WA470-6 90001 Up

SEN04409-02
WHEEL LOADER WA470 -6

WA480 -6
WA470-90001
SERIAL NUMBERS and up
WA480-90001
.
SEN04418-02
WHEEL LOADER
WA470-6
WA480-6
Machine model Serial number

WA470-6 90001 and up
WA480-6 90001 and up
00 Index and foreword 00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
WA470, 480-6 00-100 1

100 Index
SEN04418-02 Composition of shop manual
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title..................................................................................................................................... Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04409-02
00 Index and foreword .................................................................................................................... SEN04410-02

100 Index .................................................................................................................................. SEN04418-02 q
200 Foreword and general information ..................................................................................... SEN04419-01
01 Specification ............................................................................................................................... SEN04411-00

100 Specification and technical data......................................................................................... SEN04420-00
10 Structure, function and maintenance standard........................................................................... SEN04412-00

100 Engine and cooling system ................................................................................................ SEN04421-00
200 Power train......................................................................................................................... SEN04422-00
300 Steering system ................................................................................................................. SEN04423-00
400 Brake system ..................................................................................................................... SEN04424-00
500 Undercarriage and frame ................................................................................................... SEN04425-00
601 Hydraulic system, Part 1 .................................................................................................... SEN04426-00
602 Hydraulic system, Part 2 .................................................................................................... SEN04427-00
700 Work equipment................................................................................................................. SEN04428-00
800 Cab and its attachments .................................................................................................... SEN04429-00
901 Electrical system, Part 1 .................................................................................................... SEN04430-00
20 Standard value table................................................................................................................... SEN04413-01

100 Standard service value table.............................................................................................. SEN04515-01 q
30 Testing and adjusting ................................................................................................................. SEN04414-01

101 Testing and adjusting, Part 1.............................................................................................. SEN04516-01 q
40 Troubleshooting.......................................................................................................................... SEN04415-01
100 Failure code table and fuse locations ................................................................................ SEN04519-01 q
200 General information on troubleshooting............................................................................. SEN04520-01 q
301 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN04521-01 q
302 Troubleshooting by failure code (Display of code), Part 2 ................................................. SEN04522-00
303 Troubleshooting by failure code (Display of code), Part 3 ................................................. SEN04523-01 q
00-100 2 WA470, 480-6

100 Index
Composition of shop manual SEN04418-02
304 Troubleshooting by failure code (Display of code), Part 4..................................................SEN04524-01 q

309 Troubleshooting by failure code (Display of code), Part 9..................................................SEN04529-00
310 Troubleshooting by failure code (Display of code), Part 10................................................SEN04530-01 q
400 Troubleshooting of electrical system (E-mode) ..................................................................SEN04531-01 q
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN04532-01 q
600 Troubleshooting of engine (S-mode) ..................................................................................SEN04533-01 q
50 Disassembly and assembly ........................................................................................................SEN04416-01

100 General information on disassembly and assembly...........................................................SEN04534-01 q
200 Engine and cooling system ................................................................................................SEN04535-01 q
301 Power train, Part 1..............................................................................................................SEN04536-01 q
302 Power train, Part 2..............................................................................................................SEN04537-01 q
400 Brake system......................................................................................................................SEN04866-01 q
500 Undercarriage and frame ...................................................................................................SEN04538-01 q
600 Hydraulic system ................................................................................................................SEN04539-00
700 Work equipment .................................................................................................................SEN04540-00
800 Cab and its attachments.....................................................................................................SEN04541-00
900 Electrical system ................................................................................................................SEN04542-00
90 Diagrams and drawings..............................................................................................................SEN04417-00

100 Hydraulic diagrams and drawings ......................................................................................SEN04433-00
200 Electrical diagrams and drawings.......................................................................................SEN04434-00
WA470, 480-6 00-100 3

100 Index
SEN04418-02 Table of contents
Table of contents 1
00 Index and foreword

100 Index SEN04418-02
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN04419-01
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
100 Specification and technical data SEN04420-00
Specification dimension drawing ................................................................................................................... 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
10 Structure, function and maintenance standard

100 Engine and cooling system SEN04421-00
Engine mount and transmission mount......................................................................................................... 2
Cooling system.............................................................................................................................................. 3
Cooling fan pump .......................................................................................................................................... 4
Cooling fan motor.......................................................................................................................................... 12
200 Power train SEN04422-00
Power train .................................................................................................................................................... 3
Power train system diagram.......................................................................................................................... 4
Drive shaft ..................................................................................................................................................... 6
Power train piping diagram ........................................................................................................................... 7
Torque converter ........................................................................................................................................... 8
Transmission ................................................................................................................................................. 16
Transmission control valve............................................................................................................................ 34
ECMV............................................................................................................................................................ 38
Main relief valve and torque converter relief valve........................................................................................ 50
Axle ............................................................................................................................................................... 52
Differential ..................................................................................................................................................... 56
Limited slip differential................................................................................................................................... 61
Final drive...................................................................................................................................................... 68
300 Steering system SEN04423-00
Steering component layout drawing .............................................................................................................. 2
Steering column ............................................................................................................................................ 3
Steering pump ............................................................................................................................................... 4
Steering valve................................................................................................................................................ 17
Orbit-roll valve ............................................................................................................................................... 34
Stop valve...................................................................................................................................................... 42
Steering relief valve....................................................................................................................................... 43
Steering cylinder............................................................................................................................................ 44
Emergency steering motor ............................................................................................................................ 46
Emergency steering pump ............................................................................................................................ 47
Joystick steering lever linkage ...................................................................................................................... 48
00-100 4 WA470, 480-6

100 Index
Table of contents SEN04418-02
Electrical steering lever ................................................................................................................................. 49

Joystick EPC valve ........................................................................................................................................ 50
400 Brake system SEN04424-00
Brake component layout drawing .................................................................................................................. 2
Charge valve ................................................................................................................................................. 3
Brake valve.................................................................................................................................................... 10
Accumulator (for brake) ................................................................................................................................. 15
Slack adjuster ................................................................................................................................................ 16
Brake ............................................................................................................................................................. 18
Parking brake control..................................................................................................................................... 23
Parking brake ................................................................................................................................................ 24
Parking brake solenoid valve......................................................................................................................... 26
Emergency parking brake release valve ....................................................................................................... 28
500 Undercarriage and frame SEN04425-00
Axle mount and center hinge pin ................................................................................................................... 2
Tires............................................................................................................................................................... 6
601 Hydraulic system, Part 1 SEN04426-00
Hydraulic component layout drawing............................................................................................................. 2
Work equipment control lever linkage ........................................................................................................... 5
Hydraulic tank................................................................................................................................................ 8
Power train pump .......................................................................................................................................... 10
Work equipment pump .................................................................................................................................. 12
Work equipment control valve ....................................................................................................................... 32
CLSS ............................................................................................................................................................. 43
Each function and operation of each valve.................................................................................................... 48
602 Hydraulic system, Part 2 SEN04427-00
PPC valve...................................................................................................................................................... 2
Accumulator (for PPC circuit) ........................................................................................................................ 10
Accumulator (for power train circuit).............................................................................................................. 11
Accumulator (for ECSS) ................................................................................................................................ 12
Work equipment PPC cut-off solenoid valve ................................................................................................. 13
700 Work equipment SEN04428-00
Work equipment linkage ................................................................................................................................ 2
Bucket............................................................................................................................................................ 5
Bucket positioner and boom kick-out............................................................................................................. 6
Work equipment cylinder ............................................................................................................................... 12
800 Cab and its attachments SEN04429-00
Cab ................................................................................................................................................................ 3
Air conditioner................................................................................................................................................ 4
901 Electrical system, Part 1 SEN04430-00
Machine monitor system................................................................................................................................ 2
Machine monitor ............................................................................................................................................ 6
Electrical system (Transmission controller system)....................................................................................... 2
Transmission controller.................................................................................................................................. 42
Electrical system (Work equipment controller system) .................................................................................. 44
Work equipment controller............................................................................................................................. 50
Electric transmission control.......................................................................................................................... 2
Kickdown switch and hold switch .................................................................................................................. 6
Load meter cancel switch and load meter subtotal switch ............................................................................ 6
Multi-function knob ........................................................................................................................................ 7
Joystick steering knob ................................................................................................................................... 8
KOMTRAX system ........................................................................................................................................ 10
Engine starting circuit .................................................................................................................................... 12
Engine stopping circuit .................................................................................................................................. 14
Preheating circuit........................................................................................................................................... 15
WA470, 480-6 00-100 5

100 Index
Engine power mode selector circuit .............................................................................................................. 16

Engine output derating function .................................................................................................................... 17
Automatic warm-up function.......................................................................................................................... 17
Parking brake circuit...................................................................................................................................... 18
Sensor........................................................................................................................................................... 20
20 Standard value table

100 Standard service value table SEN04515-01
Standard value table for engine .................................................................................................................... 2
Standard value table for chassis ................................................................................................................... 3
30 Testing and adjusting

101 Testing and adjusting, Part 1 SEN04516-01
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Testing engine speed .................................................................................................................................... 9
Testing exhaust gas color.............................................................................................................................. 11
Testing exhaust temperature......................................................................................................................... 13
Adjusting valve clearance ............................................................................................................................. 15
Testing compression pressure ...................................................................................................................... 17
Testing blow-by pressure .............................................................................................................................. 19
Testing engine oil pressure ........................................................................................................................... 20
Testing EGR valve drive pressure................................................................................................................. 21
Testing intake air (boost) pressure ................................................................................................................ 22
Handling fuel system equipment ................................................................................................................... 23
Releasing residual pressure in fuel system................................................................................................... 23
Testing fuel pressure ..................................................................................................................................... 24
Testing fuel return and leak amount .............................................................................................................. 25
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 30
Handling of reduced cylinder mode operation............................................................................................... 31
Handling of no injection cranking operation .................................................................................................. 31
Handling of controller voltage circuit ............................................................................................................. 32
Check of muffler and muffler stack for looseness and damage .................................................................... 33
Check of muffler function .............................................................................................................................. 33
Check of installed condition of cylinder head and manifolds......................................................................... 34
Check of engine piping for damage and looseness ...................................................................................... 34
Testing and adjusting air conditioner compressor belt tension...................................................................... 35
Testing and adjusting alternator belt tension................................................................................................. 36
Adjusting transmission speed sensor............................................................................................................ 37
Adjusting directional lever length .................................................................................................................. 38
Adjusting gear shift lever length .................................................................................................................... 38
Testing FNR lever and gear shift lever .......................................................................................................... 39
Testing and adjusting power train oil pressure .............................................................................................. 40
Procedure for flushing torque converter and transmission hydraulic circuit.................................................. 54
Method of moving machine when transmission valve is broken ................................................................... 56
Check of axle final drive for oil leakage......................................................................................................... 59
Check of drive shafts for looseness, play and damage................................................................................. 59
Testing and adjusting steering stop valve ..................................................................................................... 60
Testing and adjusting steering wheel ............................................................................................................ 62
Testing steering oil pressure ......................................................................................................................... 64
Bleeding air from steering circuit................................................................................................................... 67
Testing hydraulic drive fan............................................................................................................................. 3
Adjustment of hydraulic fan speed sensor .................................................................................................... 5
Bleeding air from hydraulic drive fan circuit .................................................................................................. 6
Testing brake pedal ....................................................................................................................................... 8
Testing and adjusting brake pedal linkage .................................................................................................... 9
00-100 6 WA470, 480-6

100 Index
Testing brake performance ............................................................................................................................ 10

Testing and adjusting accumulator charge pressure ..................................................................................... 11
Testing wheel brake oil pressure ................................................................................................................... 13
Testing wear of wheel brake disc................................................................................................................... 15
Bleeding air from wheel brake circuit............................................................................................................. 16
Releasing residual pressure in brake accumulator circuit ............................................................................. 17
Testing parking brake performance ............................................................................................................... 17
Testing parking brake oil pressure ................................................................................................................. 18
Testing wear of parking brake disc ................................................................................................................ 20
Manual release method for parking brake ..................................................................................................... 21
Testing and adjusting work equipment control lever...................................................................................... 22
Testing and adjusting work equipment PPC oil pressure .............................................................................. 23
Testing and adjusting work equipment oil pressure....................................................................................... 26
Bleeding air from work equipment circuit....................................................................................................... 30
Releasing residual pressure in work equipment circuit ................................................................................. 31
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS
(Electronically Controlled Suspension System) accumulator ................................................... 32
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator ............ 38
Testing and adjusting bucket positioner......................................................................................................... 43
Testing and adjusting boom kick-out ............................................................................................................. 45
Checking proximity switch operation pilot lamp............................................................................................. 46
Procedure for testing diodes.......................................................................................................................... 47
Preparation work for troubleshooting for electrical system ............................................................................ 48
How to start KOMTRAX terminal operations ................................................................................................. 53
Indicator lamps of KOMTRAX terminal.......................................................................................................... 58
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 2
Special functions of machine monitor (EMMS).............................................................................................. 5
Pm-clinic inspection table .............................................................................................................................. 68
40 Troubleshooting
100 Failure code table and fuse locations SEN04519-01
Failure code table .......................................................................................................................................... 2
Fuse locations ............................................................................................................................................... 14
200 General information on troubleshooting SEN04520-01
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
301 Troubleshooting by failure code (Display of code), Part 1 SEN04521-01
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, 480-6 00-100 7

100 Index
Failure code [2G43ZG] (Accumulator: Low oil pressure) .............................................................................. 30

Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ......................................................... 32
Failure code [AA1ANX] (Air cleaner: Clogging) ............................................................................................ 4
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) ................................... 6
Failure code [AB00MA] (Alternator: Malfunction).......................................................................................... 8
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) ...................................................... 10
Failure code [B@BAZK] (Engine oil: Low level)............................................................................................ 13
Failure code [B@BCNS] (Coolant: Overheating) .......................................................................................... 14
Failure code [B@BCZK] (Coolant: Low level) ............................................................................................... 16
Failure code [B@C7NS] (Brake oil: Overheating)......................................................................................... 18
Failure code [b@CENS] (Torque converter oil: Overheating) ....................................................................... 20
Failure code [B@CENS] (Torque converter oil: Overheating)....................................................................... 22
Failure code [B@HANS] (Hydraulic oil: Overheating)................................................................................... 24
Failure code [CA111] (Abnormality in engine controller) ............................................................................... 26
Failure code [CA115] (Engine Ne or Bkup speed sensor error).................................................................... 29
Failure code [CA122] (Charge pressure sensor high error) .......................................................................... 30
Failure code [CA123] (Charge pressure sensor low error) ........................................................................... 32
Failure code [CA131] (Throttle sensor high error)......................................................................................... 34
Failure code [CA132] (Throttle sensor low error) .......................................................................................... 36
Failure code [CA135] (Engine oil pressure sensor high error) ...................................................................... 38
Failure code [CA141] (Engine oil pressure sensor low error) ....................................................................... 40
Failure code [CA144] (Coolant sensor high error) ........................................................................................ 42
Failure code [CA145] (Coolant sensor low error).......................................................................................... 44
Failure code [CA153] (Charge temperature sensor high error)..................................................................... 46
Failure code [CA154] (Charge temperature sensor low error) ...................................................................... 48
Failure code [CA187] (Sensor power supply 2 low error) ............................................................................. 50
Failure code [CA221] (Atmospheric pressure sensor high error).................................................................. 51
Failure code [CA222] (Atmospheric pressure sensor low error) ................................................................... 53
Failure code [CA227] (Sensor power supply 2 high error) ............................................................................ 54
Failure code [CA234] (Engine overspeed) .................................................................................................... 56
Failure code [CA238] (Ne speed sensor power supply error) ....................................................................... 58
Failure code [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 [CA342] (Calibration code inconsistency) ................................................................................ 28
Failure code [CA351] (Injectors drive circuit error)........................................................................................ 29
Failure code [CA431] (Idle validation switch error) ....................................................................................... 34
Failure code [CA432] (Idle validation action error)........................................................................................ 36
Failure code [CA441] (Battery voltage low error) .......................................................................................... 38
Failure code [CA442] (Battery voltage high error)......................................................................................... 41
Failure code [CA449] Common rail pressure high error 2............................................................................. 43
Failure code [CA451] (Common rail pressure sensor high error) ................................................................. 44
Failure code [CA452] (Common rail pressure sensor low error)................................................................... 46
Failure code [CA553] (Common rail pressure high error 1) .......................................................................... 47
Failure code [CA554] (Common rail pressure sensor in-range error) ........................................................... 48
00-100 8 WA470, 480-6

100 Index
Failure code [CA559] (Supply pump pressure very low error)....................................................................... 49

Failure code [CA689] (Engine Ne speed sensor error) ................................................................................. 53
Failure code [CA731] (Engine Bkup speed sensor phase error) ................................................................... 55
Failure code [CA757] (All continuous data lost error) .................................................................................... 55
Failure code [CA778] (Engine Bkup speed sensor error).............................................................................. 56
Failure code [CA1228] (EGR valve servo error 1)......................................................................................... 58
Failure code [CA1625] (EGR valve servo error 2)......................................................................................... 59
Failure code [CA1633] (KOMNET datalink timeout error) ............................................................................. 60
Failure code [CA2185] (Throttle sensor supply voltage high error) ............................................................... 62
Failure code [CA2186] (Throttle sensor power supply low error) .................................................................. 63
Failure code [CA2249] (Supply pump pressure very low error 2).................................................................. 3
Failure code [CA2271] (EGR valve lift sensor high error) ............................................................................. 4
Failure code [CA2272] (EGR valve lift sensor low error) ............................................................................... 6
Failure code [CA2351] (EGR valve solenoid operation short circuit) ............................................................ 7
Failure code [CA2352] (EGR valve solenoid operation disconnect).............................................................. 9
Failure code [CA2555] (Intake heater relay disconnection error) .................................................................. 10
Failure code [CA2556] (Intake heater relay short circuit error)...................................................................... 12
Failure code [D150KA] (Emergency steering relay: Disconnection).............................................................. 14
Failure code [D150KB] (Emergency steering relay: Short circuit) ................................................................. 16
Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) ............................. 18
Failure code [D160KA] (Backup lamp relay output: Disconnection).............................................................. 20
Failure code [D160KB] (Backup lamp relay output: Short circuit) ................................................................. 22
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) ............................................ 24
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) ................................................ 26
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) .......................................................................... 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
Failure code [DAQ0KK] (Transmission controller: Low source voltage)........................................................ 4
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller) ................................................ 6
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)) .................................... 14
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)............................................. 16
Failure code [DB2RKR] (CAN communication with engine controller:
Defective communication (Abnormality in target component system)...................................... 18
Failure code [DB90KK] Work equipment controller: Low source voltage (input) ........................................... 20
Failure code [DB90KT] Work equipment controller: Abnormality in controller............................................... 22
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) ...... 24
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range............. 26
WA470, 480-6 00-100 9

100 Index
Failure code [DB99KQ] (Work equipment controller model selection:

Disagreement in model selection signals) ............................................................................ 29
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system) ..................................... 30
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ........................................ 32
Failure code [DB9RMC] (CAN communication with transmission controller,
engine controller and machine monitor: Defective operation)................................................ 33
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 36
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 38
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 40
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 42
Failure code [DD1ALD] Remote positioner raise/lower set switch (raise):
Switch is kept pressed for long time..................................................................................... 44
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time..................................................................................... 46
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................... 48
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time........ 50
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time ........ 52
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) ............ 54
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)..................................... 56
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)..................... 58
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).............................. 60
Failure code [DDD1LD] (Remote positioner bucket angle set switch:
Switch is kept pressed for long time) ................................................................................... 64
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 signal: Disconnected) .................................................... 20
Failure code [DDS5KB] (Steering pressure switch signal: 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
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) ...................................................... 36
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)......................................................... 40
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)............................................ 42
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)............................................... 44
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) ................................ 46
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)............................................... 48
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ............................. 50
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) ..................... 52
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) ..................................................... 54
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)....................................... 56
Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range).................... 2
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)....................... 4
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range).......................... 6
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) ................................................... 8
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)....................................................... 10
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ...................................... 12
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...... 15
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) ....................... 18
00-100 10 WA470, 480-6

100 Index
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)........................................ 21
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) ....... 24
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) ....................................... 27
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)....... 30
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ........................ 33
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ........................................ 36
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)........ 39
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 [DLF1KA] (Transmission input speed sensor: Disconnection).................................................. 22
Failure code [DLF1LC] (Transmission input speed sensor: Short circuit) ..................................................... 23
Failure code [DLM3KA] (Fan speed sensor: Disconnection)......................................................................... 24
Failure code [DLM3LC] (Fan speed sensor: Short circuit) ............................................................................ 26
Failure code [DLT3KA] (Transmission output speed sensor: Disconnection)................................................ 28
Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range) ............................... 30
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) .................................................. 32
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) ..................................... 34
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .................................... 36
Failure code [DV00KB] (Alarm buzzer: Short circuit) .................................................................................... 38
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ......................................................... 40
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)............................................................. 42
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ........................ 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) ........................................................ 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ........................................................... 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ....................... 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) .............................................................. 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit).................................................................. 51
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ............................. 52
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) ........................ 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) ................................................................... 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)....................................................................... 9
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) .................................. 10
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) ........................................ 12
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)............................................ 14
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)........ 16
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) ......................................... 18
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ............................................. 20
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)......... 22
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) .......................................... 24
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) .............................................. 26
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line).......... 28
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) .............................................. 30
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) .................................................. 32
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) .................... 34
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) ............................................................... 36
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)................................................................... 37
WA470, 480-6 00-100 11

100 Index
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) .............................. 38
Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection) ................................................... 40
Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)....................................................... 42
Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection) ................................................ 44
Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit) .................................................... 46
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)................................................................ 48
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ................................................................... 50
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ............................... 52
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ............................................................ 54
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)................................................................ 56
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ........................... 58
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
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
400 Troubleshooting of electrical system (E-mode) SEN04531-01
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
E-13 The KOMTRAX system does not work properly................................................................................... 54
E-14 When kick-down switch is turned ON, kick-down operation does not start .......................................... 56
E-15 When hold switch is pressed, holding operation does not start............................................................ 58
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while
parking brake is applied .................................................................................................................. 60
E-17 Transmission cut-off mode cannot be set or reset................................................................................ 62
E-18 Transmission cut-off set cannot be reset.............................................................................................. 64
00-100 12 WA470, 480-6

100 Index
E-19 FNR switch mode cannot be set or reset.............................................................................................. 66

E-20 Fan reverse function cannot be used or reset ...................................................................................... 68
E-21 Discharge from loader pump does not rise from minimum level........................................................... 70
E-22 ECSS function cannot be used or reset................................................................................................ 72
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up .............................. 74
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate......................... 78
E-25 Air cleaner clogging indicator lamp does not light up............................................................................ 80
E-26 Radiator coolant level caution lamp does not light up........................................................................... 82
E-27 Hydraulic oil temperature gauge does not rise and hydraulic oil temperature caution lamp does
not light up ..................................................................................................................................... 83
E-28 Torque converter oil temperature gauge does not rise and torque converter oil temperature
caution lamp does not light up......................................................................................................... 84
E-29 Steering oil pressure caution lamp does not light up ............................................................................ 86
E-30 Abnormality in t switch (panel switch 1) input ..................................................................................... 88
E-31 Abnormality in U switch (panel switch 1) input .................................................................................... 90
E-32 Abnormality in < switch (panel switch 2) input ...................................................................................... 92
E-33 Abnormality in > switch (panel switch 2) input ...................................................................................... 94
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04532-01
Method of using troubleshooting chart ............................................................................................................. 3
Table of failure 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
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
WA470, 480-6 00-100 13

100 Index
600 Troubleshooting of engine (S-mode) SEN04533-01

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
S-16 Vibration is excessive ........................................................................................................................... 26
50 Disassembly and assembly

100 General information on disassembly and assembly SEN04534-01
How to read this manual ............................................................................................................................... 2
Coating materials list..................................................................................................................................... 4
Special tools list............................................................................................................................................. 7
Sketches of special tools............................................................................................................................... 12
200 Engine and cooling system SEN04535-01
Removal and installation of engine assembly ............................................................................................... 2
Removal and installation of engine hood assembly ...................................................................................... 6
Removal and installation of radiator assembly.............................................................................................. 9
Removal and installation of aftercooler assembly ......................................................................................... 12
Removal and installation of oil cooler assembly ........................................................................................... 14
Removal and installation of cooling fan and drive motor assembly .............................................................. 16
Removal and installation of fuel supply pump assembly............................................................................... 20
Removal and installation of fuel injector assembly ....................................................................................... 26
Removal and installation of cylinder head assembly .................................................................................... 32
Removal and installation of engine front oil seal........................................................................................... 40
Removal and Installation of engine rear oil seal ........................................................................................... 43
Removal and installation of fuel tank assembly ............................................................................................ 48
301 Power train, Part 1 SEN04536-01
Removal and installation of torque converter and transmission assembly ................................................... 2
Disassembly and assembly of torque converter and transmission assembly ............................................... 7
Disassembly and assembly of torque converter assembly (Standard specification)..................................... 40
Disassembly and assembly of torque converter assembly (Lockup specification) ....................................... 45
Disassembly and assembly of clutch pack assembly ................................................................................... 53
302 Power train, Part 2 SEN04537-01
Removal and installation of front axle assembly ........................................................................................... 2
Removal and installation of rear axle assembly............................................................................................ 4
Disassembly and assembly of axle housing assembly ................................................................................. 10
Disassembly and assembly of differential assembly..................................................................................... 19
400 Brake system SEN04866-01
Removal and installation of parking brake disc and plate ............................................................................. 2
500 Undercarriage and frame SEN04538-01
Removal and installation of center hinge pin ................................................................................................ 2
Removal and installation of counterweight.................................................................................................... 10
600 Hydraulic system SEN04539-00
Removal and installation of steering demand valve assembly...................................................................... 2
Removal and installation of work equipment valve assembly ....................................................................... 5
00-100 14 WA470, 480-6

100 Index
Removal and installation of brake charge valve assembly ............................................................................ 8

Removal and installation of hydraulic tank assembly .................................................................................... 9
Removal and installation of steering and power train pump assembly.......................................................... 11
Removal and installation of work equipment and cooling fan pump assembly ............................................. 12
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 14
700 Work equipment SEN04540-00
Removal and installation of work equipment assembly ................................................................................. 2
800 Cab and its attachments SEN04541-00
Removal and installation of operator's cab and floor frame assembly .......................................................... 2
Removal and installation of operator's cab glass (stuck glass) ..................................................................... 6
Disassembly and assembly of operator's seat assembly .............................................................................. 14
Removal and installation of air conditioner unit assembly ............................................................................. 56
900 Electrical system SEN04542-00
Removal and installation of engine controller assembly................................................................................ 2
Removal and installation of transmission controller assembly ...................................................................... 3
Removal and installation of KOMTRAX terminal assembly........................................................................... 4
90 Diagrams and drawings

100 Hydraulic diagrams and drawings SEN04433-00
Power train hydraulic circuit diagram............................................................................................................. 2
Automatic greasing circuit diagram ............................................................................................................... 4
Hydraulic circuit diagram ............................................................................................................................... 7
200 Electrical diagrams and drawings SEN04434-00
Electrical circuit diagram (1/10) ..................................................................................................................... 3
Electrical circuit diagram (10/10) ................................................................................................................... 21
Work equipment controller system electrical circuit diagram......................................................................... 23
Connector list and stereogram ...................................................................................................................... 25
WA470, 480-6 00-100 15

SEN04418-02
WA470-6, WA480-6 Wheel loader

Form No. SEN04418-02
©2009 KOMATSU
All Rights Reserved
Printed in Japan 10-09 (01)
00-100 16
SEN04419-01
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
00 Index and foreword 00
200 Foreword and general information

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
WA470, 480-6 00-200 1

SEN04419-01 Safety notice
Safety notice (Rev. 2008/08)1

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.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before w elding work, alw ays wear welding
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 WA470, 480-6

Safety notice SEN04419-01
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. larly careful to check that they are
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
WA470, 480-6 00-200 3

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00-200 4 WA470, 480-6

Safety notice SEN04419-01
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, 480-6 00-200 5

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.
00-200 6 WA470, 480-6

How to read the shop manual SEN04419-01
How to read the shop manual 1
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.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
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.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
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.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
WA470, 480-6 00-200 7

SEN04419-01 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
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.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
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.
2 Coat Places to be coated with adhesives, etc. during 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 { }.
00-200 8 WA470, 480-6

Explanation of terms for maintenance standard SEN04419-01
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence from the standard size is called the
“tolerance”.
q The tolerance with the symbols of + or – is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
–0.022
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
WA470, 480-6 00-200 9

SEN04419-01 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the “interference”.
q The range (A – B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the “standard interference”.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the “repair
limit”.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the “allowable value” or
“allowable dimension”.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 WA470, 480-6

Handling of electric equipment and hydraulic component SEN04419-01
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and
“Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
WA470, 480-6 00-200 11

SEN04419-01 Handling of electric equipment and hydraulic component
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.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 WA470, 480-6

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
WA470, 480-6 00-200 13

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.
00-200 14 WA470, 480-6

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, 480-6 00-200 15

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oil and water from the com-
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 WA470, 480-6

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.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WA470, 480-6 00-200 17

Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
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.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-200 18 WA470, 480-6

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the
hydraulic oil.
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, 480-6 00-200 19

SEN04419-01 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 – 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 WA470, 480-6

Handling of connectors newly used for engines SEN04419-01
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WA470, 480-6 00-200 21

SEN04419-01 Handling of connectors newly used for engines
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)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it “clicks”.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 WA470, 480-6

How to read electric wire code SEN04419-01
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
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.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(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)
Insulator Soft polyvinyl chloride
automobile
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, 480-6 00-200 23

SEN04419-01 How to read electric wire code
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
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
00-200 24 WA470, 480-6

How to read electric wire code SEN04419-01
3. Color codes table
(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.
4. Types of circuits and color codes
(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, 480-6 00-200 25

SEN04419-01 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
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
00-200 26 WA470, 480-6

Precautions when carrying out operation SEN04419-01
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 – 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, “Bleeding air”.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see “Disassembly and assembly”.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
WA470, 480-6 00-200 27

SEN04419-01 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) Checking muffler function
Check the muffler for abnormal sound and sound different from that of a new muffler.
If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly
and assembly”.
00-200 28 WA470, 480-6

Method of disassembling and connecting push-pull type coupler SEN04419-01
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
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, 480-6 00-200 29

SEN04419-01 Method of disassembling and connecting push-pull type coupler
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
contacts contact surface (a) of the hexag-
00-200 30 WA470, 480-6

Method of disassembling and connecting push-pull type coupler SEN04419-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
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-
WA470, 480-6 00-200 31

SEN04419-01 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6.0 – 7.5
12 19 98 – 123 10.0 – 12.5
14 22 157 – 196 16 – 20
16 24 245 – 309 25 – 31.5
18 27 343 – 427 35 – 43.5
20 30 490 – 608 50 – 62
22 32 662 – 829 67.5 – 84.5
24 36 824 – 1,030 84 – 105
27 41 1,180 – 1,470 120 – 150
30 46 1,520 – 1,910 155 – 195
33 50 1,960 – 2,450 200 – 250
36 55 2,450 – 3,040 250 – 310
39 60 2,890 – 3,630 295 – 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 12 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 17 74.5 – 90.2 7.6 – 9.2
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.)
00-200 32 WA470, 480-6

Standard tightening torque table SEN04419-01
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 – 74 6.0 – 7.5
12 17 98 – 123 10.0 – 12.5
16 22 235 – 285 23.5 – 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 – 63 { 3.5 – 6.5} 44 { 4.5}
03,04 20 Varies depending 84 – 132 { 8.5 – 13.5} 103 {10.5}
05,06 24 on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0}
10,12 33 tor. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1,010 {76.0 – 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0}
33 33 – 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 – 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 – 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
WA470, 480-6 00-200 33

SEN04419-01 Standard tightening torque table
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.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No. –
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 – 54 { 3.5 – 5.5} – 9/16-18UN 14.3
02 19 44 { 4.5}
34 – 63 { 3.5 – 6.5} 14 – –
22 54 – 93 { 5.5 – 9.5} 74 { 7.5} – 11/16-16UN 17.5
03
24 59 – 98 { 6.0 – 10.0} 78 { 8.0} 18 – –
04 27 84 – 132 { 8.5 – 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. – Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 – 16 {1.4 – 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 – 27 {2.4 – 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 – 47 {4.4 – 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 – 68 {6.1 – 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 – 95 {9.2 – 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
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 — —
00-200 34 WA470, 480-6

Standard tightening torque table SEN04419-01
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.
Thread size Tightening torque

mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
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, 480-6 00-200 35

SEN04419-01 Conversion table
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
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

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
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
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
00-200 36 WA470, 480-6

Conversion table SEN04419-01
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
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
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, 480-6 00-200 37

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
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
00-200 38 WA470, 480-6

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, 480-6 00-200 39

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
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

–13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
–13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
–12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
–12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 40 WA470, 480-6

WA470, 480-6 00-200 41

SEN04419-01

©2008 KOMATSU
All Rights Reserved
00-200 42
SEN04420-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
01 Specification 01
100 Specification and technical data

Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
WA470, 480-6 01-100 1

SEN04420-00
01-100 2 WA470, 480-6

Specification dimension drawing SEN04420-00
Specification dimension drawing 1
WA470-6 WA480-6
Check item Unit
(in P-mode) (in P-mode)
Machine weight (with BOC) kg 22,880 24,925
Operating load kg 6,720 7,820
Bucket capacity (heaped, with BOC) m3 4.2 4.6
Engine model — KOMATSU SAA6D125E-5 Diesel engine
Rated engine output
• Net [ISO 9249/SAE J1349] (*1) 203 {272}/2,000 223 {299}/2,000
kW{HP}/rpm
• Gross [SAE J1995] (*2) 204 {273}/2,000 224 {300}/2,000
A Overall length (with BOC) mm 8,825 9,170
B Overall height mm 3,500 3,500
C Overall height at max. bucket raising distance mm 5,960 6,175
D Overall width mm 3,010 3,010
E Max. ground clearance mm 525 525
F Bucket width mm 3,170 3,170
G Dumping clearance (*3) Bucket tip/BOC tip mm 3,270/3,185 3,300/3,205
H Dumping reach (*3) Bucket tip/BOC tip mm 1,190/1,235 1,370/1,410
I Bucket forward tilting angle (max. height) deg. 45 45
Bucket tip/BOC tip mm 7,610/7,640 7,670/7,700
Min. turning radius
Center of outside tire mm 6,630 6,630
Allowable traction load kN {kg} 135 {13,720} 137 {13,930}
1st (forward/reverse) 7.6/7.9 7.7/7.9
2nd (forward/reverse) 13.1/13.5 13.1/13.5
Travel speed km/h
3rd (forward/reverse) 22.9/23.6 22.9/23.6
4th (forward/reverse) 36.2/37.3 36.3/37.4
*1:
Value at min. cooling fan speed.
*2:
Value of engine unit (without cooling fan).
*3:
Value at 45° of bucket forward tilting angle.
a The rated engine output is indicated by the net value or the gross value. The gross output is the value measured on
the engine unit and the net output is the value measured under almost the same condition as the engine is mounted
on the machine.
a The rated output (net) at the maximum cooling fan speed is as follows.
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, 480-6 01-100 3

SEN04420-00 Specifications
Specifications 1
Machine model WA470-6 WA480-6

Serial No. 90001 and up 90001 and up
Machine weight kg 22,880 24,925
Weight
Machine weight (front wheel)

kg 10,345 10,590
SAE travel posture
Machine weight (rear wheel)
kg 12,535 14,335
SAE travel posture
Bucket capacity (heaped) m3 4.2 4.6
Operating load kg 6,720 7,820
Travel speed E-mode P-mode E-mode P-mode
• Forward 1st 6.6 7.6 7.1 7.7
Performance
• Forward 2nd 11.4 13.1 12.2 13.1

km/h
• Forward 3rd 19.6 22.9 21.1 22.9
• Forward 4th 30.8 36.2 31.1 36.3
• Reverse 1st 6.8 7.9 7.3 7.9
• Reverse 2nd 11.7 13.5 12.6 13.5
km/h
• Reverse 3rd 20.2 23.6 21.7 23.6
• Reverse 4th 31.7 37.3 34.0 37.4
Maximum drawbar pull
• Forward 157 {16,000} 192 {19,600} 168 {17,100} 195 {19,900}
kN {kg}
• Reverse 151 {15,400} 181 {18,500} 162 {16,500} 192 {19,600}
Gradeability deg. 25 25
Minimum turning radius
mm 6,630 6,630
(center of outside tire)
Turning radius (cutting edge tip/BOC
mm 7,610/7,640 7,670/7,700
tip) SAE travel posture
Overall length (with BOC) mm 8,825 9,170
Overall width (machine body) mm 3,010 3,010
Bucket width (with BOC) mm 3,170 3,170
Overall height (cab top) mm 3,500 3,500
Overall height at max. bucket raising
mm 5,960 6,175
distance
Wheelbase mm 3,450 3,450
Tread mm 2,300 2,300
Dimensions
Max. ground clearance mm 525 525

Max. hinge pin height mm 4,360 4,505
Dumping clearance (*1)
mm 3,270/3,185 3,300/3,205
(cutting edge tip/BOC tip)
Dumping reach (*1)
mm 1,190/1,235 1,370/1,410
Steering angle deg. 35 35
Bucket backward tilting angle
deg. 50/65 52/60
(travel posture/max. height)
Bucket forward tilting angle
deg. 45 45
(max. height)
Digging depth, 10°
mm 265/315 305/355
*1: Value at 45° of bucket forward tilting angle.
01-100 4 WA470, 480-6

Specifications SEN04420-00

Model SAA6D125E-5
4-cycle, water-cooled, in-line vertical, direct injection,
Type
with turbocharger, air-cooled aftercooler, water-cooled EGR
No. of cylinders – bore x stroke mm 6 – 125 x 50
Total piston displacement l {cc} 11.04 {11,040}
Rated output
• Net [ISO 9249/SAE J1349] (*1) 203{272}/2,000 223{299}/2,000
kW{HP}/rpm
Performance
Engine
• Gross [SAE J1995] (*2) 204{273}/2,000 224{300}/2,000

(in P-mode)
Max. torque (*1) Nm{kgm}/rpm 1,307 {133}/1,450 1,360 {139}/1,400

g/kWh
Minimum fuel consumption ratio 192 {143} 192 {143}
{g/HPh}
High idle speed under no load rpm 2,170 ± 50 2,190 ± 50
Low idle speed under no load rpm 800 (+50/0) 800 (+50/0)
Starting motor 24 V, 7.5 kW 24 V, 7.5 kW
Alternator 24 V, 50 A 24 V, 50 A
Battery (*3) 12 V, 136 Ah x 2 pieces 12 V, 136 Ah x 2 pieces
Torque converter 3-element, 1-stage, 1-phase
Power train
Counter-shaft power shift, helical and spur gear constant

Transmission
mesh type, multi-disc type, hydraulic type, modulation
Reduction gear system Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type
Final drive Planetary gear single reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle
Front axle Fixed to frame, semi-floating type

Rear axle Center-pin support, semi-floating type
Size 26.5-25-16PR 26.5-25-20PR
Rim size 22.00-25WTB 22.00-25WTB
Tire
Inflation pressure
• Front wheel kPa 350 {3.5} 420 {4.2}
• Rear wheel {kg/cm2} 280 {2.8} 350 {3.5}
4-wheel braking, independent front and
Brake system
rear wheel brake systems
Main
Brake type Enclosed wet disc type

Brake
Operating system Hydraulic system

Control system With hydraulic booster
Brake system Transmission output shaft braking system
Parking
Brake type Wet disc type

Operating system Spring-operated, hydraulic release system
Steering
Steering system Articulation system
Operating system Hydraulic system
*1:
Value at minimum cooling fan speed.
*2:
Value of engine unit (without cooling fan).
*3:
The battery capacity (Ah) is the value on the 5-hour rate.
a The rated engine output is indicated by the net value or the gross value. The gross output is the value measured on
the engine unit and the net output is the value measured under almost the same condition as the engine is mounted
on the machine.
a The rated output (net) at the maximum cooling fan speed is as follows.
WA470-6: 191 kW {256 HP} / 2,000 rpm
WA480-6: 211 kW {283 HP} / 2,000 rpm
WA470, 480-6 01-100 5

SEN04420-00 Specifications
Machine model/type WA470-6 WA480-6

Power train charge pump
• Type Gear type Gear type
• Delivery cm3/rev 80 80
Power train lubrication pump
3
• Delivery cm /rev 32 32
Steering pump
• Type Variable displacement swash Variable displacement swash
Hydraulic pump
plate piston type plate piston type

Work equipment pump
Cooling fan pump
Emergency steering pump
Hydraulic system
Type Double acting piston Double acting piston
Steering cylinder
Cylinder bore mm 90 90
Piston rod outside diameter mm 50 50
Stroke mm 441 441
Max. distance between
mm 1,296 1,296
centers of pins
Min. distance between
mm 855 855
centers of pins
Lift cylinder

Cylinder
Stroke mm 764 881

mm 2,167 2,382
centers of pins
mm 1,403 1,501
centers of pins
Bucket cylinder

Stroke mm 575 572
mm 1,795 1,855
centers of pins
mm 1,220 1,283
centers of pins
01-100 6 WA470, 480-6

Specifications SEN04420-00

Work equipment control valve
Control valve
• Type 2-spool type 2-spool type

Hydraulic system
• Set pressure MPa {kg/cm2} 34.3 {350} 34.3 {350}

Steering valve
• Type Spool type Spool type
• Set pressure MPa {kg/cm }2
24.5 {250} 24.5 {250}
Cooling fan motor
Motor
• Type Fixed displacement swash Fixed displacement swash

• Motor capacity cm3/rev 28 28
equipment
Link type Z-bar link Z-bar link

Work
Bucket cutting edge shape Flat cutting edge with BOC Flat cutting edge with BOC
WA470, 480-6 01-100 7

SEN04420-00 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
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> 1,148 1,148
<With lockup clutch> 1,193 1,193
Center driver shaft 40 40
Front drive shaft 33 33
Rear drive shaft 20 22
Front axle
<With conventional differential> 1,238 1,283
<With limited slip differential> 1,250 1,295
Rear axle
<With conventional differential> 1,168 1,280
<With limited slip differential> 1,180 1,340
Axle pivot (rear axle) 144 144
Wheel
<22.00-25WTB (1 piece)> 251 251
Tire
<26.5-25-16PR (1 piece)> 404 —
<26.5-25-20PR (1 piece)> — 421
Power train pump 20 20
Work equipment pump 103 103
Steering pump 40 40
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 1,852 1,972
Rear frame 1,735 1,735
Counterweight 1,925 3,025
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
01-100 8 WA470, 480-6

Weight table SEN04420-00
Unit: kg
Lift arm (including bushing) 1,470 1,571
Bucket link 89 108
Bell crank 390 410
Bucket (3,170 mm wide, including BOC and side guard) 2,011 2,259
Operator cab (including floor assembly) 945 945
Operator seat 35 35
Air conditioner unit 5 5
Battery (1 piece) 45 45
WA470, 480-6 01-100 9

SEN04420-00 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of the notes (Note. 1, Note. 2…) in the table, see the Operation and Maintenance Manual.
01-100 10 WA470, 480-6

Table of fuel, coolant and lubricants SEN04420-00
Unit: l
WA470-6 WA480-6
Reservoir
Rated capacity Refill capacity Rated capacity Refill capacity
Engine oil pan 47 38 47 38
Transmission case 76 65 76 65
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, 480-6 01-100 11

SEN04420-00

©2008 KOMATSU
All Rights Reserved
01-100 12
SEN04421-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
10 Structure, function and

maintenance standard 10
100 Engine and cooling system

Engine mount and transmission mount........................................................................................................... 2
Cooling system ............................................................................................................................................... 3
Cooling fan pump............................................................................................................................................ 4
Cooling fan motor.......................................................................................................................................... 12
WA470, 480-6 10-100 1

SEN04421-00 Engine mount and transmission mount
Engine mount and transmission mount 1
Unit: mm
No. Check item Criteria Remedy
Clearance between transmission
1 mount bracket and adjustment bolt
2 – 2.5 Adjust
10-100 2 WA470, 480-6

Cooling system SEN04421-00
Cooling system 1
1. Radiator 6. Aftercooler
2. Oil cooler 7. Condenser
3. Power train oil cooler 8. Cooling fan
4. Reservoir tank 9. Cooling fan motor
5. Receiver
Specifications
Radiator Oil cooler Aftercooler Power train oil cooler
Core type AL WAVE-4 CF40-1 AL WAVE PTO-OL

*1
Fin pitch (mm) 3.5/2 3.5/2 4.0/2
100 x 558 x 20-stage
Total heat dissipation
55.14 x 2 4.25 x 2 23.32 2.152
surface (m2)
Pressure valve cracking 70 ± 15
— — —
pressure (kPa {kg/cm2}) {0.7 ± 0.15}
Vacuum valve cracking 0–5
— — —
pressure (kPa {kg/cm2}) {0 – 0.05}
*1: Size of element
WA470, 480-6 10-100 3

SEN04421-00 Cooling fan pump
Cooling fan pump 1
Type: LPV30
General view
P1: Pump discharge port TO: Drain port

PE: Control piston pressure input port PAEPC: EPC output pressure pickup plug
PH: Pump discharge pressure output port PEPC: EPC valve basic pressure input port
PS: Pump suction port
1. Servo valve
2. Air bleeder
3. Command current input connector
10-100 4 WA470, 480-6

Cooling fan pump SEN04421-00
Sectional view
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, 480-6 10-100 5

Function Structure
q The pump converts the speed and torque of q Cylinder block (7) is supported on shaft (1)
the engine transmitted to its shaft into hydraulic through spline (a). Shaft (1) is supported on
energy, and delivers pressurized oil according the front and rear bearings.
to the load. q The tip of piston (6) is shaped to a concave ball
q It is possible to change the delivery by chang- and integrated with caulked shoe (5). Piston
ing the swash plate angle. (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) in each cylinder chamber of cylinder
block (7) moves relatively in the axial direction.
q Cylinder block (7) rotates relatively to valve
plate (8) while sealing the pressurized oil so
that an appropriate oil pressure balance is
maintained on this surface.
q And oil in each cylinder chamber of cylinder
block (7) is available for suction or discharge
through valve plate (8).
10-100 6 WA470, 480-6

Operation
Operation of pump
q Cylinder block (7) rotates together with shaft q If center line (X) of rocker cam (4) comes in
(1) and shoe (5) slides on plane (A). At this line with the axial direction of cylinder block (7)
time, rocker cam (4) tilts using ball (11) as a (s wash plate angle = 0) , the differ enc e
fulcrum. As a result, angle (a) of the center line between volumes (E) and (F) inside cylinder
(X) of rocker cam (4) to the line in the axial block (7) becomes 0, and the pump does not
direction of cylinder block (7) changes. Angle carry out any suction or discharge of oil. (The
(a) is called the swash plate angle. swash plate angle is not set to 0 actually, how-
q If swash plate angle (a) is made between cen- ever.)
ter line (X) of rocker cam (4) and the axis of q In short, swash plate angle (a) and the pump
cylinder block (7), plane (A) works as a cam for delivery are interrelated.
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) suctions and discharges
oil by (F) – (E).
q In other words, when cylinder block (7) rotates
and the volume of chamber (E) becomes
smaller, the oil is discharged during that stroke.
On the other hand, the volume of chamber (F)
becomes larger, and the oil is sucked in during
that stroke. (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, 480-6 10-100 7

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 movement is transmitted to
rocker cam (4). Then, rocker cam (4) sup-
ported on ball (11) sways around ball (11).
10-100 8 WA470, 480-6

Servo valve
P: EPC valve basic pressure

T: Drain
PE: Control piston pressure
PH: Pump discharge pressure
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
WA470, 480-6 10-100 9

Function
q The servo valve controls the current input to q Then, land (PE) of the servo piston pressure
the EPC valve and pump delivery (Q) so that passage is connected to the pump discharge
they will be related as shown in the diagram. pressure passage (PH) by the notch of spool
(5) and the discharge pressure is led to the
servo piston.
q When the rocker cam is pushed up by the
servo piston, the position feedback is applied
and lever (2) moves to compress spring (8).
q If spool (5) is pushed back, the pump dis-
charge circuit is shut off from the servo piston
circuit.
q The pressure in the servo piston chamber low-
ers and the rocker cam returns toward the
maximum swash plate angle.
q These processes are repeated until the swash
plate is fixed to a position where the EPC out-
put pressure is balanced with the force of
q The output pressure of EPC valve is applied to spring (8).
the piston chamber to push piston (6). q The greater the EPC output pressure, the
q Piston (6) pushes spool (5) until the pressure is smaller the swash plate angle. Conversely, the
balanced with the spring force. smaller the EPC output pressure, the greater
the swash plate angle.
10-100 10 WA470, 480-6

WA470, 480-6 10-100 11

SEN04421-00 Cooling fan motor
Cooling fan motor 1
Type: LMF28
P: From fan pump

T: From cooler to tank
TC: To tank
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}
10-100 12 WA470, 480-6

Cooling fan motor SEN04421-00
1. Output shaft 7. End cover

2. Case 8. Center spring
3. Thrust plate 9. Check valve
4. Piston assembly 10. Pilot valve
5. Cylinder block 11. Spool for reversible valve
6. Valve plate 12. Safety valve
Unit: mm
Standard size Repair limit
Free length x
Outside Installed Installed load Free Installed load
13 Spool return spring diameter
length length If damaged or
deformed, replace
58.8 N 47.1 N spring
44.84 x 12 33 —
{6 kg} {4.8 kg}
1.96 N 1.57 N
14 Check valve spring 13.0 x 6.5 9.5 {0.2 kg} — {0.16 kg}
WA470, 480-6 10-100 13

Hydraulic motor
Function
q This hydraulic motor is called a swash plate
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump
into rotary motion.
Principle of operation
q The pressurized oil sent from the hydraulic
pump flows through valve plate (7) into cylin-
der block (5). This pressurized oil can flow into
only one side of the (Y – Y) line connecting pis-
tons (4) at top dead center and bottom dead
center.
q The oil sent to one side of cylinder block (5)
presses respective pistons (4) [2 or 3 pieces],
and generates force (F1) [F1 = P x xD2/4].
q This force is applied to thrust plate (2). Since
thrust plate (2) is fixed at the specified 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 x ri) against the (Y – Y) line connecting
the top dead center and bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q Since this cylinder block (5) is splined to the
output shaft, the output shaft revolves to trans-
mit the torque.
10-100 14 WA470, 480-6

Suction valve
Function When stopping

q If the pump stops, the pressurized oil does not q If the engine is stopped and the fan pump rev-
flow into the motor. However, since the motor olution turns to 0 rpm, the pressurized oil from
continues revolution because of the force of the pump is not supplied to the port (P) any
inertia, the pressure on the outlet side of the more. As the pressurized oil is not supplied to
motor rises. (MA) side of the motor, the motor speed lowers
q When the pressurized oil stops flowing in from gradually to stop.
inlet port (P), suction valve (1) suctions the q The motor shaft is revolved by the force of
pressurized oil on the outlet side and supplies inertia while the oil flow to port (P) is gradually
it to port (MA) where there is no sufficient pres- reduced, the oil of the outlet side port (T) is
surized oil. Accordingly, generation of cavita- supplied to (MA) side by suction valve (1) to
tion at port (MA) is prevented. prevent cavitation.
Operation
When starting
q The pressurized oil from the pump is supplied
to port (P), increasing the motor input (MA)
side pressure and generating the starting
torque on the motor. As the result, the motor
starts revolution. The pressurized oil on outlet
(MB) side of the motor returns to the tank
through port (T).
WA470, 480-6 10-100 15

Operation of reversible valve
When the ON/OFF solenoid is de-energized 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 fan 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)
to 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 the normal q Motor port (MB) opens and pressurized oil
direction (clockwise). flows in to revolve the motor in reverse (coun-
terclockwise).
10-100 16 WA470, 480-6

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, 480-6 10-100 17

SEN04421-00

©2008 KOMATSU
All Rights Reserved
10-100 18
SEN04422-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

200 Power train

Power train...................................................................................................................................................... 3
Power train system diagram ........................................................................................................................... 4
Drive shaft....................................................................................................................................................... 6
Power train piping diagram ............................................................................................................................. 7
Torque converter ............................................................................................................................................. 8
Transmission................................................................................................................................................. 16
Transmission control valve............................................................................................................................ 34
ECMV............................................................................................................................................................ 38
Main relief valve and torque converter relief valve........................................................................................ 50
Axle ............................................................................................................................................................... 52
Differential ..................................................................................................................................................... 56
Limited slip differential .................................................................................................................................. 61
Final drive ..................................................................................................................................................... 68
WA470, 480-6 10-200 1

200 Power train
SEN04422-00
10-200 2 WA470, 480-6

200 Power train
Power train SEN04422-00
Power train 1
1. Transmission 5. Rear drive shaft

2. Torque converter 6. Center drive shaft
3. Engine 7. Front drive shaft
4. Rear axle 8. Front axle
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, 480-6 10-200 3

200 Power train
SEN04422-00 Power train system diagram
Power train system diagram 1
10-200 4 WA470, 480-6

200 Power train
Power train system diagram SEN04422-00
1. Front axle Outline

2. Differential q The power from engine (15) is transmitted
3. Wet-type multiple disc brake through the flywheel of the engine to torque
4. Final drive converter (16).
5. Front drive shaft The torque converter converts the transmitted
6. Center drive shaft torque according to the fluctuation of the load
7. Parking brake (wet-type multiple disc) by using oil as a medium and transmits the
8. Transmission (counter-shaft type) power to the input shaft of transmission (8).
9. Rear drive shaft The engine power is also transmitted through
10. Rear tire the pump drive gear of the torque converter to
11. Final drive steering pump (19), cooling fan pump (20),
12. Wet-type multiple disc brake power train pump (17) and work equipment
13. Differential pump (18) to drive respective pumps.
14. Rear axle q The 6 hydraulic clutches of transmission (8)
15. Engine are operated with the directional valve and
16. Torque converter gear shift valve of the transmission valve to set
17. Power train pump the transmission to one of 4 gear speeds in the
18. Work equipment pump forward or reverse travel direction.
19. Steering pump q Parking brake (7) is a wet-type multiple disc
20. Cooling fan pump brake, which is installed to the front side of the
21. Flange bearing output shaft and used to stop the machine. It is
22. Front tire operated by the solenoid valve which is actu-
ated with the parking brake switch.
q The power of transmission (8) is transmitted to
the front and rear axles.
On the front side, the power is transmitted
through center drive shaft (6), flange bearing
(21), and front drive shaft (5) to front axle (1).
On the rear side, the power is transmitted
through rear drive shaft (9) to rear axle (14).
q The power transmitted to front axle (1) and
rear axle (14) is reduced in speed by the pinion
of differentials (2) and (13), and then transmit-
ted through the differential mechanism to the
sun gear shafts.
q The power of the sun gears is further reduced
in speed by final drives (4) and (11) of the plan-
etar y mechanis m, and then tr ansmitted
through the axle shafts to the wheels.
WA470, 480-6 10-200 5

200 Power train
SEN04422-00 Drive shaft
Drive shaft 1
a The figure shows WA480-6.
1. Front drive shaft Outline

2. Flange bearing q The power from the transmission output shaft
3. Center drive shaft is transmitted through center drive shaft (3),
4. Rear drive shaft front drive shaft (1), and rear drive shaft (4) to
the front axle and rear axle.
q When the machine is articulated or when it
receives traveling impacts or working impacts,
the distances between the transmission and
the front and rear axles change. The drive
shafts absorb fluctuations in the angle and
length with the universal joints and flange
bearing (2) so that the power will be transmit-
ted without damaging the parts even when the
machine is exposed to above impacts or
changes in the component positions.
10-200 6 WA470, 480-6

200 Power train
Power train piping diagram SEN04422-00
Power train piping diagram 1
1. Cooling fan pump 7. Transmission ECMV

2. Work equipment pump 8. Power train pump
3. Hydraulic tank 9. Oil filter
4. Power train oil cooler 10. Oil filler pipe
5. Steering pump 11. Transmission assembly
6. Last chance filter
WA470, 480-6 10-200 7

200 Power train
SEN04422-00 Torque converter
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: 97)
4. Boss 10. Stator shaft
5. Turbine 11. Transmission input shaft
6. Stator
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 2.17
10-200 8 WA470, 480-6

200 Power train
Torque converter SEN04422-00
Unit: mm
Standard size Tolerance Repair limit
1 Outside diameter of pilot –0.010 Repair by hard
78 77.95
–0.040 chromium-plating
Inside diameter of PTO gear seal +0.040 or replace
150 150.5
ring contact surface 0
–0.05
2 Width 4.5
–0.15
4.1
Wear of stator shaft
seal ring
Thickness 5.5 ±0.1 5.0 Replace
Backlash of PTO drive gear and

3 PTO gear
0.17 – 0.45
WA470, 480-6 10-200 9

200 Power train
Power transmitting route Flow of oil
Power generated by engine q The oil flows through the main relief valve and
its pressure is reduced to below the set pres-
O
sure by the torque converter relief valve, and
Flywheel (1) then it flows through inlet port (A) and oil pas-
O sage of stator shaft (1) to pump (2).
Drive case (2), pump (3) and PTO drive gear (4) q The oil is given centrifugal force by pump (2)
rotate as a unit and flows into turbine (3) to transmit its energy
O to turbine (3).
Oil is used as medium q The oil from turbine (3) is sent to stator (4) and
O flows into pump (2) again. However, part of the
oil flows through between turbine (3) and stator
Turbine (6) and boss (7)
(4) and to outlet port (B). It is then cooled in
O the oil cooler and used to lubricate the trans-
Transmission input shaft (8) mission.
q The power transmitted to PTO drive gear (4) is

used as power for driving the hydraulic pumps
after being transmitted through PTO gear (5).
10-200 10 WA470, 480-6

200 Power train
With lockup clutch
1. Pilot 10. PTO drive gear (number of teeth: 97)

2. Flywheel 11. Stator shaft
3. Lockup clutch housing 12. Guide
4. Boss 13. Transmission input shaft
5. Turbine 14. Free wheel
6. Drive case 15. Race
7. Stator 16. Lockup clutch disc
8. Pump 17. Lockup clutch piston
9. PTO gear
Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.17
WA470, 480-6 10-200 11

200 Power train
10-200 12 WA470, 480-6

200 Power train
Unit: mm
1 Outside diameter of pilot –0.010
78 77.95
–0.040
Inside diameter of pilot seal ring +0.025
2 contact surface
35
0
35.5
Repair by hard
Inside diameter of clutch piston +0.081 chromium-plating
3 seal ring contact surface
270
0
270.1 or replace
Inside diameter of clutch housing +0.089
335
0
335.1
Inside diameter of PTO drive gear +0.040
150
0
150.5
Inside diameter of free wheel
6 transfer surface of race
102.555 ±0.008 102.585
Outside diameter of free wheel +0.004
7 transfer surface of stator shaft
83.6
–0.009
83.57
Inside diameter of bushing sliding +0.015
8 part
83.71
0
83.79
9 Thickness of bushing sliding part 6 ±0.05 5.5 Replace
10 Thickness of clutch plate 5 ±0.1 4.5
11 Thickness of clutch disc 5 ±0.1 4.5
12 Backlash
PTO gear
of PTO drive gear and 0.17 – 0.45
WA470, 480-6 10-200 13

200 Power train
Power transmitting route
When lockup clutch is "disengaged" When lockup clutch is "engaged"
Drive case (3), boss (9) and turbine (8) are discon- Drive case (3), boss (9) and turbine (8) are con-
nected and the torque converter works as an ordi- nected and the torque converter carries out the
nary torque converter. lockup function.
Power generated by engine Power generated by engine

O O
Flywheel (1) Flywheel (1)
O O
Clutch housing (2) Clutch housing (2)
O O
Drive case (3), pump (5) and PTO drive gear (6) Drive case (3), pump (5) and PTO drive gear (6)
rotate as a unit rotate as a unit
O O
Oil is used as medium Lockup clutch (4)
O O
Turbine (8) and boss (9) Boss (9)
O O
Transmission input shaft (10) Transmission input shaft (10)
q The power transmitted to PTO drive gear (6) is q The power transmitted to PTO drive gear (6) is
used as power for driving the hydraulic pumps used as power for driving the hydraulic pumps
after being transmitted through PTO gear (7). after being transmitted through PTO gear (7).
10-200 14 WA470, 480-6

200 Power train
Flow of oil
q The oil flow passes through the main relief

valve and its pressure is reduced to below the
set pressure by the torque converter relief
valve. The oil then flows through inlet port (A)
and the oil passage of stator shaft (1) and
guide (2) to pump (3).
q The oil is given centrifugal force by pump (3)
and flows into turbine (4) to transmit its energy
to turbine (4).
q The oil from turbine (4) is sent to stator (5) and
flows into pump (3) again. However, part of the
oil flows through between turbine (4) and stator
(5) and to outlet port (B). It is then cooled in
the oil cooler and used to lubricate the trans-
mission.
WA470, 480-6 10-200 15

200 Power train
SEN04422-00 Transmission
Transmission 1
a Transmission with lockup clutch
10-200 16 WA470, 480-6

200 Power train
Transmission SEN04422-00
A: Form power train pump (for torque converter) Outline

B: From torque converter oil cooler q The transmission on this machine consists of
C: Torque converter outlet pressure pick-up port the counter-shaft constant gear mesh mecha-
D: To power train oil cooler nism and disc clutch that provides "4 forward
E: To power train pump gear speeds and 4 reverse gear speeds."
F: From power train pump (for lubrication) q The transmission selects 1 rotation direction
and 1 gear speed by hydraulically fixing the
1. Work equipment pump and cooling fan pump counter-shaft type constant mesh gear mecha-
mounting port nisms and 2 of 6 disc clutches with the ECMV.
2. Steering pump and power train pump mounting q The transmission transmits the power being
port transmitted to the transmission input shaft to
3. Oil filler pipe mounting port the output shaft after selecting a single speed
4. Front coupling from the 1st to 4th speeds both in the forward
5. Torque converter and reverse travel. In this case, the gear speed
6. Transmission control valve (Left valve assem- change is done by a combination of F or R
bly) clutch and a clutch out of 4 speed clutches.
7. Transmission input speed sensor
8. Parking brake indicator switch
9. Rear coupling Number of plates and discs used
10. Oil level gauge
Clutch No. Number of plates Number of discs
11. Transmission oil filter
F clutch 15 14
12. Transmission case (front)
13. Main relief valve and torque converter relief R clutch 15 14
valve 1st clutch 13 12
14. Transmission case (rear) 2nd clutch 13 12
15. Drain plug 3rd clutch 9 9
16. Transmission output speed sensor 4th clutch 13 12
17. Transmission lubricating oil temperature sensor
18. Breather
19. Torque converter outlet oil temperature sensor Combinations of clutches at respective gear
20. Transmission control valve (Right valve assem- speeds and reduction ratio
bly) Gear speed Clutch used Reduction ratio
Forward 1st F x 1st 3.886
Forward 2nd F x 2nd 2.196
Forward 3rd F x 3rd 1.218
Forward 4th F x 4th 0.737
Neutral — —
Reverse 1st R x 1st 3.760
Reverse 2nd R x 2nd 2.125
Reverse 3rd R x 3rd 1.179
Reverse 4th R x 4th 0.713
WA470, 480-6 10-200 17

200 Power train
1. Input shaft 11. Transfer gear 2

2. Torque converter 12. Lower shaft
3. F clutch 13. Transfer shaft 2
4. R clutch 14. 3rd clutch
5. 4th clutch 15. Middle shaft
6. Rear coupling 16. Transfer gear 1
7. Output shaft 17. 2nd clutch
8. Output gear (number of teeth: 52) 18. Upper shaft
9. Parking brake 19. 1st clutch
10. Front coupling
10-200 18 WA470, 480-6

200 Power train
WA470, 480-6 10-200 19

200 Power train
10-200 20 WA470, 480-6

200 Power train
Unit: mm
Standard Tolerance Standard Clearance
Clearance between input gear size Shaft Hole clearance limit
bearing and front case 0 0 –0.035 –
1 100 —
–0.015 –0.035 0.015
Clearance between input gear +0.030 0 –0.042 –
45 —
bearing and input gear +0.015 –0.012 –0.015
Clearance between input shaft 0 –0.012 –0.052 –
140 —
bearing and rear case –0.018 –0.052 0.006
2
Clearance between input shaft +0.045 0 –0.060 –
80 —
bearing and input shaft +0.030 –0.015 –0.030
Clearance between input shaft 0 0 –0.015 –
3 thrust bearing and input shaft
65
–0.019 –0.015 0.019
—
Clearance between upper shaft 0 –0.016 –0.038 –
4 bearing and cage
110
–0.018 –0.038 0.002
—
Clearance between upper shaft 0 0 –0.035 –
5 bearing and rear case
120
–0.018 –0.035 0.018
—
Clearance between transfer shaft 1 0 0 –0.040 –
6 bearing and front case (rear)
150
–0.018 –0.040 0.018
—
Clearance between middle shaft 0 0 –0.035 –
7 bearing and rear case
120
–0.015 –0.035 0.015
—
Clearance between lower shaft 0 0 –0.035 –
8 bearing and rear case 120 –0.015 –0.035 0.015 —
Clearance between transfer shaft 1 0 –0.012 –0.052 –
bearing and front case (front) 160 –0.025 –0.052 0.013 —
9
Clearance between transfer shaft 1 +0.035 0 –0.050 –
bearing and transfer shaft 1 75 +0.022 –0.015 –0.022 —
Clearance between transfer shaft 2 0 –0.016 –0.038 –
bearing and cage 120 –0.018 –0.038 0.002 —
10
bearing and transfer shaft 2 (front) 65 +0.022 –0.015 0.022 —
Clearance between transfer shaft 2 0 –0.012 –0.052 – Replace
bearing and front case 130 –0.020 –0.052 0.010 —
11
bearing and front case (rear) 75 +0.032 –0.015 0.032 —
Clearance between output shaft 0 –0.020 –0.045 –
bearing and retainer 130 –0.020 –0.045 0 —
12
Clearance between output shaft +0.039 0 –0.054 –
bearing and output shaft (front) 75 +0.020 –0.015 –0.020 —
Clearance between output shaft 0 –0.012 –0.052 –
160 —
bearing and front case –0.025 –0.052 0.013
13
Clearance between output shaft +0.039 0 –0.054 –
75 —
bearing and output shaft (rear) +0.020 –0.015 –0.020
14 and transfer gear 2
128
+0.092 –0.025 –0.092
–0.092
Inside diameter of input shaft seal
ring contact surface +0.05
60 60.1
15 0
+0.076
Width of input shaft seal ring groove 3.2 3.5
0
Inside diameter of upper shaft and
+0.05
middle shaft seal ring contact 55 55.1
0
16 surface
Width of upper shaft and middle +0.076
shaft seal ring groove 3.2 0 3.5
Inside diameter of lower shaft seal +0.05
ring contact surface 50 0 50.1
17
+0.076
Width of lower shaft seal ring groove 3.2 0 3.5
18 Outside diameter of front coupling

oil seal contact surface 95
0
–0.087 94.8
19 Outside diameter of rear coupling oil

seal contact surface 105
0
–0.087 104.8
WA470, 480-6 10-200 21

200 Power train
Unit: mm
Standard clearance Clearance limit
20 Clearance between upper shaft
cage and front case 1.51 – 2.15 —
(Standard shim thickness 1.83)
21 Clearance between lower shaft cage

and front case
0.92 – 2.02
—
Replace
22 Clearance between output shaft
retainer and housing
1.14 – 1.89
—
Output shaft free rotation torque
23 difference between before and after 0.49 – 2.94 Nm {0.05 – 0.30 kgm}
shim adjustment
10-200 22 WA470, 480-6

200 Power train
Unit: mm
Clearance between PTO gear size Shaft Hole clearance limit
bearing and cage 0 –0.006 –0.028 –
1 110 — Replace
–0.015 –0.028 0.009
Clearance between PTO gear +0.021 0 –0.036 –
60 —
bearing and PTO gear +0.002 –0.015 –0.002
2. PTO gear A (number of teeth: 85)

3. PTO gear B (number of teeth: 85)
4. Strainer
WA470, 480-6 10-200 23

200 Power train
F and 1st clutches
A: F clutch oil port C: Lubricating oil port

B: 1st clutch oil port
1. Upper shaft 4. F and 1st cylinders (number of teeth: 60)

2. 1st clutch gear (number of teeth: 35) 5. F clutch
3. 1st clutch 6. F clutch gear (number of teeth: 51)
Unit: mm
Clearance between input shaft size Shaft Hole clearance limit
7 bearing and input shaft (front)
50 0 +0.035 –0.047 – —
–0.012 +0.020 –0.020
Clearance between input shaft 0 +0.035 –0.050 –
8 bearing and input shaft (rear)
55
–0.015 +0.020 –0.020
—

Thickness 1.8 ±0.06 1.6
9 1st clutch plate
Strain — 0.05 0.15
Thickness 2 ±0.05 1.8

10 F clutch plate
Strain — 0.1 0.15
+0.05 Replace
Thickness 3 2.55
–0.10
11 1st clutch disc
Strain — 0.1 0.25
Thickness 3.2 ±0.08 2.82

12 F clutch disc
Strain — 0.1 0.25
13 Load of 1st clutch wave spring

[Testing height: 3.0 mm]
902 N
{92 kg}
±90 N
{±9.2 kg}
767 N
{78.2 kg}
14 Load of F clutch wave spring

1,106 N
{113 kg}
±57 N
{±5.8 kg}
942 N
{96.1 kg}
15 Thickness of 1st clutch thrust

washer (front)
3 ±0.1 2.7
16 Thickness of 1st clutch thrust

washer (rear)
4 ±0.2 3.7
10-200 24 WA470, 480-6

200 Power train
R and 2nd clutches
A: R clutch oil port C: Lubricating oil port

B: 2nd clutch oil port
1. Middle shaft 5. R and 2nd cylinders (number of teeth: 50)

2. Transfer shaft 1 (number of teeth: 64) 6. R clutch
3. 2nd hub 7. R gear (number of teeth: 51)
4. 2nd clutch
Unit: mm
Clearance between middle shaft size Shaft Hole clearance limit
8 bearing and transfer shaft
85 +0.045 0 –0.065 – —
+0.030 –0.020 –0.030
Clearance between middle shaft 120 0 +0.016 –0.006 – —
bearing and transfer shaft –0.015 –0.006 +0.031
9
Clearance between middle shaft 55 +0.035 0 –0.050 – —
bearing and middle shaft (front) +0.020 –0.015 –0.020
10 Clearance between middle shaft

bearing and middle shaft (rear)
55 +0.035
+0.020
0
–0.015
–0.050 –
–0.020
—

Thickness 1.8 ±0.06 1.6
11 2nd clutch plate
Strain — 0.05 0.15
Replace
Thickness 2 ±0.05 1.8
12 R clutch plate
Strain — 0.1 0.15
+0.05
Thickness 3 2.55
–0.10
13 2nd clutch disc
Strain — 0.1 0.25
Thickness 3.2 ±0.08 2.82

14 R clutch disc
Strain — 0.1 0.25
15 Load of 2nd clutch wave spring

902 N
{92 kg}
±90 N
{±9.2 kg}
767 N
{78.2 kg}
16 Load of R clutch wave spring

1,106 N
{113 kg}
±57 N
{±5.8 kg}
942 N
{96.1 kg}
WA470, 480-6 10-200 25

200 Power train
3rd and 4th clutches
A: 3rd clutch oil port C: Lubricating oil port

B: 4th clutch oil port
1. Lower shaft 5. 4th gear (number of teeth: 36)

2. 3rd cylinder 6. 4th clutch
3. 3rd clutch 7. 4th cylinder
4. 3rd gear (number of teeth: 48)
Unit: mm
Clearance between lower shaft size Shaft Hole clearance limit
8 bearing and lower shaft
55 +0.035 0 –0.050 – —
+0.020 –0.015 –0.020
Inside diameter of 3rd and 4th
clutch seal ring contact surface +0.050
60 60.1
9 0
Width of 3rd and 4th clutch seal +0.076
3.2 3.5
ring groove 0
Thickness 1.7 ±0.05 1.5
10 3rd clutch plate
Strain — 0.05 0.15
Thickness 2 ±0.05 1.8 Replace

11 4th clutch plate
Strain — 0.1 0.15
Thickness 2.2 ±0.08 1.6

12 3rd clutch disc
Strain — 0.1 0.25
Thickness 3.2 ±0.08 2.82

13 4th clutch disc
Strain — 0.1 0.25
14 Load of 3rd clutch wave spring

1,010 N
{103 kg}
±101 N
{±10.3 kg}
859 N
{87.6 kg}
15 Load of 4th clutch wave spring

813 N
{83 kg}
±40 N
{±4.1 kg}
691 N
{71 kg}
10-200 26 WA470, 480-6

200 Power train
Operation of the disc clutch
Clutch is "engaged" (fixed) Clutch is "disengaged" (released)
q The oil sent from the ECMV flows through the q When the oil sent from the ECMV is shut off,
oil passage in 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 a part of the 3rd and 4th
clutches.
WA470, 480-6 10-200 27

200 Power train
Power transmitting route

Forward 1st speed
F clutch (5) and 1st clutch (9) are fixed hydraulically.

