pump is blocked by selector valve (2) changes to let the pressur-
ON/OFF selector valve (2), and port (C) opens ized oil from the pump flow through port (C)
for the tank circuit. into spool chamber (D).
q Spool (3) is pushed to the right by spring (4). q The pressurized oil in chamber (D) pushes
q Motor port (MA) opens and pressurized oil valve spool (3) to the left against spring (4).
flows in to revolve the motor in forward (clock- q Motor port (MB) opens and pressurized oil
wise). flows in to revolve the motor in reverse (coun-
terclockwise).
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01301-01
4. Safety valve
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Safety valve (1) is installed to protect the fan
system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of safety valve (1), valve (2)
of safety valve (1) opens to release the pres-
surized oil into port (T).
q By this operation, generation of abnormal pres-
sure in port (P) is prevented.
WA470-6, WA480-6 17
SEN01301-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
18
SEN01302-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01302-02 10 Structure, function and maintenance standard
Final drive...................................................................................................................................................... 62
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Power train 1
Outline
q The power from engine (3) is transmitted q The power from the transmission output shaft
through the flywheel of the engine to torque is transmitted through center drive shaft (6),
converter (2). The turbine of the torque con- front drive shaft (7), and rear drive shaft (5) to
verter is connected to the input shaft of trans- front axle (8) and rear axle (4), and then trans-
mission (1). mitted through the wheels to the tires.
q The transmission has 6 hydraulic clutches to
set itself to 4 forward gear speeds and 4
reverse gear speeds.
WA470-6, WA480-6 3
SEN01302-02 10 Structure, function and maintenance standard
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 5
SEN01302-02 10 Structure, function and maintenance standard
Drive shaft 1
a Figure indicates WA480-6.
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 7
SEN01302-02 10 Structure, function and maintenance standard
Torque converter 1
Without lockup clutch
1. Pilot 7. Pump
2. Flywheel 8. PTO gear
3. Drive case 9. PTO drive gear (Number of teeth: 99)
4. Boss 10. Stator shaft
5. Turbine 11. Input shaft
6. Stator
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 2.47
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.010 Repair by hard
78 77.95
–0.040 chromium-plating or
Inside diameter of PTO gear seal +0.035 replace
110 110.5
ring contact surface +0.000
2 –0.00
Wear of stator shaft seal Width 3 2.7
–0.10
ring
Thickness 4.3 ±0.1 3.9 Replace
Backlash between PTO drive gear
3 0.17 – 0.45
and PTO gear
WA470-6, WA480-6 9
SEN01302-02 10 Structure, function and maintenance standard
The power from engine q The oil flows through the main relief valve and
O its pressure is reduced to below the set pres-
Flywheel (1) sure by the torque converter relief valve, and
O then it flows through inlet port (A) and oil pas-
Drive case (2), pump (3) and PTO drive gear (4) sage of stator shaft (1) to pump (2).
rotate together q The oil is given centrifugal force by pump (2)
O and flows into turbine (3) to transmit its energy
Oil is used as medium to turbine (3).
O q The oil from turbine (3) is sent to stator (4) and
Turbine (6) and boss (7) flows into pump (2) again. However, part of the
O oil passes between turbine (3) and stator (4)
Transmission input shaft (8) and is sent from outlet port (B) to the oil cooler
to be cooled. It is then used to lubricate the
q The power transmitted to PTO drive gear (4) is transmission.
also used as power for driving the pump after
being transmitted through PTO gear (5).
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.26
WA470-6, WA480-6 11
SEN01302-02 10 Structure, function and maintenance standard
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.010
78 77.95
–0.040 Repair by hard
Inside diameter of pilot seal ring +0.025 chromium-plating or
2 35 35.5 replace
contact surface +0.000
Inside diameter of clutch piston seal +0.081
260 260.1
ring contact surface +0.000
3 –0.01
Wear of clutch housing Width 5 4.5
–0.04 Replace
seal ring
Thickness 6 ±0.15 5.85
Inside diameter of clutch housing +0.089
4 340 340.1 Repair by hard
seal ring contact surface +0.000
chromium-plating or
Inside diameter of PTO drive gear +0.040 replace
120 120.5
seal ring contact surface +0.000
5 –0.00
Wear of stator shaft seal Width 3.95 3.56
–0.10 Replace
ring
Thickness 4.6 ±0.1 4.14
Repair by hard
Inside diameter of stator shaft seal +0.030
6 60 60.5 chromium-plating or
ring contact surface +0.000
replace
Inside diameter of free wheel trans-
7 91.661 ±0.008 91.691
fer surface of race
Inside diameter of free wheel trans- +0.008
8 72.661 72.631
fer surface of stator shaft –0.005
Inside diameter of bushing sliding +0.015
9 72.775 72.855
part +0.000 Replace
–0.0
10 Thickness of bushing sliding part 5 4.5
–0.1
11 Thickness of clutch disc 5 ±0.1 4.5
Backlash between PTO drive gear
12 0.17 – 0.45
and PTO gear
WA470-6, WA480-6 13
SEN01302-02 10 Structure, function and maintenance standard
Drive case (3) is disconnected from boss (9) and Drive case (3) is connected to boss (9) and turbine
turbine (8) and lockup torque converter works as an (8) and lockup torque converter is locked up.
ordinary torque converter.
q The power transmitted to PTO drive gear (6) is q The power transmitted to PTO drive gear (6) is
also used as power for driving the pump after also used as power for driving the pump after
being transmitted through PTO gear (7). being transmitted through PTO gear (7).
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Oil flow
WA470-6, WA480-6 15
SEN01302-02 10 Structure, function and maintenance standard
Transmission 1
a The following figure shows the machines equipped with lockup clutch.
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 17
SEN01302-02 10 Structure, function and maintenance standard
a The following figure shows the machines equipped with lockup clutch.
1. PTO gear A (Number of teeth: 87) 10. Output gear (Number of teeth: 65)
2. PTO drive gear (Number of teeth: 99) 11. Parking brake
3. Torque converter 12. Front coupling
4. Input shaft 13. Lower shaft
5. F clutch 14. 2nd clutch
6. 4th clutch 15. Upper shaft
7. 3rd clutch 16. 1st clutch
8. Rear coupling 17. R clutch
9. Output shaft
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 19
SEN01302-02 10 Structure, function and maintenance standard
a The following figure shows the machines equipped with lockup clutch.
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 21
SEN01302-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
F and R clutches
Without lockup clutch
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 23
SEN01302-02 10 Structure, function and maintenance standard
F and R clutches
With lockup clutch
Unit: mm
No. Check item Criteria Remedy
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 25
SEN01302-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
q The oil sent from the ECMV flows through the q When the oil sent from the ECMV is shut off,
oil passage of shaft (1), is pressure-fed to the pressure of the oil acting on the back face of
back side of piston (2), and pushes piston (2) piston (2) goes down.
to the right. q Piston (2) is pushed back to the left by repul-
q Piston (2) compresses plates (3) and discs (4) sive force of wave spring (7).
and the rotation of discs (4) is stopped by the q The friction force between plates (3) and discs
frictional force. (4) is eliminated and shaft (1) and clutch gear
q As the internal teeth of disc (4) are meshed (5) are released.
with clutch gear (5), shaft (1) and clutch gear q When the clutch is released, the oil in the back
(5) transfer the power as a unit. side of piston is drained by the centrifugal force
q The oil is drained from oil drain hole (6), but the through oil drain hole (6) to prevent the clutch
drain amount is less than the amount of oil from being partially applied.
supplied, so there is no influence on the actua-
tion of the clutch.
a Oil drain hole (6) is made of only with the 1st,
2nd, 3rd, and 4th clutches.
WA470-6, WA480-6 27
SEN01302-02 10 Structure, function and maintenance standard
The power from the torque converter o (from left bottom) o (from center bottom)
O O O
Input shaft (1) 1st clutch (10) Output gear (23)
O O O
F and R cylinders (2) 1st clutch gear (12) Output shaft (24)
O O
F clutch (3) 2nd and 3rd cylinders (14)
O O
F clutch gear (5) Lower shaft (21)
O O
1st and 4th cylinders (8) Lower gear A (22)
O O
(To center top) o (To right top) o
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 29
SEN01302-02 10 Structure, function and maintenance standard
30 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 31
SEN01302-02 10 Structure, function and maintenance standard
32 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Unit: mm
No. Check item Criteria Remedy
Installed
Free length Installed load Free length Installed load
2 Flow control valve spring length
79.5 N 75.5 N
63.8 47 61.9
{8.11 kg} {7.7 kg}
WA470-6, WA480-6 33
SEN01302-02 10 Structure, function and maintenance standard
34 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
1. F clutch ECMV
2. R clutch ECMV
3. Lockup clutch ECMV
4. 4th clutch ECMV
5. 1st clutch ECMV
6. 3rd clutch ECMV
7. 2nd clutch ECMV
8. Parking brake solenoid valve
9. Last chance filter
10. Main relief valve and torque converter relief
valve
WA470-6, WA480-6 35
SEN01302-02 10 Structure, function and maintenance standard
Outline
q The oil from the pump flows through the flow control valve and oil filter to the transmission front case.
The oil is then diverged to the main relief circuit and clutch actuation circuit.
q The pressure of the oil sent to the clutch actuation circuit is regulated by the main relief valve, and then
used to actuate the clutch and parking brake through the last chance filter. The oil relieved from the
main relief valve is supplied to the torque converter.
q When the transmission gear is shifted, the ECMV increases the clutch oil pressure smoothly according
to the command current from the transmission controller to reduce the gear shifting shocks. The ECMV
also keeps the clutch pressure constant during travel.
q If the F, R, or 1st – 4th ECMV is selected, the regulated oil pressure is supplied to the selected clutch to
set the transmission in the desired gear speed.
q In the 3rd and 4th speed travel, the lockup clutch ECMV (if equipped) operates at a speed above that
being specified from the transmission controller.
q There are 2 types of ECMV's used, which have the following distinctions and differences.
Fill switch
Printing on nameplate Color
Pressure control valve (Operation pressure: Used clutch
(A) (B)
MPa {kg/cm2})
Equipped
L******* — Without slit F, R, 1st, 2nd, 3rd, 4th
0.20 {2.0}
Equipped
E******* Blue With slit L/U
0.26 {2.7}
36 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 37
SEN01302-02 10 Structure, function and maintenance standard
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
a Don't try to disassemble it since adjustment for maintaining the performance will be needed.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
38 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 39
SEN01302-02 10 Structure, function and maintenance standard
40 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 41
SEN01302-02 10 Structure, function and maintenance standard
Outline Operation
q This valve is used to switch the clutch in order When traveling in torque converter range
to regulate the clutch oil pressure to the set
pressure.
Since the modulation waveform is used for the
pressure application characteristics to the
clutch, ECMV is capable of connecting the
lockup clutch smoothly, thereby reducing
shocks resulting from gear shift. This also pre-
vents generation of peak torque in the power
train. These arrangements make the machine
comfortable to operator and enhance durability
of the power train.
42 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
q When traveling in direct (lockup) range, current q As current is conducted to proportional sole-
is supplied to proportional solenoid (1), the oil noid (1), the solenoid generates thrust in pro-
pressure force balanced with the solenoid portion to the current. The pressure is settled
force is applied to chamber (B) and pushes as the sum of this thrust of the solenoid, thrust
pressure control valve (3) to the left. As a generated by the oil pressure in clutch port and
result, pump port (P) and clutch port (A) are the repulsive force of pressure control valve
opened and oil starts filling the clutch. If the spring (2) is balanced.
clutch is filled with oil, oil pressure detection
valve (4) is operated, and fill switch (5) is
turned “ON”.
WA470-6, WA480-6 43
SEN01302-02 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
44 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Operation
WA470-6, WA480-6 45
SEN01302-02 10 Structure, function and maintenance standard
Axle 1
Front axle 1
WA470-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multi-disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Brake wear gauge
46 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA480-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multi-disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Brake wear gauge
WA470-6, WA480-6 47
SEN01302-02 10 Structure, function and maintenance standard
Rear axle 1
WA470-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multi-disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Brake wear gauge
48 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA480-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multi-disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Brake wear gauge
WA470-6, WA480-6 49
SEN01302-02 10 Structure, function and maintenance standard
Differential 1
Front differential 1
50 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
7 Thickness of pinion washer
3 ±0.08 2.8 Replace
8 Thickness of side gear washer 4 ±0.05 3.8
9 Starting torque of bevel gear 31.4 – 51.0 N {3.2 – 5.2 kg} (Outside of bevel gear) Adjust
Thickness of shim in side bearing
10 0.30 – 1.25
carrier (one side) Adjust
11 Backlash of bevel gear 0.30 – 0.41
End play of pinion 0 – 0.200
12 Replace
(or force to rotate) {1.5 – 1.7 kg (At cage bolt hole)}
Thickness of shim in housing and
13 1.49 ± 0.38 Adjust
cage assembly
WA470-6, WA480-6 51
SEN01302-02 10 Structure, function and maintenance standard
Rear differential 1
52 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
7 Thickness of pinion washer
3 ±0.08 2.8 Replace
8 Thickness of side gear washer 4 ±0.05 3.8
9 Starting torque of bevel gear 35.3 – 52.9 N {3.6 – 5.4 kg} (Outside of bevel gear) Adjust
Thickness of shim in side bearing
10 0.30 – 1.25
carrier (one side) Adjust
11 Backlash of bevel gear 0.30 – 0.41
End play of pinion 0 – 0.200
12 Replace
(or force to rotate) {1.0 – 1.1 kg (At cage bolt hole)}
Thickness of shim in housing and
13 1.26 ± 0.34 Adjust
cage assembly
WA480-6
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
7 Thickness of pinion washer
3 ±0.08 2.8 Replace
8 Thickness of side gear washer 4 ±0.05 3.8
9 Starting torque of bevel gear 31.4 – 51.0 N {3.2 – 5.2 kg} (Outside of bevel gear) Adjust
Thickness of shim in side bearing
10 0.30 – 1.25
carrier (one side) Adjust
11 Backlash of bevel gear 0.30 – 0.41
End play of pinion 0 – 0.200
12 Replace
(or force to rotate) {1.5 – 1.7 kg (At cage bolt hole)}
Thickness of shim in housing and
13 1.49 ± 0.38 Adjust
cage assembly
WA470-6, WA480-6 53
SEN01302-02 10 Structure, function and maintenance standard
54 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
1. Plate
2. Disc
3. Pinion (Number of teeth: 12)
4. Washer
5. Side gear (Number of teeth: 24)
6. Bevel gear (Number of teeth: 41)
7. Shaft
8. Pressure ring
9. Case
WA470-6, WA480-6 55
SEN01302-02 10 Structure, function and maintenance standard
56 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6 Front
WA480-6 Front
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thicknesses of washers 4
±0.05 3.8
4.1
3.4
2 Thickness of plate ±0.03 3.3
3.5
+0.04
3 Thickness of disc 3.6 3.55
–0.03
WA470-6, WA480-6 57
SEN01302-02 10 Structure, function and maintenance standard
WA470-6 Rear
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thicknesses of washers 4
±0.05 3.8
4.1
3 2.9
2 Thickness of plate ±0.02
3.1 3
+0.04
3 Thickness of disc 3 2.95
–0.03
58 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA480-6 Rear
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thicknesses of washers 4
±0.05 3.8
4.1
3 2.9
2 Thickness of plate ±0.02
3.1 3
+0.04
3 Thickness of disc 3 2.95
–0.03
WA470-6, WA480-6 59
SEN01302-02 10 Structure, function and maintenance standard
60 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 61
SEN01302-02 10 Structure, function and maintenance standard
Final drive 1
WA470-6
a The figure shows the front axle.
62 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6 Front
Unit: mm
No. Check item Criteria Remedy
WA470-6 Rear
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 63
SEN01302-02 10 Structure, function and maintenance standard
WA480-6
a The figure shows the front axle.
64 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA480-6 Front
Unit: mm
No. Check item Criteria Remedy
WA480-6 Rear
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 65
SEN01302-02 10 Structure, function and maintenance standard
Outline
q The final drive makes final reduction to
increase the drive force.
q Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
q Speed of the power transmitted being from the
differential through sun gear shaft (5) is
reduced by the planetary gear unit to increase
the drive force.
The increased drive force is transmitted
through planetary carrier (2) and axle shaft (3)
to the tire.
66 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01302-02
WA470-6, WA480-6 67
SEN01302-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
68
SEN01303-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01303-02 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Steering column 1
1. Steering wheel
2. Steering column
3. Steering tilt lock lever
4. Short column
5. Orbit-roll valve
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 3
SEN01303-02 10 Structure, function and maintenance standard
Steering pump 1
Model: LPV90
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Pump unit
WA470-6, WA480-6 5
SEN01303-02 10 Structure, function and maintenance standard
1. Bearing
2. Shaft
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Shoe retainer
11. Servo piston
12. Spring
13. Oil seal
14. Ball
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Structure
q Cylinder block (6) is supported on shaft (1)
through spline (a). Shaft (1) is supported on
the front and rear bearings.
q The end of piston (5) has a spherical hollow
and is combined with shoe (4). Piston (5) and
shoe (4) form a spherical bearing.
q Rocker cam (3) is supported on case (2) and
ball (9) and has plane (A). Shoe (4) is kept
pressed against the plane of rocker cam (3)
and slid circularly. Shoe (4) leads high-pres-
sure oil to form a static pressure bearing and
slides.
q Piston (5) in each cylinder of cylinder block (6)
moves relatively in the axial direction.
q Cylinder block (6) rotates relatively against
valve plate (7), sealing the hydraulic oil. The
hydraulic balance on the valve plate is main-
tained properly.
WA470-6, WA480-6 7
SEN01303-02 10 Structure, function and maintenance standard
Operation
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
2) Control of discharge
q If swash plate angle (a) is increased, the differ-
ence between volumes (E) and (F) is
increased, or discharge (Q) is increased.
Swash plate angle (a) is changed with servo
piston (11).
q Servo piston (11) reciprocates straight accord-
ing to the signal pressure of the PC valve and
LS valve. This straight motion is transmitted to
rocker cam (3). Then, rocker cam (3) sup-
ported on case (2) through ball (9) rocks in
rotational directions.
WA470-6, WA480-6 9
SEN01303-02 10 Structure, function and maintenance standard
Servo valve
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
PC valve LS valve
T : Drain PA : Pump pressure input
PA : Pump pressure input PE : Control piston pressure
PPL : PC valve output pressure PLS : LS pressure input
PPL : PC valve output pressure
PPLS: LS pump pressure input
WA470-6, WA480-6 11
SEN01303-02 10 Structure, function and maintenance standard
LS valve PC valve
Model: LPV63
Function
q The LS valve controls the pump discharge Function
according to the stroke of the control lever, or q The PC valve limits the oil flow to a certain
the demand flow for the actuator. level (according to the discharge pressure)
q The LS valve detects the demand flow for the even if the stroke of the control valve is
actuator from differential pressure ( PLS) increased extremely so that the horsepower
between control valve inlet pressure (PPLS) absorbed by the pump will not exceed the
and control valve outlet pressure (PLS) and engine horsepower, as long as pump dis-
controls main pump discharge (Q). ((PPLS) is charge pressure (PA) is high.
called the LS pump pressure, (PLS) the LS q In other words, the PC valve decreases the
pressure, and ( PLS) the LS differential pres- pump discharge when the load is increased
sure.) and the pump discharge pressure rises, and
q In other words, the pressure loss caused by increases it when the pump discharge pres-
flow of oil through the opening of the control sure lowers.
valve spool (= LS differential pressure PLS) q The relationship between the pump pressure
is detected, and then pump discharge (Q) is and pump discharge is shown below.
controlled to keep that pressure loss constant
and supply the pump discharge according to
the demand flow for the actuator.
q Main pump discharge pressure (PP), LS pump
pressure (PPLS), and LS pressure (PLS) are
led to the LS valve. The relationship between
LS differential pressure ( PLS) and pump dis-
charge (Q) changes as shown below.
Operation
1) Function of spring
q The spring load of spring (2) at the PC valve is
decided by the position of the swash plate.
q If servo piston (6) moves to the right, spring (2)
is compressed through lever (1) and its spring
load changes.
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
WA470-6, WA480-6 13
SEN01303-02 10 Structure, function and maintenance standard
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
When balanced
(Fig. 3)
WA470-6, WA480-6 15
SEN01303-02 10 Structure, function and maintenance standard
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Steering valve 1
WA470-6, WA480-6 17
SEN01303-02 10 Structure, function and maintenance standard
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
1. Relief valve
2. Flow control spool
3. Steering relief valve
4. Steering spool
5. Overload relief valve
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Installed
Free length Installed load Free length Installed load
6 Steering spool return spring length
58.0 N 46.4 N
37.0 32.1 —
{5.9 kg} {4.7 kg}
3.0 N 2.4 N
7 Poppet spring 20.9 18.3 —
{0.3 kg} {0.24 kg} Replace
147.1 N 117.7 N
8 Flow control spool return spring 69.7 68.5 —
{15.0 kg} {12.0 kg}
100.9 N 80.7 N
9 Steering relief valve spring 24.0 23.9 —
{10.3 kg} {8.2 kg}
55.3 N 44.2 N
10 Relief valve spring 29.8 26.5 —
{5.64 kg} {4.51 kg}
WA470-6, WA480-6 19
SEN01303-02 10 Structure, function and maintenance standard
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is kept at neutral position by right and left return springs (2).
q The pressure in port (Pa) rises and steering spool (1) compresses left return spring (2) and moves to the
left.
q The oil in port (Pa) flows through the hole of spring seat (3) and orifice (a) of steering spool (1) to port
(Pb).
q Since port (Pb) is connected through the Orbit-roll valve to the drain circuit, the oil in port (Pb) is drained.
q Since the pressure generated in port (Pa) is in proportion to the flow rate of the oil, steering spool (1)
moves to a position where the oil pressure reduced by orifice (a) is balanced with the repulsive force of
return spring (2).
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is driven back to neutral by left return spring (2).
WA470-6, WA480-6 21
SEN01303-02 10 Structure, function and maintenance standard
q The oil from the steering pump flows in port q If the oil pressure in port (Pr) rises above the
(P). set pressure, the swash plate angle of the
q Since notch (e) is closed, the oil pressure in steering pump is reduced to reduce the deliv-
port (P) is increased and then led through ori- ery.
fice (a) to pressure receiving chamber (X) to q If the oil pressure in port (P) keeps rising after
move flow control spool (1) to the left. the delivery of the pump is minimized, flow
q The oil in pressure receiving chamber (Y) is control spool (1) moves to the left further.
drained from port (T1) through orifice (b) and q If the oil pressure in pressure receiving cham-
notch (f). ber (X) rises above the set pressure, notch (d)
q If the oil pressure in pressure receiving cham- opens and the oil in port (P) is drained through
ber (X) rises above the set pressure, flow con- notch (d) and port (T1).
trol spool (1) moves to the left to open notch
(c).
q The oil in port (P) flows through notch (c) and
port (Pr) to the LS valve of the steering pump.
q Port (Pr) is connected through orifice (j) to port
(T2).
q The oil pressure in port (Pr) is set between the
pump pressure and drain pressure of port (T2)
because of the passing resistance of notch (c)
and orifice (j).
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
q If steering spool (2) operates, notch (f) closes q The excessive oil from the steering pump is
and pressure receiving chamber (Y) and port drained through notch (d) and port (T1).
(T1) are disconnected and notch (e) opens. q The oil returning from the steering cylinder is
q The oil pressure in pressure receiving chamber drained through orifice (g) and port (T1).
(Y) rises and flow control spool (1) moves to q Even after flow control spool (1) moves to the
the right and the open area of notch (d) right to close notch (d), it moves further to the
reduces. right, as long as the pressure before notch (e)
q The oil before notch (e) is led to pressure is below the set pressure.
receiving chamber (X) and the oil after notch q Since the open area of notch (c) reduces, the
(e) is led to pressure receiving chamber (Y). oil flow into port (Pr) is reduced and the oil
q If the oil pressure in pressure receiving cham- pressure in port (Pr) lowers.
ber (Y) rises higher than that in port (A), the oil q If the oil pressure in port (Pr) lowers, the LS
flowing from orifice (h) pushes and opens load valve of the steering pump increases the deliv-
check valve (3) to the left. ery of the pump to keep the oil pressure in port
q Since the oil from notch (e) flows through port (Pr) to the set pressure.
(A) to the steering cylinder, a pressure differ- q Flow control spool (1) is held at a position
ence is made between before and after notch where the pressure in port (P) is balanced with
(e). the pressure in port (Pr), thus the delivery of
q Since flow control spool (1) works to keep the the pump is kept constant.
differential pressure between before and after q If the open rate of notch (e) changes, the steer-
notch (e) to the set pressure, the oil is dis- ing pump discharges the amount of oil corre-
charged to the steering cylinder according to sponding to the open rate of notch (e) in order
the open rate of notch (e). to keep the oil pressure in port (Pr) constant.
WA470-6, WA480-6 23
SEN01303-02 10 Structure, function and maintenance standard
At neutral
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Turning left
WA470-6, WA480-6 25
SEN01303-02 10 Structure, function and maintenance standard
Turning right
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Function
q The steering relief valve is installed to the
steering valve. It maintains the oil pressure in
the steering circuit to the set pressure during
the steering operation.
WA470-6, WA480-6 27
SEN01303-02 10 Structure, function and maintenance standard
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
q The overload relief valve is installed to the q If the oil pressure in port (A) rises above the
steering valve. It protects the cylinder circuit set pressure of the relief valve, pilot poppet (4)
from abnormally high pressure that can be is pushed and opened to the right.
generated if an impact is applied to the cylinder q The oil flows through pilot poppet (4) and hole
while the steering valve is in neutral. to port (B).
q If abnormally high pressure is generated on
the cylinder side, the overload relief valve
works as a safety valve to prevent breakage of
the cylinder and hydraulic piping.
q If negative pressure is generated on the cylin-
der side, the overload relief valve works as a
suction valve to prevent occurrence of vacuum
in the circuit.
WA470-6, WA480-6 29
SEN01303-02 10 Structure, function and maintenance standard
30 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Relief valve
1. Plug
2. Spring
3. Valve
4. Valve seat
Function
q The relief valve is installed to the steering
valve. If the oil pressure in port (Pr) rises
above the set pressure, the relief valve
relieves the oil to protect the LS circuit of the
steering pump from abnormally high pressure.
WA470-6, WA480-6 31
SEN01303-02 10 Structure, function and maintenance standard
Orbit-roll valve 1
32 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Outline Structure
q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the steering pump to the right or left nected to sleeve (8) through center pin (7)
steering cylinder to decide the travel direction (which is not in contact with spool (9) while the
of the machine. steering wheel is at "neutral") and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) that have rotary type q Top (B) of drive shaft (3) is engaged with cen-
direction selecting function and Gerotor (5) ter pin (7) and united with sleeve (8) and the
(combination of rotor (5a) and stator (5b)) that bottom is engaged with the spline of rotor (5a)
operates as a hydraulic motor during the nor- of the Gerotor (5).
mal steering operation and as a hand pump q 4 ports are provided on valve body (4). Each
(the steering wheel's operating effort becomes port is respectively connected to the pump cir-
too high to operate it actually) when the oil is cuit, tank circuit, L.H. steering circuit and R.H.
not supplied because of a trouble of the steer- steering circuit. And the ports of the pump side
ing pump or engine. and tank side are connected by the check
valve in the body. If the pump or engine fails,
the oil can be sucked through this check valve
directly from the tank side.
WA470-6, WA480-6 33
SEN01303-02 10 Structure, function and maintenance standard
Operation
When steering wheel is at "neutral" position
34 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
WA470-6, WA480-6 35
SEN01303-02 10 Structure, function and maintenance standard
36 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
q As the steering wheel is "turned left", spool (9) When steering wheel is at "stop" position
being connected to the drive shaft of the steer- q As operation of the steering wheel is stopped,
ing column is rotated counterclockwise. angular displacement between spool (9) and
q Since spool (9) and sleeve (8) are connected sleeve (8) disappears and the steering wheel
by centering spring (2), spool (9) compresses is returned to the neutral position by the repul-
centering spring (2). sive force of centering spring (2).
q An angular displacement corresponding to the
amount of compression of centering spring (2)
is generated between spool (9) and sleeve (8).
q Port (A) and vertical groove (B) are connected
first being followed by the connection between
vertical groove (B) and port (E), port (E) and
vertical groove (C), and vertical groove (C) and
port (G) to the L.H. steering circuit.
q Although the connection between vertical
groove (B) and orifice (b) of port (J) to the pri-
ority valve is maintained, port (K) of sleeve (8)
starts gradually closing vertical groove (M) and
port (L).
q Port (F) of the R.H. steering circuit is con-
nected to vertical groove (D) at the same time
as port (A) and vertical groove (B) are con-
nected.
q Due to connection and disconnection of the
ports and vertical grooves, the oil from the
pump flows from port (A) to vertical groove (B)
then flows to port (E), starting rotation of the
Gerotor. The oil discharged from the Gerotor
flows to the L.H. steering cylinder head side
through port (E), vertical groove (C) and port
(G).
q Oil pressure of vertical groove (M) is transmit-
ted to port (J) through orifice (b), then supplied
from port (J) as the pilot pressure of the priority
valve.
q The oil from the R.H. steering cylinder head is
drained to the hydraulic tank through port (F),
vertical groove (D) and port (H).
WA470-6, WA480-6 37
SEN01303-02 10 Structure, function and maintenance standard
q Above figure shows the suction and discharge q The internal gear of the Gerotor advances by 1
ports (P) of the Gerotor and connections with tooth with every 1/7 turn of the steering wheel
the sleeve ports. and discharges the oil from the pump accord-
q If the steering wheel is turned to the right, ports ing to the steering angle of the steering wheel.
(a), (c), (e), (g), (i), and (k) will be connected to Accordingly, the discharge amount varies in
the pump side by the vertical grooves of the proportion to the steering angle of the steering
spool. Likewise, ports (b), (d), (f), (h), (j), and (l) wheel.
are connected to the R.H. steering cylinder
head side.
Under the condition in Fig. 1, ports (1), (2) and
(3) are in the discharge state of the Gerotor
and connected to ports (l), (b), and (d) and the
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil from the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90° continued for
above condition. Under this state, ports (2), (3),
and (4) are in the suction state and connected
to ports (k), (a), and (c). Ports (5), (6), and (7)
are in the discharge state and connected to
ports (d), (f), and (h).
q As shown above, the ports in the discharge
state of the Gerotor are connected to the ports
being connected to the steering cylinder. The
ports in the suction state are connected to the
pump circuit.
38 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
WA470-6, WA480-6 39
SEN01303-02 10 Structure, function and maintenance standard
Stop valve 1
40 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
1. Block
2. Relief valve
3. Orifice
WA470-6, WA480-6 41
SEN01303-02 10 Structure, function and maintenance standard
Steering cylinder 1
Unit: mm
No. Check item Criteria Remedy
42 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 43
SEN01303-02 10 Structure, function and maintenance standard
1. Terminal E Function
2. Terminal M q When the oil pressure in the steering circuit
lowers abnormally, the emergency steering
motor drives the emergency steering pump
responding to the signal from the transmission
controller.
Specifications
44 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
Unit: mm
No. Check item Criteria Remedy
Standard clearance Clearance limit
1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bearing
2 inside diameter and gear shaft out- 0.060 – 0.119 0.20
Replace
side diameter
Standard size Tolerance Repair limit
3 Driven depth of pin 0
10 —
–0.5
4 Torque of spline turning shaft 2.0 – 4.9 Nm {0.2 – 0.5 kgm}
Allowable
Speed Discharge pressure Standard delivery
Delivery delivery
(rpm) (MPa {kg/cm2}) (l/min) —
— Discharge oil: SAE10WCD (l/min)
Oil temperature: 45 – 55°C 20.6
3,500 67.6 62.4
{210}
Function
q The emergency steering pump is installed
together with the emergency steering motor to
the right side of the transmission. When the
engine stops or the oil pressure in the steering
circuit lowers below the specified level, the
emergency steering pump supplies oil to the
steering circuit.
WA470-6, WA480-6 45
SEN01303-02 10 Structure, function and maintenance standard
46 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
1. Body Function
2. Piston q The steering electric lever is installed to the left
3. Lever console and connected to the joystick steering
4. Disc lever.
5. Retainer q If the joystick steering lever is operated, disc
6. Lever (4) rotates and pushes down piston (2), and
7. Potentiometer potentiometer (7) rotates consequently.
8. Connector q Potentiometer (7) senses the operating angle
(stroke) of the joystick steering lever and out-
puts it as a signal voltage to the work equip-
ment controller.
q The potentiometer is installed in the lateral
direction and it outputs the 2 opposite signal
voltages shown in the above figure.
WA470-6, WA480-6 47
SEN01303-02 10 Structure, function and maintenance standard
Function
q The joystick EPC valve selects the right or left
steering circuit and adjusts the flow rate
according to the operation of the joystick steer-
ing lever.
q The solenoid of the joystick EPC valve
receives signal voltage conformed to the oper-
ating angle (stroke) of the steering electric
lever from the work equipment controller and
adjusts the flow rate in the steering circuit.
q The flow rate in the steering circuit is decided
by the signal voltage from the work equipment
controller.
48 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01303-02
WA470-6, WA480-6 49
SEN01303-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
50
SEN01304-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01304-01 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Charge valve 1
P: From pump
A: To cooling fan motor
PPC : To PPC valve
ACC1: To brake valve port PA
ACC2: To brake valve port PB
T: Drain
S1: Brake oil pressure switch (Low)
S2: Emergency brake oil pressure switch
G: Accumulator charge pressure pickup port
WA470-6, WA480-6 3
SEN01304-01 10 Structure, function and maintenance standard
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Operation
WA470-6, WA480-6 5
SEN01304-01 10 Structure, function and maintenance standard
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
WA470-6, WA480-6 7
SEN01304-01 10 Structure, function and maintenance standard
q If the pressure in port (P) (pump pressure) q If the pressure from port (PPC) (pilot pressure)
rises above the set pressure, it compresses rises above the set pressure, the oil from the
spring (1) and moves ball (2) to the left. pump compresses spring (1) and moves ball
q The pressure of the oil from the pump is (2) to the left.
reduced through orifice (a), and the resulting q The pressure of the oil from the pump is
pressure difference compresses spring (3) and reduced when the oil flows through orifice (a),
moves valve (4) to the left largely. and the pressure difference compresses spring
q Port (P) being connected to port (T) drains the (3) and moves valve (4) to the left.
pump pressure and, thereby, regulates the q Since the open area between port (PPC) and
maximum pressure in the charge circuit to pro- port (P) is reduced and the pressure drop
tect the circuit. results, the pressure in port (P) is at the current
level without being not lowered to the set pres-
sure of the relief valve.
q The pressure in port (PPC) is adjusted to a
specific desired level according to the open
area between port (PPC) and port (P) and sup-
plied as the basic pressure of the pilot circuit.
q If abnormal pressure is generated in port
(PPC), port (PPC) is connected to port (T) to
release the abnormal pressure and protect the
pilot circuit.
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
q The pressure in port (P) (pump pressure) is q When the pressure in port (ACC1) is higher
applied to the left end of sequence valve (1) than that in port (ACC2), shuttle valve (1)
and the drain pressure is applied to the right moves to the left to disconnect port (ACC1)
end. from oil passage (B).
q If the pump pressure rises above the set pres- q The open area between port (ACC2) and oil
sure of spring (2), sequence valve (1) moves to passage (B) is increased and the oil is supplied
the right and port (P) is connected to port (A). to the accumulator on port (ACC2) side.
q The oil from the pump flows through priority q When the pressure in port (ACC2) is higher
valve (3) and port (A) to the cooling fan motor than that in port (ACC1), the oil is supplied to
and is used to drive the motor. the accumulator on port (ACC1) side.
q Even when the cooling fan motor drive pres- q The oil from the pump is supplied first to the
sure is low, the pump pressure is kept above low-pressure side of the 2 systems.
the set pressure of spring (2) to protect the
accumulator charge pressure and pilot circuit
basic pressure from going low.
WA470-6, WA480-6 9
SEN01304-01 10 Structure, function and maintenance standard
Brake valve 1
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q As the brake pedal is pressed, the transmis-
sion cut-off oil pressure sensor is operated,
sending the signal to the transmission control-
ler and, as the result, setting the transmission
to neutral electrically.
Operation
When the brake pedal is pressed down
WA470-6, WA480-6 11
SEN01304-01 10 Structure, function and maintenance standard
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Balancing operation
WA470-6, WA480-6 13
SEN01304-01 10 Structure, function and maintenance standard
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (3) and free piston (4) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.
Specifications
Gas used: Nitrogen gas
Amount of gas: 2,850 cc
Charging gas pressure:3.43 ± 0.1 MPa
{35 ± 1.0 kg/cm2} (At 20°C)
Max. pressure used: 20.6 MPa {210 kg/cm2}
WA470-6, WA480-6 15
SEN01304-01 10 Structure, function and maintenance standard
Slack adjuster 1
A: Inlet port
B: Outlet port
1. Bleeder
2. Cylinder
3. Check valve
4. Piston
5. Spring
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between cylinder size Shaft Hole clearance limit
6
body and piston –0.030 +0.074 0.030 –
55 0.25
–0.076 +0.074 0.150
Standard size Repair limit
Installed Installed Installed Replace
Free length Free length
7 Check valve spring length load load
66.7 N
38.8 33 — —
{4.4 kg}
43.1 N
8 Slack adjuster spring 198 38 — —
{4.4 kg}
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Operation
1. When the brake pedal is pressed down
q Before the brake is pressed down, piston
(4) is restored as much as the amount of
stroke (S) (a full stroke). When the brake
pedal is pressed down, oil discharged 2. When the brake pedal is released
from the brake valve branches into right q When the brake is released, return spring
and left cylinders (2) from port (P) of the (7) of the brake restores piston (4) as
slack adjuster to move piston (4) as much much as the amount of oil of stroke (S)
as the amount of stroke (S) to the right and the brake returns to its released state.
and the left. In other words, return stroke (T) of brake
piston (6) depends on the amount of oil of
stroke (S) the slack adjuster and the brak-
ing time lag remains constant regardless
of the amount of wear of the brake disc.
WA470-6, WA480-6 17
SEN01304-01 10 Structure, function and maintenance standard
Brake 1
Front
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (3 pieces)
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) —
Wear of disc contact surface of Wear limit Replace
12 41.3 ±0.1
brake outer ring 0.3
Standard size Repair limit
Load of spring Installed height Installed load Installed load
13
(When 2 pieces are piled) 1,578 N 1,264 N
7.4
{161 kg} {129 kg}
Outline
q The front brake is a wet-type multi-disc brake,
which consists of piston (3), inner ring (5), disc
(9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has liners stuck to its both sides and is
installed between inner ring (5) and outer ring
(8), and they are coupled together by the
spline of sun gear shaft (6).
WA470-6, WA480-6 19
SEN01304-01 10 Structure, function and maintenance standard
Rear
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (3 pieces)
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
WA470-6 Rear
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) —
Wear of disc contact surface of Wear limit Replace
12 27.8 ±0.1
brake outer ring 0.3
Standard size Repair limit
Load of spring Installed height Installed load Installed load
13
(When 2 pieces are piled) 1,529 N 1,225 N
7.4
{156 kg} {125 kg}
WA480-6 Rear
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
10 Thickness of plate
6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) —
Wear of disc contact surface of Wear limit Replace
12 41.3 ±0.1
brake outer ring 0.3
Standard size Repair limit
Load of spring Installed height Installed load Installed load
13
(When 2 pieces are piled) 1,578 N 1,264 N
7.4
{161 kg} {129 kg}
Outline
q The rear brake is a wet-type multi-disc brake,
which consists of piston (3), inner ring (5), disc
(9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has liners stuck to its both sides and is
installed between inner ring (5) and outer ring
(8), and they are coupled together by the
spline of sun gear shaft (6).
WA470-6, WA480-6 21
SEN01304-01 10 Structure, function and maintenance standard
Operation
When brake is operated When brake is released
q As the brake pedal is pressed, oil pressure (P) q If the oil pressure is released, piston (2) is
being supplied through the hydraulic tank, brake returned by the returning force of spring (8)
charge valve to the brake cylinder acts on piston and clearance is made between inner ring (3)
(2) in the brake cylinder to move the piston. and outer ring (5), and disc (4) becomes free.
Accordingly, disc (4) between piston (2), inner The linings stuck to disc (4) have cross
ring (3), and outer ring (5) is stopped and the grooves on them. While disc (4) is turning, oil
brake is applied to the machine. flows in those grooves to cool the linings.
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Outline
q Parking brake (4) is a wet-type multi-disc brake q While the parking brake is applied (While the
built in the transmission. It is installed to the solenoid valve is turned “OFF”), the signal from
output shaft bearing and operated mechani- the transmission controller to the transmission
cally by the pressing force of the spring and solenoid valve is stopped by the neutralizer
released hydraulically. signal to keep the transmission in neutral.
q If parking brake switch (1) installed to the oper- q Emergency parking brake release valve (5) is
ator's seat is turned “ON”, parking brake sole- installed to move the machine when it is
noid valve (3) installed to valve assembly (2) stopped (and the parking brake is applied)
shuts off the oil pressure and the parking brake because of a trouble in the engine or drive sys-
is applied. tem.
q If parking brake switch (1) is turned “OFF”, the
hydraulic force in the cylinder releases the
parking brake.
WA470-6, WA480-6 23
SEN01304-01 10 Structure, function and maintenance standard
Parking brake 1
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Unit: mm
No. Check item Criteria Remedy
Basic dimensions Repair limit
Installed Installed Installed
Parking brake spring Free length Free length
9 length load load
(outside)
1,066 N 1,013 N
94 76 91.2
{108.7 kg} {103.3 kg}
Parking brake spring 557 N 529 N
10 94 76 91.2
(inside) {56.8 kg} {54.0 kg}
Basic dimensions Tolerance Repair limit Replace
Thick-
11 Plate 4.0 ±0.05 3.9
ness
Strain — 0.05 0.6
Thick-
12 Disc 3.2 ±0.08 2.97
ness
Load of wave spring 1,106 N ±57 N 940 N
13
(Testing height: 3.2 mm) {112.8 kg} {±5.8 kg} {95.9 kg}
WA470-6, WA480-6 25
SEN01304-01 10 Structure, function and maintenance standard
1. Valve assembly
2. Coil (ON/OFF type)
3. Push pin
4. Spring
5. Spool
6. Valve block
7. Check valve
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
Operation
q Setting the parking brake switch to “ON” to de- q Setting the parking brake switch to “OFF” to
energize coil (1). As the result, spool (2) is energize coil (1), moving spool (2) upward.
pushed back downward by the repulsive force q The pressurized oil from the pump flows to the
of spring (3). parking brake through port (P), inside of spool
q Pump port (P) is disconnected from parking (2) and port (A). At the same time, port (T) is
brake port (A), stopping flow of the oil from the closed and the oil is not drained.
pump to the parking brake. At the same time, q As oil pressure is applied to the piston, it com-
the oil that was operating the parking brake is presses the spring, separating the plate and
drained through port (A) and port (T). disc from each other. As the result, the parking
q As the oil that was operating the piston is brake is released.
drained, the piston being pushed back by the
spring contacts the plate and disc closely to
enable the parking brake.
WA470-6, WA480-6 27
SEN01304-01 10 Structure, function and maintenance standard
A: From accumulator
B: To parking brake solenoid valve
1. Grip
2. Valve
Function
q The emergency parking brake release valve is
installed between the accumulator and parking
brake solenoid in the brake circuit. When sup-
ply of oil pressure from the power train pump is
stopped because of an engine trouble, etc.,
opening the valve with manually allows con-
ducting the accumulator charge pressure in the
brake circuit to the parking brake cylinder.
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01304-01
WA470-6, WA480-6 29
SEN01304-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
30
SEN01305-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01305-02 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01305-02
Unit:
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
1 Thickness of thrust plate –0.15
20 —
–0.15
+0.3
2 Thickness of wear plate 5 —
–0.1
Standard Tolerance Standard Clearance Replace
Clearance between shaft and size Shaft Hole clearance limit
3
hole on front support side –0.050 +0.439 0.073 –
240 —
–0.122 +0.023 0.561
Clearance between shaft and –0.012 +0.455 0.039 –
4 190 —
hole on rear support side –0.137 +0.027 0.592
WA470-6, WA480-6 3
SEN01305-02 10 Structure, function and maintenance standard
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01305-02
Unit:
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between upper hinge size Shaft Hole clearance limit
1
pin and rear frame –0.030 +0.060 0.060 –
80 —
–0.049 +0.030 0.109
Clearance between upper hinge –0.030 +0.060 0.060 –
2 80 —
pin and spacer (small) –0.049 +0.030 0.109
Clearance between upper hinge –0.030 –0.015 0.015 –
3 80 —
pin and bearing –0.049 –0.015 0.049
Clearance between upper hinge –0.030 +0.030 0.030 –
4 80 —
and spacer (large) –0.049 +0.030 0.079
Clearance between rear frame –0.036 +0.071 0.072 –
5 95 —
and spacer (large) –0.071 +0.036 0.142
Clearance between front frame –0.025 –0.048 –0.088 –
6 130 —
and upper hinge bearing –0.025 –0.088 –0.023
Replace
Clearance between lower hinge –0.030 +0.067 0.057 –
7 80 —
pin and rear frame bushing –0.076 +0.027 0.143
Clearance between lower hinge –0.030 –0.015 0.015 –
8 80 —
pin and bearing –0.076 –0.015 0.076
Clearance between front frame –0.025 –0.048 –0.088 –
9 130 —
and lower hinge pin –0.025 –0.088 –0.023
Clearance between rear frame +0.089 +0.054 –0.089 –
10 95 —
and bushing +0.054 +0.054 0
Clearance in lower hinge pin +0.17 +0.054 –0.17 –
11 105 —
and seal press fitting part +0.08 +0.054 –0.026
Height of upper hinge spacer Standard size Tolerance Repair limit
12
(smaller one) 36 ±0.1 —
Height of upper hinge spacer
13 61.5 ±0.1 —
(larger one)
Standard thickness of shim
14 between upper hinge and 1
retainer
Standard thickness of shim
15 between upper hinge and 2
retainer
Standard thickness of shim Adjust
16 between lower hinge and 1
retainer
Tightening torque of upper 20 ± 2 Nm {2 ± 0.2 kgm} (When shim is adjusted)
17
hinge retainer mounting bolt 98 – 123 Nm {10 – 12.5 kgm} (Final value)
Tightening torque of lower 20 ± 2 Nm {2 ± 0.2 kgm} (When shim is adjusted)
18
hinge retainer mounting bolt 98 – 123 Nm {10 – 12.5 kgm} (Final value)
WA470-6, WA480-6 5
SEN01305-02 10 Structure, function and maintenance standard
Tires
The radial tires (if equipped) of this machine have the following features.
• Large gripping force • High operator comfort • Fewer frequency of burst • Less uneven wear
• Enhanced fuel consumption • Longer life • Less machine damage • Less heat generation
Structure Structure
q The cords of carcass (1) are arranged at right q The cords of carcass (1) are arranged bias
angles to the center line of tread (T) (radially). from the center line of tread (T).
q Tread (T) is stabilized and protected by several q Side wall (W) and tread (T) are integral.
strong belts (2).
q Side wall (W) and tread (T) are independent
from each other.
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01305-02
WA470-6, WA480-6 7
SEN01305-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
8
SEN01306-03
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01306-03 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 3
SEN01306-03 10 Structure, function and maintenance standard
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 5
SEN01306-03 10 Structure, function and maintenance standard
a The following figure shows the machines equipped with auxiliary control lever.
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 7
SEN01306-03 10 Structure, function and maintenance standard
Hydraulic tank 1
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Specifications
Capacity of hydraulic tank (l) 256
Quantity of oil in hydraulic tank (l) 173
Set pressure of bypass valve 0.15 ± 0.03 1. Filter element
(MPa {kg/cm2}) {1.53 ± 0.31} 2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
WA470-6, WA480-6 9
SEN01306-03 10 Structure, function and maintenance standard
Unit: mm
No. Check item Criteria Remedy
Type Standard clearance Clearance limit
1 Side clearance
SAL(4)125 0.11 – 0.16 0.20
Clearance between plain bear-
2 ing inside diameter and gear SAL(4)125 0.06 – 0.14 0.20
Replace
shaft outside diameter
Type Standard size Tolerance Repair limit
3 Driven depth of pin 0
SAL(4)125 21 —
–0.5
4 Torque of spline turning shaft 9.8 – 14.7 Nm {1.0 – 1.5 kgm}
Discharge
Standard Allowable
Delivery Speed pressure
Type delivery delivery —
— Oil: EO10-CD (rpm) (MPa
(l/min (l/min
Oil temperature: 45 – 55°C {kg/cm2})
SAL(4)125 2,200 2.9 {30} 264.2 233.9
Outline
q The power train pump is installed to the PTO
shaft of the torque converter and driven by the
shaft to supply oil to the torque converter and
transmission circuits.
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 11
SEN01306-03 10 Structure, function and maintenance standard
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Outline
q The pump unit is composed of the variable
capacity swash plate type piston pump, PC
valve, LS valve, and EPC valve.
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
WA470-6, WA480-6 13
SEN01306-03 10 Structure, function and maintenance standard
1. Shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Servo piston
11. PC valve
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 15
SEN01306-03 10 Structure, function and maintenance standard
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Control of delivery
q If swash plate angle (a) becomes larger, the
difference between volumes (E) and (F)
b ec o me s l ar g er a nd pu m p d el i v e r y ( Q )
increases.
q Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure
from the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q Space of the pressure receiving area of servo
piston (10) are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pres-
sure chamber of the small diameter piston
side.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The relationship in the size of pressure (PP) at
the small diameter piston end and pressure
(PEN) at the large diameter piston end, and
the ratio between the area receiving the pres-
sure of the small diameter piston and the large
diameter piston controls the movement of
servo piston (10).
WA470-6, WA480-6 17
SEN01306-03 10 Structure, function and maintenance standard
LS valve
Function
q The LS (load sensing) valve detects the load
and controls the delivery.
q This valve controls pump delivery (Q) accord-
ing to differential pressure (dPLS)
[ = (PP) – (PLS)] (called LS differential pres-
sure) between pump discharge pressure (PP)
and control valve outlet port pressure (PLS).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) coming from the con-
trol valve output, and pressure (PSIG) (called
the LS selector pressure) from the proportional
solenoid valve enter this valve.
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Operation
q The LS valve is a 3-way selector valve, with q Pump pressure (PP) is present in port (J) on
pressure (PLS) (LS pressure) from the inlet the small diameter side of the piston.
port of the control valve brought to spring q According to the difference in the areas on
chamber (B), and pump discharge pressure servo piston (10), servo piston (10) moves in to
(PP) brought to port (H) of sleeve (1). the direction of minimizing the swash plate
q Magnitude of the force resulting from this LS angle.
pressure (PLS), force of spring (4) and the
pump discharge pressure (self pressure) (PP)
determine the position of spool (3).
q Before starting engine, servo piston (10) is
pressed to the right. (See the figure to the
right)
q If the control lever is in neutral at start of the
engine, LS pressure (PLS) is set to 0 MPa {0
kg/cm2}. (It is connected with the drain circuit
through the control valve spool.)
q Spool (3) is pushed to the right, and port (C)
and port (D) will be connected.
q Shuttle valve output pressure (PPH) enters the
large diameter side of the piston from port (K).
WA470-6, WA480-6 19
SEN01306-03 10 Structure, function and maintenance standard
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 21
SEN01306-03 10 Structure, function and maintenance standard
q Let us take the area receiving the pressure at q The force of spring (4) is adjusted to determine
the large diameter end of the piston as (A1), the balanced stop position of this spool (3) at
the area receiving the pressure at the small the center of the standard when (PP) – (PLS) =
diameter end as (A0), and the pressure flowing 1.4 MPa {14 kg/cm2}.
into the large diameter end of the piston as
(PEN).
q If the main pump pressure (PP) of the LS valve
and the combined force of spring (4) and LS
pressure (PLS) are balanced, and the relation-
ship is (A0) × (PP) = (A1) × (PEN), servo pis-
ton (10) will stop in that position.
q And the swash plate of the pump will be held in
an intermediate position. [Spool (3) will be
stopped at a position where the distance of the
opening from port (D) to port (E) and the dis-
tance from port (C) to port (D) is almost the
same.]
q The formula (A0) : (A1) = 3 : 5 represents the
relation of pressure receiving areas across the
end of servo piston (10). And (PP) : (PEN) C 5 :
3 represents the pressure applied across the
piston when balanced.
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
PC valve
Function
q PC valve controls the flow to a certain rate cor-
responding to the discharge pressure irrespec-
tive of how much the control valve stroke is
increased, when pump discharge pressure
(PP1) (self pressure) is high.
q Uprise in the pump discharge pressure due to
increased load during work results in reducing
the pump delivery.
q If the pump discharge pressure drops, it
increases the delivery from the pump.
q In this case, relation between the mean dis-
charge pressure of the front and rear pump
(PP1) and pump delivery (Q) will become as
shown in the right figure if the relation is repre-
sented as the parameter of the current value
(X) to be given to PC-EPC valve solenoid.
q The controller continues counting the actual
engine speed.
q During low speed, command current flows
from the controller to PC-EPC valve solenoid
according to the engine speed to reduce the
pump delivery.
WA470-6, WA480-6 23
SEN01306-03 10 Structure, function and maintenance standard
Operation
1) When the actuator load is small and pump pressure (PP1) is low
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Action of spring q If port (E) and port (G) of the LS valve are con-
q The load of spring (4) at the PC valve is deter- nected, the pressure entering the large diame-
mined by the position of the swash plate. ter end of the piston from port (J) becomes
q Spring load changes as servo piston (9) makes drain pressure (PT), and servo piston (9)
spring (4) elongate or contract. moves to the left side.
q If the command current (X) to PC-EPC valve q The pump delivery will be set to the increasing
solenoid (1) changes, so does the force push- trend.
ing piston (2). q Spring (4) extends as servo piston (9) moves
q The load of spring (4) also changes according and weakens the spring force.
to the PC-EPC valve solenoid command cur- q As the spring force is weakened, spool (3)
rent (X). moves to the right, the connection between
q Port (C) of the PC valve is connected to port port (C) and port (D) is shut off and the pump
(E) of the LS valve. discharge pressure ports (B) and (C) are con-
q Self pressure (PP1) enters port (A), port (B) nected.
and the small diameter end of servo piston (9). q The pressure on port (C) rises and the pres-
q When pump pressure (PP1) is small, spool (3) sure on the large diameter end of the piston
will be positioned in the left side. also rises. Thus, the leftward move of servo
q Ports (C) and (D) are connected, and the pres- piston (9) is stopped.
sure entering the LS valve becomes drain q Stop position of servo piston (9) (= pump deliv-
pressure (PT). ery) is determined by a position where press
force generated by pump pressure (PP1) on
spool (3) and other press force by PC-EPC
valve solenoid are balanced with the force of
spring (4).
WA470-6, WA480-6 25
SEN01306-03 10 Structure, function and maintenance standard
2) When the actuator load is large, and the pump discharge pressure is high
Outline Operation
q When the load is large and pump discharge q When port (E) and port (G) of the LS valve are
pressure (PP1) is high, the force pushing spool connected, this pressure from port (J) enters
(3) to the right becomes larger and spool (3) the large diameter end of servo piston (9),
will be moved to the position shown in above stopping servo piston (9).
figure. q If main pump pressure (PP1) increases further
q Part of the pressure to be conducted from port and spool (3) moves further to the right, main
(C) to LS valve flows from port (B) to ports (C) pump pressure (PP1) flows to port (C) and acts
and (D) through LS valve. At the end of this to make the pump delivery the minimum.
flow, level of this pressure becomes approxi- q When servo piston (9) moves to the right,
mately half of main pump pressure (PP1). springs (4) and (6) are compressed and push
back spool (3).
q When spool (3) moves to the left, the openings
of port (C) and port (D) become larger.
q The pressure on port (C) (= J) is decreased
and the rightward move of servo piston (9) is
stopped.
q The position in which servo piston (9) stops at
this time is further to the right than the position
when pump pressure (PP1) is low.
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 27
SEN01306-03 10 Structure, function and maintenance standard
PC-EPC valve
C: To PC valve
P: From pilot pump
T: To tank
1. Connector
2. Coil
3. Body
4. Spring
5. Spool
6. Rod
7. Plunger
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Function Operation
q The EPC valve consists of the proportional
solenoid portion and the hydraulic valve por- 1) When signal current is 0
tion. (Coil is de-energized)
q On receiving signal current (i) from the control- q When there is no signal current flowing from
ler, the EPC valve generates EPC output pres- the controller to coil (2), coil (2) is de-ener-
sure in proportion to the signal current and gized.
outputs it to the PC valve. q Spool (5) is pushed to the left by spring (4).
q Port (P) is closed and the oil from the pilot
pump does not flow to the PC valve.
q The oil from the PC valve is drained through
ports (C) and (T) to the tank.
WA470-6, WA480-6 29
SEN01306-03 10 Structure, function and maintenance standard
30 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 31
SEN01306-03 10 Structure, function and maintenance standard
As for outside views and sectional views, only the 3-spool valve (with ECSS control valve) is shown.
1. Bucket valve
2. Lift arm valve
3. ECSS control valve
4. Cover A
5. Cover B
6. Lift arm suction valve
7. Accumulator charge valve
32 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Outside view
WA470-6, WA480-6 33
SEN01306-03 10 Structure, function and maintenance standard
Sectional view
(1/6)
34 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Installed If damaged or
× Outside Free length
5 Check valve spring length load load deformed,
diameter
replace spring
29.4 N 23.5 N
38.9 × 11.5 30.0 —
{3.0 kg} {2.4 kg}
WA470-6, WA480-6 35
SEN01306-03 10 Structure, function and maintenance standard
(2/6)
36 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
1. Spool (ECSS)
2. Spool (Lift arm)
3. Spool (Bucket)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free length
Installed Installed Free Installed
× Outside
4 Spool return spring length load length load
diameter
388 N 311 N
56.0 × 33.5 51.5 —
{39.6 kg} {31.7 kg}
If damaged or
351 N 280 N
5 Spool return spring 58.1 × 33 51.5 — deformed,
{35.8 kg} {28.6 kg}
replace spring
400 N 320 N
6 Spool return spring 70.5 × 36.4 65 —
{40.8 kg} {32.6 kg}
265 N 212 N
7 Spool return spring 53.2 × 22.3 33 —
{27.0 kg} {21.6 kg}
380 N 304 N
8 Spool return spring 56.8 × 33.8 51.5 —
{38.7 kg} {31.0 kg}
WA470-6, WA480-6 37
SEN01306-03 10 Structure, function and maintenance standard
(3/6)
38 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
(4/6)
Bucket valve
WA470-6, WA480-6 39
SEN01306-03 10 Structure, function and maintenance standard
(5/6)
40 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
ECSS valve
8. Spool
9. EPC valve
10. Accumulator charge valve
Unit: mm
No. Check item Criteria Remedy
Basic dimensions Repair limit
Free length
Installed Installed Free Installed
× Outside
11 Suction valve spring length load length load
diameter
3.04 N 2.45 N If damaged or
62.5 × 20.0 39.0 — deformed,
{0.31 kg} {0.25 kg}
replace spring
5.88 N 4.71 N
12 Check valve spring 41.5 × 8.5 31.5 —
{0.6 kg} {0.48 kg}
19.6 N 15.7 N
13 Valve spring 19.2 × 7.2 16.1 —
{2.0 kg} {1.6 kg}
WA470-6, WA480-6 41
SEN01306-03 10 Structure, function and maintenance standard
(6/6)
1. Unload valve
2. Main relief valve
3. LS bypass plug
42 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
CLSS 1
Outline of CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- q CLSS is configured with a variable capacity
tem, and has the following features: piston pump, control valves, and respective
actuators.
q Fine control not influenced by load q The hydraulic pump is configured with pump
q Controllability enabling digging even with fine body, PC valve and LS valve.
control
q Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations
q Energy saving using variable pump control
WA470-6, WA480-6 43
SEN01306-03 10 Structure, function and maintenance standard
Basic principle q The pump swash plate angle shifts toward the
maximum position if LS differential pressure
Pump swash plate angle control (dPLS) is lower than the set pressure of the LS
q The pump swash plate angle (pump delivery) valve (when the actuator load pressure is
is so controlled that the LS differential pressure high).
(dPLS), which is the differential pressure q If it becomes higher than the set pressure
between the pump discharge pressure (PPS) (when the actuator load pressure is low), the
and LS pressure (PLS) (the actuator load pres- pump swash plate angle shifts toward the mini-
sure) at the control valve outlet, will be con- mum position.
stant.
q [LS differential pressure (dPLS) = Pump dis- LS differential pressure (dPLS) and pump
charge pressure (PPS) – LS pressure (PLS)] swash plate angle
44 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
q The valve (pressure compensation valve) to q This prevents the bucket from becoming inop-
balance the load is installed to the lift cylinder erable because of excessive oil flow to the lift
head outlet side of the control valve. cylinder head due to the lowering of lift arm
q When actuators are operated simultaneously, under its own weight and compound operation
the pressure difference (dP) between the of the bucket.
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless the size of the load (pres-
sure).
q The flow of oil from the pump is divided (com-
pensated) in proportion to the area of openings
(S1) and (S2) of each valve.
WA470-6, WA480-6 45
SEN01306-03 10 Structure, function and maintenance standard
46 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Bucket spool
5. Lift arm spool
6. ECSS spool
7. Pressure compensation valve
8. Suction valve
9. Load check valve
10. Accumulator charge valve
11. Main relief valve
Set pressure: 34.3 ± 0.5 MPa {350 ± 5 kg/cm2}
12. Unload valve
Cracking pressure: 1.96 ± 0.2 MPa {20 ± 2 kg/cm2}
13. Safety-suction valve
Set pressure: 38.2 ± 0.5 MPa {390 ± 5 kg/cm2}
14. Safety-suction valve
Set pressure: 45.1 ± 0.5 MPa {460 ± 5 kg/cm2}
WA470-6, WA480-6 47
SEN01306-03 10 Structure, function and maintenance standard
48 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 49
SEN01306-03 10 Structure, function and maintenance standard
1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston
Function
q Shuttle valve (3) is pressed to the right by port
(B) pressure and ports (B) and (D) are cut off.
q Holding pressure of port (B) is led to spring
chamber (C) and piston (4) is pressed to the
left to prevent it from being separated from
valve (2).
50 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Function
q The state of division changes according to the
area ratio of pressure compensation portions
(A1) and (A2). Area ratio = (A2)/(A1)
q Since the area ratio is less than 1, spool meter-
in downstream pressure < maximum load
pressure, and the oil flow is divided greater
than by the area ratio of the opening.
WA470-6, WA480-6 51
SEN01306-03 10 Structure, function and maintenance standard
Supply of LS pressure
(LS shuttle valve)
Function Operation
q The LS pressure (PLS) means the actuator q If main spool (2) is operated, pump discharge
load pressure on the outlet side of the control pressure (PPS) flows to actuator circuit (B).
valve. q Pump discharge pressure (PPS) is led through
q Pressure compensation valve (3) upstream orifice (a) of main spool (2) to LS circuit (PLS).
pressure (spool meter-in downstream pres- q When actuator circuit (B) rises to necessary
sure) is led through main spool (2) to LS shut- pressure level, pump discharge pressure
tle valve (7). (PPS) rises.
q Connected to actuator port (B) through valve q Check valve (5) in main spool (2) opens and
(4), and makes LS pressure C actuator load the high pressure in LS circuit (PLS) flows out
pressure. to actuator circuit (B).
q Inlet pore (a) inside main spool (2) has a small q Pressure in LS circuit (PLS) becomes approxi-
diameter concurrently serving as a throttle. mately equal to that of actuator circuit pressure
(B).
52 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
LS bypass plug 1
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function
q Releases the residual pressure in LS pressure
circuit (6) from orifices (a) and (b).
q Slows down the rising rate of LS pressure to
prevent a sudden change of hydraulic pres-
sure.
q Bypass flow from LS bypass plug (5) causes a
pressure loss to be generated due to the circuit
resistance between throttle (c) of main spool
(2) and LS shuttle valve (4).
q Effective LS differential pressure drops to
improve a dynamic stability of the actuator.
WA470-6, WA480-6 53
SEN01306-03 10 Structure, function and maintenance standard
Function
q The controller automatically turns on and off
the accumulator charged with high-pressure
gas according to the travel condition.
q The ECSS control valve gives elasticity to the
vertical movement of the work equipment and
reduces rocking of the machine body during
high-speed travel to improve the operator com-
fort and prevent spillage of material for higher
working efficiency.
54 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 55
SEN01306-03 10 Structure, function and maintenance standard
56 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Function
q If the lift arm is raised and the bucket is oper-
ated simultaneously, the stroke of lift arm spool
(3) is restricted and more oil flows to the
bucket. As a result, the bucket tilting (dumping)
speed is increased.
Operation
1) Single operation
q When the lift arm is raised, the PPC pressure
is supplied to (PA2) and lift arm spool (3) and
piston (5) move to the left.
2) Compound operation
q When the lift arm is raised, if bucket dumping
operation (PB1) is carried out, (PA1) is con-
nected through the PPC valve to (T).
q Accordingly, ball (2) of check valve (1) is
pushed rightward, conducting pressure of
(PB1) to passage (a).
q The pressure of (PB1) conducted to passage
(a) pushes piston (5) right with the force of
pressure receiving area piston (5) [x/4 (φd2 –
φc2) × (PB1)].
q Accordingly, lift arm spool (3) is pushed right-
ward and then it balances at the stroke where
the force is set to the following value. [x/4φb2 ×
(PA2)] = [(x/4 (φd2 – φc2) × (PB1) + Spring (4)].
q As a result, the open area of notch (e) is
reduced and less oil is supplied to port (A2).
The excessive oil flows to (B1) and the dump-
ing speed is increased.
WA470-6, WA480-6 57
SEN01306-03 10 Structure, function and maintenance standard
1. Screw
2. Poppet (Safety valve)
3. Spring (Safety valve)
4. Spring (Main pressure reducing valve)
5. Pressure reducing valve spool
6. Poppet (Check valve)
7. Spring (Check valve)
58 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
WA470-6, WA480-6 59
SEN01306-03 10 Structure, function and maintenance standard
Function
q The discharge pressure of the hydraulic pump
is reduced and the oil is supplied to the ECSS
accumulator.
Operation
q Poppet (2) is pressed by spring (3) against the
seat and the line from port (P1) to port (T) is
closed.
q Poppet (6) is pressed to the left and the line
from port (P1) to port (PR) is closed.
q Poppet (6) is moved to the right by pressure
(P1) and the line from (P1) to (PR) is opened.
If (P1) < (PR), poppet (6) is pressed to the left
by spring (7) and the line from (P1) to (PR) is
closed.
60 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01306-03
Operation
q If pressure (P) rises above the set pressure,
poppet (3) opens and the hydraulic oil flows
through port (P1), hole (a) in spool (5), opening
of poppet (2), and tank port (T).
q Accordingly, differential pressure is made
before and after hole (a) in spool (5) and spool
(5) moves to close the opening between ports
(P) and (P1). Pressure (P) is reduced to a cer-
tain pressure (the set pressure) by the open
area at this time and supplied as pressure
(P1).
WA470-6, WA480-6 61
SEN01306-03
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
62
SEN01307-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01307-01 10 Structure, function and maintenance standard
PPC valve 1
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01307-01
1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Lever
6. Ring
7. Plate
8. Piston
9. Retainer
10. Body
WA470-6, WA480-6 3
SEN01307-01 10 Structure, function and maintenance standard
Operation
1. When in neutral
q Ports (PA) and (PB) of the bucket control valve q Ports (PA) and (PB) of the lift arm control valve
and ports (P1) and (P4) of the PPC valve are and ports (P2) and (P3) of the PPC valve are
connected through fine control hole (f) of spool connected through fine control hole (f) of spool
(1) to drain chamber (D). (1) to drain chamber (D).
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01307-01
q If rod (4) and piston (8) are pushed by lever q If lever (5) begins to return, the force of center-
(5), retainer (9) is pushed and spool (1) is also ing spring (3) and the pressure in port (P1)
pushed downward through metering spring (2). push up spool (1).
q As fine control hole (f) is disconnected from q Because of this, fine control hole (f) is con-
drain chamber (D), it is connected to pump nected to drain chamber (D), and the pressur-
pressure chamber (PP) almost simultaneously, ized oil at port (P1) is released.
and then the pilot oil of the main pump flows q If the pressure at port (P1) goes down too far,
from port (P1) to port (PB). spool (1) is pushed down by metering spring
q If the pressure in port (P1) rises, spool (1) is (2). Fine control hole (f) is shut off from drain
pushed back and fine control hole (f) is discon- chamber (D), and almost simultaneously, it is
nected from pump pressure chamber (PP) and connected to pump pressure chamber (PP).
connected to drain chamber (D) almost simul- Pump pressure is supplied until the pressure at
taneously to release the pressure in port (P1). port (P1) recovers to a pressure equivalent to
q As a result, spool (1) moves up and down to the position of the lever.
balance the force of metering spring (2) with q When the control valve spool returns, the oil in
the pressure in port (P1). The positional rela- drain chamber (D) flows in through fine control
tionship between spool (1) and body (10) hole (f') of the valve which is not in operation
(where fine control hole (f) is between drain and then flows through port (P4) into chamber
chamber (D) and pump pressure chamber (PA).
(PP)) does not change until retainer (9) comes
in contact with spool (1).
q Since metering spring (2) is compressed in
proportion to the stroke of the control lever, the
pressure in port (P1) also rises in proportion to
the stroke of the control lever.
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.
WA470-6, WA480-6 5
SEN01307-01 10 Structure, function and maintenance standard
q If lever (5) and rod (4) push down piston (8) q If rod (4) and piston (8) on the “Lower” side of
and retainer (9) pushes down spool (1), fine port (P3) are pushed down with lever (5), the
control hole (f) is disconnected from drain detent starts operation before the stroke end
chamber (D) and connected to pump pressure (the operating effort of the lever becomes
chamber (PP). heavy).
q The pilot oil from the main pump flows through q If rod (4) is pushed down further, the detent
fine control hole (f) and port (P1) into chamber operates to keep the lift arm in “float” state
(PB) to push the control valve spool. even if the lever is released.
q The oil returning from chamber (PA) flows q At the same time, the control valve is also
through port (P4) and fine control hole (f') into moved to the “Float” position to keep the lift
drain chamber (D). arm in float condition.
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01307-01
WA470-6, WA480-6 7
SEN01307-01 10 Structure, function and maintenance standard
Outline
q The accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.
Specifications
Gas used: Nitrogen gas
Amount of gas: 500 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2} (at 80°C)
Max. pressure used: 3.92 MPa {40 kg/cm2}
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01307-01
Function
q The accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.
Specifications
Gas used: Nitrogen gas
Amount of gas: 4,000 cc
Charged gas pressure: 2.94 MPa {30 kg/cm2} (at 20°C)
Max. operating pressure: 40 MPa {408 kg/cm2}
WA470-6, WA480-6 9
SEN01307-01 10 Structure, function and maintenance standard
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01307-01
Operation
When solenoid is “de-energized” When solenoid is “energized”
(When circuit is disconnected) (When circuit is connected)
q While the signal current is not flowing in coil (1) q If the signal current flows in coil (1) from out-
from outside, coil (1) is de-energized. side, coil (1) is energized.
q Spool (2) is pushed back to the left by spring q Spool (2) is pushed to the right by push pin (4).
(3). q Ports (P) and (A) are connected and the pilot
q Ports (P) and (A) are disconnected and the pressure flows from port (A) to the work equip-
pilot pressure does not flow from port (A) to the ment PPC valve.
work equipment PPC valve. At the same time, port (T) is closed and the oil
At the same time, port (T) is opened and the oil from the work equipment PPC valve does not
from the work equipment PPC valve flows in flow in the hydraulic tank.
the hydraulic tank.
WA470-6, WA480-6 11
SEN01307-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (01)
12
SEN01308-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01308-01 10 Structure, function and maintenance standard
1. Bucket
2. Bell crank
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01308-01
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
WA470-6
Unit: mm
No. Check item Criteria Remedy
WA470-6, WA480-6 3
SEN01308-01 10 Structure, function and maintenance standard
WA480-6
Unit: mm
No. Check item Criteria Remedy
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01308-01
Bucket 1
1. Bucket
2. Wear plate
3. Bolt-on cutting edge (BOC)
4. Bucket teeth (if equipped)
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
5 Wear of bucket tooth Replace
50 18.5
Clearance in bucket teeth mounting
6 Max. 0.5 — Adjust or replace
parts
7 Wear of cutting edge 93 — Reverse or replace
WA470-6, WA480-6 5
SEN01308-01 10 Structure, function and maintenance standard
1. Proximity switch
2. Bucket cylinder
3. Angle
4. Lift arm
5. Plate
Unit: mm
No. Check item Criteria Remedy
Clearance between bucket posi-
6 3–5
tioner proximity switch and angle
Adjust
Clearance between boom kick-out
7 3–5
proximity switch and plate
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01308-01
q The bucket positioner is driven electrically. As q The boom kick-out is driven electrically. As the
the bucket is set to a specified bucket angle lift arm is raised to a specific angle before
while moving from the dump position to the tilt reaching the maximum height, the boom kick-
position, the bucket positioner returns the out returns the lift arm control lever from the
bucket control lever from the “tilt” position to “raise” position to the “hold” position to stop the
the “hold” position to automatically stop the lift arm automatically at the specified height.
bucket at a proper digging angle. q Plate (5) is fixed to lift arm (4). And proximity
q Angle (3) is fixed to the rod side of bucket cyl- switch (1) is fixed to the front frame.
inder (2). And proximity switch (1) is fixed to q Moving the lift arm control lever from “lower”
the cylinder side. position to “raise” position moves lift arm (4)
q Moving the bucket control lever from “dump” upward.
position to “tilt” position moves the rod of As plate (5) comes to the specified position,
bucket cylinder (2) toward the machine front proximity switch (1) detects it is in the sensing
side. face and returns the lift arm control lever to
As angle (3) moves to a specified position, “hold” position.
proximity switch (1) detects it is away from the
sensing face and returns the bucket control
lever to “hold” position.
WA470-6, WA480-6 7
SEN01308-01 10 Structure, function and maintenance standard
q While the bucket is dumping more than the q Shifting bucket control lever (7) toward the tilt
position being set from the bucket positioner, position moves spool (8) to the position of the
angle (2) moves on to the sensing face of prox- arrow. And spool is held there by the energized
imity switch (1), turning on the proximity switch coil of detent solenoid (6). As a result, bucket
lamp. control lever (7) is held at the tilt position and
At this point, bucket positioner relay (4) is “ON” the bucket tilts.
and current flows to detent solenoid (6) of work
equipment PPC valve (5) to energize the coil.
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01308-01
WA470-6, WA480-6 9
SEN01308-01 10 Structure, function and maintenance standard
q While lift arm (3) is lower than the position q Shifting lift arm control lever (7) upward moves
being set from the boom kick-out, plate (2) is spool (8) to the position of the arrow. And spool
not on the sensing face and the lamp of prox- is held there by the energized coil of detent
imity switch (1) goes off. solenoid (6). As the result, lift arm control lever
At this point, boom kick-out relay (4) is set to (7) is held at the raise position and raising of lift
“OFF” and current flows to detent solenoid (6) arm (3) is continued.
of work equipment PPC valve (5) to energize
the coil.
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01308-01
WA470-6, WA480-6 11
SEN01308-01 10 Structure, function and maintenance standard
Bucket cylinder
Unit: mm
No. Check item Criteria Remedy
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01308-01
WA470-6, WA480-6 13
SEN01308-01
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (01)
14
SEN01309-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01309-02 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
Cab 1
WA470-6, WA480-6 3
SEN01309-02 10 Structure, function and maintenance standard
Air conditioner 1
Air conditioner piping diagram
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
WA470-6, WA480-6 5
SEN01309-02 10 Structure, function and maintenance standard
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
6. Dual pressure switch
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
WA470-6, WA480-6 7
SEN01309-02 10 Structure, function and maintenance standard
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
WA470-6, WA480-6 9
SEN01309-02 10 Structure, function and maintenance standard
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
WA470-6, WA480-6 11
SEN01309-02 10 Structure, function and maintenance standard
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
WA470-6, WA480-6 13
SEN01309-02 10 Structure, function and maintenance standard
Compressor 1
Specifications
Number of cylinders – Bore ×
7 – 29.3 × 27.4
Stroke (mm)
Piston capacity (cc/rev) 129.2
Allowable maximum speed
4,000
(rpm)
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume
135
(cc)
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
Condenser 1
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface
9.33
(m2)
Max. pressure used
3.6 {36}
(MPa {kg/cm2})
WA470-6, WA480-6 15
SEN01309-02 10 Structure, function and maintenance standard
Receiver
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
Display unit
Display Displayed Display Display
No. Display method Remarks
category items range color
Output air See above All segments below applicable level come
1
temperature drawing on (8-step display)
Gauges
See above All segments below applicable level come
2 Air flow
drawing on (4-step display)
The display indicates which is currently tak-
Circulation of When circulating Liquid
ing place – internal air circulation or exter- Black
internal air and internal air and crystal
3 nal air introduction – responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air condi-
Turns “ON” air conditioner switch, this lamp
4 Air conditioner tioner switch is
lights up.
turned “ON”
Switch block
No. Type Function Operation
It is used for selecting the internal air circulation or external air Internal air circulation
Internal/external air introduction IO
5
changeover switch (The pilot indication on the display unit varies depending on the External air introduc-
given setting.) tion
It turns on or off the cooling and the dehumidifying heating func-
6 Air conditioner switch OFF i o ON
tion.
This switch turns on or off the main power of the air conditioner.
ON: Display unit indicates the setting being specified when
7 Main power switch OFF i o ON
power was turned “OFF”.
OFF: Turns off the display unit and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO i o HI
(Adjusted in 4 steps [LO, M1, M2, HI])
Low temperature
Temperature adjusting It is used to control output air temperature.
9 IO
switch (8-step adjustment)
High temperature
WA470-6, WA480-6 17
SEN01309-02 10 Structure, function and maintenance standard
Display unit
Display Displayed Display Display
No. Display method Remarks
category items range color
Output air
Indicator panel temperature Displays the output air temperature.
(Output air (0 – 99.9°C)
1 Indicator
temperature, If an actuator or sensor fails, 3-digit failure
failure code) [*1]
alphanumeric character (failure code) are
Failure code
displayed.
All segments below applicable level come
Air blasting vol- See above fig-
2 Gauge on
ume ure
(4-step display)
The display indicates which is currently tak-
Circulation of When circulating
ing place-internal air circulation or external
internal air and internal air and
3 air introduction-responding to the operation
introduction of introducing
of the internal/external air changeover
external air external air Liquid
switch. Black
crystal
When air condi-
Turns “ON” air conditioner switch, this lamp
4 Air conditioner tioner switch is
lights up.
turned “ON”
When auto-
Pilot
(Automatic air matic air condi- This lamp lights up as the automatic air
5
conditioner) tioner switch is conditioner switch is turned “ON”.
turned “ON”
When defroster
Spurting from The lamp lights up as the defroster switch is
6 switch is turned
defroster turned “ON”.
“ON”
When FACE or The display switches between FACE spurt-
7 Mode selection FOOT spurting ing and FOOT spurting responding to the
is turned on mode selector switch operation.
*1: For details of the failure code, see Testing and adjusting.
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
Switch block
No. Name Function Operation
It is used for selecting the internal air circulation or external air Internal air circulation
Internal/external air introduction IO
8
changeover switch (The pilot indication on the display unit varies depending on the External air introduc-
given setting.) tion
It turns on or off the cooling and the dehumidifying heating func-
9 Air conditioner switch OFF i o ON
tion.
It turns on or off main power supply of the air conditioner. ON:
10 Main power switch Settings done during “OFF” are indicated on the display unit. OFF i o ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
11 Fan switch LO i o HI
(Adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It is used to control output air temperature.
12 IO
switch (0 – 99.9°C)
High temperature
Automatic air conditioner It turns on or off the cooling and the dehumidifying heating func-
13 OFF i o ON
switch tion.
It switches the spurting out mode between the FACE and FOOT
14 Mode selector switch (The pilot indication on the display unit varies depending on the FACE i o FOOT
given setting.)
15 Defroster switch It turns on or off spurting out from the defroster. OFF i o ON
WA470-6, WA480-6 19
SEN01309-02 10 Structure, function and maintenance standard
Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01309-02
WA470-6, WA480-6 21
SEN01309-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
22
SEN01310-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01310-02 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
q The service mode function is provided for the 11. Model selection function
ease of troubleshooting for the controllers on Enter the information of applicable model.
the network (including the machine monitor
itself). The major functions used in the service 12. Initialize function
mode are as follows. This function is used to set the machine moni-
tor to the state set when the machine is deliv-
1. Electrical system failure history display func- ered.
tion
The electrical system failures of each controller
saved in the machine monitor are displayed.
The information of those failures is also
deleted with this function.
6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
WA470-6, WA480-6 3
SEN01310-02 10 Structure, function and maintenance standard
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
WA470-6, WA480-6 5
SEN01310-02 10 Structure, function and maintenance standard
Machine monitor 1
Speedometer specification
1. Torque converter oil temperature gauge 22. Brake oil temperature caution lamp
2. Torque converter oil temperature caution lamp 23. Cooling fan reverse rotation pilot lamp
3. Engine coolant temperature gauge 24. Maintenance caution lamp
4. Engine coolant temperature caution lamp 25. Battery electrolyte level caution lamp (*1)
5. Speedometer or engine tachometer 26. Battery charge circuit caution lamp
6. Turn signal pilot lamp (Left) 27. Steering oil pressure caution lamp (*2)
7. Head lamp high beam pilot lamp 28. Emergency steering pilot lamp (*2)
8. Turn signal pilot lamp (Right) 29. Meter display pilot lamp
9. Hydraulic oil temperature caution lamp 30. Character display
10. Hydraulic temperature gauge 31. Power mode pilot lamp
11. Fuel level caution lamp 32. Semi automatic digging pilot lamp (*2)
12. Fuel gauge 33. Preheating pilot lamp
13. Centralized warning lamp 34. Auto-greasing pilot lamp (*2)
14. Brake oil pressure caution lamp 35. Joystick pilot lamp (*2)
15. Engine oil pressure caution lamp 36. Directional selector switch actuation pilot lamp
16. Water separator caution lamp (*1) (*2)
17. Engine oil level caution lamp 37. Economy operation pilot lamp
18. Radiator coolant level caution lamp 38. Shift Indicator
19. Transmission oil filter clogging caution lamp 39. Auto shift pilot lamp
(*1) 40. Torque converter lockup pilot lamp (*2)
20. Air cleaner clogging caution lamp (Machines 41. Shift hold pilot lamp
equipped with KOMTRAX) 42. Shift lever position pilot lamp
21. Parking brake pilot lamp
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
1. Torque converter oil temperature gauge 26. Battery charge circuit caution lamp
2. Torque converter oil temperature caution lamp 27. Steering pump oil pressure caution lamp (*2)
3. Engine coolant temperature gauge 28. Emergency steering pilot lamp (*2)
4. Engine coolant temperature caution lamp 29. Meter display pilot lamp
5. Speedometer or engine tachometer 30. Character display
6. Turn signal pilot lamp (Left) 31. Power mode pilot lamp
7. Headlamp high beam pilot lamp 32. Semi auto digging pilot lamp (*2)
8. Turn signal pilot lamp (Right) 33. Preheater pilot lamp
9. Hydraulic oil temperature caution lamp 34. Auto grease pilot lamp (*2)
10. Hydraulic oil temperature gauge 35. Joystick pilot lamp (*2)
11. Fuel level caution lamp 36. Directional selector switch actuation pilot lamp
12. Fuel gauge (*2)
13. Centralized warning lamp 37. Economy operation pilot lamp
14. Brake oil pressure caution lamp 38. Shift indicator
15. Engine oil pressure caution lamp 39. Auto-shift pilot lamp
16. Water separator caution lamp (*1) 40. Torque converter lockup pilot lamp (*2)
17. Engine oil level caution lamp 41. Shift hold pilot lamp
18. Radiator coolant level caution lamp 42. Shift lever position pilot lamp
19. Transmission oil filter clogging caution lamp (*1) 43. ECSS pilot lamp (*1)
20. Air cleaner clogging caution lamp 44. Modulation clutch temperature caution lamp (*1)
(machine equipped with KOMTRAX) 45. Display of bucket loading
21. Parking brake pilot lamp 46. Working object display
22. Brake oil temperature caution lamp 47. Addition mode: Total loading display
23. Cooling fan reverse rotation pilot lamp Reduction mode: Display of level
24. Maintenance caution lamp 48. Addition/reduction mode display
25. Battery electrolyte level caution lamp (*1)
WA470-6, WA480-6 7
SEN01310-02 10 Structure, function and maintenance standard
Q : ON
w : Flashing (1.6 sec., 50% duty)
A : Intermittent (Period: 240 msec., “ON”: 80 msec., “OFF”: 160 msec.)
E : As per separate setting condition
Priority of sounding of buzzer: Continual (w) > Intermittent (A) > Cancellation of operation > Check of accep-
tance of operation.
Display color
Central warning lamp
Display of message
Individual display
Individual display
Speedometer
Alarm buzzer
Alarm buzzer
Category No. Device Operating condition Remarks
Detection
spec. (SPM)
Reset
Load meter
spec. (LDM)
Red
warning 13 Central warning LED play.
lamp
For other than above, see
“Operating condition, central — — — — — —
warning lamp” of other items.
Max.
4 temperature When abnormality is
Caution — — — CA144 — — — CA144 When the sensor is discon-
lamps: LED detected (high temperature) nected or hot short-circuited:
Min.
When abnormality is
— — — CA145 — — — CA145
detected (low temperature)
Engine speed When engine speed display (Selectable with the machine
— — — — — —
Gauges and (SPM) is selected monitor setting)
Pointer:
meters —
Travel speed Movement When travel speed display is
— — — — — — Displays “0” when error is
(SPM) selected made in communication.
— — — — — —
(LDM) LCD (0 – 99)
(Central 2 of 4 digits are
used)
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
Display color
Central warning lamp
Display of message
Individual display
Individual display
Speedometer
Alarm buzzer
Alarm buzzer
Category No. Device Operating condition Remarks
Detection
spec. (SPM)
Reset
Load meter
spec. (LDM)
Red
Max
10 temperature When abnormality is
Caution When the sensor is discon-
lamps: LED detected 20 5 — — — DGH2KX — — — DGH2KX nected or hot short-circuited:
(out of input signal range) Min
Gauges and
meters Other than below — — — — — — Max: 10 z
Min: 85 z
Pointer:
Movement
11 When the sensor is grounded:
Red
Fuel level
12 Min. 80 z 10 1 — Q — — Q — Full
Caution
When the sensor is discon-
lamps: LED
nected or hot short-circuited:
Empty
Black
Character
30 LCD items according to the machine
display Converts travel speed pulse
Odometer — — — — — — condition and switch operation.
into travel distance
x 100 r/min
Green
When engine speed display
Engine speed 0 0 — Q — — Q — (Selectable with the machine
is selected
monitor setting)
Unit 29 LED
km/h or MPH
Green
When travel speed display is
Travel speed 0 0 — Q — — Q — (Selectable with the machine
selected
monitor setting)
Black
Actual gear 9-segment Left side: F, N, R
38 — — — — — — If error is made in communica-
speed LCD Right side: Gear speed
tion, condition is held until start-
ing switch is turned “OFF”.
Green
39 Auto shift LED tion, condition is held until start-
Other than above — — — — — — ing switch is turned “OFF”.
Green
Torque con-
40 LED tion, condition is held until start-
verter lockup Other than above — — — — — — ing switch is turned “OFF”.
When F is selected
Green
Directional
lever posi- N LED When N is selected 0 0 — Q — — Q —
tion
When R is selected
Green
WA470-6, WA480-6 9
SEN01310-02 10 Structure, function and maintenance standard
Display color
Central warning lamp
Display of message
Individual display
Individual display
Speedometer
Alarm buzzer
Alarm buzzer
Category No. Device Operating condition Remarks
Detection
spec. (SPM)
Reset
Load meter
spec. (LDM)
Green
6 Hazard lamp operates when
Turn signal LED hazard lamp switch signal is 0 0 — Q — — Q —
8 starting switch is turned “OFF”
input
Blue
High beam of high beam
7 LED 0 0 — Q — — Q —
head lamp (When head lamp and dim-
mer switch are turned “ON”)
Red
starting engine (No detection
14 LED
sure time)
Red
15 LED (CLOSED)
sure
Low oil pressure (OPEN) w Q Q B@BAZG w Q Q B@BAZG
18 LED (CLOSED)
ant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK
20 LED
clogging Clogging (OPEN) 2 1 — — — — Q — AA1ANX
Operation (OPEN) — Q — — Q —
Released (CLOSED) — — — — — —
Red
Temperature rise (1 or 2)
1. Oil temperature: Min.
130°C To be released if the oil temper-
Brake oil tem- 5 5 w Q Q B@C7NS w Q Q B@C7NS
Red
When abnormality is
— — — DGR2KA — — — DGR2KA
detected (disconnection)
When abnormality is
detected (out of input signal — — — DGR2KX — — — DGR2KX
range)
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
Display color
Central warning lamp
Display of message
Individual display
Individual display
Speedometer
Alarm buzzer
Alarm buzzer
Category No. Device Operating condition Remarks
Detection
spec. (SPM)
Reset
Load meter
spec. (LDM)
Red
24 LED 30 hours or less before main- played on the character dis-
monitor — Q — E — Q — E
tenance or maintenance time play.
Red
26 LED
circuit <Voltage hysteresis>
When abnormality is Abnormal o Normal judge-
detected
3 1 w Q Q AB00L6 — — — ment: Min. 12 V
(Unmatched engine condi- Normal o Abnormal judgement
tion and the signal) Max. 5 V
Normal (OPEN) 1 1 — — — — — — The emergency steering func-
tion can be enabled only when
Remarks
Steering oil “ADD” is selected for “13:
Red
27 LED Steering oil pressure is low
pressure (CLOSED) and engine speed 3 1 — — w Q Q DDS5L6 EMERG S/T” item using the
is above 500 rpm optional device selecting func-
tion of the machine monitor.
Green
Emergency “ADD” is selected for “13:
28 LED Operation (for less than 1
steering 1 1 — Q — — Q — EMERG S/T” item using the
min) (OPEN)
optional device selecting func-
Stop (CLOSED) — — — — — — tion of the machine monitor.
Green
“P-mode”
31 Power mode LED
Power mode selector switch
— — — — — —
“E-mode”
Green
Semiautomatic Not to be displayed when error
32 LED
digging Semi auto digging switch is made in communication
0 0 — Q — — Q —
“SOFT” or “HARD”
Not in operation — — — — — —
Operation 1 1 — Q — — Q —
Green
w w
Abnormal 3 1 — — — —
2 Hz 2 Hz
Economy mode
37 LED
of operation Economy mode operation 0 0 — Q — — Q —
5
Display of load meter E E E E E E E E
45
Black
WA470-6, WA480-6 11
SEN01310-02 10 Structure, function and maintenance standard
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
WA470-6, WA480-6 13
SEN01310-02 10 Structure, function and maintenance standard
Troubleshooting function
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
*1: When an ID entered from the “ID entry” screen is once approved, display changes directly to the “Select
function” screen without displaying the “ID entry” screen until the starting switch is turned “OFF”.
*2: These items are special to the load meter specification.
WA470-6, WA480-6 15
SEN01310-02 10 Structure, function and maintenance standard
*1: Clock will be displayed only when the load meter is installed.
a When trying to display travel speed on the character display by “MPH”, display is disabled unless the
setting is made to “Non-SI unit specification” in the “Factory mode” of the machine monitor.
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
Example of a failure code screen (Simultaneously occurring errors: D191KA, B@BCZK, CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the “>” switch in the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
WA470-6, WA480-6 17
SEN01310-02 10 Structure, function and maintenance standard
*1: These menus are displayed when “ADD” is selected for “10: RPM/SPEED” item using the Optional
device selecting function of the machine monitor.
*2: These menus are displayed when “ADD” is selected for “9: RPM OPT” item using the Optional device
selecting function of the machine monitor.
*3: These menus are displayed when “ADD” is selected for “11: LOAD METER” item using the Optional
device selecting function of the machine monitor.
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
WA470-6, WA480-6 19
SEN01310-02 10 Structure, function and maintenance standard
a Pressing “<” or “>” switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing “U” switch on the target menu screen. The screen changes to the detailed screen of the same
menu.
a Pressing “t” switch on the menu screen returns the screen to the 1st layer of the operator mode.
Electrical system failure history display func- Mechanical system failure history display func-
tion (ELECTRIC FAULT) tion (MACHINE FAULT)
a “* *” field displays total number of the failure a “* *” field displays total number of the failure
history currently recorded. (Max. 20 histories to history currently recorded. (Max. 20 histories to
be stored) be stored)
q The history is used to check on the electrical
system failures of each controller saved in the q The history is used to check on the mechanical
machine monitor. After repairing the failure system failures of each controller saved in the
content and verifying normal function, the fail- machine monitor.
ure history may be erased. a For the operating procedure of this function,
a For the operating procedure of this function, see “Special functions of machine monitor
see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
(EMMS)” in Testing and adjusting.
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
q The function is used to check on the input/out- q Before restarting engine after a long-term stor-
put signals, etc. each controller on the network ing of the machine, this function is used to
recognizes. lubricate the engine internally.
a For the operating procedure of this function, a For the operating procedure of this function,
see “Special functions of machine monitor see “Special functions of machine monitor
(EMMS)” in Testing and adjusting. (EMMS)” in Testing and adjusting.
q This function is used for the purpose of speci- q This function is used for correcting and adjust-
fying cylinder having defective combustion by ing the installation errors and manufacturing
stopping fuel injection to each cylinder from the dispersion of the sensors, solenoid valves, etc.
fuel injector. Function for changing control characteristics is
a For the operating procedure of this function, provided on user request.
see “Special functions of machine monitor These functions are also used when sensors,
(EMMS)” in Testing and adjusting. valves and controllers are replaced or added.
a For the operating procedure of this function,
see “Special functions of machine monitor
(EMMS)” in Testing and adjusting.
WA470-6, WA480-6 21
SEN01310-02 10 Structure, function and maintenance standard
q This function is used for changing the filter and q This function is used for verifying the installed
oil replacement timing and making ON/OFF state of optional devices or when changing
selection of this function. their setting.
a For the operating procedure of this function, This function is also used for installing or
see “Special functions of machine monitor removing optional devices.
(EMMS)” in Testing and adjusting. a For the operating procedure of this function,
see “Special functions of machine monitor
(EMMS)” in Testing and adjusting.
q This function is used for displaying fuel con- q This function is used for displaying or entering
sumption per operating hour. the serial number of machine.
a For the operating procedure of this function, Serial number of the set machine is used for
see “Special functions of machine monitor controlling the machine.
(EMMS)” in Testing and adjusting. a For the operating procedure of this function,
see “Special functions of machine monitor
(EMMS)” in Testing and adjusting.
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
WA470-6, WA480-6 23
SEN01310-02 10 Structure, function and maintenance standard
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
WA470-6, WA480-6 25
SEN01310-02 10 Structure, function and maintenance standard
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
3. Reduction/addition mode
q When addition mode is selected, “TOTAL q When reduction mode is selected, “REMAIN-
LOADED” is displayed at the display of addi- ING TARGET” is displayed at the display of
tion mode (1), which indicates the value reduction mode (1), which indicates the value
obtained by adding the value at the display of obtained by reducing the value at the display of
calculated bucket-loaded volume (3) to the calculated bucket-loaded volume (3) from the
value at the total loaded volume (2). value specified at the display of total loaded
q Weight calculation can be displayed by cumu- volume (2).
lating up to any 5 working objects indepen- q Weight calculation can be displayed by cumu-
dently. lating up to any 5 working objects indepen-
Working objects can be selected from types A dently.
to E at the working object display (4) in mode Working objects can be selected from types A
selection. to E at the working object display (4) in mode
q The display of total loaded volume (2) indi- selection.
cates up to 99,999 t unless data is cleared by
the load meter subtotal switch. a For the display and calculation method when
The display indicates a value to one decimal the value at the display of bucket-loaded vol-
place (in 100 kg) in the case of max. 9,999.9 t. ume (3) exceeds the value at the display of
When it exceeds 10,000 t, the decimal point remaining volume (2), see Operation and
display disappears and switches to the display Maintenance Manual “Handling the load
in 1 t. meter”.
a For details of the display of remaining volume,
a For details of the display of total loaded vol- see “Display of total loaded volume and dis-
ume, see “Display of total loaded volume and play of remaining volume”.
display of remaining volume”.
WA470-6, WA480-6 27
SEN01310-02 10 Structure, function and maintenance standard
Display of total loaded volume and display of Load meter cancel switch
remaining volume
Display of
Actual total loaded
total loaded Remarks
weight (t)
volume
– –999.5 –999.9 Display of decimal point
Display of decimal point
–999.4 – –0.1 –***.* (the second decimal
place is rounded off.)
Display of decimal point
0 – 9,999.4 ****.* (the second decimal
place is rounded off.)
Display of integer
9,999.5 – 99,999.4 ***** (the second decimal
place is rounded off.)
q When the switch (1) is pressed during the hold-
99,999.5 – 99,999 Display of integer
ing time of calculated weight (15 seconds after
Unit of calculated weight completion of calculation), the value at the dis-
q Calculated weight values are all displayed in SI play of bucket-loaded volume is canceled, and
(metric ton). the calculated weight is abandoned.
If “MPH” has been selected for speed display In this case, the display of total loaded volume
in monitor setting, however, it can be switched (display of remaining volume) newly added
to short ton (US ton) in service mode optional (reduced) is also canceled, and the previous
setting. display value is returned.
If you switch it to short ton, weight display is
also output in short ton (US ton) on the printer. Load meter subtotal switch
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
WA470-6, WA480-6 29
SEN01310-02 10 Structure, function and maintenance standard
30 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
The output format of load meter can be selected from 3 types (A, B, C) of output mode.
The output format of each mode is as follows.
a For selection of output mode and output method, see Operation and Maintenance Manual “Han-
dling the load meter”.
A-mode B-mode C-mode
(Total printer output) (Subtotal printer output) (Operation record printer output)
• Model, serial number • Model, serial number • Model, serial number
• Date and time of printing • Date and time of printing • Date and time of starting record, service
• Subtotal loading data • Loading data meter
(Type/number of loading/loaded volume) (Loaded volume) • Date and time of ending record (printing),
• Total loading data • Subtotal loading data service meter
(Total number of loading/Total loaded vol- (Type/number of loading/loaded volume) • Subtotal loading data
ume) • Total loading data (Type/number of loading/loaded volume)
(Total number of loading/Total loaded vol- • Total loading data
ume) (Total number of loading/Total loaded vol-
ume)
• Maintenance time
(Maintenance item/remaining time)
WA470-6, WA480-6 31
SEN01310-02 10 Structure, function and maintenance standard
1) No load calibration
q This function cancels the individual differ-
ence of weight inherent to the machine,
a For the calibration execution method, see
e.g. the weight of working equipment. It
“Testing and adjusting: Testing and adjust-
makes compensation (B) by offsetting the
ing the load meter”.
error between the actual weight and the
reference value (A) as shown below.
7. Calculation stop
The calculation function of the load meter is
stopped.
During the calculation stop, the display of load
meter disappears, and speed display or engine
speed display appears. No data is added to the
total data in this mode.
To restart calculation, select the addition mode
or reduction mode.
a For the calculation stop method, see
“Operation and Maintenance Manual:
Handling the load meter”.
32 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
AMP070-20P [CN-L51]
Pin No. Specification I/O Group Form of use Signal name Remarks
1 (NC) — — — —
Power supply
2 Power supply of small lamp I — —
(+24 V)
Power supply
3 Power supply of small lamp I — —
(+24 V)
Constant power
4 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Constant power
5 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Power supply
6 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
Power supply
7 SW power supply (+24 V) I — SW power supply (+24 V)
(+24 V)
8 (NC) — — — —
D_OUT_3
11 O A D/O sink —
(+24 V, sink 200 mA)
D_OUT_2
12 O A D/O sink —
(+24 V, sink 200 mA)
D_OUT_1
13 O A D/O sink —
(+24 V, sink 200 mA)
D_OUT_0
14 O A D/O sink Alarm buzzer 1 (Machine monitor)
(+24 V, sink 200 mA)
Sensor power supply output Sensor power
15 O — —
(+24 V) supply
Sensor power supply output Sensor power Lift arm pressure, angle sensor
16 O — For load meter
(+5 V) supply power supply
WA470-6, WA480-6 33
SEN01310-02 10 Structure, function and maintenance standard
AMP070-18P(1) [CN-L52]
Pin No. Specification I/O Group Form of use Signal name Remarks
D_IN_0
1 I B D/I (+24 V) Head lamp
(24 V, 5 mA)
D_IN_2
2 I B D/I (+24 V) Starting switch C signal
(24 V, 5 mA)
D_IN_4
3 I B D/I (+24 V) Auto grease A If equipped
(24 V, 5 mA)
D_IN_6
4 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_8
5 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_10
6 I B D/I (+24 V) A/B switch For load meter
(24 V, 5 mA)
D_IN_12
7 I C D/I (+24 V) Turn signal lamp, right
(NSW24 V, 5 mA)
D_IN_14
8 I C D/I (+24 V) U switch
(NSW24 V, 5 mA)
D_IN_1
10 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_3
11 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_5
12 I B D/I (+24 V) Auto grease B If equipped
(24 V, 5 mA)
D_IN_7
13 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_9
14 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_11
15 I B D/I (+24 V) +/– switch For load meter
(24 V, 5 mA)
D_IN_13
16 I C D/I (+24 V) Turn signal lamp, left
(NSW24 V, 5 mA)
D_IN_15
17 I C D/I (+24 V) t switch
(NSW24 V, 5 mA)
A_IN_0
18 I H A/I Alternator R signal
(0 – 30 V)
AMP070-12P(1) [CN-L53]
Pin No. Specification I/O Group Form of use Signal name Remarks
D_IN_16
1 I D D/I (GND) Brake oil pressure (Front)
(24 V/GND, 5 mA)
D_IN_18
2 I D D/I (GND) —
(24 V/GND, 5 mA)
D_IN_20
3 I D D/I (GND) Clogging of air cleaner
(24 V/GND, 5 mA)
D_IN_22
4 I D D/I (GND) —
(24 V/GND, 5 mA)
D_IN_24
5 I E D/I (GND) —
(24 V/GND, 5 mA)
D_IN_17
7 I D D/I (GND) Brake oil pressure (Rear)
(24 V/GND, 5 mA)
D_IN_19
8 I D D/I (GND) —
(24 V/GND, 5 mA)
D_IN_21
9 I D D/I (GND) —
(24 V/GND, 5 mA)
D_IN_23
10 I D D/I (GND) P switch For load meter
(24 V/GND, 5 mA)
D_IN_25
11 I E D/I (GND) —
(24 V/GND, 5 mA)
A_IN_1
12 I H A/I Small lamp switch
(0 – 30 V)
34 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
AMP070-18P(2) [CN-L54]
Pin No. Specification I/O Group Form of use Signal name Remarks
D_IN_26
1 I E D/I (GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28
2 I E D/I (GND) —
(24 V/GND, 5 mA)
D_IN_30
3 I E D/I (GND) Normal emergency steering
(24 V/GND, 5 mA)
D_IN_32
4 I F D/I (GND) Subtotal switch For load meter
(24 V/GND, 5 mA)
D_IN_34
5 I F D/I (GND) Dimmer switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/I (GND) Service function 2 For load meter
(24 V/GND, 5 mA)
D_IN_38
7 I G D/I (GND) < switch
(24 V/GND, 5 mA)
P_IN_0
8 I M P/I —
(0.5 Vp-p)
D_IN_27
10 I E D/I (GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/I (GND) Engine oil level
(24 V/GND, 5 mA)
12 (NC) — — — —
D_IN_33
13 I F D/I (GND) Cancel switch For load meter
(24 V/GND, 5 mA)
D_IN_35
14 I F D/I (GND) —
(24 V/GND, 5 mA)
D_IN_37
15 I G D/I (GND) > switch
(24 V/GND, 5 mA)
D_IN_39
16 I G D/I (GND) Operation of emergency steering
(24 V/GND, 5 mA)
P_IN_1
17 I M P/I —
(0.5 Vp-p)
18 (NC) — — — —
AMP070-12P(2) [CN-L55]
Pin No. Specification I/O Group Form of use Signal name Remarks
A_IN_2
1 I J A/I Fuel level sensor
(High-resistance input)
A_IN_4 Torque converter oil temperature sen-
2 I J A/I
(High-resistance input) sor
A_IN_6
3 I K A/I —
(Low-resistance input)
A_IN_8
4 I L A/I Lift arm pressure sensor (Head) For load meter
(0 – 5 V)
A_IN_10
5 — — — Battery electrolyte level If equipped
(0 – 14 V)
A_IN_3
7 I J A/I Hydraulic oil temperature sensor
(High-resistance input)
A_IN_5
8 I J A/I Brake oil temperature sensor
(High-resistance input)
A_IN_7
9 I L A/I Lift arm pressure sensor (Bottom) For load meter
(0 – 5 V)
A_IN_9
10 I L A/I Lift arm angle sensor For load meter
(0 – 5 V)
A_IN_11
12 — — — —
(0 – 14 V)
WA470-6, WA480-6 35
SEN01310-02 10 Structure, function and maintenance standard
AMP070-12P(3) [CN-L56]
Pin No. Specification I/O Group Form of use Signal name Remarks
4 S_NET(–) O N S-NET —
5 S_NET(–) O N S-NET —
7 GND O — GND —
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
AMP070-14P [CN-L57]
Pin No. Specification I/O Group Form of use Signal name Remarks
1 (NC) — — — —
2 RS232C_1_RTS I/O Q — —
4 (NC) — — — —
5 (NC) — — — —
7 (NC) — — — —
8 RS232C_1_CTS I/O Q — —
10 RS232C_1_SG O Q — —
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
14 (NC) — — — —
36 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01310-02
AMP040-8P [CN-L58]
Pin No. Specification I/O Group Form of use Signal name Remarks
Do not connect wiring
1 RS232C_0_TXD O S — —
harness on machine
Do not connect wiring
2 FLASH_SW I S — —
harness on machine
Do not connect wiring
3 RS232C_0_TXD O S — —
harness on machine
Do not connect wiring
4 (NC) — — — —
harness on machine
Do not connect wiring
5 RS232C_0_RXD I S — —
harness on machine
Do not connect wiring
6 (NC) — — — —
harness on machine
Do not connect wiring
7 RS232C_0_RXD I S — —
harness on machine
Do not connect wiring
8 GND O — — —
harness on machine
WA470-6, WA480-6 37
SEN01310-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
38
SEN01311-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01311-02 10 Structure, function and maintenance standard
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 automati-
cally.
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 con-
troller, 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 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
q In the auto shift, the transmission controller selects either shifting up or down based on the “Auto-shift
points table” stored on it after referencing the directional lever position, gear shift lever position, travel
speed, accelerator pedal opening ratio and engine speed.
WA470-6, WA480-6 3
SEN01311-02 10 Structure, function and maintenance standard
WA470-6
Unit: rpm
Engine mode and shift switch
Power mode Economy mode
Shift switch H Shift switch L Shift switch H Shift switch L
Gear shifting
F1oF2 369 – 406 340 – 369 369 – 406 340 – 369
operation
F2oF3 665 – 812 259 – 627 665 – 812 259 – 627
F2oF3
731 – 827 591 – 650 731 – 827 591 – 650
when hunting is prevented
F3oF3 (lockup) 988 – 1,182 775 – 1,034 1,016 – 1,145 775 – 1,034
F3oF2 (lockup)
1,433 1,433 1,233 1,233
when hunting is prevented
F3oF4 1,108 – 1,403 627 – 1,145 1,108 – 1,403 627 – 1,145
F4oF4 (lockup) 1,533 – 1,920 1,551 1,533 – 1,920 1,551
F4 (lockup) oF4 1,458 – 1,847 1,477 1,458 – 1,847 1,477
F4oF3 960 – 1,256 553 – 997 960 – 1,256 553 – 997
F3 (lockup) oF3 913 – 1,108 701 – 960 941 – 1,071 701 – 960
F3oF2 443 – 739 222 – 553 443 – 739 222 – 553
F3oF2
443 – 672 222 – 332 443 – 672 222 – 332
when hunting is prevented
a The output shaft speed of 1 rpm is equivalent to the travel speed of 0.0125 km/h when 23.5-25 tires are
installed.
a The output shaft speed of 1 rpm is equivalent to the travel speed of 0.0135 km/h when 26.5-25 tires are
installed.
WA480-6
Unit: rpm
Engine mode and shift switch
Power mode Economy mode
Shift switch H Shift switch L Shift switch H Shift switch L
Gear shifting
F1oF2 369 – 406 340 – 369 369 – 406 340 – 369
operation
F2oF3 665 – 812 259 – 655 665 – 812 259 – 655
F2oF3
731 – 827 591 – 687 731 – 827 591 – 687
when hunting is prevented
F3oF3 (lockup) 988 – 1,182 775 – 1,034 1,016 – 1,145 775 – 1,034
F3oF2 (lockup)
1,433 1,433 1,233 1,233
when hunting is prevented
F3oF4 1,108 – 1,440 627 – 1,182 1,108 – 1,440 627 – 1,182
F4oF4 (lockup) 1,533 – 1,920 1,551 1,533 – 1,920 1,551
F4 (lockup) oF4 1,458 – 1,847 1,477 1,458 – 1,847 1,477
F4oF3 960 – 1,256 591 – 1,034 960 – 1,256 591 – 1,034
F3 (lockup) oF3 913 – 1,108 701 – 960 941 – 1,071 701 – 960
F3oF2 443 – 739 222 – 591 443 – 739 222 – 591
F3oF2
443 – 672 222 – 369 443 – 672 222 – 369
when hunting is prevented
a The output shaft speed of 1 rpm is equivalent to the travel speed of 0.0135 km/h when 26.5-25 tires are
installed.
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Kickdown function
1. In manual-shift mode
When the directional lever is set to “F (Forward)” and the gear shift lever to “2nd”, pressing the kickdown
switch changes the gear speed to 1st.
Operation of the kickdown switch is ignored if the directional lever is set to a position other than “F (For-
ward)” or if the gear shift lever is set to a position other than the “2nd” position.
The kickdown function is reset if the directional lever is operated after the actual gear speed has been
changed to “1st” or the gear shift lever is set to any position other than “2nd”. After the function is reset,
the gear speed is changed to the one being selected from the gear speed lever.
2. In auto-shift mode
The kickdown function is enabled when the directional lever is set to a position other than “N (Neutral)”
and the gear shift lever is set to a position other than the “1st” position.
The kickdown switch allows changing the gear speed as shown in the following table.
The kickdown function is reset if the directional lever is operated after the actual gear speed is changed
or the no-shift time for hunting prevention elapses. After the reset, the auto shift based on “Auto-shift
points table” is turned on.
*1: When the lockup function was reset from the kickdown switch, following operations alone turn
it on again.
q Torque converter lockup switch is turned “OFF” once and then turned “ON” again.
q Current travel speed is increased to or beyond a specific level. Here the specific level denotes
the speed that starts activating the lockup corresponding to the “Auto-shift points table”
WA470-6, WA480-6 5
SEN01311-02 10 Structure, function and maintenance standard
*1: When the gear shift lever is set to “4th” in the auto-shift mode, the lockup function is not activated at 3rd
speed.
The lockup function is turned on at 3rd speed if the gear shift lever is set to “3rd”.
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 7
SEN01311-02 10 Structure, function and maintenance standard
1. In manual-shift mode
Range X:Travel direction is changed. (Ordinary range)
Range Y: Travel direction is changed and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds.
2. In auto-shift mode
Range X:Travel direction is changed and transmission is set to 2nd gear speed. (Ordinary range)
Range Y: Travel direction is changed, transmission is set to 2nd gear speed and alarm buzzer sounds.
Range Z: Travel direction is changed and alarm buzzer sounds. Gear speed is switched to 3rd or 4th
depending on the given travel speed. If the travel speed continues to slow down, gear speed is
shifted down to 2nd gear speed.
a Shifting up and down as well as kickdown operation is not accepted for 2 seconds succeeding to opera-
tion of the directional selector switch. When shifting up or down is done from the gear shift lever, wait for
2 seconds before starting gear shifting.
In the auto-shift mode, it is prohibited to turn on shifting up until the speed is once decelerated to 2nd.
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 9
SEN01311-02 10 Structure, function and maintenance standard
Function of neutralizer
q When the parking brake switch is turned “ON”, this function holds the transmission at neutral position,
independent of the directional lever and gear shift lever positions, in order to prevent dragging of the
parking brake.
q The safety mechanism employed on the parking brake circuit maintains the parking brake operative
when the currently turned “OFF” starting switch is turned “ON”. Thus, when the starting switch is turned
“ON”, the transmission is always set to the neutral independent of the directional lever and gear shift
lever positions.
q The economy operation pilot lamp can be constantly turned off by selecting “NO ADD” for “19. ECO
LAMP” item using the optional device selecting function of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Engine controller
m. CAN signal
n. Engine speed signal
o. Coolant temperature signal
WA470-6, WA480-6 11
SEN01311-02 10 Structure, function and maintenance standard
Fan control
q Employment of the hydraulically driven cooling fan as well as controlling its speed through control of the
hydraulic pump swash plate allows reducing the horsepower loss and noises in low temperature envi-
ronment.
q Engine speed and coolant temperature received by the engine controller and hydraulic oil temperature
and torque converter oil temperature received by the machine monitor are sent to the transmission con-
troller via the network.
q Based on the received information, the transmission controller sends the signal current to the swash
plate angle control EPC valve on the cooling fan pump, so that the valve may control the swash plate
angle in order to set the fan speed to a level suitable for the given temperature level and the engine
speed.
*1: The target fan speed is determined based on the coolant temperature, hydraulic oil temperature or
torque converter oil temperature data, whichever is higher.
*2: Within this range, the fan speed is set according to the coolant temperature, hydraulic oil temperature or
torque converter oil temperature.