Power from torque converter o (From left bottom) o (From center bottom)
O O O
Input shaft (1) 1st clutch (9) Output gear (24)
O O O
Input gear (2) 1st gear (10) Output shaft (25)
O O
F gear (3) Transfer shaft 1 (13)
O O
F clutch (5) Transfer gear 1 (14)
O O
F 1st cylinder (7) Transfer gear 2 (23)
O O
(to center top) o (to right top) o
10-200 28 WA470, 480-6

200 Power train
Forward 2nd speed
F clutch (5) and 2nd clutch (11) are fixed hydraulically.

Power from torque converter o (from left bottom) o (from center bottom)
O O O
Input shaft (1) 2nd clutch (11) Output shaft (25)
O O
Input gear (2) 2nd hub (12)
O O
F gear (3) Transfer shaft 1 (13)
O O
F clutch (5) Transfer gear 1 (14)
O O
F 1st cylinder (7) Transfer gear 2 (23)
O O
R 2nd cylinder (8) Output gear (24)
O O
WA470, 480-6 10-200 29

200 Power train
Forward 3rd speed
F clutch (5) and 3rd clutch (16) are fixed hydraulically.

O O O
Input shaft (1) 3rd gear (15) Output gear (24)
O O O
Input gear (2) 3rd clutch (16) Output shaft (25)
O O
F gear (3) 3rd cylinder (17)
O O
F clutch (5) Lower shaft (21)
O O
F 1st cylinder (7) Transfer shaft 2 (22)
O O
R 2nd cylinder (8) Transfer gear 2 (23)
O O
(to right top) o (to right top) o
10-200 30 WA470, 480-6

200 Power train
Forward 4th speed
F clutch (5) and 4th clutch (19) are fixed hydraulically.

O O O
Input shaft (1) 4th gear (18) Output gear (24)
O O O
Input gear (2) 4th clutch (19) Output shaft (25)
O O
F gear (3) 4th cylinder (20)
O O
F clutch (5) Lower shaft (21)
O O
F 1st cylinder (7) Transfer shaft 2 (22)
O O
R 2nd cylinder (8) Transfer gear 2 (23)
O O
(to right top) o (to right top) o
WA470, 480-6 10-200 31

200 Power train
Reverse 1st speed
R clutch (6) and 1st clutch (9) are fixed hydraulically.

O O O
Input shaft (1) R 2nd cylinder (8) Transfer gear 2 (23)
O O O
Input gear (2) F 1st cylinder (7) Output gear (24)
O O O
R gear (4) 1st clutch (9) Output shaft (25)
O O
R clutch (6) 1st gear (10)
(Output rotation direction is O
reversed by transmitting power of Transfer shaft 1 (13)
input gear (2) without through O
upper shaft) Transfer gear 1 (14)
O O
10-200 32 WA470, 480-6

200 Power train
WA470, 480-6 10-200 33

200 Power train
SEN04422-00 Transmission control valve
Transmission control valve 1
Left valve assembly
A: R clutch pressure pick-up port

B: 2nd clutch pressure pick-up port
C: 3rd clutch pressure pick-up port
D: From parking brake emergency release valve
E: To parking brake
F: Parking brake indicator switch mounting port
G: Parking brake oil pressure pick-up port
H: Transmission lubricating oil pressure pick-up port
1. R clutch ECMV
2. 2nd clutch ECMV
3. 3rd clutch ECMV
4. Parking brake solenoid valve
5. Last chance filter
10-200 34 WA470, 480-6

200 Power train
Transmission control valve SEN04422-00
Right valve assembly

A: Lockup clutch pressure pick-up port

B: F clutch pressure pick-up port
C: 1st clutch pressure pick-up port
D: 4th clutch pressure pick-up port
1. Lockup clutch ECMV

2. F clutch ECMV
3. 1st clutch ECMV
4. 4th clutch ECMV
WA470, 480-6 10-200 35

200 Power train
SEN04422-00 Transmission control valve
Operation table of ECMV

ECMV
F R 1st 2nd 3rd 4th L/U
Gear speed
F1 Q Q
F2 Q Q Q
F3 Q Q Q
F4 Q Q Q
R1 Q Q
R2 Q Q Q
R3 Q Q Q
R4 Q Q Q
L/U: Indicates the lockup clutch ECMV (if equipped).
Outline
q The oil from the pump flows through the oil filter to the transmission 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
keeps the clutch pressure constant during travel.
q If the F or R, and one out of 1st – 4th clutch ECMVs are selected, the regulated oil pressure is supplied
to the selected clutches to set the transmission to the desired travel direction and gear speed.
q In the 2nd, 3rd and 4th speed travel, the lockup clutch ECMV (if equipped) operates at a speed above
that being specified from the transmission controller.
q ECMV's of 3 kinds are used, which are identified and have differences as shown below.
Identification Fill switch
Printing on name plate Stamp
color Flow detector valve (operating pressure: Clutch used
(A) (C)
(B) MPa {kg/cm2})
Installed
L******* — — Not installed F, R, 1st, 2nd
(0.20 {2.0})
Installed
Q******* Pink S Installed 3rd, 4th
(0.24 {2.45})
K******* — — Not installed Not installed L/U
L/U: Indicates the lockup clutch ECMV (if equipped).
10-200 36 WA470, 480-6

200 Power train
Transmission control valve SEN04422-00
WA470, 480-6 10-200 37

200 Power train
SEN04422-00 ECMV
ECMV 1
a ECMV: Abbreviation for Electronic Control Modulation Valve
For F, R, 1st and 2nd clutches

a Don't try to disassemble ECMV since adjustment for maintaining the performance will be needed.
A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch pressure pick-up port
1. Fill switch connector

2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Name plate
10-200 38 WA470, 480-6

200 Power train
ECMV SEN04422-00
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
The proportional solenoid on this valve shown below according to the command cur-
receives the current sent from the transmission rent from the controller.
controller, and then this valve converts it into The thrust generated by the proportional sole-
oil pressure. noid is applied to the pressure control valve
q Fill switch spool to generate oil pressure as shown in the
This switch detects that the clutch is filled with figure below. Accordingly, for the purpose of
oil and has the following functions. controlling the oil flow and pressure, the com-
1. Outputs a signal (a fill signal), when the clutch mand current is controlled so that the thrust,
is filled with oil, to the controller to notify that which controls the pressure control valve, is
filling is completed. changed.
2. Keeps outputting signals (fill signals) to the
controller, while the oil pressure is applied to
the clutch, as the means to notify whether oil Current – thrust characteristics of proportional
pressure is applied or not. solenoid
Thrust – hydraulic pressure characteristics of

proportional solenoid
Range A: Before shifting gear (when draining)

Range B: During filling
Range C: Pressure regulation
Range D: During filling (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller will not

recognize completion of filling even if the fill
switch is turned "ON" during triggering (Range
D).
WA470, 480-6 10-200 39

200 Power train
SEN04422-00 ECMV
ECMV and fill switch Before shifting gear (when draining) (Range A
q For each ECMV, 1 fill switch is installed. in chart)
If the clutch is filled with oil, the fill switch is
turned "ON" by the pressure of the clutch. This
signal starts increasing the oil pressure.
Operation of ECMV
q ECMV is controlled with the command current
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current for ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
At this time, fill switch (5) is turned "OFF"
because oil pressure is not applied to pressure
detection valve (4).


D).
10-200 40 WA470, 480-6

200 Power train
ECMV SEN04422-00
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is applied to proportional solenoid (1) q When a current is supplied to proportional

with no oil in the clutch, the hydraulic force bal- solenoid (1), the solenoid generates thrust in
anced with the solenoid is applied to chamber proportion to the current. This thrust of the
(B) and pushes pressure control valve (3) to solenoid is balanced with the sum of the thrust
the left. This connects pump port (P) and generated by the oil pressure in clutch port and
clutch port (A) to feed oil into the clutch. When the reactive force of pressure control valve
the clutch is filled with oil, pressure detection spring (2), and then the pressure is settled.
valve (4) actuates to turn "ON" fill switch (5).
WA470, 480-6 10-200 41

200 Power train
SEN04422-00 ECMV
For 3rd and 4th clutches

A: To clutch
P: From pump
T: Drain
DR: Drain
1. Fill switch connector

3. Flow detector valve
4. Fill switch
7. Name plate
10-200 42 WA470, 480-6

200 Power train
ECMV SEN04422-00
Outline of ECMV ECMV and proportional solenoid

q The ECMV consists of 1 pressure control valve q For each ECMV, 1 proportional solenoid is
and 1 fill switch. installed.
q Pressure control valve The proportional solenoid generates thrust
The proportional solenoid on this valve shown below according to the command cur-
receives the current sent from the transmission rent from the controller.
controller, and then this valve converts it into The thrust generated by the proportional sole-
oil pressure. noid is applied to the pressure control valve
q Fill switch spool to generate oil pressure as shown in the
This switch detects that the clutch is filled with figure below. Accordingly, for the purpose of
oil and has the following functions. controlling the oil flow and pressure, the com-
1. Outputs a signal (a fill signal), when the clutch mand current is controlled so that the thrust,
is filled with oil, to the controller to notify that which controls the pressure control valve, is
filling is completed. changed.
2. Keeps outputting signals (fill signals) to the
controller, while the oil pressure is applied to
the clutch, as the means to notify whether oil Current – thrust characteristics of proportional
pressure is applied or not. solenoid
Thrust – hydraulic pressure characteristics of

proportional solenoid


D).
WA470, 480-6 10-200 43

200 Power train
SEN04422-00 ECMV
ECMV and fill switch Before shifting gear (when draining) (Range A
q For each ECMV, 1 fill switch is installed. in chart)
If the clutch is filled with oil, the fill switch is
turned "ON" by the pressure of the clutch. This
signal starts increasing the oil pressure.
Operation of ECMV
q ECMV is controlled with the command current
sent from the controller to the proportional
solenoid and the fill switch output signal.
The relationship between the proportional
solenoid command current for ECMV, clutch
input pressure, and fill switch output signal is
shown below.
q Under the condition where any current is not

sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
At this time, fill switch (5) is turned "OFF"
because oil pressure is not applied to flow
detector valve (4).


D).
10-200 44 WA470, 480-6

200 Power train
ECMV SEN04422-00
During filling (Range B in chart) Pressure adjustment (Range C in chart)
q If current is applied to proportional solenoid (1) q When a current is supplied to proportional

while no pressure is applied to the clutch pis- solenoid (1), the solenoid generates thrust in
ton, the thrust of the solenoid pushes ball (6) to proportion to the current. This thrust of the
the left to close the drain circuit. solenoid is balanced with the sum of the thrust
q A hydraulic force balanced with the thrust of generated by the oil pressure in clutch port and
the solenoid is applied to chamber (B) and the reactive force of pressure control valve
pressure control valve (3) moves to the left. spring (2), and then the pressure is settled.
q Oil starts filling the clutch chamber through
pump port (P) and orifice (a) of flow detector
valve (4).
q Differential pressure is generated between the
upstream side and downstream side of orifice
(a) of flow detector valve (4) and then flow
detector valve (4) moves to the left.
q If the clutch chamber is filled with oil and no oil
flows from pump port (P) to clutch port (A), the
differential pressure over orifice (a) of flow
detector valve (4) decreases to zero.
q Flow detector valve (4) is pushed back to the
right by the hydraulic force caused by the area
difference between the clutch port (A) side of
flow detector valve (4) and the drain port side
and fill switch (5) is turned "ON".
WA470, 480-6 10-200 45

200 Power train
SEN04422-00 ECMV
For lockup clutch

A: To clutch
P: From pump
T: Drain
DR: Drain

2. Sleeve
5. Name plate
10-200 46 WA470, 480-6

200 Power train
ECMV SEN04422-00
Outline of ECMV
q This valve is used to switch the clutch and to
regulate the clutch oil pressure to the set pres-
sure.
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. Above also
prevents generation of peak torque in the
power train. These arrangements make the
machine comfortable to operator and enhance
durability of the power train.
When changing from torque converter travel to

direct travel
At gear shift (in direct travel)
WA470, 480-6 10-200 47

200 Power train
SEN04422-00 ECMV
Operation
Clutch is "disengaged" (released) Clutch is "engaged" (fixed)
q Under the condition where any current is not q As current is conducted to proportional sole-
sent to the proportional solenoid (1), pressure noid (1), the oil pressure being balanced with
control valve (3) drains the oil from clutch port the solenoid force is applied to chamber (B),
(A) through drain port (T). pushing pressure control valve (3) leftward.
Above opens pump port (P) and clutch port (A)
to start filling oil to the clutch.
q If the clutch is filled with oil, this thrust of the
solenoid is balanced with the sum of the thrust
generated by the oil pressure in clutch port and
the reactive force of pressure control valve
spring (2), and then the pressure is settled.
10-200 48 WA470, 480-6

200 Power train
ECMV SEN04422-00
WA470, 480-6 10-200 49

200 Power train
SEN04422-00 Main relief valve and torque converter relief valve
Main relief valve and torque converter relief valve 1
Unit: mm
Clearance between main relief size Shaft Hole clearance limit
1 valve and valve body
28 –0.035 +0.013 0.035 – 0.078
–0.045 0 0.058
Clearance between torque
–0.035 +0.013 0.035 –
2 converter relief valve and valve 22 –0.045 0 0.058 0.078
body
Replace
Main relief valve spring Free length Installed Installed Free length Installed
3 (outside)
length load load
108 79.5 275 N 104.8 261 N
{28.0 kg} {26.6 kg}
Main relief valve spring 326 N 309 N
4 (inside)
108 79.5
{33.2 kg}
104.8
{31.5 kg}
Torque converter relief valve 173 N 164 N
5 spring
50 41
{17.6 kg}
48.5
{16.7 kg}
6. Body A: Drain (torque converter relief)

7. Piston B: Drain
8. Torque converter relief valve C: From pump
9. Piston D: Drain
10. Main relief valve E: To torque converter
P1: Main relief pressure pick-up port
P2: Torque converter relief pressure pick-up port
10-200 50 WA470, 480-6

200 Power train
Main relief valve and torque converter relief valve SEN04422-00
Outline
Torque converter relief valve Operation of main relief valve

q The torque converter relief valve constantly
regulates the torque converter inlet circuit
pressure below the set pressure to protect the
torque converter from abnormally high pres-
sure.
Set pressure: 0.91 MPa {9.31 kg/cm2}
(cracking pressure)
Main relief valve

q The main relief valve regulates the pressure in
the transmission and parking brake hydraulic
circuits to the set pressure.
Set pressure: 2.55 MPa {26.0 kg/cm2}
(at rated engine speed) q The oil from the hydraulic pump flows to port
(C) through the filter. Then it flows to chamber
(F) through orifice (a) in main relief valve (1).
Operation
Operation of torque converter relief valve
q When the oil pressure in the circuit goes

beyond the set pressure, the oil conducted to
q The oil relieved through the main relief valve chamber (F) pushes piston (2) and the result-
flows through port (E) into the torque con- ing pushing force against the spring force
verter. It also flows through orifice (b) in torque pushes main relief valve (1) leftward. This con-
converter relief valve (3) into chamber (G). nects ports (C) and (E).
q When the oil pressure to the torque converter Above operation conducts the oil from port (E)
goes beyond the set pressure, the oil con- to the torque converter.
ducted to chamber (G) pushes piston (4) and
the resulting pushing force pushes torque con-
verter relief valve (3) rightward. This connects
ports (E) and (A).
Then, the oil in port (E) is drained through port
(A).
WA470, 480-6 10-200 51

200 Power train
SEN04422-00 Axle
Axle 1
Front axle
WA470-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple disc brake
6. Coupling
7. Oil filler and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Brake wear gauge
10-200 52 WA470, 480-6

200 Power train
Axle SEN04422-00
WA480-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
8. Drain plug
9. Brake oil port
10. Air bleeder
WA470, 480-6 10-200 53

200 Power train
SEN04422-00 Axle
Rear axle
WA470-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
8. Drain plug
9. Brake oil port
10. Air bleeder
10-200 54 WA470, 480-6

200 Power train
Axle SEN04422-00
WA480-6
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
8. Drain plug
9. Brake oil port
10. Air bleeder
WA470, 480-6 10-200 55

200 Power train
SEN04422-00 Differential
Differential 1
Front differential
1. Pinion (number of teeth: 12)

2. Shaft
3. Bevel gear (number of teeth: 41)
4. Sun gear shaft
5. Bevel pinion (number of teeth: 10)
6. Side gear (number of teeth: 20)
10-200 56 WA470, 480-6

200 Power train
Differential SEN04422-00
Unit: mm
7 Thickness of pinion gear 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)
10 Thickness of shim in differential

side bearing carrier (one side)
0.30 – 1.25 Adjust
11 Backlash of bevel gear 0.30 – 0.41
12 End play of pinion

(or starting torque)
0 – 0.210
{1.5 – 1.7 kg (cage bolt hole)}
Replace

housing and cage assembly
1.49 ± 0.38 Adjust
WA470, 480-6 10-200 57

200 Power train
Rear differential

2. Shaft
4. Sun gear shaft
5. Bevel pinion (number of teeth: 10)
6. Side gear (number of teeth: 24 (WA470), 20 (WA480))
10-200 58 WA470, 480-6

200 Power train
Differential SEN04422-00
WA470-6
Unit: mm
3 ±0.08 2.8
Replace

side bearing carrier (one side)
0.30 – 1.25 Adjust

0 – 0.200
{1.0 – 1.1 kg (cage bolt hole)}
Replace

housing and cage assembly
1.26 ± 0.34 Adjust
WA480-6
Unit: mm
3 ±0.08 2.8 Replace

side bearing carrier (one side) 0.30 – 1.25 Adjust

0 – 0.210
{1.5 – 1.7 kg (cage bolt hole)} Replace

housing and cage assembly 1.49 ± 0.38 Adjust
WA470, 480-6 10-200 59

200 Power train
Outline While machine is traveling straight
q The power from the engine is transmitted to

the front and rear axles through the torque
converter, transmission and drive shaft.
q In each axle, the direction of the power is q While the machine is traveling straight, the
changed by 90° and the speed is reduced by right and left wheels rotate at the same speed.
bevel pinion (1) and bevel gear (5). Then, the Accordingly, pinion (4) in the differential
power is transmitted through pinion (4) to sun assembly does not rotate and the power of car-
gear shafts (2). rier (6) is transmitted through pinion (4) and
q Speed of the power transmitted to the sun gear side gear (3) to right and left sun gear shafts
is further reduced by the final drive of the plan- (2) evenly.
etary gear type, and then transmitted to the
axle shafts and wheels. When machine is turning
q While the machine is turning, the right and left

wheels rotate at different speeds. Accordingly,
pinion (4) and side gear (3) in the differential
rotate and transmit the power of carrier (6) to
sun gear shafts (2), depending on the differ-
ence in rotation speed between the right and
left wheels.
10-200 60 WA470, 480-6

200 Power train
Limited slip differential SEN04422-00
Limited slip differential 1

(If equipped)
a The figure shows the front axle.
1. Plate
2. Disc
4. Washer
5. Side gear (number of teeth: 24)
7. Shaft
8. Pressure ring
9. Case
WA470, 480-6 10-200 61

200 Power train
SEN04422-00 Limited slip differential
10-200 62 WA470, 480-6

200 Power train
Front axle
WA470-6
WA480-6
Unit: mm
1 Thickness of washer 4
±0.05 3.8
4.1
3.1
2 Thickness of plate ±0.02 3.0
3.2
3 Thickness of disc 3.6 ±0.07 3.5

Clearance between spider and size Shaft Hole clearance limit
4 differential pinion
35 –0.11 +0.05 0.110 – —
–0.16 0 0.210
Piston mounting portion of
–0.125 +0.089 0.125 –
5 differential housing (housing, 346
–0.214 0 0.303
—
piston)
Piston mounting portion of –0.125 +0.089 0.125 –
6 bearing carrier (piston, carrier)
326
–0.214 0 0.303
—
0 –0.045 –0.085 –
Clearance of Outer race 160 –0.025 –0.085 –0.020 —
Replace
7 differential side
bearing +0.059 0 –0.079 –
Inner race 105 +0.037 –0.020 –0.037 —
+0.025 –0.025 –0.079 –
Clearance of bearing Outer race 180.975 0 –0.054 –0.025 —
8 on pinion shaft gear
side +0.065 +0.013 –0.065 –
Inner race 76.2 +0.046 0 –0.033 —
Outer race 160 0 –0.050 –0.075 – —

Clearance of bearing –0.025 –0.075 –0.025
9 on pinion shaft
coupling side Inner race 75 +0.039 0 –0.054 – —
+0.020 –0.015 –0.020
10 Backlash between case and plate 0 – 0.5
11 Clearance between disc and plate

(total of clearance on both sides) 0.2 – 0.75
12 Backlash
disc
between side gear and
0.13 – 0.32
13 End play of side gear in axial

direction (each side) 0.2 – 0.4
WA470, 480-6 10-200 63

200 Power train
Rear axle
WA470-6
Unit: mm
±0.05 3.8
4.1
3.1
2 Thickness of plate ±0.02 3
3.2

4 differential pinion –0.110 +0.05 0.110 –
35 —
–0.160 0 0.210
–0.125 +0.089 0.125 –
5 differential housing (housing, 327 –0.214 0 0.303 —
piston)
307
–0.191 0 0.272
—
Outer race 160 0 –0.045 –0.085 – —

Clearance of –0.025 –0.085 –0.020 Replace
7 differential side
bearing Inner race 105 +0.059 0 –0.079 – —
+0.037 –0.020 –0.037
Outer race 171.45 +0.025 –0.025 –0.075 – —
Clearance of bearing 0 –0.050 –0.025
side Inner race 76.2 +0.065 +0.013 –0.065 – —
+0.046 0 –0.033
Outer race 150 0 –0.050 –0.075 – —
9 on pinion shaft
+0.020 –0.015 –0.020

(total of clearance on both sides)
0.2 – 0.75
12 Backlash
disc
between side gear and 0.09 – 0.39

direction (each side)
0.15 – 0.35
10-200 64 WA470, 480-6

200 Power train
Rear axle
WA480-6
Unit: mm
±0.05 3.8
4.1
3.1
2 Thickness of plate ±0.02 3.0
3.2

4 differential pinion –0.11 +0.05 0.110 –
35 —
–0.16 0 0.210
–0.125 +0.089 0.125 –
5 differential housing (housing, 346 –0.214 0 0.303 —
piston)
326
–0.214 0 0.303
—
Outer race 160 0 –0.045 –0.085 – —

Clearance of –0.025 –0.085 –0.020 Replace
7 differential side
bearing Inner race 105 +0.059 0 –0.079 – —
+0.037 –0.020 –0.037
Outer race 180.975 +0.025 –0.025 –0.079 – —
Clearance of bearing 0 –0.054 –0.025
side Inner race 76.2 +0.065 +0.013 –0.065 – —
+0.046 0 –0.033
Outer race 160 0 –0.050 –0.075 – —
9 on pinion shaft
+0.020 –0.015 –0.020

(total of clearance on both sides)
0.2 – 0.75
12 Backlash
disc
between side gear and 0.13 – 0.32

direction (each side)
0.2 – 0.4
WA470, 480-6 10-200 65

200 Power train
Operation of limited slip differential While machine is traveling straight

q The power from the transmission is transmitted When the drive forces of the right and left
through bevel gear (9), case (10), pressure wheels are balanced
ring (8), shaft (7), pinion (3) and side gear (5), [When the road conditions (coefficient of friction)
and then divided to the right and left shafts. under both wheels and the wheel loads are even,
q The brake unit consisting of disc (2) and plate and the center of load is at the center of the bucket]
(1) is installed to the back side of side gear (5).
It generates braking torque in proportion to the
torque transmitted from pressure ring (8) to
shaft (7).
q Since the brake torque restricts the rotation of
side gears (5) and case (10), right and left side
gears (5) cannot rotate freely. Thus, the opera-
tion of the differential is restricted.
Mechanism of generation of braking torque by

right and left side gears (5)
q Shaft (7) is supported on the cam surfaces

being provided on the surfaces of pressure
rings (8) that are facing each other.
q The power (= torque) transmitted from pres-
sure rings (8) to shaft (7) is transmitted on the q The power from the transmission is distributed
cam surfaces. Force (Fa) to separate pressure evenly by the differential gears to the right and
rings (8) from each other is generated by incli- left. Under this condition, the slip limits of the
nation of the cam surfaces in proportion to the right and left wheels are the same. Accord-
transmitted torque. ingly, even if the power from the transmission
q Separating load (Fa) acts on the brake on the may exceed the slip limits, both wheels slip
back side of each side gear (5) to generate and the differential does not work.
braking torque. No load is applied to the brake on the back
side of the side gear.
10-200 66 WA470, 480-6

200 Power train
When the drive forces of the right and left Difference in wheel drive force by type of differen-
wheels are unbalanced tials when either wheel slipped
[When the road conditions (coefficient of friction) Wheel drive force
under both wheels and the wheel loads are uneven, (drive force of slipping wheel is 1)
and either wheel slips more easily] Slipping Locked Total
Example 1. When either wheel is on soft ground in wheel wheel (Ratio)
digging work Limited slip
differential 1 2.64 3.64 (1.82)
Example 2. When either wheel is on snow and the
Conventional 1 1 2 (1)
other one is on asphalt in snow remov- differential
ing work
Example 3. When the right and left wheel loads
are unbalanced in travel on a slope Conventional differential
q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.82 times of the conventional dif-
ferential.
While machine is turning
q The same gears as that for the conventional

differential are employed for the limited slip dif-
ferential. Thus, they allow to smoothly gener-
ate a difference in rotation speed between the
outer and inner wheels that is necessary for
tuning.
q The power from the transmission is evenly

divided between the right and left by the differ-
ential gear. If, however, the divided drive force
exceeds the wheel slip limit of the slip side,
surplus of the driving force is transmitted to the
opposite side (lock side) brake through the
brake and case on the gear back side. Then
the power is distributed to the lock side wheel.
q The differential starts working only as the sur-
plus portion of the drive force has exceeded
the braking force.
WA470, 480-6 10-200 67

200 Power train
SEN04422-00 Final drive
Final drive 1
WA470-6
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)
10-200 68 WA470, 480-6

200 Power train
Final drive SEN04422-00
WA470-6 Front
Unit: mm
Clearance between planetary size Shaft Hole clearance limit
6 gear bearing and shaft +0.013 0 –0.025 – Replace
45 —
+0.002 –0.012 –0.002
Clearance between axle housing +0.1 +0.1
7 and ring gear
404
0 0
–0.1 – 0.1 —
Clearance between oil seal and
8 housing
Max. 0.2 Adjust
+0.500 +0.072 –0.050 –
Housing 200 —
Press fitting part of +0.300 0 –0.028
9 axle shaft seal 0 –0.300 –0.500 –
Shaft 160 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
Clearance of press Outer race 196.85 —
0 –0.060 –0.014
10 fitting part of axle
housing bearing +0.068 +0.025 –0.068 –
Inner race 133.35 —
+0.043 0 –0.018
+0.025 –0.014 –0.085 – Replace
0 –0.060 –0.014
housing bearing +0.058 +0.025 –0.058 –
Inner race 114.3 +0.036 0 –0.011 —
+0.025 +0.207 0.120 –
12 Clearance of guide pin 12 +0.007 +0.145 0.200 —
13 Thickness of washer
2 ±0.05 1.8
WA470-6 Rear
Unit: mm
40 —
+0.002 –0.012 –0.002
7 and ring gear
382
0 0
–0.1 – 0.1 —
8 housing
Max. 0.2 Adjust
Housing 200 +0.500 +0.072 –0.050 – —

9 axle shaft seal 0 –0.300 –0.500 –
Shaft 160 —
–0.063 –0.500 –0.237
Outer race 196.85 +0.025 –0.014 –0.085 – —
Clearance of press 0 –0.060 –0.014
housing bearing Inner race 133.35 +0.068 +0.025 –0.068 – —
+0.043 0 –0.018
Outer race 160 0 –0.045 –0.085 – —
Replace
Clearance of press –0.025 –0.085 –0.020
housing bearing Inner race 105 +0.035 0 –0.055 – —
+0.013 –0.020 –0.013
+0.025 +0.207 0.120 –
12 Clearance of guide pin 12
+0.007 +0.145 0.200
—
2 ±0.05 1.8
WA470, 480-6 10-200 69

200 Power train
WA480-6
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)
10-200 70 WA470, 480-6

200 Power train
WA480-6 Front
Unit: mm
6 gear bearing and shaft +0.013 0 -0.025 – Replace
45 —
+0.002 –0.012 -0.002
7 and ring gear
404
0 0
–0.1 – 0.1 —
8 housing
Max. 0.2 Adjust
+0.500 +0.072 –0.050 –
Housing 240 —
9 axle shaft seal 0 –0.300 –0.500 –
Shaft 180 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
0 –0.060 –0.014
housing bearing +0.068 +0.025 –0.068 –
Inner race 146.05 —
+0.043 0 –0.018
+0.025 –0.014 –0.085 – Replace
0 –0.060 –0.014
housing bearing +0.058 +0.025 –0.058 –
Inner race 114.3 +0.036 0 –0.011 —
+0.025 +0.207 0.120 –
2 ±0.05 1.8
WA480-6 Rear
Unit: mm
45 +0.002 –0.012 –0.002 —
7 and ring gear
403.4
0 0
–0.1 – 0.1 —
8 housing
Max. 0.2 Adjust
+0.500 +0.072 –0.050 –
Housing 240 —
9 axle shaft seal 0 –0.300 –0.500 –
Shaft 180 —
–0.063 –0.500 –0.237
+0.025 –0.014 –0.085 –
Clearance of press Outer race 236.538 0 –0.060 –0.014 —
housing bearing +0.068 +0.025 –0.068 –
Inner race 146.05 +0.043 0 –0.018 —
+0.025 –0.014 –0.085 – Replace
Clearance of press Outer race 177.8 0 –0.060 –0.014 —
housing bearing +0.058 +0.025 –0.058 –
Inner race 114.3 +0.036 0 –0.011 —
+0.025 +0.207 0.120 –
2 ±0.05 1.8
WA470, 480-6 10-200 71

200 Power train
Outline

q The final drive finally reduces speed of the
power from the engine 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 being transmitted 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.
10-200 72 WA470, 480-6

200 Power train
WA470, 480-6 10-200 73

SEN04422-00

©2008 KOMATSU
All Rights Reserved
10-200 74
SEN04423-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

300 Steering system

Steering component layout drawing................................................................................................................ 2
Steering column .............................................................................................................................................. 3
Steering pump................................................................................................................................................. 4
Steering valve ............................................................................................................................................... 17
Orbit-roll valve............................................................................................................................................... 34
Stop valve ..................................................................................................................................................... 42
Steering relief valve....................................................................................................................................... 43
Steering cylinder ........................................................................................................................................... 44
Emergency steering motor............................................................................................................................ 46
Emergency steering pump ............................................................................................................................ 47
Joystick steering lever linkage ...................................................................................................................... 48
Electrical steering lever................................................................................................................................. 49
Joystick EPC valve ....................................................................................................................................... 50
WA470, 480-6 10-300 1

300 Steering system
SEN04423-00 Steering component layout drawing
Steering component layout drawing 1
1. Steering cylinder (right) 7. Hydraulic tank

2. Steering valve 8. Emergency steering motor (if equipped)
3. Orbit-roll valve 9. Emergency steering pump (if equipped)
4. Stop valve (right) 10. Steering relief valve (if equipped)
5. Power train pump 11. Stop valve (left)
6. Steering pump 12. Steering cylinder (left)
10-300 2 WA470, 480-6

300 Steering system
Steering column SEN04423-00
Steering column 1
1. Steering wheel
2. Steering column
3. Tilt lever
4. Short column
5. Orbit-roll valve
Unit: mm
Clearance between steering shaft size Shaft Hole clearance limit
6 and column bushing Replace
0 +0.15
19 0.05 – 0.23 0.4
–0.08 +0.05
WA470, 480-6 10-300 3

300 Steering system
SEN04423-00 Steering pump
Steering pump 1
Type: LPV90
General view
P1: Pump discharge port PEPC: EPC basic pressure input port
P1L: Pump pressure input port PLS: Load pressure input port
PD: Drain port POP: External pilot pressure input port
PD2: Drain plug PS: Pump suction port
PEN: Control pressure pickup plug
1. Pump unit 2. Servo valve 3. Air bleeder 4. Block
10-300 4 WA470, 480-6

300 Steering system
Steering pump SEN04423-00
Pump unit
General view
P10: Pump pressure output port

PA: Control basic pressure output port
PD4: Drain port
PD5: Drain port
PDE: EPC drain port
PE: Control pressure input port
PEPC: EPC basic pressure input port
WA470, 480-6 10-300 5

300 Steering system
Sectional view
1. Bearing 9. End cap

2. Shaft 10. Shoe retainer
3. Case 11. Servo piston
4. Rocker cam 12. Spring
5. Shoe 13. Sleeve
6. Piston 14. Oil seal
7. Cylinder block 15. Ball
8. Valve plate
10-300 6 WA470, 480-6

300 Steering system
Function Structure
q The pump converts the engine rotation and q Cylinder block (6) is supported to shaft (1) by
torque transmitted to its shaft to oil pressure spline (a), and shaft (1) is supported by the
and delivers pressurized oil corresponding to front and rear bearings.
the load. q The tip of piston (5) has a spherical hollow and
q It is possible to change the delivery by chang- is joined with shoe (4) by caulking to form one
ing the swash plate angle. unit. 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 chamber of cylinder
block (6) performs relative movement in the
axial direction.
q Cylinder block (6) slides circularly on valve
plate (7) while sealing the pressurized oil, and
oil pressure balance on the valve plate is main-
tained properly.
q The pressurized oil in each cylinder in cylinder
block (6) is suctioned and discharged through
valve plate (7).
WA470, 480-6 10-300 7

300 Steering system
Operation
Operation of pump
q Cylinder block (6) rotates together with shaft q When center line (X) of rocker cam (3)
(1) and shoe (4) slides on plane (A). At this matches with the axis of cylinder block (6) (the
time, rocker cam (3) tilts using ball (9) as a ful- swash plate angle is zero), the difference
crum. As a result, angle (a) of center line (X) of between volumes (E) and (F) in cylinder block
rocker cam (3) to the line in axial direction of (6) is 0, so the oil is not sucked or discharged.
cylinder block (6) changes. Angle (a) is called (The swash plate angle is not set to 0 actually,
the swash plate angle. however.)
q In short, swash plate angle (a) and the pump
delivery are interrelated.
q If angle (a) is made between center line (X) of

rocker cam (3) and the axis of cylinder block
(6), plane (A) works as a cam for shoe (4).
q Accordingly, piston (5) slides on the inside of
cylinder block (6) and a difference is made
between volumes (E) and (F) in cylinder block
(6). As a result, each piston sucks and dis-
charges oil by the amount (F) minus (E).
q In other words, as cylinder block (6) rotates
and the volume of chamber (E) becomes
smaller, the pressurized oil is discharged dur-
ing this process. On the other hand, the vol-
ume of chamber (F) becomes larger and the oil
is sucked in this process. (In the figure, cham-
ber (F) is at the end of the suction stroke and
chamber (E) is at the end of the discharge
stroke.)
10-300 8 WA470, 480-6

300 Steering system
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
(11).
ing to the signal pressure of the PC valve and
LS valve. This straight line movement is trans-
mitted to rocker cam (3). Then, rocker cam (3)
supported on case (2) through ball (9) slides in
rotation direction.
WA470, 480-6 10-300 9

300 Steering system
Servo valve
10-300 10 WA470, 480-6

300 Steering system
IM: PC mode selector current connector

P1: Pump pressure port
P1L: Pump pressure input port
PD: Drain port
PDE: EPC drain port
PE: Control piston pressure port
PEPC: EPC basic pressure input port
PLS: Load pressure input port
T: Drain port
1. Lever
2. Spool
3. Plug
4. Seat
5. PC-EPC valve
6. Piston
7. Sleeve
8. Plug
9. Locknut
10. Spring
11. Spool
12. Ball
13. Plug
14. LS valve
15. PC valve
WA470, 480-6 10-300 11

300 Steering system
LS valve
Function
q The LS valve controls the pump delivery
according to the stroke of the control lever, or
the demand flow for the actuator.
q The LS valve detects the flow rate demanded
by the actuator by using the differential pres-
sure (dPLS) between control valve inlet pres-
sure (PPLS) and control valve outlet pressure
(PLS), and controls main pump delivery (Q).
((PPLS) stands for the LS pump pressure,
(PLS) the LS pressure, and (dPLS) the LS dif-
ferential pressure.)
q In other words, the pressure loss caused by
flow of oil through the open area of the control
valve spool (= LS differential pressure (dPLS))
is detected, and then pump delivery (Q) is con-
trolled to keep that pressure loss constant and
supply the pump delivery according to the
demand flow for the actuator.
q For the purpose of implementing this control,
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 (dPLS) and pump
delivery (Q) changes as shown below.
10-300 12 WA470, 480-6

300 Steering system
PC valve
Function When pump pressure (P1) is low

q The PC valve limits the oil flow to a certain q The pressing force of spool (10) is decreased
level (according to the discharge pressure) and spool (6) is a little to the right (Fig. 1). At
even if the travel of the control valve is this time, ports (C) and (D) are connected to
increased extremely so that the horsepower each other and the pressure in the LS valve is
absorbed by the pump will not exceed the drain pressure (PT).
engine horsepower, when pump discharge q At this time, ports (F) and (G) of the LS valve
pressure (P1) is high. are connected to each other. As a result, the
q In other words, the PC valve decreases the pressure in port (J) becomes drain pressure
pump delivery when the load on the actuator is (PT) and servo piston (9) moves to the left.
increased and the pump discharge pressure q Consequently, the pump delivery is increased.
rises, and increases it when the pump dis- q As servo piston (9) moves, lever (2) moves to
charge pressure lowers. the left and spring (3) expands, weakening its
q If the command current (X) sent to the EPC spring force. Consequently, spool (6) moves to
valve increases, the relationship between the left, disconnecting between ports (C) and
pump pressure (P1) and pump delivery (Q) (D) and connecting pump discharge pressure
moves in parallel in proportion to the thrust of ports (B) and (C).
the EPC valve solenoid. q As a result, the pressure in port (C) rises and
q In other words, the thrust of the EPC valve the piston pressure is increased and servo pis-
solenoid is added to the left-side thrust that is ton (9) stops moving to the left.
caused by the pump pressure applied to spool
(6). The relationship between pump pressure When pump pressure (P1) is high
(P1) and pump delivery (Q) therefore moves q The pressure of spool (10) is increased and
from (Y) to (Z) as the command current (X) spool (6) is a little to the left (Fig. 2). At this
increases. time, ports (C) and (B) are connected to each
oth er and t he pr e ss u re i n th e LS v al v e
becomes pump pressure (P1).
q At this time, ports (F) and (G) of the LS valve
are connected each other. As a result, the
pressure in port (J) becomes pump pressure
(P1) and servo piston (9) moves to the right.
q Consequently, the pump delivery is decreased.
q As servo piston (9) moves, lever (2) moves to
t he r ight and spr ing ( 3) is c ompr essed,
strengthening its spring force. Consequently,
spool (6) moves to the right, disconnecting
ports (C) and (B) and connecting drain pres-
sure ports (D) and (C).
q As a result, the pressure in port (C) lowers and
the piston pressure is decreased and servo
Operation piston (9) stops moving to the right.
q Accordingly, the stopping position (= pump
Action of spring delivery) of servo piston (9) is decided by the
q The spring load of spring (3) at the PC valve is position where the thrust caused by pressure
decided by the position of the swash plate. (P1) applied to spool (10) is balanced, through
q If servo piston (9) moves to the right, spring (3) spool (6), with the force of spring (3). (Fig. 3)
is compressed through lever (2) and the load
on the spring changes. When PC mode selector pressure increases or
decreases
q PC-EPC valve changes the output pressure
(PM) with the command current (X) from the
controller, and acts in the same way as when
pressure (P1) increases or decreases as the
thrust of spool (8) changes.
WA470, 480-6 10-300 13

300 Steering system
When load is light

(Fig. 1)
When load is heavy

(Fig. 2)
10-300 14 WA470, 480-6

300 Steering system
When balanced
(Fig. 3)
WA470, 480-6 10-300 15

300 Steering system
10-300 16 WA470, 480-6

300 Steering system
Steering valve SEN04423-00
Steering valve 1
P: From steering pump

Pr: To steering pump port P1L
Pa: From stop valve (left)
Pb: From stop valve (right)
A: To steering cylinder
B: To steering cylinder
T1: Drain
T2: Drain
WA470, 480-6 10-300 17

300 Steering system
SEN04423-00 Steering valve
10-300 18 WA470, 480-6

300 Steering system
1. Relief valve 4. Steering spool

2. Flow control spool 5. Overload relief valve
3. Steering relief valve
Unit: mm
Installed Installed Installed
Free length Free length
6 Steering spool return spring length load load
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, 480-6 10-300 19

300 Steering system
Operation of flow amplifier
Spool at NEUTRAL
(when Orbit-roll valve is not in operation)
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).
Spool in operation
(when oil flows in port (Pa))
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 proportional 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 reactive force of
return spring (2).
10-300 20 WA470, 480-6

300 Steering system
When spool is returned

(when steering wheel operation is stopped)
q Since both ports (Pa) and (Pb) are connected through the Orbit-roll valve to the drain circuit, steering
spool (1) is pushed back to neutral by left return spring (2).
WA470, 480-6 10-300 21

300 Steering system
Operation of flow control spool
When steering spool is at neutral position
q The oil from the steering pump flows into port q The oil pressure in port (Pr) becomes a value
(P). between the pump pressure and drain pres-
q Since notch (e) is closed, the oil pressure in sure of port (T2) because of the resistance
port (P) is increased and then led through ori- which the oil flow encounters when passing
fice (a) to chamber receiving the pressure (X) through notch (c) and orifice (j).
to move flow control spool (1) to the left. q If the oil pressure in port (Pr) rises above the
q The oil in chamber receiving the pressure (Y) set pressure, the swash plate angle of the
is drained from port (T1) through orifice (b) and steering pump is reduced to reduce the deliv-
notch (f). ery.
q If the oil pressure in chamber receiving the q If the oil pressure in port (P) keeps rising after
pressure (X) rises above the set pressure, flow the delivery of the pump is minimized, flow
control spool (1) moves to the left to open control spool (1) moves to the left further.
notch (c). q If the oil pressure in chamber receiving the
q The oil in port (P) flows through notch (c) and pressure (X) rises above the set pressure,
port (Pr) to the LS valve of the steering pump. notch (d) opens and the oil in port (P) is
q Port (Pr) is connected through orifice (j) to port drained from port (T1) through notch (d).
(T2).
10-300 22 WA470, 480-6

300 Steering system
Steering spool in operation
q If steering spool (2) operates, notch (f) closes q Since flow control spool (1) works to keep the
and chamber receiving the pressure (Y) and differential pressure across notch (e) to the
port (T1) are disconnected and notch (e) preset pressure, the oil is discharged to the
opens. steering cylinder according to the opening rate
q The oil pressure in chamber receiving the of notch (e).
pressure (Y) rises and flow control spool (1) q The excessive oil from the steering pump is
moves to the right and the opening area of drained from port (T1) through notch (d).
notch (d) reduces. q The oil returning from the steering cylinder is
q The oil before notch (e) is led to chamber drained from port (T1) through orifice (g).
receiving the pressure (X) and the oil after q Even after flow control spool (1) moves to the
notch (e) is led to chamber receiving the pres- right to close notch (d), it moves further to the
sure (Y). right, when the pressure before notch (e) is
q If the oil pressure in chamber receiving the below the preset pressure.
pressure (Y) rises higher than that in port (A), q Since the opening area of notch (c) reduces,
the oil flowing from orifice (h) pushes and the oil flow into port (Pr) is reduced and the oil
opens load check valve (3) to the left. pressure in port (Pr) lowers.
q Since the oil from notch (e) flows through port q If the oil pressure in port (Pr) lowers, the LS
(A) to the steering cylinder, a pressure differ- valve of the steering pump increases the deliv-
ence is made between before and after notch ery of the pump to keep the oil pressure in port
(e). (Pr) to the preset pressure.
WA470, 480-6 10-300 23

300 Steering system
q Flow control spool (1) is held at a position

where the pressure in port (P) is balanced with
the pressure in port (Pr), thus the delivery of
the pump is kept constant.
q If the opening rate of notch (e) changes, the
steering pump delivers the amount of oil corre-
sponding to the opening rate of notch (e) in
order to keep the oil pressure in port (Pr) con-
stant.
10-300 24 WA470, 480-6

300 Steering system
Operation of steering valve
When in neutral
q Since the steering wheel is not operated,

steering spool (1) does not move.
q The oil from the steering pump flows into port
(P).
q If the oil pressure in port (P) rises, flow control
spool (2) moves to the left, and the oil from the
steering pump is drained from port (T1)
through notch (a).
WA470, 480-6 10-300 25

300 Steering system
Turning left
q If the steering wheel is turned to the left, the

output pressure from the Orbit-roll valve enters
port (Pa), and steering spool (1) is pushed to
the right.
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (3) is pushed to the left and
opened, conducting oil to the head side of the
left steering cylinder and to the bottom side of
the right steering cylinder to turn the machine
to the left.
q The oil returning from the right and left steering
cylinders is drained from port (T1) through load
check valve (4).
10-300 26 WA470, 480-6

300 Steering system
Turning right
q If the steering wheel is turned to the right, the

output pressure from the Orbit-roll valve enters
port (Pb) and steering spool (1) is pushed to
the left.
(P), and then flows through flow control spool
(2) to steering spool (1).
q Load check valve (4) is pushed to the right and
opened, conducting the oil flows to the head
side of the right steering cylinder and to the
bottom side of the left steering cylinder to turn
the machine to the right.
q The oil returning from the right and left steering
cylinders is drained from port (T1) through load
check valve (3).
WA470, 480-6 10-300 27

300 Steering system
Steering relief valve

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
q The steering relief valve is installed to the
steering valve. It maintains the oil pressure in
the steering circuit to the preset pressure dur-
ing the steering operation.
10-300 28 WA470, 480-6

300 Steering system
Operation of steering relief valve
q If the oil pressure in the steering circuit rises to

the level being set with adjustment screw (1)
and spring (2), pilot poppet (3) opens and the
oil is drained through port (T1).
q Pressure balance between chambers receiving
the pressure (X) and (Y) is lost and flow control
spool (4) moves to the left.
q As flow control spool (4) operates, the oil from
the steering pump is drained and the pressure
in the steering circuit is kept below the set
pressure.
WA470, 480-6 10-300 29

300 Steering system
Overload relief valve

Operation
Operation as relief valve
q Port (A) and port (B) are connected to the cyl-

inder circuit and drain circuit, respectively.
q The oil flows through the hole of poppet (1) to
the inside of relief valve poppet (2).
q Check valve poppet (3) and relief valve poppet
(2) are seated securely due to the area differ-
ence between diameters (d1) and (d2).
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
steering valve. It protects the cylinder circuit
from abnormally high pressure that can be q If the oil pressure in port (A) rises above the
generated if an impact is applied to the cylinder set pressure of the relief valve, pilot poppet (4)
while the steering valve at neutral. is pushed and opened to the right.
q If abnormally high pressure is generated on q The oil flows through pilot poppet (4) and the
the cylinder side, the overload relief valve hole to port (B).
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 creation of vacuum in
the circuit.
10-300 30 WA470, 480-6

300 Steering system
Operation as suction valve
q As pilot poppet (4) opens, the oil pressure

inside of poppet (1) lowers. q If negative pressure is generated in port (A), it
q Poppet (1) moves to the right to seat pilot pop- acts on the area difference between diameters
pet (4). (d3) and (d4) and pushes and opens check
valve poppet (3) to the right.
q The oil flows through port (B) to port (A) to pre-
vent creation of vacuum.
q The oil pressure of inside of relief valve poppet

(2) becomes lower than the oil pressure in port
(A).
q The oil pushes and opens relief valve poppet
(2) to the right and flows through port (A) to
port (B), thus the circuit is protected from
abnormally high pressure.
WA470, 480-6 10-300 31

300 Steering system
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.
10-300 32 WA470, 480-6

300 Steering system
WA470, 480-6 10-300 33

300 Steering system
SEN04423-00 Orbit-roll valve
Orbit-roll valve 1
P: From charge valve 1. Gerotor

T: Drain 2. Valve body
L: To left stop valve 3. Drive shaft
R: To right stop valve 4. Centering spring
5. Needle bearing
6. Bushing
7. Center pin
8. Sleeve
9. Spool
10. Spacer
11. End cap
10-300 34 WA470, 480-6

300 Steering system
Orbit-roll valve SEN04423-00
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, 480-6 10-300 35

300 Steering system
Operation
When steering wheel is at "neutral" position
10-300 36 WA470, 480-6

300 Steering system
q When the steering wheel is at "neutral" posi-

tion, centering spring (2) sets center pin (7) to
the center of the oblong hole on spool (9) and
move of spool (9) and sleeve (8) is stopped.
q Port (A) from sleeve (8) pump, port (E) to the
Gerotor, port (F) to the R.H. steering circuit and
port (G) to the L.H. steering circuit cut off the
vertical grooves (B), (C) and (D) on spool (9).
q Orifice (b) of port (J) to the priority valve is con-
nected to vertical groove (B) on spool (9).
q Port (K) of sleeve (8) is connected to vertical
groove (M) and port (L) on spool (9).
q Due to connection and disconnection of the
ports and vertical grooves, the oil in the priority
valve being set to the pilot pressure is con-
ducted through port (J), orifice (b), vertical
groove (M) and port (K), then drained from port
(L) to the hydraulic tank.
WA470, 480-6 10-300 37

300 Steering system
When steering wheel is "turned left"
10-300 38 WA470, 480-6

300 Steering system
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, 480-6 10-300 39

300 Steering system
Connection of hand pump and sleeve
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.
10-300 40 WA470, 480-6

300 Steering system
Role of centering spring
q Centering spring (2) is composed of 4 X-

shaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is generated between spool (9)
and sleeve (8).
As a result, the ports of spool (9) and sleeve
(8) are connected and the oil is sent to the
steering cylinder. When the steering wheel
stops turning, the Gerotor also stops turning.
Then, the oil is not sent to the steering cylinder
any more and its pressure rises.
To prevent this, when the steering wheel
stopped turning, Gerotor is turned by the reac-
tion force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) to
return the steering wheel to the "neutral" posi-
tion.
WA470, 480-6 10-300 41

300 Steering system
SEN04423-00 Stop valve
Stop valve 1
A: From Orbit-roll valve 1. Boot

B: To steering valve 2. Wiper
DR: Drain 3. Seal
4. Poppet
5. Spring
6. Spool
7. Spring
10-300 42 WA470, 480-6

300 Steering system
Steering relief valve SEN04423-00
Steering relief valve 1
(If equipped)
P1: From steering pump Outline

P2: From emergency steering pump q The steering relief valve is installed to the right
T: Drain side of the transmission and used to hold the
S1: Steering pump oil pressure switch (Low) steering oil pressure to the set pressure.
S2: Steering pump oil pressure switch (Hi) Set pressure: 1.96 MPa {20 kg/cm2}
S3: Emergency steering oil pressure switch (cracking pressure at 0.5 l/min)
1. Block
2. Relief valve
3. Orifice
WA470, 480-6 10-300 43

300 Steering system
SEN04423-00 Steering cylinder
Steering cylinder 1
Unit: mm
Clearance between bushing and size clearance limit
Shaft Hole
1 mounting pin connecting frame of
cylinder rod 0 +0.174 0.100 –
55 —
–0.046 +0.100 0.220
Clearance between bushing and
0 +0.174 0.100 –
2 mounting pin connecting frame of 55
–0.046 +0.100 0.220
—
cylinder bottom Replace
Standard (a + b)
Boss width Hinge width clearance
Connecting part of steering
3 cylinder and rear frame Max. 6
65 71 (after shim adjustment)
Connecting part of steering Max. 1.5
4 cylinder and front frame 65 66.5 (after shim adjustment)
10-300 44 WA470, 480-6

300 Steering system
Steering cylinder SEN04423-00
Unit: mm
Clearance between piston rod size Shaft Hole clearance limit Replace pin and
1 and bushing bushing
–0.025 +0.152 0.020 –
50 0.516
–0.064 –0.005 0.216
Tightening torque of cylinder
2 head 677 ± 67.5 Nm {69 ± 6.9 kgm}
3 piston 1,670 ± 170 Nm {170 ± 17.0 kgm} (width across flats: 55 mm) Retighten
4 head port side plug 9.8 – 12.74 Nm {1.0 – 1.3 kgm}
WA470, 480-6 10-300 45

300 Steering system
SEN04423-00 Emergency steering motor
Emergency steering motor 1
(If equipped)
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
Model name Direct current motor
Rated voltage 24 V
Rated output 0.9 kW
10-300 46 WA470, 480-6

300 Steering system
Emergency steering pump SEN04423-00
Emergency steering pump 1
(If equipped)
Type: SBL (1) 21
Unit: mm
Standard clearance Clearance limit
1 Side clearance
0.10 – 0.15 0.19
Clearance between plain bearing
2 inside diameter and gear shaft 0.060 – 0.119 0.20 Replace
outside diameter
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}
Speed Discharge pressure Allowable
Standard delivery
Delivery delivery
(rpm) (MPa {kg/cm2}) (l/min)
(l/min) —
— Oil: SAE10WCD
Oil temperature: 45 – 55°C 20.6
3,500 {210} 67.6 62.4
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, 480-6 10-300 47

300 Steering system
SEN04423-00 Joystick steering lever linkage
Joystick steering lever linkage 1
(If equipped)
1. Joystick steering lever 10. Pad

2. HI/LOW selector switch 11. Console tilt lever
3. Arm rest height and angle adjustment lock lever 12. Block
4. Console fore-and-aft lever 13. Joystick EPC valve
5. Joystick ON/OFF switch 14. Orbit-roll valve
6. Lock 15. FNR switch
7. Lock cable 16. Horn switch
8. Steering lock switch 17. Shift-down switch
9. Electrical steering lever 18. Shift-up switch
10-300 48 WA470, 480-6

300 Steering system
Electrical steering lever SEN04423-00
Electrical steering lever 1
(If equipped)
1. Body Function
2. Piston q The electrical steering lever is installed in the
3. Lever left console. It is connected to the joystick
4. Disc steering lever.
5. Retainer q If the joystick steering lever is operated, piston
6. Lever (2) is pushed down by rotating disc (4) and
7. Potentiometer potentiometer (7) is rotated.
8. Connector q Joystick steering lever strokes are detected by
potentiometer (7) and output to work equip-
ment controller as signal voltage.
q The potentiometers are installed on each of
the left and right sides. They output two rela-
tive signal voltages shown in the figure above.
WA470, 480-6 10-300 49

300 Steering system
SEN04423-00 Joystick EPC valve
Joystick EPC valve 1
(If equipped)
Function
q The joystick EPC valve switches the left and
right steering circuits and adjusts the flow rate
depending on the operation of the joystick
steering lever.
q The joystick EPC valve solenoid receives sig-
nal voltage based on strokes of the electrical
steering lever from the work equipment con-
troller, and then adjusts the flow rate of the
steering circuit.
q The flow rate of the steering circuit is deter-
mined depending on signal voltage from the
work equipment controller.
10-300 50 WA470, 480-6

300 Steering system
Joystick EPC valve SEN04423-00
WA470, 480-6 10-300 51

SEN04423-00

©2008 KOMATSU
All Rights Reserved
10-300 52
SEN04424-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

400 Brake system

Brake component layout drawing.................................................................................................................... 2
Charge valve................................................................................................................................................... 3
Brake valve ................................................................................................................................................... 10
Accumulator (for brake) ................................................................................................................................ 15
Slack adjuster ............................................................................................................................................... 16
Brake............................................................................................................................................................. 18
Parking brake control .................................................................................................................................... 23
Parking brake................................................................................................................................................ 24
Parking brake solenoid valve ........................................................................................................................ 26
Emergency parking brake release valve....................................................................................................... 28
WA470, 480-6 10-400 1

400 Brake system
SEN04424-00 Brake component layout drawing
Brake component layout drawing 1
1. Emergency parking brake release valve 7. Hydraulic tank

2. Accumulator (for rear) 8. Slack adjuster
3. Charge valve 9. Rear brake
4. Accumulator (for front) 10. Parking brake solenoid valve
5. Brake valve 11. Parking brake
6. Cooling fan pump 12. Front brake
10-400 2 WA470, 480-6

400 Brake system
Charge valve SEN04424-00
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, 480-6 10-400 3

400 Brake system
SEN04424-00 Charge valve
1. Valve body Function

2. Sequence valve (H1) q The charge valve maintains the oil pressure
3. Relief valve (R2) from the pump to the set pressure and accu-
4. Shuttle valve (S1) mulates it in the accumulator.
5. Priority valve q When the pressure is accumulated in the accu-
6. PPC relief valve (R3) mulator, the circuit to the cooling fan motor
7. Main relief valve (R1) opens and the oil from the pump is output as
cooling fan motor drive pressure.
q When the oil pressure rises above the preset
pressure, the oil from the pump is led to the
drain circuit to reduce the load on the pump.
q The charge valve reduces the pressure of the
oil from the pump and outputs the basic pres-
sure of the pilot circuit.
10-400 4 WA470, 480-6

400 Brake system
Operation
When oil is not supplied to accumulator (cut-out state)
q Since the pressure in oil passage (B) is higher

than the set pressure of relief valve (1), piston
(2) is pushed to the right by the oil pressure
from oil passage (B).
q Relief valve (1) opens and oil passage (C) is
connected to port (T).
q The oil from the pump flows through orifices (a)
and (b) and oil passage (C) to port (T).
q Since the oil pressure is reduced across orifice
( a) , a pr ess ur e d iffer enc e i s gene ra ted
between pressure receiving chambers (D) and
(E).
q If the pressure in pressure receiving chamber
(D) becomes higher than the preset pressure
of priority valve (5), priority valve (5) com-
presses spring (6) and moves to the right.
q The open area between port (P) and orifice (c)
side is reduced and port (P) and port (A) are
connected gradually.
q The oil from the pump flows through port (P),
sequence valve (7), and port (A) to the cooling
fan motor.
WA470, 480-6 10-400 5

400 Brake system
When oil is supplied to accumulator

1. Cut-in state
q If the pressure in oil passage (B) goes below

the set pressure of relief valve (1), relief valve
(1) is returned to the left by the repulsive force
of springs (3) and (4).
q Relief valve (1) closes and oil passage (C) is
disconnected from port (T).
q Since oil passage (C) is disconnected from
port (T), pressure drop through orifice (a) is
reduced and the pressure difference between
pressure receiving chambers (D) and (E) is
reduced.
q Priority valve (5) is moved to the left by the
reactive force of spring (6).
q The open area between port (P) and orifice (c)
side is increased and port (P) and port (A) are
disconnected gradually.
q If the oil pressure from the pump becomes
higher than the pressure in ports (ACC1) and
(ACC2), it pushes up check valve (8), starting
feeding of pressure from ports (ACC1) and
(ACC2) to the accumulator.
q The oil of a specific quantity being set by the
size (area) of orifice (c) and the pressure differ-
ence across orifice (c) (equivalent to the reac-
tive force of spring (6)) is supplied, through
ports (ACC1) and (ACC2), to the accumulator.
The excessive oil flows to ports (A) and (PPC).
10-400 6 WA470, 480-6

400 Brake system
2. When pressure reaches cut-out pressure
q If the pressure in oil passage (C) reaches the

set pressure of relief valve (1), relief valve (1)
is pushed to the right by the oil pressure from
oil passage (C).
q Relief valve (1) opens and oil passage (C) is
connected to port (T).
q A pressure difference is generated between
the right side and left side of piston (2), and
piston (2) moves to the right and opens relief
valve (1) forcibly.
q Since pressure receiving chamber (E) of prior-
ity valve (5) is also connected to oil passage
(C), the pressure in pressure receiving cham-
ber (E) is set to the drain pressure.
q Since the pressure in pressure receiving
chamber (D) also goes low to the level equiva-
lent to the reactive force of spring (6), oil sup-
ply to oil passage (B) is stopped.
WA470, 480-6 10-400 7

400 Brake system
Main relief valve (R1) PPC relief valve (R3)
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 across orifice (a), and the resulting q The pressure of the oil from the pump is
pressure difference compresses spring (3) and reduced across orifice (a), and the pressure
moves valve (4) to the left largely. difference compresses spring (3) and moves
q Port (P) being connected to port (T) drains the valve (4) to the left.
pump pressure and, thereby, regulates the q Since the opening area between port (PPC)
maximum pressure in the charge circuit in and port (P) is reduced, the pressure drop
order to protect the circuit. results. So the pressure in port (P) is main-
tained at a certain level without lowering to the
set pressure of the relief valve.
q The pressure in port (PPC) is adjusted to a
specific level according to the open area
between port (PPC) and port (P) and supplied
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.
10-400 8 WA470, 480-6

400 Brake system
Sequence valve (H1) Shuttle valve (S1)
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 preset pressure of spring (2) to prevent the
accumulator charge pressure and pilot circuit
basic pressure from going low.
WA470, 480-6 10-400 9

400 Brake system
SEN04424-00 Brake valve
Brake valve 1
PA: From charge valve port ACC1 TA: Plug

PB: From charge valve port ACC2 TB: Drain
A: To rear brake SA: Stop lamp oil pressure switch
B: To front brake SB: Plug
1. Piston 4. Spool (for front)

2. Spool (for rear) 5. Cylinder (for front)
3. Cylinder (for rear)
10-400 10 WA470, 480-6

400 Brake system
Brake valve SEN04424-00
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 When the brake pedal is depressed, the trans-
mission 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
q Brake pedal (1) depressing effort is transmitted

to spool (5) through rod (2), piston (3) and
spring (4).
q As spool (5) is pushed to the right, port (TA) is
closed and the oil from the pump activates the
rear brake after being conducted through accu-
mulator, port (PA), port (A) and rear brake pis-
ton.
q As spool (5) is pushed rightward, spool (6) is
also pushed rightward, closing port (TB). The
oil from the pump flows through the accumula-
tor, port (PB) and port (B) to the front brake pis-
ton to activate the front brake.
WA470, 480-6 10-400 11

400 Brake system
When brake of one side is operated

(when the other brake failed)
q Even when only one of the brakes can work

due to leakage of oil in the front or rear brake
system, brake pedal (1) depressing effort is
capable of mechanically moving spools (5) and
(6) to the right.
Thus, the oil from the pump is normally sup-
plied to the sound brake piston, enabling it to
continue the operation. The brake, therefore, is
capable of stopping the machine as needed to
ensure the intended safety level.
10-400 12 WA470, 480-6

400 Brake system
Brake valve SEN04424-00
Balancing operation
q When the rear brake piston is filled with oil and

the oil pressure rises between port (PA) and
port (A), the oil being conducted to chamber
(E) through orifice (c) of spool (5) pushes spool
(5) leftward against the reactive force of spring
(4). As a result, port (PA) is disconnected from
port (A).
At this time, port (TA) remains closed. Thus,
the oil conducted to the brake piston is
retained and the brake remains applied.
q At the same time as spool (5) moved to the left,
the front brake piston is filled up with oil,
increasing the oil pressure between port (PB)
and port (B). Thus, the oil conducted to cham-
ber (F) through orifice (d) of spool (6) pushes
back spool (6) in leftward by the move distance
of spool (5). As the result, port (PB) and port
(B) are disconnected.
At this time, port (TB) remains closed. Thus,
the oil conducted to the brake piston is
retained and the brake remains applied.
q Oil pressure in the rear brake circuit [port (A)
side] and the brake pedal depressing effort are
balanced and oil pressure in the front brake cir-
cuit [port (B) side] and oil pressure in the rear
brake circuit [port (A) side] are balanced.
When spools (5) and (6) are moved in right-
ward to the stroke end, port (PA) and port (A)
as well as port (PB) and port (B) are opened
completely. Thus, pressure of oil to the front
and rear brake circuits becomes equal to the
oil pressure from the pump.
Thus, the braking force is adjustable by adjust-
ing the brake pedal depressing amount until
spools (5) and (6) are moved in rightward to
the stroke end.
WA470, 480-6 10-400 13

400 Brake system
When brake pedal is released
q Releasing brake pedal (1) releases the pedal

pressing effort being applied to spool (5).
q As spool (5) is pushed back to the left by back
pressure of the rear brake piston and reactive
force of spring (7), port (PA) is closed and the
oil in the rear brake piston is conducted
through port (A) to port (TA) and then drained
from port (TB) to the hydraulic tank. As the
result, the rear brake is released.
q At the same time as spool (5) is moved to the
left, spool (6) is also pushed back to the left by
back pressure of the front brake piston and
reactive force of spring (7). Thus, port (PB) is
closed and the oil in the front brake piston is
conducted through port (B) to port (TB) and
then drained from port (TB) to the hydraulic
tank. As a result, the front brake is released.
10-400 14 WA470, 480-6

400 Brake system
Accumulator (for brake) SEN04424-00
Accumulator (for brake) 1
1. Valve
2. Top cover
3. Cylinder
4. Free piston
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 (cc) 2,850
Charged pressure 3.43 ± 0.1 {35 ± 1.0}
(MPa {kg/cm2}) (at 20°C)
Max. pressure used
20.6 {210}
(MPa {kg/cm2})
WA470, 480-6 10-400 15

400 Brake system
SEN04424-00 Slack adjuster
Slack adjuster 1
A: Inlet port
B: Outlet port
1. Bleeder
2. Cylinder
3. Check valve
4. Piston
5. Spring
Unit: mm
Clearance between cylinder body size Shaft Hole clearance limit
6 and piston
55 –0.030 +0.074 0.030 – 0.25
–0.076 0 0.150
Installed Installed Installed Replace
7 Check valve spring length load load
38.8 33 66.7 N — —
{4.4 kg}
43.1 N
8 Slack adjuster spring 198 38
{4.4 kg}
— —
10-400 16 WA470, 480-6

400 Brake system
Slack adjuster SEN04424-00
Outline q If the brake pedal is kept depressed fur-

q The slack adjuster is installed to the brake oil ther, the oil pressure discharged from the
line from the brake valve to the brake piston brake valve exceeds the specified pres-
and used to keep the brake operation time lag sure, check valves (3) open, and pressure
constant. is applied to ports (C) and it works as the
braking force.
Specifications Accordingly, the time lag when the brake
Unit: MPa {kg/cm2} is applied is kept constant.
Piston operating pressure 0.01 – 0.02 {0.1 – 0.2}
Check valve cracking pressure 0.93 ± 0.05 {9.5 ± 0.5}
Check valve closing pressure 0.60 ± 0.05 {6.0 ± 0.5}
Operation
1. When brake pedal is depressed
q Before the brake pedal is depressed, pis-
tons (4) are returned by stroke (S) (all
stroke). If the brake pedal is depressed,
the oil discharged from the brake valve
enters right and left cylinders (2) through
slack adjuster port (P) and moves pistons
(4) to the right and left by stroke (S).
2. When brake pedal is released

q If the brake pedal is released, pistons (4)
are returned by stroke (S) by return spring
(7) of the brake and the brake is released.
In other words, return stroke (T) of brake
pistons (6) is decided by the oil volume for
stroke (S) of the slack adjuster and the
brake time lag is kept constant, regardless
of wear of the brake disc.
q Accordingly, brake pistons (6) are moved

by stroke (S). At this time, the clearance
between the brake piston and disc is elim-
inated but no braking force is generated.
WA470, 480-6 10-400 17

400 Brake system
SEN04424-00 Brake
Brake 1
Front brake 1
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)
10-400 18 WA470, 480-6

400 Brake system
Brake SEN04424-00
Unit: mm
10 Thickness of plate 3.2 2.7
±0.1
6 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.7 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) — Replace
Wear limit
12 Wear of disc contact surface of
brake outer ring
37.4 ±0.1
0.3
13 Load of spring
(2 lapped springs)
Installed height Installed load Installed load
1,718 N 1,374 N
7.53
{175.3 kg} {140 kg}
Outline
q The front brake is a wet multiple disc type
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 linings 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, 480-6 10-400 19

400 Brake system
SEN04424-00 Brake
Rear brake 1
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)
10-400 20 WA470, 480-6

400 Brake system
Brake SEN04424-00
WA470-6 Rear
Unit: mm
±0.1
6 5.5
Thickness of lining 1.0 0.9 (Min.) — Replace
Wear limit
brake outer ring
21.2 ±0.1
0.3
13 Load of spring
(2 lapped springs)
1,691 N 1,225 N
7.53
{172.6 kg} {125 kg}
WA480-6 Rear
Unit: mm
±0.1
6 5.5
Thickness of lining 1.0 0.9 (Min.) —
Replace
Wear limit
brake outer ring 37.4 ±0.1
0.3
13 Load of spring
(2 lapped springs)
1,718 N 1,374 N
7.53 {175.3 kg} {140 kg}
Outline
q The rear brake is a wet multiple disc type
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 linings 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, 480-6 10-400 21

400 Brake system
SEN04424-00 Brake
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, returned to the original position by the return-
pump and brake charge valve to the brake cyl- ing force of spring (8) and clearance is made
inder acts on piston (2) in the brake cylinder to between inner ring (3) and outer ring (5), and
move the piston. 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 rotating, oil
brake is applied to the machine. flows in those grooves to cool the linings.
10-400 22 WA470, 480-6

400 Brake system
Parking brake control SEN04424-00
Parking brake control 1
1. Parking brake switch

2. Transmission control valve (Left valve assembly)
3. Parking brake solenoid valve
4. Parking brake
5. Emergency parking brake release valve
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 is de-energized), the signal from the
output shaft bearing and operated mechani- 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 on the q Emergency parking brake release valve (5) is
dashboard is turned "ON", parking brake sole- installed to move the machine when it is dis-
noid valve (3) installed to valve assembly (2) abled (and the parking brake is applied)
shuts off the oil pressure and the parking brake because of a failure 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, 480-6 10-400 23

400 Brake system
SEN04424-00 Parking brake
Parking brake 1
1. Output shaft Outline

2. Spring (outside) q The parking brake is a wet-type multi-disc
3. Spring (inside) brake being operated mechanically with
4. Parking brake oil port springs (2) and (3) to brake output shaft (1).
5. Piston q The reactive force of springs (2) and (3)
6. Plate presses disc (7) against plate (6) with piston
7. Disc (5) to stop output shaft (1).
8. Wave spring q The oil pressure from parking brake oil port (4)
moves piston (5) to release the pressing force
on disc (7) and plate (6).
10-400 24 WA470, 480-6

400 Brake system
Parking brake SEN04424-00
Unit: mm
Installed Installed Installed
9 Parking brake spring (outside) length load load
1,284 N 1,220 N
94 72.3 91
{131 kg} {124 kg}
672 N 638 N
10 Parking brake spring (inside) 94 72.3
{69 kg}
91
{66 kg}
Thickness 2.0 ±0.05 1.8 Replace
11 Plate
Strain — 0.15 0.2
Thickness 3.2 ±0.10 2.75

12 Disc
Strain — 0.2 0.3
13 Load of wave spring

(testing height: 3.2 mm)
735 N
{75 kg}
±216 N
{±22 kg}
519 N
{53 kg}
WA470, 480-6 10-400 25

400 Brake system
SEN04424-00 Parking brake solenoid valve
Parking brake solenoid valve 1
1. Transmission control valve (Left valve assembly)

2. Coil (ON/OFF type)
3. Push pin
4. Spring
5. Spool
6. Valve block
7. Check valve
10-400 26 WA470, 480-6

400 Brake system
Parking brake solenoid valve SEN04424-00
Operation
When parking brake is applied (when solenoid When parking brake is released (when solenoid
is de-energized) is energized)
q Setting the parking brake switch to "ON" sets q Setting the parking brake switch to "OFF" sets
coil (1) to "OFF". As a result, spool (2) is coil (1) to "ON", moving spool (2) upward.
pushed back downward by the reactive 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 back side of
the oil that was working as back pressure of the piston, it compresses the spring, separat-
the parking brake is drained through port (A) ing the plate and disc from each other. As the
and port (T). result, the parking brake is released.
q As the back pressure of the piston is released,
the piston being pushed back by the spring
thrusts the plate and disc closely to activate
the parking brake.
WA470, 480-6 10-400 27

400 Brake system
SEN04424-00 Emergency parking brake release valve
Emergency parking brake release

valve 1
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., the
oil pressure, which is stored in the accumulator
in the brake circuit, can be supplied to the
parking brake cylinder by manually opening
this valve.
10-400 28 WA470, 480-6

400 Brake system
Emergency parking brake release valve SEN04424-00
WA470, 480-6 10-400 29

SEN04424-00

©2008 KOMATSU
All Rights Reserved
10-400 30
SEN04425-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

500 Undercarriage and frame

Axle mount and center hinge pin .................................................................................................................... 2
Tires ................................................................................................................................................................ 6
WA470, 480-6 10-500 1

SEN04425-00 Axle mount and center hinge pin
Axle mount and center hinge pin 1
1. Front axle Outline

2. Front frame q Front frame (2) and rear frame (4) are coupled
3. Rear axle with each other by the bearing with center
4. Rear frame hinge pin between them. The right and left
steering cylinders connect the front frame (2)
and rear frame (4). The articulation angle or
the turning radius of the frames is adjusted
according to the extension/retraction of the
steering cylinders.
10-500 2 WA470, 480-6

Axle mount and center hinge pin SEN04425-00
Unit: mm
1 Thickness of thrust plate 0
20 —
–0.15
+0.3
2 Thickness of wear plate 5
–0.1
—
Standard Tolerance Standard Clearance Replace

Clearance between shaft and size clearance limit
Shaft Hole
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 hole on rear support side 190 –0.137 +0.027 0.592 —
WA470, 480-6 10-500 3

SEN04425-00 Axle mount and center hinge pin
10-500 4 WA470, 480-6

Axle mount and center hinge pin SEN04425-00
Unit: mm
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 pin and spacer (small)
80
–0.049 +0.030 0.109
—
3 Clearance between upper hinge

pin and bearing
80
–0.030
–0.049
0
–0.015
0.015 –
0.049
—
4 Clearance between upper hinge

pin and spacer (large)
80
–0.030
–0.049
+0.030
0
0.030 –
0.079
—
5 Clearance between rear frame

and spacer (large)
95
–0.036
–0.071
+0.071
+0.036
0.072 –
0.142
—
6 Clearance between front frame

and upper hinge bearing
130
0
–0.025
–0.048
–0.088
–0.088 –
–0.023
—
Replace
7 Clearance between lower hinge
pin and rear frame bushing
80
–0.030
–0.076
+0.067
+0.027
0.057 –
0.143
—
8 Clearance between lower hinge

pin and bearing
80
–0.030
–0.076
0
–0.015
0.015 –
0.076
—
9 Clearance between front frame

and lower hinge bearing
130
0
–0.025
–0.048
–0.088
–0.088 –
–0.023
—
10 Clearance
and bushing
between rear frame
95
+0.089
+0.054
+0.054
0
–0.089 –
0 —
11 Clearance in seal press fitting

part of lower hinge pin 105
+0.17
+0.08
+0.054
0
–0.17 –
–0.026 —
12 Height
(small)
of upper hinge spacer
36 ±0.1 —
13 Height
(large)
of upper hinge spacer
61.5 ±0.1 —
14 Standard thickness of shim

between upper hinge and retainer 1

between upper hinge and retainer 2

between lower hinge and retainer 1
20 ± 2 Nm {2 ± 0.2 kgm} (when shim is adjusted) Adjust

17 Tightening torque of upper hinge
retainer mounting bolt
98 – 123 Nm {10 – 12.5 kgm} (final value)
20 ± 2 Nm {2 ± 0.2 kgm} (when shim is adjusted)

18 Tightening torque of lower hinge
retainer mounting bolt
98 – 123 Nm {10 – 12.5 kgm} (final value)
WA470, 480-6 10-500 5

SEN04425-00 Tires
Tires 1
If this machine is equipped with radial tires (optional), it will have the following features.
• High grip • Improvement of fuel consumption rate
• Better operator comfort • Long life
• Reduction of tire puncture rate • Less damage on machine
• Less uneven wear • Less generation of heat
Comparison of structures and characteristics of tires