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 13
SEN01311-02 10 Structure, function and maintenance standard
The fan rotation is switched from “forward” to “reverse” as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set “MANUAL”.
Engine speed over 500 rpm below 1,200 rpm.
Condition 2
[In order to prevent generation of peak pressure at switching of the rotation direction.]
Coolant temperature is below 90°C.
Condition 3
[In order to prevent overheat.]
Hydraulic oil temperature is below 90°C.
Condition 4
[In order to prevent overheat.]
Torque converter oil temperature is below 100°C.
Condition 5
[In order to prevent overheat.]
30 seconds have passed after the engine is started (after engine speed reached 500 rpm or above).
Condition 6
[In order to secure enough oil to be fed to the brake accumulator.]
The fan rotation is switched from “reverse” to “forward” as any of the following conditions is met.
While the fan reverse rotation was taking place, the fan reverse rotation switch was set to MANUAL
Condition 1
again and the engine speed went below 1,200 rpm.
Condition 2 The engine speed went below 1,200 rpm after 10 minutes from start of the fan reverse rotation.
Condition 3 Engine has stopped.
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
The fan rotation is switched from “forward” to “reverse” as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set “AUTO”.
Coolant temperature is below 90°C.
Condition 2
[In order to prevent overheat.]
Hydraulic oil temperature over 50°C and below 90°C.
Condition 3
[90°C of the upper limit is set in order to prevent overheat.]
Torque converter oil temperature is below 100°C.
Condition 4
[In order to prevent overheat.]
30 seconds have passed after the engine is started (after engine speed reached 500 rpm or above).
Condition 5
[In order to secure enough oil to be fed to the brake accumulator.]
Condition 6 The fan rotation direction switching cycle has elapsed.
The fan rotation is switched from “reverse” to “forward” as any of the following conditions is met.
While the fan reverse rotation was taking place, the fan reverse rotation switch was set to “AUTO”.
Condition 1
And then the hydraulic oil temperature went to 50°C or above.
After the specified reverse rotation duration has elapsed, the hydraulic oil temperature went to 50°C
Condition 2
or above.
Condition 3 Engine has stopped.
5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
(if equipped)
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items “Automatic fan switching cycle to reverse rotation”
and “Reverse rotation duration” with the adjusting function of the machine monitor.
a For the adjustment procedure, see “Special functions of machine monitor (EMMS)” in Testing and
adjusting.
WA470-6, WA480-6 15
SEN01311-02 10 Structure, function and maintenance standard
In P-mode
Engine speed (rpm) 700 710 770 780 790
EPC valve command
800 500 330 200 0
current (mA)
In E-mode
Engine speed (rpm) 700 710 770 780 790
EPC valve command
800 500 330 330 330
current (mA)
Oil pressure – flow rate characteristics when control is done with command current to swash plate angle
control EPC valve of work equipment pump
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
1. Command current to swash plate angle control EPC valve of work equipment pump
This function stores the EPC valve command current value data corresponding to the data of engine
speed, accelerator opening ratio and steering oil pressure. It selects an optimum pump delivery by
choosing the data with the lowest current value.
When the pump delivery increased (when the command current is decreased), this function prevents
sudden operation of the work equipment due to radical increase in flow rate by restraining 120 mA or
greater fluctuations within 0.1 second.
When the pump delivery decreased (when the command current is increased), this function prevents
sudden stop of the work equipment due to radical decrease in flow rate by restraining 60 mA or greater
fluctuations within 0.1 second.
In P-mode
Engine speed (rpm) 900 1,400 1,420 2,200
EPC valve command current (mA) 800 800 200 0
Steering pump oil pressure (MPa {kg/cm2}) 0 {0} 7.9 {80} 19.6 {200} 34.3 {350}
EPC valve command current (mA) 0 200 800 800
In E-mode
Engine speed (rpm) 900 1,400 1,420 2,200
EPC valve command current (mA) 800 800 350 350
Steering pump oil pressure (MPa {kg/cm2}) 0 {0} 7.9 {80} 19.6 {200} 34.3 {350}
EPC valve command current (mA) 350 350 800 800
WA470-6, WA480-6 17
SEN01311-02 10 Structure, function and maintenance standard
1. Contents of control
• As the transmission cut-off operating conditions are met, the transmission is set to the
neutral.
Outline
• As the transmission cut-off reset conditions are met, the transmission is released and the
transmission gear speed is controlled by the modulation.
<Operating conditions at 1st and 2nd gear speeds>
• When the transmission cut-off switch is turned “ON” and the brake pilot oil pressure
Transmission became larger than the cut-off IN pressure.
Operating
cut-off control < Operating conditions at 3rd and 4th gear speeds>
condition
• When the transmission cut-off switch is turned “ON” and the brake pilot oil pressure
became larger than the cut-off IN pressure while the accelerator pedal opening ratio is
maintained at less than 30%.
If any of the following conditions is met, the cut-off is reset.
Reset
• The transmission cut-off switch is turned “OFF”.
condition
• The brake pilot oil pressure is below the cut-off OUT pressure.
Settable
• When the transmission cut-off switch is turned “ON”.
conditions
1) Press the brake pedal up to a desired setting position. (Setting is available without press-
ing the brake pedal)
2) Press the transmission cut-off set switch.
3) This function recognizes the brake pilot pressure at which the switch was pressed.
<When the position is within the settable range>
The brake pilot pressure at which the switch was pressed is temporarily stored.
Setting <When the position is out of the settable range>
method The upper limit or lower limit brake pilot pressure within the settable range is temporarily
Setting of the stored.
transmission This function sends the information to the machine monitor via the network needed by it
cut-off point to sound the set completion buzzer (beep).
4) The pilot lamp contained in the transmission cut-off switch blinks for 2 seconds.
5) Set value is saved. (The setup mode ends)
a The setting is held after the starting switch is turned “OFF”.
1) From step 4) of the setting method (the pilot lamp contained in the transmission cut-off
switch blinks for 2 seconds), press the transmission cut-off set switch again.
2) As the blinking ends, the cut-off point is set as the default brake pilot oil pressure. This
Resetting
function sends the information to the machine monitor via the network needed by it to
method
sound the setting cancel buzzer (beep).
3) Set (Default) value is saved. (The setup mode ends)
a The setting is held after the starting switch is turned “OFF”.
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
2. Outputting conditions
Pilot lamp contained in Buzzer command
Outputting conditions transmission cut-off (Communication Cut-off point
switch output)
Controlled with the
When transmission cut-off switch is “ON“ ON Not issued
value saved last
As the set switch
When transmission cut-off switch is “ON” and
Blinks is pressed, set Brake pilot oil pressure
transmission cut-off set switch is “ON”
(For 2 seconds or completion as the set switch is
For 2.5 seconds or until reset (sensor normal)
until reset) buzzer sounds pressed is saved
Up to setting methods 2) – 5)
(beep)
Not issued No control is turned on
When transmission cut-off switch is “ON” and
Remains turned off (Error buzzer is Saved value is not mod-
transmission cut-off pressure sensor is abnormal
sounded) ified
Not issued Controlled with value
When transmission cut-off switch is “ON” and (Machine monitor saved last
ON
transmission cut-off set switch is abnormal displays an error Saved value is not mod-
indication) ified
As the set switch
When transmission cut-off switch is “ON” and is pressed, set- Default value of brake
transmission cut-off set switch is “ON” ON ting cancel pilot oil pressure is
Reset is done within 2.5 seconds buzzer sounds saved
(beep)
When transmission cut-off switch is “OFF“ OFF Not issued Not controlled
a Shift indicator of machine monitor displays “N” as long as cut-off is continued. (Directional output signal “N”)
a As long as cut-off is continued, gear speed change from the gear shift lever is unavailable. (Gear speed
change when transmission is at neutral is prohibited)
After the cut-off is reset, connecting F or R clutch enables the gear speed change.
a When the cut-off had been turned on after selecting 1st speed with the kickdown switch, 1st speed is
selected after the reset regardless of the shift mode being selected.
a When the lockup is turned on, the cut-off is activated only after the lockup is reset.
Settable range
Note 1: When the specified cut-off point is below 0.49 MPa {5 kg/cm2}, it is assumed
0.49 – 4.41 MPa as 0.49 MPa {5 kg/cm2}.
{5 – 45 kg/cm2} Note 2: When specified cut-off point is 4.41 MPa {45 kg/cm2} or above, it is assumed
as 4.41 MPa {45 kg/cm2}.
The default value is 1.47 MPa{15 kg/cm2}
Hysteresis of 0.20 MPa {2 kg/cm2} is set for the cut-off IN (for neutral) pressure and OUT (reset) pressure.
Example) When the pressure sensor is set at a position where the pressure is 0.98 MPa {10 kg/cm2},
Cut-off IN pressure = 0.98 MPa {10 kg/cm2}
Cut-off OUT pressure = 0.78 MPa {8 kg/cm2}
WA470-6, WA480-6 19
SEN01311-02 10 Structure, function and maintenance standard
ECSS function
(if equipped)
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Operation
q The operating condition of ECSS is as follows.
WA470-6, WA480-6 21
SEN01311-02 10 Structure, function and maintenance standard
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Outline
q This function constantly monitors state of the oil pressure switch of the steering circuit. If the steering oil
pressure goes low and the transmission output shaft speed (travel speed) goes to or above the emer-
gency steering “ON” value shown in the figure, it outputs the emergency steering operation signal to the
emergency steering switch relay to activate the emergency steering.
q The emergency steering switch allows operating the emergency steering motor regardless of the steer-
ing oil pressure or the transmission output shaft speed (travel speed).
a Continuous operation by use of the emergency steering switch shall be no longer than 60 seconds.
a Travel speed when the emergency steering is operated shall be 5 km/h maximum.
Emergency steering
A B
switching point
Output shaft speed [rpm]
140 148
(Reference: Travel speed
(1.9) (2.0)
[km/h])
Setting method
q The emergency steering function can be enabled only when “ADD” is selected for “13: EMERG S/T”
item using the optional device selecting function of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
WA470-6, WA480-6 23
SEN01311-02 10 Structure, function and maintenance standard
Machine monitor
l. CAN signal
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Setting method
q The directional selector switch can be enabled only when “FNR SW” is selected for “14: J/S-FNR SW”
item using the optional device selecting function of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
WA470-6, WA480-6 25
SEN01311-02 10 Structure, function and maintenance standard
q The FNR switch, kickdown switch and hold switch are installed to the head of the multi-function mono
lever (work equipment control lever).
q If the directional selector switch actuation switch is turned “ON”, you can change the travel direction with
the FNR switch at the head of the multi-function mono lever (work equipment control lever) as well as
with the directional lever of the steering column.
q You can shift and hold the gear with the kickdown switch and hold switch at the head of the multi-func-
tion mono lever (work equipment control lever) as well as with the gear shift lever of the steering col-
umn.
Machine monitor
n. CAN signal
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Precedence is
Directional lever All range
N OFF given to Disabled OFF Stopped
operation (F/N/R)
directional lever
Precedence is
FNR switch All range
N ON given to FNR Enabled ON Stopped
operation (F/N/R)
switch
Precedence is Precedence is
Other than N All range
given to directional ON given to Disabled Blinks Sounded
(F/R) (F/N/R)
lever directional lever
Directional lever Precedence is
All range Other than N
operation error OFF given to Disabled Blinks Sounded
(F/N/R) (F/R)
(Operational error) directional lever
Actuation switch Alternate Precedence is
Other than N Other than N
operation error ON/OFF given to Disabled Blinks Sounded
(F/R) (F/R)
(Operational error) operation directional lever
Kickdown function
q For details, see “Gear shift control function of transmission controller”, “Kickdown function”.
Setting method
q The FNR switch can be enabled only when “FNR SW” is selected for “14: J/S-FNR SW” item using the
optional device selecting function of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
WA470-6, WA480-6 27
SEN01311-02 10 Structure, function and maintenance standard
q The directional selector switch, shift-up switch and shift-down switch are installed to the head of the joy-
stick steering lever.
q If the joystick console is tilted forward and the joystick ON/OFF switch is set in the “ON” position, you
can change the travel direction with the directional selector switch at the head of the joystick steering
lever as well as with the directional lever of the steering column.
q If the joystick console is tilted forward and the joystick ON/OFF switch is set in the “ON” position, you
can shift the gear with the shift-up switch and shift-down switch at the head of the joystick steering lever
as well as with the gear shift lever of the steering column.
q While the joystick steering system is used, travel in the 4th gear is prohibited for safety.
a Steering is controlled by the work equipment controller.
Machine monitor
n. CAN signal
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
*1: While the joystick console is tilted back, the joystick steering system is ineffective.
WA470-6, WA480-6 29
SEN01311-02 10 Structure, function and maintenance standard
In accordance
Gear shift All ranges Forward/
MANUAL OFF with gear shift lever Ineffective OFF
operation (1/2/3/4) Reverse
(1st – 4th)
Auto gear shift in
All ranges
L/H (Auto) OFF Reverse accordance with travel Ineffective OFF
(1/2/3/4)
Auto gear shift speed (2nd – 4th)
function Auto gear shift in
All ranges
L/H (Auto) ON Forward accordance with travel Ineffective ON
(1/2/3/4)
speed (2nd – 3rd)
Shift-up and In accordance with
All ranges
shift-down MANUAL ON Forward shift-up and shift-down Effective ON
(1/2/3/4)
switch operation switches (1st – 3rd)
Setting method
q The joystick steering system can be enabled only when “J/S” is selected for “14: J/S-FNR SW” item
using the optional device selecting function of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
30 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 31
SEN01311-02 10 Structure, function and maintenance standard
32 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 33
SEN01311-02 10 Structure, function and maintenance standard
Transmission controller 1
34 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
DEUTSCH-24P [CN-L61]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 Cooling fan automatic reverse rotation switch Input 13 Work equipment pump oil pressure sensor Input
2 Torque converter lockup switch Input 14 NC —
3 Steering pump oil pressure sensor Input 15 NC —
4 Signal GND — 16 Sensor power supply output (+24 V) Output
5 Transmission cut-off set switch Input 17 Steering pressure switch (Low) Input
6 ECSS switch Input 18 Shift mode H Input
7 Cooling fan reverse rotation switch Input 19 Brake pressure sensor Input
8 NC Input 20 Memory reset Input
9 Transmission oil temperature sensor Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power supply (+5 V) Output
11 Transmission cut-off switch Input 23 Steering pressure switch (Hi) Input
12 2-stage low idle switch Input 24 Shift mode L Input
DEUTSCH-40P(1) [CN-L62]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 NC — 21 NC —
2 Kickdown switch Input 22 CAN0-L Input and output
3 ECMV fill switch 4th Input 23 NC —
4 NC — 24 Flash memory write permission signal Input
5 Directional selector switch (J/S FNR SW) R Input 25 Directional selector switch (J/S FNR SW) F Input
6 Neutralizer (parking brake) signal Input 26 Directional lever N Input
7 ECMV fill switch 2nd Input 27 ECMV fill switch R Input
8 NC — 28 Power mode switch Input
9 NC — 29 Pulse GND —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 CAN0-H Input and output
13 ECMV fill switch 3rd Input 33 NC —
14 NC — 34 NC —
15 Directional selector switch (J/S FNR SW) N Input 35 Starting switch C signal Input
16 Directional lever R Input 36 Directional lever F Input
17 ECMV fill switch 1st Input 37 ECMV fill switch F Input
18 NC — 38 Hold switch Input
19 NC — 39 NC —
20 Speed sensor Input 40 NC —
DEUTSCH-40P(2) [CN-L63]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 VB (Controller power) Input 21 GND (Controller GND) —
2 VIS (Solenoid power) Input 22 VIS (Solenoid power) Input
3 SOL_COM (Solenoid common GND) — 23 SOL_COM (Solenoid common GND) —
4 Back-up lamp relay Output 24 Starting switch ACC signal Input
5 ECMV F Output 25 ECMV 1st Output
6 ECMV 2nd Output 26 ECMV 4th Output
7 Emergency steering switch relay Output 27 Work equipment pump EPC Output
8 Pilot lamp contained in transmission cut-off switch Output 28 Cooling fan pump reverse rotation solenoid Output
9 Joystick shift-up switch Input 29 Emergency steering switch Input
10 Gear shift lever 1st Input 30 gear shift lever 3rd Input
11 VB (Controller power) Input 31 GND (Controller GND) —
12 VIS (Solenoid power) Input 32 GND (Controller GND) —
13 SOL_COM (Solenoid common GND) — 33 GND (Controller GND) —
14 Starting switch ACC signal Input 34 NC —
15 ECMV R Output 35 ECMV lockup Output
16 ECMV 3rd Output 36 Cooling fan pump EPC Output
17 ECSS solenoid Output 37 Neutral output Output
18 Power train pump bypass solenoid relay Output 38 NC —
19 Joystick shift-down switch Input 39 Directional selector switch actuation switch Input
20 Gear shift lever 2nd Input 40 Gear shift lever 4th Input
WA470-6, WA480-6 35
SEN01311-02 10 Structure, function and maintenance standard
36 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
Low mode Fine controllability during fine operation is improved and shocks made by sharp steering are reduced.
Setting method
q The joystick steering system can be enabled only when “J/S” is selected for “14: J/S-FNR SW” item
using the optional device selecting function of the machine monitor.
a For the setting procedure, see “Special functions of machine monitor (EMMS)” in Testing and adjusting.
WA470-6, WA480-6 37
SEN01311-02 10 Structure, function and maintenance standard
Troubleshooting function
q The work equipment controller monitors the input and output signals constantly for troubleshooting for
the system.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
38 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 39
SEN01311-02 10 Structure, function and maintenance standard
40 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
WA470-6, WA480-6 41
SEN01311-02 10 Structure, function and maintenance standard
42 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01311-02
DEUTSCH-40P(1) [CN-72]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 NC — 21 NC —
2 NC — 22 CAN0-L Input and output
3 Remote positioner raise/lower set SW (Lower) Input 23 NC —
4 NC — 24 Flash memory write permission signal Input
5 NC — 25 Starting switch C signal Input
6 NC — 26 NC —
7 NC — 27 NC —
8 NC — 28 NC —
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 CAN0-H Input and output
13 Remote positioner raise/lower set SW (Raise) Input 33 NC —
14 NC — 34 NC —
15 NC — 35 Work equipment lock lever lock SW Input
16 NC — 36 NC —
17 NC — 37 NC —
18 NC — 38 NC —
19 NC — 39 NC —
20 NC — 40 NC —
DEUTSCH-40P(2) [CN-73]
Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
1 VB (Controller power) Input 21 GND (Controller GND) —
2 VIS (Solenoid power) Input 22 VIS (Solenoid power) Input
3 SOL_COM (Solenoid common GND) — 23 SOL_COM (Solenoid common GND) —
4 NC — 24 Starting switch ACC signal Input
5 Bucket tilt EPC Output 25 3-spool valve extract EPC Output
6 Lift arm raise EPC Output 26 Joystick cut-off solenoid Output
7 Work equipment EPC cut-off solenoid Output 27 Magnet detent lift arm float Output
8 Remote positioner raise indicator Output 28 Steering right EPC Output
9 NC — 29 NC —
10 Bucket cylinder full stroke proximity SW Input 30 NC —
11 VB (Controller power) Input 31 GND (Controller GND) —
12 VIS (Solenoid power) Input 32 GND (Controller GND) —
13 SOL_COM (Solenoid common GND) — 33 GND (Controller GND) —
14 Starting switch ACC signal Input 34 NC —
15 EPC Output 35 3-spool valve retract EPC Output
16 EPC Output 36 NC —
17 Magnet detent lift arm raise Output 37 Magnet detent bucket tilt Output
18 Remote positioner lower indicator Output 38 Steering left EPC Output
19 NC — 39 NC —
20 Bucket positioner proximity SW Input 40 NC —
WA470-6, WA480-6 43
SEN01311-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
44
SEN01312-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01312-02 10 Structure, function and maintenance standard
2 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
WA470-6, WA480-6 3
SEN01312-02 10 Structure, function and maintenance standard
4 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
Function
WA470-6, WA480-6 5
SEN01312-02 10 Structure, function and maintenance standard
Combination switch 1
Outline
q The directional lever has 3 positions and the gear shift lever has 4 positions. The detent mechanism is
not provided to each switch but installed to the body of the combination switch. Each switch is posi-
tioned with 2 pins and fixed to the body with 3 screws. As a lever is shifted to any position, the switch
connected with the shaft operates to conduct the current only to that circuit.
Function
No. Name Operation
1 Directional lever Selects the travel direction and neutral.
2 gear shift lever Selects a gear speed.
3 gear shift lever stopper Makes the gear shift lever not movable to the 3rd or 4th during work.
4 Turn signal lever Turns the turn signal lamps ON and OFF.
After turning to the right or left, setting the steering wheel back returns the turn
5 Self-cancel
signal lever automatically to the neutral.
6 Lamp switch Turns the headlamp, clearance lamp, tail lamp, and instrument panel lamp ON.
7 Dimmer switch Selects the high or low beam of the headlamp.
Flashes the right and left turn signal lamps, turn signal pilot lamps, and indicator
8 Hazard lamp switch
lamps.
9 Hazard lamp pilot lamp Starts flashing as the hazard lamp switch is turned “ON”.
6 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
Operation
WA470-6, WA480-6 7
SEN01312-02 10 Structure, function and maintenance standard
8 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
Multi-function knob 1
(if equipped)
WA470-6, WA480-6 9
SEN01312-02 10 Structure, function and maintenance standard
10 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
WA470-6, WA480-6 11
SEN01312-02 10 Structure, function and maintenance standard
KOMTRAX system 1
(If equipped)
q KOMTRAX terminal wirelessly transmits various machine information. KOMTRAX operators refer to the
information in their offices and can provide customers with various services accordingly.
12 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
KOMTRAX terminal 1
Model: TC301
q Satellite wave is used.
Outline
q The KOMTRAX terminal can send information q There are the LED lamp and the 7-segment
via wireless communication antenna, acquiring indicator lamp in the display area, and these
various information of the machine from the lamps are used for the testing and the trouble-
network signal in the machine and the input shooting.
signal. Also, the controller incorporates CPU q KOMTRAX terminal can be used only in the
(Central Processing Unit) and provides the countries specified by the communication con-
wireless communication function and the GPS tract.
(Global Positioning System) function.
WA470-6, WA480-6 13
SEN01312-02 10 Structure, function and maintenance standard
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to
3. Slow-blow fuse secure safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the
5. Fuse box 2 directional lever is not in N (Neutral).
6. Starting switch
7. Directional lever 2. The KOMTRAX engine cut-off circuit is
8. Neutral safety relay employed to disable the engine from starting
9. KOMTRAX engine cut-off relay (if equipped) when the KOMTRAX receives an engine cut-
10. Transmission controller neutral safety relay off command issued through external opera-
11. Starting motor safety relay tion.
12. Starting motor (if equipped)
13. Alternator
14. Transmission controller
15. Engine controller
16. Machine monitor
17. KOMTRAX controller (if equipped)
18. Engine controller cut-off relay
19. CAN resistor
14 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
Operation
1. When starting switch is turned “ON”
q As the starting switch is turned “ON”, ter-
minals B and BR of the starting switch are
closed and the current flows from the bat-
tery through the starting switch and bat-
tery relay coil to the ground, thereby
closing the contact of the battery relay. As
a result, the power is supplied to each cir-
cuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.
WA470-6, WA480-6 15
SEN01312-02 10 Structure, function and maintenance standard
Operation
q Setting the starting switch to “OFF” cuts off
ACC signal from the starting switch terminal
ACC to the engine controller.
q Although ACC signal is cut off, the engine con-
troller keeps the engine controller cut-off relay
working to maintain the current flow to the
engine controller until its internal processing is
complete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation. Thus, supply of
voltage from the alternator terminal R is
aborted.
16 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
Preheating circuit 1
1. Battery Outline
2. Battery relay q The automatic preheating system is installed so
3. Slow-blow fuse that the engine will start easily in a cold district.
4. Fuse box 1 q The automatic preheating system is capable of
5. Starting switch cutting the preheating time short as the starting
6. Engine controller switch is set to “ON”. This system is also capa-
7. Machine monitor ble of automatically setting the preheating
8. Electrical intake air heater relay duration referencing temperature of intake air.
9. Electrical intake air heater q Setting the starting switch to “ON” lights the
10. Engine coolant and intake manifold intake air preheater pilot lamp of the machine monitor
temperature sensor and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating dura-
tion referencing the temperature being sent
from the engine coolant sensor and the intake
manifold intake air temperature sensor.
q The pilot lamp remains turned on as long as
preheating is continued. Keep the starting
switch in the “ON” position during this time.
Setting the starting switch to “START” from this
state resets preheating.
Operation
q Set the starting switch to “ON” to start the
engine controller. If, at this point, the engine
coolant temperature or intake manifold intake
air temperature is below the setting, the engine
controller starts up the electrical intake air
heater relay immediately after the starting
switch is turned “ON” to initiate preheating by
the electrical intake air heater.
q The preheating time is set as shown below.
WA470-6, WA480-6 17
SEN01312-02 10 Structure, function and maintenance standard
Function
q Setting the power mode selector switch to “P-
mode” increases the engine output to the max-
imum. And setting the switch to “E-mode”
reduces the working fuel consumption.
q Receiving the switch signal, the transmission
controller selects a gear speed and travel
speed matched to the power mode in the auto-
shift mode.
Operation
q Setting the power mode selector switch to “P-
mode” sends the switch signal to the transmis-
sion controller and CAN signal to the engine
controller, changing the engine torque perfor-
mance curve into “P-mode”. At the same time,
the transmission controller sends the power
mode pilot lamp lighting signal to the machine
monitor using the CAN signal format.
18 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
WA470-6, WA480-6 19
SEN01312-02 10 Structure, function and maintenance standard
20 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
2. When parking brake switch was turned “OFF When low oil pressure occurred on main
(released)” prior to turning “ON” of starting brake (when emergency brake is applied)
switch
WA470-6, WA480-6 21
SEN01312-02 10 Structure, function and maintenance standard
Sensor 1
Speed sensor
1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
q Being set in the output gear of the transmission case, this sensor outputs pulsed voltage sensing the
gear speed.
1. Connector 3. Thermistor
2. Plug
Function
q The torque converter oil temperature sensor is installed on the transmission case (rear). The hydraulic
oil temperature sensor is installed on the return line block of the hydraulic tank. The transmission oil
temperature sensor is installed on the transmission case (front). And the brake oil temperature sensor is
installed on the rear axle. They convert changes in temperature to changes in resistance of the ther-
mistors to output the results in signals.
22 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
1. Plug
2. Sensor
3. Connector
Function
q The work equipment pump oil pressure sensor Output characteristics
is installed on the work equipment control
valve and the steering pump oil pressure sen-
sor is installed on the block of the steering
pump discharge line. They are used for detect-
ing the pump discharge pressure and output it
in variable voltages.
q The lift cylinder head oil pressure sensor is
installed to the lift cylinder head piping and the
lift cylinder bottom oil pressure sensor is
installed to the lift cylinder bottom piping. They
are used for detecting the cylinder pressure
and output it in variable voltage.
WA470-6, WA480-6 23
SEN01312-02 10 Structure, function and maintenance standard
1. Sensor
2. Lead wire
3. Connector
Function
q Being installed on the tube of the front brake Output characteristics
line situated under the floor, this sensor out-
puts the brake operating pressure in variable
voltage.
24 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
q This sensor is installed under the platform situated on the right side of the operator seat. As the coolant
level goes below the specified level, the float is lowered and the switch is turned “OFF”.
WA470-6, WA480-6 25
SEN01312-02 10 Structure, function and maintenance standard
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operat-
ing angle and signal voltage is generated from the source voltage according to the change of the resis-
tance.
26 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
q The air cleaner clogging sensor is installed in the air cleaner outlet. It outputs the signal as the air
cleaner is clogged and the pressure is decreased to the specified level (negative pressure).
WA470-6, WA480-6 27
SEN01312-02 10 Structure, function and maintenance standard
1. Pedal
2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the Output characteristics
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the potentiometer
inside the sensor is output in variable voltage
from No. 2 pin.
28 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part to the left side of
the front arm. And the bucket positioner proximity switch is installed on the bucket cylinder. As long as
the plate is positioned on the detector plane, the switch lights up the operation indication lamp and turns
itself “ON”.
WA470-6, WA480-6 29
SEN01312-02 10 Structure, function and maintenance standard
1. Shaft
2. Housing
3. Bearing
4. Brush
5. Variable resistor
6. Connector
30 WA470-6, WA480-6
10 Structure, function and maintenance standard SEN01312-02
WA470-6, WA480-6 31
SEN01312-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 03-09 (01)
32
SEN01313-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01313-02 20 Standard value table
2 WA470-6, WA480-6
20 Standard value table SEN01313-02
— —
HOLD
• Engine speed: Low idle
LOWER o
• Hydraulic oil temperature: N {kg} Max. 15.7 {1.6} Max. 23.5 {2.4}
FLOAT
Work equipment control lever
HOLD
• Hydraulic oil temperature: mm 50 ± 9 50 ± 18
FLOAT
Within operating range
HOLD o
50 ± 9 50 ± 18
DUMP
Bucket
HOLD o
43 ± 9 (*) 43 ± 18 (*)
TILT
WA470-6, WA480-6 3
SEN01313-02 20 Standard value table
29.4 – 58.6
Pressing effort • Measure at 150 mm from fulcrum of N {kg} —
{3.0 – 6.0}
pedal.
aFor measuring posture, see Fig. A
Neutral (a1) 45 ± 2 —
Pressing at end of this section
deg.
angle • Engine started
Max. (a2) • a2 = a1 – a3 17 ± 2 —
B Max. 4.0 —
• Tire inflation pressure: Specified pres- mm
Clearance of wheel sure
C 2 – 10 —
lock ring
1,800 1,900 1,800 1,900
E-mode
± 50 ± 50 ± 100 ± 100
Torque converter stall
2,020 2,030 2,020 2,030
P-mode
• Coolant temperature: ± 50 ± 50 ± 100 ± 100
Engine Speed
4 WA470-6, WA480-6
20 Standard value table SEN01313-02
MPa
• Hydraulic oil temperature: {kg/cm2}
Within operating range 1.1 – 1.3 0.9 – 1.5
Steering control pressure
• Engine speed: Low idle {11 – 13} {9 – 15}
• Steering wheel: Neutral
• Point where
brake oil pres- 5.9 (+0.5/0) 5.9 (+0.98/–0.5)
Charge cut-in pressure
• Engine speed: sure warning {60 (+5/0)} {60 (+10/–5)}
Accumulator
WA470-6, WA480-6 5
SEN01313-02 20 Standard value table
6 WA470-6, WA480-6
20 Standard value table SEN01313-02
P-mode
± 0.5 ± 0.5 4.9 5.1
1.8 2.1 Max. Max.
E-mode
± 0.3 ± 0.3 2.4 2.8
Forward Sec.
1.6 1.9 Max. Max.
P-mode
Bucket • Hydraulic oil temperature: ± 0.3 ± 0.3 2.1 2.5
full stroke Within operating range 2.6 3.1 Max. Max.
• Engine speed: High idle E-mode
± 0.3 ± 0.3 3.5 4.1
Backward • Apply no load
aFor measuring posture, see P-mode 2.4 2.8 Max. Max.
Figs.H and J at end of this ± 0.3 ± 0.3 3.2 3.7
Moving section 1.6 2.1 Max. Max.
E-mode
bucket ± 0.3 ± 0.3 2.1 2.8
Backward
from level 1.5 1.9 Max. Max.
position P-mode
± 0.3 ± 0.3 2.0 2.5
• Hydraulic oil temperature:
Retraction of lift arm cyl- Within operating range Max. 30 Max. 36
Hydraulic drift
WA470-6, WA480-6 7
SEN01313-02 20 Standard value table
8 WA470-6, WA480-6
20 Standard value table SEN01313-02
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
a Fig. G
WA470-6, WA480-6 9
SEN01313-02 20 Standard value table
a Fig. H
a Fig. J
a Fig. K
10 WA470-6, WA480-6
20 Standard value table SEN01313-02
WA470-6, WA480-6 11
SEN01313-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
12
SEN01589-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01589-02 30 Testing and adjusting
2 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Testing engine oil 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
E
pressure 2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
799-101-5230 Nipple 1 14 × 1.5 mm
3
6215-81-9720 O-ring 1
Pressure gauge: 2.5, 6, 40, 60 MPa
Testing EGR valve 799-101-5002 Hydraulic tester 1
E {25, 60, 400, 600 kg/cm2}
drive pressure
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
Testing intake air
F 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing fuel 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
G
compression 2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
6732-81-3170 Adapter 1 10 × 1.0 mm o R1/8
3
6215-81-9710 O-ring 1
1 6151-51-8490 Spacer 1
2 6206-71-1770 Joint 1
Commercially
3 Hose 1
available
Testing fuel return rate Commercially
H 4 Hose 1
and leakage available
Commercially
5 Measuring cylinder 1
available
Commercially
6 Stopwatch 1
available
Testing directional lever J 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
WA470-6, WA480-6 3
SEN01589-02 30 Testing and adjusting
4 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 5
SEN01589-02 30 Testing and adjusting
6 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 7
SEN01589-02 30 Testing and adjusting
k
1) Referring to “Special function of machine
Put chocks under the tires.
k
monitor”, select the real time monitoring
When measuring, check that there are no function of the service mode.
persons around the machine. 2) Select the two-item simultaneous monitor-
ing (2 ITEMS) and then enter the following
a Measure the engine speed under the following code numbers directly.
condition. a Monitoring items
q Engine coolant temperature: [1] Code No.01001: ENG SPEED
Within operating range (Engine speed)
q Hydraulic oil temperature: [2] Code No.40100: TC OIL TEMP
Within operating range (Torque converter oil temperature)
q Torque converter oil temperature:
Within operating range
8 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 9
SEN01589-02 30 Testing and adjusting
5) Take out the filtering paper and compare it 6) Start the engine and keep it running until
with the attached scale for judgement. the engine coolant temperature rises to
6) Remove the measurement tool after the the operating range.
measurement, and make sure that the 7) Accelerate the engine suddenly or run it at
machine is back to normal condition. high idle and press the accelerator pedal
of smoke meter A2 and collect the
2. Measuring with smoke meter A2 exhaust gas into the filter paper.
1) Insert the probe of smoke meter A2 in the 8) Put the polluted filtering paper on non-pol-
outlet of the muffler (exhaust pipe) and fix luted filtering paper (more than 10 sheets)
it to the exhaust pipe with a clip. in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
10 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Testing exhaust temperature 1 3. Install sensor [1] and connect them to digital
temperature gauge [2].
a Measuring instrument for exhaust temperature a Clamp the wiring harness of the digital
temperature gauge so that it will not touch
Symbol Part No. Part name
a hot part during measurement.
Z 799-101-1502 Digital temperature gauge
WA470-6, WA480-6 11
SEN01589-02 30 Testing and adjusting
6) While pressing the brake pedal, set the 5. Procedure for measuring the maximum
directional lever, joystick steering direc- exhaust temperature
tional switch or right directional switch to Operate the machine actually and measure the
the F (forward) or R (reverse) position. maximum exhaust temperature.
k Keep pressing the brake pedal a Use the PEAK mode of the thermometer
securely. (in which the maximum value can be
7) Press the accelerator pedal gradually to saved).
the high idle. While running the engine at a The exhaust temperature largely depends
high idle, stall the torque converter and on the outside air temperature (intake air
relieve the lift arm cylinder or bucket cylin- temperature of the engine). Accordingly, if
der on the extraction side simultaneously. any abnormal value is obtained, correct it
(full stall) by the following calculation.
a Increase the exhaust temperature to a Corrected value [°C] = Measured value +
about 650°C (the state of (a) in the 2 x (20 – Outside air temperature)
figure).
a Do not keep stalling the torque con- 6. Remove the measurement tool after the mea-
verter for more than 20 seconds. Take surement, and make sure that the machine is
care that the torque converter oil tem- back to normal condition.
perature will not exceed 120°C.
8) As the exhaust temperature reached
about 650°C, release the hydraulic relief
and then decrease the exhaust tempera-
ture by stalling torque converter alone.
(the state of (b) in the figure)
a The exhaust temperature starts low-
ering from the level of the full-stall
operation. Measure the exhaust tem-
perature as it stabilized. (the state of
(c) in the figure)
a If the exhaust temperature rises in
stead of going down, set a higher full
stall temperature than the current one
(650°C).
12 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 13
SEN01589-02 30 Testing and adjusting
14 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Testing compression pressure 1 a Lead a wire under the fuel pipe which
comes out sideways from the injector and
a Measuring instruments for compression pres- pull up the wire to remove injector (do not
sure ply the upper part of the injector to remove
it).
Symbol Part No. Part name
1 795-502-1590 Compression gauge
C 2 795-471-1420 Adapter
3 6217-71-6112 Gasket
WA470-6, WA480-6 15
SEN01589-02 30 Testing and adjusting
6. Disconnect connector EGC3 of engine control- 8) Tighten the clamping bolt of the fuel pip-
ler. ing.
3 Clamping bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
16 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Testing blow-by pressure 1 9. While pressing the brake pedal, set the direc-
tional lever or switch to the F (forward) or R
a Blow-by pressure measurement tools (reverse) position.
Symbol Part No. Part Name k Keep pressing the brake pedal securely.
WA470-6, WA480-6 17
SEN01589-02 30 Testing and adjusting
Testing engine oil pressure 1 4. Start the engine and heighten the coolant tem-
perature to the operating range.
a Engine oil pressure measurement tools
Symbol Part No. Part Name 5. While running the engine at low idle and high
idle, measure the oil pressure.
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
E 2 799-401-2320 Gauge
799-101-5230 Nipple (14 × 1.5 mm)
3
6215-81-9720 O-ring
18 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Testing EGR valve drive pressure1 3. Connect hydraulic tester [1] to the nipple.
a Measuring instruments for EGR valve drive 4. Start the engine and measure the oil pressure
pressure at low idle and high idle.
a When measuring without removing the
Symbol Part No. Part name engine from the machine, measure under
799-101-5002 Hydraulic tester the condition described in the shield
E 1 machine for the machine.
790-261-1204 Digital hydraulic tester
WA470-6, WA480-6 19
SEN01589-02 30 Testing and adjusting
Testing intake air (boost) 5. Run the engine at medium or higher speed to
pressure 1 drain the oil from the hose.
a Insert the connecting parts of the gauge
a Measuring instruments for intake air (boost) and hose about a half and open the self-
pressure seal on the hose side repeatedly, and the
Symbol Part No. Part Name oil will be drained.
a If Pm kit (A) is available, you may drain
F 799-201-2202 Boost gauge kit
the oil by using the oil draining coupling
k
(790-261-1130) in that kit.
When installing and removing the measur-
a If the oil is left in the hose, the gauge does not
ing instruments, take care not to touch a
work. Accordingly, be sure to drain the oil.
hot part of the engine.
a Measure the intake air pressure (boost pres-
6. Turn the transmission cut-off selector switch
sure) under the following condition.
OFF and press the left brake pedal securely.
q Engine coolant temperature:
Within operating range
7. Turn the torque converter lockup switch (if
q Hydraulic oil temperature:
equipped) OFF.
Within operating range
q Torque converter oil temperature:
8. Set the transmission auto shift and manual
Within operating range
shift selector switch in the MANUAL position.
1. Open the engine right side cover.
9. While keeping the directional lever or forward-
reverse switch at the N (Neutral) position, set
2. Remove air boost pressure pickup plug (1)
the gear shift lever or gear shift switch to the
(R1/8).
4th position.
4. Start the engine and increase the coolant tem- 13. Remove the measurement tool after the mea-
perature to the operating range. surement, and make sure that the machine is
back to normal condition.
20 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 21
SEN01589-02 30 Testing and adjusting
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Testing tools for fuel pressure a If the fuel pressure is in the following
range, it is normal.
Symbol Part No. Part name
799-101-5002 Hydraulic tester Engine speed Fuel pressure
1
790-261-1204 Digital hydraulic tester 0.15 – 0.3 MPa
High idle
G 2 799-401-2320 Gauge {1.5 – 3 kg/cm2}
22 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
a Testing tools for fuel return and leak amount 1. Preparation work
1) Remove tube (3) between common rail (1)
Symbol Part No. Part name and return block (2).
1 6151-51-8490 Spacer
2 6206-71-1770 Joint
Commercially
3 Hose
available
H Commercially
4 Hose
available
Commercially
5 Measuring cylinder
available
Commercially
6 Stopwatch
available
WA470-6, WA480-6 23
SEN01589-02 30 Testing and adjusting
3) Insert joint H2 to common rail (1) side and a If the leakage from the pressure lim-
retighten it with the currently removed joint iter is in the following range, it is nor-
bolt. mal.
a Be sure to fit the gaskets to both ends Engine speed Leaking amount
of the joint. (rpm) (cc/min)
4) Connect inspection hose H3 to the tip of
Equivalent to rated
joint H2. Max. 10
operation
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
a The above is the preparation work for
testing the leakage from the pressure
limiter.
24 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 25
SEN01589-02 30 Testing and adjusting
26 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
a Bleed the air as follows if the engine has run 2. Install pre-fuel filter (1) to the filter head.
out of fuel or the fuel circuit equipment has a Apply engine oil thinly over the packing on
been removed and installed. the pre-fuel filter side.
a After the packing of the pre-fuel filter
1. Remove fuel pre-fuel filter (1) and fill it with touches the sealing face of the filter head,
fuel. tighten the fuel filter 3/4 turns.
a Fill the fuel filter with clean fuel and take
care that dirt will not enter it.
a Check that the cap is fitted to part (a)
(central hole) of the pre-fuel filter, and then
add fuel through part (b) (holes around the
central hole).
a After filling the pre-fuel filter with fuel,
remove the cap from part (a).
a If clean fuel is not available, do not
remove the pre-fuel filter but fill it with the
fuel by operating priming pump (4).
a Do not add fuel to fuel main filter (2) exter-
nally.
WA470-6, WA480-6 27
SEN01589-02 30 Testing and adjusting
28 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
k
leakage.
Very high pressure is generated in the high- a Inspect the high-pressure circuit parts
pressure circuit of the fuel system. If fuel concentration on the areas coated with the
leaks while the engine is running, it is dan- color checker, for fuel leakage.
gerous since it can catch fire. a If any fuel leakage is detected, repair it
After testing the fuel system or removing and inspect again from step 1.
and installing its components, check for a If any fuel leakage is not detected, inspec-
fuel leakage according to the following pro- tion is completed.
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
WA470-6, WA480-6 29
SEN01589-02 30 Testing and adjusting
30 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 31
SEN01589-02 30 Testing and adjusting
32 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Cooling system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or dam-
aged, retighten or repair.
Fuel system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or dam-
aged, retighten or repair.
WA470-6, WA480-6 33
SEN01589-02 30 Testing and adjusting
34 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 35
SEN01589-02 30 Testing and adjusting
36 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 37
SEN01589-02 30 Testing and adjusting
38 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 39
SEN01589-02 30 Testing and adjusting
40 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 41
SEN01589-02 30 Testing and adjusting
a Testing and adjusting instruments for power 1. Remove rear frame left side cover (21).
train oil pressure 2. Open engine right side cover (23).
Symbol Part No. Part Name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
K 2 799-401-2320 Gauge
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
Measuring
No. Measured oil pressure gauge
MPa {kg/cm2}
1 Main relief pressure 6 {60}
2 Torque converter relief pressure 2.5 {25}
3 Torque converter outlet pressure 1 {10}
4 Lockup clutch pressure 6 {60}
5 Transmission F clutch pressure 6 {60}
6 Transmission R clutch pressure 6 {60}
7 Transmission 1st clutch pressure 6 {60}
8 Transmission 2nd clutch pressure 6 {60}
9 Transmission 3rd clutch pressure 6 {60}
10 Transmission 4th clutch pressure 6 {60}
11 Lubrication pressure 1 {10}
42 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 43
SEN01589-02 30 Testing and adjusting
2. Measuring torque converter relief pressure 2) Start the engine and keep the directional
(inlet pressure) lever or switch at the N (Neutral) position.
a Location of torque converter relief pres- 3) While running the engine at 2,000 rpm,
sure (inlet pressure) pickup nipple (2) measure torque converter relief pressure
(inlet pressure).
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
44 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
3. Measuring torque converter outlet pressure 3) Start the engine and keep the directional
a Location of torque converter outlet pressure lever or switch at the N (Neutral) position.
pickup plug (3) 4) While running the engine at 2,000 rpm,
measure torque converter outlet pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
WA470-6, WA480-6 45
SEN01589-02 30 Testing and adjusting
4. Measuring lockup clutch pressure (Lockup 3) Turn the torque converter lockup switch
clutch specification) ON.
k This measurement is done in the travel- 4) Set the transmission auto shift and man-
ing condition. Reasonable care, there- ual shift selector switch in the AUTO posi-
fore, must be pai d to saf ety of tion.
surrounding area. 5) Start the engine and turn the parking
1) Remove lockup clutch pressure pickup brake switch OFF.
plug (4) (10 × 1.25 mm). 6) Set the gear shift lever or gear shift switch
to 3rd position.
7) Start traveling while setting the directional
lever or switch to the F (forward) position.
8) Measure the lockup clutch oil pressure as
the lockup pilot lamp came on while travel-
ing is continued with the engine at 2,000
rpm.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
46 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
5. Measuring F (forward) clutch pressure 3) Set the transmission auto shift and man-
1) Remove F (forward) clutch pressure ual shift selector switch in the MANUAL
pickup plug (5) (10 × 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever to the 4th position.
7) While pressing the brake pedal, set the
directional lever or switch to F (forward).
k Keep pressing the brake pedal
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
8) While running the engine at 2,000 rpm,
measure the F (forward) clutch oil pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
WA470-6, WA480-6 47
SEN01589-02 30 Testing and adjusting
6. Measuring R (reverse) clutch pressure 3) Set the transmission auto shift and man-
1) Remove R (reverse) clutch pressure ual shift selector switch in the MANUAL
pickup plug (6) (10 × 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 4th position.
7) While pressing the brake pedal, set the
directional lever or switch to R (reverse).
k Keep pressing the brake pedal
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
8) While running the engine at 2,000 rpm,
measure the R (reverse) clutch oil pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
48 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
7. Measuring 1st clutch pressure 3) Set the transmission auto shift and man-
1) Remove 1st clutch pressure pickup plug ual shift selector switch in the MANUAL
(7) (10 × 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 1st position.
7) While pressing the brake pedal with the
engine at low idle, set the directional lever
or switch to the F (forward) or R (reverse)
position once and then return it to N (Neu-
tral) again.
k Keep pressing the brake pedal
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
a If the directional lever or switch is in N
(Neutral), the gear speed is not
changed even if the gearshift lever is
moved. To avoid this, perform the
above operation.
8) While running the engine at 2,000 rpm,
measure the 1st clutch oil pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
2) Install nipple K3 and connect oil pressure
gauge [1] in hydraulic tester K1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
WA470-6, WA480-6 49
SEN01589-02 30 Testing and adjusting
8. Measuring 2nd clutch pressure 3) Set the transmission auto shift and man-
1) Remove 2nd clutch pressure pickup plug ual shift selector switch in the MANUAL
(8) (10 × 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 2nd position.
7) While pressing the brake pedal with the
engine at low idle, set the directional lever
or switch to the F (forward) or R (reverse)
position once and then return it to N (Neu-
tral) again.
k Keep pressing the brake pedal
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
a If the directional lever or switch is in N
(Neutral), the gear speed is not
changed even if the gearshift lever is
moved. To avoid this, perform the
above operation.
8) While running the engine at 2,000 rpm,
measure the 2nd clutch oil pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
2) Install nipple K3 and connect oil pressure
gauge [1] in hydraulic tester K1.
a Use the oil pressure gauge with
capacity 6 MPa {60 kg/cm2}.
50 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
9. Measuring 3rd clutch pressure 7) While pressing the brake pedal with the
1) Remove 3rd clutch pressure pickup plug engine at low idle, set the directional lever
(9) (10 × 1.25 mm). or switch to the F (forward) or R (reverse)
position once and then return it to N (Neu-
tral) again.
k Keep pressing the brake pedal
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
a If the directional lever or switch is in N
(Neutral), the gear speed is not
changed even if the gearshift lever is
moved. To avoid this, perform the
above operation.
8) While running the engine at 2,000 rpm,
measure the 3rd clutch oil pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
WA470-6, WA480-6 51
SEN01589-02 30 Testing and adjusting
10. Measuring 4th clutch pressure 3) Set the transmission auto shift and man-
1) Remove 4th clutch pressure pickup plug ual shift selector switch in the MANUAL
(10) (10 × 1.25 mm). position.
4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
6) While keeping the directional lever or
switch at N (Neutral) position, set the
gearshift lever in the 4th position.
7) While pressing the brake pedal with the
engine at low idle, set the directional lever
or switch to the F (forward) or R (reverse)
position once and then return it to N (Neu-
tral) again.
k Keep pressing the brake pedal
securely.
k The machine will move, so check
carefully that the surrounding area
is safe.
a If the directional lever or switch is in N
(Neutral), the gear speed is not
changed even if the gearshift lever is
moved. To avoid this, perform the
above operation.
8) While running the engine at 2,000 rpm,
measure the 4th clutch oil pressure.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
2) Install nipple K3 and connect oil pressure
gauge [1] in hydraulic tester K1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.
52 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
11. Measuring lubrication pressure 3) Start the engine and keep the directional
1) Remove lubrication pressure pickup plug lever or switch at the N (Neutral) position.
(11) (10 × 1.25 mm). 4) Measure the lubricating oil pressure while
the engine is running at 2,000 rpm.
a Make power mode selector switch “P
mode”, and work about WA470-6.
(Because engine speed does not
reach 2,000 rpm at "E mode".)
WA470-6, WA480-6 53
SEN01589-02 30 Testing and adjusting
54 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
Procedure for flushing torque 3. Fill the transmission case with oil.
converter and transmission q Add oil through oil filler (3) to the specified
level. Run the engine to circulate the oil
hydraulic circuit 1 through the system. Then, check the oil
a Metal chips and dirt in the torque converter and level again.
5
transmission hydraulic circuit shorten the lives
Transmission case: 54 l (Refill capacity)
of the torque converter and transmission and
can cause internal breakage. Accordingly,
flush the hydraulic circuit to remove the metal
chips and dirt.
WA470-6, WA480-6 55
SEN01589-02 30 Testing and adjusting
a Device for moving machine when transmission k Lower the work equipment to the ground
valve is broken fully, apply the parking brake, and put
chocks under the tires to prevent the
Symbol Part No. Part Name
machine from moving.
L 794-423-1190 Plug k When working, stop the engine.
k When working while the oil temperature is
a Even if you cannot move the machine because still high, take care not to burn your body.
of breakage of a transmission valve part (elec-
trical system, solenoid valve, spool, etc.), you
can move it by installing plugs L.
k Installation of plugs L to the ECMV is a
means to move the machine from a danger-
ous job site to a safe place where you can
repair it when you cannot move it at any
gear speed because of breakage of the
transmission control valve. Accordingly,
use this method only when the transmis-
sion control valve is broken.
k When moving the machine by this method,
observe the procedure and take care of
safety.
56 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 57
SEN01589-02 30 Testing and adjusting
Check of axle final drive for oil Check of drive shafts for
leakage 1 looseness, play and damage 1
Check axle final drive (1) for oil leakage. Check the drive shafts for damage, abnormal play
and looseness of the connecting bolts and nuts. If
If oil is leaking, check and repair the seals and they are loosened or damaged, retighten or repair.
bearings.
a See the "Disassembly and assembly" volume. Check the cross member of each universal joint by
moving it up, down, to the right and left and in both
rotating directions.
58 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 59
SEN01589-02 30 Testing and adjusting
60 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 61
SEN01589-02 30 Testing and adjusting
Measuring method
1. Start the engine.
a After starting the engine, raise the bucket
about 400 mm and release the frame lock
lever.
62 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 63
SEN01589-02 30 Testing and adjusting
3) Run the engine at high idle and turn the 2) Install adapter N4 and connect hose (4).
steering wheel to the right. When the 3) Connect nipple N2 (10 × 1.25 mm) and oil
steering relief valve operates, measure pressure gauge [1] of hydraulic tester N1.
the oil pressure. a Use the oil pressure gauge of 5.9 MPa
a When the gauge was connected to {60 kg/cm2}.
steering circuit pickup plug at the
head of the left side steering cylinder,
measure the pressure by turning the
steering wheel to the left.
64 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 65
SEN01589-02 30 Testing and adjusting
Bleeding air from steering circuit1 2. Bleeding air from steering cylinder circuit.
1) Run the engine at idle for about 5 minutes.
a Before starting the operation, make sure the
specified level of hydraulic oil is provided. 2) While running the engine at low idle, steer
a If the steering valve or the steering cylinder the machine to the right and left 4 – 5
was removed and installed, bleed air from the times.
steering circuit according to the following pro- a Stop the piston rod about 100 mm
cedure. before each stroke end and take care
not to relieve the circuit.
1. Bleeding air from steering pump
1) Remove cover (1) under the left of the 3) While running the engine at high idle, per-
operator's cab. form the operation of 2).
66 WA470-6, WA480-6
30 Testing and adjusting SEN01589-02
WA470-6, WA480-6 67
SEN01589-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
68
SEN01590-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN01590-02 30 Testing and adjusting
2 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 3
SEN01590-02 30 Testing and adjusting
2. Measuring fan drive oil pressure 4) While running the engine at high idle,
1) Open radiator grille (1). measure the fan drive oil pressure.
4 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit 1 bleeder (2), tighten air bleeder (2).
3 Air bleeder:
a Testing tools for bleeding air from hydraulic drive 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
fan circuit 4) Start the engine and run it at low idle for 5
Symbol Part No. Part Name minutes minimum.
799-101-5002 Hydraulic tester
1 2. Bleeding air from fan motor circuit
Q 790-261-1204 Digital hydraulic tester 1) Open radiator grille (1).
2 790-261-1130 Coupling
WA470-6, WA480-6 5
SEN01590-02 30 Testing and adjusting
6 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 7
SEN01590-02 30 Testing and adjusting
Adjusting
1. Adjusting link length (a)
1) Remove pin (5), ball joint (3) and rod (1).
2) Loosen locknut (4) and adjust the link
length by turning yoke (2) and ball joint
(3).
3) After adjusting link length (a), connect the
link to the brake pedal.
a Standard length (a): 213 mm
8 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 9
SEN01590-02 30 Testing and adjusting
Measuring
1. Connect oil pressure gauge [1] of hydraulic tester 4. After finishing measurement, remove the mea-
R to accumulator charge pressure pickup plug suring instruments and return the removed
(2) of accumulator charge valve (1). parts.
a Use the oil pressure gauge of 39.2 MPa
{400 kg/cm2}. Adjusting
a If the accumulator charge cut-out pressure is
adjusted, the cut-in pressure changes accord-
ing to the valve area ratio.
10 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a Measuring tools for wheel brake oil pressure 3. Remove union (3) and install adapter S4 and
Symbol Part No. Part Name nipple S5, and then install brake test kit S1.
a Use the O-ring fitted to the union.
1 793-605-1001 Brake test kit
2 790-101-1430 Coupler
3 790-101-1102 Pump
S 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
WA470-6, WA480-6 11
SEN01590-02 30 Testing and adjusting
12 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 13
SEN01590-02 30 Testing and adjusting
Bleeding air from wheel brake 5. Connect hose [1] to bleeder screw (3) of the
circuit 1 wheel brake and place hose [1] in the oil pan.
14 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 15
SEN01590-02 30 Testing and adjusting
Testing parking brake oil 2. Remove parking brake pressure pickup plug
pressure 1 (2).
16 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 17
SEN01590-02 30 Testing and adjusting
Testing wear of parking brake disc1 4. If depth (a) is above the standard, remove
parking brake disc (4) and measure its thick-
Measuring instruments ness (W), referring to Disassembly and assem-
Symbol Part No. Part Name bly, “Removal of parking brake disc”.
Commercially q Service limit thickness (W): 2.97 mm
V
available
Slide calipers a If the parking brake disc thickness is
below the service limit, replace the disc.
18 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
Manual release method for 2. Remove 2 gauge mounting bolts (2), and
parking brake 1 tighten to plug mounting portion in turn.
a Remove 2 bolts (2) on opposite sides.
a The parking brake is controlled by hydraulic a When bolts (2) are screwed in, piston (3)
pressure, so if there should be any failure in is pulled and the parking brake is
the transmission or the emergency release released.
solenoid and it becomes impossible to release a Tighten the 2 bolts uniformly a little at a
the parking brake, it is possible to release it time. (Tighten approx. 4.5 turns after the
manually to move the machine. bolts contacts the seat.)
k The manual release of the parking
brake is designed only to move the
machine from a dangerous working
area to a safe place where repairs can
be carried out. This method must not
be used except in an emergency.
k To prevent the machine from moving,
lower the bucket to the ground and put
blocks under the tires.
k Always stop the engine before carrying
out this procedure.
WA470-6, WA480-6 19
SEN01590-02 30 Testing and adjusting
Measuring
1. Operating effort of work equipment control
lever
1) Install and fix tool W1 to the work equip-
ment control lever.
a Install tool W1 to the center of the knob.
a Operate the work equipment control
lever at the ordinary operating speed
and measure the minimum necessary
effort to operate the knob.
20 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
Testing and adjusting work 3) Connect nipple X2 and oil pressure gauge
equipment PPC oil pressure 1 [1] of hydraulic tester X1.
a Use the oil pressure gauge of 5.9 MPa
a Measuring and adjusting instruments for work {60 kg/cm2}.
equipment PPC oil pressure
Symbol Part No. Part name
799-101-5002 Analog hydraulic tester
1
790-261-1204 Digital hydraulic tester
X
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
Measuring
1. PPC valve basic pressure
1) Remove rear frame left side cover (1).
WA470-6, WA480-6 21
SEN01590-02 30 Testing and adjusting
2. Measuring PPC valve output pressure 3) Connect nipple X2 and oil pressure gauge
1) Remove front frame inspection cover (4). [1] of hydraulic tester X1.
k When raising the lift arm to remove a Use the oil pressure gauge of 5.9 MPa
the inspection cover, place a stand {60 kg/cm2}.
under it to support securely.
22 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
Adjusting
a The PPC relief valve is not adjustable.
WA470-6, WA480-6 23
SEN01590-02 30 Testing and adjusting
Testing and adjusting work 3) Remove front frame inspection cover (1).
k When raising the lift arm to remove
equipment oil pressure 1
the inspection cover, place a stand
a Measuring and adjusting instruments for work under it to support securely.
equipment oil pressure
Symbol Part No. Part name
799-101-5002 Analog hydraulic tester
1
790-261-1204 Digital hydraulic tester
Y 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
1. Preparation work
1) Raise part (a) of the bucket about 30 – 50
mm and lower part (b) to the ground. 2) Connect nipple Y2 and oil pressure gauge
2) Stop the engine and operate the work [1] of hydraulic tester Y1.
equipment control lever to check that both a Use the oil pressure gauge of 39.2 MPa
parts (a) and (b) of the bucket are in con- {400 kg/cm2}.
tact with the ground.
a After lowering the bucket to the
ground, operate the work equipment
control lever 2 – 3 times to release
the residual pressure in the piping.
24 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
3) Start the engine and raise the lift arm to 2) Connect nipple Y2 and oil pressure gauge
the level position. Then, while running the [1] of hydraulic tester Y1.
engine at high idle and dumping the a Use the oil pressure gauge of 5.9 MPa
bucket, measure the oil pressure. {60 kg/cm2}.
k After measuring the oil pressure, 3) Start the engine and raise the lift arm
release the pressure in the circuit about 400 mm. Then, while running the
according to the procedure for engine at high idle, set all the levers in
installing the nipple and oil pres- neutral and measure the oil pressure.
sure gauge, and then remove the
oil pressure gauge and nipple.
WA470-6, WA480-6 25
SEN01590-02 30 Testing and adjusting
26 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 27
SEN01590-02 30 Testing and adjusting
Bleeding air from work equipment 2. Air bleeding from hydraulic cylinder
circuit 1 1) Start the engine and run it at low idle for 5
minutes minimum.
1. Bleeding air from work equipment pump 2) While running the engine at low idle, repeat
(piston pump) raising and lowering of the lift arm 4 – 5
1) Remove cover (1) under the right of the times.
operator's cab. a Do not operate the piston rod beyond
a position 100 mm in front of the
stroke end to prevent relieving.
3) Implement operation of 2) above with the
engine at high idle. Then operate the pis-
ton rod to the stroke end at low idle to
relieve it.
4) Implement the same operation as 2) and
3) above for the bucket and steering, too.
a When a cylinder is replaced, this
operation should be implemented
before connecting the piston rod.
28 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 29
SEN01590-02 30 Testing and adjusting
30 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
Ambient Ambient
Gas pressure Remarks Gas pressure Remarks
temperature temperature
°C MPa kg/cm2 °C MPa kg/cm2
15 4.34 44.2 31 4.58 46.7
16 4.35 44.4 32 4.59 46.8
17 4.37 44.5 33 4.61 47
18 4.38 44.7 34 4.62 47.2
19 4.4 44.8 35 4.64 47.3
Standard gas
20 4.41 45 36 4.65 47.5
pressure
21 4.43 45.2 37 4.67 47.6
22 4.44 45.3 38 4.68 47.8
23 4.46 45.5 39 4.7 47.9
24 4.47 45.6 40 4.71 48.1
25 4.49 45.8 41 47.3 48.2
26 4.5 45.9 42 4.74 48.4
27 4.52 46.1 43 4.76 48.5
28 4.53 46.2 44 4.77 48.7
29 4.55 46.4 45 4.79 48.8
30 4.56 46.5
WA470-6, WA480-6 31
SEN01590-02 30 Testing and adjusting
Procedure for charging accumulator with nitro- 6. Connect gas charge tool ZC1 and nitrogen gas
gen gas cylinder according to the following procedure.
k Loosen the hydraulic tank oil filler cap 1) Connect cap nut (7) of pressure reducing
gradually to release the pressure inside the valve ZC2 to the nitrogen gas cylinder.
tank.
k Operate the work equipment control lever 2
– 3 times to release the pressure inside the
PPC accumulator circuit.
k Park the machine on a flat place, lower the
work equipment to the ground, and set
chocks under the tires securely.
a The accumulator unit can be charged similarly.
1. Remove cap (2) from the charge opening of
accumulator (1).
32 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
3) Open shut-off valve (11) of nitrogen gas 10) When the charged pressure reaches to
cylinder (10) a little and set the charge the standard value, close shut-off valve
pressure of pressure reducing valve ZC2 (11) of nitrogen gas cylinder (10).
so that gas charge tool ZC1 will not be q If the pressure is too high, open pres-
damaged. su re redu cing valve (14) of gas
4) Close shut-off valve (11) of nitrogen gas charge tool ZC1 to reduce the pres-
cylinder (10) and check the pressure indi- sure, with shut-off valve (11) of nitro-
cated by the gauge. gen gas cylinder (10) closed.
WA470-6, WA480-6 33
SEN01590-02 30 Testing and adjusting
Ambient Ambient
Gas pressure Remarks Gas pressure Remarks
temperature temperature
°C MPa kg/cm2 °C MPa kg/cm2
15 4.34 44.2 31 4.58 46.7
16 4.35 44.4 32 4.59 46.8
17 4.37 44.5 33 4.61 47
18 4.38 44.7 34 4.62 47.2
19 4.4 44.8 35 4.64 47.3
Standard gas
20 4.41 45 36 4.65 47.5
pressure
21 4.43 45.2 37 4.67 47.6
22 4.44 45.3 38 4.68 47.8
23 4.46 45.5 39 4.7 47.9
24 4.47 45.6 40 4.71 48.1
25 4.49 45.8 41 47.3 48.2
26 4.5 45.9 42 4.74 48.4
27 4.52 46.1 43 4.76 48.5
28 4.53 46.2 44 4.77 48.7
29 4.55 46.4 45 4.79 48.8
30 4.56 46.5
34 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
7. Remove gas charge tool ZC1 from the accu- 10. Check for nitrogen gas pressure reduction
mulator according to the following procedure. within 1 week after charging the accumulator
1) Slowly rotate handle (1) clockwise to with nitrogen gas.
tighten hexagonal socket head bolt (2). a Test the functions within 5 minutes after
2) Open pressure reducing valve (3) to stopping the engine. (If the engine is kept
release the nitrogen gas remaining in gas stopped for more than 5 minutes, the
charge tool ZC1 and hose. brake circuit oil pressure reduces and the
3) Remove gas charge tool ZC1 from the test cannot be performed correctly)
charge opening of the accumulator. 1) Park the machine on a level place and set
the parking brake switch in the "PARK"
position.
2) Start and run the engine at medium speed
for 1 minute and then stop it.
3) Turn the starting switch to the ON position,
press the brake pedal repeatedly, and
count how many times you have pressed
when the brake oil pressure caution lamp
lights up.
q Number of pressing times is less than
5: Accumulator gas may have
reduced.
q Number of pressing times is 5 or
larger: Accumulator gas pressure is
8. Apply soap water to the charge opening of the normal.
accumulator to check that the nitrogen gas is
not leaking.
WA470-6, WA480-6 35
SEN01590-02 30 Testing and adjusting
Procedure for testing of nitrogen charging tool ZD1 and gas may leak through
gas pressure and charging of the threaded portion of gas valve (8).
When connecting the gas charging tool ZD1, fit
nitrogen gas of brake the attached O-ring (7) (part number: 07000-
accumulator 1 11009) to gas valve (8), and confirm that gas
a Testing instrument does not leak.
Sym-
Part No. Part name Remarks
bol
1 792-610-1701 Gas charge tool —
Nipple
792-610-1310 GOST
(For Russia)
Nipple
792-610-1320 CGA No. 351
(For USA)
Nipple ASA B-571-
792-610-1330
ZD (For USA) 1965
2
DIN 477-1963
NEN 3268-
Nipple
792-610-1350 1966
(For Germany)
SIS-SMS 2235/
2238
Testing of accumulator nitrogen gas pressure
BS 341 Part 1-
792-610-1360 Nipple (For UK)
1962 a The nitrogen gas pressure in the accumulator
disconnected from the machine can be mea-
k Put on proper personal protection items sured according to the following procedure,
(goggles, leather gloves and protective too.
clothes) so that the leaking nitrogen gas 1. Stop the engine and depress the brake pedal
will not touch your skin or clothes and work repeatedly to lower the oil pressure in the
on the windward side as long as possible. brake circuit to zero.
k When handling nitrogen gas in a room or a Generally, if the brake pedal is depressed
another place which is not ventilated well, 30 times, the reaction force to the brake
ventilate the work place forcibly and pedal is lost and the oil pressure is low-
observe the Oxygen Deficiency Prevention ered to zero.
Rules of the Labor Safety and Sanitation 2. Remove valve guard (2) and cap (3) from
Law. accumulator (1).
k Since the accumulator is charged with
high-pressure nitrogen gas, wrong han-
dling of it can cause an explosion and
injury or death. When handling the accumu-
lator, observe the following strictly.
q Do not bring fire near the accumulator or
put the accumulator in fire.
q Do not drill, weld or gas-cut the accumula-
tor.
q Do not give impacts to the accumulator by
hitting or rolling.
q When discarding accumulator, discharge it
of the nitrogen gas.
Precaution when connecting the gas charging 3. Connect gas charge tool ZD1 to valve (4) of
tool ZD1 accumulator (1) according to the following pro-
a The threaded portion of the adapter (5) of the cedure.
gas charging tool ZD1 is coated with sealant. If 1) Turn handle (a) of gas charge tool ZD1 to
the adapter is removed unnecessarily, gas the left until it stops.
may leak. Never remove it. q Nitrogen gas cylinder (c) must be
a The threaded portion height (B) of gas valve connected even when you measure
(8) may be shorter than the depth (A) of pack- only the gas pressure.
ing (6) from the end of adapter (5) of gas
36 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
q Close the valve of nitrogen gas cylin- (The unit of each value in the formula is
der (c) and handle (b). °C.)
q For connection of nitrogen gas cylin- Indicated gas pressure =
der (c) and gas charge tool ZD1, see Standard gas pressure x ((273 + t)/
"Procedure for charging accumulator (273 + 20))
with nitrogen gas".
2) Fit the attached O-ring (7) (part number: Charging accumulator with nitrogen gas chart
07000-11009) to gas valve (8).
Charging nitrogen gas
Ambient
temperature Front Rear Front Rear
°C Remarks
MPa kg/cm2
15 10.52 6.09 107.14 61.92
16 10.55 6.12 107.51 62.14
17 10.59 6.14 107.88 62.35
18 10.63 6.16 108.26 62.57
19 10.66 6.18 108.63 62.78
Standard
20 10.70 6.20 109.00 63.00 gas
pressure
21 10.74 6.22 109.37 63.22
22 10.77 6.24 109.74 63.43
3) Connect gas charge tool ZD1 to valve (4)
of accumulator (1). 23 10.81 6.26 110.12 63.65
24 10.85 6.28 110.49 63.86
25 10.88 6.31 110.86 64.08
26 10.92 6.33 111.23 64.29
27 10.96 6.35 111.60 64.51
28 10.99 6.37 111.98 64.72
29 11.03 6.39 112.35 64.94
30 11.07 6.41 112.72 65.15
31 11.10 6.43 113.09 65.37
32 11.14 6.45 113.46 65.58
33 11.17 6.48 113.84 65.80
34 11.21 6.50 114.21 66.01
35 11.25 6.52 114.58 66.23
36 11.28 6.54 114.95 66.44
37 11.32 6.56 115.32 66.66
38 11.36 6.58 115.70 66.87
39 11.39 6.60 116.07 67.09
40 11.43 6.62 116.44 67.30
41 11.47 6.64 116.81 67.52
42 11.50 6.67 117.18 67.73
43 11.54 6.69 117.56 67.95
44 11.58 6.71 117.93 68.16
45 11.61 6.73 118.30 68.38
4. Turn handle (a) of gas charge tool ZD1 to the t = Gas temperature at time of charge (°C)
right slowly and read the gauge. Reference: t may be assumed to be ambient
a Since the indicated value varies with the temperature.
ambient temperature, charge the gas
pressure referring to the following chart.
WA470-6, WA480-6 37
SEN01590-02 30 Testing and adjusting
5. If the gas pressure is too high or too low, adjust 3) Fit the attached O-ring (7) (part number:
it referring to "Procedure for charging accumu- 07000-11009) to gas valve (8).
lator with nitrogen gas".
a Each time the pressure is measured,
some nitrogen gas is discharged and the
pressure lowers. Add nitrogen gas by the
loss.
6. Remove gas charge tool ZD1 from accumula-
tor (1) and return the removed parts. See "Pro-
cedure for charging accumulator with nitrogen
gas".
38 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
6. Turn handle (a) slowly to the right to open Charging accumulator with nitrogen gas chart
valve (4) of accumulator (1) gradually.
a If handle (a) is turned too much, the valve Ambient
Charging nitrogen gas
core of the accumulator will be damaged temperature Front Rear Front Rear
and gas will leak. Accordingly, operate °C Remarks
MPa kg/cm2
handle (a) carefully.
15 10.52 6.09 107.14 61.92
7. Open the valve of nitrogen gas cylinder (c) fur-
ther to charge the accumulator with nitrogen 16 10.55 6.12 107.51 62.14
gas. 17 10.59 6.14 107.88 62.35
8. During the work, close the valve of nitrogen 18 10.63 6.16 108.26 62.57
gas cylinder (c) and check the nitrogen gas
19 10.66 6.18 108.63 62.78
pressure in the accumulator.
a Since the indicated value varies with the Standard
20 10.70 6.20 109.00 63.00 gas
ambient temperature, charge the gas pressure
pressure referring to the following chart.
21 10.74 6.22 109.37 63.22
(The unit of each value in the formula is
°C.) 22 10.77 6.24 109.74 63.43
Indicated gas pressure = 23 10.81 6.26 110.12 63.65
Standard gas pressure x ((273 + t)/ 24 10.85 6.28 110.49 63.86
(273 + 20))
25 10.88 6.31 110.86 64.08
26 10.92 6.33 111.23 64.29
27 10.96 6.35 111.60 64.51
28 10.99 6.37 111.98 64.72
29 11.03 6.39 112.35 64.94
30 11.07 6.41 112.72 65.15
31 11.10 6.43 113.09 65.37
32 11.14 6.45 113.46 65.58
33 11.17 6.48 113.84 65.80
34 11.21 6.50 114.21 66.01
35 11.25 6.52 114.58 66.23
36 11.28 6.54 114.95 66.44
37 11.32 6.56 115.32 66.66
38 11.36 6.58 115.70 66.87
39 11.39 6.60 116.07 67.09
40 11.43 6.62 116.44 67.30
41 11.47 6.64 116.81 67.52
42 11.50 6.67 117.18 67.73
43 11.54 6.69 117.56 67.95
44 11.58 6.71 117.93 68.16
45 11.61 6.73 118.30 68.38
WA470-6, WA480-6 39
SEN01590-02 30 Testing and adjusting
40 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 41
SEN01590-02 30 Testing and adjusting
42 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 43
SEN01590-02 30 Testing and adjusting
44 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 45
SEN01590-02 30 Testing and adjusting
46 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 47
SEN01590-02 30 Testing and adjusting
48 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
5. Ambient pressure sensor (AMBAIR PRES- 6. Boost pressure and temperature sensor
SURE) (BOOST PRESS & IMT)
Engine Ne speed sensor (CRANK SENSOR) a Disconnection and connection of connector
Engine Bkup speed sensor (CAM SENSOR) The connector of the boost pressure and
Engine oil pressure switch (OIL PRESSURE temperature sensor has a special locking
SWITCH) mechanism. Disconnect it according to
a Disconnection and connection of connectors steps (a) – (b) and connect it according to
The connectors of the ambient pressure steps (c) – (d) as shown below.
sensor, engine Ne speed sensor, engine Disconnection:
Bkup speed sensor, and engine oil pres- (a) Unlock – (b) Disconnect connector.
sure switch have a special locking mecha- Connection:
nism. Disconnect them according to steps (c) Connect connector – (d) Lock.
(a) – (c) and connect them according to
steps (d) – (f) as shown below.
Disconnection: (a) Slide lever – (b) Unlock –
(c) Disconnect connector.
Connection: (d) Connect connector – (e)
Lock – (f) Slide lever.
a Removal and installation of sensor 7. Supply pump IMV solenoid (FUEL REGU-
A deep socket is necessary for removal LATOR)
and installation of the engine oil pressure a Disconnection and connection of connector
switch. See Testing adjusting, “Trouble- The connector of the supply pump IMV
shooting tools table”. solenoid has a special locking mecha-
nism. Disconnect it according to steps (a)
– (b) and connect it according to steps (c)
– (d) as shown below.
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection:
(c) Connect connector – (d) Lock.
WA470-6, WA480-6 49
SEN01590-02 30 Testing and adjusting
8. Common rail pressure sensor (FUEL RAIL a Precautions for connecting connector
PRESS) Take care not to connect the connector
a Disconnection and connection of connector reversely.
The connector of the common rail pres- Engage lock (e) on the wiring harness
sure sensor has a special locking mecha- side with triangular notch (f) on the sensor
nism. Disconnect it according to steps (a) side (Do not engage lock (e) with square
– (b) and connect it according to steps (c) guide (g) on the opposite side of triangular
– (d) as shown below. notch (f)).
Disconnection:
(a) Unlock – (b) Disconnect connector.
Connection:
(c) Connect connector – (d) Lock.
50 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to “Manual for KOMTRAX opera-
tions administrator” for the procedure.
a Now the terminal is ready for use.
WA470-6, WA480-6 51
SEN01590-02 30 Testing and adjusting
52 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 53
SEN01590-02 30 Testing and adjusting
2. Application for the start of use 3. Opening station request of ORBCOMM ter-
a Application for the start of use is made minal
only after the sign-up test on the machine Fill in the necessary matters in the paper of
side is finished. "opening request of ORBCOMM terminal" and
1) Notify to the KOMTRAX operations send KOMTRAX service hotline by fax or mail.
administrator the following information
concerning the machine whose sign-up
test on the machine is completed.
1] Information on the machine whose
sign-up test on the machine system is
completed (model, model number
and serial number).
2] Part number and serial number of the
KOMTRAX terminal
3] Reading of the service meter when
the KOMTRAX terminal is installed
(0.1 h unit)
54 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 55
SEN01590-02 30 Testing and adjusting
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
56 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
WA470-6, WA480-6 57
SEN01590-02 30 Testing and adjusting
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by “9”.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
58 WA470-6, WA480-6
30 Testing and adjusting SEN01590-02
WA470-6, WA480-6 59
SEN01590-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
60
SEN01591-02
WA470-6
WA480-6
WA470-6 WA480-6 1
SEN01591-02 30 Testing and adjusting
Rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)
q Do not change the setting of the rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and
SW6) on the back side of the machine monitor.
2 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
WA470-6 WA480-6 3
SEN01591-02 30 Testing and adjusting
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
a Change of the indication unit of the speedometer and weight meter of the specification for the SI unit
countries cannot be set.
4 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
*1: This display is not available when the load meter function is turned off through option selection of service mode.
*2: This display is not available when the travel speed/engine speed display selecting function is turned off through
option selection of service mode.
*3: If the speed/engine speed indicated on character display is turned OFF optionally in the service mode, it is not indi-
cated.
WA470-6 WA480-6 5
SEN01591-02 30 Testing and adjusting
6 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 7
SEN01591-02 30 Testing and adjusting
8 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 9
SEN01591-02 30 Testing and adjusting
10 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
9. Travel speed/engine speed display select- 11. Action code display function
ing function If a trouble occurs, the machine monitor dis-
A unit to be used for the machine monitor plays an action code corresponding to the seri-
speed display is selectable from km/h and ousness of the trouble to alert the operator for
MPH. It is also possible to turn on or off the dis- appropriate actions.
play of the travel speed and engine speed. a The figure below shows an example of the
a For details, see the “Other functions of screen on which action code [E03] and
machine monitor” of the Operation section [CALL + Telephone number] are alter-
in the Operation and maintenance man- nately displayed.
ual. a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.
WA470-6 WA480-6 11
SEN01591-02 30 Testing and adjusting
12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code (location code + problem
failure code corresponding to the failure cur- code)
rently warned. B: Controller code
a The failure codes detected in the past are MON: Machine monitor
divided into failures of the electrical sys- TM: Transmission controller
tem and the mechanical system and are WRK: Work equipment controller
recorded as fault history. (For details, see ENG: Engine controller
“Service mode”.) C: The system where failure occurred
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 3 seconds,
the action code display screen is automat-
ically displayed.
12 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 13
SEN01591-02 30 Testing and adjusting
[4] CYLINDER CUT-OUT: Engine 2. Electrical system fault history display func-
reduced-cylinder function tion (ELECTRIC FAULT)
[5] NO INJECTION: No injection crank- The machine monitor records the past failures
ing function in the electric system as the failure codes. The
[6] TUNING: Adjustment function failure codes are displayed from the following
[7] MAINTENANCE MONITOR: Mainte- operations.
nance monitoring function 2-1. Selecting the menu
[8] OPERATION INFO: Operating infor- Select the ELECTRIC FAULT from the menu
mation display function screen of Service mode.
[9] OPTIONAL SELECT: Optional device a [**] field displays total number of the fault
selecting function history currently recorded (up to 20
[10] MACHINE No. SET: Machine serial cases).
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menu is indicated in the parts of [*].
14 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
a For details of a displayed failure code, see 2-6. Deleting all fault history
“Failure code list” of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
WA470-6 WA480-6 15
SEN01591-02 30 Testing and adjusting
16 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 17
SEN01591-02 30 Testing and adjusting
3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
18 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 19
SEN01591-02 30 Testing and adjusting
20 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA480:
Standard boom
Boom at max. height: 46.0 ± 2.0 deg
Boom at min. height: –41.3 ± 3.0 deg
WA470-6 WA480-6 21
SEN01591-02 30 Testing and adjusting
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number below (above) the display range is fixed within the display range.
22 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
20 MPa: 0.5 V
10 MPa: 1.3 V
V Only when load meter option is set
20 MPa: 2.1 V
50 MPa: 4.5 V
50 MPa: 0.5 V
10 MPa: 1.3 V
V Only when load meter option is set
20 MPa: 2.1 V
50 MPa: 4.5 V
— MPa Unused
Load weight (t) ton Only when load meter option is set
Indication of
— Unused
condition
Indication of
— Unused
condition
Indication of
— Unused
condition
Indication of
— Unused
condition
Indication of
— Unused
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
WA470-6 WA480-6 23
SEN01591-02 30 Testing and adjusting
MON: Detailed data of input and output signals [Mechanical monitor system]
Monitoring Input/Output
No. Displayed items Description of ON/OFF switch
codes signal
D-IN-0 Head lamp high beam Lighting of head lamp = ON (24 V)/OFF (OPEN)
D-IN-1 — —
D-IN-2 Starting switch C Starting switch = ON (24 V)/OFF (OPEN)
D-IN-3 — —
Auto grease A
32-1 40900 D-IN-4 (Applicable to a machine equipped with Tank empty or failed = ON (24 V)/OFF (OPEN)
optional auto grease)
Auto grease B
D-IN-5 (Applicable to a machine equipped with In operation or failed = ON (24 V)/OFF (OPEN)
optional auto grease)
D-IN-6 — —
D-IN-7 — —
D-IN-8 — —
D-IN-9 — —
Load meter mode selector switch (A/B)
D-IN-10 (Applicable to a machine equipped with Pressing of switch = ON (24 V)/OFF (OPEN)
optional load meter)
Load meter mode selector switch (+/–)
D-IN-11 (Applicable to a machine equipped with Pressing of switch = ON (24 V)/OFF (OPEN)
33-1 40901 optional load meter)
Lighting of turn signal right lamp = ON (GND)/OFF
D-IN-12 Turn signal right
(OPEN)
Lighting of turn signal left lamp = ON (GND)/OFF
D-IN-13 Turn signal left
(OPEN)
D-IN-14 U switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing of switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-18 — —
D-IN-19 — —
34-1 40902 D-IN-20 Clogged air cleaner No clogging = ON (GND)/OFF (OPEN)
D-IN-21 — —
D-IN-22 — —
Load meter total weight indication selector
D-IN-23 Pressing of switch = ON (GND)/OFF (OPEN)
switch (if equipped)
D-IN-24 — —
D-IN-25 — —
D-IN-26 Parking brake Parking brake operation = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
35-1 40903 D-IN-28 — —
D-IN-29 Engine oil level Low oil level = ON (GND)/OFF (OPEN)
Emergency steering normal Emergency steering normal = ON (GND)/OFF
D-IN-30
(Machine with optional emergency steering) (OPEN)
D-IN-31 — —
24 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
MON: Detailed data of input and output signals [Mechanical monitor system]
Monitoring Input/Output
No. Displayed items Description of ON/OFF switch
codes signal
Load meter subtotal switch
D-IN-32 Pressing of switch = ON (GND)/OFF (OPEN)
(Load meter specification)
Load meter cancel switch
D-IN-33 Pressing of switch = ON (GND)/OFF (OPEN)
(Load meter specification)
D-IN-34 High beam (dimmer switch) High beam = ON (GND)/OFF (OPEN)
36-1 40904 D-IN-35 Working fuel consumption display switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-36 Service 2 mode ON = ON(GND)/OFF(OPEN)
D-IN-37 [>] switch Pressing of switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing of switch = ON (GND)/OFF (OPEN)
Emergency steering operation (Machine Emergency steering operation = ON (GND)/OFF
D-IN-39
with optional emergency steering) (OPEN)
D-OUT-0 Alarm buzzer Output ON = (24 V)/OFF (OPEN)
D-OUT-1 — —
37-1 40952
D-OUT-2 — —
D-OUT-3 — —
WA470-6 WA480-6 25
SEN01591-02 30 Testing and adjusting
5 41400 Fan pump EPC current (command) FAN EPC DIR 0 – 1000
8 95201 Input voltage of loader pump oil pressure PUMP PRESS 0.00 – 5.00
9 95100 Output command value of loader pump EPC PUMP EPC DIR 0 – 1000
10 95300 Steering pump oil pressure S/T OIL PRESS 0.00 – 50.00
11 95301 Input voltage of steering pump oil pressure S/T OIL PRESS 0.00 – 5.00
15 41202 Transmission cut-off sensor input voltage T/M CUT OFF P 0.00 – 5.00
17 93601 Transmission oil temperature sensor input voltage T/M OIL TEMP 0.00 – 5.00
26 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
Indication of
As per version No. of application software
condition
Indication of
As per version No. of data
condition
0 – 1000 [mA]
When engine speed is below 500 rpm = 670 mA
While engine is cranked (C terminal is operated) = 800 mA mA
While fan is being prepared for reverse operation = 800 mA
While fan is operated in reverse = 0 mA
P-mode: 0 ± 10 mA
mA
E-mode: 350 ± 10 mA
0 – 32767 [min-1]
0 km/h = 0 rpm
10 km/h = 738 rpm
rpm Equipped with 26.5 – 25 tires
20 km/h = 1476 rpm
30 km/h = 2215 rpm
40 km/h = 2953 rpm
0 – 150 [°C] °C
WA470-6 WA480-6 27
SEN01591-02 30 Testing and adjusting
28 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 29
SEN01591-02 30 Testing and adjusting
30 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number below (above) the display range is fixed within the display range.
*4: If a unit is necessary, the SI unit is used.
*5: If a code or a monitoring item is displayed on the machine monitor but cannot be monitored, “Unused for
this machine” is entered.
WA470-6 WA480-6 31
SEN01591-02 30 Testing and adjusting
TM: Detailed data of input and output signals [Transmission controller system]
Monitoring Input/Output
No. Indication item Function of ON/OFF switch
codes signal
Steering pump pressure is applied
D-IN-0 Steering pressure switch (Normally open)
= ON (GND) /OFF (OPEN)
Steering pump pressure is applied
D-IN-1 Steering pressure switch (Normally closed)
= ON (OPEN) /OFF (GND)
D-IN-3 Transmission cut-off set switch Pressing switch = ON (GND) /OFF (OPEN)
37-1 40905
D-IN-4 Shift mode L Shift mode L = ON (GND) /OFF (OPEN)
D-IN-6 2-stage low idle selector switch (if equipped) Pressing switch = ON (24 V) /OFF (OPEN)
D-IN-8 • Gearshift lever 1st • Gearshift lever 1st = ON (24 V) /OFF (OPEN)
D-IN-9 • Gearshift lever 2nd • Gearshift lever 2nd = ON (24 V) /OFF (OPEN)
D-IN-10 • Gearshift lever 3rd • Gearshift lever 3rd = ON (24 V) /OFF (OPEN)
D-IN-11 • Gearshift lever 4th • Gearshift lever 4th = ON (24 V) /OFF (OPEN)
38-1 40906
• Joystick steering shift-up switch
D-IN-12 • Shift-up switch = ON (24 V) /OFF (OPEN)
(if equipped)
• Joystick steering shift-down switch
D-IN-13 • Shift-down switch = ON (24 V) /OFF (OPEN)
(if equipped)
D-IN-14 Electric emergency steering manual switch Pressing switch = ON (24 V) /OFF (OPEN)
D-IN-23 Parking brake (Neutralizer) signal Parking brake = ON (24 V) /OFF (OPEN)
32 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
TM: Detailed data of input and output signals [Transmission controller system]
Monitoring Input/Output
No. Indication item Function of ON/OFF switch
codes signal
ECMV fill switch F (Forward)
D-IN-24 ECMV fill switch F (Forward)
= ON (GND) /OFF (OPEN)
ECMV fill switch R (Reverse)
D-IN-25 ECMV fill switch R (Reverse)
= ON (GND) /OFF (OPEN)
D-IN-26 ECMV fill switch 1st ECMV fill switch 1st = ON (GND) /OFF (OPEN)
D-IN-27 ECMV fill switch 2nd ECMV fill switch 2nd = ON (GND) /OFF (OPEN)
40-1 40908
D-IN-28 ECMV fill switch 3rd ECMV fill switch 3rd = ON (GND) /OFF (OPEN)
D-IN-29 ECMV fill switch 4th ECMV fill switch 4th = ON (GND) /OFF (OPEN)
D-IN-33 — —
D-IN-34 — —
D-IN-35 — —
41-1 40942
D-IN-36 — —
D-IN-37 — —
D-IN-38 — —
D-IN-39 — —
D-OUT-2 — —
D-OUT-6 — —
D-OUT-7 — —
WA470-6 WA480-6 33
SEN01591-02 30 Testing and adjusting
TM: Detailed data of input and output signals [Transmission controller system]
Monitoring Input/Output
No. Indication item Function of ON/OFF switch
codes signal
D-OUT-8 — —
D-OUT-9 — —
D-OUT-10 — —
D-OUT-11 — —
43-1 40950
D-OUT-12 — —
D-OUT-13 — —
D-OUT-14 — —
D-OUT-15 — —
D-OUT-19 — —
44-1 40951
D-OUT-20 — —
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
34 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 35
SEN01591-02 30 Testing and adjusting
36 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*3: If a value is below (or above) the display range, it will be displayed as the lowest (highest) value in the
range.
*4: SI units alone are employed whenever a unit is needed.
*5: An item that does not allow monitoring is indicated as "Not used" though its code and item name may be
displayed on the machine monitor.
WA470-6 WA480-6 37
SEN01591-02 30 Testing and adjusting
38 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 39
SEN01591-02 30 Testing and adjusting
40 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
Operat-
ing 5 6 7 8
order
Gear
F3 F4 F3 F2
speed
Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.
Operat-
ing 9 10 11
order
Gear
7-1-2. Conformation of transmission oil tempera- N2 R2 N2
speed
ture control
Holding Min. 2 Min. 2 Min. 2
1) Start the engine, press the brake pedal
time sec. sec. sec.
fully and then release the parking brake.
2) Set the transmission shift mode in MAN-
UAL, set the FNR (directional) lever or joy-
a When performing the following opera-
stick steering FNR (directional) switch or
tion, run the engine at low idle, turn
right FNR (directional) switch in F (for-
manual switch ON, turn the torque
ward), and set the gearshift lever or gear-
converter lockup switch OFF, and turn
shift switch in the 4th position. (F4)
lockup switch OFF.
3) Make sure from “7-1-1 Preparations for
a Make sure the machine is normal
transmission ECMV current adjustment”
(failure is not detected).
that the transmission controlled oil tem-
a When stalling the torque converter,
perature is 55 – 70°C.If it is out of the
use care it may not be overheated.
range, stall the torque converter and
adjust the temperature to 55 – 70°C.
7-1-3. Adjustment of transmission ECMV current
4) Return the FNR (directional) lever or joy-
a Targets of correction are 6 types – F (forward),
stick steering FNR (directional) switch or
R (reverse), 1st, 2nd, 3rd and 4th. As the
right FNR (directional) switch to N (Neu-
adjustment of current is started, correction of
tral) and check that the oil leak tester is 55
all of above clutches is started automatically.
– 70°C after 3 minutes.
a Since the learning operation requires the spec-
5) Operate the FNR (directional) lever or joy-
ified oil temperature, the oil temperature must
stick steering FNR (directional) switch or
be adjusted to 55 – 70°C range.
right FNR (directional) switch and gear-
1) Turn on the starting switch (engine is not
shift lever or gearshift switch as shown
started) and then display T/M OIL TEMP
below to circulate the oil through the trans-
referencing “7-1-1 Preparations for trans-
mission.
mission ECMV current adjustment”.
a When performing the following opera-
2) Run the engine at low idle, release the
tion, run the engine at low idle, turn
accelerator pedal, set the FNR (direc-
manual switch ON, turn the torque
tional) lever or joystick steering FNR
converter lockup switch OFF, and turn
(directional) switch or right FNR (direc-
lockup switch OFF.
tional) switch in N (Neutral), parking brake
a Make sure the machine is normal
ON, and check that the transmission con-
(failure is not detected).
trol oil temperature is 55 – 70°C.
a When stalling the torque converter,
use care it may not be overheated.
3) Display the TUNING screen from the
menu screen of Service mode.
WA470-6 WA480-6 41
SEN01591-02 30 Testing and adjusting
Operat-
1 2 3 4
ing order
IP [IP F-1] [IP F-2] [IP F-3] [IP F-4]
ECMV/
F/1st F/2nd F/3rd F/4th
fre-
time time time time
quency
Operat-
5 6 7 8
ing order
IP [IP R-1] [IP R-2] [IP R-3] [IP R-4]
6) Press [U] switch to settle the adjustment
item. ECMV/
R/1st R/2nd R/3rd R/4th
fre-
time time time time
quency
Operat-
9 10 11 12
ing order
IP [IP 1-1] [IP 1-2] [IP 1-3] [IP 1-4]
ECMV/
1st/1st 1st/2nd 1st/3rd 1st/4th
fre-
time time time time
quency
42 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 43
SEN01591-02 30 Testing and adjusting
7-2. Setting of transmission initial learning 5) Press [U] switch to settle the adjustment
When initializing all the past initial trigger learn- item. As the item is settled, the initial
ing data stored on the transmission controller, learning reset screen appears.
employ the following procedure. a If the initial learning is not done, INITIAL
7-2-1. Reset of initial learning STATUS will be displayed.
1) Turn on the starting switch. (Engine does
not start)
2) Set the FNR (directional) lever or joystick
steering FNR (directional) switch or right
FNR (directional) switch in N (Neutral).
3) Display the TUNING screen from the
menu screen of Service mode.
44 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
7-2-2. Preparations for transmission initial learning 4) Using [U] switch, settle 2 items display of
1) Display the REAL-TIME MONITOR from the transmission control oil temperature
the menu screen of Service mode. and the trigger learning display.
a Content of the trigger learning is displayed
for each of F, R, 1st, 2nd, 3rd and 4th
clutch in the figure.
q 0: Learning not done yet
q 1: Learning completed
WA470-6 WA480-6 45
SEN01591-02 30 Testing and adjusting
4) Operate the FNR (directional) lever or joy- 7-3. Adjustment of transmission L mode shift
stick steering FNR (directional) switch or point function
right FNR (directional) switch and gear- a This function is used for modifying the shift
shift lever or gearshift switch as shown point when the shift mode switch is at L posi-
below to perform the initial learning. tion by adding a correction amount.
a The factory default setting of the correction
Operating amount shall be 0.
order
1 2 3 4 a The shift point depends on the engine mode.
When this function is used, however, the same
Gear
N2 F2 F1 F2 correction value is applied independent of the
speed
engine mode.
Holding Min. 6 Min. 6 Min. 6 Min. 4
a Some of the shift points being adjusted with
time sec. sec. sec. sec.
the shift point adjustment function may not
Operating include the following shift patterns.
5 6 7 8
order
Gear q The shift point that is used when the hunt-
F3 F4 F3 F2 ing prevention function is turned on.
speed
q The shift down point that is used when the
Holding Min. 4 Min. 4 Min. 4 Min. 4
accelerator is set to idle.
time sec. sec. sec. sec.
a After a shift point adjustment is done, confirma-
Operating tion on the machine must be done.
9 10 11
order
Gear 7-3-1. Changing the set data
N2 R2 N2 Change the set data according to the following
speed
procedure.
Holding Min. 4 Min. 4 Min. 4
time sec. sec. sec. 1) Display the “Sensor tuning function
screen” on the service mode menu
a Hold the gear shift lever in each gear screen.
speed for more than the specified time. 2) Press the [U] switch to select “TUNING”.
a If the gear shift lever is operated before
the specified time is reached, the initial
learning is not completed (TUNED is not
displayed).
46 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 47
SEN01591-02 30 Testing and adjusting
48 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 49
SEN01591-02 30 Testing and adjusting
7-17. Adjustment of lift arm angle sensor (raise) 4) Press [U] switch to settle the selection.
(For load meter) a As the selection is settled, the RAISE
1) Display the TUNING screen from the ANGLE screen will appear.
menu screen of Service mode.
50 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
7-18. Adjustment of lift arm angle sensor 4) Press [U] switch to settle the selection.
(lower) (For load meter) a As the selection is settled, the LOWER
1) Display the TUNING screen from the ANGLE screen will appear.
menu screen of Service mode.
WA470-6 WA480-6 51
SEN01591-02 30 Testing and adjusting
7-20. Adjustment of interval of fan automatic 3) With the [<] and [>] switches, select 22:
reverse operation (Automatic reverse fan Adjust interval of fan automatic reverse
(if equipped) specification) operation.
a This function is used to change the inter-
val of the forward and reverse operations
of the fan when the fan automatic reverse
operation is selected.
a The interval of the fan automatic reverse
operation is adjustable in the range from
0.1 h (6 minutes) to 200 h. It must be set
to at least twice the continuance of the fan
automatic reverse operation, however,
and cannot be set shorter than twice.
a When the machine is delivered, the inter-
val of fan automatic reverse operation is
set to 2.0 h.
a When the machine is delivered, the con-
tinuance of the fan automatic reverse 4) Press the [U] switch to settle.
operation is set to 2 minutes. a If the [U] switch is pressed, the screen
1) On the service mode menu screen, dis- to adjust the interval of fan automatic
play the TUNING screen. reverse operation is displayed.
5) With the [<] and [>] switches, select an
interval in the range from “0.1” to “200”
(Unit: h).
6) Press the [t] switch to settle the setting.
a The selected interval of fan automatic
reverse operation is not changed to a
value less than twice the continuance
of the fan automatic reverse operation.
52 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
7-21. Adjustment of continuance of fan auto- 3) With the [<] and [>] switches, select 23:
m at i c r e v e r s e o p e r a ti o n ( A u to m a ti c Adjust continuance of fan automatic
reverse fan (if equipped) specification) reverse operation.
a This function is used to change the contin-
uance of the reverse operation when the
fan automatic reverse operation is
selected.
a The continuance of the fan automatic
reverse operation is adjustable in the
range from 0.5 minutes to 10 minutes. It
must be set to below 1/2 of the interval of
the fan automatic reverse operation, how-
ever, and cannot be set longer than 1/2.
a When the machine is delivered, the con-
tinuance of fan automatic reverse opera-
tion is set to 2.0 minutes.
a When the machine is delivered, the inter-
val of the fan automatic reverse operation 4) Press the [U] switch to settle.
is set to 2.0 h. a If the [U] switch is pressed, the
1) On the service mode menu screen, dis- screen to adjust the continuance of
play the TUNING screen. fan automatic reverse operation is
displayed.
5) With the [<] and [>] switches, select a con-
tinuance in the range from “0.5” to “10”
(Unit: minute).
6) Press the [t] switch to settle the setting.
a The selected continuance of fan auto-
matic reverse operation is not
changed to a value longer than 1/2 of
the interval of the fan automatic
reverse operation.
WA470-6 WA480-6 53
SEN01591-02 30 Testing and adjusting
54 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
WA470-6 WA480-6 55
SEN01591-02 30 Testing and adjusting
6) Select “YES” or “NO” using [<] or [>] a When “Timer by item” is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
“YES” is selecte d a nd [t] switch is
pressed, the information will be deleted. If
“NO” is selected and [t] switch is
pressed, deletion is cancelled and the
maintenance interval change item screen
is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If “Timer by item” is disabled, OFF will be
displayed in the upper column.
56 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
3) Select “YES” or “NO” using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select “YES” or “NO” using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
“YES” is selected a nd [t] switch is “YES” is selected and [t] switch is
pressed, the information will be deleted. If pressed, the change will be enabled If
“NO” is selected and [t] switch is “NO” is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
to prevent resetting error.
to prevent resetting error.
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set – Elapsed time from the last replace-
ment
WA470-6 WA480-6 57
SEN01591-02 30 Testing and adjusting
2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
58 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
7) As the timer stop for all items is executed: 9. Operating information display function
a The timer function for all items is stopped It is a fuel consumption-related function and
a n d t h e M A I N T E N A N C E M O N I TO R displays the following information.
screen is restored. q Fuel consumption ratio and average fuel
a Setting for individual items is also disabled. consumption
a If cancelled: The operation is cancelled q Cumulative fuel consumption and travel
a n d t h e M A I N T E N A N C E M O N I TO R distance
screen is restored. q Cumulative fuel consumption and elapsed
8) When timer enable for all items is executed: time
a Interval time being set for all items is exe- q Loaded volume and loading frequency
cuted to the set value before disabled (This display is available only when the
independent of whether or not it is load meter is installed.)
enabled or disabled for a specific item. 1) Selecting menu
a The timer remaining time is reset. (The Display the OPERATION INFO screen
reset frequency remains the same as from the menu screen of Service mode.
before the resetting.)
a The MAINTENANCE MONITOR screen is
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I N T E N A N C E M O N I TO R
screen is restored.
WA470-6 WA480-6 59
SEN01591-02 30 Testing and adjusting
60 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 61
SEN01591-02 30 Testing and adjusting
Item Setting at
Item Display in English Contents of selection
No. delivery
62 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 63
SEN01591-02 30 Testing and adjusting
a Be sure to start setting of each option on BOOM TYPE OPTION SELECT screen. After chang-
ing or settling the option, set other items in order on the next AUTO GREASE OPTION
SELECT screen and the following screens.
64 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
10-1. Change or settlement of “BOOM TYPE OPTION 10-3. Setting tire deflection option
SELECT” a Select the tire deflection option from the list of
a If the [U] switch is pressed on the BOOM installed optional devices and their setting.
TYPE OPTION SELECT screen, “STD” or a Pressing [U] switch sequentially displays
“HI LIFT” is selected alternately. [@@]% in the following order.
a If “STD” or “HI LIFT” is selected, the oper- a The display progresses from +00 through –10.
ation receiving sound (beep) is made. Pressing [U] switch at this point returns the
q STD: Standard boom display to +00.
q HILIFT: High lift boom (Optional)
Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
10-2. Option setting/not setting selection @@ +00 +02 +04 +06 +08 +10 +12
a Among the items included in the list of
installed optional devices and their setting, Order No.8 No.9 No.10 No.11 No.12 No.13 No.14
the option setting/not setting selection @@ –02 –4 –6 –8 –10 –12 +00
applies to the following items.
a If the options are not selected, the option a As the display is switched, the sound (beep)
non-selection screen (NO ADD) is displayed. indicating acceptance of the operation will be
generated.
WA470-6 WA480-6 65
SEN01591-02 30 Testing and adjusting
11. Machine serial number input function 12. Machine model select function (MACHINE)
1) Display the MACHINE No. SET screen a The setting of the machine model of the
from the menu screen of Service mode. machine monitor can be changed with the
machine model select function.
a If the machine monitor is initialized, per-
form the machine model select operation
first.
a If the machine model select operation is
performed, the setting of options is reset.
Accordingly, start with the option select
operation and select all the options.
66 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
3) With the [<] and [>] switches, select the 13. Initialize function
machine model or tire size. This function is used only in the factory. It is,
Select model and tire size based on therefore, not used for a service purpose.
installed tire.
Machine
Tire size Display
model
WA470
26.5 – 25
Tire 26.5
WA470
WA470
23.5 – 25
Tire 23.5
WA480 26.5 – 25 WA480
a If wrong model and tire are set,
machine does not work correctly.
a Press [t] switch when stopping the model
selection.
a As the operation is stopped, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.
4) With the [U] switch, settle the changed
machine model and tire size.
a As the selection is settled, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.
a Check that the desired machine model
and tire size are displayed on the machine
model select screen.
WA470-6 WA480-6 67
SEN01591-02 30 Testing and adjusting
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine speed: 2.73 – 3.13 2.73 – 3.13
Main relief 2,000 rpm {27.9 – 31.9} {27.9 – 31.9}
pressure 2.58 – 2.98 2.58 – 2.98
Engine at low idle • Torque converter oil
{26.3 – 30.3} {26.3 – 30.3}
temperature: Within
Torque converter Engine speed: operating range Max. 0.93 Max. 0.93
inlet pressure 2,000 rpm {Max. 9.5} {Max. 9.5}
Transmission valve
68 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
WA470-6 WA480-6 69
SEN01591-02 30 Testing and adjusting
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine speed: 2.73 – 3.13 2.73 – 3.13
Main relief 2,000 rpm {27.9 – 31.9} {27.9 – 31.9}
pressure 2.58 – 2.98 2.58 – 2.98
Engine at low idle • Torque converter oil
{26.3 – 30.3} {26.3 – 30.3}
temperature: Within
Torque converter Engine speed: Max. 0.93 Max. 0.93
operating range
Transmission valve
70 WA470-6 WA480-6
30 Testing and adjusting SEN01591-02
—
Visual check of plug Rear axle excessive metal powder.
Memo
WA470-6 WA480-6 71
SEN01591-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
72
SEN01691-02
WA470-6
WA480-6
40 Troubleshooting 1
Failure code table and fuse locations
Failure code table ........................................................................................................................................... 2
Fuse locations............................................................................................................................................... 14
WA470-6, WA480-6 1
SEN01691-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
WA470-6, WA480-6 3
SEN01691-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
WA470-6, WA480-6 5
SEN01691-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
WA470-6, WA480-6 7
SEN01691-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
WA470-6, WA480-6 9
SEN01691-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
WA470-6, WA480-6 11
SEN01691-02 40 Troubleshooting
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Controller:
Controller indicates in which controller system the failure has occurred.
TM : Transmission controller system
MON : Machine monitor system
ENG : Engine controller system
WRK : Work equipment controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
12 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
a Category of record:
Category of record indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Optional equipments are also included in the table.
WA470-6, WA480-6 13
SEN01691-02 40 Troubleshooting
Fuse locations 1
Connection table of fuse box and slow blow fuse
a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box 1
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1 20 A Starting switch terminal B circuit
2 10 A Hazard lamp circuit
Machine monitor (B) circuit
3 10 A
Constant power KOMTRAX circuit
supply slow-blow 4 10 A Room lamp circuit
fuse (50 A) Transmission controller (B) circuit
5 5A
Work equipment controller (B) circuit (if equipped)
6 30 A Engine controller (A) circuit
7 10 A Spare 1
8 10 A Front working lamp circuit
9 10 A Rear working lamp circuit
10 20 A Car radio circuit and 12 V converter circuit
Switch power supply
11 10 A Turn signal lamp circuit
slow-blow fuse (50 A)
12 20 A Yellow rotary lamp circuit (if equipped)
13 10 A KOMTRAX (A) circuit (if equipped)
14 20 A Rear glass heater circuit
Switch power supply
15 5A Engine controller (B) circuit
starting switch ACC
14 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
Fuse box 2
Capacity of
Type of power supply Fuse No. Destination of power
fuse
1 10 A Horn circuit
2 10 A Transmission controller (A) circuit
3 5A Parking brake circuit
4 5A Emergency steering circuit
Work equipment positioner circuit
5 10 A
Constant power sup- Work equipment controller (A) circuit (if equipped)
ply slow-blow fuse 6 10 A Rear lamp and brake lamp circuit
(50 A) 7 20 A Wiper and washer circuit
8 20 A Air conditioner (A) circuit
9 5A Air conditioner (B) circuit
Machine monitor (B) circuit
10 10 A
Load meter printer (if equipped) circuit
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
head lamp relay 15 10 A Headlamp (left) circuit
WA470-6, WA480-6 15
SEN01691-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01691-02
WA470-6, WA480-6 17
SEN01691-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
18
SEN01692-02
WA470-6
WA480-6
40 Troubleshooting 1
General information on troubleshooting
Points to remember when troubleshooting ..................................................................................................... 2
Sequence of events in troubleshooting ........................................................................................................... 3
Testing before troubleshooting........................................................................................................................ 4
Classification and procedures of troubleshooting ........................................................................................... 5
Information contained in troubleshooting table ............................................................................................... 9
Connection table for connector pin numbers .................................................................................................11
T- branch box and T- branch adapter table................................................................................................... 47
WA470-6, WA480-6 1
SEN01692-02 40 Troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a shortcut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
2 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 3
SEN01692-02 40 Troubleshooting
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Lubricating oil and coolant
6. Check of level and type of hydraulic oil Between H and L Add oil
7. Check of level and type of transmission oil Between H and L Add oil
Retighten or
11. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
20. Check of battery electrolyte level Between U.L and L.L Add or replace
21. Check wires for discoloration, burn, and removal of cover — Replace
Electrical equipment
22. Check for removed wire clamp and drooping wire — Repair
23. Check wiring for wetting with water (Check connectors and Disconnect and dry
—
terminals for wetting with water, in particular) connectors
24. Check of slow-blow fuses and fuses for disconnection and
— Replace
corrosion
25. Check of alternator voltage (with engine at medium speed or After several-minute
Repair or replace
higher) operation: 27.5 – 29.5 V
26. Check of operating sound of battery relay (Starting switch
— Replace
OFF o ON)
4 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code “flashes” when the trouble corresponding to it is detected. Even if a failure code
“lights up” when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trou-
bleshooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is
not recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of “Phenomena looking like troubles and troubleshooting Nos.”, and then carry out trouble-
shooting related to that phenomenon in the “E-mode”, “H-mode”, or “S-mode”.
WA470-6, WA480-6 5
SEN01692-02 40 Troubleshooting
Troubleshooting
No. Phenomena looking like trouble Code
E-mode H-mode S-mode
display
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily E-1 S-1
4 Engine does not turn E-1 S-2 a)
5 Engine turns but no exhaust smoke comes out S-2 b)
Engine does not start
Exhaust smoke comes out but engine does not
6 S-2 c)
start (Fuel is injected)
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-2 S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Coolant contains oil (blows back or reduces) S-11
16 Oil pressure drops S-12
17 Oil level rises (Water or fuel is mixed in oil) S-13
18 Coolant temperature is too high (Overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
Phenomena related to power train
21 Machine does not start H-1
Torque converter lockup is not switched (engine stalls)
22 H-2
[Lockup clutch specification (If equipped)]
Torque converter lockup is not turned on
23 H-3
[Lockup clutch specification (If equipped)]
Travel speed is slow, the thrusting force is weak, the uphill traveling
24 H-4
power is weak, and the gear is not shifted
25 Large shocks are made when machine starts and gear is shifted H-5
26 Large time lag is made when machine starts and gear is shifted H-6
27 Torque converter oil temperature is high H-7
Phenomena related to steering
28 Steering does not turn H-8
29 Steering does not turn [Joystick steering specification (If equipped)] H-9
30 Steering response is low H-10
31 Steering response is low [Joystick steering specification (If equipped)] H-11
32 Steering is heavy H-12
33 Steering wheel shakes or makes large shocks H-13
Steering wheel shakes or makes large shocks [Joystick steering
34 H-14
specification (If equipped)]
6 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 7
SEN01692-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
WA470-6, WA480-6 9
SEN01692-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
a The terms of male and female refer to the pins, while the terms of male housing and female housing
refer to the mating portion of the housing.
WA470-6, WA480-6 11
SEN01692-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 13
SEN01692-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 15
SEN01692-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 17
SEN01692-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 19
SEN01692-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 21
SEN01692-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 23
SEN01692-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 25
SEN01692-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 27
SEN01692-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 29
SEN01692-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 31
SEN01692-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 33
SEN01692-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 35
SEN01692-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 37
SEN01692-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 39
SEN01692-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 41
SEN01692-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 43
SEN01692-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
WA470-6, WA480-6 45
SEN01692-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
WA470-6, WA480-6 47
SEN01692-02 40 Troubleshooting
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
48 WA470-6, WA480-6
40 Troubleshooting SEN01692-02
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9330 Case q
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* 2 P q q
Socket for engine (CRI-T3) PCV
799-601-9440* Socket for engine (CRI-T2) 3 1,2,3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* 2 A q q
Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2) 3 — q
795-799-5470 Cable for engine (HPI-T2) 3 — q
795-799-5480 Cable for engine (HPI-T2) 3 — q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
Adapter for engine (CRI-T3)
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
Socket for engine (CRI-T3)
799-601-4190* 3 1,2,3L q q
Commonrail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1,2,3,4C q q
Air intake pressure/temperature
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1,2,3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1,2,3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1,2,3,G q q
Socket for engine (CRI-T3)
799-601-4340* 2 2,PA q q
Pump actuator
Socket for engine (CRI-T3)(95)
799-601-4380* 4 1,2,3,4T q
Air intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 — q
799-601-4280* Box for controller (PUMP) 121 — q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
Multi-adapter for
799-601-9890 3, — q
DT2 – 4 and DTM2
4,
WA470-6, WA480-6 49
SEN01692-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
50
SEN01693-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1
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
WA470-6, WA480-6 1
SEN01693-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 3
SEN01693-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 5
SEN01693-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 7
SEN01693-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 9
SEN01693-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 11
SEN01693-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 13
SEN01693-02 40 Troubleshooting
Failure code [15SELH] (ECMV 1st clutch: When command current is ON,
fill signal is OFF) 1
Action code Failure code ECMV 1st clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SELH (Transmission controller)
Contents of
• When 1st ECMV solenoid output is turned ON, 1st ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 1st ECMV fill switch signal is turned OFF.
controller • If problem is removed, system is returned to normal operating state.
Problem that
• The machine may not travel at 1st speed.
appears on
• When the 1st gear speed is changed, a shock or a time lag may be made.
machine
• This failure code may also be displayed immensely after replacement of the transmission oil.
• The output state (current value) to the 1st clutch ECMV solenoid can be checked with the monitoring
function (Code: 31602, ECMV 1 DIR).
Related • The input state (ON/OFF) from the 1st fill switch can be checked with the monitoring function (Code:
information 40908, D-IN-26).
• Method of reproducing failure code: Start the engine, set the manual/auto shift selector switch in the
MANUAL position, set FNR (directional) lever, joystick steering FNR (directional) switch or right FNR
(directional) switch to the F (forward) or R (reverse), then set shift lever to 1st speed position.
14 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 15
SEN01693-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 17
SEN01693-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 19
SEN01693-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 21
SEN01693-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 23
SEN01693-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 25
SEN01693-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 27
SEN01693-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 29
SEN01693-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 31
SEN01693-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 33
SEN01693-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01693-02
WA470-6, WA480-6 35
SEN01693-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
36
SEN01694-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 2
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
WA470-6, WA480-6 1
SEN01694-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 3
SEN01694-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 5
SEN01694-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 7
SEN01694-02 40 Troubleshooting
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes ness without turning starting switch ON.
3
and standard (Disconnection or defective Wiring harnesses between terminal R (E02) Resis-
contact in connector) Max. 1 z
value in normal – L52 (female) (18) tance
state a Prepare by turning starting switch OFF and then start engine to
Grounding fault in wiring har- carry out troubleshooting.