Radial tire Bias tire
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.
Ground contact characteristics Ground contact characteristics

q Even if the tire is deformed by a load, it does q If the tire is deformed by a load, the ground
not move uselessly in ground contact and uni- contact surface is also deformed, leading to
form ground contact surface is secured stably. wasteful moves. As a result, the ground con-
tact surface becomes unstable.
Deformation characteristics Deformation characteristics

q Only side wall (W) is deformed as load is q Side wall (W) which receives loads and tread
applied and tread (T) made of strong belts (2) (T) move as one unit.
keeps stability independently.
10-500 6 WA470, 480-6

Tires SEN04425-00
WA470, 480-6 10-500 7

SEN04425-00

©2008 KOMATSU
All Rights Reserved
10-500 8
SEN04426-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

601 Hydraulic system, Part 1

Hydraulic component layout drawing .............................................................................................................. 2
Work equipment control lever linkage ............................................................................................................. 5
Hydraulic tank ................................................................................................................................................. 8
Power train pump.......................................................................................................................................... 10
Work equipment pump .................................................................................................................................. 12
Work equipment control valve....................................................................................................................... 32
CLSS............................................................................................................................................................. 43
Each function and operation of each valve ................................................................................................... 48
WA470, 480-6 10-601 1

SEN04426-00 Hydraulic component layout drawing
Hydraulic component layout drawing 1
10-601 2 WA470, 480-6

Hydraulic component layout drawing SEN04426-00
WA470, 480-6 10-601 3

SEN04426-00 Hydraulic component layout drawing
1. Work equipment control valve Outline

2. Bucket cylinder q The hydraulic system consists of the work
3. Steering valve equipment circuit and steering circuit. The
4. Cooling fan pump work equipment circuit controls the operation
5. Work equipment PPC valve of the bucket and attachments.
6. Work equipment pump q The oil in hydraulic tank (7) is sent to work
7. Hydraulic tank equipment control valve (1) by work equipment
8. Oil filler cap-breather pump (6). While the bucket and lift arm spools
9. Oil cooler of the work equipment control valve are held,
10. Power train oil cooler the oil is sent through the drain circuit of the
11. Steering pump work equipment control valve, filtrated through
12. Power train pump the filter inside the hydraulic tank, and returned
13. PPC accumulator to the tank.
14. Charge valve q If the work equipment control lever is operated,
15. ECSS (Electronic Controlled Suspension the bucket or lift arm spool of work equipment
System) accumulator (if equipped) PPC valve (5) moves to move each spool of
16. Steering cylinder work equipment control valve (1) hydraulically.
17. Lift cylinder Then, the oil flows from the work equipment
18. Emergency steering pump (if equipped) control valve to lift cylinder (17) or bucket cylin-
19. Emergency steering motor (if equipped) der (2) to move the lift arm or bucket.
20. Cooling fan motor q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (1). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q PPC accumulator (13) is installed to the PPC
pilot circuit so that the lift arm can be lowered
to t he gr o un d ev e n wh i le t he en gi ne is
stopped.
q Hydraulic tank (7) is enclosed and equipped
with oil filler cap-breather (8) having relief
valve, which pressurizes the inside of the tank
and prevent generation of a negative pressure
in the tank to prevent cavitation in the pump.
q The emergency steering system is installed so
that the operator can steer the machine by
driving emergency steering pump (18) with
electric emergency steering motor (19) even if
the machine cannot be steered normally
because of an engine stall, steering pump trou-
ble, oil leakage through the piping, etc.
(if equipped)
q Cooling fan motor (20) installed to the radiator
is driven hydraulically at a variable speed by
cooling fan pump (4).
10-601 4 WA470, 480-6

Work equipment control lever linkage SEN04426-00
Work equipment control lever linkage 1
2-lever type
1. Lift arm control lever

2. Bucket control lever
3. Work equipment lock lever
4. Arm rest
5. Work equipment PPC valve
6. Lever stand fore-and-aft lever
7. Arm rest height and angle adjustment lock lever
WA470, 480-6 10-601 5

SEN04426-00 Work equipment control lever linkage
Multi-function mono-lever type

(If equipped)
a The figure shows the machine with the auxiliary control lever.
1. Auxiliary control lever

2. Work equipment control lever
3. Arm rest
4. Work equipment PPC cut-off solenoid valve
5. Work equipment PPC valve
6. Attachment PPC valve
7. Arm rest height and angle adjustment lock lever
8. Work equipment lock switch
9. Lever stand fore-and-aft lever
10-601 6 WA470, 480-6

Work equipment control lever linkage SEN04426-00
WA470, 480-6 10-601 7

SEN04426-00 Hydraulic tank
Hydraulic tank 1
10-601 8 WA470, 480-6

Hydraulic tank SEN04426-00
1. Oil filler cap-breather Breather 1

2. Hydraulic tank
3. Drain valve
4. Drain plug
5. Sight gauge
6. Strainer
7. Filter element
8. Bypass valve
9. Suction strainer
Specifications
Hydraulic tank capacity (l) 255

Oil amount inside hydraulic
173 1. Filter element
tank (l)
Bypass valve set pressure 0.15 ± 0.03 2. Bottom plate
(MPa {kg/cm2}) {1.53 ± 0.31} 3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

q Since the hydraulic tank is pressurized and
enclosed, a negative pressure is generated in
it if the oil level in it lowers.
In this case, seam valve (4) is opened by the
differential pressure between the tank internal
pressure and the atmospheric pressure, and
then the atmosphere flows in the tank to pre-
vent generation of a negative pressure.
(Intake valve set pressure:
0 – 5.1 kPa {0 – 0.05 kg/cm2})
Prevention of pressure rise in tank

q While the hydraulic circuit is in operation, the
pressure in the hydraulic tank increases
because of rise of the oil level and temperature
in the hydraulic tank in accordance with the
operating condition of the hydraulic cylinders.
If the pressure in the tank increases above the
set pressure, bottom plate (2) is pushed up to
release the pressure in the tank and prevent it
from increasing.
(Exhaust valve set pressure:
75 ± 15 kPa {0.76 ± 0.15 kg/cm2})
WA470, 480-6 10-601 9

SEN04426-00 Power train pump
Power train pump 1
Type: SAL(3)80 + (1)32
Unit: mm
Type Standard clearance Clearance limit
SAL(3)80 0.10 – 0.15 0.19

1 Side clearance
SAL(1)32 0.10 – 0.15 0.19
Clearance between plain bearing SAL(3)80 0.078 – 0.149 0.20

2 inside diameter and gear shaft Replace
outside diameter SAL(1)32 0.064 – 0.119 0.20
Type Standard size Tolerance Repair limit
0
SAL(3)80 14 —
3 Driven depth of pin –0.5
0
SAL(1)32 10 –0.5 —
4 Torque of spline turning shaft 8.8 – 16.7 Nm {0.9 – 1.7 kgm}

Discharge Standard Allowable
Speed
Type pressure delivery delivery
(rpm)
(MPa{kg/cm2}) (l/min) (l/min) —
Delivery
— Oil: EO10-CD SAL(3)80 2,500 2.9 {30} 184 170
Oil temperature: 45 – 55°C
SAL(1)32 2,500 2.9 {30} 77.4 66.8
Outline
q The power train pump is installed to the PTO
shaft of the torque converter and driven with
the PTO shaft to supply oil pressure to the
torque converter and transmission circuits.
10-601 10 WA470, 480-6

Power train pump SEN04426-00
WA470, 480-6 10-601 11

SEN04426-00 Work equipment pump
Work equipment pump 1
Type: HPV125
General view
10-601 12 WA470, 480-6

Work equipment pump SEN04426-00
Outline
q This pump consists of a variable-displacement
swash plate type piston pump, PC valve, LS
valve and EPC valve.
IM: PC mode selector current connector

PA: Pump discharge port
PB: Pump pressure input port
PC: Pump discharge pressure pickup port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PEPB: EPC basic pressure pickup port
PEPC: EPC basic pressure port
PLS: Load pressure input port
PLSC: Load pressure pickup port
PM: PC mode selector pressure pickup port
PS: Pump suction port
1. Main pump
2. LS valve
3. PC valve
4. PC-EPC valve
WA470, 480-6 10-601 13

Sectional view
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
10-601 14 WA470, 480-6

Function q Piston (6) in each cylinder chamber of cylinder

q The pump converts the engine rotation and block (7) moves relatively in the axial direction.
torque transmitted to its shaft to oil pressure q Cylinder block (7) seals the pressurized oil to
and delivers pressurized oil corresponding to valve plate (8) and carries out relative rotation.
the load. q This surface is designed so that the oil pres-
q It is possible to change the delivery by chang- sure balance is maintained at a suitable level.
ing the swash plate angle. q The oil inside the respective cylinder chambers
of cylinder block (7) is suctioned and dis-
Structure charged through valve plate (8).
q Cylinder block (7) is set to shaft (1) with spline
(12).
q Shaft (1) is supported on bearings (13).
q Tip of piston (6) is shaped as a concave ball
and shoe (5) is caulked to it to form one unit.
q Piston (6) and shoe (5) constitute the spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
q Rocker cam (4) conducts high pressure oil to
cylinder surface (B) with cradle (2), which is
secured to the case, and forms a static pres-
sure bearing when it slides.
WA470, 480-6 10-601 15

Operation of pump
q Cylinder block (7) rotates together with shaft q As center line (X) of rocker cam (4) matches
(1), and shoe (5) slides on flat surface (A). the axial direction of cylinder block (7) (swash
q When this happens, rocker cam (4) moves plate angle (a) = 0), the difference between
along cylindrical surface (B), so angle (a) volumes (E) and (F) inside cylinder block (7)
between center line (X) of rocker cam (4) and becomes 0.
the ax ial di rec tio n of cy li nder b loc k (7) q Suction and discharge of pressurized oil is not
changes. carried out in this state. Namely pumping
q (a) is named the swash plate angle. action is not performed. (actually, however, the
swash plate angle is not set to 0)
q With center line (X) of rocker cam (4) at swash

plate angle (a) in relation to the axial direction
of cylinder block (7), flat surface (A) acts as a
cam in relation to shoe (5).
q In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between vol-
umes (E) and (F) is created inside cylinder
block (7).
q A single piston (6) suctions and discharges the
oil by the amount (F) – (E).
q As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
q On the other hand, the volume of chamber (F)
grows larger and, in this process, the oil is suc-
tioned.
10-601 16 WA470, 480-6

Control of delivery
q If the 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 Swash plate angle (a) is changed with servo
piston (10).
ing to the signal pressures of the PC and LS
valves.
q This straight line movement is transmitted
through slider (14) to rocker cam (4).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) slides on the surface
while continuing revolving movement.
q The right and left areas receiving the pressure
of servo piston (10) are different. The dis-
charge pressure (self-pressure) (PP) of the
main pump is constantly supplied to the pres-
sure chamber at the small diameter piston end.
q Output pressure (PEN) of the LS valve is
brought to the chamber receiving the pressure
at the large diameter piston end.
q The movement of servo piston (10) is con-
trolled by the difference between pressure
(PP) at the small diameter piston end and
pressure (PEN) at the large diameter piston
end and the area receiving the pressure ratio
of the small diameter piston end and large
diameter piston end.
WA470, 480-6 10-601 17

LS valve
PA: Pump port 1. Sleeve

PDP: Drain port 2. Piston
PLP: LS control pressure output port 3. Spool
PLS: LS pressure input port 4. Spring
PP: Pump port 5. Seat
PPL: Control pressure input port 6. Sleeve
PSIG: Drain port 7. Plug
8. Locknut
Function
q The LS (load sensing) valve detects the load of
the actuator and controls the delivery.
q This valve controls main pump delivery (Q)
according to differential pressure (dPLS) [=
(PP) – (PLS)], called the LS differential pres-
sure (the difference between main pump pres-
s ur e ( P P ) a nd co nt r ol va l ve ou tl et p or t
pressure (PLS)).
q Main pump pressure (PP), pressure (PLS)
(called the LS pressure) from the control valve
output port, and pressure (PSIG) (called the
LS selector pressure) from the proportional
solenoid valve are supplied to this valve.
10-601 18 WA470, 480-6

Operation
When control valve is in neutral position
q The LS valve is a 3-way selector valve. LS q Shuttle valve output pressure (PPH) is sup-
pressure (PLS) from the control valve inlet is plied to the large diameter piston end through
supplied to spring chamber (B) and pump dis- port (K).
charge pressure (PP) is supplied to port (H) of q Pump pressure (PP) is supplied to port (J) at
sleeve (1). the small diameter piston end.
q Spool (3) is positioned by the forces generated q The swash plate angle is decreased by the
by this LS pressure (PLS) and spring (4) and area difference of servo piston (10).
the force generated by pump discharge pres-
sure (self-pressure) (PP).
q Before the engine is started, servo piston (10)
is pressed to the right. (See the figure at right)
q If the control lever is at the neutral position
when the engine is started, LS pressure (PLS)
will be set to 0 MPa {0 kg/cm2}. (It is intercon-
nected to the drain circuit through the control
valve spool)
q Spool (3) is pushed to the right and ports (C)
and (D) are connected.
WA470, 480-6 10-601 19

Operation to increase pump delivery
q If the difference between pump discharge

pressure (PP) and LS pressure (PLS), or LS
differential pressure (dPLS) is decreased (for
example, if the open area of the control valve
increases and pump discharge pressure (PP)
decreases), the total of LS pressure (PLS) and
the combined force of spring (4) pushes spool
(3) to the left.
q If spool (3) moves, ports (D) and (E) are con-
nected to each other and connected to the PC
valve.
q The PC valve is connected to the drain port, so
the pressure across circuits (D) and (K)
becomes drain pressure (PT). (The operation
of the PC valve is explained later.)
q Since the pressure at the large diameter piston
end of servo piston (10) becomes drain pres-
sure (PT) and pump pressure (PP) is con-
stantly suppli ed to por t (J) at the s mall
diameter piston end, servo piston (10) is
pushed to the left and the swash plate is
moved to increase the delivery.
10-601 20 WA470, 480-6

Operation to decrease pump delivery
q If LS differential pressure (dPLS) is increased

(for example, if the open area of the control
valve decreases and pump discharge pressure
(PP) increases), pump pressure (PP) pushes
spool (3) to the right.
q If spool (3) moves, shuttle valve output pres-
sure (PPH) flows through port (C) to port (D)
and then flows through port (K) to the large
diameter piston end.
q Although main pump pressure (PP) is supplied
to port (J) at the small diameter piston end of
servo piston (10), servo piston (10) is pushed
to the right by the area difference between the
large diameter end and small diameter end. As
the result, the swash plate angle is decreased.
WA470, 480-6 10-601 21

When servo piston is balanced
q Let us take the area receiving the pressure at q The force of spring (4) is so adjusted that spool
the large diameter end of the piston as (A1), (3) will be balanced and stopped when (PP) –
the area receiving the pressure at the small (PLS) = 1.4 MPa {14 kg/cm2} at the center of
diameter end as (A0), and the pressure flowing the standard.
into the large diameter end of the piston as
(PEN).
q If main pump pressure (PP) of the LS valve is
balanced with the total of LS pressure (PLS)
and the combined force of spring (4) and (A0)
x (PP) = (A1) x (PEN), servo piston (10) stops
at the current position.
q The swash plate of the pump is held at an
intermediate position. [The swash plate stops
at a position where the open area between
ports (D) and (E) of spool (3) is almost equal to
that between ports (C) and (D)]
q The ratio of the area receiving the pressure at
both ends of servo piston (10) is (A0) : (A1) = 3
: 5, and the ratio of the pressures applied to
both ends of the balanced piston is (PP) :
(PEN) C 5 : 3.
10-601 22 WA470, 480-6

PC valve
PA: Pump port 1. Plug

PDP: Drain port 2. Servo piston assembly
PM: Mode selector pressure pilot port 3. Pin
PPL: Control pressure output port (To LS valve) 4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function
q The PC valve controls the oil flow to a certain
level in accordance with the pump discharge
pressure even if the control valve stroke is
increased when the pump discharge pressure
(PP) (self-pressure) is high.
q If the load increases and the pump discharge
pressure increases accordingly during work,
the PC valve decreases the pump delivery.
q And if the pump delivery pressure goes low, it
increases the pump delivery.
q The relationship between discharge pressure
(PP) and pump delivery (Q) in this case is
expressed at right as a parameter of command
current (X) given to the PC-EPC valve sole-
noid.
q The controller continues counting the actual
engine speed.
q In the low engine speed range, command cur-
rent (X) flows from the controller to the PC-
EPC valve solenoid according to the engine
speed to decrease the pump delivery.
WA470, 480-6 10-601 23

Operation
When actuator load is low and pump pressures (PP1) and (PP2) are low
Action of PC-EPC valve solenoid (1)

q Command current (X) from the transmission
controller flows to PC-EPC valve solenoid (1).
q This command current (X) acts on PC-EPC
valve to output the signal pressure in order to
modify the force pushing piston (2).
q Spool (3) stops at a position where the spring
set force of spring (4) is balanced with the
combined force applied to push spool (3) by
pump pressure (PP) (self-pressure).
q The pressure [port (C) pressure] output from
PC valve is changed depending on the above
position.
q The size of command current (X) is determined
by the nature of the operation (lever opera-
tion), the selected working mode, and the set
value and actual value of the engine speed.
10-601 24 WA470, 480-6

Action of spring
q The spring load of spring (4) at the PC valve is q If ports (E) and (G) of the LS valve are con-
decided by the position of the swash plate. nected to each other, the pressure entering
q The spring load changes as servo piston (9) from port (J) to the large diameter piston end
expands or compresses spring (4). becomes drain pressure (PT) and servo piston
q If the command current (X) to PC-EPC valve (9) moves to the left.
solenoid (1) changes, so does the force push- q The pump delivery will be set to the increasing
ing piston (2). trend.
q The spring load of spring (4) also changes q As servo piston (9) moves, spring (4) expands
according to PC-EPC valve solenoid command and its spring force decreases.
current (X). q If the spring force decreases, spool (3) moves
q Port (C) of the PC valve is connected to port to the right and ports (C) and (D) are discon-
(E) of the LS valve. nected from each other and pump discharge
q Self pressure (PP) enters the small diameter pressure port (B) is connected to port (C).
piston end of servo piston (9) and ports (A) and q Since the pressure in port (C) increases and
(B). the pressure at the large diameter piston end
q When pump pressure (PP) is low, spool (3) is increases, servo piston (9) stops moving to the
on the left side. left.
q Ports (C) and (D) are connected, and the pres- q The stop position for servo piston (9) [ = pump
sure entering the LS valve becomes drain discharge amount] is decided at the point
pressure (PT). where the force of spring (4) and the pushing
force of PC-EPC valve by solenoid and the
pushing force created by pressure (PP) acting
on spool (3) are in balance.
WA470, 480-6 10-601 25

When actuator load is high and 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 (PP) 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),
moves to the position shown in the diagram stopping servo piston (9).
above. q If pump pressure (PP) increases further and
q As shown in the above figure, a part of the spool (3) moves further to the right, pump pres-
pressure from port (B) flows through the LS sure (PP) flows to port (C) to minimize the
valve and port (C) to port (D) and decreases to delivery.
about a half of pump pressure (PP). q If servo piston (9) moves to the right, springs
(4) and (6) are compressed and spool (3) is
pushed back.
q If spool (3) moves to the left, the open area
between ports (C) and (D) becomes wider.
q As a result, the pressure on port (C) (= J) is
decreased and the rightward move of servo
piston (9) is stopped.
q At this time, servo piston (9) stops off on the
right side compared to when pump pressure
(PP) is low.
10-601 26 WA470, 480-6

q The relationship between pump pressure (PP)

and pump delivery (Q) is shown below.
q If command current (X) sent to PC-EPC valve

solenoid (1) increases, the relationship
between pump pressure (PP) and pump deliv-
ery (Q) is translated in parallel in proportion to
the pressing force of the PC-EPC valve sole-
noid.
q Since the pressing force of PC-EPC valve
solenoid (1) is added to the rightward pressing
force caused by the pump pressure applied to
spool (3), the relationship between pump pres-
sure (PP) and pump delivery (Q) is translated
from (A) to (B) as command current (X)
increases.
WA470, 480-6 10-601 27

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
10-601 28 WA470, 480-6

Function Operation
q The EPC valve consists of the proportional
solenoid and hydraulic valve. When signal current is 0 (coil de-energized)
q When it receives signal current (i) from the q When there is no signal current flowing from
controller, it generates the EPC output pres- the controller to coil (2), coil (2) is de - ener-
sure in proportion to the size of the signal, 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 pressurized oil from
the pilot pump does not flow to the PC valve.
q The pressurized oil from the PC valve is
drained to the tank through port (C) and port
(T).
WA470, 480-6 10-601 29

When signal current is very small (coil ener- When signal current is maximum (coil ener-
gized) gized)
q When a very small signal current flows to coil q As the signal current flows to coil (2), coil (2) is
(2), coil (2) is energized, and a propulsion force energized.
is generated on the right side of plunger (7). q When this happens, the signal current is at its
q Rod (6) pushes spool (5) to the right, and pres- maximum, so the propulsion force of plunger
surized oil flows from port (P) to port (C). (7) is also at its maximum.
q Pressures on port (C) increases and the force q Spool (5) is pushed toward the right side by rod
to act on spool (5) surface and the spring load (6).
on spring (4) become larger than the propul- q The maximum volume of pressurized oil is
sion force of plunger (7). conducted from port (P) to port (C), increasing
q Spool (5) is pushed to the left, and port (P) is the circuit pressure across EPC valve and PC
shut off from port (C). valve to the maximum level.
q Port (C) is connected to port (T). q Since port (T) is closed, the pressurized oil
q Spool (5) moves so that the propulsion force of does not flow to the tank.
plunger (7) may be balance with pressure of
port (C) + spring load of spring (4).
q The circuit pressure between the EPC valve
and the PC valve is controlled in proportion to
the size of the signal current.
10-601 30 WA470, 480-6

WA470, 480-6 10-601 31

SEN04426-00 Work equipment control valve
Work equipment control valve 1
Outline
The general view and sectional view show the 3-spool valve (with the ECSS control valve).
A1: To bucket cylinder bottom

A2: To lift cylinder bottom
ACC: To ECSS accumulator
B1: To bucket cylinder head
B2: To lift cylinder head
CAC: Pressure pickup port
CLS: Pressure pickup port
CP: Pressure sensor mounting port
CP1: Pressure pickup port
CR: Pressure pickup port
P: From front work equipment pump
PA1: Bucket dump pilot pressure
PA2: Lift arm raise pilot pressure
PACC: From ECSS controller
PB1: Bucket tilt pilot pressure
PB2: Lift arm lower pilot pressure
PLS: To work equipment pump LS port
PP: From pilot pump
PPS: To work equipment pump
T: To tank
TS: To tank
1. Bucket valve
2. Lift arm valve
3. ECSS valve
4. Cover A
5. Cover B
6. Lift arm suction valve
7. Accumulator charge valve
10-601 32 WA470, 480-6

Work equipment control valve SEN04426-00
General view
WA470, 480-6 10-601 33

Sectional view
(1/6)
10-601 34 WA470, 480-6

1. Load check valve (Bucket cylinder bottom)

2. Load check valve (Lift cylinder bottom)
3. Pressure compensation valve (Lift cylinder head)
4. Pressure compensation valve (Bucket cylinder head)
Unit: mm
Free length x If damaged or
Installed
Outside Installed load Free length Installed load
5 Check valve spring diameter
length deformed, replace
spring
29.4 N 23.5 N
38.9 x 11.5 30.0 —
{3.0 kg} {2.4 kg}
WA470, 480-6 10-601 35

(2/6)
10-601 36 WA470, 480-6

1. Spool (ECSS)
2. Spool (Lift arm)
3. Spool (Bucket)
Unit: mm
Free length x
Installed
4 Spool return spring diameter
length
388 N 311 N
56.0 x 33.5 51.5 —
{39.6 kg} {31.7 kg}
351 N 280 N If damaged or
5 Spool return spring 58.1 x 33 51.5
{35.8 kg}
—
{28.6 kg} deformed, replace
spring
400 N 320 N
6 Spool return spring 70.5 x 36.4 65
{40.8 kg}
—
{32.6 kg}
265 N 212 N
7 Spool return spring 53.2 x 22.3 33
{27.0 kg}
—
{21.6 kg}
380 N 304 N
8 Spool return spring 56.8 x 33.8 51.5
{38.7 kg}
—
{31.0 kg}
WA470, 480-6 10-601 37

(3/6)
1. Suction safety valve (Bucket cylinder bottom)

2. Suction safety valve (Lift cylinder bottom)
3. Suction safety valve (Lift cylinder head)
4. Suction safety valve (Bucket cylinder head)
10-601 38 WA470, 480-6

(4/6)
Bucket valve
1. Load check valve (Tilt)
2. Pressure compensation valve (Dump)
3. Suction safety valve (Tilt)
4. Spool
5. Suction safety valve (Dump)
WA470, 480-6 10-601 39

(5/6)
10-601 40 WA470, 480-6

Lift arm valve

1. Load check valve (Raise)
2. LS shuttle valve
3. Pressure compensation valve (Lower)
4. Suction safety valve (Lower)
5. Suction valve (Lower, Float)
6. Spool
7. Suction safety valve (Raise)
ECSS valve
8. Spool
9. EPC valve
Unit: mm
Free length x
Outside Installed Installed load Free length Installed load
11 Suction valve spring diameter
length
3.04 N 2.45 N If damaged or

62.5 x 20.0 39.0 {0.31 kg} — {0.25 kg} deformed, replace
spring
5.88 N 4.71 N
12 Check valve spring 41.5 x 8.5 31.5 {0.6 kg} — {0.48 kg}
19.6 N 15.7 N
13 Valve spring 19.2 x 7.2 16.1 {2.0 kg} — {1.6 kg}
WA470, 480-6 10-601 41

(6/6)
1. Unload valve
2. Main relief valve
3. LS bypass plug
10-601 42 WA470, 480-6

CLSS SEN04426-00
CLSS 1
Outline of CLSS
Features Composition
CLSS stands for Closed center Load Sensing Sys- q CLSS consists of a variable capacity piston
tem, and has the following features. pump, control valves, and respective actua-
tors.
q Fine control not influenced by load q The work equipment pump unit is composed of
q Controllability enabling digging even under the the main pump, PC valve, and LS valve.
fine control
q Ease of compound operation ensured by flow
divider function using the open area of spool
during compound operations
q Energy saving using variable pump control
WA470, 480-6 10-601 43

SEN04426-00 CLSS
Basic principle
Pump swash plate angle control
q The pump swash plate angle (pump delivery) q The pump swash plate shifts toward the maxi-
is so controlled that the LS differential pressure mum position if LS differential pressure (dPLS)
(dPLS) which is the differential pressure is lower than the set pressure of the LS valve
between pump discharge pressure (PPS) and (when the actuator load pressure is high).
LS pressure (PLS) (actuator load pressure) at q If it becomes higher than the set pressure
the control valve outlet will be constant. (when the actuator load pressure is low), the
q [LS differential pressure (dPLS) = Pump dis- pump swash plate shifts toward the minimum
charge pressure (PPS) – LS pressure (PLS)] position.
LS differential pressure (dPLS) and pump

swash plate angle
a For details of operation, see "Work equipment

pump".
10-601 44 WA470, 480-6

CLSS SEN04426-00
Pressure compensation control
q The valve (pressure compensation valve) to q If too much pressurized oil flows to the lift cylin-
balance the load is installed to the lift cylinder der head because of hydraulic drift of the lift
head outlet side of the control valve. arm and compound operation of the bucket,
q When actuators are operated simultaneously, the bucket may stop. The pressure compensa-
the pressure difference (dP) between the tion valve prevents this trouble.
upstream (inlet port) and downstream (outlet
port) of the spool of each valve becomes the
same regardless of 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, 480-6 10-601 45

SEN04426-00 CLSS
10-601 46 WA470, 480-6

CLSS SEN04426-00
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
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. Suction safety valve
14. Suction safety valve
WA470, 480-6 10-601 47

SEN04426-00 Each function and operation of each valve
Each function and operation of each valve 1
Pressure compensation valve 1
(Installed to cylinder head side of lift arm valve)
When high load is applied to lift arm
1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
Function Operation
q When the lift arm is operated singly or together q Actuator circuit pressure (B) exceeds pump
with the bucket, a high load is applied to it. discharge pressure (PPS) and LS pressure
q When the lift arm load pressure exceeds the (PLS).
bucket load pressure, the pressure compensa- q Shuttle valve (3) of the pressure compensation
tion valve works as a load check valve to pre- valve moves to the right.
vent a counterflow in the circuit. q Actuator circuit pressure (B) is connected to
spring chamber (C).
q Piston (4) is pushed to the left by spring (5).
q Valve (2) is also pushed to the left by piston (4)
to close pump outlet port circuit (A) and pre-
vent a counterflow from actuator circuit (B) to
pump outlet port circuit (A).
10-601 48 WA470, 480-6

Each function and operation of each valve SEN04426-00
During compound operation (Lift arm lower + Bucket tilt)
Function Operation
q When the load pressure lowers below the q If the load pressure on the bucket side
bucket pressure during compound operation, increases during compound operation, the flow
the pressure is compensated. rate in actuator circuit (B) increases.
q The load pressure on the bucket side is high q Since LS pressure (PLS) on the bucket side
and the flow rate lowers. increases, shuttle valve (3) of the pressure
compensation valve is pushed to the left.
q The pressurized oil flows through the internal
passage of piston (4) to spring chamber (C).
q Piston (4) and valve (2) are pushed to the left
to close the outlet side of pump circuit (PPS).
q Outlet pressure (A) (spool meter-in down-
stream pressure) becomes equal to the outlet
pressure of the bucket.
q Pump pressure (PPS) (spool meter-in
upstream pressure) becomes even through all
the actuators.
q Pump pressure (PPS) and outlet pressure (A)
in all the operated spools become even.
q The pump delivery is allotted to the spools in
proportion to the open area.
WA470, 480-6 10-601 49

Shuttle valve in the pressure compensation valve 1
When holding pressure at port (B) > LS pressure in spring chamber (C)
1. Hydraulic pump
2. Valve
3. Shuttle valve
4. Piston
Function
q Shuttle valve (3) is pushed to the right by the
pressure in port (B) to disconnect ports (B) and
(D) from each other.
q The holding pressure in port (B) is sent to
spring chamber (C) to press piston (4) to the
left so that piston (4) will not be separated from
valve (2).
10-601 50 WA470, 480-6

Area ratio of pressure compensation valve 1
Function
q The dividing condition changes according to
the area ratio of parts (A1) and (A2) of the
pressure compensation valve. Area ratio =
(A2)/(A1)
q Since the area ratio is less than 1, the spool
meter-in downstream pressure is lower than
the maximum load pressure and more oil than
the open area ratio is divided.
WA470, 480-6 10-601 51

Supply of LS pressure 1
(LS shuttle valve)
1. Hydraulic pump 5. Check valve

2. Main spool 6. LS circuit
3. Pressure compensation valve 7. LS shuttle valve
4. Valve
Function Operation
q LS pressure (PLS) means the actuator load q If main spool (2) is operated, pump discharge
pressure on the control valve outlet side. pressure (PPS) flows to actuator circuit (B).
q The upstream pressure of pressure compensa- q Pump discharge pressure (PPS) is sent
tion valve (3) (spool meter-in downstream through inlet hole (a) of main spool (2) to LS
pressure) is sent through main spool (2) to LS circuit (PLS).
shuttle valve (7). q If the pressure in actuator circuit (B) increases
q The above pressure is connected through to the required pressure, pump discharge pres-
valve (4) to actuator port (B) and used as the sure (PPS) increases.
LS pressure C actuator load pressure. q Check valve (5) in main spool (2) opens and
q Inlet hole (a) in main spool (2) has a small the high pressure in LS circuit (PLS) flows to
diameter and throttling function, too. actuator circuit (B).
q The pressure in LS circuit (PLS) becomes
almost the same as actuator circuit pressure
(B).
10-601 52 WA470, 480-6

LS bypass plug 1
1. Hydraulic pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass valve
6. LS circuit
Function
q The remaining pressure in LS pressure circuit
(6) is released through orifices (a) and (b).
q The speed of the rise in pressure of the LS
pressure is lowered to prevent a sharp change
of the oil pressure.
q A pressure loss is made by the circuit resis-
tance from orifice (c) of main spool (2) to LS
shuttle valve (4) because of the bypass flow
from LS bypass valve (5).
q The effective LS differential pressure
decreases to improve the dynamic stability of
the actuator.
WA470, 480-6 10-601 53

ECSS control valve 1
Function
q The controller automatically turns ON and OFF
the accumulator charged with high-pressure
gas according to the travel condition of the
machine.
q The vertical movement of the machine is
dam ped and p itch ing of the mac hin e i s
reduced during high-speed travel to enhance
the operator comfort, prevent the load from
spilling, and improve the working efficiency.
10-601 54 WA470, 480-6

Operation Accumulator pressure relief valve

q If the travel speed increases to 5 km/h or q When releasing the accumulator (ACC) pres-
higher, the signal flows to solenoid valve (2) sure, loosen plug (3) and nut (4) and open the
and the pressure is applied to (a). (PR) and (TS) circuits.
q Spool (1) moves to the left.
q If spool (1) moves, the passage from (PR) to
accumulator (ACC) is closed and those from
(A2) to accumulator (ACC) and from (B2) to (T)
are opened and the ECSS is turned ON.
q While the travel speed is 4 km/h or below, the
signal does not flow to solenoid valve (2) and
spool (1) is in the neutral position. At this time,
the passage from (PR) to accumulator (ACC)
is opened and accumulator (ACC) is charged.
q If accumulator (ACC) is charged to the set
pressure, check valve (5) is closed and the
accumulator (ACC) pressure does not
increase any more.
WA470, 480-6 10-601 55

Restriction on lift arm RAISE stroke
10-601 56 WA470, 480-6

Function Operation
q If the lift arm is raised and the bucket is oper-
ated simultaneously, the stroke of lift arm spool Single operations
(3) is regulated and more oil flows to the q When the lift arm is raised, the PPC pressure
bucket, and buc ket tilt (dump) s peed is is supplied to (PA2), and lift arm spool (3) and
increased. piston (5) move to the left.
Compound operations
q While the lift arm is being raised, if bucket
dump (PB1) is operated, (PA1) is connected
through the PPC valve to (T).
q Ball (2) of check valve (1) is pushed to the right
and the pressure in (PB1) enters passage (a).
q The (PB1) pressure supplied to passage (a)
pushes piston (5) to the right with the force of
the area receiving the pressure of piston (5)
[x/4 (ød2 – øc2) x (PB1)].
q Lift arm spool (3) is pushed to the right and
balanced at the stroke where [x/4øb2 x (PA2)]
= [x/4 (ød 2 – øc 2 ) x (PB1) + Force of spring
(4)].
q As the result, the open area of notch (e) is
reduced to decrease the oil flowing to port (A2)
and the excessive oil flows to (B1) to increase
the dumping speed.
WA470, 480-6 10-601 57

Accumulator charge valve
CR: Pressure pickup port 1. Screw

P: From main pump 2. Poppet (safety valve)
PR: To accumulator through ECSS spool 3. Spring (safety valve)
TS1: To tank 4. Spring (main pressure reducing valve)
TS2: To tank 5. Pressure reducing valve spool
TS3: To tank 6. Poppet (check valve)
7. Spring (check valve)
10-601 58 WA470, 480-6

WA470, 480-6 10-601 59

When in neutral or pressure (P) is low
Function
q Discharge pressure (P) of the hydraulic pump
is reduced and the pressurized oil is supplied
to the ECSS accumulator.
Operation
q Poppet (2) is pressed against the seat by
spring (3) and ports (P1) and (T) are discon-
nected from each other.
q Poppet (6) is pressed to the left and ports (P1)
and (PR) are disconnected from each other.
q Poppet (6) is moved to the right by the (P1)
pressure and ports (P1) and (PR) are con-
nected to each other. If the (PR) pressure
exceeds the (P1) pressure, poppet (6) is
pressed to the left by spring (7) and ports (P1)
and (PR) are disconnected from each other.
10-601 60 WA470, 480-6

When load pressure (P) is high
Operation
q If pressure (P) exceeds the set pressure, pop-
pet (3) opens and the pressurized oil flows
from port (P1) through hole (a) in spool (5) and
opening of poppet (2) to tank port (T).
q Differential pressure is generated between the
front and rear of hole (a) in spool (5) and spool
(5) moves to close the opening between ports
(P) and (P1). Pressure (P) is reduced and
adjusted to certain pressure (set pressure) by
the open area at this time and supplied as
pressure (P1).
WA470, 480-6 10-601 61

SEN04426-00

©2008 KOMATSU
All Rights Reserved
10-601 62
SEN04427-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up


PPC valve ....................................................................................................................................................... 2
Accumulator (for PPC circuit)........................................................................................................................ 10
Accumulator (for power train circuit) ..............................................................................................................11
Accumulator (for ECSS)................................................................................................................................ 12
Work equipment PPC cut-off solenoid valve................................................................................................. 13
WA470, 480-6 10-602 1

SEN04427-00 PPC valve
PPC valve 1
Work equipment PPC valve 1
P: From charge valve P3: To lift arm valve (Raise)

P1: To bucket valve (Tilt) P4: To bucket valve (Dump)
P2: To lift arm valve (Lower, Float) T: To hydraulic tank
10-602 2 WA470, 480-6

PPC valve SEN04427-00
1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Lever
6. Ring
7. Plate
8. Piston
9. Retainer
10. Body
WA470, 480-6 10-602 3

Operation
1. When in neutral
1) PPC valve for bucket 2) PPC valve for lift arm
q Ports (PA) and (PB) of the control valve q Ports (PA) and (PB) of the control valve (lift
(bucket valve) and ports (P1) and (P4) of the arm valve) and ports (P2) and (P3) of the PPC
PPC valve are connected through fine control valve are connected through fine control hole
hole (f) of spool (1) to drain chamber (D). (f) of spool (1) to drain chamber (D).
10-602 4 WA470, 480-6

2. During fine control q The control valve spool moves to a position

(Neutral o fine control) 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.
q If rod (4) and piston (8) are pushed by lever

(5), retainer (9) is pushed and spool (1) is also
pushed downward through metering spring (2).
q As fine control hole (f) is disconnected from
drain chamber (D), it is connected to pump
pressure chamber (PP) almost simultaneously,
and then the pilot oil of the main pump flows
from port (P1) to port (PB).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1). The positional rela-
tionship between spool (1) and body (10) (in
this situation, fine control hole (f) is between
drain chamber (D) and pump pressure cham-
ber (PP)) does not change until retainer (9)
comes in contact with spool (1).
q Since metering spring (2) is compressed in
proportion to the travel of the control lever, the
pressure in port (P1) also rises in proportion to
the travel of the control lever.
WA470, 480-6 10-602 5

3. During fine control 4. At full stroke

(When control lever is returned)
q If lever (5) and rod (4) push down piston (8)

q If lever (5) begins to return, the force of center- and retainer (9) pushes down spool (1), fine
ing spring (3) and the pressure in port (P1) control hole (f) is disconnected from drain
push up spool (1). chamber (D) and connected to pump pressure
q Because of this, fine control hole (f) is con- chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot oil from the main pump flows through
ized oil at port (P1) is released. fine control hole (f) and port (P1) into chamber
q If the pressure at port (P1) goes down too far, (PB) to push the control valve spool.
spool (1) is pushed down by metering spring q The oil returning from chamber (PA) flows
(2). Fine control hole (f) is shut off from drain through port (P4) and fine control hole (f') into
chamber (D), and almost simultaneously, it is drain chamber (D).
connected to pump pressure chamber (PP).
Pump pressure is supplied until the pressure at
port (P1) recovers to a pressure equivalent to
the position of the lever.
q When the control valve spool returns, the pres-
surized oil in drain chamber (D) flows in
through fine control hole (f') of the valve which
is not in operation and then flows through port
(P4) into chamber (PA).
10-602 6 WA470, 480-6

5. During lift arm float operation 6. When lift arm float operation is reset
q When returning lever (5) from the "float" posi-
tion, the rod is pushed down with a force larger
than absorptive power of the solenoid.
q The "float" state also can be reset and the
lever can be returned to the "neutral" position
by turning off the current in the solenoid (de-
energizing the solenoid).
q The lift arm raise and bucket tilt operations are

carried out similarly to the above.
q As lever (5) pushes down rod (4) and piston (8)

on port (P3) "lower" side, the detent starts
operation before the stroke end. (the operating
effort of the lever becomes heavy.)
q If rod (4) is pushed down further, the detent
operates to keep the lift arm in "float" state
even if the lever is released.
q At the same time, the control valve is also
moved to the "float" position to keep the lift arm
in float condition.
WA470, 480-6 10-602 7

Service PPC valve

(If equipped)
a For the details of operation, see the paragraph of "Work equipment PPC valve".
10-602 8 WA470, 480-6

A: To service valve
B: To service valve
P: From charge pump
T: To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
Unit: mm
No. Item Criteria Remedy
Free length x
Installed
7 Centering spring diameter
length If damaged or
deformed, replace
17.7 N 14.1 N spring
42.48 x 15.5 34 —
{1.8 kg} {1.44 kg}
16.7 N 13.3 N
8 Metering spring 23.9 x 8.1 22.9
{1.7 kg}
—
{1.36 kg}
WA470, 480-6 10-602 9

SEN04427-00 Accumulator (for PPC circuit)
Accumulator (for PPC circuit) 1
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Function
q This 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
Amount of gas (cc) 500
Charged pressure 1.18(+0.2/0) {12(+2/0)}
Max. pressure used
3.92 {40}
(MPa {kg/cm2})
10-602 10 WA470, 480-6

Accumulator (for power train circuit) SEN04427-00
Accumulator (for power train circuit) 1
1. Top cover
2. Free piston
3. Cylinder
4. End cover
5. Core
Function
q The accumulator is installed between the
power train pump and transmission ECMV.
The space between cylinder (3) and free piston
(2) is filled with nitrogen gas, which absorbs
the pulsation pressure generated by the power
train pump and secures the reliability by utiliz-
ing its compressibility.
Specifications
Amount of gas (cc) 46
Charged pressure 0.29 ± 0.05 {3 ± 0.5}
Max. pressure used
4.9 {50}
(MPa {kg/cm2})
WA470, 480-6 10-602 11

SEN04427-00 Accumulator (for ECSS)
Accumulator (for ECSS) 1
(If equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q This 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
Amount of gas (cc) 4,000
Charged pressure 2.94 {30}
Max. pressure used
40 {408}
(MPa {kg/cm2})
10-602 12 WA470, 480-6

Work equipment PPC cut-off solenoid valve SEN04427-00
Work equipment PPC cut-off solenoid valve 1
(If equipped)
P: From charge valve Outline

A: To work equipment PPC valve port P q The work equipment PPC cut-off solenoid
T: Drain valve is installed between the charge valve
and work equipment PPC valve. If the work
1. Coil (ON/OFF type) equipment lock switch is set in the "LOCK"
2. Push pin position, the solenoid is "de-energized" and the
3. Spool oil to the work equipment PPC valve is cut off
4. Spring to disable the work equipment.
5. Block
WA470, 480-6 10-602 13

SEN04427-00 Work equipment PPC cut-off solenoid valve
Operation
When solenoid valve is "de-energized" (circuit When solenoid valve is "energized" (circuit is
is closed) connected)
q Coil (1) is de-energized when no signal current q Coil (1) is energized when signal current is
is supplied to coil (1). supplied to coil (1).
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 Port (P) is connected to port (A) and the pilot
q Port (P) is disconnected from port (A) and the oil pressure flows from port (A) to the work
pilot oil pressure does not flow from port (A) to equipment PPC valve.
the work equipment PPC valve. At this time, port (T) closes and the oil from the
At this time, port (T) opens and the oil from the work equipment PPC valve does not flow to
actuator is drained into the hydraulic tank. the hydraulic tank.
10-602 14 WA470, 480-6

Work equipment PPC cut-off solenoid valve SEN04427-00
WA470, 480-6 10-602 15

SEN04427-00

©2008 KOMATSU
All Rights Reserved
10-602 16
SEN04428-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

700 Work equipment

Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 5
Bucket positioner and boom kick-out .............................................................................................................. 6
Work equipment cylinder .............................................................................................................................. 12
WA470, 480-6 10-700 1

700 Work equipment
SEN04428-00 Work equipment linkage
Work equipment linkage 1
10-700 2 WA470, 480-6

700 Work equipment
Work equipment linkage SEN04428-00
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
WA470-6
Unit: mm
Clearance between bushing and size Shaft Hole clearance limit
7 pin at each end of bucket link –0.036 +0.207 0.156 –
95 –0.090 +0.120 0.297 1.0
Clearance between bushing and –0.036 +0.207 0.156 –
8 pin connecting lift arm and bucket
95
–0.090 +0.120 0.297
1.0
9 Clearance between bushing and

pin connecting lift arm and frame
110
–0.036
–0.090
+0.207
+0.120
0.156 –
0.297
1.0
–0.036 +0.207 0.156 –
10 pin connecting bucket cylinder 120 –0.090 +0.120 0.297 1.0
bottom and frame Replace (replace
pin when it has
Clearance between bushing and –0.036 +0.207 0.156 – scuff marks, too.)
rod and bell crank
12 pin connecting bell crank and lift 125 –0.106 +0.145 0.351 1.0
arm
13 pin connecting lift cylinder rod 110
–0.090 +0.120 0.297
1.0
and lift arm
14 pin connecting lift cylinder bottom 110
–0.090 +0.120 0.297
1.0
and frame
Width of boss Width of hinge
Standard
Standard Standard clearance
15 Connecting part of bucket
cylinder and frame
size Tolerance size Tolerance
125 0 128 ±0.8 2.2 – 4.3

–0.5 Adjust the
Connecting part of lift arm and +2.5 clearance to
16 frame 127 ±2.3 130 0 0.7 – 7.8
1.5 mm or less on
Connecting part of lift arm and +1.5 each side with the
17 bucket 119 ±2.3 122 0 0.7 – 6.8 shim.
Connecting part of bucket link +3 +1.5
18 and bucket 138 –0.5 143 0 2–7
Connecting part of lift cylinder 0 +2.5
19 and frame 110 –0.5 115 0 5–8
Connecting part of bell crank and +3
20 bucket link 138 –0.5 143 ±1.5 0.5 – 7
Replace
Connecting part of bell crank and
21 lift arm 220 ±0.5 223 ±0.5 2–4
Adjust the
cylinder and bell crank
115 0
–0.5
118 ±1.5 1.5 – 5.0 clearance to
1.5 mm or less on
23 Connecting
cylinder
part of lift arm and lift 109 ±2.3 114 ±1.5 1.2 – 8.8 each side with the
shim.
WA470, 480-6 10-700 3

700 Work equipment
SEN04428-00 Work equipment linkage
WA480-6
Unit: mm
Clearance between bushing and size Shaft Hole clearance limit
7 pin at each end of bucket link –0.036 +0.307 0.256 –
110 –0.090 +0.220 0.397 1.0
8 pin connecting lift arm and bucket
110
–0.090 +0.220 0.397
1.0
9 Clearance between bushing and

pin connecting lift arm and frame
110
–0.036
–0.090
+0.207
+0.120
0.156 –
0.297
1.0
–0.036 +0.307 0.256 –
bottom and frame Replace (replace
pin when it has
Clearance between bushing and scuff marks, too.)
–0.036 +0.307 0.256 –
rod and bell crank
–0.043 +0.245 0.188 –
12 pin connecting bell crank and lift 125 –0.106 +0.145 0.351 1.0
arm
–0.036 +0.207 0.156 –
13 pin connecting lift cylinder rod 110
–0.090 +0.120 0.297
1.0
and lift arm
–0.036 +0.207 0.156 –
14 pin connecting lift cylinder bottom 110
–0.090 +0.120 0.297
1.0
and frame
Width of boss Width of hinge
Standard
Standard Standard clearance
cylinder and frame
size Tolerance size Tolerance
0
140 –0.5 143 ±0.8 2.2 – 4.3
Adjust the
16 Connecting
frame
part of lift arm and 127 ±2.3 130 +2.5
0 0.7 – 7.8 clearance to
1.5 mm or less on
each side with the
17 Connecting
bucket
part of lift arm and 140 ±2.3 143 +1.5
0 0.7 – 6.8 shim.
18 Connecting
and bucket
part of bucket link 140 +3
–0.5 143 +1.5
0 0–5
19 Connecting
and frame
part of lift cylinder 110 0
–0.5 115 +2.5
0 5–8
20 Connecting
bucket link
part of bell crank and
140
+3
–0.5 143
+1.5
0 0–5
Replace
21 Connecting
lift arm
part of bell crank and
245 ±0.5 248 ±0.5 2–4
Adjust the
cylinder and bell crank
140
0
–0.5
143 ±1.5 1.5 – 5.0 clearance to
1.5 mm or less on
23 Connecting
cylinder
part of lift arm and lift
109 ±2.3 114 ±1.5 1.2 – 8.8 each side with the
shim.
10-700 4 WA470, 480-6

700 Work equipment
Bucket SEN04428-00
Bucket 1
1. Bucket
2. Wear plate
3. Bolt-on cutting edge (BOC)
4. Bucket teeth (if equipped)
Unit: mm
5 Wear of bucket tooth Replace
50 18.5
Clearance in bucket tooth
6 mounting parts Max. 0.5 — Adjust or replace
Reverse or
7 Wear of cutting edge 93 — replace
WA470, 480-6 10-700 5

700 Work equipment
SEN04428-00 Bucket positioner and boom kick-out
Bucket positioner and boom kick-out 1
1. Proximity switch
2. Bucket cylinder
3. Angle bar
4. Lift arm
5. Plate
Unit: mm
Clearance between bucket
6 positioner proximity switch and 3–5
angle bar Adjust
Clearance between boom
7 kick-out proximity switch and plate 3–5
10-700 6 WA470, 480-6

700 Work equipment
Bucket positioner and boom kick-out SEN04428-00
Bucket positioner Boom kick-out
q The bucket positioner is driven electrically. q The boom kick-out is driven electrically. When
When the bucket is returned to an angle from the lift arm is raised to a specific angle just
the dump position toward the tilt position, the before reaching the maximum height, the
bucket positioner returns the bucket control boom kick-out returns the lift arm control lever
lever from the "tilt" position to the "hold" posi- from the "raise" position to the "hold" position
tion to automatically stop the bucket at a preset to stop the lift arm automatically at a desired
digging angle. height.
q Angle bar (3) is fixed to the rod side of bucket q Plate (5) is fixed to lift arm (4). Proximity switch
cylinder (2). Proximity switch (1) is fixed to the (1) is fixed to the front frame.
cylinder side. q Moving the lift arm control lever from "lower"
q Moving the bucket control lever from "dump" position to "raise" position moves lift arm (4)
position to "tilt" position moves the rod of upward.
bucket cylinder (2) toward the machine front When lift arm (4) comes to a specific position,
side. proximity switch (1) detects that plate (5) is
When the bucket reaches the specific position, above the sensing surface, and returns the lift
proximity switch (1) judges that angle bar (3) arm control lever to "Hold" position.
has left the sensing surface and returns the
bucket control lever to the "Hold" position.
WA470, 480-6 10-700 7

700 Work equipment
Operation of proximity switch
When bucket is tilted
q While the bucket is dumping more than the q Shifting bucket control lever (7) toward the tilt
position being preset by the bucket positioner, position moves spool (8) in the direction of the
angle bar (2) moves on to the sensing surface arrow, and the spool is held there by the ener-
of proximity switch (1), turning on the proximity gized coil of detent solenoid (6).
switch lamp. As a result, bucket control lever (7) is held at
At this point, bucket positioner relay (4) is ener- the tilt position and the bucket continues "tilt-
gized and current flows to detent solenoid (6) ing".
of work equipment PPC valve (5) to energize
the coil.
10-700 8 WA470, 480-6

700 Work equipment
a The power supply for detent solenoid (6) oper-

ation is switched on or off by alternator relay
(11).
Detent solenoid (6) circuit is cut off because R
signal from alternator (10) is not sent to alter-
nator relay (11) when the engine is stopped.
As a result, bucket control lever (7) cannot be
moved and held at the "tilt" position when
angle bar (2) is positioned at sensing surface
of proximity switch (1).
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned ON
Bucket positioner relay ON

Work equipment PPC valve detent
Power ON
solenoid circuit
Energized
solenoid
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned OFF
Bucket positioner relay OFF

Work equipment PPC valve
Power OFF
detent solenoid circuit
De-energized
solenoid
q When the bucket is tilted and moved away

from the position preset by the bucket posi-
tioner – in other words, when angle bar (2)
moves away from the sensing surface of prox-
imity switch (1), the lamp of proximity switch
(1) goes off and bucket positioner relay (4) is
turned off.
Accordingly, the circuit of detent solenoid (6) of
work equipment PPC valve (5) is turned off to
de-energize the coil.
Lift arm spool (8), which has been held by the
solenoid, receives the reactive force of spring
(9) and returns bucket control lever (7) to the
"Hold" position.
WA470, 480-6 10-700 9

700 Work equipment
When lift arm is raised
q When lift arm (3) is lower than the preset boom q Shifting lift arm control lever (7) upward moves
kick-out position, plate (2) is not at the sensing spool (8) in the direction of the arrow, and
surface and the lamp of proximity switch (1) spool is held there by the energized coil of
goes off. detent solenoid (6).
At this point, boom kick-out relay (4) is turned As the result, lift arm control lever (7) is held at
off and current is supplied to detent solenoid the raise position and lift arm (3) continues ris-
(6) of work equipment PPC valve (5) to ener- ing.
gize the coil.
10-700 10 WA470, 480-6

700 Work equipment
a The power supply for detent solenoid (6) oper-

ation is switched on or off by alternator relay
(11).
Detent solenoid (6) circuit is cut off because R
signal from alternator (10) is not sent to alter-
nator relay (11) when the engine is stopped.
As a result, lift arm control lever (7) cannot be
moved and held at the "raise" position when
plate (2) is not positioned at sensing surface of
proximity switch (1).
Function of proximity switch
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned OFF
Boom kick-out relay OFF

Power ON
solenoid circuit
Energized
solenoid
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned ON
Boom kick-out relay ON

Power OFF
solenoid circuit
De-energized
solenoid
q When raised lift arm (3) comes to the preset

boom kick-out position, or if plate (2) comes to
the sensing surface of proximity switch (1), the
lamp of proximity switch (1) lights up and cur-
rent is supplied to boom kick-out relay (4).
Accordingly, the circuit of detent solenoid (6) of
work equipment PPC valve (5) is turned off to
de-energize the coil.
Lift arm spool (8), which has been held by the
solenoid, receives the reactive force of spring
(9) and returns lift arm control lever (7) to the
"Hold" position.
WA470, 480-6 10-700 11

700 Work equipment
SEN04428-00 Work equipment cylinder
Work equipment cylinder 1
Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance Lift 95 –0.036 +0.222 0.083 – 0.612

–0.090 +0.047 0.312
1 between piston Replace bushing
rod and bushing WA470 –0.036 +0.257 0.083 –
100 0.647
–0.090 +0.047 0.347
Bucket
–0.036 +0.261 0.083 –
WA480 110 0.651
–0.090 +0.047 0.351
Lift 373 ± 54 Nm {38.0 ± 5.5 kgm}
Tightening
2 torque of cylinder WA470 530 ± 78.5 Nm {54.0 ± 8.0 kgm}
head Bucket
WA480 892 ± 137 Nm {91.0 ± 14 kgm}
Lift 294 ± 29.4 Nm {30 ± 3.0 kgm} Retighten

Tightening torque of
3 cylinder piston
Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of Lift 58.9 – 73.6 Nm {6.0 – 7.5 kgm}

4 cylinder piston lock
screw Bucket 58.9 – 73.6 Nm {6.0 – 7.5 kgm}
10-700 12 WA470, 480-6

700 Work equipment
Work equipment cylinder SEN04428-00
WA470, 480-6 10-700 13

SEN04428-00

©2008 KOMATSU
All Rights Reserved
10-700 14
SEN04429-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

800 Cab and its attachments

Cab ................................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4
WA470, 480-6 10-800 1

SEN04429-00
10-800 2 WA470, 480-6

Cab SEN04429-00
Cab 1
1. Front working lamp

2. Door (left)
3. Air conditioner external air filter (if equipped)
4. Front glass
5. Front wiper
6. KOMTRAX communication antenna (if equipped)
7. KOMTRAX GPS antenna (if equipped)
8. Radio antenna (if equipped)
9. Door (right)
10. Rear wiper
WA470, 480-6 10-800 3

SEN04429-00 Air conditioner
Air conditioner 1
Air conditioner piping diagram 1
10-800 4 WA470, 480-6

Air conditioner SEN04429-00
1. Hot water take-out piping Specifications

2. Power train oil cooler Refrigerant used R134a
3. Condenser
4. Receiver Refrigerant refilling level (g) 1,250
5. Hot water return piping
6. Compressor
7. Refrigerant piping
8. External air filter
9. Fresh/recirculation air changeover damper
10. Blower unit
11. Air conditioner unit
12. Dual pressure switch
13. Air outlet duct
14. Cool and hot box (if equipped)
15. Internal air filter
16. Sunlight sensor (machine equipped with auto-
matic air conditioner)
WA470, 480-6 10-800 5

Refrigerant circuit diagram
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
6. Dual pressure switch
Table of tightening torque for refrigerant piping adapter

Unit: Nm {kgm}
12 – 15 {1.2 – 1.5}
7 Air conditioner unit refrigerant inlet side (screw size: M16 x 1.5)
Air conditioner unit refrigerant outlet 30 – 35 {3.1 – 3.6}
8 side (screw size: M24 x 1.5)
8 – 12 {0.8 – 1.2}
9 Receiver refrigerant pipe set bolt (screw size: M16 x 1.0)
Retighten
20 – 25 {2.0 – 2.6}
10 Compressor refrigerant piping lock bolt (screw size: M8 x 1.25)
20 – 25 {2.0 – 2.6}
11 Condenser refrigerant inlet side (screw size: M22 x 1.5)
12 – 15 {1.2 – 1.5}
12 Condenser refrigerant outlet side (screw size: M16 x 1.5)
10-800 6 WA470, 480-6

WA470, 480-6 10-800 7

Air conditioner unit 1
10-800 8 WA470, 480-6

A: From receiver Outline

B: To compressor q The vertical air conditioner unit on which evap-
C: Hot water inlet orator (1) and heater core (2) is synchronized
D: Hot water outlet with the blower and intake unit to generate cool
and hot air.
1. Evaporator q The temperature adjusting switch on the air
2. Heater core conditioner panel controls air mix dampers (3)
3. Air mix damper (upper) and (4) to adjust the spurting out temperature.
4. Air mix damper (lower)
5. Expansion valve Cooler
6. Blower controller q The cooler circulates refrigerant through evap-
7. Blower motor relay orator (1) to cause heat exchange (dehumidifi-
8. Compressor clutch relay cation and cooling).
9. Air mix damper actuator q Air taken in by the blower and intake unit is
10. Evaporator temperature sensor cooled with evaporator (1) and then blown out
11. Dual pressure switch from the duct and grille.
12. Mode selector damper actuator
(machine equipped with automatic air Heater
conditioner)
q The heater circulates engine coolant in heater
13. Mode selector damper
core (2) to cause heat exchange (heating).
(machine equipped with automatic air
q Air taken in by the blower and intake unit is
conditioner)
heated with heater core (2) and then blown out
through the duct and grille.
WA470, 480-6 10-800 9

Functions of major components

Evaporator Mode selector damper actuator
q Evaporator fin is cooled by the low-pressure, (machine equipped with automatic air condi-
low-temperature refrigerant gas being sent tioner)
from the expansion valve. Air from the blower q Receiving signal current from the air condi-
motor is cooled and dehumidified when pass- tioner panel, the actuator starts the built-in
ing through the fin. motor to open or close the mode selector
damper through the link mechanism.
Heater core q The motor rotation direction is determined from
q Fin of the heater core is heated by the hot the mode selector switch on the air conditioner
water (coolant) being sent from the engine. Air panel.
from the blower motor is heated as it passes q Rotation of the motor is stopped as the con-
through the fin. tact, which is to move interlocked with the
motor, moves away or signal current from the
Expansion valve air conditioner panel is turned "OFF".
q This valve converts high-pressure, high-tem-
perature liquid refrigerant from the receiver to Evaporator temperature sensor
low-pressure, low-temperature misty refriger- q In order to prevent freezing of the evaporator, it
ant through the throttling function. senses the evaporator temperature and sends
It controls flow rate of refrigerant by changing necessary signals to the air conditioner panel.
level of throttling depending on the thermal The signal sent to the air conditioner panel is
load in the operator's cab. used to control the compressor. As the result,
temperature of the air blown out of the grille is
Blower controller adjusted depending on the volume of refriger-
q It controls the blower motor speed receiving ant circulated in the evaporator.
signal current from the air conditioner panel.
Dual pressure switch
Blower motor relay q If abnormally low or high pressure was gener-
q Signal current from the air conditioner panel ated in the refrigerant circulation circuit, this
controls the relay coil. As the relay coil is ener- switch releases the magnet clutch of the com-
gized and the switch is turned "ON", power is pressor to protect a series of cooler-related
supplied to the blower motor. equipment.
Compressor clutch relay

q Signal current from the air conditioner panel
dual pressure switch is used for controlling the
relay coil. As the relay coil is energized and the
switch is turned "ON", the magnet clutch of the
compressor is connected.
Air mix damper actuator

q It starts the built-in motor receiving signal cur-
rent from the air conditioner panel in order to
open or close the air mix damper through the
link mechanism.
q The motor rotating direction is determined as LA: 0.20 MPa {2 kg/cm2}
the air conditioner panel reads the position of LB: 0.02 MPa {0.2 kg/cm2}
the potentiometer being built in the actuator. HA: 3.14 MPa {32 kg/cm2}
This reading is done as the target temperature HB: 0.59 MPa {6 kg/cm2}
is set from the temperature adjustment switch
on the air conditioner panel.
q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
air conditioner panel is turned "OFF".
10-800 10 WA470, 480-6

Sunlight sensor
(machine equipped with automatic air condi-
tioner)
q The sunlight sensor is installed in the upper left
side corner of the dashboard.
q Sensing the intensity of sunlight, this sensor
sends the corresponding signal to the air con-
ditioner panel. The signal sent to the air condi-
tioner panel is used to control the blower motor
and compressor.
WA470, 480-6 10-800 11

Blower and intake unit 1
10-800 12 WA470, 480-6

1. Blower motor assembly Functions of major components

2. Fresh/recirculation air changeover damper
Blower motor assembly
actuator
3. Fresh/recirculation air changeover damper q It suctions air by rotating the fin installed on the
4. Recirculated internal air temperature sensor blower motor. And it is also used for sending
(machine equipped with automatic air the absorbed air to the evaporator and heater
conditioner) core.
5. Fresh external air temperature sensor
(machine equipped with automatic air Fresh/recirculation air changeover damper
conditioner) actuator
q Receiving signal current from the air condi-
tioner panel, it starts the built-in motor to open
or close the fresh/recirculation air changeover
damper through the link mechanism.
q The motor rotation direction is determined from
the fresh/recirculation air changeover switch
on the air conditioner panel.
q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
air conditioner panel is turned "OFF".
Recirculation air temperature sensor

Fresh air temperature sensor
(machine equipped with automatic air condi-
tioner)
q Sensing recirculated internal and fresh exter-
nal air temperature, the sensors send the cor-
responding signal to the air conditioner panel.
The signal sent to the air conditioner panel is
used to control the compressor. As the result,
temperature of the air blown out of the grille is
adjusted depending on the volume of refriger-
ant circulated in the evaporator.
WA470, 480-6 10-800 13

Compressor 1
A: From air conditioner unit Function

B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature misty
refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders –
7 – 29.3 x 27.4
Bore x 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)
10-800 14 WA470, 480-6

Condenser 1
A: From compressor Function

B: To receiver q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
compressor.
a If the fin crushes or is clogged with dusts, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection to prevent the fin
from being crushed.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation surface (m )
2
9.33
Max. using pressure (MPa {kg/cm2}) 3.6 {36}
WA470, 480-6 10-800 15

Receiver 1
A: From condenser Function

B: To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature liquid refrigerant from the con-
1. Sight glass denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
10-800 16 WA470, 480-6

Air conditioner panel 1
Manual air conditioner specification
Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Spurting out All segments below applicable level come
1 See above drawing
temperature on (8-step display)
Gauge
Air blasting All segments below applicable level come
2 See above drawing
volume on (4-step display)
The display indicates which is currently
Circulation of When circulating Liquid
taking place – internal air circulation or Black
internal air and internal air and crystal
3 external air introduction – responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air
Turns "ON" air conditioner switch, this lamp
4 Air conditioner conditioner switch
lights up.
is "ON"
Switch block
No. Switch name Function Operation

Circulation of
This switch is used to select either the circulation of internal air or
internal air
Internal/external air introduction of external air
5 IO
changeover switch (pilot display on the display unit is switched depending on the switch
Introduction of
setting)
external air
6 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
It turns on or off main power supply of the air conditioner.
7 Main power switch ON: Settings done during "OFF" are indicated on the display unit. OFF io ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO io HI
(adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It controls the spurting out temperature
9 IO
switch (8-step adjustment)
High temperature
WA470, 480-6 10-800 17

Automatic air conditioner specification
Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Blown out air temp. Displays the temperature of the air blowing
Indicator panel (0 – 99.9°C) out.
(blown out
1 Indicator If an actuator or sensor fails, 3-digit failure
air temp., [*1]
failure code) alphanumeric character (failure code) are
Failure code
displayed.
All segments below applicable level come
2 Gauge Air flow volume See above drawing
on (4-step display)
Recirculation of When recirculating The display indicates which is currently
internal air and internal air and taking place – recirculation or fresh air
3
introduction of introducing fresh introduction – responding to the operation of
fresh air air the FRESH/RECIRC selector switch.
When air Liquid
This lamp lights up when the air conditioner Black
4 Air conditioner conditioner switch crystal
switch is turned "ON".
is turned "ON"
When automatic
Pilot Automatic air air conditioner This lamp lights up when the automatic air
5
conditioner switch is turned conditioner switch is turned "ON".
"ON"
When defroster
Blowing from This lamp lights up when the defroster
6 switch is turned
defroster switch is turned "ON".
"ON"
When FACE or The display switches between blowing to
7 Mode selection FOOT blowing is FACE and FOOT responding to the mode
turned on selector switch operation.
*1: For details of the failure codes, see the applicable section in Testing and adjusting.
10-800 18 WA470, 480-6

Switch block
No. Name Function Operation

Recirculation of
This switch is used to select either the recirculation of internal air or
internal air
FRESH/RECIRC introduction of fresh external air
8 I O
selector switch (The pilot indication on the display unit varies depending on the given
Introduction of
setting.)
fresh air
9 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
It turns on or off main power supply of the air conditioner.
10 Main power switch ON: Settings done during "OFF" are indicated on the display unit. OFF io ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of the air sent from the fan.
11 Fan switch LO io HI
(Adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature control
12 It is used to control spurting out temperature. (0 – 99.9°C) I O
switch
High temperature
Automatic air
13 It turns on or off the cooling and the dehumidifying heating function. OFF io ON
conditioner switch
It switches the blowing out mode between FACE and FOOT
14 Mode selector switch (The pilot indication on the display unit varies depending on the given FACE io FOOT
setting.)
15 Defroster switch It turns on or off the blowing out of the air from the defroster. OFF io ON
WA470, 480-6 10-800 19

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.
Input and output signals

JAE IL-AG5-14P [CN-C48] JAE IL-AG5-22P [CN-C47]
Input and Input and
Pin Pin
Signal name output Signal name output
No. No.
signals signals
1 GND — 1 NC —
2 Sensor ground — 2 NC —
Fresh/recirculation air changeover damper 3 Blower motor relay Input
3 Input
actuator limiter Fresh/recirculation air changeover damper
4 External air temperature sensor Input 4 actuator output 1 Output
5 Evaporator temperature sensor Input Fresh/recirculation air changeover damper
5 actuator output 2 Output
6 Internal air temperature sensor Input
7 Starting switch (ON) Input 6 Mode selector actuator output 2 Output
8 Night lamp signal Input 7 Mode selector actuator output 1 Output
9 NC — 8 Air mix damper actuator output 2 Output
10 NC — 9 Air mix damper actuator output 1 Output
11 NC — 10 Actuator potentiometer power supply (5 V) —
12 NC — 11 NC —
13 Sunlight sensor 2 Input 12 NC —
14 Sunlight sensor 1 Output 13 NC —
14 NC —
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground —
10-800 20 WA470, 480-6

WA470, 480-6 10-800 21

SEN04429-00

©2008 KOMATSU
All Rights Reserved
10-800 22
SEN04430-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

901 Electrical system, Part 1

Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 6
WA470, 480-6 10-901 1

SEN04430-00 Machine monitor system
Machine monitor system 1
Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors controls the machine setting and adjustment functions are provided
condition with the sensors installed to various using the character display and the machine
parts of the machine, and then sends the result monitor mode selector switch, which is the
as network information to the machine monitor, operation switch of the character display.
which displays the information to notify the 1) Display the odometer
operator of the machine condition. 2) Resetting the filter or oil replacement time
3) Input the telephone number
q The machine monitor displays the information 4) Selecting the language
in the operator mode or service mode. 5) Adjusting the illuminance of nighttime light
6) Travel speed/engine speed display select-
q The operator mode is used to display the infor- ing function
mation to the operator normally. The major 7) Function for setting display/no-display of
functions used in the service mode are as fol- travel speed or engine speed to the char-
lows. acter display
8) Display of load meter
1. Items always displayed (machine equipped with load meter)
q Meters (speedometer or engine tachome- q Load meter display mode selecting
ter) function
q Gauges (engine coolant temperature q Loaded/Empty machine calibration
gauge, torque converter oil temperature q Resetting calibration
gauge, hydraulic oil temperature gauge, q Printer output mode selecting function
and fuel level gauge) (if equipped)
q Pilot indicators 9) Time adjustment of clock
q Service meter (machine equipped with load meter)
The following items are displayed accord-

ing to the set state of the optional device
selecting function.
q Travel speed or engine speed indication
on the character display
q Display of weight calculated by load meter
(machine equipped with load meter)
q Display of clock
(machine equipped with load meter)
2. Items displayed when abnormality is detected

q Caution lamps
q Action code (while an action code is dis-
played, if the machine monitor mode
selector switch (>) is pressed and
released, the failure code (6 digits) is dis-
played.)
3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(maintenance monitoring function)
10-901 2 WA470, 480-6

Machine monitor system SEN04430-00
q The service mode function is provided for the 10. Machine serial number input function
ease of troubleshooting for the controllers on Enters the machine serial number to identify
the network (including the machine monitor the machine.
itself). The major functions used in this mode
are as follows. 11. Model selection function
Enters the information of applicable model.
1. Electrical system failure history display func-
tion 12. Initialize function
The electrical system failures of each controller Sets the machine monitor to the state set when
saved in the machine monitor are displayed. the machine is delivered.
The information of those failures is also
deleted with this function.
2. Mechanical system failure history display func-

tion
The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.
3. Real-time monitoring function

The input and output signals recognized by
each controller on the network are displayed in
real time.
4. Engine reduced-cylinder function

This function is used for the purpose of speci-
fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
5. No injection cranking function

Before restarting engine after a long-term stor-
ing of the machine, this function is used to
lubricate the engine internally.
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.
7. Maintenance monitoring function

Changes the filter or oil replacement time and
makes ON/OFF selection of the function.
8. Operating information display function

(OPERATION INFO)
Displays fuel consumption per operating hour.
9. Optional device selecting function

Verifies the installation of optional devices or
changes their setting.
WA470, 480-6 10-901 3

SEN04430-00 Machine monitor system
System circuit diagram 1
a Items marked with "*1" in drawing may or may not installed.
10-901 4 WA470, 480-6

Machine monitor system SEN04430-00
WA470, 480-6 10-901 5

SEN04430-00 Machine monitor
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. Headlamp 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 oil 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 pilot lamp (*2)
16. Water separator caution lamp (*1) 37. Economy operation pilot lamp
17. Engine oil level caution lamp 38. Shift indicator
18. Radiator coolant level caution lamp 39. Auto shift pilot lamp
19. Transmission oil filter clogging caution lamp (*1) 40. Torque converter lockup pilot lamp (*2)
20. Air cleaner clogging caution lamp 41. Shift hold pilot lamp
(machine equipped with KOMTRAX) 42. Shift lever position pilot lamp
21. Parking brake pilot lamp
*1: Not used by this model

*2: If equipped
10-901 6 WA470, 480-6

Machine monitor SEN04430-00
Load meter specification (if equipped)
1. Torque converter oil temperature gauge 26. Battery charge circuit caution lamp
2. Torque converter oil temperature caution lamp 27. Steering 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 automatic digging pilot lamp (*2)
8. Turn signal pilot lamp (right) 33. Preheating pilot lamp
9. Hydraulic oil temperature caution lamp 34. Auto-greasing pilot lamp (*2)
10. Hydraulic oil temperature gauge 35. Joystick pilot lamp (*2)
11. Fuel level caution lamp 36. Directional selector pilot lamp (*2)
12. Fuel gauge 37. Economy operation pilot lamp
13. Centralized warning lamp 38. Shift indicator
14. Brake oil pressure caution lamp 39. Auto shift pilot lamp
15. Engine oil pressure caution lamp 40. Torque converter lockup pilot lamp (*2)
16. Water separator caution lamp (*1) 41. Shift hold pilot lamp
17. Engine oil level caution lamp 42. Shift lever position pilot lamp
18. Radiator coolant level caution lamp 43. ECSS pilot lamp (*1)
19. Transmission oil filter clogging caution lamp (*1) 44. Modulated clutch temperature caution lamp (*1)
20. Air cleaner clogging caution lamp 45. Bucket load display
(machine equipped with KOMTRAX) 46. Handled material display
21. Parking brake pilot lamp 47. Addition mode: Total load weight display
22. Brake oil temperature caution lamp Subtraction mode: Remaining target load
23. Cooling fan reverse rotation pilot lamp weight display
24. Maintenance caution lamp 48. Addition/Subtraction mode display
25. Battery electrolyte level caution lamp (*1)
*1: Not used by this model

*2: If equipped
WA470, 480-6 10-901 7

List of items displayed on monitor 1
Condition for judging that engine is running:

When either one or both of following items 1 and 2 is or are sensed, the machine monitor judges that the
engine is running.
1. The engine speed is above 500 rpm.
2. There is alternator voltage (R) and there is terminal (C) input after the starting switch is returned to "ON"
position.
Q: Turned 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:
Flashing(w) > Intermittent (A) > Cancellation of operation > Check of acceptance of operation.
Detection Operating condition
Item time
Display color
(sec) Engine stopped Engine is running
Speedometer
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
specification
Centralized
Centralized
Display of
Display of
Category No. Device Operating condition Remarks
Detection
Individual
Individual
message
message
(SPM)
display
display
Reset
Load meter
specification
(LDM)
Turned ON with errors

(E03 and E02) of each
When error occurs E E E E E E E E controller, simultaneously
Centralized displaying the message on
Red
Centralized the character display.
warning 13 LED
warning
lamp For other than above, see
"Operating condition,
— — — — — —
centralized warning lamp"
of other items.
White
Lamp switch position other
Back light — Back light LED than "OFF" — — — — — —
Other than below — — — — — — White range: 50 – 120°C

Red range: 120 – 135°C
Pointer: Alarm: Min. 120°C 10 1 — Q — — Q —

When sensor has ground
fault: Max
Torque Movement
Red
1 When sensor has

converter oil
2 disconnection or hot short:
temperature Caution
lamp: LED Alarm: Min. 130°C 10 1 w Q Q B@CENS w Q Q B@CENS Min
When abnormality is
detected 20 5 — — — DGT1KX — — — DGT1KX
(out of input signal range)
Other than below — — — — — —
Alarm: Min. 102°C 3 0 — Q — — Q — White range: 50 – 102°C

Pointer: Red range: 102 – 135°C
Engine Movement
Red
3 When sensor has ground

4 coolant Alarm: Min. 105°C w Q Q B@BCNS w Q Q B@BCNS fault: Max
temperature Caution
When sensor has
lamp: LED
When abnormality is disconnection or hot short:
detected — — — CA144 — — — CA144 Min
Gauges and (high temperature)
meters
When abnormality is
detected — — — CA145 — — — CA145
(low temperature)
Engine speed When engine speed

— — — — — —
(SPM) display is selected
Pointer:
—
Movement
Travel speed When travel speed display
— — — — — —
(SPM) is selected
(selectable with the
4 digits are displayed machine monitor setting)
when engine speed Displays "0" when
Engine speed
display is selected: 0 – — — — — — — communication error
(LDM)
3990 occurs.
5 (ones digit is fixed to 0)
2 digits are displayed
when travel speed display
Black
Travel speed is selected: 0 – 99 — — — — — —

(LDM) LCD
(central 2 of 4 digits are
used)
2 digits are displayed
Display of Displayed for 3 seconds
tilt positioner when tilt positioner set when signal is received
angle is displayed: –5 – 5 — — — — — —
set angle from work equipment
(central 2 of 4 digits are
(LDM) controller.
used)
10-901 8 WA470, 480-6


Item time
Display color
Speedometer
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
specification
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
(SPM)
display
display
Reset
Load meter
specification
(LDM)
Other than below — — — — — — White range: 50 – 100°C

Red range: 100 – 125°C
Pointer:
Hydraulic oil Movement Alarm: Min. 100°C
Red
10 temperature Caution
10 1 w Q Q B@HANS w Q Q B@HANS fault: Max
When sensor has
lamp: LED disconnection or hot short:
When abnormality is
Gauges and detected 20 5 — — — DGH2KX — — — DGH2KX Min
meters (out of input signal range)
Max: 10 z
Min: 85 z
Pointer: Other than below
— — — — — —
Movement
Red
Fuel level
12 Caution
fault: Full
lamp: LED Min. 80 z 10 1 — Q — — Q — When sensor has
disconnection or hot short:
Empty
Operates when charging
Service meter normally at 1 : 1 to the — — — — — — Displays various codes
Black
Character clock time and items according to the
30 LCD
display machine condition and
Converts travel speed switch operation.
Odometer — — — — — —
pulse into travel distance
Green Green
When engine speed x 100 r/min
Engine speed
display is selected
0 0 — Q — — Q — (selectable with the
machine monitor setting)
Unit 29 LED
km/h or MPH
When travel speed display
Travel speed is selected 0 0 — Q — — Q — (selectable with the
machine monitor setting)
In neutral, gear speed is
not displayed.
Black
Actual gear 9-segment Left side: F, N, R If communication error
38 speed LCD Right side: Gear speed — — — — — —
occurs, display is held until
starting switch is turned
"OFF".
When auto-shift is
selected
0 0 — Q — — Q — If communication error
Green
39 Auto shift LED occurs, display is held until
Other than above — — — — — — "OFF".
When lockup operates 0 0 — — — — Q — If communication error

Green
Torque
occurs, display is held until
40 converter LED starting switch is turned
lockup "OFF".
Other than above — — — — — —
When auto shift or shift

hold is selected
0 0 — Q — — Q — If communication error
Green
41 Shift hold LED occurs, display is held until

Items Other than above — — — — — — "OFF".
related to
gear shifting
Green Green Green Green Green Green Orange Green
When F is selected
F LED (when engine is stopped, 1 0 A Q Q — Q —
neutral safety is displayed)
Directional
lever N LED When N is selected 0 0 — Q — — Q —
position
When R is selected
R LED (when engine is stopped, 1 0 A Q Q — Q —
neutral safety is displayed)
If communication error
When 4th gear speed is occurs, display is held until
42 4 LED
selected
0 0 — Q — — Q — starting switch is turned
"OFF".
When 3rd gear speed is
3 LED
selected
0 0 — Q — — Q —
Gear shift
lever
position When 2nd gear speed is
2 LED
selected
0 0 — Q — — Q —
When 1st gear speed is

1 LED
selected
0 0 — Q — — Q —
When turn signal lever and Hazard lamps operate

6
8 Turn signal LED hazard lamp switch signal 0 0 — Q — — Q — even when starting switch
is input is at "OFF"
Other When the head lamp is set
symbols to high beam
Blue
High beam of
7
head lamp
LED (when head lamp and 0 0 — Q — — Q —
dimmer switch are turned
"ON")
WA470, 480-6 10-901 9


Item time
Display color
Speedometer
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
specification
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
(SPM)
display
display
Reset
Load meter
specification
(LDM)
Normal oil pressure

— — — — — —
(CLOSED)
Below set pressure (front)

(OPEN)
(detection time continues)
and 30 seconds after
5 1 — Q — w Q Q 2G42ZG
starting engine (no
detection time)
Below set pressure (rear)
(OPEN)
and 30 seconds after
5 1 — Q — w Q Q 2G43ZG
Red
Brake oil
14 LED starting engine (no
pressure
detection time)
Below set pressure (front)
(OPEN)
and for 30 seconds after
1 1 — Q — w Q Q
starting engine (no
detection time)
Below set pressure (rear)
(OPEN)
and for 30 seconds after
1 1 — Q — w Q Q
starting engine (no
detection time)
Oil pressure is normal

(CLOSED) — — — — — —
Red
Engine oil
15 LED
pressure
Oil pressure is low
(OPEN) w Q Q B@BAZG w Q Q B@BAZG
Normal oil level If low level is detected

— — — — — — when starting switch is
(CLOSED)
turned "ON", alarm is
continued even after
Red
Engine oil
17 level LED engine is started until
normal oil level is reached.
Low oil level (OPEN) 2 1 — Q — B@BAZK — — — Oil level is not checked for
300 sec, after stopping the
engine.
Other
symbols
Normal coolant level
— — — — — —
(CLOSED)
Red
Radiator
18 LED
coolant level
Low coolant level (OPEN) 30 1 — Q — B@BCZK — Q — B@BCZK
Normal (CLOSED) — — — — — —
Red
Air cleaner
20 clogging LED
Clogging (OPEN) 2 1 — — — — Q — AA1ANX
Operation (OPEN) — Q — — Q —
Red
21 Parking brake LED Released (CLOSED) — — — — — —
Engine is running, parking

brake is applied and the
directional lever is at other
0 0 — — — A Q Q
than "N"
Temperature rise
(oil temperature: Min. 5 5 — Q — — Q —
120°C) (pre-alarm)
Temperature rise (1 or 2)
1. Oil temperature: Alarm is canceled if the
Red
Brake oil Min. 130°C detected oil temperature is

22
temperature
LED 2. Oil temperature Min.
5 5 w Q Q B@C7NS w Q Q B@C7NS lower than 125°C for
125°C and travel speed consecutive 5 sec.
min. 35 km/h
When abnormality is
detected — — — DGR2KA — — — DGR2KA
(disconnection)
When abnormality is
detected — — — DGR2KX — — — DGR2KX
(out of input signal range)
10-901 10 WA470, 480-6


Item time
Display color
Speedometer
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
specification
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
(SPM)
display
display
Reset
Load meter
specification
(LDM)
Normal 0 0 — — — — — —
While fan is reversed,
Orange
Cooling fan message of "COOLING
23 reverse LED Reverse 0 0 — Q — Remarks — Q — Remarks FAN REVERSE" is
rotation displayed on character
display.
Selecting reverse rotation 0 0 — w — — w —
Ordinary — — — — — —
Message is
Red
24 Maintenance LED simultaneously displayed
monitor 30 hours or less before on the character display.
maintenance or — Q — E — Q — E
maintenance time
Voltage is normal — — — — — — If abnormality is detected

when starting switch is
returned to "ON" position,
Engine is running, alarm is continued even
alternator voltage is low, after engine is started.
w Q Q AB00MA
Red
Battery 30 1 — — —
26 charge LED and starting motor signal
circuit
C is not input <Voltage hysteresis>
Abnormal to Normal
When abnormality is judgment: Min. 12 V
detected
(nonconformity between 3 1 w Q Q AB00L6 — — — Normal to Abnormal
judgment: Max. 5 V
engine state and signal)
Oil pressure is normal The emergency steering

1 1 — — — — — — function can be enabled
(OPEN)
only when "ADD" is
Red
Steering oil
27 LED selected in"13. EMERG S/
Remarks
pressure Oil pressure is low T" in the "Optional device

(CLOSED) and engine 3 1 — — w Q Q DDS5L6 selecting function" of the
speed is 500 rpm or above machine monitor.
Operation (for more than 1

min) (OPEN) 1 1 w Q Q w Q Q The emergency steering
Other function can be enabled
Green
symbols Operation (for less than 1 only when "ADD" is
Emergency
28 steering LED min) (OPEN)
1 1 — Q — — Q — selected in"13. EMERG S/
T" in the "Optional device
selecting function" of the
machine monitor.
Stop (CLOSED) — — — — — —
Power mode selector

switch "P-mode" 0 0 — Q — — Q —
Green
31 Power mode LED

Power mode selector
— — — — — —
switch "E-mode"
Semi auto digging switch

— — — — — —
"OFF"
Green
Semi auto Not to be displayed when

32 digging LED communication error
occurs
Semi auto digging switch
"SOFT" or "HARD"
0 0 — Q — — Q —

Red
33 Preheater LED
When preheater is turned
ON
0 0 — Q — — Q —
Not in operation — — — — — —
Operation 1 1 — Q — — Q —
Green
34 Auto grease LED

Tank empty 3 1
w
— 1Hz —
w —
— 1Hz
Abnormal 3 1
w
— 2Hz —
w —
— 2Hz
WA470, 480-6 10-901 11


Item time
Display color
Speedometer
warning lamp
warning lamp
Alarm buzzer
Alarm buzzer
specification
Centralized
Centralized
Display of
Display of
Detection
Individual
Individual
message
message
(SPM)
display
display
Reset
Load meter
specification
(LDM)
When using steering

— — — — — —
wheel
The joystick steering

When the joystick is
operating
0 0 — Q — — Q — function can be enabled
only when "J/S" is selected
in "14. J/S-FNR SW" in the
Green
Selection caution to "Optional device selecting
35 Joystick LED
joystick steering
0 0 A w Q A w Q function" of the machine
monitor. Not to be
FNR switch neutral displayed when
caution when starting 0 0 A w Q A w Q communication error
switch is turned to "ON" occurs
Directional lever priority

caution
1 0 A w Q A w Q
When using the directional

— — — — — —
lever The directional selector
switch works only when
"FNR SW" is selected in
Other
symbols Directional
When directional selector
switch is operating
0 0 — Q — — Q — "14. J/S-FNR SW" in the
Green
selector "Optional device selecting
36 LED
switch function" of the machine
Directional lever priority
actuation
caution
0 0 A w Q A w Q monitor. Not to be
displayed when
communication error
Directional selector switch occurs
neutral caution
0 0 A w Q A w Q
Other than below 0 0 — — — — — —
Green
Economy
37 mode of LED
operation
Economy mode operation 0 0 — Q — — Q —
5 Load meter display E E E E E E E E

45
Black
Load meter Calculation result is
46 (LDM)
LCD
displayed by value
47
48 Load meter no-display — — — — — —
Operation when overrun prevention function operates

(machine equipped with lockup clutch)
Alarm Centralized Main Message display on character
Check item Machine monitor warning section (*2)
buzzer display
lamp
Load meter
Overrun specification w Q w —
prevention pre-
Speedometer
alarm
specification w Q — Engine speed (rpm) blinks (*1).
Load meter
specification w Q w Overrun prevention
Overrun
prevention alarm Speedometer
specification w Q — Overrun prevention
*1: The engine speed blinks.

• If the engine speed has been displayed, it starts blinking.
• If the travel speed has been displayed, the engine speed starts blinking.
• If the travel speed or the engine speed display is "OFF", the engine speed blinks
*2: If the travel speed or the tilt positioner angle has been displayed, the engine speed starts blinking.
10-901 12 WA470, 480-6

Machine monitor operation switch 1
1. Load meter display selector switch (machine equipped with load meter)
• Total weight display
2. Load meter mode selector switch (machine equipped with load meter)
• Material selection
• Addition/Subtraction selection
3. Machine monitor mode selector switch 1
WA470, 480-6 10-901 13

Setting of machine monitor 1
1. Spare rotary switch (SW1)

4. Spare dip switch (SW5-1)
a It is prohibited to change setting of spare rotary switch and DIP switch.
Troubleshooting function 1
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.
10-901 14 WA470, 480-6

Character display function 1
q Machine monitor display and setting can be changed by using the character display.
q The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.
*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, 480-6 10-901 15

Operator mode functions 1
Self-check screen (0th layer)

q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON".
q During a self-check, entry through the machine monitor operating switch is not accepted.
q After ending the self-check, the self-check screen automatically moves to 1st layer.
Normal screen (1st layer)

q When "ADD" is selected in "10. RPM/SPEED" in the "Optional device selecting function" of the machine
monitor and the travel speed is displayed at the center of the monitor, the engine speed is displayed on
the character display.
q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the charac-
ter display.
q Pressing the "U" switch changes the screen to the 2nd layer.
1. Engine speed display

2. Travel speed display
A. In the case of "km/h" display
B. In the case "MPH" display
*1: Only the load meter specification displays the clock.
a If it is requested to display travel speed on the character display in "MPH", "Non-SI unit specification"
must be selected in the "Factory mode" of the machine monitor.
10-901 16 WA470, 480-6

Failure code screen (1st layer)

q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code
screen.
q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item
of higher priority downward. If items have the same priority, the item that occurred most recently will be
displayed first.
Example of a failure code screen (simultaneously occurring errors: D191KA, B@BCZK, CA431)
*1: The screen automatically returns to the Warning screen if no switch is pressed for more than 10 sec-
onds in the normal screen display.
*2: The screen returns to the Warning screen if no switch is pressed for more than 30 seconds in the failure
code screen or if a new alarm is raised.
*3: Pressing the ">" switch in the normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
WA470, 480-6 10-901 17

Display of functions opened to the operator (2nd layer or below)

q Certain menus are not displayed unless the items in the "Optional device selecting function" of the
machine monitor are set.
q Pressing "U" switch allows selecting each menu.
q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not
pressed more than 60 seconds in the screen display of each menu.
q The language will be displayed as set in the Language selection function.
a See the "Operation and maintenance manual" for details of each menu.
*1: These menus are displayed when "ADD" is selected in "10. RPM/SPEED" in the "Optional device
selecting function" of the machine monitor.
*2: These menus are displayed when "ADD" is selected in "9. RPM OPT" in the "Optional device selecting
function" of the machine monitor.
*3: These menus are displayed when "ADD" is selected in "11. LOAD METER" in the "Optional device
selecting function" of the machine monitor.
10-901 18 WA470, 480-6

Service mode functions 1
q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.
Procedure for switching to Service Mode

1. Checking of the screen display 3. ID input and confirmation
Check that the character display is set to the Operate the machine monitor mode selector
1st layer screen in the operator mode. switches 1 and 2 and enter ID. (ID: 6491)
2. Display of ID input initial screen

Pressing "u" switch and "<" switch simulta-
neously for 5 seconds or more displays the ID
entry initial screen.
a Pressing down the 2 switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the switches.
1) The cursor (C) is located at the highest-

order digit. Pressing "<" or ">" switch
changes the value of this digit in the range
of "0" to "9".
2) Press "U" switch at the target value to
validate it.
a The cursor moves to the 2nd digit
position.
3) Confirm the values for the 2nd digit and
onward following the same procedure.
a If you have entered a wrong value to
a p os it io n whe n the c ur s or was
located at any position other than the
highest-order digit, press "t" switch
to move the cursor to the highest-
order digit to enable to input correct
value. In this case, the values already
entered remain on the screen
unchanged.
a Pressing "t" switch when the cursor
is located at the highest-order digit,
the screen returns to the "1st layer" of
the operator mode.
a If switch is not operated more than 60
seconds on the "ID entry" screen, it
automatically returns to the "1st layer"
screen of the operator mode.
4) If ID is acknowledged upon confirming the
4th digit, the screen changes to the "Elec-
trical system failure history" selector
screen.
WA470, 480-6 10-901 19

Service mode menu
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 changes the screen 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.
10-901 20 WA470, 480-6

Electrical system failure history display func- Real-time monitoring function (REAL-TIME
tion (ELECTRIC FAULT) MONITOR)
a "**" field displays total number of the failure q This function is used to check on the input/out-
history currently recorded. (max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
a For the operating procedure of this function,
q The history is used to check on the electrical see "Special functions of machine monitor
system failures of each controller saved in the (EMMS)" in Testing and adjusting.
machine monitor. After repairing the failure
content and verifying normal function, the fail-
ure history may be erased.
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
Mechanical system failure history display func- Engine reduced-cylinder function (CYLINDER
tion (MACHINE FAULT) CUT-OUT)
a "**" field displays total number of the failure q This function is used for the purpose of speci-
history currently recorded. (max. 20 histories to fying cylinder having defective combustion by
be stored) stopping fuel injection to each cylinder from the
fuel injector.
q The history is used to check on the mechanical a For the operating procedure of this function,
system failures of each controller saved in the see "Special functions of machine monitor
machine monitor. (EMMS)" in Testing and adjusting.
WA470, 480-6 10-901 21

No injection cranking function (NO INJECTION) Maintenance monitoring function (MAINTE-

NANCE MONITOR)
q Before restarting engine after a long-term stor-

ing of the machine, this function is used to q This function is used for changing the filter and
lubricate the engine internally. oil replacement timing and making ON/OFF
a For the operating procedure of this function, selection of this function.
see "Special functions of machine monitor a For the operating procedure of this function,
(EMMS)" in Testing and adjusting. see "Special functions of machine monitor
Adjustment function (TUNING) Operating information display function (OPER-

ATION INFO)
q This function is used for correcting and adjust-

ing the installation errors and manufacturing q This function is used for displaying fuel con-
dispersion of the sensors, solenoid valves, etc. sumption per operating hour.
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.
10-901 22 WA470, 480-6

Optional device selecting function (OPTIONAL Model selection function (MACHINE)

SELECT)
q This function is used for displaying or changing

q This function is used for verifying the installed the setting of model information (machine
state of optional devices or when changing model name and tire size).
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, a The figure shows a display example of WA380
see "Special functions of machine monitor TIRE 23.5.
Machine serial number input function Initialize function (INITIALIZE)

(MACHINE No. SET)
q This function is used to set the machine moni-

q This function is used for displaying or entering tor to the state set when delivered.
the serial number of machine. a Since this function is specially handled by the
Serial number of the set machine is used for factory, no modification is allowed.
controlling the machine.
WA470, 480-6 10-901 23

Load meter function 1
(load meter specification: if equipped)

1. Outline 2. Weight calculation
q The load meter classifies handled material The load meter senses lift arm operating pres-
into 5 types, measures the quantity of load sure (P) with pressure sensor (A) installed to
in the bucket, and displays the total load the bottom of the lift cylinder and pressure sen-
weight or the remaining target load weight. sor (B) installed to the head and calculates
q The load meter has the subtraction mode/ weight (W) by determining the center of gravity
addition mode selecting function, handled with lift arm angle sensor (C).
material selecting function, and total load
weight display/clear function and is oper-
ated with the load meter mode selector
switch, load meter display selector switch,
and machine monitor mode selector
switch.
q The load meter has the calibration, cali-
bration clear and load meter calculation
stop modes, which are selected with the
machine monitor mode selector switch.
q If the load meter is installed with a printer
(optional), it can print out the measured
data.
a For the operating method, see the Opera- The load weight is calculated from differential
tion and Maintenance Manual. pressure (C) between saved (and corrected by
calibration) lift arm pressure under the empty
machine (A) and calculated lift arm pressure
under the loaded machine (B).
The system calculates the load weight during
the lift arm raising operation for higher accu-
racy.
10-901 24 WA470, 480-6

Measured lift arm pressure (D) has the follow-

ing characteristics, however, since a spring
effect of the machine is generated by the tires
and work equipment operation.
Lift arm pressure (D) measured during the lift

arm raise operation is converted to calculated
pressure (B) on the following calculation stan-
dard, from which the load weight is calculated.
q Since the pressure fluctuates largely and
is not stabilized during 0.5 seconds after
the start of the lift arm raise operation (E),
it is not used for the calculation of calcu-
lated pressure (B).
q Since the spring effect of the machine has
a period of about 1 second, the average of
the pressure in every second from the
start to the stop of the lift arm raise opera-
tion is used as calculated pressure (B).
WA470, 480-6 10-901 25

Judgment of start of lift arm raise operation

The system judges that the lift arm has started and starts the calculation of the load weight when all of the
following conditions are satisfied.
The lift arm angle is –10° – –30°.
Condition 1
(range from below the level to above the ground)
The lift arm angle changes 0.1° or more in 0.1 second.
Condition 2
(The lift arm has started moving in the raise direction at a speed higher than a certain speed)
Judgment of stop of lift arm raise operation

The system judges that the lift arm has stopped and stops the calculation of the load weight when any of the
following conditions is satisfied.
The change of the lift arm angle has decreased to below 0.5° per 0.5 second.
Condition 1
(The lift arm speed in the raise direction has decreased to a speed below a certain speed)
The lift arm angle has started decreasing.
Condition 2
(If the lift arm lower operation is started, the calculation of the load weight is finished)
The lift arm angle has increased to +20° or more.
Condition 3
(The load weight calculation is stopped at the lift arm high position)
The lift arm raise speed has changed sharply.
Condition 4
(The angular velocity is 70% of the previous one or less)
Condition 5 The load weight has been calculated 7 times.
Display of calculated load weight

All the load weights calculated each time are averaged further and then displayed as the calculated load
weight.
Length of
Number of
calculation time Method of calculation and display of load weight
calculations
(sec)
The 1 calculation result is displayed as the load weight.
Once 1.5 to 2.5 In this case, however, the load weight blinks to notify the operator that the
calculation time is short and calculation accuracy is unstable.
Twice 2.5 to 3.5 The average of the 2 calculation results is displayed as the load weight.
3 times or more Min. 3.5 The average of the latest 3 calculation results is displayed as the load weight.
10-901 26 WA470, 480-6

3. Subtraction and addition modes

Display on monitor in addition mode Display on monitor in subtraction mode
In this mode, the bucket load weight of each time is In this mode, the bucket load weight of each time is
added and displayed. subtracted from the target load weight that is set in
This mode is used to grasp the production etc. advance and then the remaining target load weight
is displayed.
This mode is used for loading work of a specified
weight etc.
q If the addition mode is selected, addition mode

(1) "TOTAL LOADED" is displayed and the cal-
culated bucket load weight (3) is added to total
load weight (2) and displayed. q If the subtraction mode is selected, subtraction
q The calculated load weights of any 5 types of mode (1) "REMAINING TARGET" is displayed
handled material can be integrated and dis- and the calculated load weight in bucket load
played independently. weight (3) is subtracted from remaining target
The type of the handled material can be set by load weight (2) and displayed.
selecting one from types A – E in the handled q The calculated load weights of any 5 types of
material (4) when the mode is selected. handled material can be integrated and dis-
q Total load weight (2) displays up to 99,999t as played independently.
long as the data are not cleared with the load The type of the handled material can be set by
meter subtotal switch. selecting one from types A – E in the handled
The load weight is displayed to the first deci- material (4) when the mode is selected.
mal place (in units of 100 kg) up to 9,999.9t. If
the load weight exceeds 10,000t, the decimal a For the display and calculation method when
point disappears and then the load weight is bucket load weight (3) exceeds remaining tar-
displayed in units of 1 t. get load weight (2), see Operation and Mainte-
nance Manual, "Handling of load meter".
a For details of the total load weight display, see a For details of display of remaining target load
"Display of total load weight and remaining tar- weight, see "Display of total load weight and
get load weight". remaining target load weight".
WA470, 480-6 10-901 27

Display of total load weight and remaining target Load meter cancel switch
load weight
Display of
Actual total load
total load Remarks
weight (t)
weight
Display with decimal
Up to –999.5 –999.9
point
point
–999.4 to –0.1 –***.*
(2nd decimal place is
rounded)
point
0 to 9999.4 ****.*
(2nd decimal place is
rounded)
Display by whole number
9999.5 to 99999.4 ***** (1st decimal place is q If switch (1) is pressed in the calculated load
rounded) weight holding time (15 seconds after the cal-
99999.5 and up 99999 Display by whole number
culation is finished), the system judges that the
displayed bucket load is not dumped and dis-
cards the calculated load weight.
Unit of calculated weight At this time, the total load weight (remaining
q All the calculated weights are displayed in SI target load weight) after addition (subtraction)
units (Metric ton). of this time is also canceled and the previous
If "MPH" is selected as the speed display unit weight is displayed again.
with the monitor, however, the metric ton can
be changed to the short ton (US ton) by setting
the option code in the service mode. Load meter subtotal switch
In this case, the weight unit of the printed data
is also short ton (US ton).
k Do not change the speed display unit and

weight display unit to another unit in an SI
unit country.
q To clear the total load weight (in the addition

mode) or the remaining target load weight (in
the subtraction mode), hold down switch (1) for
2 seconds or longer.
q To print out the data, just hit switch (1).
Specifications Operation after switch is operated
Total load weight (remaining target load
Without printer
weight) is cleared.
Saved subtotal data are printed.
With printer After the subtotal data are printed out,
they are cleared.
10-901 28 WA470, 480-6

Subtotal data Auto subtotal function

q When the calculated load weight is settled, the 1) When printer (optional) is connected
following data are saved as a set. The 501st load weight is calculated and
q Type of handled material then its data are saved in the RAM and the
q Bucket load weight of each time data up to the 500th time are printed out
q Number of loadings 15 seconds after.
q Total of loaded weight After the subtotal data are printed out,
they are cleared.
Saving capacity: Min. 500 loadings After the 500th data are saved, the mes-
s a g e s o f " L O A D D ATA F U L L " a n d
"CLEAR DATA" are displayed on the char-
acter display. Measurement is continued,
however.
2) When printer (optional) is not connected

The 501st load weight is calculated and
then its data are saved in the RAM and the
data up to the 500th time are deleted to
secure the data saving area 15 seconds
after.
After the 500th data are saved, the mes-
s a g e s o f " L O A D D ATA F U L L " a n d
"CLEAR DATA" are displayed on the char-
acter display. Measurement is continued,
however.
Display on character display after 500th data are

saved
WA470, 480-6 10-901 29

4. Integrated data display function

Display of data Resetting data
q The total load weight and the total number of q Reset the integrated data of each type of A – E
loadings in the addition mode or subtraction or those of the all types.
mode are displayed. q Display "TOTAL DATA" on the character dis-
q Press the load meter display selector switch to play and press load meter mode selector
display "TOTAL DATA" on the character dis- switch (A/B) to set the handled material to A –
play." E or light up all the types and then hold down
load meter mode selector switch (A/B) for 4
seconds or longer.
a On the lower line (*****-*****h), the time when

the data were integrated is displayed on the
basis of the hour meter.
Example)
If "12300-12450h" is displayed, the inte-
grated data in the 150 hours from 12,300
hours to 12,450 hours are displayed on
the character display.
q Press load meter mode selector switch (A/B) to

set handled material (1) to A – E or light up all
the types.
If the handled material is set to A – E, inte-
grated load weight (2) and number of load-
ings (3) of each type are displayed.
If all the types are lighted up, total integrated
load weight (2) and total number of loadings
(3) of all the types of A – E are displayed.
10-901 30 WA470, 480-6

5. Printing out
(if equipped)
a This function works only when the optional printer is installed.
The load meter has 3 selectable output modes (A, B and C).
The output format of each mode is as follows.
a For the selecting and outputting method of the output modes, see "Handling of load meter" in the
Operation and Maintenance Manual.
Mode A Mode B Mode C
(total printer output) (subtotal printer output) (operation record printer output)
• Model, serial No. • Model, serial No. • Model, serial No.
• Date and time of printing • Date and time of printing • Date, time and service meter when
• Loading subtotal data • Loading data recording is started
(Type/Number of loadings/Load (Load weight) • Date, time and service meter when
weight) • Loading subtotal data recording is finished (printing)
• Loading total data (Type/Number of loadings/Load • Loading subtotal data
(Total number of loadings/Total load weight) (Type/Number of loadings/Load
weight) • Loading total data weight)
(Total number of loadings/Total load • Loading total data
weight) (Total number of loadings/Total load
weight)
• Maintenance time
(Maintenance item/Remaining time)
Example of printing out in each mode (WA600-6)
WA470, 480-6 10-901 31

6. Calibration
q There are the following 2 types in calibra- Loaded calibration
tion; the empty calibration in which the q To correct the standard pressure under the
pressure under the empty bucket is mea- loaded bucket, the difference from standard
sured and the loaded calibration in which pressure (A) near loaded calibration point (C)
the pressure under the bucket loaded with is corrected and the measured pressure is cor-
a known weight is measured. rected to (B) as shown in the following figure.
When the lift arm is raised with the bucket
tilted fully, the lift arm operating pressure
under the empty bucket (0 kg) or the
bucket loaded with a known load is saved.
q When the center of gravity of the load is
moved from the position that Komatsu has
set because of modification of the lift arm
or bucket, the empty calibration and
loaded calibration must be executed for
higher better accuracy.
a The saved calibration data are not deleted

even if the battery is kept disconnected.
a For the calibration procedure, see Testing and

Empty calibration Adjusting, "Testing and adjusting load meter".
q To cancel the weight difference of the work
equipment etc. specific to the machine, the dif-
ference from standard pressure (A) is offset 7. Stopping calculation
and the measured pressure is corrected to (B) The calculation function of the load meter can
as shown in the following figure. be stopped.
While calculation is stopped, the load meter
display is turned OFF and the travel speed or
engine speed is displayed instead and the
loads are not added to the total data.
To start calculation again, select the addition
mode or subtraction mode.
a For the calculation stopping procedure,

see Operation and Maintenance Manual,
"Handling of load meter".
10-901 32 WA470, 480-6

Input and output signals 1
AMP070-20P[CN-L51]
Pin No. Specifications I/O Group Usage 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)
Un-switched power
4 NSW power supply (+24 V) I — NSW power supply (+24 V)
supply (+24 V)
Un-switched power
5 NSW power supply (+24 V) I — supply (+24 V) NSW power supply (+24 V)
Power supply
6 SW power supply (+24 V) I — (+24 V) SW power supply (+24 V)
Power supply
7 SW power supply (+24 V) I — (+24 V) SW power supply (+24 V)
8 (NC) — — — —
9 GND I — GND GND
10 GND I — GND GND
11 D_OUT_3 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 (+24 V, sink 200 mA) O A D/O sink Alarm buzzer 1 (machine monitor)
15 Sensor power supply O — Sensor power —

output (+24 V) supply
Sensor power supply Sensor power Lift arm pressure and angle
16 O — For load meter
output (+5 V) supply sensor power supply
WA470, 480-6 10-901 33

AMP070-18P(1)[CN-L52]
D_IN_0
1 I B D/I (+24 V) Head lamp
(24 V, 5 mA)
D_IN_2
2 (24 V, 5 mA) I B D/I (+24 V) Starting switch C signal
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 (24 V, 5 mA) I B D/I (+24 V) —
D_IN_10
6 I B D/I (+24 V) A/B switch For load meter
(24 V, 5 mA)
7 D_IN_12 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)
9 GND O — GND Signal GND
D_IN_1
10 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_3
11 (24 V, 5 mA) I B D/I (+24 V) —
D_IN_5
12 I B D/I (+24 V) Auto grease B if equipped
(24 V, 5 mA)
13 D_IN_7 I B D/I (+24 V) —
(24 V, 5 mA)
14 D_IN_9 I B D/I (+24 V) —
(24 V, 5 mA)
D_IN_11
15 (24 V, 5 mA) I B D/I (+24 V) +/– switch For load meter
D_IN_13
16 (NSW24 V, 5 mA) I C D/I (+24 V) Turn signal lamp, left
D_IN_15
17 (NSW24 V, 5 mA) I C D/I (+24 V) t switch
18 A_IN_0 (0 – 30 V) I H A/I Alternator R signal
AMP070-12P(1)[CN-L53]
D_IN_16
1 (24 V/GND, 5 mA) I D D/I (GND) Brake oil pressure (front)
D_IN_18
2 (24 V/GND, 5 mA) I D D/I (GND) —
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)
5 D_IN_24 I E D/I (GND) —
(24 V/GND, 5 mA)
6 GND O — GND Sensor ground
D_IN_17
7 I D D/I (GND) Brake oil pressure (rear)
(24 V/GND, 5 mA)
D_IN_19
8 (24 V/GND, 5 mA) I D D/I (GND) —
D_IN_21
9 I D D/I (GND) —
(24 V/GND, 5 mA)
D_IN_23
10 (24 V/GND, 5 mA) I D D/I (GND) P switch For load meter
D_IN_25
11 I E D/I (GND) —
(24 V/GND, 5 mA)
12 A_IN_1 (0 – 30 V) I H A/I Small lamp switch
10-901 34 WA470, 480-6

AMP070-18P(2)[CN-L54]
D_IN_26
1 I E D/I (GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28
2 (24 V/GND, 5 mA) I E D/I (GND) —
D_IN_30
3 I E D/I (GND) Emergency steering functional
(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 (24 V/GND, 5 mA) I F D/I (GND) Dimmer switch
D_IN_36
6 I G D/I (GND) Service function 2 For load meter
(24 V/GND, 5 mA)
7 D_IN_38 I G D/I (GND) < switch
(24 V/GND, 5 mA)
P_IN_0
8 I M P/I —
(0.5 Vp-p)
9 GND O — GND GND
D_IN_27
10 I E D/I (GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 (24 V/GND, 5 mA) I E D/I (GND) Engine oil level
12 (NC) — — — —
13 D_IN_33 I F D/I (GND) Cancel switch For load meter

(24 V/GND, 5 mA)
14 D_IN_35 I F D/I (GND) —
(24 V/GND, 5 mA)
D_IN_37
15 (24 V/GND, 5 mA) I G D/I (GND) > switch
D_IN_39
16 (24 V/GND, 5 mA) I G D/I (GND) Emergency steering activation
P_IN_1
17 (0.5 Vp-p) I M P/I —
18 (NC) — — — —
AMP070-12P(2)[CN-L55]

A_IN_2
1 (high-resistance input) I J A/I Fuel level sensor
A_IN_4 Torque converter oil temperature
2 I J A/I
(high-resistance input) sensor
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)
6 GND O — GND GND
A_IN_3
7 (high-resistance input) I J A/I Hydraulic oil temperature sensor
A_IN_5
8 I J A/I Brake oil temperature sensor
(high-resistance input)
A_IN_7
9 (0 – 5 V) I L A/I Lift arm pressure sensor (bottom) For load meter
A_IN_9
10 I L A/I Lift arm angle sensor For load meter
(0 – 5 V)
11 GND O — GND GND
12 A_IN_11 — — — —
(0 – 14 V)
WA470, 480-6 10-901 35

AMP070-12P(3)[CN-L56]
1 S_NET (+) I/O N S-NET —
2 S_NET (+) I/O N S-NET —
3 CAN (+) I/O P CAN CAN(+)
4 S_NET (–) O N S-NET —
5 S_NET (–) O N S-NET —
6 GND O — GND GND
7 GND O — GND —
8 CAN (–) I/O P CAN CAN(-)
9 (NC) — — — —
10 (NC) — — — —
11 (NC) — — — —
12 (NC) — — — —
AMP070-14P[CN-L57]
1 (NC) — — — —
2 RS232C_1_RTS I/O Q — —
For load meter
3 RS232C_1_RD I Q RD Personal computer RX
For monitoring (PC)
4 (NC) — — — —
5 (NC) — — — —
For load meter
6 I — — Printer use signal
(if equipped)
7 (NC) — — — —
8 RS232C_1_CTS I/O Q — —
9 RS232C_1_TX O Q TX Printer and personal computer TX For load meter
10 RS232C_1_SG O Q — —
11 (NC) — — — —
12 (NC) — — — —
13 (NC) — — — —
14 (NC) — — — —
10-901 36 WA470, 480-6

AMP040-8P[CN-L58]
Harness is not
1 RS232C_0_TXD O S — — connected on this
machine
Harness is not
2 FLASH_SW I S — — connected on this
machine
Harness is not
3 RS232C_0_TXD O S — — connected on this
machine
Harness is not
4 (NC) — — — — connected on this
machine
Harness is not
5 RS232C_0_RXD I S — — connected on this
machine
Harness is not
6 (NC) — — — — connected on this
machine
Harness is not
7 RS232C_0_RXD I S — — connected on this
machine
Harness is not
8 GND O — — — connected on this
machine
Setting switches (On circuit board)

Switch
No. Specifications I/O Group Form of use Signal name Remarks
1 16 Posi rotary switch 1 I — — (spare)
1 26 Posi DIP switch 1 I — — (spare)

5

6
WA470, 480-6 10-901 37

SEN04430-00

©2008 KOMATSU
All Rights Reserved
10-901 38
SEN04431-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up


Electrical system (Transmission controller system) ........................................................................................ 2
Transmission controller ................................................................................................................................. 42
Electrical system (Work equipment controller system) ................................................................................. 44
Work equipment controller ............................................................................................................................ 50
WA470, 480-6 10-902 1

SEN04431-00 Electrical system (Transmission controller system)
Electrical system (Transmission controller system) 1
a Except where otherwise specified, the travel speed in this document represents the value when 26.5-25
tires are installed.
Transmission controller gear shifting control function 1
Electronic modulation function
10-902 2 WA470, 480-6

Electrical system (Transmission controller system) SEN04431-00
1. Engine
2. Torque converter
3. Transmission
4. Axle
5. Transmission controller
6. Combination switch
7. Accelerator pedal
8. Transmission ECMV
9. Engine speed sensor
10. Transmission input speed sensor
11. Transmission output speed sensor

a. Directional signal
b. Shift range signal
c. Accelerator signal
d. Transmission output speed signal
e. ECMV operation signal
f. Fill switch signal
g. Transmission input speed signal
h. Engine speed signal
q The modulation control function controls the clutch pressure so that the gear will be shifted optimally at
all the gear speeds (including the lockup clutch gear speeds) depending on the engine speed, transmis-
sion oil temperature, transmission input and output speeds, and gear shift pattern to reduce the gear
shift (clutch engagement and disengagement) shocks.
q The clutch pressure is so controlled that the difference between the input speed and output speed will
follow up the target value set according to the engine speed and throttle opening to prevent sudden
engagement of the clutch.
q When the clutch is disengaged, the disengaging pressure is kept low to reduce lowering of the torque.
q If an abnormal time lag is caused in gear shifting, the learning function corrects the modulation automat-
ically.
WA470, 480-6 10-902 3

Gear shifting display function

q The transmission controller sends the information on the state of input signals related to gear shift to the
machine monitor via network for the display of the state on the machine monitor.
1. Directional indicators
The shift lever position pilot lamps on the machine monitor indicate the position of the directional lever
based on the input data to the transmission controller.
When the directional lever is in the halfway 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 are sent to the transmission controller by error, two shift lever position pilot
lamps on the machine monitor may turn on.
As the directional lever is set to "R (reverse)" the transmission controller activates the backup lamp relay
to light the reverse lamp and sound the back-up alarm.
2. Gear speed indicators

The shift lever position pilot lamps on the machine monitor indicate the position of the gear shift lever
based on the input data to the transmission controller.
When the gear shift lever is in the halfway 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 are sent to the transmission controller by error, precedence is given to the
higher gear speed. Thus, the shift lever position pilot lamp on the machine monitor may indicate a gear
shift lever position which is different from the actual position.
3. Display of actual gear speed

The shift indicator of the machine monitor indicates the positions of the directional lever and gear speed
on the output data from the transmission controller.
When the directional lever is at "N (neutral)", the indicator displays "N". When the directional lever is at
"F (forward)" or "R (reverse)", the indicator displays gear speed along with "F" or "R".
When the parking brake is in operation, the gear speed signal is not output. Thus, the indicator displays
"N". It also displays "N" if the transmission is set to the neutral due to the activation of the transmission
cut-off.
10-902 4 WA470, 480-6

Automatic gear shifting function

q The transmission gear can be shifted by the automatic gear shifting operation in which the gear speed is
selected automatically according to the travel speed or by the manual gear shifting operation in which
the gear speed is selected with the gear shift lever.
q Operating the transmission shift mode selector switch allows switching the shift mode. When the auto-
shift is selected, the auto-shift pilot lamp on the machine monitor lights up.
q In the auto-shift mode, either shift up or shift down as well as ON or OFF of the lockup clutch (if
equipped) is selected depending on the position of the power mode selector switch.
q The auto-shift comprises two modes, "H" and "L". The shift modes shown in the following table are
turned on depending on the positions of the transmission shift mode selector switch and the power
mode selector switch.
Power mode Transmission shift mode selector switch
selector switch H L MANUAL
P-mode Auto-shift H-mode Auto-shift L-mode Manual shift mode
E-mode Auto-shift L-mode Auto-shift L-mode Manual shift mode
q In the auto-shift, the transmission controller selects either shifting up or down based on the "Auto-shift
points table" stored in it, and referring to the directional lever position, gear shift lever position, travel
speed, accelerator pedal position (throttle opening) and engine speed.
1. When the gear shift lever position is in "1st" to "4th"

The maximum gear speed (gear shifting range) used in the automatic gear shifting operation is limited.
In the automatic gear shifting operation, the machine usually starts in the 2nd gear speed. Accordingly, if
the gear shift lever is in "4th", the gear is shifted up or down between the 2nd gear and 4th gear. When
the kickdown switch is turned on and the conditions for kickdown are met, shift down to the 1st gear is
possible.
2. When the directional lever is in "N (neutral)" position

When the directional lever is set to "N (neutral)", actual transmission gear speed is fixed to the one that
had been selected prior to setting the lever to "N (neutral)".
When the directional lever is set to "N (neutral)", operating the gear shift lever does not change the
actual gear seed. Change of the actual gear speed is performed only when the directional lever is set to
"F (forward)" or "R (reverse)".
WA470, 480-6 10-902 5

Auto-shift points table

q The relationship of the output shaft speed, engine mode, gear shift switch and gear shift operation with
each other is as follows.
WA470-6
Unit: rpm
Engine mode and gear shift switch
Power mode Economy mode
Gear shift switch Gear shift switch Gear shift switch Gear shift switch
H L H L
F1 o F2 502 465 465 465
F2 o F2 (Lockup) 701 – 2,953 591 – 664 591 – 664 591 – 664
F2 o F2 (Lockup)
834 – 2,953 591 – 738 591 – 738 591 – 738
In hunting prevention mode
F2 (Lockup) o F3 923 664 – 886 664 – 886 664 – 886
F2 (Lockup) o F3
997 701 – 960 701 – 960 701 – 960
F2 o F3 797 – 886 413 – 797 413 – 760 413 – 760
F2 o F3
827 – 923 561 – 849 561 – 849 561 – 849
F3 o F3 (Lockup) 1,255 960 – 1,181 960 – 1,181 960 – 1,181
F3 o F3 (Lockup)
1,255 – 1,417 960 – 1,255 960 – 1,255 960 – 1,255
Gear shift In hunting prevention mode
operation F3 (Lockup) o F4 1,550 – 1,772 1,218 – 1,661 1,218 – 1,587 1,218 – 1,587
F3 o F4 1,255 – 1,513 723 – 1,373 723 – 1,314 723 – 1,314
F4 o F4 (Lockup) 2,030 1,536 – 1,772 1,536 – 1,772 1,536 – 1,772
F4 (Lockup) o F4 1,609 – 1,816 1,469 – 1,698 1,469 – 1,698 1,469 – 1,698
F4 o F3 997 – 1,440 650 – 1,225 650 – 1,225 650 – 1,225
F4 o F3 (Lockup) 1,661 1,476 1,476 1,476
F3 (Lockup) o F3 1,026 – 1,152 849 – 997 849 – 997 849 – 997
F3 o F2 480 – 842 325 – 731 325 – 687 325 – 687
F3 o F2
480 – 812 325 – 583 325 – 583 325 – 583
F3 o F2 (Lockup) 849 812 812 812
F2 (Lockup) o F2 568 – 627 406 – 627 406 – 627 406 – 627
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.
10-902 6 WA470, 480-6

WA480-6
Unit: rpm
Engine mode and gear shift switch
Power mode Economy mode
Gear shift switch Gear shift switch Gear shift switch Gear shift switch
H L H L
F1 o F2 502 465 465 465
F2 o F2 (Lockup) 701 – 2,953 591 – 664 591 – 664 591 – 664
F2 o F2 (Lockup)
834 – 2,953 591 – 738 591 – 738 591 – 738
F2 (Lockup) o F3 923 664 – 886 664 – 886 664 – 886
F2 (Lockup) o F3
997 701 – 960 701 – 960 701 – 960
F2 o F3 797 – 886 413 – 819 413 – 819 413 – 819
F2 o F3
827 – 923 561 – 849 561 – 849 561 – 849
F3 o F3 (Lockup) 1,255 960 – 1,181 960 – 1,181 960 – 1,181
F3 o F3 (Lockup)
1,255 – 1,417 960 – 1,255 960 – 1,255 960 – 1,255
Gear shift In hunting prevention mode
operation F3 (Lockup) o F4 1,550 – 1,772 1,218 – 1,661 1,218 – 1,587 1,218 – 1,587
F3 o F4 1,255 – 1,550 723 – 1,410 723 – 1,410 723 – 1,410
F4 o F4 (Lockup) 2,030 1,536 – 1,772 1,536 – 1,772 1,536 – 1,772
F4 (Lockup) o F4 1,609 – 1,816 1,469 – 1,698 1,469 – 1,698 1,469 – 1,698
F4 o F3 1,093 – 1,462 650 – 1,225 650 – 1,225 650 – 1,225
F4 o F3 (Lockup) 1,661 1,476 1,476 1,476
F3 (Lockup) o F3 1,026 – 1,152 849 – 997 849 – 997 849 – 997
F3 o F2 532 – 842 325 – 731 325 – 731 325 – 731
F3 o F2
532 – 812 325 – 583 325 – 583 325 – 583
F3 o F2 (Lockup) 849 812 812 812
F2 (Lockup) o F2 568 – 627 406 – 627 406 – 627 406 – 627
a The output shaft speed of 1 rpm is equivalent to the travel speed of 0.0135 km/h.
WA470, 480-6 10-902 7

Shift hold function

q The shift hold function fixes the gear speed to the speed being used at the time of hold switch pressing,
in the auto shift mode. It does not allow shift up even if the travel speed increases. It also does not allow
shift down even if the travel speed decreases.
q The shift hold pilot lamp on the machine monitor remains turned on as long as the shift hold function is
turned on. Pressing the hold switch again cancels the shift hold function and turns off the pilot lamp.
q The shift hold function is automatically canceled when the directional lever, gear shift lever or kickdown
switch is operated. In such case, the torque converter lockup is turned off.
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 not set to "F (forward)" and the gear
shift lever is not set to the "2nd" position.
The kickdown function is canceled 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 other position than "2nd" after the actual gear
speed has been changed to "1st". After the function is canceled, the gear speed is changed to the one
being selected by the gear shift 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 canceled if the directional lever is operated after the actual gear speed is
changed, or the no-shift time for hunting prevention elapses. After the cancellation, the automatic gear
shifting based on "Auto-shift points table" is carried out.
Transmission output shaft speed [rpm]
Gear speed prior Gear speed after
when kickdown switch is pressed No-shift time [sec.]
to kickdown kickdown
(Reference: travel speed [km/h])
2nd T/C All range 1st T/C 5
Below 775 (10.5) 1st T/C 5
3rd T/C
775 (10.5) or above 2nd T/C 4
Below 775 (10.5) 1st T/C 5
4th T/C
775 (10.5) or above 3rd T/C 4
2nd L/U All range 1st T/C 5
Below 775 (10.5) 1st T/C 5
3rd L/U
775 (10.5) or above 3rd T/C (*1)
Below 775 (10.5) 1st T/C 5
4th L/U
775 (10.5) or above 4th T/C (*1)
T/C: Stands for torque converter mode.
L/U: Stands for direct mode (lockup mode).
*1: If the lockup function is turned OFF by pressing the kickdown switch, it is not turned ON again until
the following condition is satisfied.
q The torque converter lockup switch is turned "OFF" and then "ON" again.
q The travel speed increases from below the lockup activation travel speed shown in "Auto-shift
points table" to above the lockup activation travel speed.
3. When forward 1st is selected

When "E-mode" is selected for the power mode and the gear speed is set to forward 1st, pressing the
kickdown switch changes the power mode to "P-mode". (One-push power max. function)
The power mode switching function is enabled, regardless of the auto or manual shift, only when for-
ward 1st is selected, and it is canceled when the actual gear speed is changed to any speed other than
1st.
10-902 8 WA470, 480-6

Torque converter lockup function

(if equipped)
q When the torque converter lockup switch is turned "ON", torque converter lockup function performs
automatic control of the lockup operation, regardless of the shift mode selection.
q The torque converter lockup pilot lamp on the machine monitor remains turned on as long as the lockup
is engaged.
q The lockup activation gear speed is as follows.
Transmission shift mode Lockup activation gear speed (lockup is activated: Q)
selector switch F1 F2 F3 F4 R1 R2 R3 R4
H Q Q Q Q Q Q
L Q Q Q Q Q Q
MANUAL Q Q Q Q Q Q
1. Lockup activation travel speed

"Auto-shift points table" lists the lockup activation travel speeds. When the manual shift is selected, the
same travel speeds as those for the auto-shift H-mode activates the lockup.
2. Lockup protection function

The lockup function is activated only when the machine travel direction coincides with the directional
lever position.
<Judging the machine travel direction>
1) The machine is judged to be stopped when the transmission controller is switched on (= starting
switch is set to "ON" position), or when the transmission output shaft speed is below 260 rpm.
2) From the above state, if the transmission output shaft speed reaches 260 rpm or above and the
directional lever is set to "F (forward)", the machine is judged to be traveling forward (if the lever is
set to "R (reverse)", traveling reverse).
a When the transmission output shaft speed is 260 rpm, the travel speed is approximately 3.2 km/h.
WA470, 480-6 10-902 9

Hunting prevention function

q The transmission controller detects and prevents hunting that can result from shifting the gear from 2nd
to 3rd and 3rd to 2nd in the auto-shift mode.
q If gear shifts of 2nd to 3rd to 2nd to 3rd are performed within 5 seconds from the previous gear shift, the
controller judges that hunting has occurred, and selects gear speed from 2nd or 3rd whichever used for
longer time.
q If the hunting prevention function is turned on, the shift point in the hunting prevention section in "Auto-
shift points table" is applied to the next automatic gear shifting.
q Hunting prevention function which is being turned on is canceled when the next gear shifting (including
the travel direction switching operation and kickdown operation) is done. When the hunting prevention
function is canceled, the ordinary auto shift point is restored.
q The transmission controller cancels the lockup if ON/OFF of the lockup in the 3rd gear occurrs consecu-
tively within 5 seconds. The shift point in the hunting prevention section in "Auto-shift points table" is
applied to the next lockup.
q The hunting prevention function related to the lockup is turned on in the manual shift mode, too, if the
controller judges that hunting is occurring.
Transmission initial learning and ECMV current adjustment

q Adjusting the settings for "Transmission initial learning setting" and "Transmission ECMV current adjust-
ment" by using the adjustment function of the machine monitor allows correcting variances of the trans-
mission itself as well as ECMV.
q Ignoring above adjustment can lead to generation of gear shift shocks or time lag.
a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and
adjusting.
Changing shift points

q The transmission controller has the function of adjusting the gear shift points for "L-mode" in auto-shift.
q When hunting is induced due to some conditions unique to a worksite, you can change the shift up/
down travel speeds by adjusting the settings for "Adjustment of transmission L-mode shift point" in the
adjustment function of the machine monitor.
adjusting.
4th gear speed restriction function

q Restriction of use of 4th gear speed becomes available only when "ADD" is selected in "23. FORBID
4TH" in 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.
10-902 10 WA470, 480-6

Function of transmission controller protection 1
Protection function prepared for travel direction

q When the directional lever is operated during high-speed travel (3rd/4th), gear shifting is controlled to
protect the transmission.
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 actual travel speed. If the travel speed continues to slow down, gear speed
is shifted down to 2nd gear speed.
a Shifting up/down and kickdown operations are not accepted for 2 seconds immediately after the travel
direction switching operation. When shifting up/down operation is done by the gear shift lever, the con-
troller waits for 2 seconds before starting gear shifting.
In the auto-shift mode, shift up is prohibited until the gear is once shifted down to 2nd.

(Reference: Travel speed [km/h]) Engine speed [rpm]
A 960 (13) D 1,700
B 1,034 (14) E 1,900
C 1,181 (16)
WA470, 480-6 10-902 11

Shift down protection function

q In order to protect the engine and pump, this function rejects the shift down operation when the machine
is traveling at a speed higher than the preset one.
q The alarm buzzer sounds as long as the shiftdown protection function is turned on.
q The buzzer continues sounding until the gear speed position of the gear shift lever coincides with the
actual gear speed. Thus, shift up operation can stop the alarm buzzer even if the travel speed is not
slowed down.
q The shift down protection functions also for the kickdown operation in the auto-shift mode. If the kick-
down switch is pressed while the machine is traveling at a higher speed than that specified in the pro-
tecting conditions, this function rejects the kickdown switch and sounds the alarm buzzer for 3 seconds.
q The operating condition of shift down protection function is as follows.
Targeted gear (Reference: travel speed [km/h])
speed of shift down
Condition for applying protection Condition for canceling protection
To 3rd gear speed 2,227 (30.2) or above Below 2,005 (27.2)
To 2nd gear speed 1,470 (19.9) or above Below 1,322 (17.9)
To 1st gear speed 1,061 (14.3) or above Below 951 (12.9)
Engine overrun prevention function

q When the transmission output shaft speed reaches a level corresponding to the engine speed of 2,500
rpm or above, this function cancels the lockup automatically in order to prevent the engine overrun.
q The alarm buzzer sounds as long as the engine overrun prevention function is turned on.
q The lockup cancel state is maintained for 5 seconds after it has been canceled. After 5 seconds from the
cancellation, if the transmission output shaft speed lowers to a level corresponding to the engine speed
of below 2,500 rpm, this function applies the lockup again.
q The operating condition of the engine overrun prevention function is as follows.
Actual gear Transmission output shaft speed [rpm]
speed (Reference: Travel speed [km/h])
F2 1,138 (15.4)
F3 2,053 (27.7)
F4 3,392 (45.8)
R2 1,176 (15.9)
R3 2,120 (28.6)
R4 3,506 (47.3)
10-902 12 WA470, 480-6

Neutralizer function
q When the parking brake switch is turned "ON", this function holds the transmission at neutral position,
regardless of the directional lever and gear shift lever positions, in order to prevent traveling of the
machine with parking brake applied.
q The safety mechanism employed on the parking brake circuit maintains the parking brake applied when
the starting switch is turned to "ON" position from "OFF" position. Thus, when the starting switch is
turned to "ON", the transmission is always set to the neutral regardless of the directional lever and gear
shift lever positions.
Maximum travel speed limiting function

q If the travel speed exceeds the set maximum
travel speed, the alarm buzzer sounds.
Unit: km/h
Model WA470-6 WA480-6
Alarm activation set
40.0 40.0
value
Alarm reset set
39.5 39.5
value
q If the travel speed exceeds the threshold value

while the transmission is locked up at the 4th
gear speed, the throttle opening upper limit is
lowered to limit the maximum travel speed.
(if equipped)
Shift range F4 R4 F4 R4
Throttle opening
91 % 87 % 90 % 85 %
upper limit (A)
Travel speed (B) 38.5 km/h 38.5 km/h
Travel speed (C) 39.5 km/h 39.5 km/h
WA470, 480-6 10-902 13

Engine control function 1
Power mode selection control

q Setting the power mode selector switch to "P-mode" sends the P-mode torque curve information to the
engine controller. At the same time, above operation sends information about the power mode to the
machine monitor, lighting up the power mode pilot lamp.
Engine shutdown prevention control

q When the engine speed is low, switching the travel direction during high-speed travel results in applying
counter torque from tires to the engine, potentially inducing the risk of the engine shutdown.
q In order to prevent the engine stop, this function sends the lower limit value of the throttle opening to the
engine controller when the travel direction is switched.
q When the direction was changed from "reverse" to "forward", this function sends as much as approxi-
mately 25% of the specified throttle lower limit position values to the engine controller. In the case of
"forward" to "reverse", as much as approximately 15% of the values are sent. This communication lasts
for two seconds after the directional selection is completed.
Fuel consumption rate improvement control

q The throttle opening upper limit is controlled to the minimum value which is necessary for rise of the
engine speed to prevent increase of the fuel consumption rate caused by rough operation.
Overheat prevention control

q The throttle opening upper limit is controlled according to the coolant temperature and torque converter
oil temperature as shown in the following table to prevent overheat.
100°C 100 % 100 %
Coolant temperature 102°C 87 % 91 %
105°C 74 % 83 %
110°C 100 % 100 %
Torque converter oil
120°C 87 % 91 %
temperature
130°C 74 % 83 %
10-902 14 WA470, 480-6

Brake load reduction control

q In the 2nd gear speed in P-mode, the throttle opening upper limit is controlled to limit the traction force
according to the transmission output shaft speed and brake oil pressure to reduce the load when the
machine travels with the brake applied.
a The throttle opening upper limit is judged by the transmission output speed and brake oil pressure and
the larger one of the obtained values is selected.
Judgment by transmission output speed Judgment by brake oil pressure

Model WA470-6 WA480-6 Model WA470-6 WA480-6
Shift range F2 R2 F2 R2 Shift range F2 R2 F2 R2
Throttle opening Throttle opening
72 % 72 % 73 % 73 % 72 % 72 % 73 % 73 %
upper limit (A) upper limit (D)
Transmission output 591 rpm 591 rpm 0.49 MPa 0.49 MPa
Brake pressure (E)
speed (B) (8.0 km/h) (8.0 km/h) {5 kg/cm2} {5 kg/cm2}
Transmission output 886 rpm 886 rpm 0.98 MPa 0.98 MPa
Brake pressure (F)
speed (C) (12.0 km/h) (12.0 km/h) {10 kg/cm2} {10 kg/cm2}
WA470, 480-6 10-902 15

Driving force cut control

q The throttle opening upper limit is restricted according to the travel speed in the 1st gear to control the
maximum drive force.
q The setting of "41: F1 PWR CUT" in the "Optional device selecting function" of the machine monitor is
different from the throttle opening upper limit, depending on the power mode.
a For the setting procedure of "1st drive force cut", see "Special functions of machine monitor (EMMS)" in
Testing and adjusting.
Transmission output speed to start drive force cut control (rpm)

P-mode Max. 111 Max. 111
Power mode
E-mode Max. 369 Max. 369
Throttle opening upper limit when 1st drive force cut is set to "ADD" (%)
P-mode 100 100 85 85
Power mode
E-mode 68 68 72 72
Throttle opening upper limit when 1st drive force cut is set to "NO ADD" (%)
P-mode 100 100 100 100
Power mode
E-mode 68 68 72 72
q When "18: TOOTH MODE" in "Optional device selecting function" of the machine monitor is set to
"ADD", the throttle opening upper limit is restricted according to the load on the work equipment in the
1st gear speed in the P-mode to reduce the drive force and give more power to the lift arm "RAISE"
operation during digging work.
a For the setting procedure of the "Tooth mode", see "Special functions of machine monitor (EMMS)" in
Transmission output speed to start drive force cut control (rpm)

Power mode P-mode Max. 369 Max. 369
Throttle opening upper limit judged by work equipment pump oil pressure (%)
0 {0} 100 100
Work equipment 19.6 {200} 100 100
discharge pressure 28.4 {290} 100 100
(MPa {kg/cm2}) 29.4 {300} 68 72
49.0 {500} 68 72
10-902 16 WA470, 480-6

Economy operation pilot lamp function 1
q In order to prompt the operator for the low fuel consumption operation, this function lights up the econ-
omy operation pilot lamp as long as the low fuel consumption operation is continued.
q The conditions for lighting up the economy operation pilot lamp is as follows.
Power mode Economy operation pilot lamp lighting condition
In this mode, low fuel consumption operation is carried out regardless of the driving
E-mode
and loading operation conditions. Thus, the lamp is constantly lighted.
The lamp is lighted when the throttle opening is maintained below 75% for more than
P-mode
0.5 seconds.
q The economy operation pilot lamp can be constantly turned off when "NO ADD" is selected in "19. ECO
LAMP" in the "Optional device selecting function" of the machine monitor.
WA470, 480-6 10-902 17

Cooling fan control function 1
1. Transmission controller Input and output signals

2. Machine monitor Transmission controller
3. Engine controller a. CAN signal
4. Cooling fan pump b. Cooling fan pump swash plate angle control sig-
4a. Swash plate angle control EPC valve nal
5. Cooling fan motor c. Cooling fan speed signal
5a. Cooling fan reverse rotation solenoid valve d. Cooling fan reverse rotation signal
6. Cooling fan reverse rotation switch e. Cooling fan automatic reverse rotation signal
7. Machine monitor mode selector switch 1 f. Cooling fan manual reverse rotation signal
9. Hydraulic oil temperature sensor Machine monitor
10. Torque converter oil temperature sensor g. CAN signal
11. Coolant temperature sensor h. "U" switch signal
12. Engine speed sensor i. "t" switch signal
13. Cooling fan speed sensor j. ">"switch signal
14. Engine k. "<"switch signal
15. Radiator l. Hydraulic oil temperature signal
m. Torque converter oil temperature signal
Engine controller
n. CAN signal
o. Engine speed signal
p. Coolant temperature signal
10-902 18 WA470, 480-6

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 waste of engine horsepower and noises in low temperature
environment.
q Engine speed and coolant temperature signals received by the engine controller, and hydraulic oil tem-
perature and torque converter oil temperature signals received by the machine monitor are sent to the
transmission controller 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.
Fan speed in accordance with temperature
*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.
Pump protection function

q In order to prevent overrun of the cooling fan motor, this function minimizes the swash plate angle of the
cooling fan pump when the engine speed reaches 2300 rpm or above.
q If the transmission controller fails to recognize the engine speed and temperature data due to a failure
on the network communication, this function sends a fixed command current (670 mA) to the swash
plate angle control EPC valve on the pump so that the pump may work as a fixed displacement pump.
WA470, 480-6 10-902 19

Control at start of engine

q At start of the engine, a fan control approach different from the usual temperature-based one is
employed.
Range A: When engine is not running [when starting switch is turned to "ON" from OFF]
q Engine speed is not recognizable when it is not running. Thus, this function sends the fixed command
current of 677 mA to the swash plate angle control EPC valve on the pump.
Range B: While cranking is taking place

q While cranking is taking place to start the engine, this function sends the command current of 800 mA to
the swash plate angle control EPC valve on the pump in order to reduce the torque needed for cranking
the engine.
Range C: For 30 seconds from start of engine.

q The swash plate angle of the cooling fan pump is so controlled that the minimum fan speed will be 750
rpm to secure the oil supplied by the cooling fan pump to the accumulator.
a If the fan speed exceeds 750 rpm because of the temperature-based controlling, priority is given to the
basic control.
Area D: Basic control is turned on

q Denotes the ordinary fan control as described in the section of "Fan speed in accordance with tempera-
ture".
10-902 20 WA470, 480-6

Fan reverse rotation function

q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation solenoid valve of the cooling fan motor is activated, reverse rotating the fan.
1. Fan manual reverse rotation function

The operator can rotate the fan in reverse direction by setting the fan reverse rotation switch to "MAN-
UAL".
As long as switching work for fan reverse rotation is taking place, the pilot lamp on the fan reverse rota-
tion switch and the lamp on the machine monitor keep blinking to inform the operator that the switching
work is underway. When the reverse rotation is suspended due to the high engine speed, high coolant
or oil temperature, this lamp also keeps on blinking until the preparation for switching is completed.
When the fan rotation switching condition is met, this function sends the throttle opening-restricting sig-
nal to the engine controller so that the engine speed may not reach 1,200 rpm while the switching work
is underway.
While the fan is rotating in reverse, the pilot lamp on the fan reverse rotation switch and the pilot lamp on
the machine monitor remain turned on.
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 to "MANUAL".

Engine speed is over 500 rpm below 1,200 rpm.
Condition 2
[In order to prevent generation of peak oil 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
Torque converter oil temperature is below 100°C.
Condition 5
30 seconds have passed after the engine is started (30 seconds after engine speed reached 500 rpm
Condition 6 or above).
[In order to ensure that enough oil is fed to the brake accumulator.]
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
While the fan is rotating in reverse, the fan reverse rotation switch is set to "MANUAL" again and the
Condition 1
engine speed goes below 1,200 rpm.
Condition 2 The engine speed goes below 1,200 rpm after 10 minutes from start of the fan reverse rotation.
Condition 3 Engine has stopped.
2. Overheat prevention function

If overheat of the coolant, hydraulic oil or torque converter oil occurs during the fan reverse rotation
(temperature caution lamp on the machine monitor lights up), this function forcibly stops the reverse
rotation and switches to the normal rotation in order to increase air flow to the radiator.
3. Fan speed during reverse rotation

While the fan reverse rotation is continued, this function sets the fan speed to the maximum by fixing the
command current to the swash plate angle control EPC valve of the fan pump.
Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the
cleaning work easier.
WA470, 480-6 10-902 21

4. Fan automatic reverse rotation function

(if equipped)
Setting the fan reverse rotation switch to "AUTO" allows changing the fan rotation direction switching
cycle and the reverse rotation duration at a specific interval.
As long as switching work for fan reverse rotation is taking place, the pilot lamp on the fan reverse rota-
tion switch and the lamp on the machine monitor keep blinking to inform the operator that the switching
work is underway. When the reverse rotation is suspended due to the high engine speed, high coolant
or oil temperature, this lamp also keeps on blinking until the preparation for switching is completed.
When the fan rotation switching condition is met, this function sends the throttle opening-restricting sig-
nal to the engine controller so that the engine speed may not reach 1,200 rpm while the switching work
is underway.
While the fan is rotating in reverse, the pilot lamp on the fan reverse rotation switch and the pilot lamp on
the machine monitor remain turned on.
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 to "AUTO".