4 ness Wiring harness between terminal R (E02) –
(Contact with ground circuit) L52 (female) (18) – circuit branch end and Resis-
Min. 1 Mz
tance
chassis ground
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
L52 Engine Voltage
5 Defective machine monitor
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
chassis ground
Holds in position Max. 1 V
8 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 9
SEN01694-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 11
SEN01694-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 13
SEN01694-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 15
SEN01694-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 17
SEN01694-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 19
SEN01694-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 21
SEN01694-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 23
SEN01694-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 25
SEN01694-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 27
SEN01694-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 29
SEN01694-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 31
SEN01694-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 33
SEN01694-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 35
SEN01694-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 37
SEN01694-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 39
SEN01694-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 41
SEN01694-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 43
SEN01694-02 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Short circuit in wiring har- without turning starting switch ON.
value in normal 3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) – EC1 (female) (With all con- Resis-
state Min. 1 Mz
tance
nectors of wiring harness disconnected)
Connecting parts among coolant temperature sensor, engine wiring
harness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
4 • Loose connector, broken lock, broken seal
connector
• Corrosive, bent, broken, forced-in, or extended pin
• Humidity in connector, entry of dirt or dust, poor insulation
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
EC1 (female) Temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
5 Defective engine controller Between (15) and
50°C 3.2 – 3.8 kz
(38)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Between (15) and
All range Min. 1 Mz
chassis ground
44 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 45
SEN01694-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 47
SEN01694-02 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 49
SEN01694-02 40 Troubleshooting
50 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 51
SEN01694-02 40 Troubleshooting
52 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 53
SEN01694-02 40 Troubleshooting
54 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 55
SEN01694-02 40 Troubleshooting
56 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 57
SEN01694-02 40 Troubleshooting
58 WA470-6, WA480-6
40 Troubleshooting SEN01694-02
WA470-6, WA480-6 59
SEN01694-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
60
SEN01695-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 3
Failure code [CA263] (Fuel temperature sensor high error) ........................................................................... 4
Failure code [CA265] (Fuel temperature sensor low error)............................................................................. 6
Failure code [CA271] (PCV1 Short circuit) ..................................................................................................... 8
Failure code [CA272] (PCV1 Disconnection)................................................................................................ 10
Failure code [CA273] (PCV2 Short circuit) ................................................................................................... 12
Failure code [CA274] (PCV2 Disconnection)................................................................................................ 14
Failure code [CA322] (Injector #1 open/short error) ..................................................................................... 16
Failure code [CA323] (Injector #5 open/short error) ..................................................................................... 18
Failure code [CA324] (Injector #3 open/short error) ..................................................................................... 20
Failure code [CA325] (Injector #6 open/short error) ..................................................................................... 22
Failure code [CA331] (Injector #2 open/short error) ..................................................................................... 24
Failure code [CA332] (Injector #4 open/short error) ..................................................................................... 26
Failure code [CA342] (Calibration code inconsistency) ................................................................................ 28
Failure code [CA351] (Injectors drive circuit error) ....................................................................................... 29
WA470-6, WA480-6 1
SEN01695-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 3
SEN01695-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 5
SEN01695-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 7
SEN01695-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 9
SEN01695-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 11
SEN01695-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 13
SEN01695-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 15
SEN01695-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 17
SEN01695-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 19
SEN01695-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 21
SEN01695-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 23
SEN01695-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 25
SEN01695-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 27
SEN01695-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 29
SEN01695-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 31
SEN01695-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 33
SEN01695-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 ×
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 ×
(Voltage when pedal pressed – Voltage
when pedal opened)
WA470-6, WA480-6 35
SEN01695-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 ×
(Voltage when pedal pressed – Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 ×
(Voltage when pedal pressed – Voltage
when pedal opened)
WA470-6, WA480-6 37
SEN01695-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 39
SEN01695-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 41
SEN01695-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 43
SEN01695-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 45
SEN01695-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 47
SEN01695-02 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 49
SEN01695-02 40 Troubleshooting
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
q Overflow valve (1): Spring is seen through both holes.
q Bypass valve (2): Spring is seen through hole on nut side.
q Fuel inlet joint (3): Gauze filter is seen through both holes.
Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
50 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle (P-mode) rpm 800 +50
+50
WA470-6, WA480-6 51
SEN01695-02 40 Troubleshooting
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Standard value Measured
Code Display item Check conditions Unit Good Bad
(Reference value) value
Low idle (P-mode) rpm 800 +50
+50
52 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 53
SEN01695-02 40 Troubleshooting
54 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 55
SEN01695-02 40 Troubleshooting
56 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 57
SEN01695-02 40 Troubleshooting
58 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 59
SEN01695-02 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – L62 (female) (22), (32) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
Disconnection in wiring har- (47) – L56 (female) (3), (8) tance
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) – L72 (female) (22), (32) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN2 (female) (A), (B) tance
60 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 61
SEN01695-02 40 Troubleshooting
62 WA470-6, WA480-6
40 Troubleshooting SEN01695-02
WA470-6, WA480-6 63
SEN01695-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
64
SEN01696-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 4
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 [D191KA] (Joystick steering neutral safety relay: Disconnection) ............................................ 24
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) ............................................... 26
WA470-6, WA480-6 1
SEN01696-02 40 Troubleshooting
Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) ........... 28
Failure code [D192KA] (ECSS solenoid: Disconnection).............................................................................. 30
Failure code [D192KB] (ECSS solenoid: Short circuit) ................................................................................. 31
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) ............................................. 32
Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection) ......................................... 34
Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit) ............................................. 36
Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line)......... 38
Failure code [D5ZHKA] (Terminal C signal: Disconnection or short circuit) .................................................. 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
Failure code [DAF5KP] (Machine monitor: Low output voltage) ................................................................... 60
Failure code [DAFRKR] (CAN communication with machine monitor:
Defective communication (Abnormality in target component system)) ..................................................... 64
2 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 3
SEN01696-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 5
SEN01696-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 7
SEN01696-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 9
SEN01696-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 11
SEN01696-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 13
SEN01696-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 15
SEN01696-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 17
SEN01696-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 19
SEN01696-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 21
SEN01696-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 23
SEN01696-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 25
SEN01696-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 27
SEN01696-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 29
SEN01696-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 31
SEN01696-02 40 Troubleshooting
Failure code [D192KY] (ECSS solenoid: Short circuit with power supply
line) 1
Action code Failure code ECSS solenoid: Short circuit with power supply line
Trouble
E01 D192KY (Transmission controller)
Contents of • Since the ECSS solenoid system is shorted with the power source, abnormal voltage was applied
trouble when ECSS solenoid output was turned OFF.
Action of
• If problem is removed, system is returned to normal operating state.
controller
Problem that
appears on • The ECSS keeps operating.
machine
• The output state (ON/OFF) to the ECSS solenoid can be checked with the monitoring function
Related (Code: 40949, D-OUT-1).
information • Applicable only to ECSS specification machines (if equipped)
• Method of reproducing failure code: Turn the starting switch ON.
32 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 33
SEN01696-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 35
SEN01696-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 37
SEN01696-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 39
SEN01696-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 41
SEN01696-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 43
SEN01696-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 45
SEN01696-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 47
SEN01696-02 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
Possible causes a Prepare with starting switch OFF, then turn starting switch ON,
and standard OFF or START and carry out troubleshooting
value in normal Defective work equipment L72 Starting switch Voltage
6
state controller
Between (25) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V
WA470-6, WA480-6 49
SEN01696-02 40 Troubleshooting
50 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 51
SEN01696-02 40 Troubleshooting
52 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine
running or stopped state) 1
Action code Failure code Terminal C signal: Signal does not match engine running or stopped
Trouble
E01 D5ZHL6 state (Machine monitor system)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and voltage is supplied to the alternator R terminal.)
Action of • None in particular.
controller • If problem is removed, system is returned to normal operating state.
Problem that
appears on • The engine does not start.
machine
• The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
Related
with the monitoring function (Code: 40900, D-IN-2).
information
• Method of reproducing failure code: Set the starting switch to START position.
WA470-6, WA480-6 53
SEN01696-02 40 Troubleshooting
54 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 55
SEN01696-02 40 Troubleshooting
56 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 57
SEN01696-02 40 Troubleshooting
58 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 59
SEN01696-02 40 Troubleshooting
Defective lift arm bottom a Prepare with starting switch OFF, then turn starting switch ON
2 pressure sensor and carry out troubleshooting.
(Internal short circuit) Lift arm bottom pres-
F16 Voltage
sure
Between (C) and (B) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Between (C) and (A) When released 0.50 – 0.90 V
When relieved 3.02 – 3.42 V
60 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
Defective lift arm head pres- a Prepare with starting switch OFF, then turn starting switch ON
3 sure sensor and carry out troubleshooting.
(Internal short circuit) Lift arm head pres-
F17 Voltage
sure
Between (C) and (B) Constant 4.85 – 5.15 V
Constant 0.50 – 4.50 V
Possible causes
Between (C) and (A) When released 0.50 – 0.90 V
and standard
value in normal When relieved 3.02 – 3.42 V
state a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Between L51 (female) (16) – F15 (female) Resis-
Grounding fault in wiring har- (C) wiring harness and chassis ground Min. 1 Mz
tance
4 ness
(Contact with ground circuit) Wiring harness between L51 (female) (16) – Resis-
Min. 1 Mz
F16 (female) (B) and chassis ground tance
Wiring harness between L51 (female) (16) – Resis-
Min. 1 Mz
F17 (female) (B) and chassis ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
5 Defective machine monitor L51 Lift arm cylinder Voltage
Between (16) and
Constant 4.85 – 5.15 V
chassis ground
WA470-6, WA480-6 61
SEN01696-02 40 Troubleshooting
62 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 63
SEN01696-02 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between L62 (female) (22), Resis-
Max. 1 z
state (32) – L56 (female) (3), (8) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
Disconnection in wiring har- (32) – L72 (female) (22), (32) tance
ness Wiring harness between L62 (female) (22), Resis-
2 Max. 1 z
(Disconnection or defective (32) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – L80 (female) (7), (8) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – CAN1 (female) (A), (B) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – CAN2 (female) (A), (B) tance
64 WA470-6, WA480-6
40 Troubleshooting SEN01696-02
WA470-6, WA480-6 65
SEN01696-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
66
SEN01697-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 5
Failure code [DAQ0KK] (Transmission controller: Low source voltage) ......................................................... 3
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller).................................................. 5
Failure code [DAQ1KA] (Terminal ACC input: Disconnection)........................................................................ 7
Failure code [DAQ2KK] (Transmission controller load power supply line:
Low source voltage (input))....................................................................................................................... 10
Failure code [DAQ9KQ] (Transmission controller model selection:
Disagreement of model selection signals) ................................................................................................ 12
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system)) ..................................................... 13
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ............................................ 15
Failure code [DB2RKR] (CAN communication with engine controller:
Defective communication (Abnormality in target component system) ...................................................... 16
Failure code [DB90KK] Work equipment controller: Low source voltage (input) .......................................... 18
Failure code [DB90KT] Work equipment controller: Abnormality in controller .............................................. 20
WA470-6, WA480-6 1
SEN01697-02 40 Troubleshooting
Failure code [DB92KK] Work equipment controller load power supply line:
Low source voltage (input) ........................................................................................................................ 21
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range ............ 23
Failure code [DB99KQ] (Work equipment controller model selection:
Disagreement in model selection signals)................................................................................................. 26
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system) ...................................................... 27
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ........................................ 29
Failure code [DB9RMC] (CAN communication with transmission controller: Defective operation)............... 30
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 34
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 36
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 38
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 40
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time ......................................................................................................... 42
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time ......................................................................................................... 44
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................... 46
Failure code [DD1FLD] Load meter mode selector switch (A/B):
Switch is kept pressed for long time ......................................................................................................... 48
Failure code [DD1GLD] Load meter mode selector switch (+/–):
Switch is kept pressed for long time ......................................................................................................... 50
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) ............ 52
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)..................................... 54
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)..................... 56
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).............................. 58
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) ........................................................................................................ 62
2 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 3
SEN01697-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 5
SEN01697-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 7
SEN01697-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 9
SEN01697-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 11
SEN01697-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between L62 (female) (22), Resis-
Max. 1 z
state (32) – L56 (female) (3), (8) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
Disconnection in wiring har- (32) – L72 (female) (22), (32) tance
ness Wiring harness between L62 (female) (22), Resis-
2 Max. 1 z
(Disconnection or defective (32) – EC2 (female) (46), (47) tance
contact in connector) Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – L80 (female) (7), (8) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – CAN1 (female) (A), (B) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – CAN2 (female) (A), (B) tance
WA470-6, WA480-6 13
SEN01697-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 15
SEN01697-02 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – L62 (female) (22), (32) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
Disconnection in wiring har- (47) – L56 (female) (3), (8) tance
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) – L72 (female) (22), (32) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – CAN2 (female) (A), (B) tance
16 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 17
SEN01697-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 19
SEN01697-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 21
SEN01697-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 23
SEN01697-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 25
SEN01697-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard without turning starting switch ON.
value in normal Wiring harness between L62 (female) (22), Resis-
Max. 1 z
state (32) – EC2 (female) (46), (47) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
Disconnection in wiring har- (32) – L56 (female) (3), (8) tance
ness Wiring harness between L62 (female) (22), Resis-
2 Max. 1 z
(Disconnection or defective (32) – L72 (female) (22), (32) tance
contact in connector) Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – L80 (female) (7), (8) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – CAN1 (female) (A), (B) tance
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
(32) – CAN2 (female) (A), (B) tance
WA470-6, WA480-6 27
SEN01697-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 29
SEN01697-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 31
SEN01697-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 33
SEN01697-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 35
SEN01697-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 37
SEN01697-02 40 Troubleshooting
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed
for long time 1
Action code Failure code < switch (Panel switch 3): Switch is kept pressed for a long time
Trouble
E01 DD17LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor.
appears on
• Some characters do not appear on the character display.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
Related be checked with the monitoring function (Code: 40904, D-IN-38).
information • The operator may not be able to use the monitoring function because of the “<” switch trouble.
• Method of reproducing failure code: Turn the starting switch ON.
38 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 39
SEN01697-02 40 Troubleshooting
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed
for long time 1
Action code Failure code > switch (Panel switch 4): Switch is kept pressed for long time
Trouble
E01 DD18LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
• None in particular.
controller
Problem that
• The operator cannot operate the monitor.
appears on
• Some characters do not appear on the character display.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4) can
Related be checked with the monitoring function (Code: 40904, D-IN-37).
information • The operator may not be able to use the monitoring function because of the > switch trouble.
• Method of reproducing failure code: Turn the starting switch ON.
40 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 41
SEN01697-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 43
SEN01697-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 45
SEN01697-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 47
SEN01697-02 40 Troubleshooting
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch
is kept pressed for long time 1
Action code Failure code Load meter mode selector switch (A/B): Switch is kept pressed for
Trouble
E01 DD1FLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (A/B) is kept CLOSED for more than contin-
trouble uous 1 minute.
Action of
• None in particular.
controller
Problem that
• The working object cannot be changed.
appears on
• Some characters do not appear on the character display.
machine
• The input state (ON/OFF) from the load meter mode selector switch (A/B) can be checked with the
Related monitoring function (Code: 40901, D-IN-10).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn the starting switch ON.
48 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 49
SEN01697-02 40 Troubleshooting
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch
is kept pressed for long time 1
Action code Failure code Load meter mode selector switch (+/–): Switch is kept pressed for
Trouble
E01 DD1GLD long time (Machine monitor system)
Contents of • The input circuit of the load meter mode selector switch (+/–) is kept CLOSED for more than continu-
trouble ous 1 minute
Action of
• None in particular.
controller
Problem that
• The operator cannot make settings of load meter addition mode.
appears on
• Some characters do not appear on the character display.
machine
• The input state (ON/OFF) from the load meter mode selector switch (+/–) can be checked with the
Related monitoring function (Code: 40901, D-IN-11).
information • Only for load meter (if equipped)
• Method of reproducing failure code: Turn the starting switch ON.
50 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 51
SEN01697-02 40 Troubleshooting
52 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 53
SEN01697-02 40 Troubleshooting
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for
long time) 1
Action code Failure code Fan reverse switch: Switch is kept pressed for long time.
Trouble
E01 DD1NLD (Transmission controller system)
Contents of • Since the fan reverse switch system is shorted with the power source, the fan reverse switch
trouble remains at ON position.
Action of
• None in particular.
controller
Problem that
appears on • Fan remains in the reverse rotation.
machine
• The input state (ON/OFF) from the fan reverse switch can be checked with the monitoring function
Related
(Code: 93400, FAN REVERSE SW).
information
• Method of reproducing failure code: Turn the starting switch ON.
54 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
Circuit diagram related to the fan reverse switch & fan automatic reverse switch
WA470-6, WA480-6 55
SEN01697-02 40 Troubleshooting
56 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
Circuit diagram related to the fan reverse switch & fan automatic reverse switch
WA470-6, WA480-6 57
SEN01697-02 40 Troubleshooting
58 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 59
SEN01697-02 40 Troubleshooting
60 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 61
SEN01697-02 40 Troubleshooting
62 WA470-6, WA480-6
40 Troubleshooting SEN01697-02
WA470-6, WA480-6 63
SEN01697-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
64
SEN01698-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 6
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)....................................................... 4
Failure code [DDK3KA] (Right FNR switch: Disconnection) ........................................................................... 6
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) ......................................................... 9
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)........................ 12
Failure code [DDK6KA] (FNR lever switch: Disconnection).......................................................................... 14
Failure code [DDK6KB] (FNR lever switch: Short circuit) ............................................................................. 18
Failure code [DDS5KA] (Steering pressure switch: Disconnected) .............................................................. 20
Failure code [DDS5KB] (Steering pressure switch: Short circuit) ................................................................. 22
Failure code [DDS5L6] (Steering: Low oil pressure)..................................................................................... 24
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) .......................................... 26
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) .................. 28
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) ...................................... 30
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)................................................ 32
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) .......................... 34
WA470-6, WA480-6 1
SEN01698-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 3
SEN01698-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 5
SEN01698-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 7
SEN01698-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 9
SEN01698-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 11
SEN01698-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 13
SEN01698-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 15
SEN01698-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 17
SEN01698-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 19
SEN01698-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 21
SEN01698-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 23
SEN01698-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 25
SEN01698-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 27
SEN01698-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 29
SEN01698-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 31
SEN01698-02 40 Troubleshooting
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long
time) 1
Action code Failure code Hold switch: Switch is kept pressed for long time
Trouble
E01 DDWLLD (Transmission controller system)
Contents of
• Since the hold switch system is shorted, holding of signals becomes unavailable.
trouble
Action of • Holds once when a grounding fault occurs, then does not control holding.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • When ground fault occurs, turns the hold switch once.
machine
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
Related
40908, D-IN-31).
information
• Method of reproducing failure code: Turn the starting switch ON.
32 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 33
SEN01698-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 35
SEN01698-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 37
SEN01698-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 39
SEN01698-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 41
SEN01698-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 43
SEN01698-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 45
SEN01698-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 47
SEN01698-02 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 49
SEN01698-02 40 Troubleshooting
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input
signal range) 1
Action code Failure code Rear brake oil temperature sensor: Out of input signal range
Trouble
E01 DGR2KX (Machine monitor system)
• Due to grounding fault in the rear brake oil temperature sensor signal system, the signal level is
Contents of
lower than normal range (Rear brake oil temperature sensor signal voltage: Max. 0.97 V (Min.
trouble
150°C))
Action of
• If problem is removed, system is returned to normal operating state.
controller
Problem that
appears on —
machine
• The input state (oil temperature) from the rear brake oil temperature sensor can be checked with the
monitoring function (Code: 30202, R BRAKE OIL).
Related
• The input state (voltage) from the rear brake oil temperature sensor can be checked with the moni-
information
toring function (Code: 30205, R BRAKE OIL).
• Method of reproducing failure code: Turn the starting switch ON.
50 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 51
SEN01698-02 40 Troubleshooting
52 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 53
SEN01698-02 40 Troubleshooting
Defective loader pump pres- Between (B) and (A) Always 4.75 – 5.25 V
sure sensor Always 0.50 – 4.5 V
1
(Internal disconnection or When in neutral 0.5 – 0.9 V
short circuit) Between (C) and (A)
When bucket is tilted
3.06 – 3.46 V
to relieve oil
Sensor voltage is measured with wiring harness connected.
Accordingly, if voltage is abnormal, check wiring harness and con-
troller, too, for another cause of trouble, and then judge.
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes without turning starting switch ON.
ness (Disconnection or
and standard 2
defective contact in connec- Wiring harness between L61 (female) (13) – Resis-
value in normal
tor) Max. 1 z
state F12 (female) (C) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring
Wiring harness between L61 (female) (13) – Resis-
3 harness Min. 1 Mz
F12 (female) (C) and chassis ground tance
(Contact with ground circuit)
Wiring harness between L61 (female) (22) – Resis-
Min. 1 Mz
F12 (female) (B) and chassis ground tance
a Prepare with starting switch OFF, then start engine, tilt bucket,
and carry out troubleshooting.
Loader pump
L61 Voltage
Defective transmission con- pressure
4
troller Always 0.50 – 4.5 V
Between (13) and When in neutral 0.5 – 0.9 V
chassis ground When bucket is tilted
3.06 – 3.46 V
to relieve oil
54 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 55
SEN01698-02 40 Troubleshooting
Defective loader pump pres- Between (B) and (A) Always 4.75 – 5.25 V
sure sensor Always 0.50 – 4.5 V
1
(Internal disconnection or When in neutral 0.5 – 0.9 V
short circuit) Between (C) and (A)
When bucket is tilted
3.06 – 3.46 V
to relieve oil
Sensor voltage is measured with wiring harness connected.
Possible causes
Accordingly, if voltage is abnormal, check wiring harness and con-
and standard
troller, too, for another cause of trouble, and then judge.
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
Hot short in wiring harness without turning starting switch ON.
2
(Contact with 24V circuit) Wiring harness between L61 (female) (13) – Resis-
Min. 1 Mz
F12 (female) (C) and chassis ground tance
a Prepare with starting switch OFF, then start engine, tilt bucket,
and carry out troubleshooting.
Loader pump
L61 Voltage
Defective transmission con- pressure
3
troller Always 0.50 – 4.5 V
Between (13) and When in neutral 0.5 – 0.9 V
chassis ground When bucket is tilted
3.06 – 3.46 V
to relieve oil
56 WA470-6, WA480-6
40 Troubleshooting SEN01698-02
WA470-6, WA480-6 57
SEN01698-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
58
SEN01699-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 7
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...................... 4
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)......................... 6
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) ........................... 8
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) ................................................... 10
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)....................................................... 12
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ...................................... 14
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...... 17
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) ....................... 20
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ....................................... 23
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub):
Short circuit with power supply line).......................................................................................................... 26
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)....................................... 29
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main):
Short circuit with power supply line).......................................................................................................... 32
WA470-6, WA480-6 1
SEN01699-02 40 Troubleshooting
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ........................ 35
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ........................................ 38
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub):
Short circuit with power supply line).......................................................................................................... 41
2 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 3
SEN01699-02 40 Troubleshooting
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out
of input signal range) 1
Action code Failure code Lift arm cylinder bottom pressure sensor: Out of input signal range
Trouble
E01 DHPCKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder bottom pressure sensor signal, the lift
arm cylinder bottom pressure sensor voltage is lower than normal range (Lift arm bottom pressure
Contents of sensor signal voltage: Below 0.3 V).
trouble • Due to hot short circuit in the lift arm cylinder bottom pressure sensor signal, the lift arm cylinder bot-
tom pressure sensor voltage is higher than normal range (Lift arm cylinder bottom pressure sensor
signal voltage: Min. 4.7 V)
Action of
• If problem is removed, system is returned to normal operating state.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder bottom pressure sensor can be checked with
the monitoring function (Code: 40400, BOOM BTM PRESS).
Related • The input state (voltage) from the lift arm cylinder bottom pressure sensor can be checked with the
information monitoring function (Code: 40402, BOOM BTM PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation
4 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 5
SEN01699-02 40 Troubleshooting
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of
input signal range) 1
Action code Failure code Lift arm cylinder head pressure sensor: Out of input signal range
Trouble
E01 DHPDKX (Machine monitor system)
• Due to disconnection or grounding fault in the lift arm cylinder head pressure sensor signal, the lift
arm cylinder head pressure sensor voltage is lower than normal range (Lift arm cylinder head pres-
Contents of sure sensor signal voltage: Below 0.3 V)
trouble • Due to hot short circuit in the lift arm cylinder head pressure sensor signal, the lift arm cylinder head
pressure sensor voltage is higher than normal range (Lift arm cylinder head pressure sensor signal
voltage: Min. 4.7 V)
Action of
• If problem is removed, system is returned to normal operating state.
controller
Problem that
appears on • Machine monitor does not display load.
machine
• The input state (oil pressure) from the lift arm cylinder head pressure sensor can be checked with the
monitoring function (Code: 40500, BOOM HEAD PRESS).
Related • The input state (voltage) from the lift arm cylinder head pressure sensor can be checked with the
information monitoring function (Code: 40501, BOOM HEAD PRESS).
• Only for load meter (if equipped)
• Method of reproducing failure code: Start engine and perform lift arm lever operation
6 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 7
SEN01699-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 9
SEN01699-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 11
SEN01699-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 13
SEN01699-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 15
SEN01699-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short
circuit with power supply line) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Short circuit with the power
Trouble
E03 DK59KY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Main) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Main) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000, BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001, BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.
WA470-6, WA480-6 17
SEN01699-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 19
SEN01699-02 40 Troubleshooting
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog
signals disagree) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK59L8 (Work equipment controller system)
• Lift arm EPC lever potentiometer (Main & Sub) input signals disagree with each other.
Contents of
(Lift arm EPC lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or
trouble
(Lift arm EPC lever potentiometer signal voltage (sum of Main and Sub): Min. 5.3 V)
• Operates with either Main or Sub potentiometer, whichever detecting a position within neutrality
±5%, as the regular potentiometer.
• Turns the output OFF if both Main and Sub potentiometers should fail to detect a position within neu-
Action of
trality ±5%.
controller
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the lever is set to
appears on neutral.
machine • If both Main and Sub potentiometers are abnormal, lift arm does not move.
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000, BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001, BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
20 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 21
SEN01699-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 23
SEN01699-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 25
SEN01699-02 40 Troubleshooting
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short
circuit with power supply line) 1
Action code Failure code Lift arm EPC lever potentiometer (Sub): Short circuit with the power
Trouble
E03 DK5AKY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the lift arm EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of • Turns the centralized warning lamp and the alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until lift arm EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the lift arm EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42000, BOOM POT1).
Related
• The input state (voltage) from the lift arm EPC lever potentiometer (Sub) can be checked with the
information
monitoring function (Code: 42001, BOOM POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever
26 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 27
SEN01699-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 29
SEN01699-02 40 Troubleshooting
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal • Work equipment lock lever: Free
state L71 Bucket EPC lever Voltage
Between (22) and
Constant 4.85 – 5.15 V
Defective work equipment (10)
4
controller Lever at neutral 2.40 – 2.60 V
Tilt operation
3.69 – 4.09 V
(Before detent)
Between (7) and (10)
Tilt operation
3.91 – 4.31 V
(Detent position)
Full dump operation 0.69 – 1.09 V
30 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 31
SEN01699-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 33
SEN01699-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 35
SEN01699-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 37
SEN01699-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 39
SEN01699-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 41
SEN01699-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01699-02
WA470-6, WA480-6 43
SEN01699-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
44
SEN01700-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 8
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) ......................... 3
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main):
Short circuit with power supply line)............................................................................................................ 6
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) .......................... 8
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub):
Short circuit with power supply line)...........................................................................................................11
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main):
Analog signals disagree)........................................................................................................................... 13
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) ................................................................... 16
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) ................................... 18
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) ................................................................. 20
Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection) ...................................... 22
Failure code [DLT3LC] (Transmission output shaft speed sensor: Out of input signal range) ...................... 24
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).................................................. 26
WA470-6, WA480-6 1
SEN01700-02 40 Troubleshooting
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)..................................... 28
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .................................... 30
Failure code [DV00KB] (Alarm buzzer: Short circuit) .................................................................................... 32
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)......................................................... 34
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ............................................................ 36
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ........................ 38
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) ....................................................... 40
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ........................................................... 41
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ....................... 42
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection).............................................................. 44
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ................................................................. 45
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ............................. 46
2 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 3
SEN01700-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 5
SEN01700-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 7
SEN01700-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 9
SEN01700-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 11
SEN01700-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 13
SEN01700-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 15
SEN01700-02 40 Troubleshooting
Possible causes Between (B) and (A) Up stroke end 3.50 – 4.17 V
and standard Lower stroke end 0.83 – 1.88 V
value in normal
a Prepare with starting switch OFF, then carry out troubleshooting
state
without turning starting switch ON.
Disconnection in wiring Wiring harness between F18 (female) (A) – Resis-
Max. 1 z
harness chassis ground tance
2
(Disconnection in wiring Wiring harness between F18 (female) (B) – Resis-
harness or defective contact) Max. 1 z
L71 (female) (8) tance
Wiring harness between F18 (female) (C) – Resis-
Max. 1 z
L71 (female) (22) tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Grounding fault in wiring Wiring harness between F18 (female) (B) – Resis- Min.
3 harness L71 (female) (8) and chassis ground tance 1 Mz
(Contact with ground circuit) Wiring harness between F18 (female) (C) –
Resis- Min.
L71 (female) (22), – circuit branch end and
tance 1 Mz
chassis ground
16 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 17
SEN01700-02 40 Troubleshooting
Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power
supply line) 1
Action code Failure code Lift arm angle sensor: Short circuit with power supply line
Trouble
E01 DKA0KY (Work equipment controller system)
Contents of • Due to hot short circuit in the lift arm angle sensor system, the signal voltage is higher than normal
trouble range (Lift arm angle sensor signal: Min. 4.7 V).
• Judges that lift arm is at the highest position.
• Resets the remote positioner function.
• Resets semi-auto digging function.
• No PC control while the lift arm is rising.
Action of
• When the remote positioner down setting is ON, turns OFF the lift arm float detent, and when the
controller
remote positioner down setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm up detent OFF.
• Even if cause of failure disappears, system does not reset itself until lift arm lever is set to N (Neu-
tral).
Problem that • Remote positioner malfunction.
appears on • Faulty semi-auto digging operation.
machine • No PC control while the lift arm is rising.
• The input state (angle) from the lift arm angle sensor can be checked with the monitoring function
(Code: 06002, BOOM ANG).
Related
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
information
(Code: 06005, BOOM ANG).
• Method of reproducing failure code: Turn the starting switch ON.
18 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 19
SEN01700-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 21
SEN01700-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 23
SEN01700-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 25
SEN01700-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 27
SEN01700-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 29
SEN01700-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 31
SEN01700-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 33
SEN01700-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 35
SEN01700-02 40 Troubleshooting
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit
Trouble
E03 DW4PKB (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system is shorted, abnormal current flows when the lift
trouble arm raise EPC solenoid output is turned ON.
• Stops outputting the signal to the lift arm raise EPC solenoid.
Action of • Stops outputting the signal to the lift arm raise detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not rise.
machine
• The output state (current value) to the lift arm raise EPC solenoid can be checked with the monitor-
Related
ing function (Code: 41900, RAISE EPC DIR).
information
• Method of reproducing failure code: Engine started + lift arm raise
36 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 37
SEN01700-02 40 Troubleshooting
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Lift arm raise EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4PKY (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid signal system is shorted with the power source, abnormal volt-
trouble age is applied when the lift arm raise EPC solenoid output is OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipments do not work.
appears on
• The lift arm raise EPC solenoid may be burnt out.
machine
• The output state (current value) to the lift arm raise EPC solenoid can be checked with the monitor-
ing function (Code: 41900, RAISE EPC DIR).
• The output state (current value) to the lift arm lower EPC solenoid can be checked with the monitor-
ing function (Code: 41901, LOWER EPC DIR).
• The output state (current value) to the bucket tilt EPC solenoid can be checked with the monitoring
function (Code: 41902, TILT EPC DIR).
Related
• The output state (current value) to the bucket dump EPC solenoid can be checked with the monitor-
information
ing function (Code: 41903, DUMP EPC DIR).
• The output state (current value) to the 3-spool valve (attachment) extend EPC solenoid can be
checked with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current value) to the 3-spool valve (attachment) retract EPC solenoid can be
checked with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine
38 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 39
SEN01700-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) 1
Action code Failure code Lift arm lower EPC solenoid: Short circuit
Trouble
E03 DW4QKB (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system is shorted, abnormal current flows when the lift
trouble arm lower EPC solenoid output is ON.
• Stops outputting the signal to the lift arm lower EPC solenoid.
Action of • Stops outputting the signal to the lift arm float magnet detent.
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on • Lift arm does not lower.
machine
• The output state (current value) to the lift arm lower EPC solenoid can be checked with the monitor-
Related
ing function (Code: 41901, LOWER EPC DIR).
information
• Method of reproducing failure code: Start engine and lower the lift arm.
WA470-6, WA480-6 41
SEN01700-02 40 Troubleshooting
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Lift arm lower EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4QKY (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid signal system is shorted with the power source, abnormal volt-
trouble age is applied when the lift arm lower EPC solenoid output is OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipments do not work.
appears on
• The lift arm lower EPC solenoid may be burnt out.
machine
• The output state (current value) to the lift arm raise EPC solenoid can be checked with the monitor-
ing function (Code: 41900, RAISE EPC DIR).
• The output state (current value) to the lift arm lower EPC solenoid can be checked with the monitor-
ing function (Code: 41901, LOWER EPC DIR).
• The output state (current value) to the bucket tilt EPC solenoid can be checked with the monitoring
function (Code: 41902, TILT EPC DIR).
Related
• The output state (current value) to the bucket dump EPC solenoid can be checked with the monitor-
information
ing function (Code: 41903, DUMP EPC DIR).
• The output state (current value) to the 3-spool valve (attachment) extend EPC solenoid can be
checked with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current value) to the 3-spool valve (attachment) retract EPC solenoid can be
checked with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
42 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 43
SEN01700-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 45
SEN01700-02 40 Troubleshooting
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Bucket tilt EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4RKY (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system is shorted with the power source, abnormal voltage
trouble is applied when the bucket tilt EPC solenoid output is OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket tilt/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipments do not work.
appears on
• The bucket tilt EPC solenoid may be burnt out.
machine
• The output state (current value) to the lift arm raise EPC solenoid can be checked with the monitor-
ing function (Code: 41900, RAISE EPC DIR).
• The output state (current value) to the lift arm lower EPC solenoid can be checked with the monitor-
ing function (Code: 41901, LOWER EPC DIR).
• The output state (current value) to the bucket tilt EPC solenoid can be checked with the monitoring
function (Code: 41902, TILT EPC DIR).
Related
• The output state (current value) to the bucket dump EPC solenoid can be checked with the monitor-
information
ing function (Code: 41903, DUMP EPC DIR).
• The output state (current value) to the 3-spool valve (attachment) extend EPC solenoid can be
checked with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current value) to the 3-spool valve (attachment) retract EPC solenoid can be
checked with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
46 WA470-6, WA480-6
40 Troubleshooting SEN01700-02
WA470-6, WA480-6 47
SEN01700-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
48
SEN01701-01
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 9
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) .......................................................... 3
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) .............................................................. 4
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line).......................... 5
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) .................................................................... 7
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) ........................................................................ 8
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) .................................... 9
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection).............................................11
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit) ............................................... 12
Failure code [DW7DKY] (Hydraulic drive fan neutral solenoid: Short circuit with power supply line) ........... 13
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)........................................ 14
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ........................................... 16
Failure code [DWM1KY] (Work equipment neutral lock solenoid:
Short circuit with power supply line).......................................................................................................... 18
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)......................................... 20
WA470-6, WA480-6 1
SEN01701-01 40 Troubleshooting
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ............................................ 22
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid:
Short circuit with power supply line).......................................................................................................... 24
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .......................................... 26
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ............................................. 28
Failure code [DWN7KY] (Lift arm float magnet detent solenoid:
Short circuit with power supply line).......................................................................................................... 30
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) .............................................. 32
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit).................................................. 34
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) .................... 36
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)............................................................... 38
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) .................................................................. 39
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) .............................. 40
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)................................................................ 42
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ................................................................... 44
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ............................... 46
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ............................................................ 48
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)................................................................ 50
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ........................... 52
2 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 3
SEN01701-01 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Bucket dump EPC solenoid: Short circuit with power supply line
Trouble
E03 DW4SKY (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system is shorted with the power source, abnormal volt-
trouble age is applied when the bucket dump EPC solenoid output is OFF.
• Turns the output to the work equipment neutral lock solenoid ON.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/dump, 3-spool valve (attachment)
Action of extract/retract EPC solenoid.
controller • Stops outputting the signal to all work equipment detent.
• Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• When the work equipment neutral lock solenoid is turned ON, all the work equipments do not work.
appears on
• The bucket dump EPC solenoid may be burnt out.
machine
• The output state (current value) to the lift arm raise EPC solenoid can be checked with the monitor-
ing function (Code: 41900, RAISE EPC DIR).
• The output state (current value) to the lift arm lower EPC solenoid can be checked with the monitor-
ing function (Code: 41901, LOWER EPC DIR).
• The output state (current value) to the bucket tilt EPC solenoid can be checked with the monitoring
function (Code: 41902, TILT EPC DIR).
Related
• The output state (current value) to the bucket dump EPC solenoid can be checked with the monitor-
information
ing function (Code: 41903, DUMP EPC DIR).
• The output state (current value) to the 3-spool valve (attachment) extend EPC solenoid can be
checked with the monitoring function (Code: 41906, 3RD EPC1 DIR).
• The output state (current value) to the 3-spool valve (attachment) retract EPC solenoid can be
checked with the monitoring function (Code: 41907, 3RD EPC2 DIR).
• Method of reproducing failure code: Start engine.
WA470-6, WA480-6 5
SEN01701-01 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 7
SEN01701-01 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power
supply line) 1
Action code Failure code Fan reverse solenoid: Short circuit with power supply line
Trouble
E01 DW7BKY (Transmission controller system)
Contents of • Since the fan reverse solenoid system is shorted with the power source, abnormal voltage is applied
trouble when the fan reverse switch output is OFF.
Action of • Disables the automatic fan reverse function (OPT).
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (OPT)
Problem that
specification.
appears on
• Forward rotation of the fan becomes unavailable.
machine
• Overheating can result.
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-4).
information
• Method of reproducing failure code: Turn the starting switch ON.
WA470-6, WA480-6 9
SEN01701-01 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 11
SEN01701-01 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 13
SEN01701-01 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 15
SEN01701-01 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 17
SEN01701-01 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 19
SEN01701-01 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 21
SEN01701-01 40 Troubleshooting
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit
Trouble
E01 DWN6KB (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is shorted, abnormal current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The lift arm remote positioner raise does not function.
appears on
• Holding the lift arm at the raise detent position becomes unavailable.
machine
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Engine started + lift arm raise detent
22 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 23
SEN01701-01 40 Troubleshooting
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short
circuit with power supply line) 1
Action code Failure code Lift arm raise magnet detent solenoid: Short circuit with power sup-
Trouble
E01 DWN6KY ply line (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is shorted with the power
trouble source, abnormal voltage is applied when the lift arm raise magnet detent solenoid output is ON.
• Stops outputting the signal to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp to stop raise stop control.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If you perform lift arm raise detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm raise magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-1).
information
• Method of reproducing failure code: Start engine.
24 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 25
SEN01701-01 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 27
SEN01701-01 40 Troubleshooting
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short
circuit) 1
Action code Failure code Lift arm float magnet detent solenoid: Short circuit
Trouble
E01 DWN7KB (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system is shorted, abnormal current
trouble flows when the lift arm float magnet detent solenoid output is turned on.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The lift arm remote positioner lower does not function.
appears on
• Holding the lift arm at the float detent position becomes unavailable.
machine
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.
28 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 29
SEN01701-01 40 Troubleshooting
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short
circuit with power supply line) 1
Action code Failure code Lift arm float magnet detent solenoid: Short circuit with power sup-
Trouble
E01 DWN7KY ply line (Work equipment controller system)
Contents of • Since the lift arm float magnet detent solenoid power supply system is shorted with the power
trouble source, abnormal voltage is applied when the lift arm float magnet detent solenoid output is OFF.
• Stops outputting the signal to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp to stop lower stop control.
controller
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
• If you perform lift arm float detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform lift arm detent operation, return of the left arm lever to neutral is affected by the
machine
suction power of the magnet (lever control is deteriorated).
• The output state (ON/OFF) to the lift arm float magnet detent solenoid can be checked with the mon-
Related
itoring function (Code: 40952, D-OUT-2).
information
• Method of reproducing failure code: Start engine
30 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 31
SEN01701-01 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 33
SEN01701-01 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 35
SEN01701-01 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 37
SEN01701-01 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 39
SEN01701-01 40 Troubleshooting
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with
power supply line) 1
Action code Failure code Fan pump EPC solenoid: Short circuit with power supply line
Trouble
E01 DX16KY (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is shorted with the power source, abnormal voltage is
trouble applied when the fan pump EPC solenoid output is OFF.
Action of • Turns the output to the fan pump EPC solenoid OFF.
controller • If problem is removed, system is returned to normal operating state.
Problem that
appears on • The fan speed is minimized.
machine
• The output state (current) to the fan pump EPC solenoid can be checked with the monitoring function
Related
(Code: 41400, FAN EPC DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.
40 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 41
SEN01701-01 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 43
SEN01701-01 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 45
SEN01701-01 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 47
SEN01701-01 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 49
SEN01701-01 40 Troubleshooting
50 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 51
SEN01701-01 40 Troubleshooting
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH4KY (Transmission controller system)
Contents of • Since the 1st ECMV solenoid system is shorted with the power source, abnormal voltage is applied
trouble when 1st clutch ECMV solenoid output is OFF.
• Stops outputting the signal to the 2nd, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF (other than 1st speed).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
steering FNR (directional) switch or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
• The output state (current value) to the 1st (1st speed) clutch ECMV solenoid can be checked with the
Related
monitoring function (Code: 31602, ECMV 1 DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.
52 WA470-6, WA480-6
40 Troubleshooting SEN01701-01
WA470-6, WA480-6 53
SEN01701-01
© 2008 KOMATSU
All Rights Reserved
Printed in Japan 02-08 (01)
54
SEN01702-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 10
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)............................................................. 4
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) ................................................................ 6
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) ............................ 8
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) ........................................................... 10
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) ............................................................... 12
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) ........................... 14
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) .............................................................. 16
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit).................................................................. 18
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) ............................. 20
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) .............................................................. 22
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) .................................................................. 24
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) .............................. 26
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) ........................................................... 28
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)............................................................... 30
WA470-6, WA480-6 1
SEN01702-02 40 Troubleshooting
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)........................... 32
Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)............................................ 34
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) ............................................... 36
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) ........... 38
Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) ............................................. 40
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) ................................................ 42
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) ............ 44
Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)...... 46
Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)...... 49
Failure code [DY30ME] Emergency steering: Operating for more than 1 minute ......................................... 52
2 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 3
SEN01702-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 5
SEN01702-02 40 Troubleshooting
6 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 7
SEN01702-02 40 Troubleshooting
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH5KY (Transmission controller system)
Contents of • When the 2nd clutch ECMV solenoid system was shorted with the power source, abnormal voltage
trouble was applied when 2nd clutch ECMV solenoid output was OFF.
• Stops outputting the signal to the 1st, 3rd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF (other than 2nd speed).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until the FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 3rd, nor 4th (the machine can travel at 2nd).
machine
• The output state (current) to the 2nd clutch ECMV solenoid can be checked with the monitoring func-
Related
tion (Code: 31603 ECMV 2 DIR).
information
• Method of reproducing failure code: Turn starting switch ON.
8 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 9
SEN01702-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 11
SEN01702-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 13
SEN01702-02 40 Troubleshooting
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH6KY (Transmission controller system)
Contents of • Since the 3rd ECMV solenoid system is shorted with the power source, abnormal voltage is applied
trouble when 3rd clutch ECMV solenoid output is OFF.
• Stops outputting the signal to the 1st, 2nd, and 4th clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF (other than 3rd speed).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
steering FNR (directional) switch or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd or 4th (the machine can travel at 3rd).
machine
• The output state (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring
Related
function (Code: 31604, ECMV 3 DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.
14 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 15
SEN01702-02 40 Troubleshooting
16 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 17
SEN01702-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 19
SEN01702-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 21
SEN01702-02 40 Troubleshooting
22 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 23
SEN01702-02 40 Troubleshooting
24 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 25
SEN01702-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 27
SEN01702-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 29
SEN01702-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 31
SEN01702-02 40 Troubleshooting
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with
power supply line) 1
Action code Failure code 4th clutch ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXHHKY (Transmission controller system)
Contents of • Since the 4th ECMV solenoid system is shorted with the power source, abnormal voltage is applied
trouble when 4th clutch ECMV solenoid output is OFF.
• Stops outputting the signal to the 1st, 2nd, and 3rd clutch ECMV solenoids.
• Also stops outputting the signal to the F (Forward) and R (Reverse) clutch ECMV solenoids when the
Action of speed clutch output is OFF (other than 4th speed).
controller • Turns the centralized warning lamp and alarm buzzer ON.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
steering FNR (directional) switch or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The transmission does not shift into 1st, 2nd or 3rd (the machine can travel at 4th).
machine
• The output state (current value) to the 4th clutch ECMV solenoid can be checked with the monitoring
Related
function (Code: 31605, ECMV 4 DIR).
information
• Method of reproducing failure code: Turn the starting switch ON.
32 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 33
SEN01702-02 40 Troubleshooting
34 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 35
SEN01702-02 40 Troubleshooting
36 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 37
SEN01702-02 40 Troubleshooting
38 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 39
SEN01702-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 41
SEN01702-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 43
SEN01702-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 45
SEN01702-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 47
SEN01702-02 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
Defective emergency steer- Issues this failure code [DY30MC]. Relay (L126):
ing relay (L126) (Internal dis- Normal
1
continuity or defective Relay (L126):
Does not issue this failure code [DY30MC].
contact) Defective
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Resis- 200 –
Between L105 (male) (9) and (10)
Possible causes tance 400 z
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
state Wiring harness between L105 (female) (12) Resis-
Max. 1 z
– R13 terminal tance
Wiring harness discontinuity Wiring harness between R14 terminal – Resis-
Max. 1 z
2 (Disconnection or defective chassis ground tance
contact) Wiring harness between battery relay R01
Resis-
terminal – emergency steering relay R02 ter- Max. 1 z
tance
minal
Wiring harness between emergency steering Resis-
Max. 1 z
relay – emergency steering motor tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
3 Wiring harness ground fault
Between L54 (female) (3), R37 (female) (2) – Resis-
Min. 1 Mz
body tance
WA470-6, WA480-6 49
SEN01702-02 40 Troubleshooting
50 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 51
SEN01702-02 40 Troubleshooting
52 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 53
SEN01702-02 40 Troubleshooting
54 WA470-6, WA480-6
40 Troubleshooting SEN01702-02
WA470-6, WA480-6 55
SEN01702-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
56
SEN01703-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting of electrical system
(E-mode)
Installing positions of fuses ............................................................................................................................. 3
Information in troubleshooting table ................................................................................................................ 6
E-1 Engine does not start ............................................................................................................................... 8
E-2 Wiper does not operate .......................................................................................................................... 14
E-3 Windshield washer does not operate ..................................................................................................... 18
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off................................... 21
E-5 Working lamp does not light up or go off ................................................................................................ 29
E-6 Turn signal lamp and hazard lamp do not light up or go off ................................................................... 34
E-7 Brake lamp does not light or it keeps lighting up .................................................................................... 40
E-8 Backup lamp does not light or it keeps lighting up ................................................................................. 42
E-9 Backup buzzer does not sound or it keeps sounding ............................................................................. 44
E-10 Horn does not sound or it keeps sounding ........................................................................................... 46
E-11 Alarm buzzer does not sound or it keeps sounding.............................................................................. 48
E-12 Air conditioner does not operate or stop .............................................................................................. 50
WA470-6, WA480-6 1
SEN01703-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
Fuse box 1
Capacity of
Type of power supply Fuse No Destination of power
fuse
1 20 A Starting switch terminal B circuit
2 10 A Hazard lamp circuit
Machine monitor (B) circuit
Constant power 3 10 A
KOMTRAX circuit (if equipped)
supply
4 10 A Room lamp circuit
Slow-blow fuse
(50 A) Transmission controller (B) circuit
5 5A
Work equipment controller (B) circuit (if equipped)
6 30 A Engine controller (A) circuit
7 10 A Spare 1
8 10 A Front working lamp circuit
9 10 A Rear working lamp circuit
Switch power supply 10 20 A Car radio circuit and 12V converter circuit
Slow-blow fuse 11 10 A Turn signal lamp circuit
(50 A) 12 20 A Yellow rotary lamp circuit (if equipped)
13 10 A KOMTRAX (A) circuit (if equipped)
14 20 A Rear glass heater circuit
Switch power supply
15 5A Engine controller (B) circuit
Starting switch ACC
WA470-6, WA480-6 3
SEN01703-02 40 Troubleshooting
Fuse box 2
Capacity of
Type of power supply Fuse No Destination of power
fuse
1 10 A Horn circuit
2 10 A Transmission controller (A) circuit
3 5A Parking brake circuit
4 5A Emergency steering circuit (if equipped)
Work equipment positioner circuit
5 10 A
Switch power supply Work equipment controller (A) circuit (if equipped)
Slow-blow fuse 6 10 A Rear lamp and brake lamp circuit
(50 A) 7 20 A Wiper and washer circuit
8 20 A Air conditioner (A) circuit
9 5A Air conditioner (B) circuit
Machine monitor (B) circuit
10 10 A
Load meter printer (if equipped) circuit
11 20 A Main lamp circuit
Switch power supply 12 10 A Clearance lamp (right) circuit
Lamp switch 13 10 A Clearance lamp (left) circuit
Switch power supply 14 10 A Headlamp (right) circuit
Head lamp relay 15 10 A Headlamp (left) circuit
4 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 5
SEN01703-02 40 Troubleshooting
<Described contents>
• Standard value in normal state required to judge the
assumed cause (good or not)
• Remarks required to judge whether the cause is good
1
<Phenomenon of defective harness>
• Disconnection in wiring
The connector connection is defective or wiring harness is
disconnected.
• Ground fault
A harness not connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
A harness not connected to the power (24 V) circuit comes
2
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Causes by which a trouble is A harness of an independent circuit abnormally comes into
and standard assumed to be defected contact with one of the other circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector numbers and handling of T-
adapter
For troubleshooting, insert or connect T-adapter shown
3 below unless especially specified.
• When “male” or “female” is not indicated for a connector
number, disconnect the connector, and insert the T-
adapters in both the male and female.
• When “male” or “female” is indicated for a connector
number, disconnect connector, and insert the T-adapter
in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
4 leads as shown below unless especially specified.
• Connect the plus (+) lead to a pin or harness indicated in
the front.
• Connect the minus (–) lead to a pin or harness indicated
in the rear.
6 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 7
SEN01703-02 40 Troubleshooting
8 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 9
SEN01703-02 40 Troubleshooting
10 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 11
SEN01703-02 40 Troubleshooting
12 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 13
SEN01703-02 40 Troubleshooting
14 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 15
SEN01703-02 40 Troubleshooting
Contents of
(2) Rear wiper does not operate.
trouble
Related
• Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information
16 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 17
SEN01703-02 40 Troubleshooting
18 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 19
SEN01703-02 40 Troubleshooting
20 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light
up or go off 1
Contents of
(1) Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off.
trouble
• Since the lamp system main circuit is disconnected or shorted with the chassis ground, none of the
lamps lights up.
• Headlamp at SMALL position: Clearance lamp, tail lamp, license lamp, machine monitor night lamp
light up.
• Headlamp at HEAD position: Above lamps and headlamp light up.
Related
• The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
information
with the monitoring function (Code: 40200, SMALL LAMP).
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
with the monitoring function (Code: 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: 40904, D-IN-34).
WA470-6, WA480-6 21
SEN01703-02 40 Troubleshooting
Contents of
(2) Either of headlamp (low and high beams) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
• Carry out the following troubleshooting when the clearance lamp, tail lamp, and license lamp light up
and go off normally.
Related
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
information
with the monitoring function (Code: 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: 40904, D-IN-34).
22 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 23
SEN01703-02 40 Troubleshooting
Contents of
(3) Headlamp (low beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
information
with the monitoring function (Code: 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: 40904, D-IN-34).
24 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
Contents of
(4) Headlamp (high beam) does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
chassis ground.
• Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
• The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
information
with the monitoring function (Code: 40900, D-IN-0).
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: 40904, D-IN-34).
WA470-6, WA480-6 25
SEN01703-02 40 Troubleshooting
26 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 27
SEN01703-02 40 Troubleshooting
28 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 29
SEN01703-02 40 Troubleshooting
30 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
Contents of
(2) Rear working lamp does not light up or go off.
trouble
Related • The switch, lamp, or wiring harness of the rear working lamp system is defective.
information • When the front working lamp and side working lamp (if equipped) light up (go off)
WA470-6, WA480-6 31
SEN01703-02 40 Troubleshooting
32 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 33
SEN01703-02 40 Troubleshooting
E-6 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch
Related
(right turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-12).
information
• The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left
turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-13).
34 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 35
SEN01703-02 40 Troubleshooting
Contents of
(2) Turn signal lamp does not light up or go off.
trouble
• The switch, lamp, or wiring harness of the turn signal lamp system is defective.
• When the hazard lamp lights up.
Related • The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
information (right turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-12).
• The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
(left turn signal lamp) can be checked with the monitoring function (Code: 40901, D-IN-13).
36 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 37
SEN01703-02 40 Troubleshooting
Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related • The switch or lamp of the hazard lamp is defective.
information • Carry out the following troubleshooting when the turn signal lamp flashes normally.
38 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 39
SEN01703-02 40 Troubleshooting
40 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 41
SEN01703-02 40 Troubleshooting
42 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 43
SEN01703-02 40 Troubleshooting
44 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 45
SEN01703-02 40 Troubleshooting
46 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 47
SEN01703-02 40 Troubleshooting
48 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 49
SEN01703-02 40 Troubleshooting
50 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 51
SEN01703-02 40 Troubleshooting
52 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 53
SEN01703-02 40 Troubleshooting
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
6. LED-C6 (Download write state)
54 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
L80 connector
WA470-6, WA480-6 55
SEN01703-02 40 Troubleshooting
56 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 57
SEN01703-02 40 Troubleshooting
E-15 When hold switch is pressed, holding operation does not start 1
Contents of
• When hold switch is pressed, holding operation does not start.
trouble
• The hold switch system is disconnected or shorted with the power source.
• The hold switch cannot be changed.
Related
• The input state (ON/OFF) from the hold switch can be checked with the monitoring function (Code:
information
40908, D-IN-31).
• If failure code [DDWLLD] is displayed, carry out troubleshooting for it first.
58 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 59
SEN01703-02 40 Troubleshooting
60 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 61
SEN01703-02 40 Troubleshooting
62 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 63
SEN01703-02 40 Troubleshooting
64 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 65
SEN01703-02 40 Troubleshooting
66 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 67
SEN01703-02 40 Troubleshooting
68 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 69
SEN01703-02 40 Troubleshooting
E-21 Discharge from loader pump does not rise from minimum level 1
Contents of
• Discharge from loader pump does not rise from minimum level.
trouble
• Since the loader pump PC-EPC solenoid system is shorted with the power source, the loader pump
Related discharge is minimized.
information • The state (current) of the loader pump PC-EPC solenoid can be checked with the monitoring function
(Code: 41401 PUMP EPC).
70 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 71
SEN01703-02 40 Troubleshooting
72 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 73
SEN01703-02 40 Troubleshooting
E-23 When parking brake is turned ON, parking brake indicator lamp
does not light up 1
Contents of
• When parking brake is turned ON, parking brake indicator lamp does not light up.
trouble
• The parking brake indicator switch circuit is shorted or shorted with the chassis ground.
• When the parking brake switch is operated, the parking brake operation sensor circuit is CLOSED.
• The parking brake does not work.
Related
• The input signal (ON/OFF) from the parking brake indicator switch can be checked with the monitoring
information
function (Code: 40903, D-IN-26).
• The input signal (ON/OFF) (neutralizer signal) from the parking brake switch can be checked with the
monitoring function (Code: 40907, D-IN-23).
74 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 75
SEN01703-02 40 Troubleshooting
76 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 77
SEN01703-02 40 Troubleshooting
E-24 When emergency brake operates, brake oil pressure caution lamp
does not operate 1
Contents of
• When emergency brake operates, brake oil pressure caution lamp does not operate.
trouble
• The brake accumulator pressure switch circuit is shorted or shorted with the chassis ground.
• When the emergency brake operates, the accumulator pressure sensor circuit is CLOSED (and the
brake oil pressure is judged normal).
Related
• When the emergency brake operates or the brake oil pressure lowers, the brake oil pressure caution
information
lamp does not light up.
• The input signal (ON/OFF) from the brake accumulator pressure switch can be checked with the mon-
itoring function (Code: 40902, D-IN-16).
78 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 79
SEN01703-02 40 Troubleshooting
80 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 81
SEN01703-02 40 Troubleshooting
82 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil
temperature caution lamp does not light up 1
Contents of • Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does not
trouble light up.
• The hydraulic oil temperature sensor circuit is disconnected.