Coolant temperature is below 90°C.
Condition 2
Hydraulic oil temperature is 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
30 seconds have passed after the engine is started (30 seconds after engine speed reached 500 rpm
Condition 5 or above).
[In order to ensure that enough oil is fed to the brake accumulator.]
Condition 6 The fan rotation direction switching interval or the reverse rotation duration has elapsed.
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
The fan reverse rotation switch is set to a position other than "AUTO" while the fan is rotating in
Condition 1
reverse.
Condition 2 The fan reverse rotation duration has elapsed.
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 "Adjustment of interval of fan automatic reverse
operation" and "Adjustment of continuance of fan automatic reverse operation" with the adjusting func-
tion of the machine monitor.
adjusting.
10-902 22 WA470, 480-6

WA470, 480-6 10-902 23

Work equipment pump and steering pump swash plate control function 1
q The work equipment pump and steering pump swash plate control function comprises the functions
named "Engine shutdown prevention control at low idle", "Overheat prevention control" and "Pickup
assist function when engine speed is low". Comparing results of calculations done on respective con-
trols, this function selects the value that makes the pump delivery smaller (the value that sets a larger
value for the command current to the swash plate angle control EPC valve).
q A balance between the digging force and the traction force in respective modes is achieved by switching
the oil pressure at which pump delivery is lowered. This change is done by switching the power mode
using the power mode selector switch.
Engine shutdown prevention control at low idle

q Engine shutdown can result from radical increase in load at low idle. In order to prevent this problem
when the engine speed is below low idle, this function restricts the pump delivery at high pressure by
controlling the pump swash plate angle through EPC.
Work equipment pump

Engine speed (rpm) 700 710 770 780 790
EPC valve command current (mA) 800 500 330 200 0
Oil pressure flow rate characteristics when control is done with command current to swash plate angle con-
trol EPC valve of work equipment pump
A: When EPC valve command current is 0 mA

B: When EPC valve command current is 300 mA
C: When EPC valve command current is 500 mA
D: When EPC valve command current is 800 mA
10-902 24 WA470, 480-6

Steering pump
Engine speed (rpm) 700 710 770 780 790
EPC valve command current (mA) 800 500 330 200 0
Oil pressure flow rate characteristics when control is done with command current to swash plate angle con-
trol EPC valve of steering pump
A: When EPC valve command current is 0 mA

B: When EPC valve command current is 300 mA
C: When EPC valve command current is 500 mA
D: When EPC valve command current is 800 mA
Overheat prevention control

q The delivery of the work equipment is controlled according to the hydraulic oil temperature to prevent
overheat.
Below 100°C 0 mA 0 mA
Hydraulic oil 100°C to below 102°C 300 mA 300 mA
temperature condition 102°C to below 105°C 350 mA 350 mA
105°C or above 400 mA 400 mA
WA470, 480-6 10-902 25

Pickup assist function when engine speed is low

q Compound operation of the work equipment and steering at a low engine speed can make the engine
pickup poor because the pump absorption torque becomes larger compared with the torque generated
by the engine.
q It is a function prepared to help improving the engine pickup. When the accelerator pedal is depressed
from a low engine speed, this function sends the command current corresponding to the steering oil
pressure to the swash plate angle control EPC valve of the work equipment pump and steering pump in
order to reduce the load on the engine by controlling the pump swash plate.
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 on the
engine speed, throttle opening and steering oil pressure. It selects an optimum pump delivery by choos-
ing the data with the lowest current value.
When the pump delivery increases (when the command current is decreased), this function prevents
sudden movement of the work equipment due to radical increase in flow rate, by restraining the change
in the current per 0.1 second within 60 mA.
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 the change in the
current per 0.1 second within the set value.
<Set value>
WA470-6: 120 mA
WA480-6: 100 mA
In P-mode
Engine speed (rpm) 900 1,400 1,420 2,200
EPC valve command current (mA) 800 800 200 0
Throttle opening (%) 0 38 40 100

Steering oil pressure (MPa {kg/cm2}) 0 {0} 14.7 {150} 17.6 {180} 34.3 {350}
In E-mode
Engine speed (rpm) 900 1,400 1,600 2,200
Throttle opening (%) 0 38 40 100

10-902 26 WA470, 480-6

2. Command current to swash plate angle control EPC valve of steering pump
The swash plate control of the steering pump is carried out when every condition in the following table is
met.
Condition 1 The difference between the actual engine speed and the target engine speed is 200 rpm or more.
The work equipment EPC current is at the set value or higher.
<Set value>
Condition 2
WA470-6: 200 mA
WA480-6: 300 mA
Condition 3 The work equipment pump pressure is 9.8 MPa {100 kg/cm2} or higher.
When the pump delivery increases (when the command current is decreased), this function prevents
sudden swing due to radical increase in flow rate, by restraining the change in the current per 0.1 sec-
ond within 60 mA.
When the pump delivery decreased (when the command current is increased), this function prevents
sudden stop of swing due to radical decrease in flow rate, by restraining the change in the current per
0.1 second within the set value.
<Set value>
WA470-6: 80 mA
WA480-6: 120 mA
WA470-6
In P-mode
In E-mode
WA480-6
In P-mode
In E-mode
WA470, 480-6 10-902 27

Transmission cut-off function 1
q The transmission cut-off oil pressure sensor detects the brake pilot pressure when the right and left
brake pedals are depressed, and sets the transmission to the neutral.
q The transmission can be cut-off at any brake pedal position by memorizing, in the controller, the brake
pilot pressure at the brake pedal depressing position at which the transmission is to be set to the neu-
tral.
1. Contents of control
• If the transmission cut-off activation condition is satisfied, the transmission is set in neu-
tral.
Outline
• If the transmission cut-off cancel condition is satisfied, the cut-off is reset and the trans-
mission is shifted by modulation.
<Operating condition in 1st or 2nd gear speed>
• The transmission cut-off switch is "ON" and the brake pilot oil pressure is above the cut-
Transmission
Operating off IN pressure.
cut-off control
condition <Operating condition in 3rd or 4th gear speed>
• The transmission cut-off switch is "ON", the throttle opening is below 30%, and the
brake pilot oil pressure is above the cut-off IN pressure.
When either of the following conditions is satisfied, the cut-off is canceled.
Cancel
• The transmission cut-off switch is "OFF".
condition
• The brake pilot oil pressure is below the cut-off OUT pressure.
Condition for
enabling • The transmission cut-off switch is turned "ON".
setting
1) Depress the brake pedal down to a desired setting position. (Setting is also available
without depressing the brake pedal)
2) Press the transmission cut-off set switch.
3) This function recognizes the brake pilot pressure at which the switch is 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
Setting of
temporarily stored.
transmission
This function sends the information to the machine monitor via the network needed
cut-off point
by it to sound the set completion buzzer (beep).
4) The pilot lamp contained in the transmission cut-off switch blinks for 2 seconds.
5) The set value is stored. (The setup mode ends)
a The setting is held even 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) When the blinking ends, the cut-off point is reset to the default brake pilot oil pressure
Resetting
point. This function sends the information to the machine monitor via the network
method
needed by it to sound the setting cancel buzzer (beep)
3) The set (default) value is stored. (The setup mode ends)
a The setting is held even after the starting switch is turned "OFF".
10-902 28 WA470, 480-6

2. Outputting conditions
Pilot lamp contained Buzzer command
Outputting conditions in transmission (communication Cut-off point
cut-off switch output)
Controlled with the value
When transmission cut-off switch is "ON" Turned ON Not issued
stored last
When transmission cut-off switch is "ON" and When the set switch
Blinks Brake pilot oil pressure
transmission cut-off set switch is "ON" is pressed, set
(for 2 seconds or until when the set switch is
For 2.5 seconds or until reset (sensor normal) completion buzzer
reset) pressed is stored
Up to setting methods 2) – 5) sounds (beep)
When transmission cut-off switch is "ON" and Not controlled
Not issued
transmission cut-off pressure sensor is Remains turned off Stored value is not
(error buzzer sounds)
abnormal changed
Not issued Controlled with the value
When transmission cut-off switch is "ON" and (machine monitor stored last
Turned ON
transmission cut-off set switch is abnormal displays an error Stored value is not
indication) changed
When the set switch
When transmission cut-off switch is "ON" and
is pressed, setting Default value of brake
transmission cut-off set switch is "ON" Turned ON
cancel buzzer sounds pilot oil pressure is stored
Reset is done within 2.5 seconds
(beep)
When transmission cut-off switch is "OFF" Turned OFF Not issued Not controlled
a Shift indicator on 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 released, connecting F or R clutch enables the gear speed change.
a When the cut-off is turned on after selecting 1st speed with the kickdown switch, 1st speed is resumed
after the cut-off release, regardless of the shift mode being selected.
a When the lockup is turned on, the cut-off is activated only after the lockup is released.
3. Settable range of transmission cut-off point

Note 1:If the point is set below 0.49 MPa {5 kg/cm2}, 0.49 MPa {5 kg/cm2} is used as the set
Settable range value.
0.49 – 4.41 MPa Note 2:If the point is set to 4.41 MPa {45 kg/cm2} or above, 4.41 MPa {45 kg/cm2} is used as the
{5 – 45 kg/cm2} set value.
The default value is 1.47 MPa {15 kg/cm2}.
Give a hysteresis of 0.20 MPa {2 kg/cm2} to the cut-off IN (neutralizing) and OUT (reset) pressures.
Example) When the pressure sensor is set to the position of 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, 480-6 10-902 29

ECSS function 1
(If equipped)
1. Transmission controller Outline

2. Gear shift lever q When the machine travels at high speed, the
3. Speed sensor damping effect of the accumulator charged
4. ECSS switch with high-pressure gas and the automatic con-
5. ECSS cut-off oil pressure switch trol of the lift cylinder circuit relief pressure
6. 1st clutch ECMV under each travel condition damp the vertical
7. 2nd clutch ECMV movement of the work equipment and reduce
8. 3rd clutch ECMV rocking of the chassis. As a result, the operator
9. 4th clutch ECMV comfort is improved, spillage of material is pre-
10. ECSS solenoid valve vented, and the working efficiency is improved.
Input and output signals Setting method

a. Gear shift lever "1st" signal q The ECSS can be enabled only when "ADD" is
b. Gear shift lever "2nd" signal selected in "20. E.C.S.S." in the "Optional
c. Gear shift lever "3rd" signal device selecting function" of the machine mon-
d. Gear shift lever "4th" signal itor.
e. Travel speed signal a For the setting procedure, see "Special func-
f. Pulse GND tions of machine monitor (EMMS)" in Testing
g. ECSS switch "ON" signal and adjusting.
h. 1st clutch ECMV operation signal
i. 2nd clutch ECMV operation signal
j. 3rd clutch ECMV operation signal
k. 4th clutch ECMV operation signal
l. ECMV GND
m. ECMV GND
n. ECSS operation signal
10-902 30 WA470, 480-6

Operation
q The operating condition of ECSS is as follows.
Output shaft speed [rpm]
ECSS cut-off oil pressure ECSS operation
ECSS switch Gear speed (Reference: Travel speed
switch signal
[km/h])
OFF 1st – 4th ON/OFF
1st – 4th 0 – Max. ON (lift arm in operation)
OFF
1st
ON
Max. 221 (3) OFF (lift arm stopped)
2nd – 4th
369 (5) or above ON
ECSS switching point A B

Output shaft speed [rpm] 221 369
(Reference: Travel speed [km/h]) (3) (5)
WA470, 480-6 10-902 31

Electric emergency steering function 1
(If equipped)

2. Emergency steering switch Transmission controller
3. Emergency steering switch relay a. CAN signal
4. Emergency steering relay b. Emergency steering switch signal
5. Emergency steering electric motor c. Steering oil pressure signal (Lo)
6. Emergency steering pump d. Steering oil pressure signal (Hi)
7. Machine monitor e. Emergency steering operation signal
7a. Steering oil pressure caution lamp f. Travel speed signal
7b. Emergency steering pilot lamp
8. Engine controller Machine monitor
9. Speed sensor g. CAN signal
10. Engine speed sensor h. Emergency steering operation signal
11. Steering pump oil pressure switch (Lo) i. Steering oil pressure signal (Lo)
12. Steering pump oil pressure switch (Hi)
13. Emergency steering oil pressure switch Engine controller
14. Steering pump j. CAN signal
15. Steering valve k. Engine speed signal
16. Steering cylinder
10-902 32 WA470, 480-6

Outline
q This function constantly monitors the signals from the oil pressure switch in the steering circuit. If the
steering oil pressure goes low and the transmission output shaft speed (travel speed) goes to or above
the emergency steering "ON" value shown in the figure, it outputs the emergency steering activation sig-
nal 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 activated shall be 5 km/h maximum.
Emergency steering switching point A B

Output shaft speed [rpm] 140 148
(Reference: Travel speed [km/h]) (1.9) (2.0)
Setting method
q The emergency steering function can be enabled only when "ADD" is selected in "13. EMERG S/T" in
the "Optional device selecting function" of the machine monitor.
Self-check operation of emergency steering

q The emergency steering system automatically checks its operability 3 seconds after (on completion of
machine monitor self-check) the starting switch is turned to "ON" position.
The self-check, however, is not performed in the following cases.
1) When the starting switch is set to the "START" position and the starting motor starts
2) When the engine is already in operation
(when the engine speed of above 500 rpm is detected)
3) While the steering oil pressure is being sensed
4) When the automatic preheater operates
5) When an error related to the emergency steering is detected in the process of self-check by the
machine monitor
6) In the case where engine run time after the previous self-check is shorter than 10 seconds
(when the engine operation at 500 rpm for minimum 10 seconds has not been detected)
q When self-check of the emergency steering is started, the emergency steering activation signal is output
for up to a maximum of 3 seconds.
q If the machine monitor detects the emergency steering operation pressure within 3 seconds, the
machine monitor transmits the emergency steering operation sensing signal to the transmission control-
ler through network. Receiving the signal, it ends self-check of the emergency steering.
q If the machine monitor does not detect the emergency steering operation pressure within 3 seconds, the
transmission controller is unable to recognize the emergency steering operation sensing signal from the
machine monitor, and thus generates an error message.
WA470, 480-6 10-902 33

Multifunction single lever function 1
(If equipped)
q The FNR switch, kickdown switch and hold switch are installed to the head of the multifunction single
lever (work equipment control lever).
q If the directional selector switch actuation switch is turned "ON", the travel direction can be changed with
the FNR switch at the top of the multifunction single lever (work equipment control lever), independent
from the directional lever of the steering column.
q The gear speed can be changed or held by operating the kickdown switch or hold switch at the head of
the multifunction single lever (work equipment control lever), independent from the gear shift lever of the
steering column.

2. Directional lever Transmission controller
3. Multifunction single lever a. CAN signal
4. Directional selector switch actuation switch b. Directional lever "F" signal
5. Starting switch c. Directional lever "N"signal
6. Neutral safety relay d. Directional lever "R" signal
7. Transmission controller neutral safety relay e. FNR switch "F" signal
8. Starting motor f. FNR switch "N" signal
9. Machine monitor g. FNR switch "R" signal
9a. Directional selector pilot lamp h. Kickdown switch "ON" signal
i. Hold switch "ON" signal
j. Directional selector switch actuation switch
"ON" signal
k. Starting switch ACC signal
l. Starting switch C signal
m. Transmission controller neutral signal
Machine monitor
n. CAN signal
10-902 34 WA470, 480-6

Operation of FNR switch function

q If the directional selector switch actuation switch is turned "ON", the command current is sent to the
transmission controller so that the directional selector signal of the FNR switch will function.
q To operate the directional selector switch actuation switch, both of the directional lever and FNR switch
must be set in "N (neutral)" for safety. If the directional selector switch actuation switch is operated while
both are not in "N (neutral)", the directional selector pilot lamp of the machine monitor flashes and the
alarm buzzer sounds.
q While the travel direction can be changed with the FNR switch, the directional selector pilot lamp of the
machine monitor and the pilot lamp contained in the directional selector switch actuation switch light up.
q Even while the travel direction can be changed with the FNR switch, if the directional lever is set in "F
(forward)" or "R (reverse)", the travel direction is changed according to the operation of the directional
lever. At this time, the system judges that the travel direction is not changed normally and flashes the
directional selector pilot lamp of the machine monitor and sounds the alarm buzzer.
q If the directional selector pilot lamp of the machine monitor flashes and the alarm buzzer sounds, they
are not reset and the operation of the FNR switch is not accepted until both of the directional lever and
FNR switch are set in "N (neutral)".
q The travel direction switching operation is changed under the operating conditions of each lever and
switch as shown in the following table.
Operating condition Machine monitor output
Travel direction FNR
Directional switching switch Directional
Directional Alarm
FNR switch selector switch operation function selector
lever buzzer
actuation switch pilot lamp
Directional lever All range Conformed to Turned Turned
N OFF Ineffective
operation (F/N/R) directional lever OFF OFF
FNR switch All range Conformed to Turned
N ON Effective Turned ON
operation (F/N/R) FNR switch OFF
Priority given to Other than N All range Conformed to
ON Ineffective Flashing Turned ON
directional lever (F/R) (F/N/R) directional lever
Directional lever
All range Other than N Conformed to
operation error OFF Ineffective Flashing Turned ON
(F/N/R) (F/R) directional lever
(Wrong operation)
Actuation switch Simultaneous
Other than N Other than N Conformed to
operation error operation to ON Ineffective Flashing Turned ON
(F/R) (F/R) directional lever
(Wrong operation) and OFF
Safety function at start of engine

q When the engine is started, if the directional selector switch actuation switch is turned "ON" and the
FNR witch is not in "N (neutral)", the signal flows to the transmission controller neutral safety relay to cut
out the starting motor circuit and consequently the engine does not start.
Shift hold function

a For details, see "Gear shift control function of transmission controller", "Shift hold function".
Kickdown function
a For details, see "Gear shift control function of transmission controller", "Kickdown function".
Setting method
q The FNR switch functions only when the "FNR SW" is selected in "14. J/S-FNR SW" in the "Optional
device selecting function" of the machine monitor.
WA470, 480-6 10-902 35

Joystick steering function 1
(If equipped)
q The directional selector switch and shift-up and shift-down switch are installed to the head of the joystick
steering lever.
q If the joystick console is tilted forward and the joystick ON/OFF switch is turned "ON", the travel direction
can be changed with the directional selector switch at the head of the joystick steering lever, indepen-
dent from the directional lever of the steering column.
q If the joystick console is tilted forward and the joystick ON/OFF switch is turned "ON", the gear can be
shifted with the shift-up and shift-down switch at the head of the joystick steering lever, independent
from the gear shift lever of the steering column.
q While the joystick is operated, travel in the 4th gear is prohibited for safety.
a Steering is controlled with the work equipment controller.

2. Directional lever Transmission controller
3. Joystick steering lever a. CAN signal
4. Console lock switch b. Directional lever "F" signal
5. Joystick ON/OFF switch c. Directional lever "N"signal
6. Starting switch d. Directional lever "R" signal
7. Neutral safety relay e. Directional selector switch "F" signal
8. Transmission controller neutral safety relay f. Directional selector switch "N" signal
9. Starting motor g. Directional selector switch "R" signal
10. Machine monitor h. Shift-up signal
10a. Joystick pilot lamp i. Shift-down signal
j. Joystick steering system "ON" signal
k. Starting switch ACC signal
l. Starting switch C signal
m. Transmission controller neutral signal
Machine monitor
n. CAN signal
10-902 36 WA470, 480-6

Operation of directional selector switch function

q If the joystick console is tilted forward and the joystick ON/OFF switch is turned "ON", the command cur-
rent is sent to the transmission controller so that the directional selector signal of the directional selector
switch will function.
q To operate the joystick ON/OFF switch, both of the directional lever and directional selector switch
switch must be set in "N (neutral)" for safety. If the joystick ON/OFF switch is operated while both are not
in "N (neutral)", the joystick pilot lamp of the machine monitor flashes and the alarm buzzer sounds.
q While the travel direction can be changed with the directional selector switch, the joystick pilot lamp of
the machine monitor and the pilot lamp contained in the joystick ON/OFF switch light up.
q Even while the travel direction can be changed with the directional selector switch, if the directional lever
is set in "F (forward)" or "R (reverse)", the travel direction is changed according to the operation of the
directional lever. At this time, the system judges that the travel direction is not changed normally and
flashes the joystick pilot lamp of the machine monitor and sounds the alarm buzzer.
q If the joystick pilot lamp of the machine monitor flashes and the alarm buzzer sounds, they are not reset
and the operation of the directional selector switch is not accepted until both of the directional lever and
directional selector switch are set in "N (neutral)".
q The travel direction switching operation is changed under the operating conditions of each lever and
switch as shown in the following table.
Operating condition Machine monitor output
Directional
(*1) Travel direction
Directional Joystick selector
Directional Joystick switching Joystick Alarm
selector ON/OFF switch
lever console tilt operation
switch switch function pilot lamp buzzer
position
Directional lever All range Forward/ Conformed to Turned Turned
N OFF Ineffective
operation (F/N/R) Reverse directional lever OFF OFF
Directional Conformed to
All range Turned
selector switch N ON Forward directional Effective Turned ON
(F/N/R) OFF
operation selector switch
Other
Priority given to All range Conformed to
than N ON Forward Ineffective Flashing Turned ON
directional lever (F/N/R) directional lever
(F/R)
Directional lever Other
All range Forward/ Conformed to
operation error than N OFF Ineffective Flashing Turned ON
(F/N/R) Reverse directional lever
(Wrong operation) (F/R)
Actuation switch Other Other Simultaneous
Conformed to
operation error than N than N operation to Forward Ineffective Flashing Turned ON
directional lever
(Wrong operation) (F/R) (F/R) ON and OFF
*1: While the joystick console is tilted in reverse, the joystick steering system is ineffective.

q When the engine is started, if the joystick ON/OFF switch is turned "ON" and the directional selector
switch is not in "N (neutral)", the signal flows to the transmission controller neutral safety relay to cut out
the starting motor circuit and consequently the engine does not start.
WA470, 480-6 10-902 37

Shift-up and shift-down function

q Only while the joystick steering system is selected and the transmission shift mode selector switch is in
the "MANUAL" position, the gear can be shifted with the shift-up and shift-down switch.
q The gear cannot be shifted up above the gear speed of the gear shift lever with the shift-up switch. The
gear cannot be shifted to the 4th gear speed for safety.
Operating condition
Shift-up and
Transmission shift-down Joystick pilot
Joystick Joystick Gear shift operation
Gear shift shift mode switch lamp
ON/OFF console tilt
lever selector function
switch position
switch
Conformed to gear
Gear shift lever All range Forward/
MANUAL OFF shift lever Ineffective Turned OFF
operation (1/2/3/4) Reverse
(1st – 4th)
Automatic gear
All range L/H shifting according to
OFF Reverse Ineffective Turned OFF
(1/2/3/4) (Automatic) travel speed
Automatic gear (2nd – 4th)
shifting function Automatic gear
All range L/H shifting according to
ON Forward Ineffective Turned ON
(1/2/3/4) (Automatic) travel speed
(2nd – 3rd)
Shift-up and Conformed to shift-up
All range
shift-down MANUAL ON Forward and shift-down switch Effective Turned ON
(1/2/3/4)
switch operation (1st – 3rd)
Setting method
q The joystick steering system functions only when "J/S" is selected in "14. J/S-FNR SW" in the "Optional
10-902 38 WA470, 480-6

WA470, 480-6 10-902 39

a Items marked with "*1" in drawing may or may not installed.
10-902 40 WA470, 480-6

WA470, 480-6 10-902 41

SEN04431-00 Transmission controller
Transmission controller 1
10-902 42 WA470, 480-6

Transmission controller SEN04431-00

DEUTSCH-24P [CN-L61]
Pin Input/Output Pin Input/Output
Signal name Signal name
No. signals No. signals
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 output (+24 V) Output
5 Transmission cut-off set switch Input 17 Steering pressure switch (Lo) 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]
1 NC — 21 NC —
2 Kickdown switch Input 22 CAN0-L Input/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 Switch R Input
8 NC — 28 Power mode switch Input
9 NC — 29 Pulse GND —
10 NC — 30 Cooling fan speed sensor Input
11 NC — 31 NC —
12 NC — 32 CAN0-H Input/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 Tachograph Output 38 Hold switch Input
19 Tachograph Output 39 Pulse GND —
20 Speed sensor Input 40 Transmission input speed sensor Input
No. Signal name signals No. Signal name signals
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
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 IVS power supply (+5 V) Output
15 ECMV R Output 35 ECMV L/U 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 Steering pump EPC Output
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, 480-6 10-902 43

SEN04431-00 Electrical system (Work equipment controller system)
Electrical system (Work equipment controller system) 1
(If equipped)
Joystick steering function 1
q If the joystick console is tilted forward and the joystick ON/OFF switch is turned "ON", the operator can
steer the machine with only the joystick steering lever without using the steering wheel.
q Even in the joystick operation mode, the operator can steer the machine with the steering wheel. If the
joystick steering lever and the steering wheel are operated in the opposite directions, the machine is
articulated in the direction of the larger steering force.
a The travel direction and the gear speed are controlled by the transmission controller.
1. Work equipment controller Input and output signals

2. Transmission controller Work equipment controller
3. Speed sensor a. CAN signal
4. Console lock switch b. Steering speed "HI" signal
5. Joystick ON/OFF switch c. Potentiometer power supply
6. HI/LOW selector switch d. Joystick lever angle A signal
7. Joystick lever angle potentiometer A e. Potentiometer GND
8. Joystick lever angle potentiometer B f. Joystick lever angle B signal
9. Joystick cut-off relay g. EPC valve GND
10. Steering right EPC valve h. Joystick cut-off signal
11. Steering left EPC valve i. Steering right EPC valve control signal
12. Steering valve j. Steering left EPC valve control signal
13. Orbit-roll valve
14. Steering wheel Transmission controller
15. Steering cylinder k. Travel speed signal
l. Joystick steering system "ON" signal
m. CAN signal
10-902 44 WA470, 480-6

Electrical system (Work equipment controller system) SEN04431-00

q When the engine is started, if the joystick ON/OFF switch is turned "ON" and the joystick steering lever
is not in "N (neutral)", the signal flows to the transmission controller neutral safety relay to cut out the
starting motor circuit and consequently the engine does not start.
Safety function at selection of joystick steering system

q If the joystick ON/OFF switch is turned "ON" while the joystick steering lever is operated, steering with
the joystick steering lever cannot be continued until it is returned to "N (neutral)" once.
q When the engine is started according to a procedure other than that described in the Operation and
Maintenance Manual, steering with the joystick steering lever cannot be started until it is returned to "N
(neutral)" once.
Steering speed selecting function

q The steering speed can be changed for each type of work by setting the HI/LOW selector switch.
q The HI mode of high response is suitable for the ordinary V-shape loading and the LOW mode is suit-
able for the work which requires fine control or in which steering shocks should be reduced.
Shocks which cause material spill during the ordinary work are reduced and the performance follow the
HI mode
lever operation is improved.
The fine control performance is improved during fine operation and the shocks caused by sharp steering
LOW mode
are reduced.
Travel speed sensitive steering function

q The reaction characteristics to the lever operation is controlled according to the travel speed.
q When the travel speed is 7 km/h or below and the lever operating distance is long, the steering speed is
increased for higher V-shape loading efficiency.
q When the travel speed is increased, the steering speed is increased in the range above the middle point
of the lever operating distance to improve the steering performance during high-speed travel and to
eliminate the difference in the operation feeling between the HI and LOW modes.
Starting current adjustment

q The difference in the operation feeling during the operation with the joystick steering lever can be
reduced by adjusting the items in "Adjusting joystick steering right lever EPC starting points" and "Joy-
stick steering left lever EPC starting points" with the adjustment function of the machine monitor.
adjusting.
Setting method
q The joystick steering system functions only when "J/S" is selected in "14. J/S-FNR SW" in the "Optional
WA470, 480-6 10-902 45

Troubleshooting function 1
q The work equipment controller monitors the input and output signals constantly for self-diagnosis of 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.
10-902 46 WA470, 480-6

WA470, 480-6 10-902 47

10-902 48 WA470, 480-6

WA470, 480-6 10-902 49

SEN04431-00 Work equipment controller
Work equipment controller 1
10-902 50 WA470, 480-6

Work equipment controller SEN04431-00

1 Bucket control lever potentiometer B Input 13 Lift arm control lever potentiometer B Input
2 NC — 14 Auxiliary control lever potentiometer B Input
3 Joystick lever potentiometer B Input 15 NC —
4 Signal GND — 16 NC —
5 NC — 17 Semiautomatic digging switch (SOFT) Input
6 NC — 18 NC —
7 Bucket control lever potentiometer A Input 19 Lift arm control lever potentiometer A Input
8 Lift arm angle sensor Input 20 Auxiliary control lever potentiometer A Input
9 Joystick lever potentiometer A Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power supply (+5 V) Output
11 HI/LOW selector switch Input 23 Semiautomatic digging switch (HARD) Input
12 NC — 24 NC —
1 NC — 21 NC —
2 NC — 22 CAN0-L Input/Output
3 Remote positioner raise/lower set switch (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/Output
13 Remote positioner raise/lower set switch (Raise) Input 33 NC —
14 NC — 34 NC —
15 NC — 35 Work equipment lock lever lock switch Input
16 NC — 36 NC —
17 NC — 37 NC —
18 NC — 38 NC —
19 NC — 39 NC —
20 NC — 40 NC —
No. Signal name signals No. Signal name signals
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 pull-out 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 setting display Output 28 Steering right EPC Output
9 NC — 29 NC —
10 Bucket cylinder stroke end proximity switch Input 30 NC —
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 Bucket dump EPC Output 35 3-spool valve pull-in EPC Output
16 Lift arm lower EPC Output 36 NC —
17 Magnet detent lift arm raise Output 37 Magnet detent bucket tilt Output
18 Remote positioner lower setting display Output 38 Steering left EPC Output
19 NC — 39 NC —
20 Bucket positioner proximity switch Input 40 NC —
WA470, 480-6 10-902 51

SEN04431-00

©2008 KOMATSU
All Rights Reserved
10-902 52
SEN04432-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up


Electric transmission control ........................................................................................................................... 2
Kickdown switch and hold switch.................................................................................................................... 6
Load meter cancel switch and load meter subtotal switch .............................................................................. 6
Multi-function knob.......................................................................................................................................... 7
Joystick steering knob..................................................................................................................................... 8
KOMTRAX system........................................................................................................................................ 10
Engine starting circuit.................................................................................................................................... 12
Engine stopping circuit.................................................................................................................................. 14
Preheating circuit .......................................................................................................................................... 15
Engine power mode selector circuit .............................................................................................................. 16
Engine output derating function .................................................................................................................... 17
Automatic warm-up function ......................................................................................................................... 17
Parking brake circuit ..................................................................................................................................... 18
Sensor........................................................................................................................................................... 20
WA470, 480-6 10-903 1

SEN04432-00 Electric transmission control
Electric transmission control 1
10-903 2 WA470, 480-6

Electric transmission control SEN04432-00
1. Transmission controller 9. Transmission cut-off oil pressure sensor

2. Hold switch 10. Brake valve
3. Kickdown switch 11. Gear shift lever
4. Parking brake switch 12. Directional lever
5. Transmission cut-off switch 13. Transmission input speed sensor
6. Transmission cut-off set switch 14. Transmission output speed sensor
7. Relay 15. Transmission ECMV
8. Fuse box
Function
No. Function Operation
Selection of travel direction
1 The travel direction can be changed by operating the directional lever.
and neutral
2 Selection of gear speed The gear speed can be changed by operating the gear shift lever.
The gear can be downshifted by pressing the kickdown switch without operating
the gear shift lever. In the manual gear shift mode, the gear is downshifted to the
3 Kickdown 1st only while the transmission is in the forward 2nd. In the auto-shift mode, the
gear is downshifted according to the gear speed and travel speed before the
switch is pressed.
If the hold switch is pressed in the auto-shift mode, the current gear speed is held.
4 Hold Gear is not upshifted even if the travel speed increases, and is not downshifted
even if the travel speed lowers.
While the transmission cut-off selector is "ON", the transmission is set to neutral at
5 Transmission cut-off
the preset brake pedal position.
The brake pedal depressing amount, at which the transmission is set to neutral
6 Transmission cut-off set
with the transmission cut-off function, can be adjusted.
The transmission cut-off function can be turned ON and OFF. While this function is
7 Transmission cut-off selection
"OFF", the left brake pedal works as the ordinary brake (right brake pedal).
While the parking brake is applied, the transmission is set to neutral. With this
8 Neutralizer function, the machine does not travel while the parking brake is applied, thus
seizure of the parking brake is prevented.
While the directional lever is not in "N (neutral)", the engine does not start even if
9 Neutral safety the starting switch is operated, thus an accident caused by sudden start of the
machine is prevented.
When the machine travels in reverse, the backup lamp and backup buzzer are
10 Alarm
turned ON to give warning to the people around the machine.
WA470, 480-6 10-903 3

SEN04432-00 Electric transmission control
Combination switch 1
Outline
q The directional lever has 3 positions and the gear shift lever has 4 positions. Each switch is positioned
with 2 pins and fixed to the body with 3 screws. Each switch is positioned with 2 pins and fixed to the
body with 3 screws. When 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 bucket operation.
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 signal
5 Self-cancel
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 blinking when the hazard lamp switch is turned "ON".
10-903 4 WA470, 480-6

Electric transmission control SEN04432-00
Operation
q Shaft (2) of directional (or gear shift) lever (1)

on the combination switch is made one with
magnet (3). As lever (1) moves, magnet (3)
moves, too.
q Control switch (5) having Hall ICs (4) in it is
installed under magnet (3). Hall ICs (4) are
arranged on the board for respective lever
positions.
q When the directional lever is set to the "F (for-
ward)" position, magnet (3) comes to directly
above Hall IC (4) for the "F" position of the con-
trol switch. Magnet (3) magnetizes Hall IC (4)
through the clearances and case (6).
q Hall IC (4) is set in the magnetism sensor cir-
cuit. Upon detecting the magnetism of magnet
(3), it sends the "F (forward)" position signal of
the directional lever to the current amplifier cir-
cuit. The current amplifier circuit outputs the
signal to operate the transmission ECMV.
WA470, 480-6 10-903 5

SEN04432-00 Kickdown switch and hold switch
Kickdown switch and hold switch 1
Load meter cancel switch and load meter subtotal switch 1
(machines equipped with load meter)
1. Switch A (white wiring harness) Function

2. Switch B (yellow wiring harness) q These switches are installed to the knob of the
3. Spring lift arm control lever. Switch A (1) works as the
4. Wiring harness kickdown switch and switch B (2) works as the
hold switch.
q If the machine is equipped with the load meter,
these switches are installed to the knob of the
bucket control lever. Switch A (1) works as the
cancel switch and switch B (2) works as the
subtotal switch.
q Both of switch A (1) and switch B (2) are of
momentary type, that is, their contacts are
closed only while they are pressed.
10-903 6 WA470, 480-6

Multi-function knob SEN04432-00
Multi-function knob 1
(If equipped)
1. FNR switch Function

2. Kickdown switch q FNR switch (1) is an alternate switch. Its con-
3. Hold switch trol signal is sent to the transmission controller
to change the travel direction.
q Kickdown switch (2) and hold switch (3) are
momentary switches. Their control signals are
sent to the transmission controller to shift or
hold the gear.
WA470, 480-6 10-903 7

SEN04432-00 Joystick steering knob
Joystick steering knob 1
(If equipped)
1. Directional selector switch Function

2. Horn switch q Directional selector switch (1) is an alternate
3. Shift down switch switch. Its control signal is sent to the transmis-
4. Shift up switch sion controller to change the travel direction.
q Horn switch (2) is a momentary switch. While it
is pressed, the horn relay operates and the
horn sounds.
q Shift up switch (3) and shift down switch (4) are
momentary switches. Their control signals are
sent to the transmission controller to shift the
gear.
q The N.C. (Normally closed) contact side of shift
up switch (3) and shift down switch (4) is not
connected.
10-903 8 WA470, 480-6

Joystick steering knob SEN04432-00
WA470, 480-6 10-903 9

SEN04432-00 KOMTRAX system
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.
a To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
KOMTRAX terminal transmits the following information:

1. Operation map
2. Service meter
3. Location information
4. Error history
etc.
10-903 10 WA470, 480-6

KOMTRAX system SEN04432-00
KOMTRAX terminal 1
Model: TC301
q Satellite wave is used.
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

Pin No. Signal name Input/Output Pin No. Signal name Input/Output
signal signal
1 NC — 21 Operation mode selection 1 Input
2 NC — 22 Operation mode selection 2 Input
3 NC — 23 NC —
4 NC — 24 NC —
5 NC — 25 NC —
6 NC — 26 NC —
7 CAN0_L Input/Output 27 Starting switch C signal Input
8 CAN0_H Input/Output 28 Alternator R signal Input
9 NC — 29 NC —
10 NC — 30 NC —
11 NC — 31 NC —
12 NC — 32 NC —
13 NC — 33 NC —
14 NC — 34 NC —
15 NC — 35 NC —
16 NC — 36 Starting switch ACC signal Input
17 NC — 37 Power supply GND —
18 NC — 38 Power supply GND —
19 NC — 39 Constant power supply (24 V) Input
20 Immobilize signal Output 40 Constant power supply (24 V) Input
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, 480-6 10-903 11

SEN04432-00 Engine starting circuit
Engine starting circuit 1
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 circuit is employed
8. Neutral safety relay to disable the engine from starting when the
9. KOMTRAX engine cut-off relay (if equipped) KOMTRAX terminal receives an engine cut
10. Starting motor neutralizer relay command issued through external operation.
11. Transmission controller neutral safety relay (if equipped)
12. Starting motor safety relay
13. Starting motor
14. Alternator
16. Engine controller
17. Machine monitor
18. KOMTRAX controller (if equipped)
19. Engine controller cut-off relay
20. CAN resistor
10-903 12 WA470, 480-6

Engine starting circuit SEN04432-00
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.
2. Neutral safety circuit

q Setting the directional lever to "N (neu-
tral)" conducts the current from contact N
of the directional lever to the coil of the
neutral safety relay.
3. When starting switch is set to "START"

q When the starting switch is set to "START"
position, the current flows through the
starting switch terminal C, KOMTRAX
engine cut-off relay, neutral safety relay
and transmission controller neutral safety
relay to the starting motor safety relay to
start the engine.
q When the directional lever is set to any
position other than "N (neutral)", the neu-
tral safety relay is not activated, and the
engine will not crank.
q As KOMTRAX terminal receives the exter-
nally applied engine cut-out command,
KOMTRAX engine cut-out relay is acti-
vated, shutting down the circuit from the
starting switch terminal C to the starting
motor safety relay. Thus, engine start-up
becomes unavailable.
(if equipped)
WA470, 480-6 10-903 13

SEN04432-00 Engine stopping circuit
Engine stopping circuit 1
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 is cut off, the engine controller
keeps the engine controller cut-out relay work-
ing to maintain the current flow to the engine
controller until its internal processing is com-
plete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alter-
nator stops power generation, stopping supply
of the voltage from the alternator terminal R.
And the current from the starting switch termi-
nal BR is also stopped and the contact of the
battery relay is opened. Consequently, the
power being supplied to each circuit of the
machine is stopped.
10-903 14 WA470, 480-6

Preheating circuit SEN04432-00
Preheating circuit 1
1. Battery Operation
2. Battery relay q Set the starting switch to "ON" position to start
3. Slow-blow fuse the engine controller. At this point, if the engine
4. Fuse box 1 coolant temperature or the intake manifold air
5. Starting switch temperature is below the set value, the engine
6. Engine controller controller operates the electrical intake air
7. Machine monitor heater relay to start preheating immediately
8. Electrical intake air heater relay after the starting switch is turned "ON".
9. Electrical intake air heater q The preheating time is set as shown below.
10. Engine coolant temperature and intake mani-
fold air temperature sensor
Outline
q The automatic preheating system is installed
so that the engine will start easily in a cold dis-
trict.
q The automatic preheating system is capable of
cutting the preheating time short as the starting
switch is set to "ON". This system is also capa-
ble of automatically setting the preheating
duration referencing temperature of intake air.
q Setting the starting switch to "ON" position
lights the preheating pilot lamp on the machine
monitor and starts preheating of intake air with
the electrical intake air heater.
The engine controller sets the preheating time
referring to the temperature detected by the
engine coolant temperature and intake mani-
fold 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.
WA470, 480-6 10-903 15

SEN04432-00 Engine power mode selector circuit
Engine power mode selector circuit 1
1. Power mode selector switch

3. Machine monitor
4. Engine controller
Function
q Setting the power mode selector switch to "P-
mode" increases the engine output to the max-
imum, and to "E-mode" reduces the fuel con-
sumption.
q The switch signal is sent to the transmission
controller, and it 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. Then, the transmission control-
ler sends a CAN signal to the engine controller
to change the engine torque curve into "P-
mode". At the same time, the transmission
controller sends the power mode pilot lamp
lighting signal in the CAN signal format to the
machine monitor.
10-903 16 WA470, 480-6

Engine output derating function SEN04432-00
Engine output derating function 1 Automatic warm-up function 1
q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque function warms it up by increasing the engine
or speed. low idle speed.
q If the coolant temperature is below 20°C at
q Following figure shows the engine torque per- starting of the engine, this function increases
formance when the torque was derated. the low idle speed to 1,020 rpm. The time for
increasing the low idle speed depends on the
coolant temperature as shown in the figure
below.
q If the coolant temperature reaches 30°C, or the
throttle opening remains at 70% or above for 3
seconds or longer during this process, the
automatic warm-up function is automatically
canceled and the engine speed returns to 800
rpm.
A: Derated to approximately 30% of the maximum

torque point
B: Derated to approximately 50% of the rated out-
put point
q Following figure shows the engine torque per-

formance when the engine speed was derated.
A: Derated near to the engine speed at maximum

torque point
WA470, 480-6 10-903 17

SEN04432-00 Parking brake circuit
Parking brake circuit 1
Operation When starting switch is turned "ON"

1. When parking brake switch is turned "ON
(applied)" prior to turning "ON" of starting
switch
1. Parking brake relay

2. Parking brake switch
3. Brake oil pressure caution relay
4. Rear brake oil pressure switch q While parking brake switch (2) is turned
5. Emergency brake oil pressure switch "ON (applied)", current from the battery
6. Parking brake solenoid valve relay flows through parking brake switch
7. Transmission controller (2) to the coil of parking brake relay (1)
8. Machine monitor and closes the contact.
q As parking brake relay (1) contact is
When starting switch is turned "OFF" closed, current from the battery relay
q Turning the starting switch to "OFF" position keeps on flowing to the coil, holding the
opens contact of parking brake relay (1). Thus, relay contact closed, until current from the
current to the parking brake circuit is stopped battery relay is cut off.
and operation of the parking brake is started. q At this time, current does not flow to park-
Accordingly, when the starting switch is turned ing brake solenoid valve (6). Thus, the
"OFF", current is not supplied to parking brake parking brake remains applied.
solenoid valve (6) regardless of the position of q Recognizing the status (ON) of parking
parking brake switch (2), so the parking brake brake switch (2), transmission controller
remains applied. (7) sets the transmission to the neutral as
long as the parking brake is applied. This
prevents the machine from moving off/
traveling with parking brake applied.
q Turning OFF (released) the parking brake
switch (2) conducts the current from the
battery relay through parking brake relay
(1), parking brake switch (2), emergency
brake oil pressure switch (5) to parking
brake solenoid valve (6) to release the
parking brake.
10-903 18 WA470, 480-6

Parking brake circuit SEN04432-00
2. When parking brake switch is turned "OFF When oil pressure loss occurs in main
(released)" prior to turning "ON" of starting brake (when emergency brake is applied)
switch
q If oil pressure of the main brake lowers,

q While the parking brake switch (2) is OFF contact of rear brake oil pressure switch
(released), the current does not flow to (4) (the switch with high operating pres-
parking brake relay (1) and its contact sure setting) opens first, cutting off current
remains open. to coil of brake oil pressure caution relay
q Turning "ON" the starting switch from this (3).
state does not conduct current to parking q Then contact of brake oil pressure caution
brake solenoid valve (6). Accordingly, the relay (3) opens, cutting off the current to
parking brake is not released automati- machine monitor (8). And machine moni-
cally. tor generates the alarm.
q Then contact of emergency brake oil pres-
sure switch (5) (the switch with the lower
operating pressure setting than that of
rear brake oil pressure switch (4)), opens
cutting off the current to parking brake
solenoid valve (6). And the parking brake
is applied.
q In this case, unlike the parking brake
application by turning "ON (applied)" of
the parking brake switch, flow of the oper-
ation signal from parking brake switch (2)
to the transmission controller (7) is main-
tained. Thus, the transmission is not set to
the neutral.
q Therefore, when the emergency brake is
applied, this control logic allows not only
reducing the braking distance, using the
engine brake in parallel, but also moving
the machine even if the emergency brake
is applied.
WA470, 480-6 10-903 19

SEN04432-00 Sensor
Sensor 1
Transmission input speed sensor

Transmission output speed sensor
Cooling fan speed sensor
1. Wire 3. Terminal 5. Connector

2. Magnet 4. Housing
Function
q The transmission input speed sensor and transmission output speed sensor are installed to the trans-
mission case, and the cooling fan speed sensor is installed to the fan motor bracket. These sensors out-
put pulse voltages by sensing the gear speeds.
10-903 20 WA470, 480-6

Sensor SEN04432-00
Torque converter oil temperature sensor

Hydraulic oil temperature sensor
Transmission oil temperature sensor
Brake oil temperature sensor
1. Connector 2. Plug 3. Thermistor
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). The brake oil temperature sensor is
installed on the rear axle. They convert changes in temperature to changes in resistance of the ther-
mistors, and output the conversion results as the temperature signals.
WA470, 480-6 10-903 21

SEN04432-00 Sensor
Work equipment pump oil pressure sensor

Steering pump oil pressure sensor
Lift cylinder head oil pressure sensor
Lift cylinder bottom oil pressure sensor
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 voltages.
10-903 22 WA470, 480-6

Sensor SEN04432-00
Transmission cut-off oil pressure sensor
1. Sensor
2. Lead wire
3. Connector
Function
q This sensor is installed on the tube of the front Output characteristics
brake line situated under the floor, this sensor
outputs the brake operating pressure in vari-
able voltage.
WA470, 480-6 10-903 23

SEN04432-00 Sensor
Coolant level sensor
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 machine body. As the oil level
goes below the specified level, the float is lowered and the switch is turned "OFF".
10-903 24 WA470, 480-6

Sensor SEN04432-00
Fuel level sensor
1. Connector 4. Body 7. Spacer

2. Float 5. Spring
3. Arm 6. Contact
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.
WA470, 480-6 10-903 25

SEN04432-00 Sensor
Air cleaner clogging sensor

(machine equipped with KOMTRAX)
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
q This 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).
10-903 26 WA470, 480-6

Sensor SEN04432-00
Accelerator pedal sensor
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
pedal pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.
Idle validation signal

q The sensor detects the accelerator pedal oper-
ation. As the accelerator pedal is released, it
outputs the signal being entered to No. 5 pin
from No. 4 pin. And as the accelerator pedal is
pressed, it outputs the signal being entered to
No. 6 pin from No. 4 pin.
WA470, 480-6 10-903 27

SEN04432-00 Sensor
Boom kick-out proximity switch

Bucket positioner proximity switch
1. Switch 3. Operation indication lamp

2. Locknut 4. Connector
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame.
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".
10-903 28 WA470, 480-6

Sensor SEN04432-00
Lift arm potentiometer

1. Oil seal 4. Brush

2. Case 5. Shaft
3. Resistor assembly 6. Connector
Function
q This potentiometer is installed to the front Output characteristics
frame. The lift arm moves the variable resistor
through the link installed to it. The resistance of
the variable resistor changes as the lift arm
angle changes, and the source voltage is
changed according to the lift arm angle and
output as the signal voltage.
WA470, 480-6 10-903 29

SEN04432-00

©2008 KOMATSU
All Rights Reserved
10-903 30
SEN04515-01
WHEEL LOADER 1OP MANUAL
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
20 Standard value table 20
100 Standard service value table

Standard value table for engine ...................................................................................................................... 2
Standard value table for chassis ..................................................................................................................... 3
WA470, 480-6 20-100 1

SEN04515-01 Standard value table for engine
Standard value table for engine 1
Machine model WA470-6, WA480-6

Engine SAA6D125E-5
Standard value Service limit
Item Measurement condition Unit for new machine value
WA470-6 WA480-6 WA470-6 WA480-6
1,880 2,020 1,880 2,020
High idle (E-mode)
± 50 ± 50 ± 50 ± 50
2,170 2,190 2,170 2,190
Engine speed High idle (P-mode) rpm ± 50 ± 50 ± 50 ± 50
Low idle (E-mode) 800 (+50/0) 800 (+50/0)
Low idle (P-mode) 800 (+50/0) 800 (+50/0)
Exhaust temperature
Whole speed range
(Turbocharger outlet °C Max. 700 700
(Ambient temperature: 20°C)
temperature)
Intake air pressure kPa Min. 100 Min. 113 80 93
At rated output
(Boost pressure) (mmHg) {Min. 750} {Min. 850} {600} {700}
Discol-
oration
At sudden acceler- Max. 25
(%) —
Engine coolant temperature: ation {Bosch
{Max. 2.5}
Exhaust gas color
Within operating range reading}
Bosch
At high idle Max. 1.0 —
reading
Air intake valve 0.33 —
Valve clearance Normal temperature mm
Exhaust valve 0.71 —
Compression pres- Engine oil temperature: 40 – 60°C MPa Min. 2.9 2.0
sure Engine speed: 200 – 250 rpm {kg/cm2} {Min. 30} {20}
At rated output
kPa Max. 1.47 2.94
Blow-by pressure Engine coolant temperature:
(mmH2O) {Max. 150} {300}
Within operating range
At rated output
0.29 – 0.69 0.18
Engine coolant temperature: SAE0W30EOS
{3.0 – 7.0} {1.8}
Within operating range SAE5W40EOS MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.05 0.03
Engine coolant temperature: SAE30DH
{Min. 0.5} {0.3}
Min. 1.18
At low idle —
EGR valve drive MPa {Min. 12}
pressure {kg/cm2} Min. 1.43
At high idle —
{Min. 14.6}
Oil temperature All engine speed ranges (Inside oil pan) °C 90 – 110 120
Deflection made by finger Alternator –
13 – 16 13 – 16
pressure of about 58.8 N {6 kg} crankshaft pulley
Belt tension Air conditioner mm
Deflection made by finger
compressor – 25 – 26 25 – 26
pressure of about 98 N {10 kg}
crankshaft pulley
20-100 2 WA470, 480-6

Standard value table for chassis SEN04515-01
Standard value table for chassis 1
* : The value shows the value before the detent.

Machine model WA470, 480-6
Directional lever Category

WA470-6 WA480-6 WA470-6 WA480-6
No
Operating 5.9 (+4.9/–3.0)
FORWARD, N {kg} Max. 16.7 {1.7}
effort {0.6 (+0.5/–0.3)}
REVERSE • Engine stopped
No • Measure at center of lever knob
Travel FORWARD, mm 35 ± 10 35 ± 20
REVERSE
5.9 (+4.9/–3.0)
1st o 2nd Max. 16.7 {1.7}
{0.6 (+0.5/–0.3)}
Operating 5.9 (+4.9/–3.0)
Gear shift lever
2nd o 3rd N {kg} Max. 16.7 {1.7}

effort {0.6 (+0.5/–0.3)}
• Engine stopped 5.9 (+4.9/–3.0)
3rd o 4th • Measure at center of lever knob Max. 16.7 {1.7}
{0.6 (+0.5/–0.3)}
1st 2nd 35 ± 10 35 ± 20
Travel 2nd 3rd mm 35 ± 10 35 ± 20
3rd 4th 35 ± 10 35 ± 20
HOLD o
Max. 12.8 {1.3} (*) Max. 19.6 {2.0} (*)
RAISE
RAISE o
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD
HOLD o
Max. 12.8 {1.3} (*) Max. 19.6 {2.0} (*)
LOWER
Lift arm
LOWER o
Operating effort
— —
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

FLOAT o
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD
HOLD o
Max. 17.7 {1.8} Max. 26.5 {2.7}
DUMP
HOLD o
Bucket Max. 12.8 {1.3} (*) Max. 19.6 {2.0} (*)
TILT
TILT o
Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLD
HOLD
43 ± 9 (*) 43 ± 18 (*)
RAISE
HOLD
Lift arm 43 ± 9 (*) 43 ± 18 (*)
LOWER
• Engine speed: Low idle
Travel
HOLD
• Hydraulic oil temperature: mm 50 ± 9 50 ± 18
FLOAT
HOLD o
50 ± 9 50 ± 18
DUMP
Bucket
HOLD o
43 ± 9 (*) 43 ± 18 (*)
TILT
WA470, 480-6 20-100 3

SEN04515-01 Standard value table for chassis

Category

WA470-6 WA480-6 WA470-6 WA480-6
• Engine stopped
Play mm Max. 20 Max. 50
• Machine facing straight to front
• Flat, level, straight, dry, and paved road
6.9 – 12.6 Max. 19.6
Steering wheel
Operating effort • Engine speed: Low idle N {kg}

{0.7 – 1.3} {Max. 2.0}
(Bucket empty)
• Engine speed: High idle
Turns (Not including play) Turns 3.5 ± 0.4 3.5 ± 0.8
• Left lock – right lock
• Engine started
Low idle 4.1 ± 0.4 Max. 6.2
Operating • Hydraulic oil temperature:
Sec.
time Within operating range
High idle • Left lock – right lock 3.5 ± 0.4 Max. 5.3
• Engine speed: 1,200 rpm

• Hydraulic oil temperature:
Frame
Clearance between front Within operating range

mm 43 ± 5 —
frame and rear frame • Flat, level, straight, dry, and paved
road
• At max. steering angle
• Engine started
Accelerator pedal
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 —
aFor measuring posture, see Fig. B 323 ± 30 Min. 264

Pressing effort N {kg}
Brake pedal
at end of this section {32.9 ± 3.0} {Min. 26.9}

Neutral (a1) • Engine speed: Low idle 53 —
Pressing
angle Max. (a2) deg. 15 (+1/0) —
Play 5±1 —
Fitting of wheel lock A aFor measuring posture, see Fig. C Max. 2.5 —
ring at end of this section
Tires
B Max. 4.0 —
• Tire inflation pressure: Specified pres- mm
Clearance of wheel sure
C 2 – 10 —
lock ring
1,710 1,740 1,710 1,740
E-mode
± 50 ± 50 ± 100 ± 100
Torque converter stall
1,800 1,860 1,800 1,860
P-mode
• Coolant temperature: ± 50 ± 50 ± 100 ± 100
Engine Speed
Within operating range 1,870 1,970 1,870 1,970

• Torque converter oil temper- E-mode ± 100 ± 100 ± 200 ± 200
Hydraulic stall ature: Within operating rpm
range 2,140 2,150 2,140 2,150
P-mode
• Hydraulic oil temperature: ± 100 ± 100 ± 200 ± 200
Within operating range 1,670 1,690 1,670 1,690
E-mode
Torque converter stall + ± 100 ± 100 ± 200 ± 200
hydraulic stall 1,750 1,810 1,750 1,810
P-mode
± 100 ± 100 ± 200 ± 200
20-100 4 WA470, 480-6


Category

WA470-6 WA480-6 WA470-6 WA480-6
• Engine speed: 2.45 ± 0.2 2.45 ± 0.2
Low idle {25.0 ± 2.0} {25.0 ± 2.0}
Main relief pressure • Torque con-
verter oil tem- 2.55 ± 0.2 2.55 ± 0.2
perature: {26.0 ± 2.0} {26.0 ± 2.0}
Torque converter relief • Engine speed: Within operat- Max. 0.93 Max. 0.93
Transmission, torque converter
(inlet) oil pressure 2,000 rpm ing range (60 – {Max. 9.5} {Max. 9.5}
80°C)
Torque converter outlet port 0.59 ± 0.05 0.59 ± 0.05
oil pressure {6 ± 0.5} {6 ± 0.5}
2.35 ± 0.15 2.35 ± 0.15
1st, 2nd MPa
{24.0 ± 1.5} {24.0 ± 1.5}
{kg/cm2}
• Torque converter oil temperature: 2.30 ± 0.15 2.30 ± 0.15
ECMV output 3rd, 4th
Within operating range (60 – 80°C) {23.5 ± 1.5} {23.5 ± 1.5}
(clutch) oil
• Engine speed: 2,000 rpm 2.06 ± 0.15 2.06 ± 0.15
pressure F–R • Manual switch: ON {21.0 ± 1.5} {21.0 ± 1.5}
Lockup 1.66 ± 0.15 1.66 ± 0.15
(if equipped) {17.0 ± 1.5} {17.0 ± 1.5}
• Torque converter oil temperature:
0.17 ± 0.05 0.17 ± 0.05
Lubrication pressure Within operating range (60 – 80°C)
{1.75 ± 0.5} {1.75 ± 0.5}
• Engine speed: 2,000 rpm
24.5 ± 1.23 24.5 (+1.23/–2.45)
Steering relief pressure Within operating range
{250 ± 12.5} {250 (+12.5/–25)}
Steering
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
Low idle lamp goes out

MPa
• Hydraulic oil tem- • Point where oil
{kg/cm2}
perature: pressure is
Within operating range going up and 9.8 (+0.98/0} 9.8 (+1.5/–0.5}
Charge cut-out pressure
{100 (+10/0)} {100 (+15/–5)}
then starts to
go down
7.6 7.7 7.6 7.7
1st
± 0.4 ± 0.4 ± 0.5 ± 0.5
13.1 13.1 13.1 13.1
2nd
± 0.7 ± 0.7 ± 0.9 ± 0.9
P-mode
Power transmitting system
22.9 22.9 22.9 22.9

3rd
± 1.1 ± 1.1 ± 1.6 ± 1.6
36.2 36.3 36.2 36.3
4th
Travel speed FOR- ± 1.8 ± 1.8 ± 2.5 ± 2.5
km/h
(Bucket empty) WARD 6.6 7.1 6.6 7.1
1st
± 0.3 ± 0.4 ± 0.5 ± 0.5
11.4 12.2 11.4 12.2
2nd
± 0.6 ± 0.6 ± 0.8 ± 0.9
E-mode
19.6 21.1 19.6 21.1
3rd
± 1.0 ± 1.1 ± 1.4 ± 1.5
30.8 33.1 30.8 33.1
4th
± 1.5 ± 1.7 ± 2.2 ± 2.3
WA470, 480-6 20-100 5


Category

WA470-6 WA480-6 WA470-6 WA480-6
7.9 7.9 7.9 7.9
1st
± 0.4 ± 0.4 ± 0.6 ± 0.6
13.5 13.5 13.5 13.5
2nd
± 0.7 ± 0.7 ± 0.9 ± 0.9
P-mode
Power transmitting system
23.6 23.6 23.6 23.6

3rd
± 1.2 ± 1.2 ± 1.7 ± 1.7
37.3 37.4 37.3 37.4
4th
Travel speed ± 1.9 ± 1.9 ± 2.6 ± 2.6
REVERSE km/h
(Bucket empty) 6.8 7.3 6.8 7.3
1st
± 0.3 ± 0.4 ± 0.5 ± 0.5
11.7 12.6 11.7 12.6
2nd
± 0.6 ± 0.6 ± 0.8 ± 0.9
E-mode
20.2 21.7 20.2 21.7
3rd
± 1.0 ± 1.1 ± 1.4 ± 1.5
31.7 34.0 31.7 34.0
4th
± 1.6 ± 1.7 ± 2.2 ± 2.4
• Hydraulic oil temperature: 4.8 ± 0.4 Min. 4.2
Brake oil pressure
Within operating range {48.9 ± 4.1} {Min. 42.7}
MPa
• Engine stopped {kg/cm2}
Lowering of brake oil pres- Max. 0.49 Max. 0.49
• Measure lowering of oil pressure from
sure {Max. 5.0} {Max. 5.0}
4.9 MPa {50 kg/cm2} in 5 min.
• Tire inflation pressure:
Specified pressure
Wheel brake
• Flat, level, straight, dry, and paved

road
Performance • Speed when applying brake: 20 km/h, m Max. 5 Max. 5
braking delay: Within 0.1 sec.
• Brake pedal operating effort: Specified
operating effort 323 ± 30 N {32.9 ± 3 kg}
• Measure braking distance
Shaft protrusion
• Oil pressure: 4.9 MPa {50 kg/cm2} reaches wear
Disc wear mm Shaft protrusion 0
• Pedal depressed fully limit position
(Max. 2.4 mm)
• Torque converter oil temperature: Min. 2.27 Min. 2.27
Parking brake oil pressure
Within operating range MPa {Min. 23.1} {Min. 23.1}
Parking brake solenoid valve • Engine speed: Low idle {kg/cm2} Min. 2.27 Min. 2.27
basic pressure • Parking brake: OFF {Min. 23.1} {Min. 23.1}
Parking brake
• Tire inflation pressure:

Specified pressure
• Flat paved road with 1/5 (11° 20')
Performance grade. Dry, paved road surface — Holds in position Holds in position
• Machine at operating condition
aFor measuring posture, see Figs. D
and E at end of this section
Disc thickness mm 3.2 ± 0.08 2.97
20-100 6 WA470, 480-6


Category

WA470-6 WA480-6 WA470-6 WA480-6
3.72 (+0.2/0) 3.72 (+0.2/–0.2)
PPC valve basic pressure Within operating range
{38 (+2/0)} {38 (+2/–2)}
Lift arm
RAISE, MPa
PPC
• Hydraulic oil temperature: 3.72 (+0.1/–0.1) 3.72 (+0.1/–0.2)

PPC valve FLOAT; {kg/cm2}
Within operating range {38 (+1/–1)} {38 (+1/–2)}
output pres- Bucket
DUMP, TILT • Engine speed: High idle
sure
• Control lever operated fully
Lift arm 2.2 ± 0.25 2.2 ± 0.39
LOWER {22.5 ± 2.5} {22.5 ± 4}
Work equipment relief pres- 34.3 ± 1.77 34.3 (+1.77/–4.41)
sure {350 ± 18} {350 (+18/–45)}
1.96 ± 0.20 1.96 ± 0.40
Unload pressure • Engine speed: High idle MPa
{20 ± 2} {20 ± 4}
• Work equipment control lever: Neu- {kg/cm2}
tral
Within operating range 1.37 ± 0.2 1.37 ± 0.39
LS differential pressure
• Engine speed: High idle {14 ± 2} {14 ± 4}
• Lift arm lever: at half stroke
6.3 7.1 Max. Max.
E-mode
• Hydraulic oil temperature: ± 0.5 ± 0.5 8.4 9.5
Lift arm RAISE Within operating range 5.4 6.1 Max. Max.
• Engine speed: High idle P-mode
± 0.5 ± 0.5 7.2 8.1
• Apply no load
aFor measuring posture, see E-mode 3.8 3.9 Max. Max.
Figs. F and G at end of this ± 0.5 ± 0.5 5.1 5.2
Work equipment
Lift arm LOWER

section 3.7 3.8 Max. Max.
Work equipment speed
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
Retraction of lift arm cyl- Within operating range Max. 30 Max. 36
Hydraulic drift
inder rod • Stop engine and leave for 5 minutes,

then measure for 15 minutes.
mm
• Apply no load to bucket and set lift
Retraction of bucket cyl- arm and bucket in level position.
aFor measuring posture, see Fig. K Max. 20 Max. 24
inder rod
at end of this section
WA470, 480-6 20-100 7


Category

WA470-6 WA480-6 WA470-6 WA480-6
• Engine coolant temperature: Min.
95°C
Max. fan speed 1,450 ± 100 1,450 ± 200
• Hydraulic oil temperature: Min. 95°C
Min. 105°C
• Engine speed: Low idle rpm
• Engine coolant temperature:
Max. 75°C
Min. fan speed • Hydraulic oil temperature: Max. 75°C 600 ± 50 600 ± 100
Hydraulic drive fan

Max. 85°C
• Air conditioner: OFF
Min. 95°C 14.2 ± 1.4 14.2 ± 2.1
Fan drive pressure
• Hydraulic oil temperature: Min. 95°C {145 ± 15} {145 ± 22}
Min. 105°C MPa
• Engine speed: High idle {kg/cm2}
Fan reverse solenoid output Min. 95°C 14.2 ± 1.4 14.2 ± 2.1
pressure • Hydraulic oil temperature: Min. 95°C {145 ± 15} {145 ± 22}
Min. 105°C
20-100 8 WA470, 480-6

Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
WA470, 480-6 20-100 9

a Fig. G a Fig. K
a Fig. H
a Fig. J
20-100 10 WA470, 480-6

WA470, 480-6 20-100 11

SEN04515-01

©2009 KOMATSU
All Rights Reserved
20-100 12
SEN04516-01
WHEEL LOADER 1SHOP MANUAL
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
30 Testing and adjusting 30
101 Testing and adjusting, Part 1

Tools for testing, adjusting, and troubleshooting............................................................................................. 3
Testing engine speed ...................................................................................................................................... 9
Testing exhaust gas color ..............................................................................................................................11
Testing exhaust temperature......................................................................................................................... 13
Adjusting valve clearance ............................................................................................................................. 15
Testing compression pressure ...................................................................................................................... 17
Testing blow-by pressure .............................................................................................................................. 19
Testing engine oil pressure ........................................................................................................................... 20
Testing EGR valve drive pressure................................................................................................................. 21
Testing intake air (boost) pressure ................................................................................................................ 22
Handling fuel system equipment................................................................................................................... 23
Releasing residual pressure in fuel system .................................................................................................. 23
Testing fuel pressure..................................................................................................................................... 24
Testing fuel return and leak amount.............................................................................................................. 25
Bleeding air from fuel circuit.......................................................................................................................... 28
Testing fuel circuit for leakage....................................................................................................................... 30
Handling of reduced cylinder mode operation .............................................................................................. 31
Handling of no injection cranking operation .................................................................................................. 31
Handling of controller voltage circuit ............................................................................................................. 32
Check of muffler and muffler stack for looseness and damage .................................................................... 33
Check of muffler function .............................................................................................................................. 33
Check of installed condition of cylinder head and manifolds ........................................................................ 34
Check of engine piping for damage and looseness ...................................................................................... 34
WA470, 480-6 30-101 1

SEN04516-01
Testing and adjusting air conditioner compressor belt tension...................................................................... 35

Testing and adjusting alternator belt tension................................................................................................. 36
Adjusting transmission speed sensor............................................................................................................ 37
Adjusting directional lever length .................................................................................................................. 38
Adjusting gear shift lever length .................................................................................................................... 38
Testing FNR lever and gear shift lever .......................................................................................................... 39
Testing and adjusting power train oil pressure .............................................................................................. 40
Procedure for flushing torque converter and transmission hydraulic circuit.................................................. 54
Method of moving machine when transmission valve is broken ................................................................... 56
Check of axle final drive for oil leakage......................................................................................................... 59
Check of drive shafts for looseness, play and damage................................................................................. 59
Testing and adjusting steering stop valve ..................................................................................................... 60
Testing and adjusting steering wheel ............................................................................................................ 62
Testing steering oil pressure ......................................................................................................................... 64
Bleeding air from steering circuit................................................................................................................... 67
30-101 2 WA470, 480-6

Tools for testing, adjusting, and troubleshooting SEN04516-01
Tools for testing, adjusting, and troubleshooting 1
Testing and Sym-

Part No. Part Name Q'ty Remarks
adjusting item bol
1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 – 9
Testing exhaust gas
A Commercially
color 2 Smoke meter 1
available
Adjusting valve Commercially
B Clearance gauge 1
clearance available
1 795-502-1590 Gauge assembly 1 0 – 7 MPa {0 – 70 kg/cm2}
Testing compression
C 2 795-471-1420 Adapter 1
pressure
3 6217-71-6112 Gasket 1
Testing blow-by
D 799-201-1504 Blow-by checker 1 0 – 5 kPa {0 – 500 mmH2O}
pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Testing engine oil 1
E 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
pressure
799-101-5230 Nipple 1 14 × 1.5 mm
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 1 MPa {10 kg/cm2}
1 {25, 60, 400, 600 kg/cm2}
Testing EGR valve
E
drive pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 799-101-5210 Nipple 1 R1/4
Testing intake air
F 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
(boost) pressure
{25, 60, 400, 600 kg/cm2}
Testing fuel 1
G 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
compression
799-101-5160 Nipple 1 R1/8
2 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
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}
WA470, 480-6 30-101 3

SEN04516-01 Tools for testing, adjusting, and troubleshooting
Testing and Sym-

adjusting item bol
{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 790-261-1231 Elbow 1 Male: 10 × 1.25 mm, Female: R1/8

790-301-1271 Joint 1 10 × 1.25 mm
Testing power train oil 790-301-1530 Elbow 1 Both of male and female R1/8
K
pressure
790-101-5160 Nipple 1 R1/8
2 07000-11008 O-ring 1
799-101-5220 Nipple 1 10 × 1.25 mm
3
07002-11023 O-ring 1
4 799-401-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Method of moving
machine when trans- L 794-423-1190 Plug 1 20 × 1.5 mm
mission valve is broken
Testing and adjusting
M 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
steering wheel
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 799-101-5220 Nipple 1 10 × 1.25 mm
N
steering oil pressure 2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
4 799-401-3200 Adapter 1 Size 03
Testing hydraulic drive 799-101-5002 Hydraulic tester 1
P {25, 60, 400, 600 kg/cm2}
fan
1 {25, 60, 400, 600 kg/cm2}
Bleeding air from
Q
hydraulic drive fan circuit 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
2 790-261-1130 Coupling 1
Testing and adjusting Pressure gauge: 2.5, 6, 40, 60 MPa
accumulator charge R {25, 60, 400, 600 kg/cm2}
pressure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Testing wheel brake oil
S 4 790-301-1720 Adapter 1 20 × 1.5 mm o R1/8
pressure
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Testing wear of wheel Commercially
T Slide calipers 1
brake disc available
{25, 60, 400, 600 kg/cm2}
Testing parking brake 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
U
oil pressure
790-261-1231 Elbow 1 10 × 1.25 mm
799-101-5160 Nipple 1 R1/8
30-101 4 WA470, 480-6

Testing and Sym-

adjusting item bol
Testing wear of parking Commercially
V Slide calipers 1
brake disc available
Testing and adjusting 1 79A-264-0021 Push-pull scale 1
work equipment control W Commercially
lever 2 Scale 1
available
799-101-5002 Analog hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting
work equipment PPC X 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
oil pressure 799-101-5220 Nipple 1
2 10 × 1.25 mm
07002-11023 O-ring 1
Pressure gauge:2.5, 6, 40, 60 MPa
1 {25, 60, 400, 600 kg/cm2}
Testing and adjusting 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 60 MPa {600 kg/cm2}
work equipment oil Y
799-101-5220 Nipple 1 10 × 1.25 mm
pressure 2
07002-11023 O-ring 1
3 799-401-2701 Differential pressure gauge 1
Measuring coolant,
oil and exhaust Z 799-101-1502 Digital thermometer 1
temperature
799-601-4130 T-adapter — For Ne sensor
799-601-4330 Socket — For Bkup sensor
799-601-4240 Socket — For atmospheric pressure sensor
799-601-4250 Socket — For boost pressure sensor
799-601-4180 T-adapter — For EGR gas sensor
799-601-9420 T-adapter — For common rail pressure
799-601-4150 T-adapter — For oil pressure sensor
795-799-5540 T-adapter — For boost temperature sensor
For coolant temperature sensor
795-799-5530 T-adapter —
Engine troubleshooting For fuel temperature sensor
for controllers, sensors, ZA 799-601-9020 T-adapter — For EGR valve solenoid
and actuators For EGR valve solenoid
799-601-9030 T-adapter —
For bypass valve stroke sensor
799-601-9430 T-adapter — For supply pump PCV
799-601-9020 T-adapter — For injector
799-601-4260 T-adapter — For controller (4-pole)
799-601-9320 T-box —
For 24-pole type
799-601-9310 Plate —
799-601-4350 T-box — For 60-pole type
WA470, 480-6 30-101 5

Testing and Sym-

adjusting item bol
799-601-2500
or
799-601-2700
or
799-601-2800
or T-adapter 1
799-601-7100
or
799-601-4700
or
799-601-8000
799-601-2600 • T-adapter box 1 Econo (Excl. 799-601-2700)
799-601-2740 • Adapter for MIC 1 For MIC-5P
799-601-4101
or
799-601-4201
or T-adapter assembly 1
799-601-9000
or
799-601-9200
799-601-9020 • Adapter for DT 1 For DT2P
799-601-9030 • Adapter for DT 1 For DT3P
For DT6P (Excl. 799-601-4101 and
799-601-9050 • Adapter for DT 1
799-601-4201)
For DT12P (Excl. 799-601-4101 and
Diagnosis for chassis 799-601-9110 • Adapter for DT 1
799-601-4201)
related controller,
ZB 799-601-7000
sensor, actuator and
or
harness
799-601-7100
799-601-7400
or
799-601-8000
799-601-7010 • Adapter for X 1 For X1P
799-601-7050 • Adapter for SWP 1 For SWP6P (Excl. 799-601-8000)
799-601-7060 • Adapter for SWP 1 For SWP8P (Excl. 799-601-8000)
799-601-7070 • Adapter for SWP 1 For SW14P (Excl. 799-601-8000)
For M1P (Excl. 799-601-7000 and
799-601-7080 • Adapter for M 1
799-601-7100)
799-601-7090 • Adapter for M 1 For M2P
799-601-7150 • Adapter for S 1 For S10P
799-601-7310 Adapter for SWP 1 For SW12P
799-601-7320 Adapter for SWP 1 For SW16P
799-601-7500 T-adapter assembly 1
799-601-7520 • Adapter for 070 1 For 070-12P
30-101 6 WA470, 480-6

Testing and Sym-

adjusting item bol
799-601-7530 • Adapter for 070 1 For 070-14P
799-601-7540 • Adapter for 070 1 For 070-18P
799-601-7550 • Adapter for 070 1 For 070-20P
799-601-9000
Diagnosis for chassis
799-601-9200
related controller,
ZB 799-601-9030 • Adapter for DT 1 For DT3P
sensor actuator and
harness 799-601-9110 • Adapter for DT (Gray) 1 For DT12PGR
799-601-9120 • Adapter for DT (Black) 1 For DT12PB
799-601-9290 • Adapter for HD30 1 For HD30-31P
799-601-9350 • Adapter for DRC 1 For DRC-40
799-601-9360 • Adapter for DRC 1 For DRC-24
Commercially
1 Gas charge tool 1
available
Commercially
2 Pressure reducing valve 1
available
Commercially
3 Charging hose 1
Procedure for testing of available
nitrogen gas pressure Commercially Nipple
and charging of nitro- 1
available (For Russia)
gen gas of ECSS ZC
(Electronically Con- Commercially Nipple
1
trolled Suspension Sys- available (For USA)
tem) accumulator Commercially Nipple
4 1
available (For USA)
Commercially Nipple
1
available (For Germany)
Commercially Nipple
1
available (For UK)
1 792-610-1701 Gas charge tool 1
Nipple
792-610-1310 1
(For Russia)
Procedure for testing of Nipple
792-610-1320 1
nitrogen gas pressure (For USA)
and charging of nitro- ZD Nipple
gen gas of brake accu- 2 792-610-1330 1
(For USA)
mulator
Nipple
792-610-1350 1
(For Germany)
Nipple
792-610-1360 1
(For UK)
Measuring operating 79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
effort and pressing —
force 79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and Commercially

— Scale 1
hydraulic drift available
Measuring work Commercially
— Stopwatch 1
equipment speed available
Measuring voltage and Commercially
— Tester 1
resistance available
Removal and installation
Commercially 3.26 mm torque wrench
of boost pressure and — Torque wrench 1
available (KTC Q4T15 or equivalent)
temperature sensor
WA470, 480-6 30-101 7

Testing and Sym-

adjusting item bol
of engine oil pressure — 795-799-6210 Deep socket 1 27 mm deep socket
sensor
Commercially 21 mm deep socket
of engine coolant — Deep socket 1
available (MITOLOY 4ML-21 or equivalent)
temperature sensor
30-101 8 WA470, 480-6

Testing engine speed SEN04516-01
Testing engine speed 1 2. Measuring torque converter stall speed
k
1) Referring to “Special function of machine
Stop the machine on a level ground and monitor”, select the real time monitoring
lower the work equipment and touch per- function of the service mode.
fectly to the ground.
k
2) Select the two-item simultaneous monitor-
Apply the parking brake and lock the tires ing (2 ITEMS) and then enter the following
with chocks.
k
code numbers directly.
When measuring, check that there are no a Monitoring items
persons around the machine. [1] Code No.01001: ENG SPEED
(Engine speed)
a Measure the engine speed under the following [2] Code No.40100: TC OIL TEMP
condition. (Torque converter oil temperature)
q Engine coolant temperature:
q Hydraulic oil temperature:
q Torque converter oil temperature:
1. Measuring engine speed (low idle and high

idle)
1) Referring to “Special function of machine
monitor”, select the real time monitoring
function of the service mode.
2) Display “ENG SPEED” from the monitor-
ing items of the machine monitor.
a Monitoring item: ENG SPEED
3) Start the engine.
Code No. 01001: ENG SPEED
4) Turn the transmission cut-off switch OFF
(Engine speed)
and press the left brake pedal securely.
5) Turn the torque converter lockup switch (if
equipped) OFF.
6) Set the transmission shift mode selector
switch in the MANUAL position.
7) While keeping the FNR lever or switch at
the N (Neutral) position, set the gearshift
lever or gear shift switch to the 4th posi-
tion.
8) Release the parking brake.
9) While pressing the brake pedal, set the
FNR lever or switch to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal
securely.
3) Start the engine, set it in the measuring 10) While running the engine at high idle,
condition, and measure the engine speed. press the accelerator pedal gradually.
When the torque converter stalls, mea-
sure the engine speed.
a Measure the stall speed 2 – 3 times.
a Do not keep stalling the torque con-
verter for more than 20 seconds. Take
care that the torque converter oil tem-
perature will not exceed 120°C.
a Measure the torque converter stall
speed when the power mode and
economy mode are turned on.
WA470, 480-6 30-101 9

SEN04516-01 Testing engine speed
3. Measuring hydraulic stall speed 4. Measuring torque converter stall and

1) Referring to “Special function of machine hydraulic stall (full stall) speed
monitor”, select the real time monitoring 1) Set the machine monitor as in “2. Measur-
function of the service mode. ing torque converter stall speed”.
2) Select the two-item simultaneous monitor- 2) Start the engine.
ing (2 ITEMS) and then enter the following 3) Turn the transmission cut-off switch OFF
code numbers directly. and press the left brake pedal securely.
a Monitoring items 4) Turn the torque converter lockup switch (if
[1] Code No.01001: ENG SPEED equipped) OFF.
(Engine speed) 5) Set the transmission shift mode selector
[2] Code No. 04401: HYD TEMP switch in the MANUAL position.
(hydraulic oil temperature) 6) While keeping the FNR lever or switch at
the N (Neutral) position, set the gearshift
lever in the 4th position.
FNR lever or switch to the F (forward) or R
(reverse) position.
securely.
9) While running the engine at high idle, stall
the torque converter and relieve the lift
arm cylinder or bucket cylinder on the
extraction side simultaneously and mea-
sure the engine speed at this time.
3) Run the engine at high idle. verter for more than 20 seconds. Take
4) Relieve the lift arm cylinder or bucket cyl- care that the torque converter oil tem-
inder on the extraction side and measure perature will not exceed 120°C.
the engine speed. a Measure the full stall speed when the
a Measure the hydraulic stall speed power mode and economy mode are
when the power mode and economy turned on.
mode are turned on.
30-101 10 WA470, 480-6

Testing exhaust gas color SEN04516-01
Testing exhaust gas color 1 2. Measuring with smoke meter A2

1) Insert the probe of smoke meter A2 in the
a Necessary tools outlet of the muffler (exhaust pipe) and fix
Symbol Part No. Part Name it to the exhaust pipe with a clip.
1 799-201-9001 Handy smoke checker
A Commercially
2 Smoke meter
available
k Stop the machine on a level ground and

lower the work equipment and touch per-
k Apply the parking brake and lock the tires
with chocks.
k When installing and removing the testing
instruments, take care not to touch a hot part.
a If an air source and an electric power source
are not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2. 2) Connect the probe hose, receptacle of the
a Measure the exhaust gas color under the fol- accelerator switch, and air hose to smoke
lowing condition. meter A2.
q Engine coolant temperature: Within oper- a Keep the pressure of the supplied
ating range compressed air at 1.5 MPa {15 kg/
cm2} or below.
1. Measuring with handy smoke checker A1 3) Connect the power cable to a 100 V AC
1) Stick a sheet of filter paper to smoke receptacle.
checker A1. a Confirm that the smoke meter power
2) Insert the exhaust gas intake pipe in the switch is in the OFF position, before con-
muffler (exhaust pipe). necting the power cable to an outlet.
3) Start the engine and heighten the engine 4) Loosen the cap nut of the suction pump
coolant temperature to the operating range. and fit the filter paper.
4) Accelerate the engine suddenly or run it at a Fit the filter paper securely so that the
high idle and operate the handle of smoke exhaust gas will not leak.
checker A1 so that the filter paper will 5) Turn on the power switch of smoke meter A2.
absorb the exhaust gas.
6) Start the engine and keep it running until

5) Take out the filtering paper and compare it the engine coolant temperature rises to
with the attached scale for judgement. the operating range.
6) Remove the measurement tool after the 7) Accelerate the engine suddenly or run it at
work, and make sure that the machine is high idle and press the accelerator pedal
back to normal condition. of smoke meter A2 and collect the
exhaust gas into the filter paper.
WA470, 480-6 30-101 11

SEN04516-01 Testing exhaust gas color
8) Put the polluted filtering paper on non-pol-

luted filtering paper (more than 10 sheets)
in the filtering paper holder, and read the
indicated value.
9) Remove the measurement tool after the
work, and make sure that the machine is
back to normal condition.
30-101 12 WA470, 480-6

Testing exhaust temperature SEN04516-01
Testing exhaust temperature 1 3. Install sensor [1] and connect them to digital
temperature gauge [2].
a Necessary tools 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

with chocks.
k Install and remove the testing instrument
after the exhaust manifold is cooled.
a Measure the exhaust temperature under the
following condition.
q Coolant temperature: Within operating
range
q Hydraulic oil temperature: Within operat-
ing range
q Power train oil temperature: Within operat-
ing range
1. Open the left side cover of the engine and

remove turbocharger heat insulation cover (1).
4. Procedure for periodic measurement done in

preventive maintenance
a To prevent the torque converter from over-
heating, increase the exhaust temperature
once through full-stall operation (torque
2. Remove exhaust temperature measurement converter stall + hydraulic stall), and then
plug (2). measure the exhaust temperature while
only the torque converter is stalled.
1) Start the engine and heighten the coolant
temperature to the operating range.
2) Turn off the transmission cut-off switch
and press the left brake pedal securely.
switch in the MANUAL position.
4) Set the gear shift lever or gear shift switch
to the 4th speed while keeping the FNR
lever or switch at the N (Neutral) position.
WA470, 480-6 30-101 13

SEN04516-01 Testing exhaust temperature
6) While pressing the brake pedal, set the 5. Procedure for measuring the maximum
FNR lever or switch to the F (forward) or R exhaust temperature
(reverse) position. Operate the machine actually and measure the
k Keep pressing the brake pedal maximum exhaust temperature.
securely. a Use the PEAK mode of the thermometer
7) Press the accelerator pedal gradually to (in which the maximum value can be
the high idle. While running the engine at saved).
high idle, stall the torque converter and a The exhaust temperature largely depends
relieve the lift arm cylinder or bucket cylin- on the outside air temperature (intake air
der on the extraction side simultaneously. temperature of the engine). Accordingly, if
(full stall) any abnormal value is obtained, correct it
a Increase the exhaust temperature to by the following calculation.
about 650°C (the state of (a) in the a Corrected value [°C] = Measured value +
figure). 2 x (20 – Outside air temperature)
verter for more than 20 seconds. Take 6. Remove the measurement tool after the work,
care that the torque converter oil tem- and make sure that the machine is back to nor-
perature will not exceed 120°C. mal condition.
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).
30-101 14 WA470, 480-6

Adjusting valve clearance SEN04516-01
Adjusting valve clearance 1 3. According to the following procedures, adjust

the clearance of valve marked with q in the
a Necessary tools valve arrangement figure.
Commercially
B Clearance gauge
available
a Adjust the valve clearance in the following con-

dition.
q Engine coolant temperature: Within operating
range
1. Open the engine side cover and remove cylin-

der head cover (1).
1) To adjust the valve clearance, insert clear-

ance gauge B into clearance (b) between
rocker arm (4) and crosshead (5), and
adjust the valve clearance with adjustment
screw (6).
a With the clearance gauge inserted,
turn the adjustment screw so that
clearance gauge can move with a
light force.
2) While holding adjustment screw (6),
tighten locknut (7).
3 Locknut:
2. Rotate the crankshaft forward, align of damper 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
“1.6TOP” stamp line (a) to pointer (8), and then a After tightening the locknut, check the
set the No.1 cylinder to the compression top valve clearance again.
dead center.
a Always crank forward using damper
mounting bolt (width across flats: 24 mm)
to prevent loosening the bolt.
a When No. 1 cylinder is at the compression
top dead center, the rocker arms on both
intake side and exhaust side can be
moved by the valve clearance with the
hand. If the rocker arms cannot be moved,
rotate the crankshaft one more turn.
4. After finishing the adjustment of all the valves

marked with q, rotate the crankshaft 360° for-
ward and align “1.6TOP” stamp line (a) of the
damper to pointer (8) in order to set the No.6
cylinder to the compression top dead center.
WA470, 480-6 30-101 15

SEN04516-01 Adjusting valve clearance
5. Referring to step 3-1) and 2), adjust the clear-

ance of the valves marked with Q in the valve
arrangement figure.
a It also can be done by rotating the crank-
shaft forward by 120° at one time and
adjusting the valve clearance of each cyl-
inder in the sequence of the firing order.
a Firing order: 1 – 5 – 3 – 6 – 2 – 4
6. After finishing adjustment, set to the original

condition.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
3 Air intake connector hose clamp bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Air cleaner intake hose clamp bolt:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
3 Air cleaner mounting band bolt:
9.8 – 11.76 Nm {1.0 – 1.2 kgm}
30-101 16 WA470, 480-6

Testing compression pressure SEN04516-01
Testing compression pressure 1 7. Install rocker arm assembly and adjust valve
clearance.
a Necessary tools 3 Rocker arm assembly mounting bolts:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Refer to “Adjusting valve clearance”.
1 795-502-1590 Gauge assembly
C 2 795-471-1420 Adapter
3 6217-71-6112 Gasket
k When measuring the compression pres-

sure, take care not to burn yourself on the
exhaust manifold, muffler, etc. or get
caught in a rotating part.
a Measure the compression pressure after the
engine is warmed up.
(Engine oil temperature: 40 – 60°C)
1. Remove engine hood assembly, referring to

the section “Removal and installation of engine 8. Remove cover (2).
hood assembly” in Disassembly and assembly.
2. Remove 6 cylinder head covers (1).
9. Disconnect connector EC3 (3).
3. Referring to “Adjusting valve clearance”, set

the cylinder to be tested to the compression
top dead center.
4. Remove fuel injector assembly, referring to the

section “Removal and installation of fuel injec-
tor assembly” in Disassembly and assembly.
5. Install gasket C3 to the tip of adapter C2 and

then install adapter C2 to the mounting hole of
the injector.
a Fix the adapter with the holder for injector.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a Leakage can be prevented by applying a
little amount of engine oil to the fitting
faces of the adapter and gauge.
6. Connect compression gauge C1 to adapter

C2.
WA470, 480-6 30-101 17

SEN04516-01 Testing compression pressure
k Be sure to disconnect the connector.

Otherwise, engine may start during the
measurement and this may create a
dangerous condition.
k Since connector (EC3) includes the
power source circuit of engine control-
ler, cover the connector on the harness
side with a vinyl sheet, etc. to prevent
electric leakage and ground fault.
a Adjust mode of the machine monitor “no
injection cranking mode” can be set.
10. Crank the engine with the starting motor and

check the compression pressure.
a Measure the pressure when the pointer of
the gauge is stabilized.
11. Remove the measurement tool after the work,

and make sure that the machine is back to nor-
mal condition.
a Install fuel injector assembly, referring to
the section “Removal and installation of
fuel injector assembly” in Disassembly
and assembly.
30-101 18 WA470, 480-6

Testing blow-by pressure SEN04516-01
Testing blow-by pressure 1 9. While pressing the brake pedal, set the FNR
lever or switch to the F (forward) or R (reverse)
a Necessary tools position.
Symbol Part No. Part Name k Keep pressing the brake pedal securely.
D 799-201-1504 Blow-by checker

10. Press the accelerator pedal gradually to the
k Stop the machine on a level ground and high idle. While running the engine at high idle,
lower the work equipment and touch per- stall the torque converter and measure the
fectly to the ground. blow-by pressure.
k Apply the parking brake and lock the tires a Do not keep stalling the torque converter
with chocks. for more than 20 seconds. Take care that
a Measure the blow-by pressure under the fol- the torque converter oil temperature will
lowing condition. not exceed 120°C.
q Engine coolant temperature: a Normally, the blow-by pressure should be
Within operating range measured while the engine is operated at
q Hydraulic oil temperature: the rated output. In the field, however, an
Within operating range approximate value can be obtained by
q Torque converter oil temperature: stalling the torque converter.
Within operating range a If it is impossible to run the engine at the
rated output or stall the torque converter,
1. Pull out blow-by hose (1) at the right side of the measure while the engine is running at
rear axle on the right side of the chassis. high idle. The value obtained in this case
is about 80% of the blow-by pressure at
2. Stop the engine. Install nozzle [1] and hose [2] the rated output.
of blow-by checker D to blow-by hose (1) and a Precaution for measuring blow-by pressure
connect them to gauge [3]. The blow-by pressure may vary largely
with the engine condition. If the measured
value is judged abnormal, check for
increase of oil consumption, bad exhaust
gas color, deterioration of oil, high deterio-
ration speed of oil, etc. which are related
to the abnormal blow-by pressure.
3. Start the engine and increase the engine cool-

ant temperature to the operating range.
4. Turn the transmission cut-off switch OFF and

press the left brake pedal securely.
5. Turn the torque converter lockup switch (if 11. Remove the measurement tool after the work,
equipped) OFF. and make sure that the machine is back to nor-
mal condition.
6. Set the transmission shift mode selector switch
in the MANUAL position.
7. While keeping the FNR lever or switch at the N

(Neutral) position, set the gear shift lever or
gear shift switch to the 4th position.
8. Release the parking brake.
WA470, 480-6 30-101 19

SEN04516-01 Testing engine oil pressure
Testing engine oil pressure 1 4. Start the engine and heighten the coolant tem-
perature to the operating range.
a Necessary 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
799-101-5160 Nipple (R1/8)
2 799-401-2320 Gauge

with chocks.
a Measure the engine oil pressure under the fol-
lowing condition.
1. Open the engine right side cover. and make sure that the machine is back to nor-
mal condition.
2. Remove oil pressure inspection plug (1).
3. Install nipple E1 (R1/8) and then connect

gauge E2 (1 MPa {10 kg/cm2}).
30-101 20 WA470, 480-6

Testing EGR valve drive pressure SEN04516-01
Testing EGR valve drive pressure 1 4. Install nipple E2 (R1/4) and connect gauge (6
MPa {60 kg/cm2}) [1] of hydraulic tester E1.
a Necessary tools
1
E 790-261-1204 Digital hydraulic tester
2 790-101-5210 Nipple (R1/4)

with chocks.
1. Open the engine right side cover.

5. Start the engine and measure the oil pressure
2. Remove cover (1). at low idle and high idle.
3. Remove oil pressure pickup plug (3) of timing

6. After finishing measurement, remove the work
gear cover (2).
instruments and return the removed parts.
q Replace the removed plug with new one.
When reusing it, remove the sticking gas-
ket sealant from it with a wire brush and
apply new adhesive or gasket sealant to it
before installing.
2 Plug:
Adhesive LT-2 or gasket sealant LG-6
3 Plug: 16.7 – 37.2 Nm {1.7 – 3.8 kgm}
WA470, 480-6 30-101 21

SEN04516-01 Testing intake air (boost) pressure
Testing intake air (boost) pressure1 5. Run the engine at medium or higher speed to
drain the oil from the hose.
a Necessary tools a Insert the connecting parts of the gauge
Symbol Part No. Part Name and hose about a half and open the self-
seal on the hose side repeatedly, and the
F 799-201-2202 Boost gauge kit
oil will be drained.
k
a If Pm kit (A) is available, you may drain
Stop the machine on a level ground and
lower the work equipment and touch per- the oil by using the oil draining coupling
fectly to the ground. (790-261-1130) in that kit.
k Apply the parking brake and lock the tires a If the oil is left in the hose, the gauge does not
with chocks. work. Accordingly, be sure to drain the oil.
k When installing and removing the testing
instruments, take care not to touch a hot 6. Turn the transmission cut-off switch OFF and
part of the engine. press the left brake pedal securely.
a Measure the intake air pressure (boost pres-
sure) under the following condition. 7. Turn the torque converter lockup switch (if
q Engine coolant temperature: equipped) OFF.
q Hydraulic oil temperature: 8. Set the transmission shift mode selector switch
Within operating range in the MANUAL position.
q Torque converter oil temperature:
Within operating range 9. While keeping the FNR lever or switch at the N
(Neutral) position, set the gear shift lever or
1. Open the engine right side cover. gear shift switch to the 4th position.
2. Remove air boost pressure pickup plug (1). 10. Release the parking brake.
11. While pressing the brake pedal, set the FNR

lever or switch to the F (forward) or R (reverse)
position.
k Keep pressing the brake pedal securely.
12. Press the accelerator pedal gradually to the

high idle. While running the engine at high idle,
stall the torque converter and measure the
intake air pressure (boost pressure).
a Do not keep stalling the torque converter
for more than 20 seconds. Take care that
the torque converter oil temperature will
not exceed 120°C.
3. Install nipple (R1/8) [1] in boost gauge kit F
and connect pressure gauge [2].

4. Start the engine and increase the coolant tem- mal condition.
perature to the operating range.
30-101 22 WA470, 480-6

Handling fuel system equipment SEN04516-01
Handling fuel system equipment 1 Releasing residual pressure in

a Precautions for testing and maintaining fuel fuel system 1
system a Pressure is generated in the low-pressure cir-

The common rail fuel injection system (CRI) cuit and high-pressure circuit of the fuel sys-
consists of more precise parts than the con- tem while the engine is running.
ventional fuel injection pump and nozzle. If for- Low-pressure circuit:
eign matter enters this system, it can cause a Feed pump – Fuel filter – Supply pump
trouble. High-pressure circuit:
When testing and maintaining the fuel system, Supply pump – Common rail – Injector
take care more than the past. If dust, etc. sticks a The pressure in both low-pressure circuit and
to any part, wash that part thoroughly with high-pressure circuit lowers to a safety level
clean fuel. automatically 30 seconds after the engine is
a Precautions for replacement of fuel filter car- stopped.
tridge a Before the fuel circuit is tested and its parts are
The fuel filter cartridge used must be a genuine removed, the residual pressure in the fuel cir-
Komatsu part. cuit must be released completely. Accordingly,
The fuel injection pump and nozzle of the com- observe the following.
mon rail type fuel injection system (CRI) are k Before testing the fuel system or removing
consisted of more precision parts than those its parts, wait at least 30 seconds after stop-
used for the current pumps and nozzles. This ping the engine until the residual pressure
system, therefore, employs a special filter with in the fuel circuit is released. (Do not start
highly efficient filtering performance to prevent the work just after stopping the engine
mixing of foreign substances. Thus, substitut- since there is residual pressure.)
ing it with a non-genuine filter could cause
troubles in the fuel system. It is strictly prohib-
ited to use such part.
WA470, 480-6 30-101 23

SEN04516-01 Testing fuel pressure
Testing fuel pressure 1 3. Run the engine at high idle and measure the
fuel pressure.
a Necessary tools a If the fuel pressure is in the following
Symbol Part No. Part name range, it is normal.
Engine speed Fuel pressure
1 790-261-1204 Digital hydraulic tester
G 0.15 – 0.3 MPa
799-101-5160 Nipple (R1/8) High idle
{1.5 – 3 kg/cm2}
2 799-401-2320 Gauge

with chocks.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel fil-
ter to the supply pump.
k Since the pressure in the high-pressure cir-
cuit from the supply pump through the
common rail to the injector is very high, it
cannot be measured.
1. Remove fuel pressure pickup plug (1) from the

fuel filter head. 4. Remove the measurement tool after the work,
mal condition.
2. Install nipple [1] (R1/8) of hydraulic tester G1

and connect it to gauge G2 (1 MPa {10 kg/
cm2}).
30-101 24 WA470, 480-6

Testing fuel return and leak amount SEN04516-01
Testing fuel return and leak amount 1
a Necessary tools 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
a Prepare an oil pan of about 20 l to receive the

fuel flowing out during the test.
with chocks.
WA470, 480-6 30-101 25

SEN04516-01 Testing fuel return and leak amount
2) Insert spacer H1 to return block (2) side a If the leakage from the pressure lim-
and retighten it with the currently removed iter is in the following range, it is nor-
joint bolt. mal.
a Be sure to fit the gaskets to both ends Engine speed Leaking amount
of the spacer. (rpm) (cc/min)
3) Insert joint H2 to common rail (1) side and
Equivalent to rated
retighten it with the currently removed joint Max. 10
operation
bolt.
a Be sure to fit the gaskets to both ends
of the joint.
4) Connect inspection hose H3 to the tip of
joint H2.
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.
5) After finishing testing, stop the engine.
3. Testing return rate from injector

a During testing injector return amount,
keep the end of hose H3 connected to
pressure limiter and insert the other end to
oil pan (receiver).
1) Disconnect fuel return hose (4) of return
block (2).
a Block the fuel hose side with plugs,
2. Testing leakage from pressure limiter etc. and fix it to the frame.
1) Adjust routing to prevent its slacking of Plug: 07376-70315
inspection hose H3 and insert the hose
end to the oil pan (saucer).
2) Referencing “Testing engine speed”, set
up the condition necessary for checking
the engine speed.
3) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
4) After making sure that the engine speed is
stabilized, measure leakage volume per
minute by use of measuring cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
30-101 26 WA470, 480-6

Testing fuel return and leak amount SEN04516-01
2) Connect inspection hose H4 to return

block (2) side.
a Bind the connecting part of the test
hose with a wire, etc. to prevent it
from coming off.
3) Adjust routing to prevent its slacking of
inspection hose H4 and insert the hose
end to the oil pan (container).
7) After finishing testing, stop the engine.
4. Work after finishing testing

After finishing all testing, remove the testing
tools and return the removed parts.
4) Referencing “Testing engine speed”, set

up the condition necessary for checking
the engine speed.
5) Start the engine and operate at the equiv-
alent to rated operation (torque converter
stall load).
6) After making sure that the engine speed is
stabilized, measure return rate per minute
by use of measuring cylinder H5.
a You may test for 20 seconds and
judge by multiplying the result by 3.
a If the supply pump is not supplying
fuel, the engine speed may not rise.
In this case, record the engine speed,
too, during the test.
a If the return rate (spill) from the injec-
tor is in the following range, it is nor-
mal.
Rated output speed Return (Spill) limit
(rpm) (cc/min)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
WA470, 480-6 30-101 27

SEN04516-01 Bleeding air from fuel circuit
Bleeding air from fuel circuit 1

with chocks.
a Bleed the air as follows if the engine has run
out of fuel or the fuel circuit equipment has
been removed and installed.
1. Remove fuel pre-fuel filter (1) and fill it with

fuel.
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.
30-101 28 WA470, 480-6

Bleeding air from fuel circuit SEN04516-01
2. Install pre-fuel filter (1) to the filter head.

a Apply engine oil thinly over the packing on
the pre-fuel filter side.
a After the packing of the pre-fuel filter
touches the sealing face of the filter head,
tighten the fuel filter 3/4 turns.
6. Tighten wing bolt (7) of priming pump securely

to lock lever (8).
3. Remove air bleeding plug (3) of fuel main filter

(2) and operate priming pump (4).
a Operate the priming pump until fuel flows
through plug hole and when fuel is con-
firmed, tighten the plug.
3 Air bleeding plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Remove fuel pressure measuring plug (5) for

the fuel filter and operate priming pump (4).
a Operate the priming pump until fuel flows
7. Crank the engine with the starting motor and
through plug hole and when fuel is con-
start the engine.
firmed, tighten the plug.
a The air in the high-pressure circuit is bled
3 Fuel measuring plug:
automatically if the engine is cranked.
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
a If the engine does not start, there still may
be air in the low-pressure circuit. In this
5. Loosen air bleeder (6) of the fuel supply pump
case, repeat the above procedure from
and operate priming pump (4) 90 – 100 times.
step 3.
a Operate the priming pump until the fuel
flows out of the air bleeder and tighten the
air bleeder. Then, operate the priming
pump several times more until it becomes
heavy.
3 Air bleeder:
4.9 – 6.9 Nm {0.5 – 0.7 kgm}
WA470, 480-6 30-101 29

SEN04516-01 Testing fuel circuit for leakage
Testing fuel circuit for leakage 1 9. Inspect the fuel piping and the devices for fuel
k
leakage.
Stop the machine on a level ground and a Inspect the high-pressure circuit parts
lower the work equipment and touch per- concentration on the areas coated with the
k
color checker, for fuel leakage.
Apply the parking brake and lock the tires a If any fuel leakage is detected, repair it
with chocks.
k
and inspect again from step 1.
Very high pressure is generated in the high- a If any fuel leakage is not detected, inspec-
pressure circuit of the fuel system. If fuel tion is completed.
leaks while the engine is running, it is dan-
gerous since it can catch fire.
After testing the fuel system or removing
and installing its components, check for
fuel leakage according to the following pro-
cedure.
a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at a speed less than 1,000 rpm

and stop it after its rotation is stabilized.
3. Inspect the fuel piping and the devices for fuel

leakage.
a Inspect the high-pressure circuit parts
concentration on the areas coated with the
a If any fuel leakage is detected, repair it
4. Run the engine at low idle.

leakage.
6. Run the engine at high idle.

leakage.
8. Run the engine at high idle to apply load to the

engine.
a At stalling the torque converter.
30-101 30 WA470, 480-6

Handling of reduced cylinder mode operation SEN04516-01
Handling of reduced cylinder Handling of no injection cranking

mode operation 1 operation 1
a Reduced cylinder mode operation means to a No injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The purpose
the number of effective cylinders. The pur- and effect of this operation are as follows.
poses and effects of this operation are as fol- q Before the engine is started after it or the
lows. engine unit has been stored for a long period,
1. This operation is used to find out a cylinder the no injection cranking is performed to lubri-
which does not output power normally (or, cate the engine parts and protect them from
combustion in it is abnormal). seizure.
2. When engine speed and output do not change a To implement no injection cranking operation,
from the normal operation (all cylinder operat- see “Special functions of monitor panel”.
ing mode) even though the fuel injection has
been cut out for any cylinder, the cylinder is
suspected to be defective.
The following problems can be considered:
q Leaking of cylinder head gasket
q Defective injection of injector
q Defective piston, piston ring or cylinder
liner
q Defective valve mechanism (valve sys-
tem)
q Defective electrical system
3. Since the injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, the reduced cylinder mode
operation can be obtained by easier operations
of the switches when compared with the
mechanical fuel injection system. This allows
to narrow down the causes of the incident eas-
ily.
a To implement reduced cylinder mode
operation, see “Special functions of moni-
tor panel”.
WA470, 480-6 30-101 31

SEN04516-01 Handling of controller voltage circuit
Handling of controller voltage

circuit 1
1. Disconnection or connection of the connector

between the engine controller and engine must
be done after turning off the starting switch.
2. It is prohibited to start the engine when T-

adapter is inserted or connected, for trouble-
shooting purpose, to the connector between
the engine controller and engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
30-101 32 WA470, 480-6

Check of muffler and muffler stack for looseness and damage SEN04516-01
Check of muffler and muffler Check of muffler function 1
stack for looseness and damage 1

a Check the muffler for abnormal sound and dif-
1. Check the muffler and muffler stack visually for ference in sound from a new machine. If it
a crack and damage. If any part is damaged, makes abnormal sound, repair it, referring to
replace it. the Troubleshooting Volume.
2. Check the mounting bolts and nuts of the muf-

fler and muffler stack for looseness. If they are
loosened, retighten them.
WA470, 480-6 30-101 33

SEN04516-01 Check of installed condition of cylinder head and manifolds
Check of installed condition of Check of engine piping for

cylinder head and manifolds 1 damage and looseness 1
Check the installed condition of the cylinder head Air intake and exhaust systems:
and air intake manifold and exhaust manifold. If Check the piping for damage, looseness of the
they are loosened, retighten them. mounting bolts and nuts, and suction of air and
a For the tightening torque, see the “Disassem- leakage of exhaust gas through the joints. If it
bly and assembly” volume. is loosened or damaged, retighten or repair.
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 damaged,
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 damaged,
retighten or repair.
30-101 34 WA470, 480-6

Testing and adjusting air conditioner compressor belt tension SEN04516-01
Testing and adjusting air Adjusting

conditioner compressor belt a If the deflection of the belt is abnormal, adjust it
tension 1
according to the following procedure.
1. Loosen air conditioner compressor mounting

Testing bolts (3).
1. Open engine right side cover.
2. Loosen locknut (4) and adjust the air condi-
2. Remove cover (2). tioner compressor belt tension by turning
adjustment bolt (5).
a Check each pulley for breakage, wear of
the V-groove and V-belt, and contact of
the V-belt and V-groove.
a If the V-belt is so lengthened that the
adjustment allowance is eliminated or it
has a cut or a crack, replace it.
3. After adjusting the tension, tighten locknut (4)

and air conditioner compressor mounting bolts
(3).
a If the V-belt is replaced, adjust its tension
again after 1 operating hour.
3. Press the intermediate point between air con-

ditioner compressor pulley and drive pulley
with a finger and measure deflection (a).
a Pressing force: Approx. 98 N {Approx. 10
kg}
a Deflection (a): 25 – 26 mm
WA470, 480-6 30-101 35

SEN04516-01 Testing and adjusting alternator belt tension
Testing and adjusting alternator Adjusting

belt tension 1 a If the deflection is out of the standard range,
adjust it according to the following procedure.
Testing 1. Loosen locknut (3) and bolts (4) and (5).

1. Open engine left side cover.
2. Move alternator (7) with adjustment nut (6) to
2. Remove cover (2). adjust the tension of belt (8).
3. Tighten bolts (5) and (4) and tighten locknut

(1).
3 Bolt (5): 107.8 – 147 Nm {11 – 15 kgm}
3 Bolt (4): 28.4 – 38.2 Nm {2.9 – 3.9 kgm}
a After adjusting, test the belt tension again.
3. Press the intermediate point of the belt

between alternator pulley and crankshaft pul-
ley with a finger and measure deflection (a) of
the belt.
a Pressing force: Approx. 58.8 N {Approx. 6 kg}
a Deflection (a): 13 – 16 mm
30-101 36 WA470, 480-6

Adjusting transmission speed sensor SEN04516-01
Adjusting transmission speed 4. Return sensor (4) by 1/2 – 1 turn.

sensor 1
a Adjust clearance (a) between the sensor
tip and gear (5) tooth tip to approx. 0.75 –
1.5 mm.
1. Remove cover (1) on the right side of the rear
frame. 5. Fix sensor (4) with locknut (3).
3 Nut: 49 – 69 Nm {5.0 – 7.0 kgm}
2. Disconnect connector REV. OUT (2).
3. Loosen locknut (3) and tighten sensor (4) until

its tip touches the tip of gear (5) lightly.
a Before installing the sensor, check that its
tip is free from a steel chip, flaw, etc.
a Apply gasket sealant between the case
and threaded part of the sensor.
2 Threaded part: Gasket sealant (LG-5)
WA470, 480-6 30-101 37

SEN04516-01 Adjusting directional lever length
Adjusting directional lever length 1 Adjusting gear shift lever length 1
Lever (1) can be adjusted to 2 lengths ((A) and (B)). Lever (4) can be adjusted to 3 lengths ((A), (B) and
To adjust it, remove screw (3) from the underside of (C)). To adjust it, remove screw (5) from the under-
its knob (2). Slide knob (2) and tighten screw (3) side of its knob (6). Slide knob (6) and tighten
again. screw (5) again.
a When the machine is shipped, the knob is a When the machine is shipped, the knob is
installed to position (A). installed to position (B).
3 Tightening torque for screw (3): 3 Tightening torque for screw (5):
0.784 ± 0.098 Nm {8 ± 1 kgcm} 0.784 ± 0.098 Nm {8 ± 1 kgcm}
2 Screw: LOCTITE (Threebond 1301B) 2 Screw: LOCTITE (Threebond 1301B)
30-101 38 WA470, 480-6

Testing FNR lever and gear shift lever SEN04516-01
Testing FNR lever and gear shift

lever 1
Necessary tools
Symbol Part No. Part Name
J 79A-264-0021 Push-pull scale

with chocks.
Operating effort of FNR lever (1) and gear shift

lever (2)
1. Stop the engine.
2. Install tool J or a spring balance at the center

of the control lever knob end and pull it in the
operating direction to measure the operating
effort at that time.
a Figure shows the work of FNR lever.
Stroke of FNR lever (1) and gear shift lever (2)

1. Stop the engine.
2. Make mark (a) at the center of the control lever

knob. Move the knob in the operating direction
and measure its stroke.
a Figure shows the work of FNR lever.
WA470, 480-6 30-101 39

SEN04516-01 Testing and adjusting power train oil pressure
Testing and adjusting power train oil pressure 1
30-101 40 WA470, 480-6

Testing and adjusting power train oil pressure SEN04516-01
WA470, 480-6 30-101 41

a Necessary tools a Remove rear frame side covers (21), (22).

790-261-1204 Digital hydraulic tester
Elbow (Male: 10 x 1.25 mm,
790-261-1231
Female: R1/8)
1
790-301-1271 Joint (10 x 1.25 mm)
Elbow (Both of male and
K 790-301-1530
female: R1/8)
799-101-5160 Nipple (R1/8)
2 07000-11008 O-ring
799-101-5220 Nipple (10 x 1.25 mm)
3
07002-11023 O-ring
4 799-401-2320 Gauge
Oil pressure measuring point and measuring

gauge
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}

with chocks.
a Measure the power train oil pressure under the
q Transmission oil temperature:
a Turn the transmission cut-off switch OFF and
use the left brake.
a The torque converter exit pressure is mea-
sured at the oil cooler entrance.
30-101 42 WA470, 480-6

Measurement 3) Connect oil pressure gauge (6 MPa {60

1. Measuring transmission main relief pressure kg/cm2}) [3].
1) Remove transmission main relief pressure 4) Start the engine and keep the FNR lever
pickup plug (1). or switch at the N (Neutral) position.
5) While running the engine at low idle and
2,000 rpm, measure the transmission
main relief 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 elbow (Male: 10 x 1.25 mm,

Female: R1/8) [1] of hydraulic tester K1
and install nipple (R1/8) [2].

WA470, 480-6 30-101 43

2. Measuring torque converter relief pressure 3) Connect oil pressure gauge (6 MPa {60
(inlet pressure) kg/cm2}) [3].
1) Remove torque converter relief pressure 4) Start the engine and keep the FNR lever
(inlet pressure) pickup plug (2). or switch at the N (Neutral) position.
5) While running the engine at 2,000 rpm,
measure torque converter relief pressure
(inlet pressure).
2) Install elbow (Male: 10 x 1.25 mm,

Female: R1/8) [1] of hydraulic tester K1
and install nipple (R1/8) [2].

30-101 44 WA470, 480-6

3. Measuring torque converter outlet pressure 4) Connect oil pressure gauge (1 MPa {10 kg/
1) Remove torque converter outlet pressure cm2}) K4.
pickup plug (3). 5) Start the engine and keep the FNR lever
or switch at the N (Neutral) position.
measure torque converter outlet pressure.
2) Fit O-ring K2 to joint (10 x 1.25 mm) [1] of

hydraulic tester K1 and install them to the
measuring point.
3) Install elbow (Both male and female: R1/8)

[2] and nipple (R1/8) [3] to the above
assembly in order.
WA470, 480-6 30-101 45

4. Measuring lockup clutch pressure (Lockup 3) Turn the torque converter lockup switch
clutch specification) ON.
k This measurement is done in the traveling 4) Set the transmission shift mode selector
condition. Reasonable care, therefore, switch in the AUTO position.
must be paid to safety of surrounding 5) Start the engine and turn the parking
area. brake switch OFF.
1) Remove lockup clutch pressure pickup 6) Set the gear shift lever or gear shift switch
plug (4). to 3rd position.
7) Start traveling while setting the FNR 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.
2) Connect nipple K3 and oil pressure gauge

[1] in hydraulic tester K1.
a Use the oil pressure gauge of 6 MPa
{60 kg/cm2}.

30-101 46 WA470, 480-6

5. Measuring F (forward) clutch pressure 3) Set the transmission shift mode selector
1) Remove F (forward) clutch pressure switch in the MANUAL position.
pickup plug (5). 4) Press the brake pedal.
5) Start the engine and turn the parking
brake switch OFF.
N (Neutral) position, set the gearshift lever
to the 4th position.
FNR lever or switch to F (forward).
securely to prevent machine from
traveling.
k Take care of safety around the
machine extremely.
measure the F (forward) clutch oil pressure.
2) Connect nipple K3 and oil pressure gauge a Make power mode selector switch “P
[1] in hydraulic tester K1. mode”, and work about WA470-6.
a Use the oil pressure gauge of 6 MPa (Because engine speed does not
{60 kg/cm2}. reach 2,000 rpm at "E mode".)

WA470, 480-6 30-101 47

6. Measuring R (reverse) clutch pressure 3) Set the transmission shift mode selector
1) Remove R (reverse) clutch pressure switch in the MANUAL position.
pickup plug (6). 4) Press the brake pedal.
brake switch OFF.
in the 4th position.
FNR lever or switch to R (reverse).
traveling.
machine extremely.
measure the R (reverse) clutch oil pressure.
2) Connect nipple K3 and oil pressure gauge a Make power mode selector switch “P
[1] in hydraulic tester K1. mode”, and work about WA470-6.
a Use the oil pressure gauge of 6 MPa (Because engine speed does not
{60 kg/cm2}. reach 2,000 rpm at "E mode".)

30-101 48 WA470, 480-6

7. Measuring 1st clutch pressure 3) Set the transmission shift mode selector
1) Remove 1st clutch pressure pickup plug switch in the MANUAL position.
(7). 4) Press the brake pedal.
brake switch OFF.
in the 1st position.
7) While pressing the brake pedal with the
engine at low idle, set the FNR lever or
switch to the F (forward) or R (reverse)
position once and then return it to N (Neu-
tral) again.
traveling.
2) Connect nipple K3 and oil pressure gauge machine extremely.

[1] in hydraulic tester K1. a If the FNR lever or switch is in N
a Use the oil pressure gauge of 6 MPa (Neutral), the gear speed is not
{60 kg/cm2}. changed even if the gearshift lever is
moved. To avoid this, perform the
above operation.
measure the 1st clutch oil pressure.

WA470, 480-6 30-101 49

8. Measuring 2nd clutch pressure 3) Set the transmission shift mode selector
1) Remove 2nd clutch pressure pickup plug switch in the MANUAL position.
brake switch OFF.
in the 2nd position.
tral) again.
traveling.

a Use the oil pressure gauge with (Neutral), the gear speed is not
capacity 6 MPa {60 kg/cm2}. changed even if the gearshift lever is
above operation.
measure the 2nd clutch oil pressure.

30-101 50 WA470, 480-6

9. Measuring 3rd clutch pressure 8) While pressing the brake pedal with the
1) Remove 3rd clutch pressure pickup plug engine at low idle, set the FNR lever or
(9). switch to the F (forward) or R (reverse)
tral) again.
traveling.
machine extremely.
a If the FNR lever or switch is in N
(Neutral), the gear speed is not
changed even if the gearshift lever is
above operation.
measure the 3rd clutch oil pressure.
2) Install elbow (Male: 10 x 1.25 mm, a Make power mode selector switch “P
Female: R1/8) [1] of hydraulic tester K1 mode”, and work about WA470-6.
and install nipple (R1/8) [2]. (Because engine speed does not
3) Connect oil pressure gauge (6 MPa {60

kg/cm2}) [3]. 10) Remove the measurement tool after the
4) Set the transmission shift mode selector work, and make sure that the machine is
switch in the MANUAL position. back to normal condition.
5) Press the brake pedal.
brake switch OFF.
in the 3rd position.
WA470, 480-6 30-101 51

10. Measuring 4th clutch pressure 3) Set the transmission shift mode selector
1) Remove 4th clutch pressure pickup plug switch in the MANUAL position.
brake switch OFF.
in the 4th position.
tral) again.
traveling.

a Use the oil pressure gauge of 6 MPa (Neutral), the gear speed is not
{60 kg/cm2}. changed even if the gearshift lever is
above operation.
measure the 4th clutch oil pressure.

30-101 52 WA470, 480-6

11. Measuring lubrication pressure 5) Remove the measurement tool after the
1) Remove lubrication pressure pickup plug work, and make sure that the machine is
(11). back to normal condition.
Adjustment
1. Adjusting transmission main relief valve
k Stop the engine before starting adjust-
ment of the transmission main relief
valve.
a If the transmission main relief pressure is
out of the specified range, adjust it accord-
ing to the following procedure.
1) Remove plug (13) from main relief and
torque converter relief valve (12).
2) Install nipple K3 and connect oil pressure

gauge K4.
a Use the oil pressure gauge of 1.0 MPa
{10 kg/cm2}.
2) Remove inner spring (14) and outer spring

(15).
3) Adjust the pressure by changing the num-
ber of shims (16).
a Standard shim thickness:
3.5 mm (0.5 × 7 piece)
a Quantity of adjustment per shim:
3) Start the engine and keep the FNR lever 0.04 MPa {0.4 kg/cm2}
or switch at the N (Neutral) position.
4) Measure the lubricating oil pressure while
the engine is running at 2,000 rpm.
WA470, 480-6 30-101 53

SEN04516-01 Procedure for flushing torque converter and transmission hydraulic circuit
Procedure for flushing torque

converter and transmission
hydraulic circuit 1
a Metal chips and dirt in the torque converter and

transmission hydraulic circuit shorten the lives
of the torque converter and transmission and
can cause internal breakage. Accordingly,
flush the hydraulic circuit to remove the metal
chips and dirt.
a Flush the hydraulic circuit in the following
cases.
q When metal chips are circulated in the
hydraulic circuit because of damage of the
torque converter, transmission, or another
hydraulic device.
q When the torque converter or transmis-
sion is overhauled or repaired.
1. Install a new filter cartridge.

1) Open inspection cover (1) on the left side
of the rear frame.
3. Flush the hydraulic circuit according to the fol-

lowing procedure.
1) Start the engine and run it at low idle with-
out operating the gearshift lever or direc-
tional lever for about 20 minutes.
a Increase the engine speed to about
1,500 rpm sometimes.
a If the engine coolant temperature
2) Remove the drain plug of the transmission gauge does not rise to the operating
case to drain the oil. range because of low ambient tem-
3) Replace filter cartridge (2) with new one. perature, continue the warm-up oper-
q Part No.: 714-07-28712 ation further.
2) Operate or drive the machine for at least
2. Fill the transmission case with oil. 20 minutes.
a Add oil through oil filler (3) to the specified a Use all the gear speeds (Forward,
level. Run the engine to circulate the oil reverse, and 1st – 4th).
through the system. Then, check the oil 3) Run the engine at low idle for about 20
level again. minutes, similarly to 1).
5 Transmission case: 65 l (Refill capacity)
4. Remove the drain plug of the transmission
case to drain the oil.
30-101 54 WA470, 480-6

Procedure for flushing torque converter and transmission hydraulic circuit SEN04516-01
5. Replace the new filter cartridge.

q Part No.: 714-07-28712
k If the cartridge used for flushing is
used for long hours, it is clogged
quickly. Accordingly, be sure to
replace it with new one.
a After the O-ring of the filter cartridge
touches the filter head, tighten the fil-
ter cartridge 2/5 turns.
6. Add oil to the transmission case and check the

oil level again.
WA470, 480-6 30-101 55

SEN04516-01 Method of moving machine when transmission valve is broken
Method of moving machine when transmission valve is broken 1
a Locations of ECMV assemblies and connector Nos.
a Device for moving machine when transmission transmission control valve. Accordingly,
valve is broken use this method only when the transmis-
sion control valve is broken.
k
When moving the machine by this method,
L 794-423-1190 Plug observe the procedure and take care of
safety.
a Even if you cannot move the machine because k Stop the machine on a level ground and
of breakage of a transmission valve part (elec- lower the work equipment and touch per-
trical system, solenoid valve, spool, etc.), you fectly to the ground.
can move it by installing plugs L. k Apply the parking brake and lock the tires
k Installation of plugs L to the ECMV is a with chocks.
means to move the machine from a danger- k When working, stop the engine.
ous job site to a safe place where you can k When working while the oil temperature is
repair it when you cannot move it at any still high, take care not to burn your body.
gear speed because of breakage of the
30-101 56 WA470, 480-6

Method of moving machine when transmission valve is broken SEN04516-01
1. Remove left side covers (1), (2) from the rear

frame.
4. Referring to the previous page, remove 2

ECMV solenoids (4) from the 2nd ECMV and F
or R ECMV and install plugs L.
q For forward travel: F solenoid and 2nd
solenoid
q For reverse travel: R solenoid and 2nd
solenoid
a If a wrong solenoid is removed, the trans-
mission may be broken. Take care.
a Install each plug L with its projection side
toward the ECMV. Check that the O-ring is
fitted to the mating face.
a Take care that mud or dirt will not enter the
removed solenoids and valves.
2. Remove mud and dirt from around the ECMV.
3. Disconnect all the connectors (3) from each

ECMV (12 pieces, lockup clutch spec: 13
pieces).
WA470, 480-6 30-101 57

SEN04516-01 Method of moving machine when transmission valve is broken
5. Press the brake pedal securely.
6. Start the engine, release the parking brake,

and then release the brake pedal gradually to
start and move the machine.
a If the parking brake cannot be released
because of a trouble in the electrical sys-
tem, see “Method of releasing parking
brake manually”.
k Remove the chocks.
k If the engine is started, the transmis-
sion is engaged and the machine starts
immediately. Accordingly, when start-
ing the engine, check the moving direc-
tion of the machine and secure safety
around the machine thoroughly and
keep pressing the brake pedal.
k After moving the machine, stop the
engine, apply the parking brake, and
put chocks under the tires.
7. Remove the using tool after the work, and

make sure that the machine is back to normal
condition.
30-101 58 WA470, 480-6

Check of axle final drive for oil leakage SEN04516-01
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 Disassemble the axle housing assembly. For Check the cross member of each universal joint by
details, see Disassembly and assembly, “Dis- moving it up, down, to the right and left and in both
assembly and assembly of axle housing rotating directions.
assembly”.
Check the sliding parts of the front drive shaft by
moving them up or in both rotating directions sev-
eral times.
a For the tightening torque, see Structure, func-
tion and maintenance standard, “Drive shaft”.
WA470, 480-6 30-101 59

SEN04516-01 Testing and adjusting steering stop valve
Testing and adjusting steering Adjusting

stop valve 1 a When the clearance between the front and
rear frames is out of the specified range, adjust
Testing it according to the following procedure.
1. Straighten the front frame and rear frame. 1. Loosen locknut (2) and tighten stopper bolt (1)
2. Make sure locknut (2) of stopper bolt (1) is not to minimize distance (a) so that it will not touch
loosened. the end of steering stop valve (3) when the
machine is steered.
3. Start the engine and turn the steering wheel to

the right and left. Measure the clearance 2. Run the engine at low idle and then bring front
between the front frame stopper and rear frame and rear frame into contact each other
frame stopper when above operation is exe- by turning the steering wheel slowly.
cuted. k Use care in this operation so that your
k Stop the engine before measuring the body or arm may not be caught
clearance. between the front and rear frames.
a If the checkup is not available because of 3. Stop the engine and loosen stopper bolt (1)
missing frame stopper and the like, do until it touches the end of steering stop valve
necessary repair and then make sure (3).
clearance is provided on both sides. 4. Run the engine at low idle and return the steer-
ing wheel gradually at least 10°.
30-101 60 WA470, 480-6

Testing and adjusting steering stop valve SEN04516-01
5. Loosen stopper bolt (1) by 8.5 turns (Distance

c: Approx. 15 mm) and fix it with locknut (2).
a Adjust the right and left sides by steps 1 –
5 above.
6. Start the engine, turn the steering wheel, and

check that there is a clearance between front
frame (4) and rear frame (5) when steering
stop valve (3) touches stopper bolt (1) and the
steering wheel is stopped.
WA470, 480-6 30-101 61

SEN04516-01 Testing and adjusting steering wheel
Testing and adjusting steering Measuring operating effort of steering wheel

wheel 1 a Measure the operating effort of the steering
wheel under the following condition.
a Necessary tools q Road: Flat, level, paved, and dry road
Symbol Part No. Part name q Engine coolant temperature:
M 79A-264-0021 Push-pull scale
q Tire inflation pressure: Specified pressure
Measuring play of steering wheel
q Engine: Low idle (No load on bucket)
a Measure the play of the steering wheel under
the following condition.
Measuring method
q Engine: Stopped
q Position of machine: Straight travel condition 1. Install push-pull scale M to the steering wheel
knob.
Measuring method a Install push-pull scale M to the center.
1. Move the steering wheel to the right and left 2 – 3
times and check that the steering mechanism is 2. Start the engine.
in neutral, and then make mark (A) on the a After starting the engine, raise the bucket
machine monitor frame. about 400 mm and release the frame lock
lever.
2. Turn the steering wheel to the right and make
mark (B) at a position where the operating 3. Pull push-pull scale M in the tangential direc-
effort becomes heavy. tion and read it while the steering wheel is
moving smoothly.
a The operating effort is not the value indi-
cated when the steering wheel starts mov-
ing.
3. Turn the steering wheel to the left and make

mark (C) at a position where the operating
effort becomes heavy. Then, measure the
straight distance between marks (B) and (C).
30-101 62 WA470, 480-6

Testing and adjusting steering wheel SEN04516-01
Measuring operating time of steering wheel

a Measure the operating time of the steering
wheel under the following condition.
q Road: Flat, level, paved, and dry road
q Tire inflation pressure: Specified pressure
q Engine speed: Low idle and high idle
Measuring method
1. Start the engine.
a After starting the engine, raise the bucket
about 400 mm and release the frame lock
lever.
2. Turn the steering wheel to the right or left

stroke end.
3. Turn the steering wheel to the right or left

stroke end and measure the full-stroke time.
a Do not turn the steering wheel forcibly but
turn it at the speed of 60 revolutions per
minute.
a While running the engine at low idle and
high idle, measure the time to turn the
steering wheel to the right and left respec-
tively.
WA470, 480-6 30-101 63

SEN04516-01 Testing steering oil pressure
Testing steering oil pressure 1 1. Steering relief pressure

1) Remove steering circuit oil pressure
a Necessary tools pickup plug (2) (10 × 1.25 mm) on the right
Symbol Part No. Part Name steering cylinder head side.
1
799-101-5220 Nipple (10 × 1.25 mm)
N 2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
4 799-401-3200 Adapter (Size 03)
a Measure the steering oil pressure under the

2) Connect nipple N2 and oil pressure gauge
[1] of hydraulic tester N1.
Measuring
k Loosen the oil filler cap of the hydraulic
{400 kg/cm2}.
tank to release the internal pressure of the
hydraulic tank, then operate the steering
wheel 2 – 3 times to release the residual
pressure from the piping.
k Apply frame lock lever (1).
30-101 64 WA470, 480-6

Testing steering oil pressure SEN04516-01
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.
4) Run the engine at low idle, keep the steer-

ing wheel in neutral, and measure the oil
pressure.
4) After finishing measurement, remove the

measuring instruments and return the
removed parts.
2. Steering pilot circuit pressure

1) Disconnect steering control circuit pres-
sure hose (4) of steering valve assembly
(3) through the clearance between the
front side of the operator's cab and front
frame.

removed parts.
WA470, 480-6 30-101 65

SEN04516-01 Testing steering oil pressure
Adjusting 2. Adjusting steering control circuit pressure

k When adjusting the oil pressure, be sure to 1) Remove the operator's cab and floor frame
stop the engine. assembly. For details, see Disassembly
1. Steering relief pressure and assembly, “Removal and installation of
1) If the steering relief pressure is abnormal, operator's cab and floor frame assembly”.
adjust steering relief valve (5) of steering 2) Remove servo assembly (9) from steering
valve assembly (3) according to the fol- pump assembly (8) and install new one.
lowing procedure.
2) Loosen locknut (6) and turn adjustment

screw (7) to adjust the pressure.
a Adjustment screw:
q Turned to the right, the pressure
rises.
q Turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw:
Per turn:
17.8 MPa {181.5 kg/cm2}
3 Locknut:
27 – 31 Nm {2.8 – 3.2 kgm}
30-101 66 WA470, 480-6

Bleeding air from steering circuit SEN04516-01
Bleeding air from steering circuit 1 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 right of the 3) While running the engine at high idle, per-
operator's cab. form the operation of 2).
4) While running the engine at low idle, move

the piston rod to the stroke end and
relieve the circuit.
2) While the engine is stopped, loosen air

bleeder (2) and connect air bleeder hose
[1].
a Put the other end of hose [1] in the
container.
3) As oil free from air started to flow out of air

bleeder (2), tighten air bleeder (2).
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4) Start the engine and run it at low idle for 5
minutes minimum.
WA470, 480-6 30-101 67

SEN04516-01

©2009 KOMATSU
All Rights Reserved
30-101 68
SEN04517-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Testing hydraulic drive fan .............................................................................................................................. 3
Adjustment of hydraulic fan speed sensor ...................................................................................................... 5
Bleeding air from hydraulic drive fan circuit .................................................................................................... 6
Testing brake pedal......................................................................................................................................... 8
Testing and adjusting brake pedal linkage ...................................................................................................... 9
Testing brake performance ........................................................................................................................... 10
Testing and adjusting accumulator charge pressure......................................................................................11
Testing wheel brake oil pressure................................................................................................................... 13
Testing wear of wheel brake disc .................................................................................................................. 15
Bleeding air from wheel brake circuit ............................................................................................................ 16
Releasing residual pressure in brake accumulator circuit............................................................................. 17
Testing parking brake performance............................................................................................................... 17
Testing parking brake oil pressure ................................................................................................................ 18
Testing wear of parking brake disc................................................................................................................ 20
Manual release method for parking brake .................................................................................................... 21
Testing and adjusting work equipment control lever ..................................................................................... 22
Testing and adjusting work equipment PPC oil pressure.............................................................................. 23
Testing and adjusting work equipment oil pressure ...................................................................................... 26
Bleeding air from work equipment circuit ...................................................................................................... 30
Releasing residual pressure in work equipment circuit................................................................................. 31
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS
(Electronically Controlled Suspension System) accumulator ................................................................ 32
Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator............ 38
WA470, 480-6 30-102 1

SEN04517-01
Testing and adjusting bucket positioner ........................................................................................................ 43

Testing and adjusting boom kick-out ............................................................................................................. 45
Checking proximity switch operation pilot lamp ............................................................................................ 46
Procedure for testing diodes ......................................................................................................................... 47
Preparation work for troubleshooting for electrical system ........................................................................... 48
How to start KOMTRAX terminal operations................................................................................................. 53
Indicator lamps of KOMTRAX terminal ......................................................................................................... 58
30-102 2 WA470, 480-6

Testing hydraulic drive fan SEN04517-01
Testing hydraulic drive fan 1 2. Measuring fan drive oil pressure

a Measurement condition
a Necessary tools q Engine speed: High idle
Symbol Part No. Part Name q Engine coolant temperature: Min. 95°C
q Hydraulic oil temperature: Min. 95°C
P q Torque converter oil temperature: Min. 105°C
790-261-1204 Digital hydraulic tester 1) Remove 2 bolts (1) and open radiator
grille (2).

with chocks.
k When removing the oil pressure pickup
plug and disconnecting the hose, loosen
the oil filler cap of the hydraulic tank to
release the internal pressure of the tank.
1. Measuring fan speed

a Measurement condition (Max. fan speed)
q Engine speed: High idle
q Engine coolant temperature: Min. 95°C
2) Remove cover (3).
q Hydraulic oil temperature: Min. 95°C
q Torque converter oil temperature: Min. 105°C
a Measurement condition (Min. fan speed)
q Engine speed: Low idle
q Engine coolant temperature: Max. 75°C
q Hydraulic oil temperature: Max. 75°C
q Torque converter oil temperature: Max. 85°C
q Air conditioner: OFF
1) Referring to “Testing engine speed”, con-
firm it in a standard value engine speed.
2) Display “FAN SPEED” from the monitoring
items of the machine monitor.
a Code No. 10007: FAN SPEED
(Fan speed)
3) Connect oil pressure gauge [1] of hydrau-

lic tester P to pressure pickup nipple (4).
a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
3) Set it in the measuring condition, and

measure the fan speed.
WA470, 480-6 30-102 3

SEN04517-01 Testing hydraulic drive fan
4) While running the engine at high idle,

measure the fan drive oil pressure.

30-102 4 WA470, 480-6

Adjustment of hydraulic fan speed sensor SEN04517-01
Adjustment of hydraulic fan 4. Loosen locknut (6) and tighten sensor (7) until
speed sensor 1
its tip lightly touches the plate (8).
a Check that the sensor tip is free from iron
dust and flaws.
1. Remove 2 bolts (1) and open radiator grille (2). a Apply gasket sealant between the case
and threaded portion of the sensor.
2 Threaded portion:
Gasket sealant (LG-5)
2. Remove cover (3) and guard (4).
5. Return sensor (7) a half to one turn.

a Adjust clearance (a) between the sensor
tip and plate (8) from 2.25 to 3.75 mm
6. Fix sensor (7) with locknut (6).

3 Nut: 49 – 68.7 Nm {5 – 7 kgm}
3. Disconnect connector G12 (5).
WA470, 480-6 30-102 5

SEN04517-01 Bleeding air from hydraulic drive fan circuit
Bleeding air from hydraulic drive 3) As oil free from air started to flow out of air
fan circuit bleeder (2), tighten air bleeder (2).
3 Air bleeder:
1
a Necessary tools 7.8 – 9.8 Nm {0.8 – 1.0 kgm}

Symbol Part No. Part Name 4) Start the engine and run it at low idle for 5
minutes minimum.
1
Q 790-261-1204 Digital hydraulic tester 2. Bleeding air from fan motor circuit
2 790-261-1130 Coupling 1) Remove 2 bolts (1) and open radiator
grille (2).
a Before starting the operation, make sure the

specified level of hydraulic oil is provided.
with chocks.
1. Bleeding air from fan pump

1) Remove cover (1) under the right of the
operator's cab.
2) Remove cover (3).
2) While the engine is stopped, loosen air

bleeder (2) of the fan pump and connect
air bleeder hose [1].
a Put the other end of hose [1] in the
container.
30-102 6 WA470, 480-6

Bleeding air from hydraulic drive fan circuit SEN04517-01
3) Connect hose [1] of hydraulic tester Q1 to

pressure pickup nipple (4) and connect air
bleeder coupling Q2 to the outlet end of
the hose.
a Put the outlet end of the hose in an oil
receiver.
4) Run the engine. When the oil flows out of

the outlet end of the hose, stop the
engine.
5) After finishing bleeding air, remove the
tools and return the removed parts.
WA470, 480-6 30-102 7

SEN04517-01 Testing brake pedal
Testing brake pedal 1
a Measurement condition
Measuring pressing angle of pedal

1. Install push gauge [1] to the foot of the mea-
surer.
a Set the push gauge in a position 150 mm
from the fulcrum of the pedal.
2. While running the engine at low idle, measure

pedal pressing angle (a1).
3. Apply angle gauge [2] to the brake pedal and

measure neutral angle (a1) and maximum
pressing angle (a2).
q (a2): Pressing angle at pressing effort of
323 ± 30 N {32.9 ± 3.0 kg}
30-102 8 WA470, 480-6

Testing and adjusting brake pedal linkage SEN04517-01
Testing and adjusting brake pedal

linkage 1
Testing
1. Check linkage mounting pin (7), pin hole of
lever (6) and lever bushing for play, and adjust
them if necessary.
2. Check that the link length (a = 200 mm) is in

the standard range.
a Measure the distance between the cen-
ters of pin (6) and ball joint (3).
3. Measure the moving distance of rod (8) and

check that clearance (b) is in the standard
range.
a At this time, the brake pedal must be in
contact with the stopper.
4. Check the bolts and nuts of each part for

looseness. If they are loosened, retighten.
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
2. Adjusting rod play (b)

1) Loosen locknut (7) and turn rod (8) to set
its tip to the booster push rod and then
return it 1/4 turns.
a Moving distance in 1/2 turn: 0.75 mm
2) Tighten nut (7).
a Standard play (b): 0 – 0.3 mm
WA470, 480-6 30-102 9

SEN04517-01 Testing brake performance
Testing brake performance 1
a Measure the brake performance under the fol- Measuring method

lowing condition. 1. Start the engine and drive the machine.
q Road: Flat, level, paved, and dry road
q Braking initial speed: 20 km/h 2. Set the gear shift lever or gear shift switch to
q Tire inflation pressure: Specified pressure 4th position for run up.
q Tire size: 26.5-25
q Brake pedal pressing force: Specified press- 3. When the travel speed becomes the braking
ing force initial speed of 20 km/h, press the left brake
323 ± 30 N {32.9 ± 3 kg} pedal with the specified force.
q Pressing time lag: 0.1 second a Decide the approach course and braking
point in advance and apply the brake at
that braking point.
4. Measure the distance from the braking point to

the stop point.
a Perform the above measurement 3 times
and obtain the average.
30-102 10 WA470, 480-6

Testing and adjusting accumulator charge pressure SEN04517-01
Testing and adjusting 2. Connect oil pressure gauge [1] of hydraulic

accumulator charge pressure 1
tester R to accumulator charge pressure
pickup plug (4) of accumulator charge valve
a Necessary tools (3).
Symbol Part No. Part Name a Use the oil pressure gauge of 40 MPa
{400 kg/cm2}.
R
a Measure the accumulator charge pressure

under the following condition.
q Engine coolant temperature: Within oper-
ating range
ing range
with chocks. 3. Measure the accumulator charge cut-in pres-
sure.
Measuring a While running the engine at low idle, when
1. Remove covers (1) and (2) on the right side of the brake oil pressure caution lamp on the
the machine. machine monitor goes off, measure the oil
pressure.
q Cut-in pressure: 5.9 (+0.5/0) MPa
{60 (+5/0) kg/cm2}
4. Measure the accumulator charge cut-out pres-

sure.
a After the accumulator charge cut-in opera-
tion, the rising oil pressure gauge lowers
suddenly. Measure the oil pressure at this
time.
q Cut-out pressure: 9.8 (+0.98/0) MPa
{100 (+10/0) kg/cm2}
5. After finishing measurement, remove the mea-

suring instruments and return the removed
parts.
WA470, 480-6 30-102 11

SEN04517-01 Testing and adjusting accumulator charge pressure
Adjusting
a If the accumulator charge cut-out pressure is
adjusted, the cut-in pressure changes accord-
ing to the valve area ratio.
1. Loosen locknut (6) of unload relief valve (accu-

mulator charge cut-out valve) (5) and turn
adjustment screw (7) to adjust the pressure.
a If the adjustment screw is
q Turned to the right, the pressure rises.
q Turned to the left, the pressure lowers.
a Quantity of adjustment per turn of adjust-
ment screw: 1.45 MPa {14.8 kg/cm2}
3 Locknut: 11.8 – 16.7 Nm {1.2 – 1.7 kgm}
a After finishing measurement, check the

accumulator charge cut-in and cut-out
pressures again according to the above
measurement procedure.
30-102 12 WA470, 480-6

Testing wheel brake oil pressure SEN04517-01
Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a Necessary tools 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

with chocks.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measure the wheel brake oil pressure under
q Engine coolant temperature: Within operating
range
q Hydraulic oil temperature: Within operating range
1. Remove front frame inspection cover (1).

k When raising the lift arm to remove the
inspection cover, place a stand under it
to support securely.
4. Loosen bleeder screw (4) to bleed air.
a Bleed air by operating pump S3.
WA470, 480-6 30-102 13

SEN04517-01 Testing wheel brake oil pressure
5. Tighten bleeder screw (4). Operate pump S3

and raise the pressure to 4.9 MPa {50 kg/cm2},
and then tighten stop valve [1].
6. Leave the brake circuit pressurized for 5 min-

utes and check lowering of the pressure.
a If the hose is moved while the pressure is
m easure d , t h e p re s s u re f l u c t u at e s.
Accordingly, do not move the hose.
a After testing the pressure, operate pump
S3 to lower the pressure in brake test kit
S1, and then remove brake test kit S1.
a After finishing testing, install the brake
tube and bleed air from the brake circuit.
a After finishing testing, remove the measuring
instruments and return the removed parts.
Brake test kit S
30-102 14 WA470, 480-6

Testing wear of wheel brake disc SEN04517-01
Testing wear of wheel brake disc 1
a Necessary tools
Commercially
T Vernier calipers
available

with chocks.
1. Remove cap (1) from the axle housing.
4. After testing, return cap (1).

2. Press the brake pedal to the stroke end. 3 Cap (1): 29.4 – 39.2 Nm {3.0 – 4.0 kgm}
3. Push in shaft (2) and measure its projection (x)

(distance of wear) from end face (a) of guide
(3) with vernier calipers T.
a Keep pressing the brake pedal during
measurement.
a If shaft (2) is projected from guide (3) to
the grooved part, replace the disc.
q Projection (x) from (a): Distance of
wear
q Projection (y) from (a): Repair limit
(2.4 mm)
a If face (b) of the shaft is seen, the disc is
worn to the repair limit.
WA470, 480-6 30-102 15

SEN04517-01 Bleeding air from wheel brake circuit
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.
k Stop the machine on a level ground and 6. Press the brake pedal and then loosen bleeder
lower the work equipment and touch per- screw (3) to bleed air.
fectly to the ground. a Return the brake pedal slowly after tight-
k Apply the parking brake and lock the tires ening bleeder screw (3).
with chocks.
a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
a Bleed air from the front brake circuit and rear
brake circuit similarly (3 places each).
1. Start the engine to accumulate pressure in the

accumulator and then stop the engine.
2. Remove front frame inspection cover (1).

k When lift arm is raised and inspection
cover is removed, the support stand is
put under the lift arm.
7. Repeat this operation until the oil flowing
through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
screws (2) and (3) while the oil is flowing.
8. Bleed air from other brake cylinders, too, using

the same procedure.
a When a complete bleeding is required, it is
advisable to start the operation from the
brake cylinder situated farthest from the
brake pedal.
a As accumulated pressure in the accumu-
lator is decreased, start the engine to
accumulate pressure in the accumulator.
3. Connect either end of hose [1] to bleeder Then bleed air using the same procedure
screw (2) of the slack adjuster and put the as described above.
other end of hose [1] in the oil receiver. a After finishing bleeding air, run the engine
at low idle and check the oil level in the
4. Press the brake pedal and then loosen bleeder hydraulic tank. If the level is low, add oil up
screw (2) to bleed air. to the specified level.
a Return the brake pedal slowly after tight-
ening bleeder screw (2).
30-102 16 WA470, 480-6

Releasing residual pressure in brake accumulator circuit SEN04517-01
Releasing residual pressure in Testing parking brake

brake accumulator circuit 1 performance 1
k Before disconnecting any of the following a Measurement condition

brake accumulator circuits, release resid- q Tire inflation pressure: Specified pressure
ual pressure in that brake circuits. q Road: 1/5 gradient (11° 20'), flat, and dry road
q Machine: Ready for operation
q Piping between accumulator charge valve and
brake accumulator Measuring method
q Between accumulator charge valve and park- 1. Start the engine and set the machine in the
ing brake solenoid valve straight travel position, and then drive up a
q Piping between brake accumulator and brake slope of 1/5 gradient with no load in the bucket.
valve on both sides
2. Press the brake to stop the machine, set the
1. Stop the engine. directional lever in the N position, and stop the
engine.
2. Press the brake pedal at least 100 times to
release the pressure from the brake accumula- 3. Turn the parking brake switch ON (to park),
tor circuit. and then release the brake gradually. At this
time, the machine must not move.
a When the engine is stopped, the parking
brake is turned ON (to park) automatically.
a Measure the parking brake performance
on an uphill and a downhill.
WA470, 480-6 30-102 17

SEN04517-01 Testing parking brake oil pressure
Testing parking brake oil pressure1 2. Remove parking brake pressure pickup plug
(2).
a Necessary tools
U Elbow (Male: 10 × 1.25 mm,
790-261-1231
Female: R1/8)
799-101-5160 Nipple (R1/8)

k Put chocks under the tires.
k Install and remove the measuring instru-
ments after the oil temperature lowers fully.
a Measure the parking brake oil pressure under

q Power train oil temperature:
Parking brake pressure

1. Remove rear frame left side cover (1).
3. Install elbow (Male: 10 x 1.25 mm, Female: R

1/8) [1] of hydraulic tester U and install nipple
(R 1/8) [2].
30-102 18 WA470, 480-6

Testing parking brake oil pressure SEN04517-01
4. Connect oil pressure gauge (6 MPa {60 kg/

cm2}) [3].
5. Run the engine at low idle and measure the

parking brake pressure.
k Keep pressing the brake pedal for
safety.
a Measure the oil pressure at turning OFF of
the parking brake.

mal condition.
WA470, 480-6 30-102 19

SEN04517-01 Testing wear of parking brake disc
Testing wear of parking brake disc 1 4. If depth (a) is above the standard, remove
parking brake disc (4) and measure its thick-
a Necessary tools ness (W), referring to Disassembly and assem-
Symbol Part No. Part Name bly, “Removal and installation of parking brake
disc”.
Commercially
V Slide calipers q Service limit thickness (W): 2.97 mm
available
a If the parking brake disc thickness is
below the service limit, replace the disc.
a If the parking brake does not work effectively,
check the parking brake disc for wear accord-
ing to the following procedure.
k Put chocks under the tires.
k When checking, stop the engine.
1. Drain the oil from the transmission case.

6 Transmission case: 65 l (refill capacity)
2. Remove either one of two bolts (1).

a Prepare a container to receive oil flowing q Refilling with oil (Transmission case)
out of the bolt hole. Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
3. Measure depth (a) from the end of cage (2) to

piston (3) with slide calipers V.
q Standard depth (a): Max. 38.3 mm
30-102 20 WA470, 480-6

Manual release method for parking brake SEN04517-01
Manual release method for 3. Remove 2 bolts (2), and tighten to plug mount-
parking brake 1
ing 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. 3 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 Lower the work equipment to the
ground and lock the tires with chocks
so that the machine will not move dur-
ing the work.
k Always stop the engine before carrying
out this procedure.
1. Drain the oil from the transmission case.

6 Transmission case:
65 l (refill capacity)
2. Remove 2 bolts (1). (left and right)

a Prepare a container to receive oil flowing
out of the bolt hole.
q Refilling with oil (transmission case)

After carrying out the manual release method
for the parking brake, add oil through the oil
filler to the specified level. Run the engine to
circulate the oil through the system, then check
the oil again.
WA470, 480-6 30-102 21

SEN04517-01 Testing and adjusting work equipment control lever
Testing and adjusting work 2. Stroke of work equipment control lever

equipment control lever 1
1) Operate the work equipment control lever
and measure its stroke at each position.
a Necessary tools a Apply a mark to the lever knob and
Symbol Part No. Part name measure the stroke with scale W2.
a If the stroke is out of the standard
1 79A-264-0021 Push-pull scale
range, check for play of the linkage
W Commercially and wear of the bushing.
2 Scale
available
a Measure and test the work equipment control

lever under the following condition.
ing range
with chocks.
k Apply the frame lock bar to the frame.
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.
30-102 22 WA470, 480-6

Testing and adjusting work equipment PPC oil pressure SEN04517-01
Testing and adjusting work 2) Remove oil pressure pickup plug (3) from
equipment PPC oil pressure 1
the underside of PPC accumulator.
a Necessary tools
1
X
799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring

with chocks. 3) Connect nipple X2 and oil pressure gauge
k Loosen the oil filler cap of the hydraulic [1] of hydraulic tester X1.
tank gradually to release the internal pres- a Use the oil pressure gauge of 6 MPa
sure of the hydraulic tank {60 kg/cm2}.
k Operate the work equipment control lever 2
– 3 times to release the pressure from the
PPC accumulator circuit.
a Measure the work equipment PPC oil pressure
ing range
Measuring
1. PPC valve basic pressure
1) Remove covers (1) and (2) on the right side
of the machine.

operate the work equipment control lever
and measure the PPC basic pressure.

removed parts.
WA470, 480-6 30-102 23

SEN04517-01 Testing and adjusting work equipment PPC oil pressure
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.