• When the hydraulic oil temperature rises, the hydraulic oil temperature gauge does not rise.
Related • When the hydraulic oil temperature rises to 110°C, the hydraulic oil temperature caution lamp does
information not light up.
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401 HYD TEMP).
WA470-6, WA480-6 83
SEN01703-02 40 Troubleshooting
E-28 Torque converter oil temperature gauge does not rise and torque
converter oil temperature caution lamp does not light up 1
Contents of • Torque converter oil temperature gauge does not rise and torque converter oil temperature caution
trouble lamp does not light up.
• The torque converter oil temperature sensor circuit is disconnected.
• When the torque converter oil temperature rises, the torque converter oil temperature gauge does not
rise.
Related
• When the torque converter oil temperature rises to 120°C, the torque converter oil temperature cau-
information
tion lamp does not light up.
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100, TC OIL TEMP).
84 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 85
SEN01703-02 40 Troubleshooting
86 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 87
SEN01703-02 40 Troubleshooting
88 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 89
SEN01703-02 40 Troubleshooting
90 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 91
SEN01703-02 40 Troubleshooting
92 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 93
SEN01703-02 40 Troubleshooting
94 WA470-6, WA480-6
40 Troubleshooting SEN01703-02
WA470-6, WA480-6 95
SEN01703-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
96
SEN01704-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting of hydraulic and
mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 3
Table of failure modes and causes ................................................................................................................. 6
H-1 The machine does not start.................................................................................................................... 10
H-2 Torque converter lockup is not switched off (engine stalls)
[Machine with lockup clutch (if equipped)] ................................................................................................ 12
H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] ........................ 13
H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak,
and the gear is not shifted......................................................................................................................... 14
H-5 Shocks are large at the times of starting and shifting gear .................................................................... 16
H-6 Time lag is large at the times of starting and shifting gear ..................................................................... 18
H-7 The torque converter oil temperature is high ......................................................................................... 20
H-8 Steering does not turn ............................................................................................................................ 21
H-9 Steering does not turn [Machine with joystick steering (if equipped)] .................................................... 22
H-10 Steering response is poor .................................................................................................................... 23
WA470-6, WA480-6 1
SEN01704-02 40 Troubleshooting
H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]............................ 24
H-12 Steering is heavy .................................................................................................................................. 25
H-13 When machine turns, it shakes or makes large shocks ....................................................................... 26
H-14 When machine turns, it shakes or makes large shocks
[machine with joystick steering (if equipped)]............................................................................................ 27
H-15 The wheel brake does not work or does not work well......................................................................... 28
H-16 The wheel brake is not released or it drags ......................................................................................... 29
H-17 The parking brake does not work or does not work well ...................................................................... 30
H-18 The parking brake is not released or it drags (including emergency release system) ......................... 31
H-19 Lift arm does not rise............................................................................................................................ 32
H-20 Lift arm speed is low or rising force of lift arm is insufficient................................................................. 33
H-21 When rising, the lift arm comes to move slowly at specific height........................................................ 34
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) ....................................................... 34
H-23 Hydraulic drift of the lift arm is large ..................................................................................................... 34
H-24 The lift arm wobbles during operation .................................................................................................. 34
H-25 Bucket does not tilt back ...................................................................................................................... 35
H-26 Bucket speed is low or tilting back force is insufficient ......................................................................... 36
H-27 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 37
H-28 The bucket cylinder cannot hold down the bucket ............................................................................... 37
H-29 Hydraulic drift of the bucket is large ..................................................................................................... 37
H-30 The bucket wobbles during travel with cargo (The work equipment valve is set to “HOLD”) ............... 37
H-31 Lift arm and bucket control levers do not move smoothly and are heavy ............................................ 38
H-32 During operation of the machine, engine speed lowers remarkably or engine stalls ........................... 39
H-33 Large shock is made when work equipment starts and stops .............................................................. 39
H-34 When work equipment circuit is relieved singly, other work equipment moves .................................... 39
H-35 ECSS does not operate, and pitching, bouncing occur........................................................................ 40
2 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
WA470-6, WA480-6 3
SEN01704-02 40 Troubleshooting
Operate the machine in the same way as in 6. Repeat the operation in Steps 3, 4, and 5 until
Step 1, and if any problem occurs, put a check the cause is narrowed down to 1 item (1 com-
against the item. (In Troubleshooting item 5 in mon item).
the diagram below, the problem was re- a If cause items are 2 or more, continue until
enacted.) number of items becomes minimum.
4 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
WA470-6, WA480-6 5
SEN01704-02 40 Troubleshooting
Torque converter lockup is not turned on [Lockup clutch specification (if equipped)] Q Q
Travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the
Q Q Q Q Q Q Q Q Q Q
gear is not shifted
Large shocks are made when machine starts and gear is shifted Q Q Q Q Q
Large time lag is made when machine starts and gear is shifted Q Q Q Q Q
Torque converter oil temperature is high Q Q Q Q Q Q Q
Steering does not turn Q
Steering does not turn [Joystick steering specification (if equipped)] Q
Steering response is poor Q
Steering
6 WA470-6, WA480-6
Q
Q
Q
Q
Q
Defective operation of relevant ECMV
Q Q
Defect of transmission controller system
Q
Q
Internal breakage of transmission
Q Q
Q
Q Q
War or seizure of relevant clutch
Q
Low oil pressure due to defective transmission valve
Defective clutch piston
The relevant clutch piston seal is defective
WA470-6, WA480-6
40 Troubleshooting
Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft
Q
Q Q Q
Clogging of transmission breather
Q
Q
Defective transmission oil temperature sensor
Q
Defective transmission output shaft speed sensor
Defective seal of work equipment and steering system
Q
Q
hydraulic pump shaft
Clogging or air intake on steering pump suction side
Q Q
Defective steering pump
Q Q
Q Q Q
Defective steering pump servo
Defective Orbit-roll
Q Q
Q
Defective steering stop valve
Defective steering main relief valve
Defective flow control spool
Q
Defective steering spool of steering valve
Defective overload relief valve
Q Q Q Q Q Q
Q Q Q Q Q Q Q
Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q Q
Defective seal of steering cylinder piston
Clogging of joystick steering solenoid valve line filter
Q
Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q Q Q
Defective joystick steering solenoid valve
Q
Defective steering wheel or steering shaft
Defective seal of brake piston
Q
Defective operation of brake piston
Failure inside wheel brake valve
Q
Q Q Q Q
Wear or abnormality of wheel brake disc
Contact of metallic site due to complete wear on
Q
Q
wheel brake disc
Q
Q
Q
Q
Q
Q
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN01704-02
SEN01704-02 40 Troubleshooting
Torque converter lockup is not turned on [Lockup clutch specification (if equipped)]
Travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the gear is not shifted
Large shocks are made when machine starts and gear is shifted
Large time lag is made when machine starts and gear is shifted
Torque converter oil temperature is high
Steering does not turn Q
Steering does not turn [Joystick steering specification (if equipped)] Q
Steering response is poor Q
Steering
8 WA470-6, WA480-6
Q
Defective operation of parking brake piston
Q
Q
Q
Q
The parking brake piston seal is defective
Q
Wear of parking brake disc
Pinching due to peeling of parking brake disc
Q Q
Defective harness of parking brake switch line
Q
Q
Q
Q
Q
Q
Q
Q
Q
Clogging or air intake on work equipment pump suction side
WA470-6, WA480-6
40 Troubleshooting
Q
Defective work equipment controller
Defective work equipment pump
Q Q
Defective work equipment pump servo
Q
Q
Defective work equipment valve body
Defective work equipment main relief valve
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Q Q Q Q Q
Defective work equipment unload valve
Q Q Q Q Q Q
Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Q Q Q Q Q Q
Defective lift arm spool of work equipment valve
Q Q
Q Q
Q
Q
Q
Q
Q
Defective bucket spool of work equipment valve
Malfunction of lift arm pressure compensation valve of work
Q
Q
Q
Q
Q
Q
Q
Q
Q
equipment
Q
Q
equipment valve
Q
Q
Q
Q
Q
equipment valve
Q
Q
Q
Q
Q
Q
Q
Malfunction of PPC valve spool
Q Q
Defective PPC valve body
Malfunction of bucket pressure compensation valve of work
Q
Q
Q
Q
Q
equipment
Q
Q
Q
Q
Malfunction of work equipment back pressure valve
Q
Q
Q
Defective lift arm cylinder
Q
Defective bucket cylinder
Q
Q
Q
Q
Q
Defective seal of lift arm cylinder piston
Q
Q
Q
Q
Q
Q
Defective seal of bucket cylinder piston
Q
Defective stroke of lift arm EPC lever
Q
Defective stroke of bucket EPC lever
Q
Defect in electric system of lift arm or bucket EPC lever
Q
Clearance error of pin or bush of working equipment linkage
Q
Defective ECSS solenoid valve
Q
Q
Q
Q
Q
Q
Q
Defective ECSS charge valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
9
SEN01704-02
SEN01704-02 40 Troubleshooting
Torque converter
Torque converter
Parking brake
Transmission
release valve
Check valve
denly?
ECMV
o Seizure of clutch, breakage of parts
Did any abnormal noise occur at the time
and where?
Remedy E E E E E E E E E
No. x x * * * x x x
Diagnosis x C x x x x x x x
1 The machine does not start at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q
2 The machine does not start at specific gear speeds Q Q Q Q Q
When the transmission oil temperature is low, the charg-
3 ing pump or the transmission filter causes any abnormal Q Q
noise
When the transmission oil temperature rises, the machine
4 Q Q Q Q
comes not to start
Metal (Aluminum, copper, iron, etc.) powders are adhered
5 Q Q Q
to the transmission filter or the strainer
The speed is higher at all gear
6 When the stall speed of Q Q Q Q Q Q Q Q
speeds
the torque converter is
The speed is higher at specific
7 measured Q Q Q Q Q
gear speeds
The oil pressure is low at all
8 Q Q Q Q Q Q Q
gear speeds
When the ECMV output The oil pressure is low at spe-
9 Q Q Q Q
(Clutch) oil pressure is cific gear speeds
measured The oil pressure does not
10 become stable as the gauge Q Q
vibrates
When the torque converter relief (Inlet) oil pressure is
11 Q Q Q Q Q Q
measured, the oil pressure is low
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
10 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1 – R4 but is displayed at F1 – F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1 – F4 but is displayed at R1 – R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA470-6, WA480-6 11
SEN01704-02 40 Troubleshooting
H-2 Torque converter lockup is not switched off (engine stalls) [Machine
with lockup clutch (if equipped)] 1
Checks before troubleshooting Cause
q Is the oil level of transmission case appropriate? a b
12 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Remedy
E
No. Diagnosis Transmission x x x x C x
x
controller self-diagnosis code
1 Main relief oil pressure is low Q
2 Main relief oil pressure is normal, but lockup oil pressure is low or 0 Q Q Q Q Q
3 Main relief oil pressure and oil pressure is normal, but lockup oil pressure is low or 0 Q
4 Time to lockup actuation takes long 15SJLH Q
WA470-6, WA480-6 13
SEN01704-02 40 Troubleshooting
H-4 The travel speed is slow, the thrusting force is weak, the uphill
traveling power is weak, and the gear is not shifted 1
Ask the operator about the following questions. Causes
q Has the abnormality occurred suddenly?
Torque converter
Torque converter
Torque converter
Parking brake
Transmission
oil cooler
Others
ECMV
Did any abnormal noise occur at the time and where?
q Have any abnormal signs come to occur gradually?
o Wear of related equipment, defective seal
Defective seal of work equipment and steering system hydraulic pump shaft
level ground and on a slope to check whether the
abnormality actually occurs or is a matter of operator's
sense
Clogging of breather
q Is the operating method correct?
Clogging of strainer
Remedy C E E E E E E E C E
No. x x x * * x x
Diagnosis x x x x x x x x x x
1 Any abnormality occurs at all gear speeds Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Any abnormality occurs at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, the charging pump or
3 Q Q
the transmission filter causes any abnormal noise
4 The torque converter oil temperature rises abnormally high Q Q Q Q Q Q Q Q Q Q Q
5 The transmission oil level rises or falls Q Q Q Q Q
Metal powders (Aluminum, copper, iron, etc.) are adhered to the
6 Q Q Q
transmission filter and the strainer
The engine low idle and high idle speeds are measured to be abnor-
7 Q Q Q
mal
8 When the stall speed of the The speed is high Q Q Q Q Q Q Q Q Q Q
9 torque converter is measured The speed is low Q
The oil pressure drops as the tem-
10 Q Q Q Q
perature rises
The oil pressure is low at all gear
11 Q Q Q Q Q Q Q Q Q
When the ECMV output (Clutch) speeds
oil pressure is measured The oil pressure is low at specific
12 Q Q Q Q
gear speeds
The oil pressure does not become
13 Q Q
stable as the gauge vibrates
When the torque converter relief (Inlet) oil pressure is measured, the
14 Q Q Q
oil pressure is low. (No. 11 – 13 are normal.)
When the oil pressure at the torque converter outlet is measured,
15 Q
the oil pressure is low. (No. 14 is normal.)
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
14 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1 – R4 but is displayed at F1 – F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1 – F4 but is displayed at R1 – R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA470-6, WA480-6 15
SEN01704-02 40 Troubleshooting
H-5 Shocks are large at the times of starting and shifting gear 1
Ask the operator about the following questions. Causes
q Did shocks become large suddenly?
Torque converter
Parking brake
Transmission
o Breakage of related equipment
Sensors
ECMV
Did any abnormal noise occur at the time and where?
q Did shocks become large gradually?
o Wear of related equipment, defective seal
Clogging of strainer
q Isn't the engine speed high at the time of low idle?
q Isn't play of each drive shaft large?
q Is the initial learning of transmission completed?
(Refer to the section “Testing and adjusting”.)
Remedy C E E
No. x x * ** * * x x **
Diagnosis x x x
1 Shocks are large at all gear speeds Q Q Q Q Q Q Q Q
2 Shocks are large at specific gear speeds Q Q Q Q Q Q
3 When the ECMV output The oil pressure is low at all gear speeds Q Q Q Q Q Q
4 (Clutch) oil pressure is The oil pressure is low at specific gear speeds Q Q Q
5 measured The oil pressure is high at all gear speeds Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
**: Proceed to the paragraph of “Troubleshooting of transmission controller system (TM mode).”
16 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1 – R4 but is displayed at F1 – F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1 – F4 but is displayed at R1 – R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA470-6, WA480-6 17
SEN01704-02 40 Troubleshooting
H-6 Time lag is large at the times of starting and shifting gear 1
Ask the operator about the following:
q Did the time lag become large suddenly? Cause
o Breakage of related equipment
Torque converter
Parking brake
Transmission
Did any abnormal noise occur at the time and where?
Sensor
q Has the time lag become large gradually?
ECMV
o Wear of related equipment, defective seal
Check of abnormality
q Did any of the following abnormal phenomena occur at the same time: a b c d e f g h i j
The traveling speed is slow, the braking is weak, the uphill travelling
Clogging of strainer
Remedy C E E
No. x x * * x x **
Diagnosis x x x
1 Time lag is large at all gear speeds Q Q Q Q Q Q Q
2 Time lag is large at specific gear speeds Q Q Q Q
When the transmission oil temperature is low, any abnormal noise occurs from the
3 Q Q
charging pump or the transmission filter
4 The torque converter oil temperature is heated abnormally high Q Q Q Q
5 When the ECMV output (Clutch) The oil pressure is low at all gear speeds Q Q Q Q Q
6 oil pressure is measured The oil pressure is low at specific gear speeds Q Q Q
a Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*: Proceed to the paragraph of “Defective clutch and ECMV specifying method (Check by failure code).”
**: See Troubleshooting by failure code (Display of code)
18 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
q
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
Remedy Failure
No. x x x x x x x x x x x x
Diagnosis code
(1) The code is not displayed at R1 – R4 but is displayed at F1 – F4 15SAL1 Q Q
When the failure code is 15SAL1 after the diagnosis in (1), the failure code
1
(2) comes not to be displayed when the F fill switch connector (CN-F.SW) is dis-
connected. When the failure code is 15SALH, the failure code comes not to be 15SALH Q
displayed when the ECMV is replaced with any one other than F clutch ECMV
(1) The code is not displayed at F1 – F4 but is displayed at R1 – R4 15SBL1 Q Q
When the failure code is 15SBL1 after the diagnosis in (1), the failure code
2
(2) comes not to be displayed when the R fill switch connector (CN-R.SW) is dis-
connected. When the failure code is 15SBLH, the failure code comes not to be 15SBLH Q
displayed when the ECMV is replaced with any one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1 Q Q
When the failure code is 15SEL1 after the diagnosis in (1), the failure code
3 comes not to be displayed when the 1st fill switch connector (CN-1.SW) is dis-
(2) connected. When the failure code is 15SELH, the failure code comes not to be 15SELH Q
displayed when the ECMV is replaced with any one other than the 1st clutch
ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1 Q Q
When the failure code is 15SFL1 after the diagnosis in (1), the failure code
4 comes not to be displayed when the 2nd fill switch connector (CN-2.SW) is
(2) disconnected. When the failure code is 15SFLH, the failure code comes not to 15SFLH Q
be displayed when the ECMV is replaced with any one other than the 2nd
clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1 Q Q
When the failure code is 15SGL1 after the diagnosis in (1), the failure code
5 comes not to be displayed when the 3rd fill switch connector (CN-3.SW) is dis-
(2) connected. When the failure code is 15SGLH, the failure code comes not to be 15SGLH Q
displayed when the ECMV is replaced with any one other than the 3rd clutch
ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1 Q Q
When the failure code is 15SHL1 after the diagnosis in (1), the failure code
6 comes not to be displayed when the 4th fill switch connector (CN-4.SW) is dis-
(2) connected. When the failure code is 15SHLH, the failure code comes not to be 15SHLH Q
displayed when the ECMV is replaced with any one other than the 4th clutch
ECMV
WA470-6, WA480-6 19
SEN01704-02 40 Troubleshooting
Torque converter
Torque converter
Torque converter
charging pump
Transmission
stalls and does the temperature fall at the time of no
Main relief
oil cooler
Others
load? o Selection of improper gear speed
Did any abnormal noise occur at the time and where?
q Does the oil temperature rise only at the time of lifting?
o Improvement of operating method
a b c d e f g h i j k l
Checking for abnormalities
Clogging of breather
appropriate?
Clogging of strainer
Remedy C E E EEEE C E
No. x x
Diagnosis x x x x x x x x x
When the transmission oil temperature is low, the charging
1 Q Q
pump or the transmission filter causes any abnormal noise
Traveling speed, braking force and uphill travelling power do not
2 Q Q Q Q Q Q Q Q Q Q Q
occur at all gear speeds
Traveling speed, braking force and uphill travelling power do not
3 Q
occur at specific gear speeds
4 The transmission oil level rises or falls Q Q Q
Metal powers (Aluminum, copper, iron, etc.) are adhered to the
5 Q Q Q
transmission filter and the strainer
The engine low idle and high idle speeds are measured to be
6 Q Q Q
abnormal
When the stall speed of the torque converter is measured, the
7 Q Q Q Q Q Q Q Q Q
speed is high
The oil pressure drops as the tempera-
8 Q
ture rises
The oil pressure is low at all gear
9 When the ECMV output speeds Q Q Q Q Q
(Clutch) oil pressure is
The oil pressure is low at specific gear
10 measured Q
speeds
The oil pressure does not become sta-
11 Q Q
ble as the gauge vibrates
When the torque converter relief (Inlet) oil pressure is mea-
12 Q Q Q
sured, the oil pressure is low. (No. 9 – 11 are normal.)
When the oil pressure at the torque converter outlet is mea-
13 Q
sured, the oil pressure is low. (No. 12 is normal.)
20 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Hydraulic cylinder
q
Hydraulic pump
Steering valve
Charge valve
Did the machine cause any abnormal noise at the time and where?
Stop valve
Orbit-roll
Testing before troubleshooting
q Is oil level in hydraulic tank correct? Is the type of oil correct?
q Is the steering shaft broken?
q Is the steering stop valve properly adjusted? a b c d e f g h i j k
q Has the lock bar been removed from the frame?
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
WA470-6, WA480-6 21
SEN01704-02 40 Troubleshooting
H-9 Steering does not turn [Machine with joystick steering (if equipped)]1
Ask the operator about the following questions.
q Did the problem suddenly start? Causes
o Breakage of related equipment
Hydraulic cylinder
Hydraulic pump
Steering valve
Charge valve
Did the machine cause any abnormal noise at the time and
Stop valve
Orbit-roll
Joystick
where?
Defective Orbit-roll
Clogged line filter
Remedy E EEEE C EEE
No. E x x x
Diagnosis x x x x x x x x x
Steering does not move (steering wheel mode
1 Q
When joystick ON/OFF only)
2 switch is operated Steering does not move (joystick mode only) Q Q
3 Steering does not move in either mode Q Q Q Q Q Q Q Q Q Q
4 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q Q Q
5 Steering turns only in one direction (left or right) Q Q
6 Joystick steering is heavy in both directions (left and right) Q Q Q Q
7 Joystick steering is heavy in one direction (left or right) Q
8 Work equipment moves Q Q Q Q Q Q Q Q Q
9 Work equipment does not move Q Q Q Q
10 Abnormal noise comes from around PTO Q
11 Abnormal noise comes from around fan pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in
12 Q Q Q Q Q Q Q Q Q Q Q
When steering relief both directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure in
13 Q Q
one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be
14 Q Q Q Q Q
low or there is no oil pressure
When joystick steering EPC solenoid valve output pressure is measured,
15 Q Q Q Q Q Q
oil pressure is found to be low or there is no oil pressure
16 When Orbit-roll basic Oil pressure is low Q Q Q Q
17 pressure is measured There is no oil pressure Q Q Q
22 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Hydraulic cylinder
Hydraulic pump
Steering valve
Charge valve
Did the machine cause any abnormal noise at the time and
Stop valve
Orbit-roll
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal
WA470-6, WA480-6 23
SEN01704-02 40 Troubleshooting
Hydraulic cylinder
q Did the problem suddenly start?
Joystick steering
Steering pump
solenoid valve
Steering valve
Charge valve
o Breakage of related equipment
Stop valve
Did the machine cause any abnormal noise at the time and
where?
q Did the problem gradually appear?
o Wear of steering related parts, defective seal
a b c d e f g h i j k l m n
Testing before troubleshooting
No.
Remedy EClogged line filter
E
EEEE C
x
EEEE
x
E
Diagnosis x x x x x x x x x x x
Turning, response of joystick steering is poor in both directions (left
1 Q Q Q Q Q Q Q Q Q Q Q Q
and right)
Turning, response of joystick steering is poor in one direction (left or
2 Q Q
right)
3 Joystick steering is heavy in both directions (left and right) Q Q Q
4 Joystick steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q Q
7 Abnormal noise comes from around PTO Q
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low or there is no oil pressure
9 Q Q Q Q Q Q Q Q Q Q Q
When steering relief in both directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure
10 Q Q
in one direction (left or right)
When joystick steering solenoid valve output pressure is measured, oil
11 Q Q Q Q Q Q
pressure is found to be low or there is no oil pressure
When steering pump servo assembly is replaced, oil pressure is found
12 Q
to be normal
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is left in the steering, check the operation of the work equipment also.
24 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Hydraulic pump
q
Steering valve
Charge valve
Stop valve
Orbit-roll
Others
Measure the operating effort and turning speed, and check the Standard value table to
see if they are abnormal.
Defective Orbit-roll
Remedy E E E E E E
No.
Diagnosis x x x x x x
1 Steering wheel is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering wheel is heavy in one direction (left or right) Q
3 Steering wheel is heavy even when joint between steering shaft and Orbit-roll is disconnected Q
Oil pressure is low or there is no oil pressure in both directions (left and
4 Q Q Q Q
When steering relief right)
pressure is measured Oil pressure is low or there is no oil pressure in one direction (left or
5 Q
right)
When Orbit-roll output pressure is measured, oil pressure is found to be low or there is no oil
6 Q Q Q Q
pressure
7 When Orbit-roll basic Oil pressure is low Q Q
8 pressure is measured There is no oil pressure Q
WA470-6, WA480-6 25
SEN01704-02 40 Troubleshooting
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Cylinder
Testing before troubleshooting
q Is the steering wheel play correct?
q Is there any abnormality in the connection between the steering shaft and
the Orbit-roll?
q Is the tire inflation pressure correct? a b c d e f g h i
Defective Orbit-roll
Remedy E E E E E E EE
No. E
Diagnosis x x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one directions (left or right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
Steering wheel jerks or there is excessive shock when steering is operated to end of
4 Q
its stroke
5 Work equipment also jerks Q Q
Oil pressure is unstable in both directions
6 Q Q Q Q Q Q Q
When steering relief pressure is mea- (left and right)
sured Oil pressure is unstable in one direction
7 Q Q
(left or right)
Oil pressure is unstable in both directions
8 Q Q Q
When Orbit-roll discharge pressure (left and right)
(steering pilot pressure) was measured Oil pressure is unstable in one direction
9 Q
(left or right)
10 When Orbit-roll basic pressure is measured, oil pressure is found to be unstable Q Q
26 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Hydraulic pump
Steering valve
Testing before troubleshooting
Charge valve
Stop valve
Cylinder
q Has the machine monitor displayed any failure code?
o See the troubleshooting by failure code (Display of code)
q Is play of the steering wheel appropriate?
q Is there any abnormality in the connection between the steering shaft and
the Orbit-roll?
q Is the tire inflation pressure correct?
a b c d e f g h i
Remedy E E EEE EE
No. x E
Diagnosis x x x x x x x
1 When machine turns, it shakes or jerks in both directions (left and right) Q Q Q Q Q Q Q
2 When machine turns, it shakes or jerks in one direction (left or right) Q Q
3 During operations or when traveling (steering is neutral), the machine shakes or jerks Q Q Q
Steering wheel jerks or there is excessive shock when steering is operated to end of
4 Q
its stroke
5 Work equipment also jerks Q Q
Oil pressure is unstable in both directions
6 Q Q Q Q Q Q Q
When steering relief pressure is mea- (left and right)
sured Oil pressure is unstable in one direction
7 Q Q
(left or right)
Oil pressure is unstable in both directions
8 When output pressure from the joystick Q Q Q
(left and right)
steering solenoid valve (steering pilot cir-
Oil pressure is unstable in one direction
9 cuit pressure) was measured Q
(left or right)
When basic pressure of joystick steering (Orbit-roll basic pressure) is measured, oil
10 Q Q
pressure is found to be unstable
WA470-6, WA480-6 27
SEN01704-02 40 Troubleshooting
H-15 The wheel brake does not work or does not work well 1
Ask the operator about the following questions. Causes
Has the brake come not to turn suddenly? o Breakage of brake
Charge valve
q
Wheel brake
Accumulator
Brake valve
Fan pump
q Has the brake come not to work gradually?
Others
o Weakening of seals and wear of lining and disc
Remedy E E E E E E E E E
No. E
Diagnosis x x x x x x x x x
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q
2 When the brake pedal is stepped on, a strong resistance is felt Q
3 To get the specified braking force, an abnormal leg-power is required Q Q Q Q Q
4 When the brake works, an abnormal noise occurs from the axle brake Q Q
5 The machine does not travel well (insufficient drawbar pull) Q
When the four wheels are jacked up, the axle is placed on a table and the brake is
6 Q Q Q Q Q Q
applied at the forward 1st speed, only a specific wheel rotates
An airflow is observed in bleeding air from the brake circuit, and the brake returns
7 Q
to normal after the bleeding
8 Brake oil leaks abnormally from the axle during inspection Q
9 Much metal powders are mixed in the axle oil Q
10 The brake pedal leg-power and stroke are normal, but the brake does not work well Q Q Q Q
11 The brake does not work often when the engine is stopped Q Q Q Q
12 The accumulator is not charged, and a buzzer sounds Q Q Q
13 The brake works after some time lag Q
28 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Wheel brake
q Has the brake pedal returned completely?
Brake valve
q Is the parking brake released completely?
WA470-6, WA480-6 29
SEN01704-02 40 Troubleshooting
H-17 The parking brake does not work or does not work well 1
Ask the operator about the following: Cause
Has the brake come not to work suddenly? o Breakage of related equipment
Parking brake
q
Solenoid
Did the machine cause any abnormal noise at the time and where?
Valve
q Has the brake come not to work gradually?
o Wear of related equipment, defective seal
30 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Transmission valve
q Check if the parking brake emergency release switch is not turned ON.
q Check if the parking brake is automatically applied when the engine stops.
Wiring harness
Parking brake
Solenoid
a b c d e
q The parking brake is not released even if the emergency parking brake release valve is opened.
The following causes are considered:
a. Malfunction of emergency parking brake release valve
b. Insufficient gas pressure of accumulator for brake or breakage of piston seal
WA470-6, WA480-6 31
SEN01704-02 40 Troubleshooting
Tank – Pump
PPC valve
Cylinder
what part)
q Has the speed lowered? o Wear of parts and fatigue of springs
Malfunction of spool
Defective fan pump
Remedy C E E E E EEEE
No. x x x
Diagnosis E x x x x x x x x
1 Bucket does not move and lift arm does not rise Q Q Q Q Q Q Q
2 Lift arm can raise chassis but does not rise Q Q Q
3 Bucket moves but lift arm does not rise Q Q Q Q
4 Lift arm can rise when not loaded but cannot when loaded Q Q Q Q Q
5 Hydraulic pump is making abnormal sound Q Q Q
6 Hydraulic drift of lift arm cylinder is large Q Q
7 When lift arm and bucket are operated simultaneously, lift arm does not rise Q Q
8 Fan does not rotate Q Q Q
When work equipment pump and servo assembly is replaced, lift arm moves
9 Q
normally
32 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1
Testing before troubleshooting Causes
Bypass valve
Tank – Pump
PPC valve
Cylinder
sound made)?
Malfunction of spool
Defective fan pump
A
Remedy C E E E E EEEEE
No. x E x x x
Diagnosis E x x x x x x x x x
x
Tilting force and speed of bucket are abnormal and rising speed of
1 Q Q Q Q Q Q Q Q Q Q
lift arm is low
Tilting force and speed of bucket are normal and rising speed of lift
2 Q Q Q Q Q
arm is low
3 After oil temperature rises, tilting back speed lowers more in step 1. Q
4 Hydraulic pump is making abnormal sound Q Q Q
5 Hydraulic drift of the cylinder is large Q Q Q
6 Relief pressure of relief valve of work equipment valve is low Q Q Q Q Q Q
7 Relief pressure of relief valve of work equipment valve is too high Q
When lift arm and bucket are operated simultaneously, rising speed
8 Q
of lift arm is too low
When work equipment pump and servo assembly is replaced, lift
9 Q
arm moves normally
WA470-6, WA480-6 33
SEN01704-02 40 Troubleshooting
H-21 When rising, the lift arm comes to move slowly at specific height 1
Checks before troubleshooting
q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see “H-20 Lift arm speed is low or rising force of lift
arm is insufficient”
H-22 The lift arm cylinder cannot hold down the bucket (Bucket floats) 1
See “H-20 Lift arm speed is low or rising force of lift arm is insufficient.”
34 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
Tank – Pump
PPC valve
Cylinder
(From what part)
q Has the speed lowered?
o Wear of parts and fatigue of springs
Malfunction of spool
Defective fan pump
C
Remedy C E E E E EEEE E
No. x E x x
Diagnosis E x x x x x x x x x
x
1 Lift arm does not move and bucket does not tilt back Q Q Q Q Q Q Q
2 Bucket can raise chassis but does not tilt back Q Q Q
3 Lift arm moves but bucket does not tilt back Q Q Q Q
Bucket can tilt back when not loaded but cannot when used for digging
4 Q Q Q Q Q Q Q
or scooping
5 Hydraulic pump is making abnormal sound Q Q Q
6 Hydraulic drift of bucket cylinder is large Q Q Q Q
When lift arm and bucket are operated simultaneously, bucket does
7 Q Q
not tilt back
8 Fan does not rotate Q Q Q —
When work equipment pump and servo assembly is replaced, lift arm
9 Q
moves normally
WA470-6, WA480-6 35
SEN01704-02 40 Troubleshooting
Tank – Pump
PPC valve
Cylinder
mal sound made)?
A C
Remedy C E E E E EEE EEE
No. x E E x x
Diagnosis E x x x x x x x x x x
x x
Rising force and speed of lift arm are abnormal and tilting back
1 Q Q Q Q Q Q Q Q Q Q
force and speed of bucket are low
Rising force and speed of lift arm are normal and tilting back
2 Q Q Q Q Q Q
force and speed of bucket are low
After oil temperature rises, tilting back speed lowers more in
3 Q
step 1.
4 Hydraulic pump is making abnormal sound Q Q Q
5 Hydraulic drift of the cylinder is large Q Q Q Q
6 Relief pressure of relief valve of work equipment valve is low Q Q Q Q Q Q Q
Relief pressure of relief valve of work equipment valve is too
7 Q
high
When lift arm and bucket are operated simultaneously, tilting
8 Q
back speed of bucket is too low.
When work equipment pump and servo assembly is replaced,
9 Q —
bucket moves normally
36 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
For other abnormal phenomena during bucket operation, see “H-26 Bucket speed is low or tilting back
force is insufficient.”
H-30 The bucket wobbles during travel with cargo (The work equipment
valve is set to “HOLD”) 1
Checks before troubleshooting
q Pin of work equipment linkage and “play of bushing” (Is any abnormal noise heard?)
Cause
q Defective seal of bucket cylinder piston
q Defective operation of suction safety valve on bucket cylinder head side. For other abnormal phenom-
ena, refer to diagnoses for relevant abnormal phenomena.
WA470-6, WA480-6 37
SEN01704-02 40 Troubleshooting
H-31 Lift arm and bucket control levers do not move smoothly and are
heavy 1
Checking for abnormalities Causes
q Refer to the standard value table and check if the lever operating efforts are large practi- PPC valve
cally. a b c d
38 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
H-33 Large shock is made when work equipment starts and stops 1
Cause
q Wastes in work equipment valve PPC line
q Defective PPC valve
q Defective operation of control valve spool
q Defect in electrical system of lift arm or bucket EPC lever (if equipped)
WA470-6, WA480-6 39
SEN01704-02 40 Troubleshooting
Solenoid valve
q
Accumulator
Controller
Did any abnormal noise occur at the time and where?
Sensor
q Has pitching, bouncing occurred gradually? o Wear of related equipment, defective seal
40 WA470-6, WA480-6
40 Troubleshooting SEN01704-02
WA470-6, WA480-6 41
SEN01704-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
42
SEN01705-02
WA470-6
WA480-6
40 Troubleshooting 1
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart............................................................................................................ 3
S-1 Starting performance is poor. ................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly.......................................................................................................... 12
S-4 Engine stops during operation................................................................................................................ 13
S-5 Engine does not rotate smoothly ............................................................................................................ 14
S-6 Engine lacks output (or lacks power) ..................................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion) ................................................................................. 16
S-8 Oil is consumed much (or exhaust gas color is blue)............................................................................. 17
S-9 Engine oil becomes contaminated quickly ............................................................................................. 18
S-10 Fuel consumption is excessive............................................................................................................. 19
S-11 Coolant contains oil (blows back or reduces) ....................................................................................... 20
S-12 Oil pressure drops ................................................................................................................................ 21
S-13 Oil level rises (Water, fuel in oil) ........................................................................................................... 22
S-14 Coolant temperature rises too high (Overheating) ............................................................................... 24
S-15 Abnormal noise is made....................................................................................................................... 25
WA470-6, WA480-6 1
SEN01705-02 40 Troubleshooting
2 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
Questions:
Information to be obtained by questioning the user
or operator, and which corresponds to the sections
(A) and (B) in the right chart.
Section (A) includes basic information, and section
(B) contains items which can be obtained depend-
ing on the level of the user or operator.
Check items:
Items checked by the serviceman in order to nar-
row down the causes, section (C) of the right chart
is corresponding to them.
Causes:
Items to be narrowed down by the questions and
check items.
The serviceman narrows down the causes to highly
probable causes according to the information from
(A), (B) and (C).
Troubleshooting:
Items to be verified at the end in order to check if
the narrowed down causes are the true factors
causing the failure. The verification is carried out
by applying diagnostic tools or implementing direct
inspection in the order of probability.
WA470-6, WA480-6 3
SEN01705-02 40 Troubleshooting
4 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
The 5 items of [causes] and the 3 items of [questions] and [check items] have a cause-and-effect relation-
ship.
The “Step 1” to “Step 3” in the below figure, will explain how to narrow down the [causes] from the cause-and
effect relationship and lead to [troubleshooting].
WA470-6, WA480-6 5
SEN01705-02 40 Troubleshooting
Defective injector
maximum. This phenomenon does not indicate a trou-
ble, however.
w
spills
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
6 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA470-6, WA480-6 7
SEN01705-02 40 Troubleshooting
Degree of machine
Machine operated for long period EEE
operation
Condition of horn when Does not sound. Q Q w
starting switch is turned ON Horn volume is low w
Battery electrolyte level is low w
Battery terminal is loose w
No operating sound from battery relay when starting switch is turned ON Q w
When starting switch is turned to START, pinion does not move out Q Q w
Check items
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to flow out
q
Carry out troubleshooting in E-mode
(*1)
Inspect flywheel ring gear directly q
Specific gravity of electrolyte and voltage of battery are low q
Troubleshooting
Replace
Replace
Replace
Replace
Correct
Remedy
8 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
WA470-6, WA480-6 9
SEN01705-02 40 Troubleshooting
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA271], and Code [CA272]
*3: Troubleshooting by failure code (Display of code), Code [CA273], and Code [CA274]
10 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
c) Exhaust smoke comes out but engine does not start Cause
When engine is and the air breathing plug is removed from the fuel filter, fuel
Q w w
cranked with starting fails to discharge
motor, Spill flow drops, when spill hose is separated from injector w
When exhaust manifold is touched immediately after starting engine, temperature of
w
some cylinders is low
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter, strainer directly q
Inspect fuel feed pump gauze filter directly q
Carry out troubleshooting by “Rail Press Very Low Error (*1)” q
Testing a single unit injector indicates defective spraying q
Specific gravity of electrolyte and voltage of battery are low q
Coolant temperature gauge indication is not normal (when the gauge is installed) q
Intake air heater mount does not warm up during preheating operation q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA470-6, WA480-6 11
SEN01705-02 40 Troubleshooting
Black w Q w w
When engine is cranked, abnormal noise is heard from around cylinder head w
When engine is cranked, abnormal noise is heard from around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w w
There is hunting from engine (rotation is irregular) Q Q w Q
Blow-by gas is excessive w
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
12 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Add
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA470-6, WA480-6 13
SEN01705-02 40 Troubleshooting
Carry out troubleshooting by failure code “Abnormal EGR valve servo (*1)”. q
When air is bled from fuel system, air comes out q
q
Troubleshooting
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Clean
Clean
Refill
Remedy
14 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA122], and Code [CA123]
*3: Troubleshooting by failure code (Display of code), Code [CA263], and Code [CA265]
WA470-6, WA480-6 15
SEN01705-02 40 Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA1228], and Code [CA1625]
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*3: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]
16 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
Turbocharger
Worn or damaged valve (stem, guide, and seal)
q Extended operation for long hours in low or high
idle (continuous no load operation for 20 minutes
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA470-6, WA480-6 17
SEN01705-02 40 Troubleshooting
operation
Non-specified fuel is being used Q
Engine oil replenishment increasing Q w
Oil filter clogging monitor indicates clogging when the oil temperature rises (with the
w Q
monitor installed)
Metal particles are found when oil is drained in oil filter Q Q w
Inside of exhaust pipe is contaminated with oil w
Engine oil temperature rises quickly w
w
Check items
Replace
Replace
Clean
Clean
Clean
—
Remedy
18 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
*2: Troubleshooting by failure code (Display of code), Code [CA144], and Code [CA145]
WA470-6, WA480-6 19
SEN01705-02 40 Troubleshooting
q
Troubleshooting
Remedy
20 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
operation
Oil pressure monitor indicates low pressure level (with monitor installed) Q w
Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation &
w
Maintenance Manual
Indicates a drop of hydraulic pressure during low idle w Q Q
Oil pressure monitor Indicates a drop of oil pressure during low and high Q w w w Q Q Q
(With monitor idle
installed) Indicates a drop of oil pressure on a slope w
Indicates a drop of oil pressure occasionally w Q Q
Oil level monitor indicates low level (with monitor installed) w w
Oil pan oil level is in short w
w w
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
—
Remedy
*1: Troubleshooting by failure code (Display of code), Code [CA135], and Code [CA141]
WA470-6, WA480-6 21
SEN01705-02 40 Troubleshooting
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to
q
flow out (*1)
When compression pressure is measured, the oil pressure is low q
q
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
22 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
WA470-6, WA480-6 23
SEN01705-02 40 Troubleshooting
operation
Suddenly increased Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Coolant temperature gauge Rises quickly Q w
(when installed) Does not go down from red range w
Radiator coolant level monitor indicates low level (with monitor installed) Q w
Engine oil level has risen, oil is cloudy white w Q
Fan belt tension is low w
Turning the fan pulley causes a looseness. w
Cloudy white oil is floating on coolant w
Excessive air bubbles inside radiator, coolant spurts back w
When light bulb is held behind radiator, no light passes through w
Check items
Radiator shroud and inside of underguard are clogged with dirt or mud w w
Coolant leakage from cracks in the radiator hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden load w
Power train oil temperature gauge enters red range faster than engine coolant
temperature gauge (when oil temperature and coolant temperature gauge are w
installed)
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
24 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
Gradually increased Q Q
Condition of abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is being used Q
Engine oil must be added more frequently w
Metal particles are found when oil is drained in oil filter w w
Leakage of air between turbocharger and cylinder head w
When engine is cranked, abnormal noise is heard from around turbocharger w
When engine is cranked, abnormal noise is heard from around EGR gas piping w
When engine is cranked, abnormal noise is heard from around cylinder head w w
When engine is cranked, abnormal noise is heard from around muffler w
Check items
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
WA470-6, WA480-6 25
SEN01705-02 40 Troubleshooting
Replace
Replace
Replace
Adjust
Adjust
Remedy
26 WA470-6, WA480-6
40 Troubleshooting SEN01705-02
WA470-6, WA480-6 27
SEN01705-02
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
28
SEN02202-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02202-01 50 Disassembly and assembly
4:
ber respectively.
Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in “Removal” section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2]••• etc. and their
sented in the section of “Sketches of part numbers, part names and quantities are
special tools”. not described.
q Part No. of special tools starting with q Marks shown in the “Installation” section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
WA470-6, WA480-6 3
SEN02202-01 50 Disassembly and assembly
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g × 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g × 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
Grease
SYG2-400T-A
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold 16 kg Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
16 kg Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond — 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
WA470-6, WA480-6 5
SEN02202-01 50 Disassembly and assembly
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Feature: Urea (organic system) grease with heat
Grease
22M-54-27230 20 ml
PRIMER tainer (Effective period: four months after date of
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
PRIMER tainer (Effective period: four months after date of
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
a Tools with part number 79 T- - means that they are not available from Komatsu Ltd. (i.e.
tools to be made locally).
* *** ****
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See
Sketches of special tools).
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
WA470-6, WA480-6 7
SEN02202-01 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
WA470-6, WA480-6 9
SEN02202-01 50 Disassembly and assembly
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
A3 Wrench
A5 Push tool
WA470-6, WA480-6 11
SEN02202-01 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A6 Push tool
A8 Push tool
12 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
C1 Bracket
WA470-6, WA480-6 13
SEN02202-01 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
C5 Spacer
14 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
C7 Spacer
C8 Push tool
WA470-6, WA480-6 15
SEN02202-01 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
C9 Push tool
16 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
WAKU26
WA470-6, WA480-6 17
SEN02202-01 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
C13 Bracket
D1 Plate
18 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D3 Spacer
WA470-6, WA480-6 19
SEN02202-01 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D4 Push tool
D7 Push tool
20 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D7 Spacer
D7 Push tool
WA470-6, WA480-6 21
SEN02202-01 50 Disassembly and assembly
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D9 Support
D9 Support
22 WA470-6, WA480-6
50 Disassembly and assembly SEN02202-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D10 Holder
WA470-6, WA480-6 23
SEN02202-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
24
SEN02203-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02203-01 50 Disassembly and assembly
1. Drain coolant.
5 Coolant: Approx. 61 l
2. Drain hydraulic oil. 7. Remove clamp (2) for the hose between the
5
torque converter and oil cooler and clamp (3)
Hydraulic oil:Approx. 270 l (WA470-6) for the air conditioner hose.
Approx. 275 l (WA480-6)
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
9. Disconnect air conditioner compressor top 14. Remove plate (12) on the bottom oil cooler.
connector E10 (6).
12. Loosen the clamps and disconnect aftercooler 17. Remove the clamp and disconnect battery
hoses (9) and (10) on the engine side. relay wiring E07A (16).
13. Loosen the clamp and disconnect radiator 18. Disconnect connector ER4 (17).
cooler hoses (11) on the radiator side.
WA470-6, WA480-6 3
SEN02203-01 50 Disassembly and assembly
19. Disconnect starter wiring (18) and ground 22. Remove 5 clamps (23) and (24) for air condi-
cable (19). tioner hoses.
20. Disconnect harness connectors ER2 (20), ER3 23. Temporarily lift engine assembly (25).
(21) and ER1 (22), and then remove the
clamp.
a The connectors are arranged in the order
of ER2, ER3 and ER1 (22) from the top.
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
[*1]
q Belt tension adjustment
Adjust the compressor belt tension, referenc-
ing to "Testing and adjusting air compressor
belt tension" in "Testing and adjusting."
[*2]
3 Mounting bolt: 490 – 608 Nm {50 – 62 kgm}
[*3]
a When connecting the engine to the torque con-
verter, adjust height of the torque converter
shaft and ring gear so that they can be
26. Lift off engine assembly (25). smoothly inserted.
a Before lifting off the engine, make sure
every necessary harness and piping is q Refilling with coolant
disconnected. Add coolant up to the specified level. Run the
4 Engine assembly: 1340 kg engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
WA470-6, WA480-6 5
SEN02203-01 50 Disassembly and assembly
Removal
k Park the machine on level ground and
lower the bucket to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery.
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
8. Remove clamp (10) for breather tube (4). 14. Open right and left side battery covers (17) and
(18), and then remove 2 mounting bolts for
9. Remove clamp (11) for dust indicator tube (7) each of right and left side radiator guards (19)
and harness (8). and (20).
WA470-6, WA480-6 7
SEN02203-01 50 Disassembly and assembly
17. Temporarily lift hood assembly (24). 20. Lift off hood assembly (24).
4 Hood assembly: 310 kg
18. Remove 4 mounting bolts for top bracket (25).
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
Removal and installation of 11. Remove the clamps in 2 places and discon-
radiator assembly 1 nect hose (11) and harness (12).
1. Drain coolant.
5 Coolant: Approx. 61 l
WA470-6, WA480-6 9
SEN02203-01 50 Disassembly and assembly
16. Remove condenser (8). 20. Disconnect bottom radiator connection hose
(20).
17. Remove the bottom mounting bolt, and then a Disconnect one side alone.
remove bracket (9).
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 11
SEN02203-01 50 Disassembly and assembly
Removal and installation of 8. Remove 3 clamps for oil cooler hose (7).
aftercooler assembly 1
9. Remove the bottom mounting bolt of con-
Removal denser bracket (6) and place it beside the
k Park the machine on level ground and engine.
lower the bucket to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery.
6. Disconnect hose (5) for the air aftercooler. 11. Temporarily lift air aftercooler (9), and then
remove 3 mounting bolts.
7. Remove 2 top mounting bolts for condenser
mounting bracket (6).
12 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 13
SEN02203-01 50 Disassembly and assembly
Removal and installation of oil 6. Disconnect hose (5) from oil cooler tube (6).
cooler assembly 1
Removal
k Park the machine on level ground and
lower the bucket to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery.
3. Remove left side plate (2). 7. Disconnect bottom hose (7) from block (8).
14 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 15
SEN02203-01 50 Disassembly and assembly
Removal and installation of 4. Remove the mounting bolts for right and left
cooling fan and drive motor side grilles (4).
assembly 1
Removal
k Park the machine on level ground and
lower the bucket to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Loosen the oil filler cap of the hydraulic
tank to release the internal pressure.
k Disconnect the negative (–) terminal from
the battery.
2. Open front grille (3). 5. Open the battery cover and remove the bottom
mounting bolts for right and left side radiator
guards (5) and (6).
16 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
7. Disconnect rear work light left-connector C04 12. Disconnect fan buzzer connector G10 (12) and
(8) and right-connector C05 (9). fan motor solenoid connector G11 (13).
8. Remove 3 clamps for harness (10). 13. Remove 3 clamps for harness (10).
WA470-6, WA480-6 17
SEN02203-01 50 Disassembly and assembly
17. Remove fan motor solenoid connector (19) 20. Remove 4 mounting bolts, and then remove
and harness clamp (20). fan motor assembly (23).
18 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
[*2]
a Clean and degrease the shaft of fan motor
assembly (23) and the tapered part of boss
(28) before assembling.
a Install fan (22) as shown in the figure.
a When installing boss (28), match it with fan
motor shaft key (29).
WA470-6, WA480-6 19
SEN02203-01 50 Disassembly and assembly
New/Remodel
Sym-
Necessity
Part No. Part name
bol
Sketch
Q'ty
1 795-630-5500 Standard puller t 1
A1 2 01010-81090 Bolt t 1
3 01643-31032 Washer t 1
Removal
k Park the machine on level ground and
lower the bucket to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from 6. Remove bottom plate (3).
the battery.
20 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
9. Remove fuel inlet hose (12) on the priming 14. Remove fuel tubes (21) and (22) plus tube (23)
pump. between the supply pump and fuel filter. [*5]
12. Remove priming pump (17) along with bracket 17. Remove clamp mounting bracket (29).
(18). a A spacer is used for the bracket. Take
a A spacer is used below the bracket. Take care not to lose the spacer. [*6]
care not to lose the spacer. [*3]
18. Remove common rail side 2 fuel sprary pre-
vention caps (30) and supply pump side 2 fuel
sprary prevention caps (31).
WA470-6, WA480-6 21
SEN02203-01 50 Disassembly and assembly
20. Remove cover (34). [*7] 22. Remove nut (37), and then washer (38). [*8]
a When removing the washer (38), use a
magnet so that it may not be inadvertently
dropped inside the case.
26. Install tool A1-2 again for fixing the gear when
installing.
22 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 23
SEN02203-01 50 Disassembly and assembly
1. Confirm that shaft key (42) is directed almost 5. Tighten high-pressure pipes (32) and (33) and
straight up. high-pressure pipe clamp mounting bracket
with the fingers.
2. While matching shaft key (42) with key way (a)
on the gear side, install fuel supply pump 6. Tighten lubrication tube (24) with the fingers.
assembly (41).
7. Tighten the sleeve nuts of high-pressure pipes
(32) and (33) permanently.
3 Sleeve nut
(Common rail side):
39.2 – 58.8 Nm {4 – 6 kgm}
(Supply pump side):
39.2 – 49 Nm {4 – 5 kgm}
24 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
[*4]
3 Mounting bolt of clamp (19):
27 – 34 Nm {2.8 – 3.5 kgm}
[*5]
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*6]
a Spacer length: 50 mm
[*7]
3 Cover mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*8]
3 Nut (37): 127 – 147 Nm {13 – 15 kgm}
q Bleeding air
Bleed air from the fuel circuit referencing to
"Bleeding air from fuel circuit" in Testing and
adjusting.
WA470-6, WA480-6 25
SEN02203-01 50 Disassembly and assembly
Removal and installation of fuel 7. Sling the muffler assembly (6), then remove it
injector assembly 1 from the turbocharger.
4 Muffler assembly: 55 kg
Removal
k Stop the machine on a level ground and
lower the work equipment and touch per-
fectly to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery beforehand.
26 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 27
SEN02203-01 50 Disassembly and assembly
20. Remove high-pressure pipe sleeve nut (32) on 25. Remove rocker arm and shaft assembly (39).
the common rail side, and then pull out high- a When installing the rocker arm, loosen the
pressure pipe sleeve nut (33) on the injector locknut to prevent excessive force to the
side. push rod, and then loosen the adjuster
screw enough.
21. Remove oil high-pressure pipe (34).
28 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 29
SEN02203-01 50 Disassembly and assembly
3. Install the fuel injector wiring harness accord- 5. Install the high-pressure pipe according to the
ing to the following procedure. following procedure.
1) Tighten holder (53) with bolt (37). k The clamp used for fixing a high-pressure
3 Bolt (37): pipe must be a genuine Komatsu part and it
27 – 34 Nm {2.8 – 3.5 kgm} must be tightened to the specified torque.
2) Tighten nuts (36) alternately. k Never bend a high-pressure pipe for the
3 Nuts (36): convenience sake.
2.0 – 2.4 Nm {0.2 – 0.24 kgm} k Before Installing a high-pressure pipe, con-
firm the following points.
If any abnormality was found, replace it
with another healthy one. Otherwise, leak-
age of fuel can result.
q Check that the taper seal portion of the
connection ((a) portion: areas 2 mm inside
the tip) is free from visually recognizable
striations (b) or patchy dents (c).
q Check that nails are not caught by steps in
portion (d) (2 mm inside the tip) (this por-
tion is free from deformation).
30 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
[*4]
a When installing the spacers of clamps (8),
check the following.
q For fuel tube (10) length: 14 mm
q For fuel tube (11) length: 30 mm
3 Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
[*5]
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*6]
a Spacer length: 34.2 mm
q Bleeding air
Bleed air from the fuel circuit referencing to
"Bleeding air from fuel circuit" in Testing and
adjusting.
WA470-6, WA480-6 31
SEN02203-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Sketch
Q'ty
A2 790-331-1110 Wrench q 1
Removal
1. Remove the fuel injector assembly. For details,
see "Removal and installation of fuel injector
assembly."
a Carry out the following work simulta-
neously. 2. Disconnect connector EGR (9) and connector
SEGR (10).
1) Disconnect connector PFUEL (1) at the
left rear of the engine. 3. Disconnect connector J1939 (11).
32 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
4. Disconnect connector E10 (12). 10. Remove clamp (18) and remove bracket
assembly (19).
5. Loosen and remove air conditioner compres- a A spacer is used for the engine side
sor belt (13). For details, see Testing and bracket-mounting bolt. Take care not to
adjusting, "Testing and adjusting air condi- lose the spacer. [*5]
tioner compressor belt tension." [*3]
11. Remove 4 mounting bolts of tube (17) on the
6. Remove the mounting bolts of air conditioner EGR cooler side and remove tube (17) and
compressor (14) and move the air conditioner bracket (21).
compressor toward the machine frame. a Take care not to lose the 1 spacer of the
mounting bolt of bracket (21) on the cylin-
der block side and 2 spacers on the EGR
side. [*6]
WA470-6, WA480-6 33
SEN02203-01 50 Disassembly and assembly
13. Remove tube (23). 16. Remove harness clamp (28) and spacer (29).
a 8 spacers are used for the mounting bolts.
Take care not to lose the spacers. [*7] 17. Remove bracket (30).
34 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
21. Remove bracket (37) from the engine front 24. Remove water tube (40). [*13]
side lift plate (36). [*11]
WA470-6, WA480-6 35
SEN02203-01 50 Disassembly and assembly
27. Temporarily lift intake manifold (45), remove 31. Remove 6 mounting bolts (49) and 1 auxiliary
the mounting bolt and remove intake manifold bolt (50), and then lift off cylinder head assem-
(45). bly (51).
4 Intake manifold: 30 kg
36 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
Installation
1. Install the cylinder head assembly.
a Confirm that the cylinder head mounting
face and inside of the cylinder are free
from dirt or foreign matter and install the
gasket to the cylinder block.
a When installing the gasket, confirm that
the grommet is not peeled or removed.
WA470-6, WA480-6 37
SEN02203-01 50 Disassembly and assembly
[*2]
3 Joint: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*3]
a Adjust the air conditioner compressor belt ten-
sion. For details, see Testing and adjusting,
"Testing and adjusting air conditioner compres-
sor belt tension."
[*4]
a Length of spacer: 60.5 mm
38 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
[*5] [*15]
a Length of spacer: 12 mm a Check that the push rod is inserted in the cam
follower.
[*6]
a Length of EGR cooler side spacer: 41.6 mm [*16]
a Length of cylinder block side spacer: 26.2 mm a Adjust the crosshead in the following proce-
dure.
[*7] 1) Loosen locknut (52) and return adjustment
a Length of spacer: 18 mm screw (53) to the original position.
2) Hold the top face of crosshead (47) lightly,
[*8] and then screw in adjustment screw (53).
a Length of spacer: 10 mm 3) After adjustment screw (53) is in contact
3 Joint bolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm} with the valve stem, screw it in further by
20°.
[*9] 4) Tighten locknut (52) in this position.
3 Union sleeve nut: 2 Crosshead guide and crosshead
40 – 44 Nm {4.1 – 4.5 kgm} top face: Engine oil (EO30)
3 Locknut:
[*10] 58.7 ± 5.9 Nm {6.0 ± 0.6 kgm}
3 EGR valve mounting bolt:
59 – 74 Nm {6.0 – 7.5 kgm}
[*11]
3 Head cover side mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*12]
a Exhaust manifold installation procedure
1) Manually screw in all exhaust manifold-
mounting bolts by 2 to 3 threads.