2) Remove oil pressure pickup plug (10 × operate the work equipment control lever
1.25 mm) (5) of the measured PPC circuit. and measure the PPC valve output pres-
a A: Attachment sure.
B: Attachment
C: Lower and float lift arm
D: Raise lift arm
E: Dump bucket
F: Tilt bucket

removed parts.
30-102 24 WA470, 480-6

Testing and adjusting work equipment PPC oil pressure SEN04517-01
Adjusting
a The PPC relief valve is not adjustable.
1. Remove PPC relief valve cartridge assembly

(7) from accumulator charge valve assembly
(6) and replace it.
3 PPC relief valve cartridge assembly:
25 – 33.9 Nm {2.6 – 3.5 kgm}
2. After replacing the cartridge assembly, mea-

sure the PPC oil pressure again.
WA470, 480-6 30-102 25

SEN04517-01 Testing and adjusting work equipment oil pressure
Testing and adjusting work

equipment oil pressure 1
a Necessary tools
799-101-5002 Analog hydraulic tester
1
Y 799-101-5220 Nipple (10 × 1.25 mm)
2
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge

3) Remove front frame inspection cover (1).
k When raising the lift arm to remove
with chocks. the inspection cover, place a stand
a Measure the work equipment oil pressure under it to support securely.
ing range
Combination of actuator and valve

a Note that different actuators relieve different
valves.
a The No. of each actuator in the following table
shows the order from the top, when the control
valve is seen from the front of the machine.
(The attachment actuator is used when 1
attachment is installed.)
No. Actuator Relieved valve
1 Attachment Safety valve 2. Measuring work equipment relief pressure
2 Lift arm Main relief valve 1) Remove pump pressure pickup plug (10 ×
1.25 mm) (2) from the work equipment
Tilt Safety valve
3 Bucket control valve.
Dump Main relief valve
1. Preparation work
1) Raise part (a) of the bucket about 30 – 50
mm and lower part (b) to the ground.
2) Stop the engine and operate the work
equipment control lever to check that both
parts (a) and (b) of the bucket are in con-
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.
30-102 26 WA470, 480-6

Testing and adjusting work equipment oil pressure SEN04517-01
2) Connect nipple Y2 and oil pressure gauge

[1] of hydraulic tester Y1.
{400 kg/cm2}.
2) Connect nipple Y2 and oil pressure gauge

[1] of hydraulic tester Y1.
{60 kg/cm2}.
3) Start the engine and raise the lift arm to
the level position. Then, while running the
engine at high idle and dumping the
bucket, measure the oil pressure.
3) Start the engine and raise the lift arm

about 400 mm. Then, while running the
engine at high idle, set all the levers in
neutral and measure the oil pressure.
k After measuring the oil pressure,
release the pressure in the circuit
according to the procedure for
installing the nipple and oil pres-
sure gauge, and then remove the
oil pressure gauge and nipple.
3. Measuring unload pressure

1) Remove pump pressure pickup plug (10 ×
1.25 mm) (2) from the work equipment
control valve.

release the pressure in the circuit
according to the procedure for
installing the nipple and oil pres-
sure gauge, and then remove the
oil pressure gauge and nipple.
WA470, 480-6 30-102 27

SEN04517-01 Testing and adjusting work equipment oil pressure
4. Measuring work equipment LS differential

pressure
a Before measuring the LS control circuit
pressure, check that the work equipment
relief pressure and work equipment PPC
oil pressure are normal.
a To obtain the LS differential pressure,
measure the pump discharge pressure
and LS pressure (actuator load pressure)
simultaneously and calculate the differ-
ence between them.
1) Remove pump pressure pickup plug (10 ×

1.25 mm) (2) and LS pressure pickup plug
(10 × 1.25 mm) (3) from the work equip- 3) Start the engine and raise the lift arm
ment control valve. about 400 mm.
when the following condition is satisfied,
measure the pump pressure and LS pres-
sure (actuator load pressure) simulta-
neously.
q When all the levers are in neutral and
when the lift arm lever is moved half-
way
a While measuring, take care not to
move the lift arm cylinder to the
stroke end.
a Calculation of LS differential pressure:
LS differential pressure = Pump dis-
charge pressure – LS pressure
2) Install nipple Y2 and connect oil pressure a If the LS differential pressure is as fol-
gauge [1] of hydraulic tester Y1 or differ- lows, it is normal.
ential pressure gauge Y3.
Position of lever LS differential pressure
a When using the differential pressure
gauge, connect the high pressure Unload pressure
All levers in neutral
side to the pump pressure side and (See standard value)
connect the low pressure side to the Specified LS differential
Lift arm lever in LIFT stroke
LS pressure side. position
pressure
Since the differential pressure gauge (See standard value)
needs a 12V power source, connect it
to a battery.
a When using the oil pressure gauge,
use the oil pressure gauge of 39.2 MPa
{400 kg/cm2}.
Since the differential pressure is about
1.5 MPa {15 kg/cm 2 } at maximum,
measure it by installing the same gauge
to the pickup plugs alternately.
30-102 28 WA470, 480-6

Testing and adjusting work equipment oil pressure SEN04517-01
5) After finishing measurement, remove the a After finishing adjustment, “Measur-

measuring instruments and return the ing work equipment relief pressure” is
removed parts. done again.
release the pressure in the circuit 2. Adjusting LS differential pressure
according to the procedure for 1) Remove the operator's cab and floor
installing the nipple and oil pres- frame assembly. For details, see Disas-
sure gauge, and then remove the sembly and assembly, “Removal and
oil pressure gauge and nipple. installation of operator's cab and floor
frame assembly”.
Adjusting 2) Remove LS valve (9) from work equip-
a The unload valve is not adjustable. ment pump assembly (8) and replace it.
1. Adjusting work equipment relief pressure

1) Adjust main relief valve (5) from work
equipment control valve (4).
2) Loosen locknut (6) and turn adjustment

screw (7) to adjust the pressure.
a If the adjustment screw is
q Turned to the right, the pressure
rises.
q Turned to the left, the pressure
lowers.
a Quantity of adjustment per turn of
adjustment screw:
12.6 MPa {128 kg/cm2}
3 Locknut:
29.4 – 39.2 Nm {3 – 4 kgm}
WA470, 480-6 30-102 29

SEN04517-01 Bleeding air from work equipment circuit
Bleeding air from work equipment 2. Air bleeding from hydraulic cylinder
circuit 1
minutes minimum.
k Stop the machine on a level ground and 2) While running the engine at low idle, repeat
lower the work equipment and touch per- raising and lowering of the lift arm 4 – 5
fectly to the ground. times.
k Apply the parking brake and lock the tires a Do not operate the piston rod beyond
with chocks. a position 100 mm in front of the
stroke end to prevent relieving.
1. Bleeding air from work equipment pump 3) Implement operation of 2) above with the
(piston pump) engine at high idle. Then operate the pis-
1) Remove cover (1) under the right of the ton rod to the stroke end at low idle to
operator's cab. 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.
2) Stop the engine and then loosen air

bleeder (2) to connect air bleeding hose
[1].
a Put the other end of hose [1] in the oil
receiver.
3) When hydraulic oil containing no bubbles

flows out of air bleeder hose [1], tighten
the air bleeder.
3 Air bleeder:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
minutes minimum.
30-102 30 WA470, 480-6

Releasing residual pressure in work equipment circuit SEN04517-01
Releasing residual pressure in 2) Loosen locknut (4) of ECSS pressure

work equipment circuit 1
relief plug (3) on work equipment control
valve (2).
k Stop the machine on a level ground and 3) Loosen adjustment plug (5) 1/2 – 1 turn to
lower the work equipment and touch per- release the accumulator pressure.
with chocks.
1. Releasing residual pressure from the cir-

cuit between respective hydraulic cylinders
and control valve
a When disconnecting the pipes between
respective hydraulic cylinders and work
equipment, release the residual pressure
in the circuit according to the following
procedure.
1) Stop the engine.
2) Loosen the oil filler cap gradually to
release the internal pressure of the
hydraulic tank
3) Set the work equipment lock lever to free
position.
4) Turn the starting switch ON.
5) Release residual pressure operating the
work equipment lever.
2. Releasing residual pressure from ECSS

(travel damper) circuit
k When disconnecting the piping of the
travel damper circuit (between the
accumulator for ECSS and work equip-
ment control valve), release pressure
of the accumulator for the ECSS 4) After releasing residual pressure, tighten
according to the following procedure. plug (5) and locknut (4) securely in this
1) Remove inspection cover (1) on the front order.
frame. a Loosen locknut (4) to the maximum
k When raising the lift arm to remove
before tightening plug (5). After tight-
the inspection cover, place a stand ening plug (5), tighten locknut (4).
3 Plug:
under it to support securely.
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
3 Locknut:
19.6 – 27.5 Nm {2.0 – 2.8 kgm}
WA470, 480-6 30-102 31

Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of ECSS (Electronically
SEN04517-01 Controlled Suspension System) accumulator
Procedure for testing of nitrogen Testing accumulator nitrogen gas pressure

gas pressure and charging of k Loosen the hydraulic tank oil filler cap
nitrogen gas of ECSS gradually to release the pressure inside the

tank.
(Electronically Controlled
Suspension System) accumulator – 3 times to release the pressure inside the
a
k Park the machine on a flat place, lower the
Testing and adjusting ECSS accumulator
nitrogen gas pressure
work equipment to the ground, and set
Sym- Applicable chocks under the tires securely.
Part No. Part name
bol standard
Commercially Gas charge a The accumulator unit can be tested similarly.
1 1. Remove cap (2) from the charge opening of
available tool
accumulator (1).
Commercially Pressure
2
available reducing valve
2. Loosen hexagonal socket head bolt (3) a little
Commercially
3
available
Charging hose (about 1/2 turn) counterclockwise with hexago-
nal wrench of 6 mm (SW6).
Commercially Nipple
GOST
available (For Russia)
Commercially Nipple
ZC CGA No.351
available (For USA)
Commercially Nipple ASA B-571-
available (For USA) 1965
4
DIN 477-1963
NEN 3268-
Commercially Nipple
1966
available (For Germany)
SIS-SMS
2235/2238
Commercially Nipple BS 341
available (For UK) Part1-1962
a The testing and adjusting tools for the HYDAC

made accumulators are commercially avail- 3. Rotate handle (4) of gas charge tool ZC1 coun-
able. Ask a distributor for them. terclockwise until it stops.
Type (Reference)
FPU-1 250 F4.0 G6 A3 K 4. Close pressure relief valve (5).
k Put on proper protective gears (glasses,
leather gloves, protective clothes) and 5. Tighten cap nut (6) onto the charge opening of
work on the windward side as long as pos- accumulator (1) with the hand and adjust pres-
sible so that leaking nitrogen gas will not sure gauge (7) of gas charge tool ZC1 to a
touch your skin and clothes. conspicuous place.
k When handling nitrogen gas in a poorly
ventilated place such as a room, ventilate 6. Slowly rotate handle (4) counterclockwise to
the place forcibly. loosen hexagonal socket head bolt (3) and
k The accumulator is charged with high-pres- open.
sure nitrogen gas. Improper handling of it
can cause a serious accident resulting in 7. When the pointer of pressure gauge (7) moves
injury or death. When handling, observe the to the maximum point, rotate handle (4)
following. counter to close fully.
q Do not bring a fire near the accumulator or a This pressure is the enclosed pressure
put the accumulator in a fire. inside the accumulator.
q Do not drill, weld or gas-cut the accumula-
tor.
q Do not give an impact to the accumulator
by hitting or rolling.
q When scrapping the accumulator, dis-
charge the gas from it.
30-102 32 WA470, 480-6

Controlled Suspension System) accumulator SEN04517-01
a Since the indication fluctuates according to the

temperature at measurement, refer to the fol-
lowing table when testing the gas pressure.
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, 480-6 30-102 33

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.
– 3 times to release the pressure inside the
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).
2. Loosen hexagonal socket head bolt (3) a little

(about 1/2 turn) counterclockwise with hexago-
nal wrench of 6 mm (SW6). q Using nipple ZC4, connect the hose
according to the specifications of the nitro-
gen gas cylinder.
Connect cap nut (8) of charging hose ZC3
to pressure reducing valve ZC2.
2) Connect cap nut (9) of charging hose ZC3
to check valve (5) of gas charge tool ZC1.
3. Rotate handle (4) of gas charge tool ZC1 coun-

terclockwise until it stops.
4. Close pressure relief valve (5).
5. Tighten cap nut (6) onto the charge opening of

accumulator (1) with the hand and adjust pres-
sure gauge (7) of gas charge tool ZC1 to a
conspicuous place.
30-102 34 WA470, 480-6

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. sure reducing 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.
5) Slowly rotate handle (12) counterclock-

wise to loosen the hexagonal socket head
bolt (13) and open.
6) Further open shut-off valve (11) of nitro-

gen gas cylinder (10) to charge the accu-
mulator with nitrogen gas.
7) Repeat this process until charged pres-
sure reaches to the standard value.
8) If the pressure in the accumulator is
higher than the set pressure, open pres-
sure reducing valve (14) of gas charge
tool ZC1 to reduce the pressure.
9) During the work, close shut-off valve (11)
of nitrogen gas cylinder (10) from time to
time and check the nitrogen gas pressure
in the accumulator.
a For the nitrogen gas pressure check pro-
cedure, see "Testing accumulator nitrogen
gas pressure".
WA470, 480-6 30-102 35

a Since the indication fluctuates according to the

temperature at measurement, refer to the fol-
lowing table when testing the gas pressure.
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
30-102 36 WA470, 480-6

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.
9. Install cap (3) and valve guard (2) to accumula-

tor (1).
WA470, 480-6 30-102 37

SEN04517-01 Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator
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
30-102 38 WA470, 480-6

Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator SEN04517-01
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, 480-6 30-102 39

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".
Procedure for charging accumulator with nitro-

gen gas
a The accumulator disconnected from the
machine can be charged with nitrogen gas
according to the following procedure, too. 4) Connect gas charge tool ZD1 to valve (4)
1. Stop the engine and depress the brake pedal of accumulator (1).
repeatedly to lower the oil pressure in the 5) Connect gas charge tool ZD1 and nitrogen
brake circuit to zero. gas cylinder (c).
a Generally, if the brake pedal is depressed q Use nipple ZD2 to connect the hose,
30 times, the reaction force to the brake depending on the specification of the
pedal is lost and the oil pressure is low- nitrogen gas cylinder.
ered to zero.
2. Remove valve guard (2) and cap (3) from
accumulator (1).
3. Connect gas charge tool ZD1 and nitrogen gas

cylinder (c) to valve (4) of accumulator (1)
1) Turn handle (a) of gas charge tool ZD1 to
the left until it stops.
2) Turn handle (b) to the left to open.
4. Open nitrogen gas cylinder (c) slightly to dis-

charge nitrogen gas at pressure of 0.19 – 0.29
MPa {2 – 3 kg/cm2}.
5. After nitrogen gas starts flowing out of handle
(b), close handle (b).
30-102 40 WA470, 480-6

Procedure for testing of nitrogen gas pressure and charging of nitrogen gas of brake accumulator SEN04517-01
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
t = Gas temperature at time of charge (°C)

Reference: t may be assumed to be ambient
temperature.
9. After the accumulator is charged to the stan-

dard pressure, close the valve of nitrogen gas
cylinder (c).
q If the accumulator is charged too much,
turn handle (b) to the left slowly with the
valve of nitrogen gas cylinder (c) closed to
release the nitrogen gas gradually to
adjust pressure.
WA470, 480-6 30-102 41

10. Remove gas charge tool ZD1 from valve (4) of

accumulator (1) according to the following pro-
cedure.
1) Turn handle (a) to the left to close the
valve of the accumulator.
2) Turn handle (b) to the left to open and dis-
charge nitrogen gas remaining in gas
charge tool ZD1 and hoses.
3) Remove gas charge tool ZD1 from valve
(4) of the accumulator.
11. Apply soap water to valve (4) of the accumula-
tor to check that nitrogen gas is not leaking.
12. Install cap (3) and valve guard (2) to accumula-
tor (1).
3 Cap: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
13. In a week after charging the accumulator with

nitrogen gas, check that the nitrogen gas pres-
sure has not lowered.
a Check the functions in 5 minutes after
stopping the engine. (If the engine is
stopped for more than 5 minutes, the
brake circuit pressure lowers and the func-
tions cannot be checked accurately.)
1) Stop the machine on a level place and set
the parking brake switch to the "PARK-
ING" position.
2) Start the engine and run it at medium
speed for 1 minute and then stop it.
3) Turn the starting switch to the ON position
and depress the brake pedal repeatedly.
Count the number of depressing until the
brake oil pressure caution lamp lights up.
q If number of depressing is less than
5: Accumulator gas pressure may
have lowered.
q If number of depressing is 5 or more:
Accumulator gas pressure is normal.
30-102 42 WA470, 480-6

Testing and adjusting bucket positioner SEN04517-01
Testing and adjusting bucket Adjusting

positioner 1 1. Adjusting clearance
1) Adjust and fix switch nut (4) so that clear-
k
ance (b) between the end of switch pro-
Stop the machine on a level ground and tector (3) and switch sensitive surface (1)
lower the work equipment and touch per- will be in the standard range.
fectly to the ground. a Standard clearance (b): 0.5 – 1.0 mm
k
3 Switch nut:
Apply the parking brake and lock the tires
with chocks. 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
a Engine coolant temperature: Within operating
range
a Hydraulic oil temperature: Within operating range
Testing
1. While the engine is stopped, check that clear-
ance (a) between proximity switch (1) and sen-
sor bar (2) is in the standard range.
a Clearance (a): 3 – 5 mm
2) Adjust and fix the shim and proximity

switch bracket mounting bolt so that clear-
ance (a) between the sensitive surface of
proximity switch (1) and sensor bar (2) will
be in the standard range.
a Clearance (a): 3 – 5 mm
a Adjust sensor bar (2) with the shim so
that clearance (a) will be in the stan-
dard range through the stroke of the
2. While running the engine at middle speed sensor bar.
(1,500 rpm), check the operating point. (Check
3 times and obtain the average.)
WA470, 480-6 30-102 43

SEN04517-01 Testing and adjusting bucket positioner
2. Adjusting mounting position

(stopping position)
1) Lower the bucket to the ground and set it
to a desired cutting angle, and then return
the lever to the holding position and stop
the engine.
2) Loose 2 mounting bolts (5) and adjust the
position of switch protector (3) so that the
rear end of sensor bar (2) will be at the
center of the sensitive surface of proximity
switch (1), and then tighten 2 mounting
bolts (5).
3) Check again that clearance (a) between
proximity switch (1) and sensor bar (2) is 3
– 5 mm.
q You may check by turning the starting
switch ON and turning the pilot lamp
ON and OFF. (When the pilot lamp is
turned OFF, the bucket stops.)
a After adjusting, start the engine, oper-

ate the bucket control lever, and
check that the switch operates at the
desired position.
30-102 44 WA470, 480-6

Testing and adjusting boom kick-out SEN04517-01
Testing and adjusting boom Adjusting

kick-out 1 1. Start the engine and raise the lift arm to a
desired position and then stop the engine.
k Be sure to apply the work equipment
k Stop the machine on a level ground and lock lever.
k
2. Loosen 2 bolts (3) and adjust plate (2) so that
Apply the parking brake and lock the tires its top will meet the center of switch (1) and
with chocks. then fix the bolts.
Testing 3. If clearance (b) is out of the specified range,

1. Start the engine and move the lift arm control loosen locknut (3) of switch (1) and adjust
lever to operate proximity switch (1) and then switch (1) so that clearance (b) between the
stop the engine. sensitive surface of switch (1) and plate (2) will
k Be sure to apply the work equipment be in the specified range, and then tighten the
lock lever. locknut.
3 Switch nut:
2. With the engine stopped, check that the center 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
of switch (1) and the top of plate (2) meet at a After adjusting, operate the work equip-
point (a). ment and check that the switch operates
at the desired position.
3. Check that clearance (b) between the sensitive

surface of switch (1) and plate (2) is in the
specified range.
a Standard clearance (b): 3 – 5 mm
WA470, 480-6 30-102 45

SEN04517-01 Checking proximity switch operation pilot lamp
Checking proximity switch

operation pilot lamp 1
Proximity switch operation pilot lamp (Red)

The proximity switch has a pilot lamp to indicate its
operating condition. Use this pilot lamp when
adjusting the proximity switch.
q A: Operation pilot lamp (Red)
Positional relationship between sensitive surface

Proximity switch Operation pilot lamp Remarks
of proximity switch and sensing object
Near ON Operates when center of
Bucket positioner
Far OFF switch is near
Near ON Operates when center of
Boom kick-out
Far OFF switch is far
30-102 46 WA470, 480-6

Procedure for testing diodes SEN04517-01
Procedure for testing diodes 1
a Check an assembled-type diode (8 pins) and

independent diode (2 pins) in the following
manner.
a The conductive directions of the assembled-
type diode are indicated on the surface of the
diode as shown in the following figure.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
a The conductive directions of the single diode is (–) to the cathode (N) of diode.
indicated on the surface of the diode as shown 2] Apply the red (+) lead of the tester to
in the following figure. the cathode (N) side of the diode and
apply the black (–) lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ever, wh en the conn ectio n 2 ] is
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective (Inter-
1. When using digital type circuit tester nal short circuit)
1) Switch the testing mode to diode range q The pointer does not swing with both
and confirm the indicated value. the connections of 1] and 2]: Defec-
a Voltage of the battery inside is dis- tive (Internal breaking of wire)
played with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe (–) to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
WA470, 480-6 30-102 47

SEN04517-01 Preparation work for troubleshooting for electrical system
Preparation work for

troubleshooting for electrical
system 1
a When carrying out troubleshooting for an elec-

trical circuit related to the machine monitor,
transmission controller, work equipment con-
troller, or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
a Disconnect and connect the connectors of spe-
cial lock types according to the following pro-
cedure.
1. Machine monitor 2) Remove interior cover (2) from the front

1) Disconnect the following connectors from left side.
cover (1). a Remove the cap and mounting bolts.
q Connector L01:Parking brake switch 3) Remove cover (1).
q Connector L07:Machine monitor mode
selector switch 1
q Connector L08:Machine monitor mode
selector switch 2
q Connector S01:Front working lamp
switch
q Connector S02:Rear working lamp
switch
q Connector S07:ECSS switch
(If equipped)
a Pull the switch out of the cover and
disconnect each connector.
a If you insert your hands from under
the cover and disconnect a connector
forcibly, you many damage the con-
4) Remove 3 bracket mounting bolts (4) of
nector or switch. Take care.
machine monitor (3) and reverse the
machine monitor.
a Take care not to pull the wiring har-
ness forcibly.
30-102 48 WA470, 480-6

Preparation work for troubleshooting for electrical system SEN04517-01
5) Connect diagnosis T-adapters to connec- 2. Transmission controller

tors L51, L52, L53, L54, L55, L56, and 1) Remove covers (6) and (7) from the rear
L57 of machine monitor (5). of the cab.
2) Connect diagnosis T-adapters to connec-

tors L61, L62, and L63 of transmission
controller (8).
a If the connectors cannot be discon-
nected and connected easily, remove
the transmission controller.
a Since the connectors are secured
with screws, loosen those screws
before disconnecting.
a When connecting the connectors
again, tighten their screws to the
specified torque.
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
WA470, 480-6 30-102 49

3. Work equipment controller (if equipped) 4. KOMTRAX terminal

1) Remove covers (6) and (7) from the rear 1) Remove cover (10)
of the cab.
2) Connect diagnosis T-adapter to connec-

2) Connect diagnosis T-adapters to connector L80 of KOMTRAX terminal (11).
tors L71, L72, and L73 of work equipment a If the connector cannot be discon-
controller (9). nected and connected easily, remove
a If the connectors cannot be discon- the KOMTRAX terminal.
nected and connected easily, remove a Since the connector is secured with
the work equipment controller. screws, loosen those screws before
a Since the connectors are secured disconnecting.
with screws, loosen those screws a When connecting the connector again,
before disconnecting. tighten its screws to the specified
a When connecting the connectors torque.
again, tighten their screws to the 3 Screw:
specified torque. 2.2 – 2.8 Nm {0.23 – 0.29 kgm}
3 Screw:
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
30-102 50 WA470, 480-6

Preparation work for troubleshooting for electrical system SEN04517-01
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

A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See Testing adjust-
ing, “Troubleshooting tools table”.
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, 480-6 30-102 51

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.
9. Engine coolant temperature sensor (COOL-

ANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant tem-
a Precautions for disconnecting connector perature sensor has a special locking
The direction of the lock of the connector mechanism. Disconnect it according to
varies with the tightened position of the steps (a) – (b) and connect it according to
sensor and the lock may be in a direction steps (c) – (d) as shown below.
in which it is difficult to reset (on the under- Disconnection:
side or engine side). (a) Unlock – (b) Disconnect connector.
In this case, pinch the lock in direction (a) Connection:
with bent-nose nippers (commercially (c) Connect connector – (d) Lock.
available), and the lock is reset.
Since the lock clicks when it is reset, dis-
connect the connector after a click is
heard.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See Testing adjusting, “Trouble-
shooting tools table”.
30-102 52 WA470, 480-6

How to start KOMTRAX terminal operations SEN04517-01
How to start KOMTRAX terminal operations 1
Procedure to start KOMTRAX

If installed before Countries 1) Register a machine on the KOMTRAX web screen. For instructions, see
delivery except Japan “Global KOMTRAX Web Reference Manual (For Key Person)”.
2) After the machine is registered, proceed to make activation request by
pressing “Apply” button on the KOMTRAX web screen. For instructions,
see “Global KOMTRAX Web Reference Manual (For Key Person)”.
3) After the machine is activated, press start button on the KOMTRAX web
screen to start communication. For instructions, see “Global KOMTRAX
Web Reference Manual (For Key Person)”.
If installed after Countries 1) Follow the “installation procedure” and installed devices.
delivery except Japan 2) Follow the procedures explained in “Station opening check in machine
side” and perform on-board inspection.
3) Register a machine on the KOMTRAX web screen. For instructions, see
“Global KOMTRAX Web Reference Manual (For Key Person)”. To check
necessary information in advance, see “Application for start of use”.
4) After the machine is registered, proceed to make activation request by
pressing “Apply” button on the KOMTRAX web screen. For instructions,
see “Global KOMTRAX Web Reference Manual (For Key Person)”.
5) After the machine is activated, press “Start” button on the KOMTRAX web
screen to start communication. For instructions, see “Global KOMTRAX
Web Reference Manual (For Key Person)”.
For detailed procedures to start KOMTRAX operation, please contact the division in charge of KOMTRAX.
WA470, 480-6 30-102 53

SEN04517-01 How to start KOMTRAX terminal operations
Station opening check in machine side 3. When about 5 seconds elapsed after the start-
a Complete steps 3. to 5. within 60 seconds. If ing switch was set to ACC, make sure that the
60 seconds or above elapsed, begin with step 7-segment indicator lamp changes to hyphen
1. again. “–” on the KOMTRAX terminal.
1. Turn OFF the starting switch and then, after
making sure 5 seconds have elapsed, proceed
to the next step.
2. Visually check that check connectors 1 and 2

are connected.
q Check connector 1: CHK0
q Check connector 2: CHK1
4. Disconnect inspection connector 1, and wait

for about 5 seconds as it is.
a Ensure that the connector is discon-
nected.
5. Reconnect inspection connector 1, and wait for

about 5 seconds as it is.
a If the KOMTRAX terminal detects that
the connector was disconnected and
connected, the dot on the 7-segment
indicator lamp blinks a few times.
30-102 54 WA470, 480-6

6. Make sure that the 7-segment indicator lamp is a As [Normal] is indicated, proceed to the
indicated normally on the KOMTRAX terminal. next step.
a If so, the 7-segment indicator lamp will a If “–” remains displayed, execute steps 1.
indicate characters “d”, “0”, and “–” repeat- to 5. again.
edly for 30 seconds after step 5. was
ended.
a Those characters, even if displayed nor-
mally, will change to a character other
than hyphen “–”after 30 seconds or above
elapsed.
The display may change to a character
other than “0” even within 30 seconds.
7. Turn the starting switch to START position for

about 5 seconds, and make sure that the
engine does not start.
a If the engine starts, re-execute the proce-
dure above from step 1.
a Do not return the starting switch to OFF
position.
8. Turn the starting switch from ACC position to

START position again, and make sure that the
engine starts.
9. Make sure that the KOMTRAX terminal's indi-

cator lamps are normally turned on.
a Move on to the next step if you can check
that the display is [Normal]. (It takes from
90 seconds to 15 minutes before the dis-
play turns normal.)
a If [GPS position data detection trouble] is
indicated, check if there is any abnormality
on the GPS antenna or cable. If there is
any abnormality, repair it and start from
procedure 1. again.
a If [Reception trouble] is indicated, check if
there is any abnormality on the appear-
ance of the communication antenna or
cable. If there is any abnormality, repair it
then repeat from procedure 1. again.
a If [GPS position data detection trouble and
reception trouble] is indicated, check if
there is any abnormality on the GPS
antenna/cable or communication antenna/
cable. If there is any abnormality, repair it
and start from procedure 1. again.
WA470, 480-6 30-102 55

SEN04517-01 How to start KOMTRAX terminal operations
a If [Network trouble] is indicated, check the 10. Turn the starting switch OFF.
display of [LED-C4] referring to “Lamp dis-
play of KOMTRAX terminal”. If the CAN is 11. Make sure that the 7-segment indicator lamp is
not recognized, check the CAN harness of displayed normally after 5 seconds elapsed.
the KOMTRAX terminal, and then if there a When [Normal] appears, station opening
is any abnormality, repair it and start from check is completed.
procedure 1. again. a If [Abnormal] appears, station opening
[A]: Normal check does not end normally, so you
[B]: GPS position data detection trouble should perform the procedure above from
[C]: Reception trouble step 1. again.
[D]: GPS position data detection trouble a If station opening check ends normally, it
and reception trouble should not be rechecked.
[E]: Network trouble
30-102 56 WA470, 480-6

Application for the start of use

a Application for the start of use should be made
only after the sign-up test is finished.
1. Notify the KOMTRAX operations administrator
of the following information about the machine
that completed the station opening check in
the machine side.
1) Information (model, part number, and
serial number) about the machine that
completed the station opening check in
the machine side
2) Part number and serial number of
KOMTRAX terminal
3) Value of service meter when the
KOMTRAX terminal was installed (in 0.1
hours)
2. 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 For the procedure applied out of Japan,
refer to “Global KOMTRAX Web Refer-
ence Manual (For Key Person)”.
a Now the terminal is ready for use.
WA470, 480-6 30-102 57

SEN04517-01 Indicator lamps of KOMTRAX terminal
Indicator lamps of KOMTRAX terminal 1
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)
30-102 58 WA470, 480-6

Indicator lamps of KOMTRAX terminal SEN04517-01
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.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
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)
5 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
WA470, 480-6 30-102 59

SEN04517-01 Indicator lamps of KOMTRAX terminal
2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.
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)
*2: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
30-102 60 WA470, 480-6

Indicator lamps of KOMTRAX terminal SEN04517-01
WA470, 480-6 30-102 61

SEN04517-01

©2009 KOMATSU
All Rights Reserved
30-102 62
SEN04518-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor.............................. 2
Special functions of machine monitor (EMMS) ............................................................................................... 5
Pm-clinic inspection table ............................................................................................................................. 68
WA470, 480-6 30-103 1

SEN04518-01 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor 1
1. Items to be set when sensor or controller is replaced, reassembled or added

a If any of the following components and parts is replaced or reassembled, initialize the sensors,
solenoids, etc. with the machine monitor.
a Adjust the items in alphabetical order (A –) with the machine monitor.
Correspondence chart of device, parts and adjustment item

Replaced, reassembled, or added component or option Adjustment item
Machine monitor D, E, F, G
Change of tire size E
Transmission A, B, C
Transmission controller A, B, C, D, E
Transmission ECMV solenoid A, B, C
Work equipment controller D, E
Taking automobile inspection E
Addition or removal of option E
Adjustment item chart

Adjustment item Contents of adjustment Description No. (*1)
A Resetting transmission initial learning 7-2
B Transmission initial learning 7-2
C Adjustment of transmission ECMV current 7-1
D Selection of machine model 12
E Selection of option 10
F Inputting of machine serial No. 11
G Setting of service meter and travel distance integrated value — (*2)
*1: Description No. of “Service mode” in “Special functions of machine monitor (EMMS)”
*2: Refer to Service News (No. AT06329) for set points.
30-103 2 WA470, 480-6

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor SEN04518-01
2. Adjustment for user's needs

If the user makes the following indications or requests, change or adjust the items shown below with the
machine monitor.
Correspondence chart of remarks or request and adjustment item

Contents of indication/request Adjustment item
Change indication unit of speedometer G
Turn ECO lamp OFF H
Change interval of fan automatic reverse operation (Automatic reverse fan specification) J
Change continuance of fan automatic reverse operation (Automatic reverse fan specification) K
Travel speed is indicated too quickly/slowly L
Turn engine speed/travel speed on character display OFF M
Adjustment item chart

Adjustment item Contents of change/adjustment Description No. (*1)
G Setting of option/Selection of speed unit 10
H Setting of option/Selection of indication of ECO lamp 10
Adjustment of sensor/Adjustment of interval of fan automatic
J 7–18
reverse operation
Adjustment of sensor/Adjustment of continuance of fan automatic
K 7–19
reverse operation
L Setting of option/Change of tire size 10
Setting of option/Change of indication of engine speed or travel
M 10
speed on normal screen of character display
*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.
WA470, 480-6 30-103 3

SEN04518-01 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
Note: Do not change the position of the rotary switches (SW1, SW2, and SW3) and DIP switches
(SW5 and SW6) on the back side of the machine monitor.
30-103 4 WA470, 480-6

Special functions of machine monitor (EMMS) SEN04518-01
Special functions of machine monitor (EMMS) 1
Normal functions and special functions of machine monitor

The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
Operator mode Service mode
1 Service meter/clock display function (*2) 2 Electrical system fault history display function
2 Load meter function (If equipped) (*1) 3 Mechanical system fault history display function
3 Odometer display function 4 Real-time monitoring function
4 Maintenance monitoring function 5 Engine reduced-cylinder function
5 Telephone number input function 6 No injection cranking function
6 Language selection function 7 Adjustment function
7 Monitor brightness adjustment function ⇔ 8 Maintenance monitoring function
8 Time adjustment function (*2) 9 Operating information display function
Travel speed/engine speed display selecting
9 10 Optional device selecting function
function
Travel speed/engine speed display/non-display
10 11 Machine serial number input function
selecting function (*3)
11 Action code display function 12 Model selection function
12 Failure code display function 13 Initialize function
*1: This display is not available when the load meter function is turned off through OPT selection of service mode.
*2: This display is not available when the travel speed/engine speed display selecting function is turned off through OPT
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, 480-6 30-103 5

SEN04518-01 Special functions of machine monitor (EMMS)
Functions and flow of the service mode
30-103 6 WA470, 480-6

WA470, 480-6 30-103 7

30-103 8 WA470, 480-6

Operator mode 3. Odometer display function

a Following overviews the operator mode. Press [U] switch from the ordinary service
a See the section “Structure, function and main- meter and clock display screen to display the
tenance standard” or the Operation and main- odometer.
tenance manual for details of the operator The load meter specifications displays the
mode. odometer as [<] switch is pressed succeeding
to display of the load meter function.
1. Service meter/clock display function a For details, see the “Other functions of
Turning on the starting switch displays the ser- machine monitor” of the “Operation” sec-
vice meter in the upper space and the clock in tion in the Operation and maintenance
the lower space. manual.
2. Load meter function (if equipped) 4. Maintenance monitoring function

Press [U] switch from the ordinary service 1) Filter, oil replacement time display (auto-
meter and clock display screen to display the matic display)
load meter function. As the filter or oil replacement time draws
a For more information, see the section close, the machine monitor automatically
Structure, function and maintenance stan- displays its information to alert operator's
dard, “Load meter function”, and Attach- attention.
ment options, “Using load meter” of the 2) Resetting replacement time (selection
Operation and maintenance manual. menu)
As maintenance operation for a filter or oil
is completed, the machine monitor allows
resetting the time interval through the
switch operation.
WA470, 480-6 30-103 9

5. Telephone number input function 7. Monitor brightness adjustment function

Telephone numbers are entered through the Brightness of the machine monitor is adjustable
switch operation. And modification or cancella- in seven levels through the switch operation.
tion of the phone numbers in the machine a Adjustment of brightness is available in
monitor is also available through the switch two approaches – adjustment of the moni-
operation. tor alone and separate adjustment of the
a When action code [E03] is displayed, a monitor and liquid crystal.
phone number is displayed along with a For details, see the “Other functions of
[CALL]. machine monitor” of the Operation section
a For details, see the “Other functions of in the Operation and maintenance manual.
machine monitor” of the Operation section
in the Operation and maintenance man-
ual.
6. Language selection function

Switch operation allows selecting a display lan-
guage of the machine monitor.
a Functions of the service mode are con-
stantly displayed in English since they are
exempted from the display selection func-
tion.
a A desired language is selectable from
English, Japanese, German, French, Ital-
ian, Spanish and Swedish.
a For details, see the “Other functions of
machine monitor” of the Operation section 8. Time adjustment function
in the Operation and maintenance man- The time indicated by the clock of the machine
ual. monitor is adjustable.
in the Operation and maintenance manual.
30-103 10 WA470, 480-6

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.
10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
in the Operation and maintenance man-
ual.
WA470, 480-6 30-103 11

a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
• Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
• When an overrun-related item is displayed
Slow down the engine or machine speed.
E02 Not displayed
• When an overheat-related item is displayed
Stop the machine and run the engine at mid speed with no load.
E03 Displayed • Stop the engine and machine immediately and contact a serviceman.
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.
a For details of a displayed failure code, see

“Failure code list”.
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
30-103 12 WA470, 480-6

Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
When using Service mode, carry out the fol- mode).
lowing special operation to switch the screen When the cursor is at a location other
display. than the leftmost position, pressing
1-1. Checking screen display the switch returns the cursor to the
Make sure that the machine monitor is set to leftmost position.
the operator mode and any of “Service meter”, If any switch operation is not done for
“Action code” or “Failure code” is displayed on 60 seconds or more from ID input
the screen. screen, the normal screen is automat-
1-2. Displaying ID input initial screen ically turned on.
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.
1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 – 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit, 1-5. Selecting service mode menu
move to the highest-order digit using [t] a Pressing [<] and [>] switches from the
switch to repeat the procedure from the menu screen displays Service mode
first. In this case, values that had been menus endlessly in the following order.
entered remain as they are until modified. a The menus are displayed in the field indi-
When the cursor is at the highest-order cated with [*] mark.
digit, it can move to the higher layer using [1] ELECTRIC FAULT: Electrical system
[t] switch. (*1). fault history display function
[2] MACHINE FAULT: Mechanical sys-
tem fault history display function
[3] REAL-TIME MONITOR: Real-time
monitoring function
WA470, 480-6 30-103 13

[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 [*].
2-2. Displaying fault history

Press [U] button while the menu is selected to
display the recorded fault history.
1-6. Completion of mode and function

Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the mode screen or
menu screen to be used next.
a Note, however, that [t] switch functions
as an execution key on [YES/NO] screen.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces- 2-3. Displayed fault history
sary). The electric system fault history display func-
2) When ending an operation completely: tion displays the following information.
Turn the starting switch off from the cur- A: Record number
rent state. B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
30-103 14 WA470, 480-6

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.
2) Press [U] switch to display the ALL

CLEAR screen.
3) Select “YES” or “NO” using [<] or [>]
switch.
a The selected cursor will start flashing. If
“YES” is selected and [t] switch is
2-4. Switching fault history display pressed, the information will be deleted. If
Pressing [<] or [>] switch while a set of fault “NO” is selected and [t] switch is
history is on the screen displays another set of pressed, deletion is cancelled and the
recorded fault history. "Maintenance interval change item"
2-5. Deleting individual fault history screen is restored.
1) Press [U] switch while the target fault his- a By default, the cursor is set to NO (cancel)
tory of deletion is on the screen to turn on to prevent resetting error.
CLEAR screen. a Information of the currently occurring fail-
2) Select “YES” or “NO” using [<] or [>] switch. ure is not deletable.
“YES” is selected 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 Information of the currently occurring fail-
ure is not deletable.
WA470, 480-6 30-103 15

3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Elapsed time 1 (Elapsed time on service
history currently recorded. meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a For details of a displayed failure code, see
"Failure code list" of the failure code dis-
play function.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [–] is indicated in the display
space.
3-2. Displaying fault history
Press [U] switch while the menu is selected to
display the recorded fault history.
3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.
30-103 16 WA470, 480-6

4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] TRANSMISSION: Transmission con-
(for each controller) troller system
q 2 items simultaneous display [3] BOOM: Work equipment controller
(code input) system (*1)
4-1. Selecting the menu [4] ENGINE: Engine controller system
Select REAL-TIME MONITORING from the [5] 2 ITEMS: 2 items display
menu screen of Service mode. *1: The menu is indicated in the parts of
[*].
4-2. Displaying sub menu

Press [U] switch while the menu is selected to 4-4. Setting the 1 item individual monitoring
display the sub menu initial screen. 1) Select the target controller system of mon-
itoring from the sub menu screen.
2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.
WA470, 480-6 30-103 17

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.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
4) Display data for 1 item individual monitor- value.
ing a The cursor moves to the 2nd position.
The 1 item individual monitoring screen 3] Set the value in the same order and
displays the following information. then press [U] switch.
A: Item display aWhen you have entered a wrong value
B: Monitoring codes (5 digits) to a position except the highest-order
1: Monitoring data digit (C), the cursor can move to the
(including the unit used) highest-order digit using [t] switch
a See the “Real-time monitoring code and repeat the procedure from the
list” for details. first. In this case, values that had
been entered remain as they are until
modified. When the cursor is at the
highest-order digit, it can move to the
higher layer using [t] switch.
30-103 18 WA470, 480-6

3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing. Pressing [U]
switch again restores the active state.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the “Real-time monitoring code list”
for details.
WA470, 480-6 30-103 19

Real-time monitoring code table

MONITOR PANEL [Machine monitor system]
Monitoring item Indication item Data indication range
No. Monitoring code
(*1) (*2) (*3)
1 20200 Part No. of monitor software VERSION Arabic numerals
2 20221 Version of application software VERSION (APP) Arabic numerals
3 20222 Version of data VERSION (DATA) Arabic numerals
4 01001 Engine speed ENG SPEED 0 – 3000
5 40000 Travel speed SPEED 0 – 50
6 04202 Fuel level FUEL SENSOR 0 – 100
7 04207 Fuel level FUEL SENSOR 0.00 – 5.00
8 04103 Engine coolant temperature COOLANT TEMP –40 – 210
9 40100 Torque converter oil temperature TC OIL TEMP 24 – 131
10 40101 Torque converter oil temperature TC OIL TEMP 0.00 – 5.00
11 04401 Hydraulic oil temperature HYD TEMP 24 – 131
12 04404 Hydraulic oil temperature HYD TEMP 0.00 – 5.00
13 30202 Rear brake oil temperature R BRAKE OIL 24 – 131
14 30205 Rear brake oil temperature R BRAKE OIL 0.00 – 5.00
15 04302 Battery charge level ALTERNATOR R 0.0 – 30.0

16 40200 Small lamp voltage SMALL LAMP 0.0 – 30.0
17 40300 Electrolyte level A BATTERY A 0.0 – 30.0
18 40301 Electrolyte level B BATTERY B 0.0 – 30.0
19 06001 Boom angle BOOM ANG –90 – 90
30-103 20 WA470, 480-6


Unit Remarks
Contents of indication in normal state
(*4) (*5)
Indication of
As per part No. of software
condition
Indication of
As per version No. of application software
condition
Indication of
As per version No. of data
condition
Low idle : 800 (+50/0) rpm
High idle: WA470:2170 ± 50 rpm (P-mode)
1880 ± 50 rpm (E-mode) rpm
WA480:2190 ± 50 rpm (P-mode)
2020 ± 50 rpm (E-mode)
WA470: F1/R1: 7.6/7.9 km/h ±5% (P-mode)
F2/R2: 13.1/13.5 km/h ±5% (P-mode)
F3/R3: 22.9/23.6 km/h ±5% (P-mode)
F4/R4: 36.2/37.3 km/h ±5% (P-mode)
km/h
WA480: F1/R1: 7.7/7.9 km/h ±5% (P-mode)
F2/R2: 13.1/13.5 km/h ±5% (P-mode)
F3/R3: 22.9/23.6 km/h ±5% (P-mode)
F4/R4: 36.3/37.4 km/h ±5% (P-mode)
0 – 100% %
Gauge FULL (100%, 10 z): 0.31 V
When sensor is disconnected or has hot short: Gauge
Gauge 1/2 (50%, 24 z): 0.69 V
V EMPTY
Caution (80 z): 1.74 V
When sensor has ground fault: Gauge FULL
Gauge EMPTY (0%, 85 z): 1.81 V
Engine coolant temperature: Max. 100°C
Depends on condition of machine (°C) °C
Data are received from engine controller
Depends on condition of machine (°C) °C Overheating: 120°C
Gauge enters red range(120°C): 1.62 V When sensor is disconnected or has hot short: Gauge MIN
V
(80°C): 2.91 V When sensor has ground fault: Gauge MAX
Depends on condition of machine (°C) °C Hydraulic tank oil temperature Max. 100°C
Gauge enters red range(120°C): 1.62 V When sensor is disconnected or has hot short: Gauge MIN
V
(80°C): 2.91 V When sensor has ground fault: Gauge MAX
Depends on condition of machine (°C) °C
(120°C): 1.62 V
V
1(80°C): 2.91 V
Depends on condition of machine (0.0 – 30 V) V
Depends on condition of machine (0.0 – 30 V) V
Min. 2 V V Only when option is set
— V Unused
WA470:
Standard boom
Boom at max. height: 45.7 ± 2.0 deg
Boom at min. height: –40.3 ± 3.0 deg
High lift boom
deg (°) Only when load meter option is set
WA480:
Standard boom
WA470, 480-6 30-103 21


Monitoring item Indication item Data indication range
No. Monitoring code
(*1) (*2) (*3)
20 06003 Boom angle BOOM ANG 0.00 – 5.00
21 40400 Boom bottom pressure BOOM BTM PRESS 0.00 – 50.00
22 40402 Boom bottom pressure BOOM BTM PRESS 0.00 – 5.00
23 40500 Boom head pressure BOOM HEAD PRESS 0.00 – 50.00
24 40501 Boom head pressure BOOM HEAD PRESS 0.00 – 5.00
25 40600 Calibration pressure CAL PRESS 0.00 – 50.00

26 40800 Weight calculated by load meter MES LOAD 0.00 – 50.00
27 30802 Setting condition of rotary switch SW1, SW2, SW3 F, F, F
28 30904 Setting condition of DIP switch SW5-1, SW5-2 ON/OFF, ON/OFF
See separate table

32 40900 Input signal D_IN_0-7 D-IN--0------7
(Page 24)
See separate table

(Page 24)
See separate table

(Page 24)
See separate table
(Page 24)
See separate table

(Page 25)
See separate table

37 40952 Output signal D_OUT_0-3 D-OUT--0--3
(Page 25)
*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.
30-103 22 WA470, 480-6


Unit Remarks
(*4) (*5)
WA470:
Standard boom
Boom at max. height: 3.77 ± 0.3 V
Boom at min. height: 1.38 ± 0.5V
High lift boom
Boom at max. height: 3.88 ± 0.3 V V Only when load meter option is set
Boom at min. height: 1.49 ± 0.5 V
WA480:
Standard boom
Boom at max. height: 3.78 ± 0.3 V
Boom at min. height: 1.35 ± 0.5V
Depends on condition MPa Only when load meter option is set
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
Only when optional load meter is set, rated load is applied,

Depends on condition MPa engine speed is high idle, lift arm lever is operated to
stroke end, and arm is level: Approx. 0.5 MPa {5.1 kg/cm2}
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
*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, 480-6 30-103 23

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 — —
30-103 24 WA470, 480-6

MON: Detailed data of input and output signals [Mechanical monitor system]
No. Displayed items Description of ON/OFF switch
codes signal
Load meter subtotal switch
(Load meter specification)
Load meter cancel switch
(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, 480-6 30-103 25

TRANSMISSION [Transmission controller system]

Monitoring Monitoring item Indication item Data indication range
No.
code (*1) (*2) (*3)
1 20201 Part No. of transmission controller ROM VERSION Arabic numerals
2 20223 Version No. of application software VERSION APP 20223
3 20224 Version No. of data VERSION DATA 20224
4 41600 Selection of engine mode ENGINE MODE Arabic numerals
5 41400 Fan pump EPC current (command) FAN EPC DIR 0 – 1000
6 10007 Fan speed FAN SPEED 0 – 2000
7 93400 Fan reverse switch input FAN REVERSE SW Arabic numerals
8 95200 Loader pump oil pressure PUMP PRESS 0.00 – 50.00
9 95201 Input voltage of loader pump oil pressure PUMP PRESS 0.00 – 5.00
10 95100 Output command value of loader pump EPC PUMP EPC DIR 0 – 1000
11 95600 Steering pump EPC current (command) ST EPC DIR 0 – 1000
12 95300 Steering pump oil pressure S/T OIL PRESS 0.00 – 50.00
13 95301 Input voltage of steering pump oil pressure S/T OIL PRESS 0.00 – 5.00
14 31200 Transmission input shaft speed T/M SPEED: IN 0 – 3000
15 31400 Transmission output shaft speed T/M SPEED: OUT 0 – 3000
16 41203 Setting of transmission cut-off operation T/M CUT SET 0 – 50.00
17 41201 Transmission cut-off pressure T/M CUT OFF P 0.00 – 50.00
18 41202 Transmission cut-off sensor input voltage T/M CUT OFF P 0.00 – 5.00
19 93600 Transmission oil temperature T/M OIL TEMP 0 – 150
20 93601 Transmission oil temperature sensor input voltage T/M OIL TEMP 0.00 – 5.00
30-103 26 WA470, 480-6


Unit Remarks
(*4) (*5)
Indication of
As per part No. of software
condition
Indication of
As per version No. of application software
condition
Indication of
As per version No. of data
condition
0: Power mode Indication of

2: Economy mode 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
600 – 1450 [rpm] rpm

0: When fan reverse switch is in FORWARD
Indication of
1: While manual reverse switch is operated
condition
2: When fan reverse switch is in AUTO REVERSE
When work equipment is in neutral: 2.0 ± 2.0 MPa

MPa
When work equipment circuit is relieved: 34.3 ± 2.0 MPa
When work equipment is in neutral: 0.70 ± 0.2 V

V
When work equipment circuit is relieved: 3.26 ± 0.2 V
P-mode: 0 ± 10 mA
mA
E-mode: 350 ± 10 mA
0 – 1000 [mA] mA
When steering is in neutral: 2.0 ± 2.0 MPa
Nm
When steering circuit is relieved: 24.4 ± 2.0 MPa
When steering is in neutral: 0.70 ± 0.2 V

V Not used
When steering circuit is relieved: 2.44 ± 0.2 V
0 – 3000 [min-1] rpm
0 – 3000 [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
Indicated value changes according to cut-off setting

0.00 – 50.00 [MPa] MPa
operation
When foot brake is released: 0.00 ± 0.1 MPa

0.00 – 50.00 [MPa] MPa When foot brake is pressed: Indicated value changes
according to brake pressing operation
When foot brake is released: 1.00 ± 0.1 V

0.00 – 50.00 [V] V When foot brake is pressed: Indicated value changes
according to brake pressing operation
0 – 150 [°C] °C
0.00 – 5.00 [V]

4.72 V = 0°C
4.33 V = 30°C
V
3.55 V = 60°C
2.20 V = 100°C
1.61 V = 120°C
WA470, 480-6 30-103 27


No.
code (*1) (*2) (*3)
21 95400 Throttle correction command output THROTTLE MOD –100 – 100
22 44200 Throttle upper limit value output THROT LIMIT UP 0 – 100.0
23 44201 Throttle lower limit value output THROT LIMIT LO 0 – 100.0
24 93801 Acceleration mode THROTTLE MODE Arabic numerals
25 95000 Lockup selector switch input signal LOCK UP SW Arabic numerals
26 31602 1st ECMV current (command) ECMV 1 DIR 0 – 1000
27 31603 2nd ECMV current (command) ECMV 2 DIR 0 – 1000
28 31604 3rd ECMV current (command) ECMV 3 DIR 0 – 1000
29 31605 4th ECMV current (command) ECMV 4 DIR 0 – 1000
30 31608 F (Forward) ECMV current (command) ECMV F DIR 0 – 1000
31 31609 Lockup clutch ECMV current (command) ECMV LU DIR 0 – 10000
32 31606 R (Reverse) ECMV current (command) ECMV R DIR 0 – 1000
ECSS (Electronically Controlled Suspension System)

33 93300 ECSS V DIR 0 – 1000
solenoid valve current (command)
0 – 2550
34 41802 1st fill time FILL TIME 1
(When not filled: 0)
0 – 2550
35 41803 2nd fill time FILL TIME 2
0 – 2550
36 41804 3rd fill time FILL TIME 3
0 – 2550
37 41805 4th fill time FILL TIME 4
0 – 2550
38 41808 F (Forward) fill time FILL TIME F
0 – 2550
39 41806 R (Reverse) fill time FILL TIME R
See separate table
(Page 32)
See separate table
41 40906 Input signal D_IN_8-15 D-IN--8-----15
(Page 32)
See separate table
42 40907 Input signal D_IN_16-23 D-IN-16-----23
(Page 32)
See separate table
(Page 33)
See separate table
(Page 33)
30-103 28 WA470, 480-6


Unit Remarks
(*4) (*5)
0 [%] % 0% is always indicated
100% is usually indicated
%
When F1 drive is limited: Limit data is indicated
0% is usually indicated
When engine stall prevention device operates,
Changing operation from F2 to R2: Max. 15%
%
Changing operation from R2 to F2: Max. 25%
When 2-stage low idle system operates:
As per idle set value
Changes according to operation of accelerator pedal

When accelerator pedal is released = 0
When accelerator pedal is pressed partially (Release
Indication of
side) = 1
condition
When accelerator pedal is pressed partially (Pressing
side) = 2
When accelerator pedal is pressed fully = 3
0: Lockup selector switch OFF Indication of
1: Lockup selector switch ON condition
Indicated value changes when clutch is used
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
mA
0 – 1000 [mA]
Solenoid valve OFF: 0 [mA]
mA
Solenoid valve ON: 800 [mA]
Each time clutch is used, previous fill time is indicated
msec
0 – 2550 [msec], When not filled: 0
msec
msec
msec
msec
msec
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
Indication of
condition
WA470, 480-6 30-103 29


No.
code (*1) (*2) (*3)
See separate table
45 40949 Output signal D_OUT_0-7 D-OUT-0------7
(Page 33)
See separate table
46 40950 Output signal D_OUT_8-15 D-OUT-8-----15
(Page 34)
See separate table
47 40951 Output signal D_OUT_16-23 D-OUT-16----23
(Page 34)
48 94100 Clutch trigger initial learning flag TRIG FR1234 0/1(ON/OFF)
30-103 30 WA470, 480-6


Unit Remarks
(*4) (*5)
Indication of
condition
Indication of
Unused for this machine
condition
Indication of
Unused for this machine
condition
0: ON Indication of
1: OFF condition
*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, 480-6 30-103 31

TM: Detailed data of input and output signals [Transmission controller system]
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-2 Transmission cut-off switch Pressing switch = ON (GND) /OFF (OPEN)
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-5 Shift mode H Shift mode H = ON (GND) /OFF (OPEN)
D-IN-6 2-stage low idle selector switch (if equipped) Pressing switch = ON (24 V) /OFF (OPEN)
D-IN-7 ECSS selector switch 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)
Right FNR (directional) or joystick steering

D-IN-15 Pressing switch = ON (24 V) /OFF (OPEN)
selector switch (if equipped)
D-IN-16 C terminal signal Start of starting motor = ON (24 V) /OFF (OPEN)
Right FNR (directional) switch or joystick

D-IN-17 steering (directional) switch F (Forward) F (Forward) = ON (24 V) /OFF (OPEN)
(if equipped)
D-IN-18 steering (directional) switch N (Neutral) N (Neutral) = ON (24 V) /OFF (OPEN)
(if equipped)
39-1 40907 D-IN-19 steering (directional) switch R (Reverse) R (Reverse) = ON (24 V) /OFF (OPEN)
(if equipped)
D-IN-20 FNR (Directional) lever F (Forward) F (Forward) = ON (24 V) /OFF (OPEN)
D-IN-21 FNR (Directional) lever N (Neutral) N (Neutral) = ON (24 V) /OFF (OPEN)
D-IN-22 FNR (Directional) lever R (Reverse) R (Reverse) = ON (24 V) /OFF (OPEN)
D-IN-23 Parking brake (Neutralizer) signal Parking brake = ON (24 V) /OFF (OPEN)
30-103 32 WA470, 480-6

codes signal
ECMV fill switch F (Forward)
D-IN-24 ECMV fill switch F (Forward)
ECMV fill switch R (Reverse)
D-IN-25 ECMV fill switch R (Reverse)
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-30 Kick-down switch Pressing switch = ON (GND) /OFF (OPEN)
D-IN-31 Shift hold switch Pressing switch = ON (GND) /OFF (OPEN)
Engine mode selector switch (Power mode)

D-IN-32 Engine mode selector switch
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-0 Electric emergency steering relay Output ON = ON (24 V) /OFF (OPEN)
D-OUT-1 ECSS solenoid Output ON = ON (24 V) /OFF (OPEN)
D-OUT-2 — —
D-OUT-3 Neutral safety relay Output ON = ON (24 V) /OFF (OPEN)

42-1 40949
D-OUT-4 Fan reverse solenoid Output ON = ON (24 V) /OFF (OPEN)
Low-temperature bypass solenoid

D-OUT-5 Output ON = ON (24 V) /OFF (OPEN)
(if equipped)
D-OUT-6 — —
D-OUT-7 — —
WA470, 480-6 30-103 33

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-16 Transmission cut-off indicator Output ON = ON (24 V) /OFF (OPEN)
D-OUT-17 Low-temperature bypass solenoid Output ON = ON (24 V) /OFF (OPEN)
D-OUT-18 Backup lamp relay Output ON = ON (24 V) /OFF (OPEN)
D-OUT-19 — —
44-1 40951
D-OUT-20 — —
D-OUT-21 — —
D-OUT-22 — —
D-OUT-23 — —
30-103 34 WA470, 480-6

WA470, 480-6 30-103 35

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
2 03200 Battery voltage POWER SUPPLY 0.0 – 480.0 V
3 01002 Engine speed ENG SPEED 0 – 4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP –40 – 210 °C
5 04105 Engine coolant temperature sensor voltage COOLANT TEMP 0.00 – 5.00 V
6 37200 Engine oil pressure sensor ENG OIL PRESS –99.9 – 999.9 kPa
7 37201 Engine oil pressure sensor voltage ENG OIL PRESS 0.00 – 5.00 V
8 42700 Engine oil temperature ENG OIL TEMP –40 – 210 °C
9 42702 Engine oil temperature sensor voltage ENG OIL TEMP 0.00 – 5.00 V
10 36400 Common rail pressure RAIL PRESS 0 – 400 MPa
11 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 – 5.00 V
12 37400 Atmospheric pressure AMBIENT PRESS –99.9 – 999.9 kPa
13 37402 Atmospheric pressure sensor voltage AMBIENT PRESS 0.00 – 5.00 V
14 18400 Air intake temperature INTAKE TEMP –50 – 200 °C
15 18401 Air intake temperature sensor voltage INTAKE TEMP 0.00 – 5.00 V
16 04204 Fuel temperature FUEL TEMP –40 – 210 °C
17 14201 Fuel temperature sensor voltage FUEL TEMP 0.00 – 5.00 V
18 18500 Boost temperature CHG TEMP –50 – 200 °C
19 18501 Boost temperature sensor voltage CHG TEMP 0.00 – 5.00 V
20 36500 Boost pressure CHG PRESS-A –99.9 – 999.9 kPa
21 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 – 5.00 V
22 17900 EGR valve differential pressure EGR DIF PRESS –99.9 – 999.9 kPa
EGR valve differential pressure sensor
23 17901 EGR DIF PRESS 0.00 – 5.00 V
voltage
24 18000 EGR valve inlet pressure EGR IN PRESS-A –99.9 – 999.9 kPa
25 18002 EGR valve inlet pressure sensor voltage EGR IN PRESS-A 0.00 – 5.00 V
26 18100 EGR valve position EGR VALVE POS 0.00 – 99.99 mm
27 18101 EGR valve position sensor voltage EGR VALVE POS 0.00 – 5.00 V
28 18700 Engine output torque OUTPUT TORQUE –24000 – 24000 Nm
29 36700 Equivalent torque TORQUE RATIO 0 – 100 %
30 31706 Final accelerator position FINAL THROTTLE 0 – 100 %
31 37300 Momentary fuel consumption FUEL RATE 0.0 – 999.9 1/h
32 18600 Final injection volume command (in weight) INJECT COMMAND 0 – 1000 mg
33 36300 Final injection timing command TFIN INJECT TIMING –180.0 – 180.0 CA
34 31701 Accelerator pedal position THROTTLE POS 0 – 100 %
35 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 – 5.00 V
36 18200 Bypass valve position BPS VALVE POS 0.00 – 99.99 mm
37 18202 Bypass valve position sensor voltage BPS VALVE POS 0.00 – 5.00 V
Status
38 18300 Idle validation signal IVS 1 ON/OFF
display
Status
39 18301 Idle validation signal IVS 2 ON/OFF
display
40 18900 Engine controller internal temperature ECM IN TEMP –40 – 210 °C
Final common rail pressure command
41 36200 PRESS COMMAND 0 – 400 MPa
PFIN
42 17201 PCV valve close timing (BTDC standard) PCV TIMING 180.0 – 180.0 CA
30-103 36 WA470, 480-6

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit Remarks
No.
code (*1) (*2) (*3) (*4) (*5)
Status
43 17500 Selection of engine mode POWER MODE 0–4
display
Status
44 18800 Water-in-fuel sensor WATER IN FUEL ON/OFF Not used
display
Incoming value is
displayed as is Status
45 00400 Name of selected model (upper 8 digits) MACHINE ID (H)
(Upper 8 digits of display
16 characters)
Incoming value is
displayed as is Status
46 00401 Name of selected model (lower 8 digits) MACHINE ID (L)
(Lower 8 digits of display
16 characters)
Incoming value is
Status
47 20216 Build version BUILD VER displayed as is
display
(8 characters)
Incoming value is
Status
48 20217 Calibration data version CAL VER displayed as is
display
(8 characters)
*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, 480-6 30-103 37

5. Engine reduced-cylinder function (CYLIN- 3) Selecting a cylinder to be reduced

DER CUT-OUT) Using [<] or [>] switch, select a cylinder to
The engine reduced-cylinder function denotes be reduced from No. 1 – No. 6 cylinders
setting the injector of a single cylinder or two or and then settle the selected cylinder using
more cylinders to electrically no injection state [U] switch.
and turns on the operation on reduced-cylinder a The cylinder to be reduced is selectable
condition. When any cylinders of the engine while the engine is run.
were suspected for abnormal output (combus- a Any number of cylinders can be reduced –
tion), this approach is used to single out the a single unit or two or more units.
failed cylinder. q [>] switch: Advances the cursor right-
1) Selecting the menu ward
Display the CYLINDER CUT-OUT screen q [<] switch: Advances the cursor left-
from the menu screen of Service mode. ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

Press [U] switch while the menu is
selected to display the sub menu.
a As the reduced-cylinder command is

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
30-103 38 WA470, 480-6

4) Cancelling a reduced cylinder 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the reduced-cylinder switch is hit, a communication error should
command from the engine controller. The be suspected.
black display will disappear.
a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the instruction screen will appear.
function capable of lubricating the engine a In such case, stop the engine once and
through no injection cranking. When a machine then do the set up again.
has been stored for a long time, this function is
used to lubricate the engine prior to its restart
in order to prevent its wear or damages out of
oil.
The no injection cranking must be set up while
the engine is stopped.
1) Selecting menu
Display the NO INJECTION screen from
menu screen of Service mode.
WA470, 480-6 30-103 39

7. Adjustment function (TUNING) 7-1. Adjustment of transmission ECMV current

The machine monitor implements initial setting 7-1-1. Preparations for transmission ECMV current
after disassembly or replacement of the trans- adjustment
mission, or after replacement or addition of 1) Display the REAL-TIME MONITOR from
sensor and EPC valve or controller. Through the menu screen of Service mode.
the initial setting, the machine monitor corrects
and adjusts the installation error or manufac-
turing variations of individual parts.
a Adjustment function
Re
No. Adjustment item
marks
Adjustment of transmission ECMV
7-1
current
7-2 Setting of transmission initial learning
Adjustment of transmission L mode
7-3
gearshift point
Adjustment of lift arm angle sensor
7-4 (*1)
(raise) (for EPC lever)
Adjustment of neutral zone dispersion 2) Press [U] switch to display the sub menu
7-5 (*1)
of lift arm raise lever and EPC and then select TRANSMISSION using [<]
Adjustment of neutral zone dispersion or [>] switch. (TRANSMISSION screen)
7-6 (*1)
of lift arm lower (float) lever and EPC
Adjustment of neutral zone dispersion
7-7 (*1)
of bucket tilt lever and EPC
7-8 (*1)
of bucket dump lever and EPC
7-9 of 3rd (3-spool valve) EPC cylinder (*1)
extension lever and EPC
7-10 of 3rd (3-spool valve) EPC cylinder (*1)
retraction lever and EPC
Adjustment of starting point disper-
7-11 sion of joystick steering right lever (*1)
and EPC
Adjustment of starting point disper-
3) Press [U] switch to settle the real-time
7-12 sion of joystick steering left lever and (*1) monitoring of the transmission controller.
EPC a As the selection is settled, the application
program version of the transmission con-
7-13 Change of lift arm lever pattern (*1)
troller will be displayed.
7-14 Change of bucket lever pattern (*1) q [20223] : ID number of display item
Adjustment of lift arm lower stop mod- q [******]: Display of data
7-15 (*1)
ulation (Program version)
Adjustment of pump cut-off pressure
7-16 (*1)
during raise of lift arm
7-17
(upper) (Load meter specification)
7-18
(lower) (Load meter specification)
Adjustment of 2-stage low idle throttle
7-19 (*1)
position
Adjustment of interval of fan auto-
7-20
matic reverse operation
Adjustment of continuance of fan
7-21
automatic reverse operation
(*1): This item is not used.
30-103 40 WA470, 480-6

4) Using [<] or [>] switch, move the cursor to

Operat-
the T/M OIL TEMP screen.
ing 1 2 3 4
q [93600]: ID number of transmission order
control oil temperature
Gear
q [******]: Display of transmission con- N2 F2 F1 F2
speed
trol oil temperature
Holding Min. 2 Min. 2 Min. 2 Min. 2
time sec. sec. sec. sec.
Operat-
ing 5 6 7 8
order
Gear
F3 F4 F3 F2
speed
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.
switch in the MANUAL, set the FNR lever
a When performing the following opera-
or switch to the F (forward), and set the
tion, set the transmission shift mode
gearshift lever or gearshift switch in the
selector switch in the MANUAL and
4th position. (F4)
turn the torque converter lockup
3) Make sure from “7-1-1 Preparations for
switch OFF.
transmission ECMV current adjustment”
a Make sure the machine is normal
that the transmission controlled oil tem-
(failure is not detected).
perature is 55 – 70°C.If it is out of the
a When stalling the torque converter,
range, stall the torque converter and
use care it may not be overheated.
adjust the temperature to 55 – 70°C.
4) Return the FNR lever or switch to the N
7-1-3. Adjustment of transmission ECMV current
(Neutral) and check that the oil leak tester
a Targets of correction are 6 types – F (forward),
is 55 – 70°C after 3 minutes.
R (reverse), 1st, 2nd, 3rd and 4th. As the
5) Operate the FNR lever or switch and gear-
adjustment of current is started, correction of
shift lever or gearshift switch as shown
all of above clutches is started automatically.
below to circulate the oil through the trans-
a Since the learning operation requires the spec-
mission.
ified oil temperature, the oil temperature must
a When performing the following opera-
be adjusted to 55 – 70°C range.
tion, run the engine at low idle, turn
1) Turn on the starting switch (engine is not
manual switch ON, turn the torque
started) and then display T/M OIL TEMP
converter lockup switch OFF, and turn
referencing “7-1-1 Preparations for trans-
lockup switch OFF.
mission ECMV current adjustment”.
a Make sure the machine is normal
2) Run the engine at low idle, set the FNR
(failure is not detected).
lever or switch in N (Neutral), parking
a When stalling the torque converter,
brake ON, and check that the transmis-
use care it may not be overheated.
sion control oil temperature is 55 – 70°C.
WA470, 480-6 30-103 41

3) Display the TUNING screen from the 7) Using [U] switch, select AUTO from the
menu screen of Service mode. automatic correction (AUTO) and manual
correction (MANUAL) selection screen to
settle the automatic correction.
4) Hold down [U] switch for 5 seconds mini-

mum to display 01: TM TRIGGER screen.
a Selecting ECMV TUNING AUTO displays
IP in the character display, automatically
starting transmission ECMV current
adjustment.
5) Using [<] or [>] switch from the sub menu,

select 02: ECMV TUNING.
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]
ECMV/
R/1st R/2nd R/3rd R/4th
6) Press [U] switch to settle the adjustment fre-
time time time time
quency
item.
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
30-103 42 WA470, 480-6

Operat- a Codes for abnormal end

13 14 15 16
ing order Reason CODE
IP [IP 2-1] [IP 2-2] [IP 2-3] [IP 2-4] Deviation from correc-
1
ECMV/ tion condition
2nd/1st 2nd/2nd 2nd/3rd 2nd/4th
fre- Absence of fill 2
time time time time
quency
In excess of correc-
3
Operat- tion value
17 18 19 20
ing order
a If abnormal end code “1” (NG1: Deviation
IP [IP 3-1] [IP 3-2] [IP 3-3] [IP 3-4] from correction condition) was displayed,
ECMV/
3rd/1st 3rd/2nd 3rd/3rd 3rd/4th
set the condition again referencing “7-1-1
fre- Preparations for transmission ECMV cur-
time time time time
quency rent adjustment” and repeat the correction.
a If abnormal end code “2” (NG2: Absence
Operat-
21 22 23 24 of fill) was displayed, implement trouble-
ing order
shooting of the failure codes 15STLH and
IP [IP 4-1] [IP 4-2] [IP 4-3] [IP 4-4] DXHTKA. If the state is normal, repeat the
ECMV/ operation starting from “7-1-1 Prepara-
4th/1st 4th/2nd 4th/3rd 4th/4th
fre-
time time time time
tions for transmission ECMV current
quency adjustment” and repeat the correction.
(The value of T depends on the applica-
8) As the correction is normally completed, ble gear speed.)
OK is displayed in the character display. a If the abnormal end code “3” (NG3: In
excess of correction value) was displayed,
execute the troubleshooting of failure
code 15STL1. Then after making sure the
condition is normal, implement “7-1-1
Preparations for transmission ECMV cur-
rent adjustment” again. (The value of T
depends on the applicable gear speed.)
9) As the operation ended normally, turn the
starting switch off and the corrected value
will be stored on the transmission control-
ler after 3 seconds.
a When it is required to turn on the starting
switch immediately after the adjustment,
maintain the starting switch, just in case,
a If the correction is not normally ended, the at off position for 10 seconds minimum
code for abnormal end will be indicated. and then turn it on.
(Following shows an example of the oper-
ation in which the 1st time correction of
the 3rd position has ended abnormally).
WA470, 480-6 30-103 43

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 lever or switch in N (Neutral).
3) Display the TUNING screen from the
a When the initial learning is completed,

TUNED will be displayed.

1] When TUNED is displayed, press [U]

switch to display the initial learning
reset screen.
2] Press [<] or [>] switch from the initial
learning reset screen to move the cur-
sor to YES position and then press
[t] switch to reset the initial learning.
3] When suspending the reset opera-
tion, select NO from above 2] or press
[t] switch on TUNED screen.
30-103 44 WA470, 480-6

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
2) Press [U] switch to display the sub menu,

select 2 ITEMS using [<] or [>] switch and
then settle the selection using [U] switch.
(SEL ITEMS 1,2 screen)
7-2-3. Implementation of transmission initial learn-

ing
a Before starting the transmission initial learning,
be sure to implement “7-1 Adjustment of trans-
mission ECMV current” and “7-2-1 Reset of ini-
tial learning”. Then start the initial learning
a Implement the gearshift operation using actual
travel, bench travel or while pressing the wheel
brake.
k When actual travel is employed for the
operation, be sure to choose a spacious
field while paying reasonable care to the
3) From the SEL ITEMS 1,2 screen, enter ID environment.
number 93600 of the transmission control a When executing the operation, the engine shall
oil temperature and ID number 94100 for be set to low idle, manual switch to ON and
displaying the trigger learning. lockup switch to OFF.
a Referring to “4-5. Setting 2 items 1) Start the engine, press the brake pedal
simultaneous monitoring”. fully and then release the parking brake.
switch in the MANUAL, set the FNR lever
or switch in F (forward), and set the gear-
shift lever or gearshift switch in the 4th
position.
3) Make sure from “7-2-2 Preparations for
transmission initial learning” that the trans-
mission control oil temperature is 55 –
70°C. If it is out of the range, stall the
torque converter and adjust the tempera-
ture to 55 – 70°C. (If the initial learning is
performed while the oil temperature is out
of the specified range, time lags and gear-
shift shocks can result).
WA470, 480-6 30-103 45

4) Operate the FNR lever or switch and gear- 7-3. Adjustment of transmission L mode shift
shift lever or gearshift switch as shown point function
below to perform the initial learning. a This function is used for modifying the shift
point when the shift mode switch is at L posi-
Operating tion by adding a correction amount.
order
1 2 3 4 a The factory default setting of the correction
amount shall be 0.
Gear
speed
N2 F2 F1 F2 a The shift point depends on the engine mode.
When this function is used, however, the same
correction value is applied independent of the
engine mode.
Operating a Some of the shift points being adjusted with
5 6 7 8 the shift point adjustment function may not
order
Gear include the following shift patterns.
F3 F4 F3 F2 q The shift point that is used when the hunt-
speed
ing prevention function is turned on.
q The shift down point that is used when the
accelerator is set to idle.
Operating a After a shift point adjustment is done, confirma-
9 10 11
order tion on the machine must be done.
Gear
N2 R2 N2 7-3-1. Changing the set data
speed
Change the set data according to the following
Holding Min. 4 Min. 4 Min. 4
time sec. sec. sec. procedure.
1) Display the “Sensor tuning function
a Hold the gear shift lever in each gear screen” on the service mode menu
speed for more than the specified time. screen.
a If the gear shift lever is operated before 2) Press the [U] switch to select “TUNING”.
the specified time is reached, the initial
learning is not completed (TUNED is not
displayed).
7-2-4. Conformation of completion of transmission

initial learning
1) Referencing “7-2-2 Preparations for trans-
mission initial learning”, make sure 111111
is marked on ID number 94100, indicating
that the initial learning is completed.
2) Press [t] switch to end confirmation of the
initial learning.

30-103 46 WA470, 480-6

7-3-2. Clearing an adjusted shift point 7-3-3. Adjustment of shift point

1) Using [<] or [>] switch, select 04: SHIFT Adjustment of transmission ECMV current
rpm screen from the sub menu. a The shift point in the “L mode” of the auto shift
mode can be changed by this operation.
The following shift patterns can be changed.
No. Gear shift pattern to be changed

0 ALL CLEAR
1 F2T/C → F3T/C
3 F3 T/C → F4 T/C
6 F4T/C → F3T/C
7 F3 T/C → F2 T/C
8 F3L/U ON
9 F3L/U OFF
10 F4L/U ON
2) Press [U] switch to settle the selection.
11 F4L/U OFF
a As the selection is settled, 0: ALL
CLEAR will be displayed in the lower
space. a Change the speed to change F2T/C to F3T/C
3) Press [U] switch to settle ALL CLEAR. according to the following procedure. The
a As all the stored values are cleared, other shift patterns can be also adjusted simi-
the screen returns to the shift point larly.
adjustment item. 1) On the sub-menu of “Shift point adjust-
a If [t] switch is pressed, the stored ment”, select “1: F2TC > F3TC” (F2T/C →
value is not cleared and the screen F3T/C) with the [<] or [>] switch.
returns to the adjustment items.
WA470, 480-6 30-103 47

2) Press the [U] switch to settle the adjust-

ment item.
3) If the adjustment item is settled, shift point
adjustment screen “1: F2TC > F3TC” (1:
F2T/C → F3T/C) is displayed.
4) Press the [U] switch to settle “1: F2TC >
F3TC” (1: F2T/C → F3T/C).
5) If the adjustment item is settled, the “Input

shift point adjustment value” screen is dis-
played.
6) On the “Input adjustment value” screen,
the adjustment value currently input is
indicated.
7) Change the adjustment quantity to a
desired value with the [<] or [>] switch. 8) After the adjustment quantity is set to a
a The unit of shift point adjustment is 50 desired value, press the [t] switch to
rpm of the transmission output shaft complete the setting.
speed.
q The transmission output shaft speed
of 50 rpm is equivalent to the travel
speed of about 0.65 km/h. If the
transmission output shaft speed is
increased by 50 rpm, the shift point is
increased by about 0.65 km/h. If the
former is decreased by 50 rpm, the
latter is decreased by about 0.65 km/
h.
30-103 48 WA470, 480-6

7-4. Adjustment of lift arm angle sensor (Raise)

(for EPC lever) function
a This item is not used.
7-5. Adjustment of lift arm raise lever and varia-

tions in the dead zone of EPC
7-6. Adjustment of lift arm lower (float) lever

and variations in the dead zone of EPC
7-7. Adjustment of bucket tilt lever and varia-

tions in the dead zone of EPC
7-8. Adjustment of bucket dump EPC starting

current
7-9. Adjustment of 3-spool valve EPC cylinder

extraction lever and variations in the dead
zone of EPC
7-10. Adjustment of 3-spool valve EPC cylinder

retraction lever and variations in the dead
zone of EPC
7-11. Adjustment of joystick steering right lever

and variations at EPC starting point
7-12. Adjustment of joystick steering left lever

and variations at EPC starting point
7-13. Modification of lift arm lever pattern

7-14. Modification of bucket lever pattern

7-15. Adjustment of lift arm lower stop modula-

tion
7-16. Adjustment of pump cut-off pressure in lift

arm raise
WA470, 480-6 30-103 49

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.
5) Press [U] switch after raising the lift arm to

2) Hold down [U] switch for 5 seconds mini- the upper limit position (cylinder stroke end).
mum to display 01: TM TRIGGER screen. 6) 2 times of buzzer beep notify completion
of the setting.
a 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
the specified value. In this case, adjust-
ment does not start.
7) Press [u] switch to end the adjustment
mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
underway will be stopped even if it is not
completed.
8) When the adjustment did not end suc-
cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
position so that the voltage displayed on
item of 18: RAISE ANGLE.
the real time monitoring may fall within the
following range and then implement the
sensor adjustment again.
Lift arm position Voltage range
Upper limit position
0.5 – 4.5 V
(Stroke end of raised cylinder)
30-103 50 WA470, 480-6

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.
5) Press [U] switch after lowering the lift arm

2) Hold down [U] switch for 5 seconds mini- to the lower limit position (cylinder stroke
mum to display 01: TM TRIGGER screen. end).
6) 2 times of buzzer beep notify completion
of the setting.
a 1 second-long beep indicates that the set
lift arm angle voltage is not conforming to
the specified value. In this case, adjust-
ment does not start.
7) Press [t] switch 2 times to end the adjust-
ment mode.
a If [t] switch is pressed while the calibra-
tion is continued, the calibration currently
underway will be stopped even if it is not
completed.
8) When the adjustment did not end suc-
cessfully, check the lift arm angle sensor
voltage from the real time monitoring.
a Adjust the lift arm angle sensor mounting
item of 19: LOWER ANGLE.
position so that the voltage displayed on
the real time monitoring may fall within the
following range and then implement the
sensor adjustment again.
Lift arm position Voltage range

Lower limit position
0.5 – 4.5 V
(Stroke end of lowered cylinder)
7-19. Adjustment of 2-stage low idle throttle

position
WA470, 480-6 30-103 51

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.
2) Hold down the [U] switch for at least 5

seconds to display 01: Transmission trig-
ger adjustment select screen.
30-103 52 WA470, 480-6

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.
2) Hold down the [U] switch for at least 5

seconds to display 01: Transmission trig-
ger adjustment select screen.
WA470, 480-6 30-103 53

8. Maintenance monitoring function

The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
3) Using [<] or [>] switch, select the item for
which the maintenance interval is to be
changed from the following.
30-103 54 WA470, 480-6

List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG FILT 500
Fuel pre-filter 41 FUEL P FILT 500
Fuel filter 03 FUEL FILT 1000
Corrosion resistor (if equipped) 06 CORR RES 1000
Transmission oil 12 TM OIL 1000
Transmission oil filter 13 TM FILT 1000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic tank breather element 05 HYD BREATH 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000
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.
5) Maintenance interval time change proce-

dure
1] This cursor is located at the highest-
order digit. Pressing [<] or [>] switch
changes the value of this digit in the
range of 0 – 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
value.
a The cursor moves to the 2nd digit.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.
WA470, 480-6 30-103 55

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
maintenance interval change item screen
is restored.
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.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3) Inter-
val time change screen displays the a If “Timer by item” is enabled, ON will be
“Selection between enabling or disabling displayed in the upper column.
timer by item” screen.
a When “Timer by item” is enabled, the
order of display is ON o OFF.
30-103 56 WA470, 480-6

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
8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
value – Elapsed tim e since the last
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
was executed.
2) Using [<] or [>] switch, select the INITIALIZE a Set enable for enable or disable of individ-
screen from the following table. ual items.
8-4. Selection between timer stop for all items and

enable by item
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
WA470, 480-6 30-103 57

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.
3) Press [U] switch to display the ALL

ITEMS o OFF screen.
a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select “YES” or “NO” using [<] or [>]
switch.
“YES” is selected and [t] switch is
maintenance interval change item screen
is restored.
4) Press [<] or [>] switch when selecting the to prevent resetting error.
ALL ITEMS o ON.
30-103 58 WA470, 480-6

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.
2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
3) Using [<] or [>] switch, select the item to
be displayed from 1] – 4] on the fuel con-
sumption ratio and average fuel consump-
tion screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column displays fuel con-
sumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q Above value is computed from the
fuel consumption ratio and travel dis-
tance (odometer distance).
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the aver-
age fuel consumption [L/h] from the
last resetting.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.
WA470, 480-6 30-103 59

a The lower column displays the

elapsed time [h] from the last reset-
ting.
the upper limit.
tion in which the engine is run.
2] Cumulative fuel consumption and travel

distance
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
a The lower column displays the travel 4] Loaded volume and loading frequency
distance [km or mile] from the last screen
resetting. a The upper column displays the
q The unit km or mile shall be selected loaded volume [ton] from the last
depending on that used on the odom- resetting.
eter. q Upper limit: Counting is stopped at
q The counting is stopped at 99999.9, 199999999.9 or 999999999.9.
the upper limit. q Short ton or metric ton depends on
a Calculation is done only for the dura- optional setting.
tion in which the engine is run. a The lower column displays the load-
ing frequency from the last resetting.
q Upper limit: Counting starts stopped
at 65000 or 99999999999.
tion in which the engine is run and the
optional device is used.
3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit.
30-103 60 WA470, 480-6

4) Deleting display data 7] Press [U] switch when the intended

a Data on screens 5) – 8) allow deletion. value appeared to specify it as the set
a Select a desired item and then delete it value.
using [U] switch. a The cursor moves to the 2nd digit.
a Use [t] switch when canceling deletion of 8] Set the values up to the lowest digit in
data. the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [–] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the –50 – +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [–] position and the value
remains as it is.
5) Setting gain correction
a Gain correction denotes the function of
correcting cumulative fuel consumption.
a Gain correction is available only from the
fuel consumption ratio and average fuel
consumption screen.
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of –50.0 to +50.0.
3] Move the cursor to [+] or [–].
4] Pressing [<] or [>] switch alternately
displays [+] and [–].
5] Press [U] switch to settle [+] or [–].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 – 9.
WA470, 480-6 30-103 61

10. OPTIONAL SELECT function

a The procedure for setting an option is as follows; Set the option and turn the starting switch OFF. After
the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again, and
the option is effective.
a Before setting an option, check that the machine model has been selected. (Select the machine model
before setting the option.)
a Optional component setting table
Item Setting at
Item Display in English Contents of selection
No. delivery
Set following items according to boom specification.