2) Tighten mounting bolts [1] to [3] to the
specified torque, and then tighten other
mounting bolts.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm} [*17]
3 Rocker housing mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
[*13]
3 Joint bolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*14]
3 Clip fixation nut:
9.8 – 26.5 Nm {1.0 – 2.7 kgm}
WA470-6, WA480-6 39
SEN02203-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Sketch
Q'ty
Seal puller
A3 795-931-1100 q 1
assembly
1 795T-521-1140 Push tool t 1 Q
A4 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 9
Removal
1. Remove the aftercooler assembly. For details,
see "Removal and installation of aftercooler
assembly."
5. Remove engine front oil seal (5).
2. Loosen and remove the air conditioner com-
a Before removing the seal, drive in it a little
pressor belt and alternator belt. For details,
to separate.
see Testing and adjusting, "Testing and adjust-
a Take care not to damage the seal contact
ing air conditioner compressor belt tension"
faces of front cover (6) and crankshaft (7).
and "Testing and adjusting alternator belt ten-
a If it is difficult to remove the seal, remove it
sion".
according to the following procedure.
1) Drill several holes about 3 mm in diameter
3. Sling the damper (1) temporarily, loosen 6
into engine front oil seal (5).
mounting bolts (2), then remove the damper.
a Remove all the chips.
[*1]
2) Replace the tip of tool A3 with the drill-
4 Damper: 15 kg type tip and insert it in one of the holes
drilled in the above step.
3) Pull hammer [1] of tool A3 toward you and
remove the engine front seal with impact
forces.
a Perform the above procedure at sev-
eral places so that the seal will not
slant.
40 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
Tool A3 Installation
a Check the rims of the crankshaft end, sliding
surfaces of the lip, and front cover for flaws,
burrs, rust, etc.
1. Install engine front oil seal (5) to front cover (6)
and press fit it with a plastic hammer until seal
lip (a) is inserted in crankshaft (7).
a Take care not to mistake the installed
direction of the seal.
a While taking care not to damage the seal,
hit its periphery evenly to press fit.
a Take care that the seal lip will not be
caught in the crankshaft.
2 Seal lip (50 – 80% of space in lip):
Grease (G2-LI)
WA470-6, WA480-6 41
SEN02203-01 50 Disassembly and assembly
[*1]
3 Bolt: 98 – 123 Nm {10 – 12.5 kgm}
[*2]
3 Bolt
M14: 157 – 196 Nm {16 – 20 kgm}
M16: 245 – 309 Nm {25 – 31.5 kgm}
42 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
New/Remodel
shaft (4).
a If it is difficult to remove the seal, remove it
Necessity
Sym-
Part No. Part name
bol
Sketch
according to the following procedure.
Q'ty
Seal puller
A5 795-931-1100 q 1
assembly
1 795T-421-1340 Push tool t 1 Q
A6 2 01010-61635 Bolt t 3
3 01643-31645 Washer t 3
1 795-931-1220 Push tool t 1
A7 2 01010-61650 Bolt t 3
3 01643-31645 Washer t 3
1 795T-421-1320 Push tool t 1 Q
A8 2 01010-61645 Bolt t 3
3 01643-31645 Washer t 9
WA470-6, WA480-6 43
SEN02203-01 50 Disassembly and assembly
44 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
1. Set large inside diameter side (c) of guide (6) 4. Install tool A6-1 and tighten 3 bolts (A6-2)
of engine rear oil seal (2) to the end of crank- evenly until they stop to press fit engine rear oil
shaft (4). seal (2).
a Take care not to mistake the installed a Do not fit washers to bolts (A6-2).
direction. a When press fitting the seal, take care not
to damage the seal lip with the tool, etc.
WA470-6, WA480-6 45
SEN02203-01 50 Disassembly and assembly
Procedure for installing sleeved seal 2. Apply sleeve (5) to sleeve and seal assembly
a Clean, degrease, and dry the contact face (2) to the end of crankshaft (4) and tighten 3
against the flywheel housing. bolts (A7-2) of tool A7-1 evenly to press fit
a Check that the end corners of the crankshaft, sleeve and seal assembly (2).
lip sliding surfaces, and housing are free from a Fit 1 washer (A7-3) each to bolts (A7-2),
flaws, burrs, rust, etc. and tighten them until the end of tool A7-1
a Do not apply oil or grease to the crankshaft touches the end of crankshaft (4).
and the inside cylinder of sleeve (5) and seal
lip (b) of the slash part. Wipe off the oil from the
crankshaft.
a Handle the engine rear oil seal (2) and sleeve
as an assembly and never separate them.
46 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
[*1]
a Tighten the flywheel mounting bolts in the
order shown in the following figure.
2 Mounting bolt: Engine oil (EO30)
3 Mounting bolt
1st time : 147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd time: 289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
WA470-6, WA480-6 47
SEN02203-01 50 Disassembly and assembly
Removal and installation of fuel 6. Loosen clamp (6) and pull out hose (7).
tank assembly 1
Removal
k Stop the machine on a level ground and
lower the work equipment and touch per-
fectly to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery beforehand.
1. Drain fuel.
5 When fuel tank is full: 413 l
48 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
10. Support the front bottom of the fuel tank 13. Remove fuel tank assembly rear side mounting
assembly with jack [1]. bolt (15) from the counterweight. [*2]
11. Remove 2 fuel tank assembly mounting bolts 14. Lower the fuel tank assembly gradually with
(14). [*1] the jack [1] and the hoist, and get enough
clearance for inserting a hand between the
assembly and rear frame.
WA470-6, WA480-6 49
SEN02203-01 50 Disassembly and assembly
18. Adjusting the jack height, lower the hoist grad- Installation
ually until fuel tank assembly (20) becomes q Carry out installation in reverse order of
parallel to the ground and support the assem- removal.
bly there using block [3].
a Confirm whether all necessary harnesses [*1] [*2]
and pipes are connected. a Tightening torque is observed strictly.
3 Fuel tank mounting bolt:
4 Fuel tank assembly (when empty):
785 – 980 Nm {80 – 100 kgm}
220 kg
50 WA470-6, WA480-6
50 Disassembly and assembly SEN02203-01
WA470-6, WA480-6 51
SEN02203-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
52
SEN02204-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02204-01 50 Disassembly and assembly
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
9. Remove 2 clamps and remove connectors R36 12. Disconnect torque converter hoses (12) and
(5), R37 (6), R40 (7) and R 86 (8). (13).
10. Remove 2 hose clamps (9) and (10). 13. Disconnect hose (14), and then remove tube
(15) from PTO oil tank.
WA470-6, WA480-6 3
SEN02204-01 50 Disassembly and assembly
16. Remove transmission oil filler tube (19). 25. Disconnect discharge tube (37).
30. Loosen the clip to take out plate (45), and then
21. Remove suction tube assembly (30) from work disconnect tube (43).
equipment pump (29).
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
31. Disconnect pressure sensor connector (47), 37. Remove clamp (59) and remove hoses (60)
and then remove block (48). and (61).
32. Disconnect hose (49), remove clamp (50) and 38. Remove clamp plate (62) and remove hose
disconnect tube (51). (63).
34. Remove clamp (53) and disconnect hose (54). 40. Remove 3 clamps (65) for the air conditioner
hose and harness.
WA470-6, WA480-6 5
SEN02204-01 50 Disassembly and assembly
41. Thoroughly loosen mounting bolts (66) for the 45. Lift the torque converter and transmission
right and left side engine rear mounts. [*3] assembly up to a position where 2 mounting
a When removing the torque converter and bolts (72) for the bottom of mount brackets (71)
transmission assembly, the machine front can be removed on both sides.
side is lifted above the rear side at a slant.
Thus, make sure that the engine rear
mount mounting bolts must be loosened.
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 7
SEN02204-01 50 Disassembly and assembly
New/Remodel
plate (1).
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-501-5000 Unit repair stand t 1
B1 2 790-901-2110 Bracket t 1
3 790-901-4240 Plate t 1 R
Disassembly
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
3. Stator 6. Bearing
1) Reverse the stator shaft and pump Remove bearing (15) from gear (13).
assembly to install.
2) Remove snap ring (9).
3) Remove stator (10).
4. Stator shaft
Using forcing screws [1], push stator shaft (11)
end and disconnect from pump assembly (12).
5. Gear
Remove gear (13) from pump (14).
WA470-6, WA480-6 9
SEN02204-01 50 Disassembly and assembly
2. Gear
Install gear (13) to pump (14). 2) Push inner race of bearing and install
2 Mounting bolt: Adhesive (LT-2) pump assembly (12) to shaft (11).
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
4. Stator
1) Install stator (10).
2) Install snap ring (9)
.
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 11
SEN02204-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-501-5000 Unit repair stand q 1
B1 2 790-901-2110 Bracket q 1
3 790-901-4240 Plate q 1 R
B2 793-647-1110 Wrench t 1 N 2] Using forcing screw [4], remove stator
shaft (5).
Disassembly 3] Remove seal ring (6) from stator shaft
1. Perform steps 1 through 8 described in “Disas- (5)
sembly and assembly of transmission assem- .
bly”.
a Perform the disassembly procedure with
the torque converter assembly placed on
a block (or with it secured to tool B1).
12 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 13
SEN02204-01 50 Disassembly and assembly
2. Turbine, case
Install complete turbine (31) to block [5] to
mount drive case (33).
a Height (h) of block [5]: Approx. 90 mm
14 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
3. Disc
Install disc (40).
a Apply engine oil to the sliding surface of
the disc before installation.
5. Bearing
Using pushing tool [10], pressure-fit bearing
(28).
a After press fitting the bearing, drop 6 cc of
engine oil and then turn the bearing 10
turns.
WA470-6, WA480-6 15
SEN02204-01 50 Disassembly and assembly
6. Plate and snap ring 2) Install snap ring (17) to stator (16).
Fit spacer (24) and then install snap ring (23). 3) Fit race and free wheel assembly (15) to
stator (16) before installing snap ring (14).
7. Pilot
Install pilot (22) and then tighten bolt (17a).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
16 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
2] Fit guide and bearing assembly (8) 5] Using tool C3, tighten nut (4).
and gear (10) to pump (9) before a Screw the bolt in the stator shaft
tightening mounting bolt (7). and secure it using bar [3] before
2 Mounting bolt: loosening the nut.
Adhesive (LT-2) 2 Nut: Adhesive (LT-2)
3 Mounting bolt: 3 Nut: 147.1 – 176.5 Nm {15 –
58.8 – 73.5 Nm 18 kgm}
{6.0 – 7.5 kgm}
WA470-6, WA480-6 17
SEN02204-01 50 Disassembly and assembly
18 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
Disassembly and assembly of 3. Steering pump and power train pump assembly
transmission assembly 1 1) Remove pipe and hose assembly (3).
2) Remove filter (4).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 793T-607-1240 Bracket t 2 N Q
C1
2 01010-81640 Bolt t 8
1 790-101-5421 Grip t 1
C6 2 01010-51240 Bolt t 1
3 793T-607-1150 Pushing tool t 1 N Q
1 790-101-5421 Grip t 1
2 01010-51240 Bolt t 1
C7 3) Remove pipe and hose assembly (5).
3 793T-607-1150 Pushing tool t 1 N Q
4) Lift up steering pump and power train
4 793T-607-1160 Spacer t 1 N Q pump assembly (6) and then remove it.
1 793T-607-1220 Lifting tool t 1 N Q 4 Steering pump and power train
Disassembly
1. Mount brackets
Remove mount brackets (1) on both sides.
WA470-6, WA480-6 19
SEN02204-01 50 Disassembly and assembly
4. Work equipment and cooling fan drive 6) Remove speed sensor (16a).
pump assembly
Lift up work equipment and cooling fan drive
pump assembly (7) and then remove it.
4 Work equipment and cooling fan drive
pump assembly: 127 kg
20 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 21
SEN02204-01 50 Disassembly and assembly
8. Torque converter assembly 2) Install the rear housing on blocks with the
1) Install rear housing (23) on blocks with the PTO gear down.
torque converter down. 3) Support shaft (29) with jack [4].
2) Remove mounting bolts (24) from the
torque converter assembly and then install
the guide mounting bolts.
3) Lift up rear housing (23) and then remove
torque converter assembly (25).
a For the disassembly of the torque
converter assembly, see "Disassem-
bly and assembly of torque converter
assembly."
9. PTO gear
1) Remove snap ring (26), plate (27) and
snap ring (28).
22 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
5) Jack down with jack [4] to pull shaft (29) 2) Using tools C11-3 and -4, simultaneously
out and then remove PTO gear (33). lift up 1st-/4th-speed clutch pack assembly
(36) and 2nd-/3rd-speed clutch pack
assembly (37) to remove them.
4 Clutch pack assembly: 160 kg
WA470-6, WA480-6 23
SEN02204-01 50 Disassembly and assembly
24 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 25
SEN02204-01 50 Disassembly and assembly
26 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 27
SEN02204-01 50 Disassembly and assembly
28 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 29
SEN02204-01 50 Disassembly and assembly
8) Lift up the torque converter and transmis- 5) Turn the output shaft to turn the 2nd/3rd-
sion assembly to support the bottom of speed clutch shaft 20 turns.
front housing (24) and rear housing (23) a Look through the mounting hole of
with blocks. cover (55a) for bearing case (55) to
9) Remove tool C1. check the shaft for rotation.
6) Check the tightening torque of the bearing
case mounting bolt.
a If the tightening torque fluctuates,
repeat steps 2) and 3).
7) Using a thickness gauge, measure any
three or four points equally divided on the
periphery for clearance between front
housing (24) and bearing case (55).
30 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
3 Valve assembly:
No. 17, 17a, 19, 20:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
No. 18:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
WA470-6, WA480-6 31
SEN02204-01 50 Disassembly and assembly
32 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-201-2170 Plate t 1
2 790-201-2730 Spacer t 1
C2
3 796-465-1120 Push tool t 1
4 790-201-2740 Spacer t 1
1 793-607-1110 Seal holder t 1 N
C3
2 793-607-1120 Seal holder t 1 N
C12 799-301-1500 Oil leak tester kit t 1
3. End plate
Disassembly
k
1) Push end plate (6) using C vice [3] or the
When mounting the clutch pack on the
like to remove snap ring (7).
block or the like, be careful not to drop it as
2) Remove end plate (6).
it is slippery due to oil. Otherwise, your fin-
gers might get caught between the block
and the clutch pack.
4. Clutch plate
1) Remove spring plate (8) from the housing.
WA470-6, WA480-6 33
SEN02204-01 50 Disassembly and assembly
5. Piston
Remove piston (14) by injecting air into the for- 7. Reverse gear
ward-side oil hole in the shaft. 1) Remove spacer (17), thrust washer (18)
and reverse gear (16).
2) Remove needle bearing (19) from the
reverse gear.
8. End plate
9. Clutch plate
10. Piston
a For procedures 8 to 10, disassemble the
clutch pack in the same way as in proce-
dures 3 to 5 for the forward clutch.
34 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
4. Clutch plate
2. 1st gear 1) Remove plate (38), disc (39) and spring
1) Remove snap ring (32) to remove thrust (40) from the housing.
washer (33) and 1st speed gear (34).
a Reuse of snap ring (32) is not allowed.
Use a new part for the assembly.
5. Piston
2) Remove needle bearing (35) from the 1st Remove piston (42) by injecting air into the
speed gear. reverse-side oil hole in the shaft.
WA470-6, WA480-6 35
SEN02204-01 50 Disassembly and assembly
8. End plate
9. Clutch plate
10. Piston
a For procedures 8 – 10, disassemble the
clutch pack in the same way as in proce-
dures 3 – 5 for the 1st speed clutch.
36 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
2) Remove needle bearing (53a) from the 2) Then, remove thrust washer (58a).
3rd speed gear (53).
5. Piston
Remove piston (59) by injecting air into the
3rd-speed-side oil hole in the shaft.
3. End plate
1) Push end plate (54) using C vice [11] or
the like to remove snap ring (55).
2) Remove end plate (54).
WA470-6, WA480-6 37
SEN02204-01 50 Disassembly and assembly
38 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 39
SEN02204-01 50 Disassembly and assembly
4. End plate
1) Push end plate (72) using C vice [13] or
the like to install snap ring (73).
a At this time, check to see that snap
ring (73) is firmly engaged in the
groove.
[Forward clutch]
6. Forward-side piston
1) Lubricate the piston seal in the same way
as for the reverse clutch, then install it to
piston (14).
2) Install piston (14) in the same way as for
the reverse clutch.
2 Sliding surface of piston seal:
Transmission oil
3) Install thrust washer (12).
40 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
7. Clutch plate
1) Install plate (9), disc (10) and spring (11)
in this order.
a Install them in the same way as for
the reverse clutch.
WA470-6, WA480-6 41
SEN02204-01 50 Disassembly and assembly
2. 4th-speed-side piston
1) Install 4th-speed-side piston (75).
a At this time, be careful not to damage
the piston seal.
2 Sliding surface of piston seal:
Transmission oil
2) Install thrust washer (78).
42 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
4. End plate
Push end plate (82) using C vice [14] or the
like to install snap ring (83).
a At this time, check to see that snap ring
(83) is firmly engaged in the groove.
WA470-6, WA480-6 43
SEN02204-01 50 Disassembly and assembly
9. 1st-speed gear
1) Install needle bearing (35) to 1st-speed
gear (34).
2) Mount the 1st gear to the shaft.
7. Clutch plate
Install plate (38), disc (39) and spring (40) in
this order.
a Install them in the same way as for the
4th-speed clutch.
44 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
3) Install thrust washer (33) and snap ring 2) Move 1st-speed gear (34) up and down to
(32). confirm the clearance (d) between idler
a Reuse of snap ring (32) is not allowed. gear (31) and thrust washer (33), is within
Use a new part for the assembly. the standard range.
If widening the opening of snap ring Standard value (d): 0.26 – 0.74 mm
excessively, the snap ring may be
deformed. Thus, the opening must
keep to the minimum when assem-
bling it.
WA470-6, WA480-6 45
SEN02204-01 50 Disassembly and assembly
4. End plate
Push end plate (91) using C vice [15] or the
2. 2nd-speed-side piston like to install snap ring (92).
1) Install 2nd-speed-side piston (85).
a At this time, be careful not to damage
the piston seal.
2 Sliding surface of piston seal:
Transmission oil
2) Install thrust washer (87).
5. 2nd-speed gear
1) Install 2nd-speed gear (63), then needle
bearing (64).
a If the spline does not align with the
gear, turn it slightly instead of forcing
it onto the spline.
46 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
2) Install thrust washer (62) and snap ring 2) Press-fit bearing (60a) using tool C2-3, 4.
(61).
a Reuse of snap ring (61) is not
allowed. Use a new part for the
assembly.
If widening the opening of snap ring
excessively, the snap ring may be
deformed. Thus, the opening must
keep to the minimum when assem-
bling it.
WA470-6, WA480-6 47
SEN02204-01 50 Disassembly and assembly
8. Clutch plate
Install housing plate (56), disc (57) and spring
(58) in this order.
a At this time, install them in the same way
as for the 2nd-speed clutch.
48 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 49
SEN02204-01 50 Disassembly and assembly
New/Remodel
Necessity
Symbol Part No. Part name
Sketch
Q'ty
1 790-101-5421 Grip t 1
C4 2 01010-51240 Bolt t 1
3 793T-607-1130 Push tool t 1 N Q
1 790-101-5421 Grip t 1
2 01010-51240 Bolt t 1
C5
3 793T-607-1130 Push tool t 1 N Q
4 793T-607-1140 Spacer t 1 N Q
C8 797T-423-1360 Push tool t 1 Q
C9 793T-607-1170 Push tool t 1 N Q 3. Cage assembly
C10 793T-607-1180 Push tool t 1 N Q 1) Remove the mounting bolt and use forcing
1 793T-607-1190 Bracket t 1 N Q screw [1] to remove cage (5).
2) Remove shim (6).
C13 2 425-15-13320 Plate t 1
3) Remove dust seal (7) and oil seal (8) from
3 01050-62220 Bolt t 1 the cage.
Disassembly
1. Rear coupling
Remove rear coupling (1a).
50 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
5. Spring and bearing 4) Remove plate (16), spring (18) and disc
1) Remove spring (12) (12 springs). (19).
2) Remove bearing (13) together with spacer
(14) and separate them if necessary.
WA470-6, WA480-6 51
SEN02204-01 50 Disassembly and assembly
9. Output shaft
1) Install eyebolt [4] to remove output shaft 2) Install gear (23) to output shaft (22).
(22) together with gear (23).
52 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
4. Piston
2) Install guide bolt [5] on the front housing 1) Install the O-ring and backup ring on the
and install parking brake case (20). piston.
a The backup ring shall be assembled
on the outside of piston.
2 O-ring: Grease (G0-LI or G2-LI)
2) Install eyebolt [2], then install piston (15).
WA470-6, WA480-6 53
SEN02204-01 50 Disassembly and assembly
6. Cover
1) Install cover (11) so as to fit to the guide 2) Install coupling (3) and plate (2) and
bolt that were mounted in procedure 2-2). tighten bolt (1).
2) Tighten the through bolt (10) for parking 3 Bolt:
brake case and cover mounting bolt (9). 662 – 829 Nm {67.5 – 84.5 kgm}
a Equally tighten them several times.
54 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 55
SEN02204-01 50 Disassembly and assembly
56 WA470-6, WA480-6
50 Disassembly and assembly SEN02204-01
WA470-6, WA480-6 57
SEN02204-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
58
SEN02205-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02205-01 50 Disassembly and assembly
Removal and installation of front 3. Wind around the front tire and wheel assembly
axle assembly 1 (2) with the nylon sling and lift it. Then remove
the mounting bolt to remove the tires. [*1]
4
Removal
k
Front tire and wheel assembly: 700 kg
Park the machine on level ground and
lower the bucket to the ground.
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
[*2]
3 Drive shaft mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*3]
3 Front axle assembly mounting bolt:
1450 – 1784 Nm {148 – 182 kgm}
q Bleeding air
Bleed air from the brake circuit, referencing to
"Bleeding air from respective portions" in Test-
7. Temporarily lift the front axle assembly and set ing and adjusting.
jack [2] at the bottom.
WA470-6, WA480-6 3
SEN02205-01 50 Disassembly and assembly
Removal and installation of rear 4. Start the engine and set the bucket to the
axle assembly 1 dumping posture. Then lift the machine gradu-
ally until the front tires are lifted above the
Removal ground, and set stand [2] at the bottom of the
k Park the machine on level ground and front frame.
lower the bucket to the ground.
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
7. Wind around the front tire and wheel assembly 11. Remove 2 harness clamps (6).
(3) with the nylon sling and lift it. Then remove
the mounting bolt to remove the rear tires and
wheel assembly.
[*1]
4 Rear tire and wheel assembly: 680 kg
WA470-6, WA480-6 5
SEN02205-01 50 Disassembly and assembly
14. Disconnect brake hoses (10) and (11). 17. Temporarily lift the rear axle assembly, set jack
[4] at the bottom of rear support (14) and
remove right and left side mounting nuts (15).
[*3]
18. Using chain block [5], fix the right and left sides
of rear support (14) to rear axle assembly
(16a).
a This is necessary for preventing rotation of
the rear support during removal.
19. Pull out both the rear axle assembly and the
rear support to the machine rear side using the
jack and hoist.
a Pull them out until the front socket of the
rear axle is disengaged from the front sup-
port.
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
20. Gradually lowering the jack and hoist, and 22. Remove front support (17) and retainer (18) on
remove rear axle and support assembly (16). the machine side. [*4]
4 Rear axle and support assembly:
1500 kg
21. Lift one side of the rear axle assembly with the
hoist and support the other side with pallet jack
[6] or fork lift. Pull out the rear axle and support
assembly to th e la teral directio n of the
machine. Then lift rear axle and support
assembly (16) again to set the assembly in a
stable state.
WA470-6, WA480-6 7
SEN02205-01 50 Disassembly and assembly
[*1]
3 Rear tire mounting bolt:
823 – 1029 Nm {84 – 105 kgm}
[*2]
3 Rear drive shaft mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*3]
2 Rear axle assembly mounting bolt:
Engine oil (EO-10)
3 Rear axle assembly mounting nut:
1,180 – 1,470 Nm {120 – 150 kgm}
26. Remove thrust washer (23) from the rear sup-
port. [*4]
2 Front support retainer mounting bolt:
27. Remove the mounting bolts, and then remove Adhesive (LT-2)
thrust plate (24) and thrust washer (23). [*8] 3 Front support retainer mounting bolt:
1,180 – 1,470 Nm {120 – 150 kgm}
28. Remove rear support (14).
4 Rear support assembly: 150 kg [*5]
a Direct the lip unit of the packing (19) toward
the machine front side, and then fit it securely
29. Remove packing (25) and bushing (26) from in the groove.
the rear support. [*9]
[*6]
a Direct the lip unit of the packing (20) toward
the axle housing side, and then fit it securely in
the groove.
a Direct chamfered portion (c) of bushing (21)
toward the axle housing, and then install it so
that clearance (d) meets the following dimen-
sion.
Clearance (d): 0.5 mm
2 Front support bushing contact surface:
Grease (G2-LI)
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
[*7]
2 Thrust cap mounting bolt: Adhesive (LT-2)
3 Thrust cap mounting bolt:
245 – 308 Nm {25 – 31.5 kgm}
[*8]
2 Thrust plate mounting bolt: Adhesive (LT-2)
3 Thrust plate mounting bolt:
245 – 308 Nm {25 – 31.5 kgm}
[*9]
a Direct the lip unit of the packing (25) toward
the axle housing side, and then fit it securely in
the groove.
a Direct chamfered portion (a) of bushing (21)
toward the axle housing, and then install so
that clearance (b) meets the following dimen-
sion.
Clearance (b): 0.5 mm
2 Rear support bushing contact surface:
Grease (G2-LI)
q Bleeding air
Bleed air from the brake circuit, referencing to
"Bleeding air from respective portions" in Test-
ing and adjusting.
WA470-6, WA480-6 9
SEN02205-01 50 Disassembly and assembly
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 793T-622-1330 Push tool t 1 N Q
D7 2 793T-622-1340 Spacer t 1 N Q
3 793T-622-1350 Push tool t 1 N Q
1 790-201-2320 Plate t 1
D8 2 790-201-2770 Spacer t 1
3 790-201-2760 Spacer t 1
1 793T-622-1370 Support t 2 N Q
D9 2 793T-622-1380 Support t 2 N Q
3 01016-30860 Bolt t 6 3. Axle housing assembly
D10 793T-622-1510 Holder t 1 N Q 1) Temporarily suspend the axle housing
assembly (8) and remove the housing
Disassembly mounting bolt.
a When removing axle housing assem-
1. Draining oil bly on both sides, place an identifica-
Remove the plug (1) and drain the oil. tion mark on the housing and the
6
differential case to avoid confusion.
Axle oil 2) Remove the axle housing assembly.
WA470-6 (front) : 60 l 4 Axle housing assembly: 280 kg
(rear) : 56 l
WA480-6 (front) : 59 l
(rear) : 59 l
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
5. Ring gear
Pull up the ring gear (12) in balance using the
puller [2] from the axle housing (13).
4. Planetary carrier assembly a Adjust the height by setting the spacer [3]
1) Remove the axle shaft mounting bolt (9) at the tip of the puller bolt.
and remove the planetary carrier assem- a Be careful not to let the puller nail come off
bly (10) by suspending. from the ring gear.
4 Planetary carrier assembly: 65 kg
6. Axle shaft
1) Suspend the axle housing (14).
2) Hit the edge of the axle shaft (15) with a
copper hammer and pull it out.
4 Axle housing: 160 kg
WA470-6, WA480-6 11
SEN02205-01 50 Disassembly and assembly
8. Axle housing
Remove the bearing outer races (18) and (19)
and oil seal (17) from the axle housing (14).
12 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
Assembly
1. Axle housing
1) Press in the bearing outer races (18) and
(19) into the axle housing (14).
2. Axle shaft
Press in the oil seal (17) and bearing (16) into
the axle shaft (15) at the same time using tools
D7-1 (D7-3 for WA480-6) and D7-2.
a Press in the oil seal sleeve (17a) until it is
flush with the (d) surface of the axle shaft
and make sure that it leaves no space
between the bearing (16).
WA470-6, WA480-6 13
SEN02205-01 50 Disassembly and assembly
4. Selecting shims
2) Suspend the axle housing (14) vertically 1) Install planetary carrier (20) to the spline
and slowly lower by aligning its position to of axle shaft (15). Then, install tool D10
the oil seal (17). and tighten mounting bolt (9) with your fin-
a Insert the axle housing using its gers.
weight. a Install planetary carrier (20) without
2 Insertion part of the oil seal, bearing: the gear.
Axle oil a When tightening mounting bolt (9),
a Keep tool D9 mounted until step 3). remove all adhesive from it and its
Do not dismount after mounting the mating bolt hole.
housing. 2) While turning axle housing (14), tighten
3) Insert the axle shaft (15) to the bearing mounting bolt (9).
(26) using tool D8-1 and D8-2 (D8-3 for 3 Bolt:
WA470-6 rear axle). WA470-6 front and WA480-6 front
2 Bearing periphery: Axle oil and rear:
823 – 1,029 Nm {84 – 105 kgm}
WA470-6 rear:
610 – 765 Nm {62 – 78 kgm}
3) After fitting bearings (16) and (26) suffi-
ciently, measure the starting torque at hole
(h) of axle housing (14).
q Starting torque
WA470-6 front:
21.6 – 57.8 N {2.2 – 5.9 kg}
WA470-6 rear:
21.6 – 54.9 N {2.2 – 5.6 kg}
WA480-6 front and rear:
63.7 – 122.5 N {6.5 - 12.5 kg}
14 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
a If the starting torque is below the standard 4) Using a depth micrometer, measure the
value, perform the following work. distance (H) from the end surface of tool
1] Remove planetary carrier (20). D10 to the axle shaft end surface.
2] Referring to steps 3-3), press fit bear- 5) Subtract thickness (t) of tool D10 from
ing (26) further. dimension (H) and set the result as (H – t),
3] Perform steps 1) – 3) and check that and then decide the shim thickness.
the starting torque is in the standard q Shim thickness = (H – t) +0.05
+0
range. 6) Remove planetary carrier (20).
a If the starting torque is above the standard
value, perform the following work.
1] Loosen bolt (9) by 1 – 2 turns.
2] Hold 2 parts of axle shaft and housing
assembly (8) and sling it by 20 – 30
mm similarly when you install the axle
housing.
3] Rotating axle shaft (15), hit the flange
with a copper hammer, etc. in the
direction of the arrow several times to
eliminate the excessive preload on
bearings (16) and (26).
a Do not hit the axle shaft too
much. If you do so, oil seal (17)
will be damaged.
q Lowering distance of axle
shaft
(Reference value): 0.3 mm
4] Perform steps 2) and 3) and check
that the starting torque is in the stan-
dard range.
WA470-6, WA480-6 15
SEN02205-01 50 Disassembly and assembly
6. Ring gear
Insert the ring gear (12) into the axle housing
(14) and then insert pin (12a).
a Set by aligning the housing and the pin
4) Insert the shaft while aligning the shaft hole of the ring gear (12).
(22) and spring pin (22a). a Carefully and horizontally insert the ring
2 Shaft: Oil (Axle oil) gear to avoid tilting.
a Align the shaft (22) and the hole of 7. Planetary carrier assembly
the carrier (20) and hit in the spring 1) Set the shim (11) selected in step 4.-5) to
pin (21) until it is flush (j) with the car- the edge of the axle shaft.
rier (20). 2) Mount the planetary carrier assembly (10)
and tighten the mounting bolt (9).
a Wash and completely degrease the
bolt mounting hole of the axle shaft
and mounting bolt.
k Be fully careful not to get your fin-
ger in between the gears when set-
ting the planetary carrier.
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
WA470-6 for front, WA480-6 for front/
rear: 823 – 1,029 Nm {84 – 105 kgm}
WA470-6 for rear:
610 – 765 Nm {62 – 78 kgm}
16 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
a Clean the edge of the shaft and the 8. Axle housing assembly
planetary carrier spline part before 1) Wash and degrease the axle housing (14)
setting them. and mounting surface of the differential
housing, and wholly apply the gasket seal-
ant.
a Apply gasket sealant [6] in continuous
beads.
a The gasket sealant shall be applied
only to the outside of the wear sensor
mounting hole (h).
2 Mating face of the housing:
Gasket sealant LG-6 (Loctite 515)
WA470-6, WA480-6 17
SEN02205-01 50 Disassembly and assembly
9. Oiling
1) Tighten the drain plug and fill from the fill
o p e n i n g u n t i l t h e s ta n d a r d l e v e l i s
reached.
5 Axle oil
WA470-6 (front) : 60 l
(rear) : 56 l
WA480-6 (front) : 59 l
(rear) : 59 l
2) Remove the plug of the oil level and check
if the oil is filled up close to the lower edge
of the plug hole.
18 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
New/Remodel
3. Rear support (Rear differential)
Remove the rear support (6) by referring to
Necessity
Symbol Part No. Part name
“Removal and installation of rear axle assem-
Sketch
bly” section
Q'ty
1 790-501-5000 Unit repair stand q 1
D1 2 790-901-2110 Bracket q 1
3 790T-901-3440 Plate q 1 N Q
1 793T-622-1310 Push tool t 1 N Q
D2 2 790-101-5421 Grip t 1
3 01010-51240 Bolt t 1
1 793T-622-1310 Push tool t 1 N Q
2 793T-622-1320 Spacer t 1 N Q
D3
3 790-101-5421 Grip t 1
4 01010-51240 Bolt t 1
D4 793T-622-1360 Push tool t 1 N Q
1 796-765-1110 Push tool t 1
D5
2 790-201-2750 Spacer t 1
1 790-301-1720 Adapter t 1
2 799-101-5002 Hydraulic kit t 1
D6
3 793-605-1001 Brake tester t 1
4 790-101-1102 Hydraulic pump t 1
1 796-751-1510 Wrench t 1
D11
2 01010-50620 Bolt t 2
D12 799-301-1500 Oil leak tester kit t 1
Disassembly
a Description of a differential in the subsequent
photos and illustrations in this manual refers to 4. Axle housing assemblies
a front differential unless a distinction is made Remove right and left axle housing assemblies
between front and rear differentials. by referring to “Disassmbly of axle housing
a The internal structure of front and rear differen- Assembly” section.
tials is identical, excluding the shape in
appearance. 5. Differential assembly
Place the differential assembly (7) on the block
1. Brake pipe [1] and ensure stability (or install on tool D1).
1) Disconnect the tube (1). a When tool D1 is used, remove the cage
2) Remove the slack adjuster (2). (Front dif- assembly by referring to procedure 8.
ferential)
a The slack adjuster of the rear differ-
ential is installed on the rear frame.
WA470-6, WA480-6 19
SEN02205-01 50 Disassembly and assembly
6. Cover 4) Blow air into the brake tube joint (15) and
Remove the cover (8). remove the piston (16).
20 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
6) Lift the cage assembly and remove it. 3) Remove all bearing carrier mounting bolts
4 Cage assembly: 55 kg and attach the guide bolt [3].
4) Screw in the forcing screw [4] and remove
the bearing carrier (24).
a Identify the right and left bearing carri-
ers to avoid confusion.
a Check the thickness and the number
of shims to refer to them when re-
assembling.
9. Bearing carrier
1) Sling the differential case and face the
mounting surface of the cover removed in
the step 6.
2) Temporarily lift the differential bearing car-
rier assembly (23).
WA470-6, WA480-6 21
SEN02205-01 50 Disassembly and assembly
10. Differential carrier assembly 2) Remove bearing (63) from case (62).
1) Remove the differential carrier assembly
(23) from the differential case (25).
a Care should be taken to prevent the
sling from coming off.
a The figure shows the limited slip dif-
ferential specification.
4 Differential carrier assembly:
110 kg
22 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
6) Remove side gear (70) and washer (71) a When removing the cover (28), it is
from case (72). detached with the washer (30) fitted
in a groove at the back.
WA470-6, WA480-6 23
SEN02205-01 50 Disassembly and assembly
4) Remove the pressure ring (33) and side 7) Remove the 2 discs (39) and 2 plates (40).
gear (34). 8) Remove the washer (41).
5) Remove the pinion gear (35) and spider 9) Reverse the case (29) and remove the
shaft (36). bolt (42) to detach the bevel gear (43) and
bearing (29a).
24 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
WA470-6, WA480-6 25
SEN02205-01 50 Disassembly and assembly
4) Make the pinion gear (45) upright and 7) Press fit the oil seal (50) into cage (44)
install it in the cage (44). using tool D2.
5) Press the bearing inner race (46) into pin- a Press it into the cage, so that dimen-
ion gear while turning the cage (44) by sion C becomes 14 ± 0.5 mm.
using tool D4. 2 Oil seal lip: Grease (G2-LI)
a Coat the axle oil on the bearing inner
race.
2. Coupling
1) Install the protector (18) in the cage (44).
2) Install the coupling (19), O-ring (19a),
shim (17a) and holder (17b) in the pinion
gear (45) and tighten the mounting bolts
(17).
a Temporarily tighten the mounting
b o l ts ( 1 7 ) a n d r e t i g h t e n i t a ft e r
assembling the differential case.
a When inserting the coupling (19),
great care should be taken not to
damage the seal.
26 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
WA470-6, WA480-6 27
SEN02205-01 50 Disassembly and assembly
7) Install the pressure ring (38) and side gear 10) Install the disc (32) and plate (31) in this
(37). order.
a When installing the disc, set cuts (a)
and (b) accurately.
a The thickness of the disc depends on
the differential. Accordingly, refer to
the following when installing the disc.
q For rear differential of WA470-6:
3.0 mm (Part No. 424-22-27411)
q For front differential of WA470-6
and front and rear differentials of
WA480-6: 3.6 mm (Part No. 421-
22-27411)
2 Plate and disc: Axle oil
28 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
WA470-6, WA480-6 29
SEN02205-01 50 Disassembly and assembly
30 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
WA470-6, WA480-6 31
SEN02205-01 50 Disassembly and assembly
7. Cage assembly
1) Fit the O-ring (20a) into groove of the cage
assembly (20).
5) Install any shims (22) in right and left bear- 2 O-ring: Oil (axle oil)
ing carriers (24) and tighten the bearing a Apply oil lightly.
carrier mounting bolts (24d).
a Select shims with reference to the
thickness and the number of right and
left shims at the time of disassembly.
a Tighten the bevel gear while turning
it.
2 Bearing: Axle oil
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
32 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
8. Adjusting backlash
1) Measure the backlash of bevel gear using 9. Testing tooth contact
dial gauge [7]. 1) Apply a thin coat of red lead to the tooth
a Reference value of backlash: 0.30 – surfaces of the pinion gear, and turn the
0.41 mm bevel gear to both directions (backward
a Test the backlash at three points on and forward). Then, check the tooth con-
the circumference of the bevel gear tact pattern on the bevel gear.
and check that variations in measure- 2) Center of the tooth contact shall be at the
ment values are at 0.1 mm or less. center of tooth height and at about 33%
(x) of the tooth length from the small end
(C). Tooth contact width shall be 30 – 60%
(y) of the tooth length.
Check that there is no hard contact in any
of the tooth tip (A), tooth bottom (B) and
small end (C) or big end (D).
a By adjusting as above, the correct
tooth contact can be obtained when
load is applied.
WA470-6, WA480-6 33
SEN02205-01 50 Disassembly and assembly
a After adjusting the tooth contact, check If the bevel gear is too close to the pinion gear
the backlash again. a The tooth contact pattern is as follows.
1) Decrease shim (d) to move the pinion
gear in direction (C).
2) Adjust shims (a) and (b) to move bevel
gear in direction (D).
34 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
11. Brake
1) Install the seal in the piston (16) and install
it in the differential carrier assembly.
a The number (15) denotes brake tube
joint.
WA470-6, WA480-6 35
SEN02205-01 50 Disassembly and assembly
6) Install the outer plate (11) and shaft (9) 13. Cover
and tighten bolts (10). Install the cover (8) on the differential case
(7).
2 Cover mounting surface:
Liquefied gasket (Loctite 515)
3 Mounting bolt:
157 – 196 Nm {16 – 20 kgm}
36 WA470-6, WA480-6
50 Disassembly and assembly SEN02205-01
18. Lubrication
1) Feed oil to the specified level through filler
opening with the drain plug tightened.
6 Axle oil
WA470-6 (front) : 60 l
(rear) : 56 l
WA480-6 (front) : 59 l
(rear) : 59 l
2) Remove the oil level plug and check that
the oil level is close to the lower edge of
the plug hole.
WA470-6, WA480-6 37
SEN02205-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
38
SEN02206-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02206-01 50 Disassembly and assembly
Removal and installation of center 4. Jack up front frame (33) and put blocks [2]
hinge pin 1 under its right and left portions, while adjusting
its height.
Special tools a Place rollers [3] between blocks [2] and
front frame so that the front frame can be
New/Remodel
pulled out.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-101-2300 Push puller t 1
2 793-520-2370 Push tool t 1
3 793-520-2350 Push tool t 1
E1 4 793-520-2540 Guide t 1
5 793-520-2360 Bar t 2
6 790-101-1120 Hydraulic pump t 1
7 790-101-2102 Puller (30 ton) t 1
Removal
k Park the machine on level ground and 5. Set jack [4] at the rear counterweight section.
lower the bucket to the ground.
k Disconnect the negative (–) terminal from
the battery.
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02206-01
7. Remove lock bolt (2) and pull out pin (3) on the 10. Disconnect hoses (15), (16), (17), (18), (19),
right and left side steering cylinder rods. [*2] (20), (21), (22) and (23) on the front frame
a Shorten the cylinder piston rod after side.
removing the pin.
a Check the number and thickness of shims
used between the frame and rod.
11. Remove lock bolt (24), and then pull out lower
hinge pin (25). [*3]
WA470-6, WA480-6 3
SEN02206-01 50 Disassembly and assembly
14. Remove plate (30), and then pull out upper 17. Remove bolts from the upper hinge of front
hinge pin (31). [*6] frame (35), and then remove retainer (36). [*8]
a While adjusting height of the front frame a Check the number and thickness of shims
and rear frame from the jack, pull out the used between the retainer and frame.
pin with your hand.
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02206-01
19. Remove spacer (37) and dust seal (38) from the 23. Remove dust seal (42) from the retainer (41).
bottom of the upper hinge of front frame (33). [*14]
[*10]
WA470-6, WA480-6 5
SEN02206-01 50 Disassembly and assembly
[*2]
a Adjust shims so that the clearance (a) and (b)
between the cylinder and frame becomes the
specified values.
Clearance (a) and (b): Max. 0.5 mm
a Existence of the clearance is a must.
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02206-01
WA470-6, WA480-6 7
SEN02206-01 50 Disassembly and assembly
6) Press bushing (35) in the lower hinge of 3) Equally tighten retainer (29) using 3
rear frame (34) using the press and the mounting bolts (26). Then measure clear-
like. ance (c) between the hinge and retainer at
two places (compute the mean) and select
the shim to be used.
Clearance (c) = 0.2 mm max.
3 Retainer mounting bolt (when shim is
adjusted):
19.6 ± 2 Nm {2 ± 0.2 kgm}
a After adjusting the shim, temporarily
tighten the retainer mounting bolt so
that it does not turn.
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02206-01
WA470-6, WA480-6 9
SEN02206-01 50 Disassembly and assembly
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02206-01
8. Remove 2 mounting bolts for the bottom of top 12. Temporarily lift weight-adjusting small counter
grille assembly (6). (12), and then remove mounting bolts (13) and
(14) to lift off the counter. [*1]
a Spacers are used for the 2 bolts at the bot-
tom.
4 Weight-adjusting small counter: 396 kg
9. Open the rear grille and remove stay (9) for the
under mirror.
Installation
q Carry out installation in reverse order of
removal.
[*1]
3 Weight-adjusting small counter mounting
bolt:
1520 – 1912 Nm {155 – 195 kgm}
[*2]
3 Large counter mounting bolt:
1520 – 1912 Nm {155 – 195 kgm}
WA470-6, WA480-6 11
SEN02206-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
12
SEN02207-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02207-01 50 Disassembly and assembly
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
7. Disconnect pilot hose (6). 12. Disconnect tubes (12) and (13).
WA470-6, WA480-6 3
SEN02207-01 50 Disassembly and assembly
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
WA470-6, WA480-6 5
SEN02207-01 50 Disassembly and assembly
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
18. Lift and pull out work equipment valve assem- Installation
bly (29) to the front side. q Carry out installation in reverse order of
a When pulling out the assembly, set wood removal.
material [1] on the front frame to protect it
from getting damages. q Refilling with oil (Hydraulic tank)
a Add hydraulic oil up to the specified level.
a Run the engine to circulate the oil through
the system. Then, check the oil level
again.
WA470-6, WA480-6 7
SEN02207-01 50 Disassembly and assembly
Installation
q Carry out installation in reverse order of
removal.
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
2. Remove the hood, referencing to "Removal 9. Disconnect 3 left side hoses (7), (8) and (9).
and installation of hood."
WA470-6, WA480-6 9
SEN02207-01 50 Disassembly and assembly
12. Remove clamp (15) and plate (16), and then 15. Remove 3 bracket mounting bolts (22) on each
remove transmission breather (17). side.
13. Disconnect tube (18) and hose (19) in the rear 16. Lift off hydraulic tank assembly (23).
4
side of the hydraulic tank.
Hydraulic tank assembly: 260 kg
q Bleeding air
Bleed air from the pump circuit, referencing to
"Bleeding air from respective portions" in Test-
ing and adjusting.
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
Removal and installation of 9. Remove suction tube (8) and discharge tube
steering and power train pump (9) on the power train pump.
assembly 1 10. Disconnect hose (11) from the tee side of
Removal steering pump discharge tube (10).
k Park the machine on level ground and
lower the bucket to the ground. 11. Loosen the clip to take out plate (12), and then
k Install the lock bar on the frame, apply the disconnect steering pump discharge tube (10).
parking brake and put chocks under the a Check valve (13) is tightened together
tires. with the block on the tee side of discharge
k Disconnect the negative (–) terminal from tube (10). Take care in the disconnection
the battery beforehand. so that they may not be inadvertently
dropped.
1. Drain hydraulic oil.
5 Hydraulic oil: Approx. 275 l
5. Remove steering pump suction tube assembly 12. Remove steering pump suction elbow (14).
(1).
WA470-6, WA480-6 11
SEN02207-01 50 Disassembly and assembly
[*1]
3 Pump assembly mounting bolt:
235 – 265 Nm {23.5 – 29.5 kgm}
q Bleeding air
Bleed air from the pump circuit, referencing to
"Bleeding air from respective portions" in Test-
14. Lift off pump assembly (16). ing and adjusting.
4 Steering and power train pump assem-
bly: 69 kg
12 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
Removal and installation of work 8. Remove pump suction tube assembly (7).
equipment and cooling fan pump
assembly 1
Removal
k Park the machine on level ground and
lower the bucket to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery beforehand.
4. Remove the operator's cab and floor frame 12. Disconnect charge pressure discharge hose
assembly, referencing to "Removal and instal- (14).
lation of operator's cab and floor frame assem-
bly." 13. Remove 4 mounting bolts for discharge tube
(15) on the work equipment pump side.
5. Remove clamp (1) and disconnect connectors
R71 (2) and R29 (3).
WA470-6, WA480-6 13
SEN02207-01 50 Disassembly and assembly
[*1]
3 Pump assembly mounting bolt (M12 × 4):
98 – 123 Nm {10 – 12.5 kgm}
3 Pump assembly mounting bolt (M16 × 2):
235 – 285 Nm {23 – 29.5 kgm}
q Bleeding air
Bleed air from the pump circuit, referencing to
15. Temporarily lift the pump assembly and "Bleeding air from respective portions" in Test-
remove 6 mounting bolts (17). [*1] ing and adjusting.
14 WA470-6, WA480-6
50 Disassembly and assembly SEN02207-01
WA470-6, WA480-6 15
SEN02207-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
16
SEN02208-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02208-01 50 Disassembly and assembly
Removal and installation of work 6. Install support stand [1] at the lift arm end, and
equipment assembly 1 release the remaining pressure in the hydraulic
piping.
Removal
k Park the machine on level ground and 7. Temporarily sling lift cylinder (6) and remove
lower the bucket to the ground. mounting pin (5). [*4]
k Install the lock bar on the frame, apply the a When shims are used, check their number
parking brake and put chocks under the tires. and thickness.
a When lowering the lift cylinder, put the
1. Temporarily lift the bucket link, and remove pin block [2] into the top of the axle.
4
(1). [*1] Lift cylinder: 190 kg (WA470-6)
a Fix the bucket link using the lever block. 200 kg (WA480-6)
a When shims are used, check their number
and thickness.
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02208-01
14. Pull out dust seal (16) and bushing (17) from
lift arm (15). [*8]
WA470-6, WA480-6 3
SEN02208-01 50 Disassembly and assembly
15. Pull out dust seal (18) and bushing (19) from Installation
bell crank (13). q Carry out installation in reverse order of
removal.
[*1]
a Install the bucket link according to the following
procedure.
1) Sling bucket link (11) and install O-rings
(22).
2) Align the pin holes of bucket (23) and
bucket link (11).
16. Pull out dust seal (20) and bushing (21) from k Never insert your finger in the pin
bucket link (11). holes.
a Take care that the O-ring will not be
caught.
3) Insert shims so that clearances (a) on the
right and left sides will be even, install pin
(1), and lock with the bolt.
q Clearance (a): Max. 1.5 mm
q Set shim thicknesses: 1.0 mm
[*2]
a Install the pin according to the following proce-
dure.
1) Install O-rings (24) to bucket (23).
2) Operate the lift arm control lever to align
the pin holes of bucket (23) and lift arm
(15).
k Never insert your finger in the pin
holes.
a Take care that the O-ring will not be
caught.
3) Insert shims so that clearances (b) on the
right and left sides will be even, install pin
(2), and lock with the bolt.
q Clearance (b): Max. 1.5 mm
q Set shim thicknesses: 1.0 mm
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02208-01
[*7]
a Fix the bucket link to the bell crank using the
lever block.
[*8]
a Use puller [4] etc. to press fit bushing.
2 Inside of bushing:
Molybdenum disulphide grease (LM-P)
a The lift arm is shown as an example in the
figure.
[*3] [*4]
k When aligning holes of the pins, absolutely
do not insert fingers into a pin hole.
[*5]
Referring to Testing and adjusting, "Testing and
adjusting boom kick-out", adjust the installed posi-
tion and then confirm the operation.
[*6]
a Install the lift arm, bell crank, and bucket link a Install the dust seal with lip (a) out.
assembly according to the following proce- a The lift arm (bucket side) is shown as an exam-
dure. ple in the figure.
1) Sling the lift arm, bell crank, and bucket
link assembly and align the pin holes of
front frame (25) and lift arm (15).
k Never insert your finger in the pin
holes.
2) Insert shims so that clearances "d" on the
right and left sides will be even, install pin
(10), and lock with the bolt.
q Clearance (d): Max. 1.5 mm
q Set shim thicknesses: 3.0 mm
k After installing the pin, set a sup-
port stand at the lift arm end.
q Greasing
After finishing installation, grease each pin.
2 Each pin:
Molybdenum disulphide grease (LM-G)
WA470-6, WA480-6 5
SEN02208-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
6
SEN02209-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02209-01 50 Disassembly and assembly
Removal and installation of 5. Take out filter (1a) and remove box (1b).
operator's cab and floor frame
assembly 1
Removal
k Stop the machine on a level ground and
lower the work equipment and touch per-
fectly to the ground.
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the negative (–) terminal from
the battery beforehand.
k If the radiator coolant temperature is high,
you may scald yourself with the hot coolant
when disconnecting the heater hoses and
draining the coolant. Wait until the coolant 6. Remove right side cove (2).
is cooled, and then drain the coolant.
2. Drain coolant.
6 Coolant: 61 l
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 3
SEN02209-01 50 Disassembly and assembly
18. Remove 4 brake booster mounting bolts and 21. Remove the clamp and disconnect heater
pull out brake booster (24) from the bracket. hoses (33) and (34).
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
[*1]
Charge the air conditioner circuit with refrigerant
(R134a air conditioner gas).
a Take care that dirt, dust, water, etc. will not
enter the air conditioner circuit.
q Quantity of refrigerant gas (R134a):
1,250 ± 50 g
[*2]
3 Floor frame mounting nut:
1,175 – 1,470 Nm {120 – 150 kgm}
q Bleeding air
Bleed air referring to "Bleeding air from steer-
ing circuit", "Bleeding air from wheel brake cir-
cuit", and "Bleeding air from work equipment
circuit" in the section of Testing and Adjusting.
WA470-6, WA480-6 5
SEN02209-01 50 Disassembly and assembly
Necessity
Symbol
Sketch
a
Q’ty
N/R
Part number Part name When using knife [4], insert a screwdriver in
the cut to widen it and move the knife forward.
1 793-498-1120 Clear plate t 2
2 2 793-498-1130 Plate t 2
X
3 793-498-1110 Magnet t 2
3 793-498-1210 Lifter (Suction cup) t 2
Removal
a The operator's cab glasses of this machine are
fully stuck with adhesive.
a Remove the window glass to be replaced
according to the following procedure.
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 7
SEN02209-01 50 Disassembly and assembly
a Take care that the corner (part (b)) of both- 5. Position the replacement glass.
sided adhesive tape (4) will not float. 1) Stick X2-2 (thin steel sheet) to tool X2-1
(spacer) with adhesive.
q Spacer thickness (t): 5 mm
2) Match tool X2-3 (magnet) to tools X2-1
and X2-2 and set them to the 2 lower
places of the window glass sticking part of
operator's cab (2).
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 9
SEN02209-01 50 Disassembly and assembly
a Do not apply the primer more than 2 SUNSTAR PENGUINE SEAL 580
times. (If it is applied more than 2 SUPER “S”
times, its performance will be low- 2 Adhesive (October – April):
ered.) SUNSTAR PENGUINE SEAL 580
a Parts to be coated with primer: Apply SUPER “W”
the primer to the sticking surface of
a The using limit of the adhesive is 4 months
window glass (3) and all over dimen-
after the date of manufacture. Do not use
sion (d) on both-sided adhesive tape
the adhesive after this limit.
(4) and operator's cab (2).
a Keep the adhesive in a dark place where
q Dimension to apply primer (d):
the temperature is below 25°C.
23 mm
a Never heat the adhesive higher than
a Do not apply the primer to the 30°C.
boarder about 5 mm wide between a When reusing the adhesive, remove the
the black part and transparent part of all hardened part from the nozzle tip.
the glass. 1) Break aluminum seal (10) of the outlet of
a After applying the primer, leave it for adhesive cartridge (9) and install the nozzle.
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off with white gasoline.
(If wrong primer is applied, the glass
will not be stuck.)
10 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
2) Cut the tip of the adhesive nozzle (11) so 5) Apply adhesive (12) to the outside of both-
that dimensions (f) and (g) will be as fol- sided adhesive tape (4) of the operator's
lows. cab.
q Dimension (f) : 10 mm a Before applying the adhesive, check
q Dimension (g): 12 mm that the primer is applied to the sur-
face to which the adhesive will be
applied.
WA470-6, WA480-6 11
SEN02209-01 50 Disassembly and assembly
8. Install window glass (3). a Check that clearance (k) between the
a If the glass is positioned wrongly, the front side of the front glass and right
adhesive must be removed and cleaned, and left side glasses is even.
and then the primer and adhesive must be q Clearance (k): 5 mm
applied again. Accordingly, position the
glass very carefully when sticking it.
1) Similarly to step 5, match tools X2-1, X2-2,
and X2-3 and set them to the 2 lower places
of the window glass sticking part of opera-
tor's cab (2).
12 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
10. If the front glass and the right and left front 3) Remove the caulking material projected
glasses are replaced, seal them. from the joint with cardboard [8] etc.
1) Stick masking tapes (14) along the parts to
be sealed shown in the figure.
a Stick the masking tapes to both inside
and outside of the operator's cab.
WA470-6, WA480-6 13
SEN02209-01 50 Disassembly and assembly
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of 2 clips (2) of headrest stay (1) on both
sides.
14 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
2) Apply force (b) to part (a) of each clip (2) 2. Back seat
in the direction of the arrow to turn the clip 1) Disconnect 3 air hoses (5) from the rear
and release it from part (d) of headrest left of back seat (4).
stay (1), and then pull out up headrest (3). a Before disconnecting the air hoses, check
their types.
WA470-6, WA480-6 15
SEN02209-01 50 Disassembly and assembly
4) Apply force (E) to the right side of back 2) Push cushion slide stopper wire (9) down
seat (4) in the direction of the arrow. with screwdriver [1], etc.
5) Applying the force to back seat (4), pull its 3) Keeping the state in 2), pull out cushion
right side up. seat (8) forward and remove it.
6) Slide back seat (4) sideway and remove it.
4. Armrest
3. Cushion seat q The procedure for disassembling left-hand
1) Push cushion adjuster lever (7) inward armrest (10) is shown below.
and slide cushion seat (8) to the front end.
16 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
1) Remove plastic cap (12) from the armrest a There are 2 position adjustment
hinge. washers (16) installed to each bolt
a Use a flat-head screwdriver, etc. to between the armrest and back seat.
remove the cap. Take care not to lose them.
2) Loosen armrest hinge mounting bolt (13).
5. Suspension cover
3) Remove plastic cap (14), and then remove 1) Remove right-hand hinge cover (17).
lower mounting bolt (15A) (M8 bolt) of left- 2) Remove plastic plate (18) from the rear
hand armrest (10). with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
WA470-6, WA480-6 17
SEN02209-01 50 Disassembly and assembly
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
18 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 19
SEN02209-01 50 Disassembly and assembly
20 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 21
SEN02209-01 50 Disassembly and assembly
6. Headrest
1) Insert headrest (3) in back seat (4).
a Check that 2 clips (2) on both sides
are locked securely.
22 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
I. Upper seat
Removal
1) Remove the storage box by referring to "1.
Removal and installation of storage box".
2) Undo the 4 screws (1), and remove the
backrest upholstery (2).
3) Undo the 5 screws (4), and remove the
seat pad (5).
4) Disconnect the connectors (3) and (6).
Installation
1) Connect the connectors (3) and (6).
2) Install the seat pad (5), and fix it with the 5
Removal screws (4).
1) Open the storage box (1). 3) Install the backrest upholstery (2), and fix
2) Remove the hook (3). it with the 4 screws (1).
3) Undo the screws (2) and remove the stor- 4) Install the storage box by referring to "1.
age box (1). Removal and installation of storage box".
Installation
1) Set the storage box (1) and fix it with the
screws (2).
2) Install the hook (3).
WA470-6, WA480-6 23
SEN02209-01 50 Disassembly and assembly
Removal Removal
1) Remove the storage box by referring to "1. 1) Remove the cover (1).
Removal and installation of storage box". 2) Unscrew the hexagon nuts (2) and
2) Remove the backrest upholstery by refer- remove the nuts and washers (3).
ring to "2. Removal and installation of seat 3) Remove the armrests (4).
pad and backrest upholstery".
3) Drill off the rivets (1), loosen the spring
steel sheets (2) from the L-bar (3) and Installation
remove them. 1) Set the armrests (4).
4) Unhook the L-bars (3) from the catch ele- 2) Put the washers (3) and tighten hexagon
ment (4). nuts (2).
5) Undo the hexagon socket screw (5) and 3 Hexagon nuts: 25 Nm {2.6 kgm}
remove the adjusting knob (6) with the 3) Install the cover (1).
toothed wheel (7).
6) Drill off the rivet (8), remove the wrap
spring brake element (9) and the catch
element (4).
Installation
1) Install the wrap spring brake element (9)
and the catch element (4), and fix them
with the rivets (8).
2) Install the adjusting knob (6) and the
toothed wheel (7), and tighten the hexa-
gon socket screw (5).
3) Install the catch element (4) to the L-bars
(3) and fix with the rivets (1).
4) Install the 2 spring steel sheets (2) to the
L-bar (3), and fix with the rivets (1).
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
and backrest upholstery".
6) Install the storage box by referring to "1.
Removal and installation of storage box".
24 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 25
SEN02209-01 50 Disassembly and assembly
7) Install the backrest upholstery by referring 7. Disassembly and assembly of seat angle
to "2. Removal and installation of seat pad and seat depth adjuster
and backrest upholstery".
8) Install the storage box by referring to "1.
Removal and installation of storage box".
Disassembly
1) Remove the storage box by referring to "1.
Removal and installation of storage box".
2) Remove the backrest upholstery by refer-
ring to "2. Removal and installation of seat
pad and backrest upholstery".
3) Remove the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
Disassembly
4) Fold the backrest (1) forwards.
1) Remove the seat pad by referring to "2.
5) Unscrew 3 flat-headed screws (2), remove
Removal and installation of seat pad and
the adaptor plate (3) and the flat-headed
backrest upholstery".
screw (4).
2) Remove the switch by the following proce-
6) Remove the lever (5) and handle (6).
dure. (If equipped)
1] Disconnect the spring (1).
2] Tilt the switch-plate (2) forwards and
Assembly
remove it.
1) Fold the backrest(1) forwards.
3] Drill off the rivet (3) and remove the
2) Install the handle (6) and the lever (5).
seat switch (4).
3) Tighten the 3 flat-headed screws (4),
install the adaptor plate (3) and then
tighten the flat-headed screw (2).
a The lifter of the flat-headed screw (4)
must engage into the nut of the adap-
tor plate (3).
3 Flat-headed screw:
12 Nm {1.2 kgm}
4) Install the armrests by referring to "4.
Removal and installation of armrests". (If
equipped)
5) Install the backrest upholstery by referring
to "2. Removal and installation of seat pad
and backrest upholstery".
6) Install the storage box by referring to "1.
Removal and installation of storage box".
26 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
3) Remove the flexible support plate (7) by 1] Turn the lever (14) clockwise until it
the following procedure. snaps-in, install the plate (15).
1] Press the spring plate (5) ("P" posi- 2] Install the spring (13) to hook (a) of
tion) inwards (arrow), operate the the lever (14) and hook (b) of the
lever for seat angle adjustment (6). plate (15).
2] Pull the flexible support plate (7) to 3] Install the cover (9), the levers for
backwards and remove it. seat angle and seat depth adjustment
4) Remove the plate (15) by the following (6), (10), the linkage rod (11) and the
procedure. locking lever (12), then tighten the
1] Drill off the rivet and remove the hexagon socket screws (8).
spring steel sheet (5). 4] Install the spring steel sheet (5) and
2] Unscrew the hexagon socket screws fix it with the rivet.
(8), remove the cover (9), the levers 6) Install the flexible support plate by the fol-
for seat angle and seat depth adjust- lowing procedure.
ment (6), (10), the linkage rod (11) 1] Press the spring plate (5) ("P" posi-
and the locking lever (12). tion) inwards (arrow), operate the
3] Remove the spring (13). lever for seat angle adjustment (6).
4] Turn the lever (14) clockwise until it 2] Swivel the flexible support plate (7)
snaps-in, pull the plate (15) to the upwards and install it.
very front and remove it. 3] Install the end hook of the linkage rod
5) Remove the covers on the right and left (11) to the position (c) of the lever
side by referring to "8. Removal and instal- (10), and the other side of hook of the
lation of covers". linkage rod (11) to the port (d) of the
6) Unscrew the nut (16), remove the lever lever (14).
(14) and the screw (17).
7) Drill off the rivet (18) and remove the
spring steel sheets (19).
8) Drill off the rivet (20) and remove the
locating element (21).
Assembly
1) Install the locating element (21) and fix it
with the rivet (20).
2) Install the spring steel sheets (19) and fix
it with the rivet (18).
3) Set the lever (14) and the screw (17), and
fix with nut (16).
4) Install the covers on the right and left side
by referring to "8. Removal and installation
of covers".
5) Assemble the plate (15) by the following
procedure.
WA470-6, WA480-6 27
SEN02209-01 50 Disassembly and assembly
Removal
1) Remove the seat pad by referring to "2.
Removal and installation of seat pad and
backrest upholstery".
2) Remove spring(1) and switch-plate (2). (If
equipped)
3) Remove the flexible support plate by fol-
lowing procedure.
1] Press the spring sheet inwards
(arrow), operate the lever for seat
angle adjustment (3).
2] Pull the flexible support plate (4) to
backwards and remove it.
4) Remove the spring (5).
7) Install the switch (4) by the following pro- 5) Turn the lever (6) clockwise until it snaps-
cedure. (If equipped) in, pull the plate (7) to the very front and
1] Install the seat switch (4) and fix it remove it.
with the rivet (3). 6) Drill off the rivet (8) and remove the wash-
2] Tilt the switch-plate (2) forwards and ers (9).
install it. 7) Unhook the covers (10) by pulling them
3] Install the spring (1). forwards and remove them in an upward
8) Install the seat pad by referring to "2. direction.
Removal and installation of seat pad and
backrest upholstery".
Installation
8. Removal and installation of covers 1) Install the covers (10) of right and left.
2) Install the washers (9) and fix it with the
rivet (8).
3) Turn the lever (6) clockwise until it snaps-
in, then install the plate (7).
4) Remove the spring (5) (see 7. Disassem-
bly and assembly of seat angle and seat
depth adjuster).
5) Install the flexible support plate (4) (see 7.
Disassembly and assembly of seat angle
and seat depth adjuster).
6) Install spring (1) and switch-plate (2) (see
7. Disassembly and assembly of seat
angle and seat depth adjuster). (If
equipped)
7) Install the seat pad by referring to "2.
Removal and installation of seat pad and
backrest upholstery".
28 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 29
SEN02209-01 50 Disassembly and assembly
Removal
1) Remove the upper part of the seat by
Removal referring to "I. Upper seat".
1) Remove the upper part of the seat by 2) Remove the top cover by referring to "1.
referring to "I. Upper seat". Removal and installation of top cover".
2) Pull the connecting cable (3) inwards 3) Bore out 2 rivet heads and drive out blind
through the upper cover (2). rivets (1), remove the front cover (2).
3) Remove the 2 bellows pins (1) and take
the upper cover (2) off.
Installation
1) Install the front cover (2) and fix it with the
Installation 2 rivets (1).
1) Install the connecting cable (3) inwards 2) Install the top cover by referring to "1.
through the upper cover (2). Removal and installation of top cover".
2) Install the upper cover (2) and fix it with 3) Install the upper part of the seat by refer-
the 2 bellows pins (1). ring to "I. Upper seat".
3) Install the upper part of the seat by refer-
ring to "I. Upper seat".
30 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
Installation
Removal 1) Install the wire insert (5) to the bellows (2).
1) Remove the upper part of the seat by 2) Install the bellows (2).
referring to "I. Upper seat". 3) Fix the bellows (2) with pins (3) to the
2) Remove the bellows (2) from the upper lower part of the suspension (6) in the
part of the suspension (1) by following reverse order of their removal.
procedure. 4) Fix the connecting cable with the cable tie
1] Take bellows pins (4) off on the front. (10). (If equipped)
2] Take bellows pins (3) off on the left 5) Fix the bellows (2) with pins (3) to the
side of the top. upper part of the suspension (1) in the
3] Remove 2 bellows pins (4) on the reverse order of their removal.
back and take 2 bellows pins (3) off 6) Install the upper part of the seat by refer-
the upper part of the suspension sys- ring to "I. Upper seat".
tem (1).
4] Take 3 bellows pins (3) on the right
side off the upper part of the suspen-
sion (1) and pull the bellows (2) over
the handle for vertical shock absorber
adjustment (9).
3) Remove the bellows (2) from the lower
part of the suspension (6) by the following
procedure.
1] Take 3 bellows pins (3) on the front
side off the lower part of the suspen-
sion (6).
2] Release 2 bellows pins (3) on the left
side from the lower part of the sus-
pension (6).
3] Release 4 bellows pins (3) on the
back side from the lower part of the
suspension (6).
4] Remove a cable tie (10) on the right
side from the connecting cable, and
take 2 bellows pins (3) off the lower
part of the suspension (6). (If
equipped)
4) Lift the bellows (2) over the lower part of
the suspension (6) and remove the bel-
lows (2) in a downward direction.
5) Remove the wire insert (5) from the bel-
lows (2).
WA470-6, WA480-6 31
SEN02209-01 50 Disassembly and assembly
32 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Put the Bowden pull wire (5) to the upper
part of the suspension (4) through the
location of the mounting hole marked
before removing the Bowden pull wire (5).
3) Install the fork (11) and compression
spring (10), and take the Bowden pull wire
(5) to the fork (11).
4) Install the fixation (12) to the fork (11).
5) Take the Bowden pull wire (5) to the bear-
ing (9).
6) Put the fixation (12) to the vertical shock
absorber (13).
7) Install the Bowden pull wire (5) and fix it
with the cable tie (8) at the marked points.
a Install the Bowden pull wire according
to the marking.
8) Install the bearing for Bowden pull wire (6)
and fix it with the rivet (7).
9) Install the Bowden pull wire (5) to the
bearing for Bowden pull wire (6).
10) Install the Bowden pull wire (5) to the han-
dle for vertical shock absorber adjustment
(1).
11) Install the handle for vertical shock
absorber adjustment (1) to the upper part
of the suspension (4).
12) Tighten Torx screw (2).
3 Torx screw: 2.25 Nm {0.23 kgm}
13) Install the bellows off by referring to "3.
Removal and installation of bellows".
14) Install the top cover by referring to "1.
Removal and installation of top cover".
15) Install the upper part of the seat by refer-
ring to "I. Upper seat".
WA470-6, WA480-6 33
SEN02209-01 50 Disassembly and assembly
34 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 35
SEN02209-01 50 Disassembly and assembly
Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Install the support (9) to the lower part of
the suspension (2).
3) Install the compressor (3) to the support
(9).
4) Install the compressed-air hose (7) and fix
it with cable tie (4) at the marked points.
a Loosely apply the cable tie (4) until
the locking head of the cable tie (4) is
located slightly over the front curve of
compressor (3) and while the com-
pressor (3) can be still moved.
a Align the compressor (3) and use the
pliers to tighten the locking head of
the cable tie (4) to 310 Nm{31.6 kgm}
in the direction shown (arrow).
5) Put the fitting (8) to the compressed-air
hose (7).
6) Install them to the spike of the compressor
(3).
7) Fix the compressor (3) with the cable ties
(4) at marked points.
a Fix the cable tie according to the
marking.
8) Fix the compressed-air hose (7) with cable
tie (12) at the marked points.
9) Connect the electric connector of the flat
plug (11).
10) Connect the right-angle plug (10) to the
height level control unit (1).
11) Install the compressor cable (5) and fix it
with cable tie (6) at the marked points.
a Tie back any excess length of the
compressor cable (5).
12) Install the bellows off by referring to "3.
Removal and installation of bellows".
13) Install the top cover by referring to "1.
Removal and installation of top cover".
14) Install the upper part of the seat by refer-
ring to "I. Upper seat".
36 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
Removal 9) Pull the air input hoses (10) and (11) off
1) Remove the upper part of the seat by the pneumatic spring (see "8. Removal
referring to "I. Upper seat". and installation of air hose").
2) Remove the top cover by referring to "1. 10) Mark the place where the cable is fas-
Removal and installation of top cover". tened with the right-angle plugs (13) and
3) Take the bellows off by referring to "3. (14) and the cable tie and then remove the
Removal and installation of bellows". cable tie.
4) Move the suspension system to the high- 11) Mark the place where the Bowden pull
est position. wire (19) is fastened with the cable tie and
k Risk of crushing! Secure the sus- remove the cable tie.
pension between the swinging 12) Unhook the Bowden pull wires (3) and
structure and lower part of the sus- (19) from the height level control (1).
pension system with suitable spac- 13) Mark and then disconnect the right-angle
ers. plugs (13) and (14) from the height level
5) Loosen up the 2 circlips (17) from the stud control unit (1).
(18) and then remove them. 14) Remove the 2 hexagon nuts (4) from the
6) Knock out the stud (18) from the lower thread of the height level control (1).
part of the suspension (15) and then 15) Remove the plate (7), loop of the webbing
remove it. (5) and the edge protection strip (6).
a Firmly hold the webbing (5) and let it 16) Remove the height level control (1) from
carefully roll back to the rewinder on the upper part of the suspension (8).
the height level controller (1). 17) Undo the Torx screw (9) and take the
7) Remove the 2 buffers (16) from the loop of attachment for Bowden pull wire (2) off the
the webbing (5). height level valve (1).
8) Mark the points where the air input hoses a To do this, first release the 2 catchers
(10) and (11) are fastened with 5 cable on the backside of the attachment for
ties (12) and remove the cable ties (12). Bowden pull wire (2) and take the
attachment for Bowden pull wire (2)
off the height level valve (1).
WA470-6, WA480-6 37
SEN02209-01 50 Disassembly and assembly
Installation
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Install the height level controller.
3) Install the Bowden pull wire (3) to the
attachment for Bowden pull wire (2).
4) Install the attachment for Bowden pull wire
(2) to the height level controller (1).
5) Tighten the Torx screw (9) to height level
controller (1).
a Finger-tighten the Torx screw (9).
6) Install the height level control (1) to the
upper part of the suspension (8).
7) Install the plate (7), loop of the webbing
(5) and the edge protection strip (6).
8) Install the 2 hexagon nuts (4) to the thread
of the height level controller (1).
9) Connect the right-angle plugs (13) and
(14) to the height level controller (1) at the
marked point.
10) Install the Bowden pull wires (3) and (19)
to the height level controller (1).
11) Install the Bowden pull wire (19) and fix it
with the cable tie at the marked points.
12) Install the right-angle plugs (13) and (14)
and fix them with the cable tie at the
marked points.
13) Install the air input hoses (10) and (11) to
the pneumatic spring (see "8. Removal
and installation of air hose").
14) Fix the air input hoses (10) and (11) with
the 5 cable ties (12) at the marked points.
15) Install the 2 buffers (16) to the loop of the
webbing (5).
16) Install the stud (18) to the lower part of the
suspension (15).
17) Install the 2 circlips (17) to the stud (18)
and then remove them.
18) Install the bellows by referring to "3.
Removal and installation of bellows".
19) Install the top cover by referring to "1.
Removal and installation of top cover".
20) Install the upper part of the seat by refer-
ring to "I. Upper seat".
38 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 39
SEN02209-01 50 Disassembly and assembly
a Disconnect the hose not more than 1 to 2 7) Pull the compressed-air hose (11) off the
times. Check the hose for damage before con- compressor (5) and remove it. (Refer to
necting it. "6. Removal and installation of compres-
sor")
8) Pull the compressed-air hose with angle
Removal (8) off the pneumatic spring (9) and then
1) Remove the upper part of the seat by off the air tank (10).
referring to "I. Upper seat". a When pulling the hoses out, the
2) Remove the top cover by referring to "1. retaining ring of the quick coupling
Removal and installation of top cover". (13) must first be completely pressed
3) Take the bellows off by referring to "3. back (e.g. using a flat pliers) to avoid
Removal and installation of bellows". marks.
4) Move the suspension system to the high- 9) Mark the points where the compressed-air
est position. hose with angle (8) is fastened with cable
k Risk of crushing! Secure the sus- ties (6), (7) and (12) and then remove the
pension between the swinging cable ties (6), (7) and (12).
structure and lower part of the sus- 10) Remove the air hose with angle (8).
pension system with suitable spac- 11) Mark the points where the air input hoses
ers. (3) and (4) are fastened with the cable ties
5) Mark the points where the compressed-air (2) and (6) and remove the cable ties (2)
hose (11) is fastened with the cable tie and (6).
(12) and remove the cable tie (12). 12) Pull the air input hoses (3) and (4) out of
6) Pull the compressed-air hose (11) off the the pneumatic spring (9).
pneumatic spring (9). 13) Remove the height level controller (1) with
a When pulling the hoses out, the air input hoses (3) and (4).
retaining ring of the quick coupling a To ensure the tightness, the air input
(13) must first be completely pressed hoses (3) and (4) cannot be removed
back (e.g. using a flat pliers) to avoid from the height level control (1).
marks.
40 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 41
SEN02209-01 50 Disassembly and assembly
9. Removal and installation of Bowden pull 8) Undo the 3 cross-head screws (7).
wires and handle for height adjustment 9) Take the Bowden pull wires (1) and (6) off
the holder for Bowden pull wire (4), and
then pull them out of the upper part of the
suspension (2).
10) Remove the holder (4) for Bowden pull
wire.
11) Replace the handle (5), if required.
a The handle (5) and holder for Bowden
pull wire (4) are wedged into the 2
latching noses (arrow) at the lower
part of the holder for Bowden pull wire
(4). Carefully separate the parts.
a To remove the handle, use a screw-
driver to bend open the handle (5)
between the handle (5) and holder for
Bowden pull wire (4) so that the 2
latching noses are released from the
handle (5).
a Take the handle (5) off the holder for
Bowden pull wire (4).
Installation
1) Install the handle (5) to holder (4), if
removed.
a When the handle (5) is deformed,
replace it.
2) Install the Bowden pull wires (1) and (6) to
the holder for Bowden wire (4).
a Adjust the new Bowden pull wire to
Removal the length of the old one (excess
1) Remove the upper part of the seat by length of the wire).
referring to "I. Upper seat". 3) Install the holder (4) to the upper part of
2) Remove the top cover by referring to "1. the suspension (2) and tighten the 3
Removal and installation of top cover". cross-head screws (7).
3) Take the bellows off by referring to "3. 4) Install the Bowden pull wire (6) to the
Removal and installation of bellows". height level controller. (See "7. Removal
4) Mark the points where the Bowden pull and installation of height level controller".)
wire (1) is fastened with the 2 cable ties 5) Install the Bowden pull wire (1) to the
(3), and then remove the cable ties (3). height level controller (See "7. Removal
5) Mark the points where the Bowden pull and installation of height level controller".)
wire (6) is fastened with the 2 cable ties 6) Fix the Bowden pull wire (6) with the 2
(8), and then remove the cable ties (8). cable ties (8) at the marked points.
6) Take the Bowden pull wire (1) off the a Loosely fix the Bowden pull wire with
height level controller and pull it out of the the cable ties at the marked points
holder for Bowden pull wire (See "7. and make sure it is not distorted.
Removal and installation of height level 7) Fix the Bowden pull wire (1) with the 2
controller".) cable ties (3) at the marked points.
a To release the tension of the Bowden a Loosely fix the Bowden pull wire with
pull wire (1), press the handle for the cable ties at the marked points
height adjustment (5) upwards. and make sure it is not distorted.
7) Take the Bowden pull wire (6) off the 8) Install the bellows by referring to "3.
height level controller. (See "7. Removal Removal and installation of bellows".
and installation of height level controller") 9) Install the top cover by referring to "1.
a To release the tension of the Bowden Removal and installation of top cover".
pull wire (6), press the handle for 10) Install the upper part of the seat by refer-
height adjustment (5) upwards. ring to "I. Upper seat".
42 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 43
SEN02209-01 50 Disassembly and assembly
44 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Remove the 2 air input hoses, com- ers.
pressed-air hose and air input hose with 2) Turn the spring system by 180° and place
angle from the pneumatic spring (6) by it onto the upper part (1).
referring to "8. Removal and installation of 3) Slightly compress the pneumatic spring
compressed-air hoses". (6) and install the pneumatic spring (6) to
5) Undo the counter sunk screw (3) from the the swinging structure (5) and lower part
pneu matic sp rin g (6 ) a nd rem ove it of the suspension (2).
together with the washer (4). 4) Tighten the counter sunk screw (7) to the
6) Move the suspension system to the high- pneumatic spring (6).
est position. 3 Counter sunk screw (6):
k Risk of crushing! Secure the sus- 6 Nm {0.61 kgm}
pension between the swinging 5) Turn the spring system by 180° and place
structure and lower part of the sus- it onto the upper part (1).
pension system with suitable spac- 6) Put the washer (4) to the pneumatic spring
ers. (6) and tighten the counter sunk screw (3).
7) Turn the spring system by 180° and place 3 Counter sunk screw (3):
it onto the upper part (1). 6 Nm {0.61 kgm}
8) Undo the counter sunk screw (7) from the
pneumatic spring (6).
9) Slightly compress the pneumatic spring
(6) and remove it from the swinging struc-
ture (5) and lower part of the suspension
(2).
WA470-6, WA480-6 45
SEN02209-01 50 Disassembly and assembly
46 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Move the suspension system to the high- ers.
est position. 2) Install the clamp (5) to the bracket (6), if
k Risk of crushing! Secure the sus- removed.
pension between the swinging a Replace the clamp with new one, if
structure and lower part of the sus- required.
pension system with suitable spac- 3) Install the air tank (3) to bracket (2) and
ers. clamp (5).
5) Remove the air hose with angle (4) from 4) Install the air hose with angle (4) to the air
the air tank (3) by referring to "8. Removal tank (3) by referring to "8. Removal and
and installation of compressed-air hoses". installation of compressed-air hoses".
6) Remove the air tank (3) from bracket (2) 5) Install the bellows by referring to "3.
and clamp (5). Removal and installation of bellows".
7) Take the clamp (5) off the bracket (6) in a 6) Install the top cover by referring to "1.
downward direction, if required. Removal and installation of top cover".
a To do this, use a screwdriver to press 7) Install the upper part of the seat by refer-
through the hole (arrow) in the ring to "I. Upper seat".
bracket against the catchers (arrow)
of the clamp (5) and pull the clamp (5)
out in a downward direction.
WA470-6, WA480-6 47
SEN02209-01 50 Disassembly and assembly
Removal Installation
1) Remove the upper part of the seat by 1) Move the suspension system to the high-
referring to "I. Upper seat". est position.
2) Remove the top cover referring to "1. k Risk of crushing! Secure the sus-
Removal and installation of top cover". pension between the swinging
3) Take the bellows off by referring to "3. structure and lower part of the sus-
Removal and installation of bellows". pension system with suitable spac-
4) Move the suspension system to the high- ers.
est position. 2) Connect the right-angle plug (6) to the
k Risk of crushing! Secure the sus- height level control unit (1).
pension between the swinging 3) Connect the electric connection (flat plug)
structure and lower part of the sus- of the compressor cable (4) to the cable
pension system with suitable spac- harness of the connector plug (2) and
ers. cable harness of the machine power con-
5) Mark the points where the cable of the nector (3).
machine power connector (3) is fastened 4) Fix the cable harness of the connector
with the cable tie (8) on the upper part of plug (2) and cable harness of the machine
the suspension (7) and remove the cable power connector (3) with the cable ties (5)
tie (8). at the marked points.
6) Mark places where the cable harness of a Run the cable harnesses (2) and (3)
the connector plug (2) and cable harness and fix them with the cable ties (5) so
of the machine power connector (3) are that they are neither squeezed nor
fastened with the cable ties (5) and otherwise damaged.
remove the cable ties (5). 5) Fix the cable of the machine power con-
7) Disconnect the electric connection (flat nector (3) with the cable tie (8) on the
plug) of the compressor cable (4) to the upper part of the suspension (7) at the
cable harness of the connector plug (2) marked points.
and cable harness of the machine power
connector (3).
8) Disconnect the right-angle plug (6) from
the height level control unit (1).
48 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 49
SEN02209-01 50 Disassembly and assembly
50 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
Assembly
1) Move the suspension system to the high-
est position.
k Risk of crushing! Secure the sus-
pension between the swinging
structure and lower part of the sus-
pension system with suitable spac-
ers.
2) Push the upper part of the suspension (1)
forwards until the cut-outs (arrow) on the
left and right sides at the guiding rails (2)
are located at the same height with the
front rollers (8) of the swinging structure
(7).
3) Install the upper part of the suspension (1)
on the back rollers (6) and the front rollers
(8) of the swinging structure (7).
a Apply acid-free multi-purpose lubri-
cant to the side surfaces (F) of the 2
guiding rails (2) of the rollers (6).
4) Install the stops (9) and fix with the 2 rivets
(10).
5) Install Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
6) Install the height level controller to the
upper part of the suspension (1) by refer-
ring to "7. Removal and installation of
height level controller".
7) Install the vertical shock absorber to the
upper part of the suspension (1) by refer-
ring to "5. Removal and installation of ver-
tical shock absorber".
8) Install the Bowden pull wire and handle to
the upper part of the suspension (1) by
referring to "4. Removal and installation of
Bowden pull wires and handle for vertical
shock absorber".
9) Install the bellows by referring to "3.
Removal and installation of bellows".
10) Install the top cover by referring to "1.
Removal and installation of top cover".
11) Install the upper part of the seat by refer-
ring to "I. Upper seat".
WA470-6, WA480-6 51
SEN02209-01 50 Disassembly and assembly
52 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 53
SEN02209-01 50 Disassembly and assembly
54 WA470-6, WA480-6
50 Disassembly and assembly SEN02209-01
WA470-6, WA480-6 55
SEN02209-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
56
SEN02210-01
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN02210-01 50 Disassembly and assembly
2. Drain coolant.
5 Coolant: Approx. 61 l
6. Disconnect harness connector (6).
3. Remove left side cover (1).
7. Remove blower assembly (7).
2 WA470-6, WA480-6
50 Disassembly and assembly SEN02210-01
8. Remove front wiper (8). 12. Disconnect connectors S01 (17), S02 (18),
C17(19) and C21 (20) in the lower right side of
the front cover.
11. Disconnect connectors S31 (13), S32 (14), L07 15. Disconnect 7 connectors (23) on the backside
(15) and L08 (16) in the lower left side of the of monitor assembly (23) and remove the mon-
front cover. itor assembly.
WA470-6, WA480-6 3
SEN02210-01 50 Disassembly and assembly
16. Disconnect connector C12 (24) and remove 20. Disconnect 2 harness clamps (32).
wiper motor (25).
21. Remove bracket (33).
17. Disconnect wiper washer hose (26).
4 WA470-6, WA480-6
50 Disassembly and assembly SEN02210-01
[*1]
Charge the air conditioner circuit with air condi-
tioner gas (R134a) from the air compressor valve.
a Take care to prevent the hose of the air condi-
tioner circuit from entry of dusts, dirt or water.
a Before proceeding to the installation, check
that the O-ring is provided at the air conditioner
hose connection.
a Check the O-ring for scratches or degradation.
2 O-ring: ND-OIL8
q Quantity of refrigerant: 1,250 ± 50 g
WA470-6, WA480-6 5
SEN02210-01 50 Disassembly and assembly
6 WA470-6, WA480-6
50 Disassembly and assembly SEN02210-01
WA470-6, WA480-6 7
SEN02210-01 50 Disassembly and assembly
Removal and installation of 4. Disconnect antenna cable (4) and GPS cable
KOMTRAX controller assembly 1 (5).
Installation
q Carry out installation in reverse order of
2. Remove clamp (2). removal.
8 WA470-6, WA480-6
50 Disassembly and assembly SEN02210-01
WA470-6, WA480-6 9
SEN02210-01
© 2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
10
SEN00805-00
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN00805-00 90 Diagrams and drawings
2 WA470-6, WA480-6
90 Diagrams and drawings SEN00805-00
WA470-6, WA480-6 3
Hydraulic circuit diagram
Hydraulic circuit diagram WA470-6, WA480-6 1
a Items marked with *1 in drawing may or may not installed.
SEN00805-00
WA470-6, WA480-6 5
SEN00805-00
© 2006 KOMATSU
All Rights Reserved
Printed in Japan 06-06 (01)
8
SEN00806-02
WA470-6
WA480-6
WA470-6, WA480-6 1
SEN00806-02 90 Diagrams and drawings
2 WA470-6, WA480-6
Electrical circuit diagram (1/14)
Electrical circuit diagram (1/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
3
Electrical circuit diagram (2/14)
Electrical circuit diagram (2/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
5
Electrical circuit diagram (3/14)
Electrical circuit diagram (3/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
7
Electrical circuit diagram (4/14)
Electrical circuit diagram (4/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
9
Electrical circuit diagram (5/14)
Electrical circuit diagram (5/14) WA380-6 1
WA380-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
11
Electrical circuit diagram (6/14)
Electrical circuit diagram (6/14) Common to WA380-6 and WA430-6 1
Common to WA380-6 and WA430-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
13
Electrical circuit diagram (7/14)
Electrical circuit diagram (7/14) Common to WA380-6 and WA430-6 1
Common to WA380-6 and WA430-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
15
Electrical circuit diagram (8/14)
Electrical circuit diagram (8/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
17
Electrical circuit diagram (9/14)
Electrical circuit diagram (9/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
19
Electrical circuit diagram (10/14)
Electrical circuit diagram (10/14) Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
21
Electrical circuit diagram (11/14)
Electrical circuit diagram (11/14) WA430-6 1
WA430-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
23
Electrical circuit diagram (12/14)
Electrical circuit diagram (12/14) Common to WA470-6 and WA480-6 1
Common to WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
25
Electrical circuit diagram (13/14)
Electrical circuit diagram (13/14) Common to WA470-6 and WA480-6 1
Common to WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
27
Electrical circuit diagram (14/14)
Electrical circuit diagram (14/14) Common to WA470-6 and WA480-6 1
Common to WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
29
Work equipment controller system electrical circuit diagram
Work equipment controller system electrical circuit diagram Common to WA380-6, WA430-6, WA470-6 and WA480-61
Common to WA380-6, WA430-6, WA470-6 and WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN00806-02
WA470-6, WA480-6
31
Connector arrangement diagram
Connector arrangement diagram WA470-6, WA480-6
Connector Number Address of Connector Number Address of Connector Number Address of Connector Number Address of
Model Component name Model Component name Model Component name Model Component name
No. of pins stereogram No. of pins stereogram No. of pins stereogram No. of pins stereogram
1.PS DT 2 1st ECMV solenoid AG-6 F05 090 II 2 Horn, Lo F-1 L04 SWP 14 Intermediate connector (Shift switch) T-8 Intermediate connector
LL8 DT2(Gr) 8
1.SW DT 2 1st ECMV fill switch AG-6 F09 DT-T 3 Bucket proximity switch C-3 L05 DT-T 2 Steering wheel horn switch S-7 (Joystick steering specification) (if equipped)
2.PS DT 2 2nd ECMV solenoid AG-6 F10 DT-T 3 Boom proximity switch C-5 L07 SWP 6 Machine monitor mode selector switch 1 T-1 Intermediate connector
LR1 DTHD 1 Y-3
(Floor wiring harness – rear wiring harness)
2.SW DT 2 2nd ECMV fill switch AF-5 F12 DT-T 3 Work equipment pump pressure sensor D-1 L08 SWP 6 Machine monitor mode selector switch 2 T-1
Intermediate connector
3.PS DT 2 3rd ECMV solenoid AF-1 F13 DT-T 2 E.C.S.S. solenoid F-1 L09 DT-T 2 Stop lamp switch W-1 LR11 DT-T 2 X-2
(Floor wiring harness – rear wiring harness)
3.SW DT 2 3rd ECMV fill switch AF-1 F14 DT-T 2 E.C.S.S. cut-off switch E-1 L11 DT-T 2 Intermediate connector (Air suspension seat) U-9, AA-6 Intermediate connector
LR12 DTHD 1 X-2
4.PS DT 2 4th ECMV solenoid AE-1 F15 DT-T 3 Boom potentiometer C-5 Right FNR (Directional) switch or multi-function lever (Floor wiring harness – rear wiring harness)
L12 DT-T 4 P-1
4.SW DT 2 4th ECMV fill switch AE-1 F16 DT-T 3 Boom bottom pressure sensor G-1 (if equipped) Intermediate connector
LR13 DT-T 2 X-2
Lift arm neutral lock switch (joystick steering (Pump bypass solenoid) (if equipped)
AL1 DT 6 Intermediate connector (Air conditioner wiring harness) S-1 F17 DT-T 3 Boom head pressure sensor G-1 L13 DT2 2
specification) (if equipped) LR2 DT 2 Intermediate connector (Multi-coupler solenoid)
C01 YAZAKI 9 AM/FM radio G-9 Lift arm angle potentiometer
F18 DT2 2 L130 YAZAKI 5 Relay No. 10, transmission bypass X-9 LR3 DT 1 Intermediate connector
C02 M 2 Speaker, right I-9 (Lift arm/bucket EPC specification) (if equipped)
Bucket positioner L131 YAZAKI 5 Relay No. 11, headlamp X-9 Intermediate connector
C03 M 2 Speaker, left J-9 F19 DT2 2 LR4 DTHD 1 Y-2
(Lift arm/bucket EPC specification) (if equipped) Lift arm kick-down & hold switch or multi-function lever (Floor wiring harness – rear wiring harness)
C04 DT-T 2 Front working lamp, right F-8 L14 DT-T 4 O-4, P-2
Lift arm raise EPC (if equipped) Intermediate connector
F20 DT2 2 LR5 DT-T 6 A-2
C05 DT-T 2 Front working lamp, left J-9 (Lift arm/bucket EPC specification) (if equipped) L15 DT-T 4 Bucket lever (Load meter specification) (if equipped) O-4, P-2 (Auto grease wiring harness) (if equipped)
C07 KES1 2 Room lamp J-9 Lift arm lower EPC L17 M 4 DC24V/DC12V converter W-9 Intermediate connector
F21 DT2 2 LR6 DTHD 1 X-2
(Lift arm/bucket EPC specification) (if equipped) (Floor wiring harness – rear wiring harness)
C08 M 1 Door switch, right F-8 L18 YAZAKI 2 12VDC socket W-9
Bucket tilt EPC Intermediate connector
C09 M 1 Door switch, left J-9 F22 DT2 2 L19 M 4 Flasher unit Z-1 LR8 DTHD 1 Y-2
(Lift arm/bucket EPC specification) (if equipped) (Floor wiring harness – rear wiring harness)
C10 YAZAKI 2 Cigarette lighter F-7 L20 M 2 Caution buzzer Z-5 LT1 HD30 31 Intermediate connector (Transmission wiring harness) Y-3, AG-8
Bucket dump EPC
C12 M 6 Front wiper motor E-7 F23 DT2 2 L21 S 10 Intermediate connector (Front/Rear wiper switch) R-7
(Lift arm/bucket EPC specification) (if equipped) MLT DTM 12 Multi-function lever switch (if equipped)
C140 DT-T 4 Tachograph (if equipped) Z-5 3-spool valve (Attachment) extension EPC Bucket dump detent solenoid NE FRAMATOME 3 Ne speed sensor AN-2
F24 DT2 2 L25E DT2 2
C141 DT-T 6 Tachograph (if equipped) Z-4 (Lift arm/bucket EPC specification) (if equipped) (Joystick steering specification) (if equipped)
PAMB AMP 3 Ambient pressure sensor AM-5
C15 M 4 Rear wiper motor K-9 3-spool valve (Attachment) retraction EPC L25S DT-T 2 Electrical detent PPC valve P-1
F25 DT2 2 PB.PS DT 2 Parking brake solenoid AG-7
(Lift arm/bucket EPC specification) (if equipped) Lift arm raise detent solenoid
C17 SWP 6 Caution lamp, yellow rotary lamp (if equipped) Q-5 L26E DT2 2 PB.SW DT 2 Parking brake indicator switch AG-8
Lift arm EPC cut-off solenoid (Joystick steering specification) (if equipped)
C18 DT 2 Caution lamp (if equipped) F26 DT2 2
(Lift arm/bucket EPC specification) (if equipped) L26S DT-T 2 Electrical detent PPC valve P-1 PCV1 SUMITOMO 2 Supply pump 1 AL-1
C18A M 1 W/lamp F30 (Terminal) 1 GND (Front frame) H-1 PCV2 SUMITOMO 2 Supply pump 2 AL-1
Lift arm lower detent solenoid
C19 SWP 6 Rear glass heater switch H-9 L27 DT2 2
F30 (Terminal) 1 GND (Front frame) (Joystick steering specification) (if equipped) PD DT-T 6 Idle validation switch P-5
C21 SWP 6 Caution lamp, rotary lamp (if equipped) Q-5 F31 DT-T 2 Multi-coupler extension solenoid L27S DT-T 2 Electrical detent PPC valve P-1 PDV 2 Accelerator pedal O-5
C22 DT 3 Rotary lamp (if equipped) F32 DT-T 2 Diode Lift arm EPC lever RES DT 2 Intermediate connector AL-5
L28 DT2 4
C25 4 Intermediate connector (Caution lamp, rotary lamp) F-8 (Joystick steering specification9 (if equipped)
F33 DT-T 2 Multi-coupler retraction solenoid PIM SUMITOMO 4 Boost pressure sensor AN-4
C29 M 1 Intermediate connector F-9 Bucket EPC lever
F34 DT-T 2 Diode L29 DT2 4 POIL FRAMATOME 3 Engine oil pressure sensor AN-3
(Joystick steering specification9 (if equipped)
C33 (Terminal) 1 Rear glass heater I-9 F35 (Terminal) 1 Fog lamp, right (if equipped) R.PS DT 2 R (Reverse) ECMV solenoid AG-7
3-spool valve (Attachment) EPC lever
C35 (Terminal) 1 Rear glass heater K-9 L30 DT2 4
F35A (Terminal) 1 Fog lamp (right) (if equipped) (Joystick steering specification) (if equipped) R.SW DT 2 R (Reverse) ECMV fill switch AG-7
C39 (Terminal) 1 GND (Radio body) G-9 F36 (Terminal) 1 Fog lamp, left (if equipped) L31 M 6 Interval wiper timer Z-2 R01 (Terminal) 1 Battery relay N-4
C40 (Terminal) 1 GND() G-9 F36A (Terminal) 1 Fog lamp (left) (if equipped) Joystick steering potentiometer R02 (Terminal) 1 Slow blow fuse B-8
L34 DT2 4
C41 SWP 6 Fog lamp (if equipped) Q-4 Intermediate wiring harness (Joystick steering specification) (if equipped) R02 (Terminal) 1 Emergency steering relay N-3
FF1 DT-T 12 G-1
C47 (Terminal) 1 GND (Beacon) (Front wiring harness – rear wiring harness) Joystick steering right EPC R03 (Terminal) 1 Slow blow fuse A-9
L35 DT2 2
C47 JAE IL-AG5 22 Air conditioner controller H-9 Intermediate wiring harness (Joystick steering specification) (if equipped)
FF2 DT-T 8 C-2 R04 (Terminal) 1 Battery relay N-4
C48 JAE IL-AG5 14 Air conditioner controller G-9 (Front wiring harness – rear wiring harness) Joystick steering left EPC
L36 DT2 2 R04 (Terminal) 1 Slow blow fuse B-8
Intermediate wiring harness (Joystick steering specification) (if equipped)
C49 DT2(B) 12 Intermediate connector (Air conditioner controller) D-6 FF3 DT-T 6 G-1 R05 (Terminal) 1 Slow blow fuse B-8
(Front wiring harness – rear wiring harness) Intermediate connector (Joystick steering EPC)
C50 DT2(Gr) 12 Intermediate connector (Air conditioner controller) E-6 L36A DT 4
Intermediate connector (Joystick steering specification) (if equipped) R06A (Terminal) 1 Slow blow fuse B-9
C52 S 3 Multi-coupler switch (if equipped) H-9 FL1 DRC12 70 Z-3
(Floor wiring harness – rear wiring harness) Joystick steering lever switch R06B (Terminal) 1 Slow blow fuse A-9
L37 DTM 12
C60 AMP 2 Daylight sensor F-7 Intermediate connector (Joystick steering specification) (if equipped)
FL2 DT-T 8 X-2 R10 (Terminal) 1 Slow blow fuse A-9
C61 SHINAGAWA 5 Caution lamp, yellow rotary lamp relay (if equipped) X-9 (Floor wiring harness – rear wiring harness) Joystick steering neutral lock switch
L38 DT2 3 R11 (Terminal) 1 Slow blow fuse B-9
Intermediate connector (Lift arm EPC) (Joystick steering specification) (if equipped)
JIDOSYA FL7 DT2(Br) 8 R13 (Terminal) 1 Emergency steering relay C-7
C62 5 Caution lamp, rotary lamp relay (if equipped) X-9 (Joystick steering specification) (if equipped) Joystick steering ON/OFF switch
DENKI KOGYO L39 DT2 6
Intermediate connector (Lift arm EPC) (Joystick steering specification) (if equipped) R14 (Terminal) 1 Emergency steering relay C-7
JIDOSYA FL8 DT2(G) 8
C63 6 Caution lamp, rotary lamp relay (if equipped) X-9 (Joystick steering specification) (if equipped) Joystick steering speed mode switch R15 (Terminal) 1 Battery relay C-7
DENKI KOGYO L40 DT2 6
Intermediate connector (3-spool valve) (Attachment (Joystick steering specification) (if equipped)
C64 SHINAGAWA 6 Fog lamp relay (if equipped) X-9 FL9 DT2 4 R16 (Terminal) 1 Battery relay B-8
EPC) (Joystick steering specification) (if equipped) JIDOSYA Joystick steering cut-off relay
C65 DT 3 Rotary lamp (if equipped) L41 6 R20 DT-T 6 Intermediate connector (Rear combination lamp, left) N-5
FS1 L 2 Intermediate connector (Fuse box B) Y-1 DENKI KOGYO (Joystick steering specification) (if equipped)
C91 M 1 Intermediate connector (Warning lamp) Intermediate connector R21 DT-T 6 Intermediate connector (Rear combination lamp, right) M-9
FS11 X 3 Intermediate connector (Fuse box B) Z-1 L44 M 6 V-9
G SUMITOMO 3 G sensor AL-1 (Load meter printer wiring harness) R22 (Terminal) 1 GND M-9
FS2 L 2 Intermediate connector (Fuse box A) Y-1
CAN1 DT-T 3 Diode AN-3 L45 D-sub25 25 Printer R29 DT-T 2 Hydraulic fan EPC L-9
FS3 SWP 16 Intermediate connector (Fuse box B) Y-2
CAN2 DT-T 3 CAN terminal resistor Q-2 L46 HOSHIDEN 4 Printer R30 DT-T 6 Rear combination lamp, left N-6
FS4 SWP 12 Intermediate connector (Fuse box A) Y-2
CHK0 X 1 KOMTRAX test connector Y-8 L51 AMP 070 20 Machine monitor Q-3 R31 DT 6 Rear combination lamp, right M-9
FS5 SWP 6 Intermediate connector (Fuse box A) Y-1
CHK1 X 1 KOMTRAX test connector X-8 L52 AMP 070 18 Machine monitor Q-3 R32 DT-T 2 Coolant level sensor F-7
FS6 X 1 Intermediate connector (Fuse box B) Z-1
CL1 SWP 8 Intermediate connector (Cab wiring harness) A-4, O-6 L53 AMP 070 12 Machine monitor Q-3 R33 DT-T 2 Fuel level sensor N-4
FS7 X 1 Intermediate connector (Fuse box B) Z-1
CL2 SWP 12 Intermediate connector (Cab wiring harness) A-5, O-7 L54 AMP 070 18 Machine monitor R-7 R36 DT-T 2 Pressure switch (Steering pump) I-1
PFUEL AMP 3 Common rail pressure sensor AN-3
CL21 SWP 16 Intermediate connector O-7 L55 AMP 070 12 Machine monitor Q-6 R37 DT-T 2 Pressure switch (Emergency steering) I-1
G04 DT-T 2 Left rear working lamp N-9
CL24 X 2 Intermediate connector (Multi-coupler) A-4 L56 AMP 070 12 Machine monitor Q-3 R38 DT 6 Auto grease controller
G05 DT-T 2 Right rear working lamp M-9
CL26 X 2 Intermediate connector (Cab wiring harness) O-5 L57 AMP 070 14 Machine monitor Q-6 R40 X 2 Pressure switch (Steering pump) J-1
G10 DT-T 2 Backup buzzer N-8
CL26 X 2 Intermediate connector A-3 L61 DRC26 24 Transmission controller Y-7 R43 KES1 2 Front windshield washer L-1
G11 DT-T 2 Fan reverse solenoid N-8
CL27 SWP 6 Side wiper (if equipped) A-4 L62 DRC26 40 Transmission controller Y-8 R45 KES1 2 Rear windshield washer L-2
GR1 DT-T 4 Intermediate connector (Rear working lamp) L-9
CN1 DT 2 Injector #1 AJ-3 L63 DRC26 40 Transmission controller Y-8 R47 DT-T 2 Hydraulic oil temperature sensor E-7
HEAD DT-T 3 Headlamp, right D-6
CN2 DT 2 Injector #2 AK-4 Work equipment controller R50 (Terminal) 1 GND (Rear frame) N-6
HEAD DT-T 3 Headlamp, left H-1 L71 DRC26 24
(Joystick steering specification) (if equipped) R52 DT-T 2 Emergency brake switch I-1
CN3 DT 2 Injector #3 AK-4
J01 M6409-0073 20 Junction connector V-1 Work equipment controller
CN4 DT 2 Injector #4 AL-5 L72 DRC26 40 R54 DT-T 2 Rear brake pressure switch I-1
J02 M6409-0073 20 Junction connector V-1 (Joystick steering specification) (if equipped)
CN5 DT 2 Injector #5 AL-5 R60 DT-T 2 Rear brake oil temperature sensor L-2
J03 M6409-0071 20 Junction connector U-1 Work equipment controller
CN6 DT 2 Injector #6 AM-5 L73 DRC26 40 R71 DT-T 2 Loader pump EPC L-9
(Joystick steering specification) (if equipped)
J04 M6440-0128 20 Junction connector V-1
COMBI DT-T 3 Combination lamp, right D-6 L80 DRC26 40 KOMTRAX controller R73 DT-T 3 Brake oil pressure sensor (For transmission cut-off) K-1
J05 M6409-0075 20 Junction connector U-1
COMBI DT-T 3 Combination lamp, left H-1 L100 (Terminal) 1 GND (Floor) Y-3 R86 DT-T 3 Steering pump pressure sensor J-1
J06 M6409-0603 20 Junction connector U-9
D04 DT-T 2 Diode Z-4 L101 SWP 16 Intermediate connector (Relay) Z-2 R87 DT 2 Intermediate connector A-2
J07 M6409-0603 20 Junction connector U-1
D05 DT-T 2 Diode W-1 L102 SWP 16 Intermediate connector (Relay) Z-2 R90 (Terminal) 1 Heater relay E terminal B-6
J08 M6409-0071 20 Junction connector U-1
D06 DT-T 2 Diode Z-4 L103 SWP 16 Intermediate connector (Relay) Z-3 REV OUT DT 2 Speed sensor AE-4
J09 M6440-0128 20 Junction connector U-1
D07 DT-T 2 Diode Z-4 L104 SWP 16 Intermediate connector (Relay) W-9 S1 DT-T 2 Electric detent PPC valve O-3
J10 M6409-0075 20 Junction connector U-1
D08 DT-T 2 Diode W-1 L105 SWP 12 Intermediate connector (Relay) V-9 S01 SWP 6 Front working lamp Q-4
J11 M6409-0075 20 Junction connector U-1
D09 DT-T 2 Diode W-2 L106 SWP 16 Intermediate connector (Relay) V-9 S02 SWP 6 Rear working lamp Q-5
J12 M6409-0603 20 Junction connector U-1
D11 11 Diode unit L107 SWP 12 Intermediate connector (Wiper timer) Z-5 S03 SWP 6 Transmission cut-off switch P-9
J13 M6409-0073 20 Junction connector U-9
D11 DT-T 2 Diode Z-3 L111 YAZAKI 5 Relay No. 1 winker & hazard Z-8 S04 SWP 6 FNR selector switch Q-9
J14 M6409-0075 20 Junction connector U-9
D12 DT-T 2 Diode Z-3 L112 YAZAKI 5 Relay No. 2 air cleaner clock (if equipped) Z-8 S05 SWP 6 Transmission cut-off set switch Q-9
J15 M6409-0603 20 Junction connector U-1
DIODE DT 2 Diode L113 YAZAKI 5 Relay No. 3, joystick safety relay Y-8 S06 SWP 6 Torque converter lockup ON/OFF switch P-8
J16 M6409-0075 20 Junction connector Q-6
E01 DT-T 2 Starting motor AK-5 L114 YAZAKI 5 Relay No. 4, fog lamp (1) Y-8 S07 SWP 6 E.C.S.S. switch S-1
J17 M6440-0128 20 Junction connector Q-6
E02 (Terminal) 1 Alternator R terminal AM-8 L116 YAZAKI 5 Relay No. 6, neutral safety Z-8 S14 SWP 6 Upper and lower section remote position ON/OFF switch Q-9
J18 M6409-0075 20 Junction connector U-1
E04 (Terminal) 1 Alternator E terminal AM-7 L117 YAZAKI 5 Relay No. 7, backup lamp Z-8 S15 SWP 6 Automatic digging switch R-9
J19 M6409-0603 20 Junction connector Q-5
E05 (Terminal) 1 Heater relay C-6 L118 YAZAKI 5 Relay No. 8, stop lamp Z-8 S16 SWP 6 Hydraulic fan selector switch R-9
J20 M6409-0603 20 Junction connector U-1
E06 (Terminal) 1 Heater relay B-8 L119 YAZAKI 5 Relay No. 9, horn Y-8 S17 SWP 6 Auto grease switch (if equipped) H-9
J21 M6409-0075 20 Junction connector U-1
E06A DT-T 2 Diode N-6 L120 YAZAKI 5 Relay No. 10, parking brake Y-9 S19 SWP 6 Emergency steering check switch Q-9
J22 M6409-0071 20 Junction connector
E07A (Terminal) 1 Heater relay AL-6 L123 YAZAKI 5 Relay No. 3, boom detent Y-9 S21 SWP 6 Engine power mode switch P-8
Junction connector
E07B (Terminal) 1 Electrical intake air heater AJ-3 J41 M6409-0128 20 L124 YAZAKI 5 Relay No. 4, bucket detent Y-9 S22 DT-T 4 Auto-shift mode switch P-8
(Joystick steering specification) (if equipped)
E10 DT-T 2 Air conditioner compressor magnet clutch AK-1 Junction connector L125 YAZAKI 5 Relay No. 5, boom detent alternate X-9 S3 DT-T 2 Electric detent PPC valve O-3
J42 M6409-0128 20
E14A (Terminal) 1 GND (Engine) AN-3 (Joystick steering specification) (if equipped) L126 YAZAKI 5 Relay No. 6, emergency steering X-9 S31 SWP 6 Load meter mode selector switch (if equipped) T-1
E14B (Terminal) 1 GND (Engine) AN-3 Junction connector L127 YAZAKI 5 Relay No. 7, front working lamp Y-9 S32 SWP 6 Load meter display selection (if equipped) U-1
J44 M6409-0071 20
(Joystick steering specification) (if equipped) S33 SWP 6 Remote positioner bucket raise/lower (if equipped) Q-9
E15 (Terminal) 1 GND (Engine) AL-6 L128 YAZAKI 5 Relay No. 8, rear working lamp Y-9
Junction connector S34 SWP 6 2-stage idle function switch R-9
E26 DT-T 2 Engine oil level sensor AL-5 J45 DT2(B) 8 L129 YAZAKI 5 Relay No. 9, rear glass with heater X-9
(Joystick steering specification) (if equipped)
E33 DT-T 2 Intermediate connector N-3 JIDOSYA S4 DT-T 2 Electric detent PPC valve O-3
Junction connector L141 5 Front washing relay
E45 DT-T 2 Dust indicator K-9 J46 DT2 6 DENKI KOGYO S40 DT 4 Starting motor switch T-8
(Joystick steering specification) (if equipped)
EC1 DRC26 60 Engine controller AN-2 J1939 DT 3 CAN AJ-3 L142 DT 2 Diode SEGR DT 4 EGR valve position sensor AJ-2
EC2 DRC26 50 Engine controller AN-2 Junction connector L143 DT 2 Diode SV DT-T 12 KOM-NET (CAN) SV connector Z-5
JL1 DT2(Gr) 8 AA-4
EC3 DTP 4 Engine controller AM-1 (Joystick steering specification) (if equipped) L144 DT 2 Diode T21 DT 2 Pump bypass solenoid (if equipped)
EGR DT 2 EGR valve AK-1 JL2 DTM 12 Joystick lever switch AA-4 L145 DT 2 Diode TC.T DT 2 Torque converter oil temperature sensor (Monitor) AH-1
ER1 DT-T 4 Intermediate connector (Engine controller) M-2, AJ-5 JS1 SWP 6 Joystick ON/OFF switch AB-6 L146 DT 2 Diode TEL DT-T 12 Intermediate connector (KOMTRAX) U-9
ER2 DT-T 12 Intermediate connector (Engine controller) M-2, AK-5 JS2 SWP 6 Steering speed mode switch AA-6 L147 DT 2 Diode TFUEL PACKARD 2 Fuel temperature sensor AN-5
ER3 L 2 Intermediate connector (Engine controller) M-2, AJ-4 JS3 DT2 4 Joystick lever potentiometer AA-6 L171 YAZAKI 5 Engine controller cut relay Y-8 TGN (Terminal) 1 GND (Transmission body) AF-5
ER4 DT-T 6 Intermediate connector N-5, AL-6 JS4 DT2 2 Joystick neutral lock switch AB-4 L172 YAZAKI 5 Engine controller cut relay Z-8 TIM PACKARD 2 Boost temperature sensor AN-4
F.PS DT 2 F (Forward) ECMV solenoid AE-2 JT1 DT 8 Junction connector AF-5 L173 X 4 Intermediate connector (Relay) Z-2 TM.T DT 2 Transmission lubricating oil temperature sensor AH-2
F.SW DT 2 F (Forward) ECMV fill switch AE-1 JT2 DT 6 Junction connector AD-4 L175 YAZAKI 6 Brake oil pressure caution, emergency brake relay Y-8 TWTR PACKARD 2 Engine coolant temperature sensor AM-7
F01 DT-T 6 Intermediate connector (headlamp, right) C-5 L01 SWP 6 Parking brake switch R-7 LL5 DT-T 3 Intermediate connector (Work equipment controller) Z-9 W60 SHINAGAWA 5 KOMTRAX engine cut relay X-8
F02 DT-T 6 Intermediate connector (Headlamp, left) H-1 L02 SWP 6 Lighting switch S-8 LL6 DT-T 12 Intermediate connector (Work equipment controller) Z-8
F03 090 II 2 Horn, Hi C-4 L03 SWP 6 Turn & Hazard switch S-8 LL7 DT-T 12 Intermediate connector (Work equipment controller) Z-8
SEN00806-02
WA470-6, WA480-6 33
90 Diagrams and drawings SEN00806-02
WA470-6, WA480-6 35
SEN00806-02
© 2007 KOMATSU
All Rights Reserved
Printed in Japan 12-07 (01)
36