Boom specification LIFT BOOM 1 STD • If standard boom is used, select “STD”.
• If high lift boom (optional) is used, select “HI LIFT”.
Auto grease AUTO GREASE 2 NO ADD If there is option, select “ADD”.
Electrolyte level sensor BAT LIQUID 3 NO ADD If there is option, select “ADD”.
Transmission filter
TRANSM CLOG 4 NO ADD If there is option, select “ADD”.
clogging sensor
Printer PRINTER 5 NO ADD If there is option, select “ADD”.
Set to “0” normally and do not change.
Tire size TIRE SIZE 6 0 If after than “0” is selected, only the travel speed in monitor
changes.
Selection of short ton SHORT TON 7 NO ADD Since setting is made specially in factory, it cannot be changed.
Unit of travel speed SPEED (UNIT) 8 MPH Since setting is made specially in factory, it cannot be changed.
Machine which must take
RPM OPT 9 NO ADD Select “NO ADD” and do not change it.
automobile inspection
Indication of engine
Normally select “ADD” and do not change it.
speed/travel speed on
RPM/SPEED 10 ADD If “NO ADD” is selected, engine speed or travel speed in the
normal screen of
character display is not displayed.
character display
Load meter LOAD METER 11 ADD Select “NO ADD” and do not change it.
Emergency steering EMERG S/T 13 ADD If option is not installed, select “NO ADD”.
When joystick steering or right FNR (directional) switch is
Joystick steering and/or installed, set necessary items.
right FNR (directional) J/S-FNR SW 14 NON • When only steering wheel is used, set “NON”.
switch are/is not installed • When joystick steering is set, set “J/S”.
• When right FNR (directional) switch is set, set “FNR SW”.
Joystick steering 4th and
J/S 4TH L/U 15 ADD “NO ADD” is selected, 4th and lockup clutch do not operate in
lockup clutch function
joystick steering mode.
Low-temperature bypass
BYPASS SOL 16 NO ADD If there is option, select “ADD”.
solenoid function
Loader pump high altitude
HIGHLAND MD 17 NO ADD Select “NO ADD” and do not change it.
mode
Tooth mode TOOTH MODE 18 ADD Normally select “ADD” and do not change it.
Operation of ECO lamp ECO LAMP 19 ADD If “NO ADD” is selected, ECO lamp in monitor always stays
OFF.
ECSS E.C.S.S 20 ADD If there is option, select “ADD”.
Torque converter lockup LOCK UP 22 NO ADD If there is option, select “ADD”.
If there is option, select “ADD”.
Prohibition of 4th FORBID 4TH 23 NO ADD If “ADD” is selected, transmission is not set in 4th in auto-shift
and manual shift modes.
Throttle lock THROT LOCK 24 NO ADD Select “NO ADD” and do not change it.
Work equipment controller WORK LOCK 29 NO ADD If controller is installed, select “ADD”.
EPC 3-piece lever EPC 3RD 31 NO ADD If there is option, select “ADD”.
EPC lever EPC LEVER 32 NO ADD If there is option, select “ADD”.
1st gear speed drive
F1 PWR CUT 41 ADD Normally select “ADD” and do not change it.
force cut
30-103 62 WA470, 480-6

1) Display the OPTIONAL SELECT screen

from the menu screen of Service mode.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: LIFT BOOM screen will appear.
a If the [t] switch is pressed, the
screen returns to the OPTIONAL
SELECT screen.
WA470, 480-6 30-103 63

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.
30-103 64 WA470, 480-6

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.
a If the options are selected, the option

elected screen (ADD) is displayed. 10-4. Storing option selection
1) When the option selection was changed,
turn off the starting switch once to stop the
controller operation completely. (After turn-
ing off the starting switch, wait for 15 sec-
onds without doing any switch operation.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
a [U] switch allows alternately displaying

the option non-selection screen and the
option-selected screen.
WA470, 480-6 30-103 65

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.
12-1. Implementing the model change

1) Display the MACHINE screen from the
a The currently selected machine model
and tire size are displayed on the lower
2) Press [U] switch to display the MACHINE line.
No. screen. q WA380 TIRE 23.5
3) Enter the serial number according to the q WA380 TIRE 20.5
following procedure. q WA430 TIRE 26.5
a The cursor is positioned at the high- q WA430 TIRE 23.5
est-order digit. q WA470 TIRE 26.5
1] Pressing [<] or [>] switch increases or q WA470 TIRE 23.5
decreases the value at the cursor q WA480 TIRE 26.5
position. Select a desired value using
these switches. ex. WA380
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the imme-
diately preceding screen is restored.
a Pressing [t] switch while entry is taking
place will move the cursor the highest-
order digit. In this case, repeat entry
from the highest-order digit.
a If [t] switch is pressed while the cur-
sor is at the highest-order digit, the 2) Hold down [U] switch for 5 seconds to
immediately preceding screen will be display the model selection screen.
restored.
30-103 66 WA470, 480-6

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,
a Select model and tire size based on therefore, not used for a service purpose.
installed tire.
a If wrong model and tire are set,
machine does not work correctly.
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 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.
12-2. Storing model change

1) When the model change was done, turn off
the starting switch once to stop the controller
operation completely. (After turning off the
starting switch, wait for 15 seconds without
doing any switch operation.)
2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
WA470, 480-6 30-103 67

SEN04518-01 Pm-clinic inspection table
Pm-clinic inspection table 1
WA470-6 Serial No. 90001 and up

Machine serial No. #
Engine serial No.
hour inspection SAA6D125E-5 #
Work instruction No. Date of execution Service meter Inspector
Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.

a Working mode: P-mode
Standard
Service limit Measure-
Item Condition Unit value for new Good Bad
value ment result
machine
Engine at low idle 800 – 850 800 – 850
Engine at high idle 2,120 – 2,220 2,120 – 2,220
Engine at high idle and torque converter
1,750 – 1,850 1,700 – 1,900
stalled
Engine speed rpm
Engine at high idle and work equipment
2,040 – 2,240 1,940 – 2,340
relieved
Torque converter stalled + Work equipment
1,650 – 1,850 1,550 – 1,950
relieved
At rated output
kPa Max. 1.47 2.94
Blow-by pressure Engine coolant temperature: operating
Engine
{mmH2O} {Max. 150} {300}

range
At rated output
SAE0W30EOS 0.29 – 0.69 0.18
Engine coolant tempera-
SAE5W40EOS {3.0 – 7.0} {1.8}
Lubricating oil ture: operating range MPa
SAE10W30DH
pressure Engine speed: low idle {kg/cm2}
SAE15W40DH Min. 0.05 0.03
SAE30DH {Min. 0.5} {0.3}
ture: operating range
kPa Min. 100 80
Boost pressure At rated output
{mmHg} {Min. 750} {600}
Exhaust Engine at all speed range
°C Max. 700 Max. 700
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine speed: 2.35 – 2.75 2.35 – 2.75
Main relief 2,000 rpm {24 – 28} {24 – 28}
pressure 2.25 – 2.65 2.25 – 2.65
Engine at low idle • Torque converter oil
{23 – 27} {23 – 27}
temperature: Within
Torque converter Engine speed: Max. 0.93 Max. 0.93
operating range
Transmission, Torque converter
inlet pressure 2,000 rpm {Max. 9.5} {Max. 9.5}

Torque converter Engine speed: 0.54 – 0.64 0.54 – 0.64
outlet pressure 2,000 rpm {5.5 – 6.5} {5.5 – 6.5}
1st 2.20 – 2.50 2.20 – 2.50
2nd • Torque converter oil {22.5 – 25.5} {22.5 – 25.5}
MPa
3rd temperature: 2.15 – 2.45 2.15 – 2.45
{kg/cm2}
ECMV output 4th Within operating range {22 – 25} {22 – 25}
(clutch) pressure F • Engine speed: 1.91 – 2.21 1.91 – 2.21
R 2,000 rpm {19.5 – 22.5} {19.5 – 22.5}
• Manual switch: ON 1.51 – 1.81 1.51 – 1.81
Lockup
{15.5 – 18.5} {15.5 – 18.5}
• Torque converter oil
temperature: Within
0.12 – 0.22 0.12 – 0.22
Lubrication pressure operating range
{1.25 – 2.25} {1.25 – 2.25}
• Engine speed:
2,000 rpm
30-103 68 WA470, 480-6

Pm-clinic inspection table SEN04518-01
Pm-clinic inspection table

Standard
value ment result
machine
Steering
Secure frame with frame lock bar.

MPa 23.3 – 25.7 22.0 – 25.7
Steering relief pressure Engine at high idle
{kg/cm2} {237.5 – 262.5} {225 – 262.5}
Torque converter oil temperature: Within operat-
Parking brake inlet ing range MPa Min. 2.27 Min. 2.27
pressure Engine at low idle {kg/cm2} {Min. 23.1} {Min. 23.1}
As parking brake is released
Tire inflation pressure: Specified pressure
Parking brake
Test on flat and dry paved slope of 1/5 (11° 20'). — Stopped Stopped
performance
Set machine in operating state.
Parking brake disc
mm 3.12 – 3.28 2.97
thickness
Measure when brake
5.9 – 6.4 5.4 – 6.88
Charge cut-in pressure oil pressure warning
Hydraulic oil temperature: lamp goes off. {60 – 65} {55 – 70}
Engine at low idle Measure when brake
9.8 – 10.78 9.4 – 11.3
Brake
Charge cut-out pressure oil pressure starts

MPa {100 – 110} {95 – 115}
lowering after rising.
{kg/cm2}
Hydraulic oil temperature: Within operating range 4.4 – 5.2 Min. 4.2
Brake oil pressure
Engine at low idle {44.8 – 53} {Min. 42.7}
Engine: Stopped
Lowering of brake oil Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9 MPa
pressure {Max. 5.0} {Max. 5.0}
{50 kg/cm2} in 5 minutes.
Test on flat, level, straight, and dry paved road.
Braking initial speed: 20 km/h,
Wheel brake performance Delay in pressing pedal: Max 0.1 sec m Max. 5 Max. 5
Brake pedal pressing force:
Specified force, 293 – 353 Nm {29.9 – 35.9 kg}
Measure braking distance.
Wear of wheel brake disc Measure with disc wear indicator. mm 0 Max. 2.4
Work equipment valve relief 32.5 – 36.1 29.9 – 36.1
Bucket circuit relieved
pressure MPa {332 – 368} {305 – 368}
Work equipment valve LS Work equipment control {kg/cm2} 1.17 – 1.57 0.98 – 1.76
P-mode
differential pressure Hydraulic oil tempera- lever moved halfway {12 – 16} {10 – 18}
Work equipment
ture: Within operating Rising time 4.9 – 5.9 Max. 7.2

Lift arm speed range
Engine at high idle Lowering time 3.2 – 4.2 Max. 4.9
sec
Bucket full stroke time 2.1 – 2.7 Max. 3.2
Bucket tilt back speed
Bucket at level time 1.2 – 1.8 Max. 2.0
Hydraulic oil tempera- Bucket cylinder Max. 20 Max. 24
Hydraulic drift of work ture: Within operating mm/
equipment range 15 min.
Engine: Stopped Lift cylinder Max. 30 Max. 36
Engine speed: High idle

Engine coolant temperature: Min. 95°C
Max. fan speed 1,350 – 1,550 1,250 – 1,650
Hydraulic oil temperature: Min. 95°C
Torque converter oil temperature: Min. 105°C
Engine speed: Low idle rpm
Hydraulic drive fan

Min. fan speed Hydraulic oil temperature: Max. 75°C 550 – 650 500 – 700
Torque converter oil temperature: Max. 85°C
Air conditioner: OFF
Engine coolant temperature: Min. 95°C 12.8 – 15.6 12.1 – 16.3
Fan drive pressure
Hydraulic oil temperature: Min. 95°C {130 – 160} {123 – 167}
Torque converter oil temperature: Min. 105°C MPa
Engine speed: High idle {kg/cm2}
Fan reverse solenoid Engine coolant temperature: Min. 95°C 12.8 – 15.6 12.1 – 16.3
output pressure Hydraulic oil temperature: Min. 95°C {130 – 160} {123 – 167}
Draining of differential Front axle There must not be
Axle
—
Visual check of plug Rear axle excessive metal powder.
Memo
WA470, 480-6 30-103 69

SEN04518-01 Pm-clinic inspection table

Machine serial No. #
Engine serial No.
hour inspection SAA6D125E-5 #
Work instruction No. Date of execution Service meter Inspector
Year: Month: Day: hours
Interview with operator and walk-around check

Is there abnormality before starting inspection? Outside temperature
Max. °C
Min. °C
Altitude m
Maximum coolant temperature (overheated)? Maximum torque converter oil temperature

(During operation) (overheated)? (During operation)
a If machine is cold, warm it up.

a Working mode: P-mode
Standard
value ment result
machine
Engine at low idle 800 – 850 800 – 850
Engine at high idle 2,140 – 2,240 2,140 – 2,240
Engine at high idle and torque converter
1,810 – 1,910 1,760 – 1,960
stalled
Engine speed rpm
Engine at high idle and work equipment
2,050 – 2,250 1,950 – 2,350
relieved
Torque converter stalled + Work equipment
1,710 – 1,910 1,610 – 2,010
relieved
At rated output
kPa Max. 1.47 2.94
Blow-by pressure Engine coolant temperature: operating
Engine
{mmH2O} {Max. 150} {300}

range
At rated output
SAE0W30EOS 0.29 – 0.69 0.18
SAE5W40EOS {3.0 – 7.0} {1.8}
Lubricating oil ture: operating range MPa
SAE10W30DH
pressure Engine speed: low idle {kg/cm2}
SAE15W40DH Min. 0.05 0.03
SAE30DH {Min. 0.5} {0.3}
ture: operating range
kPa Min. 113 93
Boost pressure At rated output
{mmHg} {Min. 850} {700}
Exhaust Engine at all speed range
°C Max. 700 Max. 700
temperature Outside temperature: 20°C
a When shifting transmission gear to forward/reverse position, apply brake securely. Good Bad
Engine speed: 2.35 – 2.75 2.35 – 2.75
Main relief 2,000 rpm {24 – 28} {24 – 28}
pressure 2.25 – 2.65 2.25 – 2.65
Engine at low idle • Torque converter oil
{23 – 27} {23 – 27}
temperature: Within
Torque converter Engine speed: Max. 0.93 Max. 0.93
operating range
Transmission, Torque converter
inlet pressure 2,000 rpm {Max. 9.5} {Max. 9.5}

Torque converter Engine speed: 0.54 – 0.64 0.54 – 0.64
outlet pressure 2,000 rpm {5.5 – 6.5} {5.5 – 6.5}
1st 2.20 – 2.50 2.20 – 2.50
2nd • Torque converter oil {22.5 – 25.5} {22.5 – 25.5}
MPa
3rd temperature: 2.15 – 2.45 2.15 – 2.45
{kg/cm }
2
ECMV output 4th Within operating range {22 – 25} {22 – 25}
(clutch) pressure F • Engine speed: 1.91 – 2.21 1.91 – 2.21
R 2,000 rpm {19.5 – 22.5} {19.5 – 22.5}
• Manual switch: ON 1.51 – 1.81 1.51 – 1.81
Lockup
{15.5 – 18.5} {15.5 – 18.5}
• Torque converter oil
temperature: Within
0.12 – 0.22 0.12 – 0.22
Lubrication pressure operating range
{1.25 – 2.25} {1.25 – 2.25}
• Engine speed:
2,000 rpm
30-103 70 WA470, 480-6

Pm-clinic inspection table SEN04518-01

Standard
value ment result
machine
Steering
Secure frame with frame lock bar.

MPa 23.3 – 25.7 22.0 – 25.7
Steering relief pressure Engine at high idle
{kg/cm2} {237.5 – 262.5} {225 – 262.5}
Torque converter oil temperature: Within operat-
Parking brake inlet ing range MPa Min. 2.27 Min. 2.27
pressure Engine at low idle {kg/cm2} {Min. 23.1} {Min. 23.1}
As parking brake is released
Parking brake
Test on flat and dry paved slope of 1/5 (11° 20'). — Stopped Stopped
performance
Set machine in operating state.
Parking brake disc
mm 3.12 – 3.28 2.97
thickness
Measure when brake
5.9 – 6.4 5.4 – 6.88
Charge cut-in pressure oil pressure warning
Hydraulic oil temperature: lamp goes off. {60 – 65} {55 – 70}
Engine at low idle Measure when brake
9.8 – 10.78 9.4 – 11.3
Brake
Charge cut-out pressure oil pressure starts

MPa {100 – 110} {95 – 115}
lowering after rising.
{kg/cm2}
Hydraulic oil temperature: Within operating range 4.4 – 5.2 Min. 4.2
Brake oil pressure
Engine at low idle {44.8 – 53} {Min. 42.7}
Engine: Stopped
Lowering of brake oil Max. 0.49 Max. 0.49
Measure lowering of oil pressure from 4.9 MPa
pressure {Max. 5.0} {Max. 5.0}
{50 kg/cm2} in 5 minutes.
Test on flat, level, straight, and dry paved road.
Braking initial speed: 20 km/h,
Wheel brake performance Delay in pressing pedal: Max 0.1 sec m Max. 5 Max. 5
Brake pedal pressing force:
Specified force, 293 – 353 Nm {29.9 – 35.9 kg}
Measure braking distance.
Wear of wheel brake disc Measure with disc wear indicator. mm 0 Max. 2.4
Work equipment valve relief 32.5 – 36.1 29.9 – 36.1
Bucket circuit relieved
pressure MPa {332 – 368} {305 – 368}
Work equipment valve LS P-mode Work equipment control {kg/cm2} 1.17 – 1.57 0.98 – 1.76
differential pressure Hydraulic oil tempera- lever moved halfway {12 – 16} {10 – 18}
Work equipment
ture: Within operating Rising time 5.6 – 6.6 Max. 8.1

Lift arm speed range
Engine at high idle Lowering time 3.3 – 4.3 Max. 5.1
sec
Bucket full stroke time 2.5 – 3.1 Max. 3.7
Bucket tilt back speed
Bucket at level time 1.6 – 2.2 Max. 2.5
Hydraulic oil tempera- Bucket cylinder Max. 20 Max. 24
Hydraulic drift of work ture: Within operating mm/
equipment range 15 min.
Engine: Stopped Lift cylinder Max. 30 Max. 36

Engine coolant temperature: Min. 95°C
Max. fan speed 1,350 – 1,550 1,250 – 1,650
Hydraulic oil temperature: Min. 95°C
Engine speed: Low idle rpm
Hydraulic drive fan

Min. fan speed Hydraulic oil temperature: Max. 75°C 550 – 650 500 – 700
Torque converter oil temperature: Max. 85°C
Air conditioner: OFF
Engine coolant temperature: Min. 95°C 12.8 – 15.6 12.1 – 16.3
Fan drive pressure
Hydraulic oil temperature: Min. 95°C {130 – 160} {123 – 167}
Torque converter oil temperature: Min. 105°C MPa
Engine speed: High idle {kg/cm2}
Fan reverse solenoid Engine coolant temperature: Min. 95°C 12.8 – 15.6 12.1 – 16.3
output pressure Hydraulic oil temperature: Min. 95°C {130 – 160} {123 – 167}
Draining of differential Front axle There must not be
Axle
—
Visual check of plug Rear axle excessive metal powder.
Memo
WA470, 480-6 30-103 71

SEN04518-01

©2009 KOMATSU
All Rights Reserved
30-103 72
SEN04519-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
40 Troubleshooting 40
100 Failure code table and fuse locations

Failure code table ........................................................................................................................................... 2
Fuse locations............................................................................................................................................... 14
WA470, 480-6 40-100 1

SEN04519-01 Failure code table
Failure code table 1
Failure Action Category of Reference

Troubled part Trouble Controller
code code record document No.
TORQFLOW Electrical
1500L0 Double meshing TM E03
transmission system
When command current is Electrical
15SAL1 ECMV F clutch TM E03
OFF, fill signal is ON system
15SALH ECMV F clutch TM E01
ON, fill signal is OFF system
15SBL1 ECMV R clutch TM E03
15SBLH ECMV R clutch TM E01
15SEL1 ECMV 1st clutch TM E03
15SELH ECMV 1st clutch TM E01
When command current is Electrical Troubleshooting
15SFL1 ECMV 2nd clutch TM E03
OFF, fill signal is ON system by failure code,
When command current is Electrical Part 1
15SFLH ECMV 2nd clutch TM E01 SEN04521-01
15SGL1 ECMV 3rd clutch TM E03
15SGLH ECMV 3rd clutch TM E01
15SHL1 ECMV 4th clutch TM E03
15SHLH ECMV 4th clutch TM E01
Electrical
2F00MA Parking brake Malfunction MON E03
system
Mechanical
2G43ZG Accumulator Low oil pressure MON E03
system
Electrical
44K0L4 Bucket positioner ON/OFF signals disagree WRK E01
system
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Signal does not match
Electrical
AB00L6 Alternator engine running or stopped MON E03
system
state
Mechanical
AB00MA Alternator Malfunction MON E03 Troubleshooting
system
by failure code,
Low oil pressure and derat- Mechanical
B@BAZG Engine oil pressure ENG E03 Part 2
ing of engine speed system
SEN04522-00
Mechanical
B@BAZK Engine oil Low oil level MON E01
system
Mechanical
B@BCNS Coolant Overheating ENG E02
system
Mechanical
B@BCZK Coolant Low oil pressure MON E01
system
40-100 2 WA470, 480-6

Failure code table SEN04519-01

Mechanical
B@C7NS Brake oil Overheating MON E02
system
Mechanical
b@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@CENS Torque converter oil Overheating MON E02
system
Mechanical
B@HANS Hydraulic oil Overheating MON E02
system
Electrical
CA111 Engine controller Internal failure ENG E03
system
Engine Ne, Bkup speed Electrical
CA115 Abnormality ENG E03
sensor system
Charge pressure Electrical
CA122 Abnormally high level ENG E03
sensor system
Charge pressure Electrical
CA123 Abnormally low level ENG E03
sensor system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03
system
Engine oil pressure Electrical Troubleshooting
CA135 High error ENG E01
sensor system by failure code,
Engine oil pressure Electrical Part 2
CA141 Low error ENG E01 SEN04522-00
sensor system
Coolant temperature Electrical
sensor system
Coolant temperature Electrical
sensor system
Charge temperature Electrical
sensor system
Charge temperature Electrical
sensor system
Electrical
CA187 Sensor power supply 2 Voltage low error ENG E03
system
Ambient pressure Electrical
sensor system
Ambient pressure Electrical
CA222 Low error ENG E01
sensor system
Electrical
CA227 Sensor power supply 2 Voltage high error ENG E03
system
Mechanical
CA234 Engine Overspeed ENG E02
system
Electrical
CA238 Ne speed sensor Supply power voltage error ENG E03
system
Fuel temperature Electrical
sensor system Troubleshooting
Fuel temperature Electrical by failure code,
CA265 Low error ENG E01
sensor system Part 3
Electrical SEN04523-01
CA271 PCV1 Short circuit ENG E03
system
WA470, 480-6 40-100 3


Electrical
CA272 PCV1 Disconnection ENG E03
system
Electrical
CA273 PCV2 Short circuit ENG E03
system
Electrical
CA274 PCV2 Disconnection ENG E03
system
Circuit in injector #1 Electrical
CA322 Disconnection or short ENG E03
system system
system system
system system
system system
system system
system system
Electrical
CA342 Engine controller Data incompatibility ENG E03
system
Electrical
CA351 Injectors drive circuit Error ENG E03
system
Electrical
CA352 Sensor power supply 1 Voltage low error ENG E03
system Troubleshooting
Electrical by failure code,
CA386 Sensor power supply 1 Voltage high error ENG E03
system Part 3
CA431 Idle validation switch Abnormality ENG E01
system
Processing of idle Electrical
validation system
Electrical
CA441 Power supply voltage Abnormally low ENG E03
system
Electrical
CA442 Power supply voltage Abnormally high ENG E03
system
Electrical
CA449 Common rail pressure 2 Abnormally high ENG E03
system
Common rail pressure Electrical
sensor system
Common rail pressure Electrical
sensor system
Electrical
CA553 Common rail pressure 1 Abnormally high ENG E03
system
Electrical
CA559 Supply pump Pressure very low error 1 ENG E03
system
Engine Ne speed Electrical
sensor system
Engine Bkup speed Electrical
CA731 Abnormality of phase ENG E03
sensor phase system
Electrical
CA757 Engine controller Loss of all data ENG E03
system
40-100 4 WA470, 480-6


Engine Bkup speed Electrical
sensor system
Electrical
CA1228 EGR valve servo Error 1 ENG E03
system
Electrical Troubleshooting
CA1625 EGR valve servo Error 2 ENG E03
system by failure code,
Electrical Part 3
CA1633 KOMNET Abnormality ENG E03 SEN04523-01
system
Power supply voltage high Electrical
CA2185 Throttle sensor ENG E03
error system
Power supply voltage low Electrical
CA2186 Throttle sensor ENG E03
error system
Electrical
CA2249 Supply pump Pressure very low error 2 ENG E03
system
Electrical
CA2271 EGR valve lift sensor High error ENG E03
system
Electrical
CA2272 EGR valve lift sensor Low error ENG E03
system
Electrical
CA2351 EGR valve solenoid Operation short circuit error ENG E03
system
Operation disconnection Electrical
CA2352 EGR valve solenoid ENG E03
error system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Short circuit in intake air Electrical
CA2556 — ENG E01
heater relay system
Emergency steering Electrical
D150KA Disconnection TM E03
relay system
D150KB Short-circuit TM E03
relay system Troubleshooting
Emergency steering Electrical by failure code,
D150KY Power supply line short TM E03
relay system Part 4
Backup lamp relay Electrical SEN04524-01
output system
Backup lamp relay Electrical
D160KB Short circuit TM E01
output system
Joystick steering neural Electrical
safety relay system
D191KB Short-circuit TM E01
safety relay system
D191KY Power supply line short TM E01
safety relay system
Electrical
D192KA ECSS solenoid Disconnection TM E01
system
Electrical
D192KB ECSS solenoid Short-circuit TM E01
system
Electrical
D192KY ECSS solenoid Power supply line short TM E01
system
Joystick steering Electrical
D193KA Disconnection WRK E03
solenoid cut-off relay system
WA470, 480-6 40-100 5


D193KB Short-circuit WRK E03
D193KY Power supply line short WRK E03
Disconnection or short cir- Electrical
D5ZHKA Terminal C signal TM E01
cuit system
Electrical
D5ZHKB Terminal C signal Power supply line short TM E01
system
Disconnection or short cir- Electrical
D5ZHKZ Terminal C signal WRK E01
cuit system Troubleshooting
Signal does not match by failure code,
Electrical Part 4
D5ZHL6 Terminal C signal engine running or stopped MON E01
system SEN04524-01
state
DA80L4 Auto grease controller ON/OFF signals disagree MON ∗ Electrical

system
Hydraulic oil Electrical
DAF3KK Low source voltage (input) MON E03
temperature system
DAF5KP Low output voltage MON E01
temperature system
Defective communication
CAN communication Electrical
DAFRKR (Abnormality in target com- TM E03
with machine monitor system
ponent system)
Electrical
DAQ0KK Transmission controller Low source voltage TM E03
system
Electrical
DAQ0KT Transmission controller Abnormality in controller TM E01
system
Electrical
DAQ1KA Terminal ACC input Disconnection TM E03
system
Transmission controller Electrical
DAQ2KK Low source voltage (input) TM E03
load power supply line system
Transmission controller Disagreement of model Electrical
DAQ9KQ MON E03
model selection selection signals system
CAN communication Defective communication
DAQRKR with transmission (Abnormality in target com- MON E03
controller ponent system)
Part 5
Transmission controller Electrical SEN04525-01
DAQRMA Malfunction MON E03
option setting system
Defective communication
CAN communication Electrical
DB2RKR (Abnormality in target com- TM E03
with engine controller system
ponent system)
Work equipment Electrical
DB90KK Low source voltage (input) WRK E03
controller system
DB90KT Abnormality in controller WRK E01
controller system
Work equipment
Electrical
DB92KK controller load power Low source voltage (input) WRK E03
system
supply line
∗: This failure code is not used in this machine.

It is listed in the mechanical system failure code table, however.
40-100 6 WA470, 480-6


Work equipment
Electrical
DB95KX controller power supply Out of input signal range WRK E03
system
output
Work equipment
Disagreement of model Electrical
DB99KQ controller model MON E03
selection signals system
selection
CAN communication Defective communication
Electrical
DB9RKR with work equipment (Abnormality in target com- TM E03
system
controller ponent system)
DB9RMA Malfunction MON E03
controller option setting system
CAN communication
with transmission
Electrical
DB9RMC controller, engine Defective operation WRK E03
system
controller and machine
monitor
Switch is kept pressed for Electrical
DD15LD t switch (Panel switch 1) MON E01
long time system
DD16LD U switch (Panel switch 2) MON E01
long time system
DD17LD < switch (Panel switch 3) MON E01
long time system
Switch is kept pressed for Electrical Troubleshooting
DD18LD > switch (Panel switch 4) MON E01
long time system by failure code,
Remote positioner Part 5
DD1ALD raise/lower set switch WRK E01 SEN04525-01
long time system
(RAISE)
Remote positioner
DD1BLD raise/lower set switch WRK E01
long time system
(LOWER)
Load meter subtotal Switch is kept pressed for Electrical
DD1CLD MON E01
switch long time system
Load meter mode
DD1FLD selector switch MON E01
long time system
(A/B)
Load meter mode
DD1GLD selector switch MON E01
long time system
(+/–)
Load meter display Switch is kept pressed for Electrical
DD1HLD MON E01
selector switch long time system
DD1NLD Fan reverse switch TM E01
long time system
Fan automatic reverse Electrical
DD1NL4 Abnormality in input signal TM E01
switch system
Parking brake switch Electrical
DDB6L4 ON/OFF signals disagree TM E03
(Neutralizer) system
Remote positioner Switch is kept pressed for Electrical
DDD1LD WRK E01
bucket angle set switch long time system
WA470, 480-6 40-100 7


DDE5MA Malfunction MON E01
drive switch system
Electrical
DDK3KA Right FNR switch Disconnection TM E03
system
Joystick steering FNR Electrical
DDK4KA Disconnection TM E03
switch system
Joystick steering shift- Signals consecutive input Electrical
DDK5L4 TM E01
up and down switch disagree system
Electrical
DDK6KA FNR lever switch Disconnection TM E03
system
Electrical
DDK6KB FNR lever switch Short-circuit TM E03
system
Steering pressure Electrical
DDS5KA Disconnection TM E01
switch signal system
Steering pressure Electrical
DDS5KB Short-circuit TM E01
switch signal system
Electrical
DDS5L6 Steering Low oil pressure MON E03
system
Shift mode selector Electrical
DDT0L4 ON/OFF signals disagree TM E01
switch system
Transmission cut-off set Switch is kept pressed for Electrical
DDT4LD TM E01
Switch is kept pressed for Electrical Troubleshooting
DDW9LD Kickdown switch TM E01
long time system by failure code,
Switch is kept pressed for Electrical Part 6
DDWLLD Hold switch TM E01 SEN04526-01
long time system
Load meter cancel Switch is kept pressed for Electrical
DDY0LD MON E01
Transmission shift lever Electrical
DF10KA Disconnection TM E01
switch system
Transmission shift lever Electrical
DF10KB Short-circuit TM E01
switch system
Transmission oil Electrical
DGF1KA Disconnection TM E01
temperature sensor system
Transmission oil Electrical
DGF1KB Short-circuit TM E01
DGH2KX Out of input signal range MON E01
Rear brake oil Electrical
DGR2KA Disconnection MON E01
Rear brake oil Electrical
DGR2KX Out of input signal range MON E01
Torque converter oil Electrical
DGT1KX Out of input signal range MON E01
Loader pump pressure Electrical
DH21KA Disconnection TM E01
sensor system
Loader pump pressure Electrical
DH21KB Power supply line short TM E01
sensor system
40-100 8 WA470, 480-6


Lift arm cylinder bottom Electrical
DHPCKX Out of input signal range MON E01
pressure sensor system
Lift arm cylinder head Electrical
DHPDKX Out of input signal range MON E01
pressure sensor system
Left brake pressure Electrical
DHT1KX Out of input signal range TM E01
sensor system
Steering pump pressure Electrical
DHT8KA Disconnection TM E01
sensor system
Steering pump pressure Electrical
DHT8KB Short-circuit TM E01
sensor system
Lift arm EPC lever Electrical
DK59KA Disconnection WRK E03
potentiometer (Main) system
DK59KY Power supply line short WRK E03
potentiometer (Main) system Troubleshooting
Lift arm EPC lever Electrical by failure code,
DK59L8 Analog signals disagree WRK E03
potentiometer (Main) system Part 7
Lift arm EPC lever Electrical SEN04527-01
DK5AKA Disconnection WRK E03
potentiometer (Sub) system
DK5AKY Power supply line short WRK E03
Bucket EPC lever Electrical
DK5BKA Disconnection WRK E03
DK5BKY Power supply line short WRK E03
DK5BL8 Analog signals disagree WRK E03
DK5CKA Disconnection WRK E03
DK5CKY Power supply line short WRK E03
Joystick steering EPC
Electrical
DK5FKA lever potentiometer Disconnection WRK E03
system
(Main)
Electrical
DK5FKY lever potentiometer Power supply line short WRK E03
system
(Main)
Electrical
DK5GKA lever potentiometer Disconnection WRK E03
system
(Sub)
Joystick steering EPC Troubleshooting
DK5GKY lever potentiometer Power supply line short WRK E03
system Part 8
(Sub)
SEN04528-01
Electrical
DK5FL8 lever potentiometer Analog signals disagree WRK E03
system
(Main and sub)
Electrical
DKA0KA Lift arm angle sensor Disconnection WRK E01
system
Electrical
DKA0KY Lift arm angle sensor Power supply line short WRK E01
system
Electrical
DKA0L0 Lift arm angle sensor Double meshing WRK E01
system
WA470, 480-6 40-100 9


Transmission input Electrical
DLF1KA Disconnection TM E01
speed sensor system
Transmission input Electrical
DLF1LC Short-circuit TM E01
speed sensor system
Electrical
DLM3KA Fan speed sensor Disconnection TM E01
system
Electrical
DLM3LC Fan speed sensor Short-circuit TM E01
system
Transmission output Electrical
DLT3KA Disconnection TM E03
speed sensor system
Transmission output Electrical
DLT3LC Out of input signal range TM E03
speed sensor system
Transmission cut-off Electrical
DT20KB Short-circuit TM E01
indicator lamp system
Remote positioner raise
DUM1KB Short-circuit WRK — —
set indicator lamp
Remote positioner
DUM2KB Short-circuit WRK — —
lower set indicator lamp Troubleshooting
DV00KB Warning buzzer Short-circuit MON E01
system Part 8
Lift arm raise EPC Electrical SEN04528-01
DW4PKA Disconnection WRK E03
solenoid system
Lift arm raise EPC Electrical
DW4PKB Short-circuit WRK E03
solenoid system
Lift arm raise EPC Electrical
DW4PKY Power supply line short WRK E03
solenoid system
Lift arm lower EPC Electrical
DW4QKA Disconnection WRK E03
solenoid system
DW4QKB Short-circuit WRK E03
solenoid system
DW4QKY Power supply line short WRK E03
solenoid system
Electrical
DW4RKA Bucket tilt EPC solenoid Disconnection WRK E03
system
Electrical
DW4RKB Bucket tilt EPC solenoid Short-circuit WRK E03
system
Electrical
DW4RKY Bucket tilt EPC solenoid Power supply line short WRK E03
system
Bucket dump EPC Electrical
DW4SKA Disconnection WRK E03
solenoid system
Bucket dump EPC Electrical
DW4SKB Short-circuit WRK E03
solenoid system
Bucket dump EPC Electrical Troubleshooting
DW4SKY Power supply line short WRK E03
solenoid system by failure code,
Electrical Part 9
DW7BKA Fan reverse solenoid Disconnection TM E01 SEN04529-00
system
Electrical
DW7BKB Fan reverse solenoid Short-circuit TM E01
system
Electrical
DW7BKY Fan reverse solenoid Power supply line short TM E01
system
40-100 10 WA470, 480-6


Work equipment neutral Electrical
DWM1KA Disconnection WRK E01
lock solenoid system
DWM1KB Short-circuit WRK E01
DWM1KY Power supply line short WRK E01
Lift arm raise magnet Electrical
DWN6KA Disconnection WRK E01
detent solenoid system
DWN6KB Short-circuit WRK E01
DWN6KY Power supply line short WRK E01
Lift arm float magnet Electrical
Bucket tilt magnet Electrical
detent solenoid system Troubleshooting
DX16KA Fan pump EPC Disconnection TM E01
system Part 9
DX16KB Fan pump EPC Short-circuit TM E01
system
Electrical
DX16KY Fan pump EPC Power supply line short TM E01
system
Loader pump PC-EPC Electrical
DXA1KA Disconnection TM E01
solenoid system
Loader pump PC-EPC Electrical
DXA1KB Short-circuit TM E01
solenoid system
Steering pump PC-EPC Electrical
DXANKA Disconnection TM E01
solenoid system
Steering pump PC-EPC Electrical
DXANKB Short-circuit TM E01
solenoid system
Electrical
DXH1KA Lockup ECMV solenoid Disconnection TM E01
system
Electrical
DXH1KB Lockup ECMV solenoid Short-circuit TM E01
system
Electrical
DXH1KY Lockup ECMV solenoid Power supply line short TM E03
system
1st clutch ECMV Electrical
DXH4KA Disconnection TM E03
solenoid system
DXH4KB Short-circuit TM E03
solenoid system
DXH4KY Power supply line short TM E03
solenoid system
WA470, 480-6 40-100 11


2nd clutch ECMV Electrical
solenoid system
solenoid system
solenoid system
3rd clutch ECMV Electrical
solenoid system
solenoid system
solenoid system
R clutch ECMV Electrical
solenoid system
solenoid system
solenoid system
Electrical
DXH8KA F clutch ECMV solenoid Disconnection TM E03
system
Electrical
DXH8KB F clutch ECMV solenoid Short-circuit TM E03
system
DXH8KY F clutch ECMV solenoid Power supply line short TM E03
4th clutch ECMV Electrical Part 10
DXHHKA Disconnection TM E03 SEN04530-01
solenoid system
4th clutch ECMV Electrical
DXHHKB Short-circuit TM E03
solenoid system
4th clutch ECMV Electrical
DXHHKY Power supply line short TM E03
solenoid system
Joystick steering right Electrical
DXHLKA Disconnection WRK E03
EPC solenoid system
DXHLKB Short-circuit WRK E03
EPC solenoid system
DXHLKY Power supply line short WRK E03
EPC solenoid system
Joystick steering left Electrical
DXHMKA Disconnection WRK E03
EPC solenoid system
DXHMKB Short-circuit WRK E03
EPC solenoid system
DXHMKY Power supply line short WRK E03
EPC solenoid system
Electrical emergency Electrical
DY30MA Malfunction TM E01
steering pump system
Electrical emergency Electrical
DY30MC Defective operation TM E03
steering pump system
Operates for one minute or Electrical
DY30ME Emergency steering MON E02
more system
40-100 12 WA470, 480-6

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.
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, 480-6 40-100 13

SEN04519-01 Fuse locations
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
40-100 14 WA470, 480-6

Fuse locations SEN04519-01
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
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
Slow blow fuse

Slow-blow Capacity of
Type of power supply Destination of power
fuse No. fuse
Spare 1, engine controller (A) circuit, transmission controller (B)
circuit, work equipment controller (B) circuit (if equipped), room
Constant power
1 50 A lamp circuit, machine monitor (B) circuit, KOMTRAX (B) circuit (if
supply
equipped), hazard lamp circuit and starting switch (B) terminal
circuit
Main lamp circuit, machine monitor (A) circuit, load meter printer
(if equipped) circuit, air conditioner (B) circuit, air conditioner (A)
circuit, wiper and washer circuit, back-up lamp and brake lamp
2 50 A circuit, work equipment positioner circuit, work equipment con-
troller (A) circuit (if equipped), emergency steering circuit (if
equipped), parking brake circuit, transmission controller (A) cir-
cuit and horn circuit
Switch power supply Rear glass heater circuit, KOMTRAX (A) circuit (if equipped), yel-
low rotary lamp circuit (if equipped), turn signal lamp circuit, car
3 50 A radio circuit, cigar lighter circuit, 12 V converter circuit, air sus-
pension seat (if equipped) circuit, rear working lamp circuit and
front working lamp circuit
4 120 A Charging circuit
5 120 A Heater relay circuit
WA470, 480-6 40-100 15

SEN04519-01 Fuse locations
Locations and numbers of fuse boxes and slow blow fuse
40-100 16 WA470, 480-6

Fuse locations SEN04519-01
WA470, 480-6 40-100 17

SEN04519-01

©2009 KOMATSU
All Rights Reserved
40-100 18
SEN04520-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
200 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, 480-6 40-200 1

SEN04520-01 Points to remember when troubleshooting
Points to remember when troubleshooting 1
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to con-
nect it properly.
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.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to
carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed pro-
cedure.
2. Points to ask user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any inves-
tigation or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 – 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part
exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure
occurred. Then, remove the root cause.
40-200 2 WA470, 480-6

Sequence of events in troubleshooting SEN04520-01
Sequence of events in troubleshooting 1
WA470, 480-6 40-200 3

SEN04520-01 Testing before troubleshooting
Testing before troubleshooting 1
Item Criteria Remedy
1. Check of level and type of fuel — Add fuel
2. Check for foreign matter in fuel

— Clean or drain
Check fuel filter and fuel pre-filter for clogging
3. Check of level and type of oil in engine oil pan Between H and L Add oil
Lubricating oil and coolant
Between FULL and

4. Check of coolant level Add coolant
LOW
5. Check of air cleaner for clogging No red Clean or replace
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
8. Check of engine oil filter for clogging — Replace
9. Check of hydraulic oil filter for clogging — Replace
10. Check of transmission oil filter for clogging — Replace
Retighten or
11. Check of battery terminal cables for looseness and corrosion —
replace
Electrical parts
12. Check of alternator terminal cables for looseness and Retighten or

—
corrosion replace
13. Check of starting motor terminal cables for looseness and Retighten or
—
corrosion replace
14. Check of operation of instruments — Repair or replace

mechanical equipment
15. Check for abnormal noise and smell — Repair

Hydraulic and
16. Check for oil leakage — Repair
17. Bleeding air — Bleed air
18. Check of effect of brake — Repair or adjust
19. Check of battery voltage (with engine stopped) 20 – 30 V Charge or replace
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)
40-200 4 WA470, 480-6

Classification and procedures of troubleshooting SEN04520-01
Classification and procedures of troubleshooting 1
Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
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]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code dis-
play mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that 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, 480-6 40-200 5

SEN04520-01 Classification and procedures of troubleshooting
Phenomena looking like troubles and troubleshooting Nos.
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)]
40-200 6 WA470, 480-6

Classification and procedures of troubleshooting SEN04520-01
Phenomena related to brake

35 Wheel brake does not work or braking force is low H-15
36 Wheel brake is not reset or drags H-16
37 Parking brake does not work or braking force is low H-17
Parking brake does not reset or drags (including emergency release
38 H-18
system)
Phenomena related to work equipment
39 Lift arm does not rise H-19
40 Lift arm speed is low or rising force of lift arm is insufficient H-20
41 When lift arm rises, its speed lowers at specific height H-21
42 Bucket cannot be held with lift arm cylinder (Bucket floats) H-22
43 Hydraulic drift of lift arm is large H-23
44 Lift arm shakes during operation H-24
45 Bucket does not tilt-back H-25
46 Bucket speed is low or tilt-back force is insufficient H-26
47 Bucket speed lowers during tilt-back operation H-27
48 Bucket cannot be held with bucket cylinder H-28
49 Hydraulic drift of bucket is large H-29
Bucket shakes while machine is traveling with load (Work equipment
50 H-30
valve is in HOLD)
Lift arm and bucket control levers do not move smoothly and are
51 H-31
heavy
Engine speed lowers remarkably or engine stalls during work equip-
52 H-32
ment control
53 Large shock is made when work equipment starts and stops H-33
When work equipment is relieved singly, other work equipment
54 H-34
moves
55 ECSS does not operate, and pitching or bouncing occurs H-35
Others
56 Wiper does not operate E-2
57 Windshield washer does not operate. E-3
Headlamp, clearance lamp, tail lamp, and license lamp do not light up
58 E-4
or go off
59 Working lamp does not light up or go off E-5
60 Turn signal lamp and hazard lamp do not light up or go off E-6
61 Brake lamp does not light or it keeps lighting up E-7
62 Backup lamp does not light or it keeps lighting up E-8
63 Backup buzzer does not sound or it keeps sounding E-9
64 Horn does not sound or it keeps sounding E-10
65 Alarm buzzer does not sound or it keeps sounding E-11
66 Air conditioner does not operate or stop E-12
67 KOMTRAX system does not operate normally E-13
When kick-down switch is turned ON, kick-down operation does not
68 E-14
start
69 When hold switch is pressed, holding operation does not start E-15
Transmission is kept in neutral, or brake drags
70 E-16
when directional lever is operated while parking brake is applied
71 Transmission cut-off mode cannot be set or reset E-17
WA470, 480-6 40-200 7

SEN04520-01 Classification and procedures of troubleshooting
72 Transmission cut-off set cannot be reset E-18

73 FNR switch mode cannot be set or reset E-19
74 Fan reverse function cannot be used or reset E-20
75 Discharge from loader pump does not rise from minimum level E-21
76 ECSS function cannot be used or reset E-22
When parking brake is turned ON, parking brake indicator lamp does
77 E-23
not light up
When emergency brake operates, brake oil pressure caution lamp
78 E-24
does not operate
79 Air cleaner clogging indicator lamp does not light up E-25
80 Radiator coolant level caution lamp does not light up E-26
Hydraulic oil temperature gauge does not rise and hydraulic oil tem-
81 E-27
perature caution lamp does not light up
Torque converter oil temperature gauge does not rise and torque con-
82 E-28
verter oil temperature caution lamp does not light up
83 Steering oil pressure caution lamp does not light up E-29
84 Abnormality in t switch (panel switch 1) input E-30
40-200 8 WA470, 480-6

Information contained in troubleshooting table SEN04520-01
Information contained in troubleshooting table 1
Action code Failure code

Monitor Trouble Problem that appears on machine
Monitor display
display
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of Action taken by machine monitor or controller to protect system or devices when engine con-
controller troller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related
Information related to detected trouble or troubleshooting
information
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
• Standard value in normal state to judge assumed cause
(good or not)
1 • Remarks required to judge whether the cause is good
<Phenomenon of defective wiring harness>

• Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
• Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
• Hot short circuit
2 A harness not connected to the power (24 V) circuit comes
into contact with the power (24 V) circuit.
• Short circuit
Possible causes Possible causes of trouble A harnesses of an independent circuit abnormally comes
and standard is assumed to be detected into contact with one of another circuit.
value in normal (The order number indicates
state a serial number, not a priority <Notes on troubleshooting>
sequence.) (1) Method of indicating connector number and handling T-
branch
For troubleshooting, insert or connect T-branch adapter
3 as shown below unless especially specified.
• When “male” or “female” is not indicated for a con-
nector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
• When “male” and “female” is indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (–)
leads as shown below unless especially specified.
4 • Connect the plus (+) lead to a pin or harness indi-
cated in the front.
• Connect the minus (–) lead to a pin or harness indi-
cated in the rear.
WA470, 480-6 40-200 9

SEN04520-01 Information contained in troubleshooting table
Related circuit diagram
This is the excerpted circuit diagram related to trouble

• Connector No.: Indicates (Model – No. of pins) (Color)
• "Connector No. and pin No." from each branching/
merging point: Shows the ends of branch or source of
merging within the parts of the same wiring harness.
• Arrow (io): Roughly shows the location on the
machine.
40-200 10 WA470, 480-6

Connection table for connector pin numbers SEN04520-01
Connection table for connector pin numbers (Rev. 2009.04)
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, 480-6 40-200 11

SEN04520-01 Connection table for connector pin numbers
40-200 12 WA470, 480-6

WA470, 480-6 40-200 13

40-200 14 WA470, 480-6

WA470, 480-6 40-200 15

40-200 16 WA470, 480-6

WA470, 480-6 40-200 17

40-200 18 WA470, 480-6

WA470, 480-6 40-200 19

40-200 20 WA470, 480-6

WA470, 480-6 40-200 21

40-200 22 WA470, 480-6

WA470, 480-6 40-200 23

40-200 24 WA470, 480-6

WA470, 480-6 40-200 25

40-200 26 WA470, 480-6

WA470, 480-6 40-200 27

40-200 28 WA470, 480-6

WA470, 480-6 40-200 29

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T- branch box and T- branch adapter table SEN04520-01
T- branch box and T- branch adapter table (Rev. 2009.03)1
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
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
WA470, 480-6 40-200 47

SEN04520-01 T- branch box and T- branch adapter table
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

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 — q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 — q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
40-200 48 WA470, 480-6

T- branch box and T- branch adapter table SEN04520-01
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
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
799-601-4140 3 FCIG q q
Atomosphere pressure
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160 2 4160 q q
Oil pressure switch
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190* 3 1,2,3L q q
Commonrail pressure
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
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,
“*” Shows not T-adapter but socket.
WA470, 480-6 40-200 49

SEN04520-01

©2009 KOMATSU
All Rights Reserved
40-200 50
SEN04521-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
301 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
Failure code [2G43ZG] (Accumulator: Low oil pressure).............................................................................. 30
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) ......................................................... 32
WA470, 480-6 40-301 1

301 Troubleshooting by failure code (Display of code), Part 1
SEN04521-01
40-301 2 WA470, 480-6

Failure code [1500L0] (TORQFLOW transmission: Double meshing) SEN04521-01
Failure code [1500L0] (TORQFLOW transmission: Double meshing) 1
Action code Failure code TORQFLOW transmission: Double meshing

Trouble
E03 1500L0 (Transmission controller)
Contents of
• A combination for double meshing is input as a fill signal.
trouble
Action of • Turns the centralized warning lamp and alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
• The transmission may be broken.
appears on
• The machine does not travel.
machine
Related
• Method of reproducing failure code: Turn the starting switch ON.
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 See failure codes [15SAL1], [15SBL1], [15SEL1], [15SFL1], [15SGL1], and [15SHL1].
state
WA470, 480-6 40-301 3

SEN04521-01 Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
Failure code [15SAL1] (ECMV F clutch: When command current is OFF,

fill signal is ON) 1
Action code Failure code ECMV F clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SAL1 (Transmission controller)
Contents of • When F ECMV solenoid output is turned OFF, F ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the F ECMV fill switch signal is turned ON.
controller • 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 • F travel is enabled, but R travel is disabled.
machine
• The output state (current value) to the F clutch ECMV solenoid can be checked with the monitoring
function (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-24).
• Method of reproducing failure code: Start engine
Causes Standard value in normal state/Remarks on troubleshooting

When there is no residual pressure other than the F clutch oil pres-
1 F clutch oil pressure error sure, the failure code is displayed. (See Troubleshooting of hydrau-
lic and mechanical system (H-mode)
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
• Turn transmission cut-off switch OFF.
• Turn parking brake switch OFF.
• Keep pressing brake pedal to prevent machine from traveling.
FNR (directional)
Defective F ECMV fill switch lever, joystick steer-
2
(Internal short circuit) ing
F.SW (male) Resistance
FNR (directional)
switch or right FNR
(directional) switch
Between (1) and F (Forward) Max. 1 z
Possible causes
and standard chassis ground Other than above Min. 1 Mz
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Grounding fault in wiring har- without turning starting switch ON.
3 ness
(Contact with ground circuit) Wiring harness between L62 (female) (37) – Resis- Min.
F.SW (female) (1) and chassis ground tance 1 Mz
troubleshooting.
FNR (directional)
Defective transmission con- lever, joystick steer-
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (37) and F (Forward) Max. 1 V
chassis ground Other than above 8 – 10 V
40-301 4 WA470, 480-6

Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) SEN04521-01
WA470, 480-6 40-301 5

SEN04521-01 Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
Failure code [15SALH] (ECMV F clutch: When command current is ON,

fill signal is OFF) 1
Action code Failure code ECMV F clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SALH (Transmission controller)
Contents of
• When F ECMV solenoid output is turned ON, F ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the F ECMV fill switch signal is turned OFF.
controller • If problem is removed, system is returned to normal operating state.
Problem that
appears on • When the travel direction 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 F clutch ECMV solenoid can be checked with the monitoring
function (Code: 31608, ECMV F DIR).
Related
• The input state (ON/OFF) from the F fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-24).
• Method of reproducing failure code: Start engine and then set FNR (directional) lever, joystick steer-
ing FNR (directional) switch, or right FNR (directional) switch to F (forward).

This failure code is displayed if there was no F clutch oil pressure
1 F clutch oil pressure error when F ECMV solenoid output is turned ON. (See Troubleshooting
of hydraulic and mechanical system (H-mode))
troubleshooting.
FNR (directional)
Defective F ECMV fill switch lever, joystick steer-
2
(Internal disconnection) ing
F.SW (male) Resistance
FNR (directional)
switch or right FNR
Between (1) and F (Forward) Max. 1 z
Possible causes
value in normal Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
3
(Disconnection or defective Wiring harnesses between L62 (female) (37) Resis-
contact in connector) Max. 1 z
– F.SW (female) (1) tance
troubleshooting.
FNR (directional)
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (37) and F (Forward) Max. 1 V
40-301 6 WA470, 480-6

Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) SEN04521-01
WA470, 480-6 40-301 7

SEN04521-01 Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
Failure code [15SBL1] (ECMV R clutch: When command current is OFF,

fill signal is ON) 1
Action code Failure code ECMV R clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SBL1 (Transmission controller)
Contents of • When R ECMV solenoid output is turned OFF, R ECMV fill switch signal ON is input, and clutch is not
trouble released.
• Judges that the R ECMV fill switch signal is turned ON.
controller • Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
Problem that
appears on • The machine can travel in the R position, but cannot travel in the F position.
machine
• The output state (current value) to the R clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).

When there is no residual pressure other than the R clutch oil pres-
1 R clutch oil pressure error sure, the failure code is displayed. (See Troubleshooting of hydrau-
lic and mechanical system (H-mode))
troubleshooting.
FNR (directional)
Defective R ECMV fill switch lever, joystick steer-
2
R.SW (male) Resistance
FNR (directional)
switch or right FNR
Between (1) and R (Reverse) Max. 1 z
Possible causes
3 ness
R.SW (female) (1) and chassis ground tance 1 Mz
troubleshooting.
FNR (directional)
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (27) and R (Reverse) Max. 1 V
40-301 8 WA470, 480-6

Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) SEN04521-01
WA470, 480-6 40-301 9

SEN04521-01 Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
Failure code [15SBLH] (ECMV R clutch: When command current is ON,

Action code Failure code ECMV R clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SBLH (Transmission controller)
Contents of • When R ECMV solenoid output is turned ON, clutch does not mesh because R ECMV fill switch ON
trouble signal is not input and the condition requires to set the engine speed at 500 rpm or below.
Action of • Judges that the R ECMV fill switch signal is turned OFF.
Problem that
appears on • When the travel direction is changed, a shock or a time lag may be made.
machine
• This failure code may also be displayed immediately after replacement of the transmission oil.
• The output state (current value) to the R clutch ECMV solenoid can be checked with the monitoring
function (Code: 31606, ECMV R DIR).
Related
• The input state (ON/OFF) from the R fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-25).
• Method of reproducing failure code: Start engine, then set FNR (directional) lever, joystick steering
FNR (directional) switch, or right FNR (directional) switch to R (reverse).

This failure code is displayed if there was no R clutch oil pressure
R (Reverse) clutch oil pres-
1 when F ECMV solenoid output is turned ON. (See Troubleshooting
sure error
of hydraulic and mechanical system (H-mode)
troubleshooting.
FNR (directional)
Defective R ECMV fill switch lever, joystick steer-
2
R.SW (male) Resistance
FNR (directional)
switch or right FNR
Between (1) and R (Reverse) Max. 1 z
Possible causes
value in normal Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
3
– R.SW (female) (1) tance
troubleshooting.
FNR (directional)
4
troller ing
L62 Voltage
FNR (directional)
switch or right FNR
Between (27) and R (Reverse) Max. 1 V
40-301 10 WA470, 480-6

Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) SEN04521-01
WA470, 480-6 40-301 11

SEN04521-01 Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON)
Failure code [15SEL1] (ECMV 1st clutch: When command current is

OFF, fill signal is ON) 1
Action code Failure code ECMV 1st clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SEL1 (Transmission controller)
Contents of • When 1st ECMV solenoid output is turned OFF, 1st ECMV fill switch signal ON is input, and clutch is
trouble not released.
• Judges that the 1st ECMV fill switch signal is turned ON.
• Holds 2nd, 3rd, and 4th proportional solenoid outputs OFF.
Action of
• Turns the centralized warning lamp and alarm buzzer ON.
controller
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever, joystick
Problem that
appears on • The machine can travel at 1st, but not at 2nd, 3rd, and 4th.
machine
• 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).

When there is not residual pressure other than the 1st clutch oil
pressure, the failure code is displayed.
1 1st clutch oil pressure error
(See Troubleshooting of hydraulic and mechanical system (H-
mode)
troubleshooting.
Defective 1st ECMV fill
2 • Keep pressing brake pedal to prevent machine from traveling.
switch (Internal short circuit)
1.SW (male) Shift lever Resistance
Between (1) and 1st (1st speed) Max. 1 z
chassis ground Other than above Min. 1 Mz
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Grounding fault in wiring har- without turning starting switch ON.
value in normal 3 ness
state
1.SW (female) (1) and chassis ground tance 1 Mz
troubleshooting.
• Set the auto shift and manual shift selector switch in the MANUAL
Defective transmission con- position.
4
troller • Set FNR (directional) lever, joystick steering FNR
(directional) switch or right FNR (directional) switch to the F (for-
ward) or R (reverse) position.
L62 Shift lever Voltage
Between (17) and 1st (1st speed) Max. 1 V
40-301 12 WA470, 480-6

Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) SEN04521-01
WA470, 480-6 40-301 13

SEN04521-01 Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF)
Failure code [15SELH] (ECMV 1st clutch: When command current is ON,
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.
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
• The output state (current value) to the 1st clutch ECMV solenoid can be checked with the monitoring
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.

This failure code is displayed if 1st clutch oil pressure were absent
when 1st ECMV solenoid output is turned ON.
1 1st clutch oil pressure error
mode)
troubleshooting.
Defective 1st ECMV fill • Turn parking brake switch OFF.
2 switch (Internal disconnec- • Keep pressing brake pedal to prevent machine from traveling.
tion) 1.SW (male) Shift lever Resistance
Between (1) and 1st (1st speed) Max. 1 z
Possible causes Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
and standard ness without turning starting switch ON.
value in normal 3
state contact in connector) Max. 1 z
– 1.SW (female) (1) tance
troubleshooting.
4
Between (17) and 1st (1st speed) Max. 1 V
40-301 14 WA470, 480-6

Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) SEN04521-01
WA470, 480-6 40-301 15

SEN04521-01 Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON)
Failure code [15SFL1] (ECMV 2nd clutch: When command current is

Action code Failure code ECMV 2nd clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SFL1 (Transmission controller)
Contents of • When 2nd ECMV solenoid output is turned OFF, 2nd ECMV fill switch signal ON is input, and clutch
trouble is not released.
• Judges that the 2nd ECMV fill switch signal is turned ON.
• Holds 1st, 3rd, and 4th proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 2nd, but not at 1st, 3rd, and 4th.
machine
• The output state (current value) to the 2nd clutch ECMV solenoid can be checked with the monitor-
ing function (Code: 31603, ECMV 2 DIR).
Related
• The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-27).

When there is no residual pressure other than the 2nd clutch oil
1 2nd clutch oil pressure error
mode)
troubleshooting.
Defective 2nd ECMV fill
Between (1) and 2nd (2nd speed) Max. 1 z
state
troubleshooting.
4
Between (7) and 2nd (2nd speed) Max. 1 V
40-301 16 WA470, 480-6

Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) SEN04521-01
WA470, 480-6 40-301 17

SEN04521-01 Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF)
Failure code [15SFLH] (ECMV 2nd clutch: When command current is

ON, fill signal is OFF) 1
Action code Failure code ECMV 2nd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SFLH (Transmission controller)
Contents of
• When 2nd ECMV solenoid output turned ON, 2nd ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 2nd ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 2nd speed.
appears on
• When the 2nd gear speed is changed, a shock or a time lag may be made.
machine
• The output state (current value) to the 2nd clutch ECMV solenoid can be checked with the monitor-
ing function (Code: 31603, ECMV 2 DIR).
Related • The input state (ON/OFF) from the 2nd fill switch can be checked with the monitoring function (Code:
• Method of reproducing failure code: Start engine, set the manual/auto shift selector switch in the
(directional) switch to the F (forward), R (reverse), then set shift lever to 2nd speed position.

This failure code is displayed if 2nd clutch oil pressure were absent
when 2nd ECMV solenoid output is turned ON.
1 2nd clutch oil pressure error
mode)
troubleshooting.
Defective 2nd ECMV fill • Turn parking brake switch OFF.
Between (1) and 2nd (2nd speed) Max. 1 z
value in normal 3
– 2.SW (female) (1) and chassis ground tance
troubleshooting.
4
Between (7) and 2nd (2nd speed) Max. 1 V
40-301 18 WA470, 480-6

Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) SEN04521-01
WA470, 480-6 40-301 19

SEN04521-01 Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON)
Failure code [15SGL1] (ECMV 3rd clutch: When command current is

Action code Failure code ECMV 3rd clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SGL1 (Transmission controller)
Contents of • When 3rd ECMV solenoid output is turned OFF, 3rd ECMV fill switch signal ON is input, and clutch is
• Judges that the 3rd ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 4th proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 3rd, but not at 1st, 2nd, and 4th.
machine
• The output state (current value) to the 3rd clutch ECMV solenoid can be checked with the monitoring
Related
• The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-28).

When there is no residual pressure other than the 3rd clutch oil
1 3rd clutch oil pressure error
mode)
troubleshooting.
Defective 3rd ECMV fill
Between (1) and 3rd (3rd speed) Max. 1 z
state
troubleshooting.
4
Between (13) and 3rd (3rd speed) Max. 1 V
40-301 20 WA470, 480-6

Failure code [15SGL1] (ECMV 3rd clutch: When command current is OFF, fill signal is ON) SEN04521-01
WA470, 480-6 40-301 21

SEN04521-01 Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF)
Failure code [15SGLH] (ECMV 3rd clutch: When command current is

Action code Failure code ECMV 3rd clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SGLH (Transmission controller)
Contents of • When 3rd ECMV solenoid output is turned ON, clutch does not mesh because 3rd ECMV fill switch
trouble ON signal is not input and the condition requires to set the engine speed at 500 rpm or below.
Action of • Judges that the 3rd ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 3rd speed.
appears on
• When the 3rd gear speed is changed, a shock or a time lag may be made.
machine
• This code may also be displayed immensely after replacement of the transmission oil.
Related • The input state (ON/OFF) from the 3rd fill switch can be checked with the monitoring function (Code:
(directional) switch to the F (forward), R (reverse), and then set shift lever to 3rd speed position.

This failure code is displayed if 3rd clutch oil pressure were absent
when 3rd ECMV solenoid output is turned ON.
1 3rd clutch oil pressure error
mode)
troubleshooting.
Defective 3rd ECMV fill • Turn parking brake switch OFF.
Between (1) and 3rd (3rd speed) Max. 1 z
value in normal 3
troubleshooting.
4
Between (13) and 3rd (3rd speed) Max. 1 V
40-301 22 WA470, 480-6

Failure code [15SGLH] (ECMV 3rd clutch: When command current is ON, fill signal is OFF) SEN04521-01
WA470, 480-6 40-301 23

SEN04521-01 Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON)
Failure code [15SHL1] (ECMV 4th clutch: When command current is

Action code Failure code ECMV 4th clutch: When command current is OFF, fill signal is ON
Trouble
E03 15SHL1 (Transmission controller)
Contents of • When 4th ECMV solenoid output is turned OFF, 4th ECMV fill switch signal ON is input, and clutch is
• Judges that the 4th ECMV fill switch signal is turned ON.
• Holds 1st, 2nd, and 3rd proportional solenoid outputs OFF.
Action of
controller
Problem that
appears on • The machine can travel at 4th, but not at 1st, 2nd, and 3rd.
machine
• The output state (current) to the 4th clutch ECMV solenoid can be checked with the monitoring func-
tion (Code: 31605, ECMV 4 DIR).
Related
• The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
information
40908, D-IN-29).

When there is no residual pressure other than the 4th clutch oil
1 4th clutch oil pressure error
mode))
troubleshooting.
Defective 4th ECMV fill
Between (1) and 4th (4th speed) Max. 1 z
state
troubleshooting.
4
troller • Set FNR (directional) lever, joystick steering FNR (directional)
switch or right FNR (directional) switch to the F (forward) or R
(reverse) position.
Between (3) and 4th (4th speed) Max. 1 V
40-301 24 WA470, 480-6

Failure code [15SHL1] (ECMV 4th clutch: When command current is OFF, fill signal is ON) SEN04521-01
WA470, 480-6 40-301 25

SEN04521-01 Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF)
Failure code [15SHLH] (ECMV 4th clutch: When command current is

Action code Failure code ECMV 4th clutch: When command current is ON, fill signal is OFF
Trouble
E01 15SHLH (Transmission controller)
Contents of
• When 4th ECMV solenoid output is turned ON, 4th ECMV fill switch signal ON is not input.
trouble
Action of • Judges that the 4th ECMV fill switch signal is turned OFF.
Problem that
• The machine may not travel at 4th speed.
appears on
• When the 4th gear speed is changed, a shock or a time lag may be made.
machine
• This code may also be displayed immensely after replacement of the transmission oil.
• The output state (current value) to the 4th clutch ECMV solenoid can be checked with the monitoring
function (Code: 31605, ECMV 4).
Related • The input state (ON/OFF) from the 4th fill switch can be checked with the monitoring function (Code:
(directional) switch to the F (forward), R (reverse), then set shift lever to 4th speed position.

This failure code is displayed if 4th clutch oil pressure were absent
when 4th ECMV solenoid is turned ON.
1 4th clutch oil pressure error
mode))
troubleshooting.
Defective 4th ECMV fill • Turn parking brake switch OFF.
Between (1) and 4th (4th speed) Max. 1 z
value in normal 3
troubleshooting.
4
troller • Set FNR (directional) lever, joystick steering FNR (directional)
switch or right FNR (directional) switch to the F (forward) or R
(reverse) position.
Between (3) and 4th (4th speed) Max. 1 V
40-301 26 WA470, 480-6

Failure code [15SHLH] (ECMV 4th clutch: When command current is ON, fill signal is OFF) SEN04521-01
WA470, 480-6 40-301 27

SEN04521-01 Failure code [2F00MA] (Parking brake: Malfunction)
Failure code [2F00MA] (Parking brake: Malfunction) 1
Action code Failure code Parking brake: Malfunction

Trouble
E03 2F00MA (Machine monitor system)
Contents of
• While the F or R clutch is operated, the parking brake operation sensor circuit remains OPEN.
trouble
Problem that
appears on • Although the parking brake lamp is turned on, a gear speed other than neutral is actually selected.
machine
• This code may also be displayed if engine stalls or the emergency brake is operated while the
machine is traveling.
Related • The input state (ON/OFF) from the brake parking indicator switch can be checked with the monitor-
information ing function (Code: 40903, D-IN-26).
• Method of reproducing failure code: Turn the starting switch ON, parking brake operation switch
OFF, operate to forward and reverse.

Defective fuse No. 3 of fuse
1 If the fuse is burnt, the circuit probably has a grounding fault.
box 2
a Prepare with starting switch OFF, disconnect PB.SW connector
and then start the engine to carry out troubleshooting.
Defective parking brake indi-
2 cator switch PB.SW (male) Parking brake Resistance
(Internal disconnection) Released Max. 1 z
Between (1) and (2)
Operating Min. 1 Mz
and standard Disconnection in wiring har- without turning starting switch ON.
value in normal ness Wiring harness between L54 (female) (1) – Resis-
state 3 Max. 1 z
(Disconnection or defective PB.SW (female) (1) tance
contact) Wiring harness between PB.SW (female) (2) Resis-
Max. 1 z
– chassis ground tance
troubleshooting.
Parking brake oil
4 Defective machine monitor L54 Voltage
pressure
Between (1) and Released Max. 1 V
chassis ground Operating 20 – 30 V
40-301 28 WA470, 480-6

Failure code [2F00MA] (Parking brake: Malfunction) SEN04521-01
WA470, 480-6 40-301 29

SEN04521-01 Failure code [2G43ZG] (Accumulator: Low oil pressure)
Failure code [2G43ZG] (Accumulator: Low oil pressure) 1
Action code Failure code Accumulator: Low oil pressure

Trouble
E03 2G43ZG (Machine monitor system)
Contents of • After the engine is started, the brake accumulator pressure sensor circuit once reaches the specified
trouble pressure, then the circuit conditions turns to OPEN.
Problem that
• Low brake accumulator oil pressure
appears on
• The brake may not work.
machine
• The input state (ON/OFF) from the brake oil pressure sensor can be checked with the monitoring
Related
function (Code: 40902, D-IN-17).
information

box 2
Low brake accumulator oil Check the brake accumulator oil pressure.
2
pressure (See Testing and adjusting.)
troubleshooting.
Brake accumulator oil
R54 (Male) Resistance
pressure
Defective brake oil pressure
3 sensor Pressure normal
(Internal disconnection) Min. 5.88 MPa Max. 1 z
Min. {60 kg/cm2}
Between (1) and (2)
Low pressure
Max. 3.92 MPa Min. 1 Mz
Possible causes Max. {40 kg/cm2}
and standard
state Disconnection in wiring har- without turning starting switch ON.
ness Wiring harness from L53 (female) (7) to R54 Resis-
4 Max. 1 z
(Disconnection or defective (female) (1) tance
contact) Wiring harness from R54 (female) (2) to Resis-
Max. 1 z
chassis ground tance
a Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch ON.
Brake accumulator oil
L53 (female) Resistance
pressure
5 Defective machine monitor Pressure normal

Min. 5.88 MPa Max. 1 z
Wiring harnesses Min. {60 kg/cm2}
between (7) – chassis
ground Low pressure
Max. 3.92 MPa Min. 1 Mz
Max. {40 kg/cm2}
40-301 30 WA470, 480-6

Failure code [2G43ZG] (Accumulator: Low oil pressure) SEN04521-01
WA470, 480-6 40-301 31

SEN04521-01 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) 1
Action code Failure code Bucket positioner: ON/OFF signals disagree

Trouble
E01 44K0L4 (Work equipment controller system)
• The signals input from the bucket proximity switch are combined impossibly.
• After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, full stroke
Contents of signal ON was detected for one second.
trouble • After bucket level-over signal ON and full stroke signal OFF were continued for 3 seconds, bucket
level-over signal OFF was detected for one second.
• If problem is removed, system is returned to normal operating state.
Action of
• Judged to be below bucket level.
controller
Problem that
appears on • Bucket lever does not function
machine
• Only for electric lever (If equipped)
• The input state (ON/OFF) from the bucket cylinder full stroke proximity switch can be checked with
the monitoring function (Code: 40911, D-IN-8).
Related
• The input state (ON/OFF) from the bucket cylinder level proximity switch can be checked with the
information
monitoring function (Code: 40911, D-IN-9).
• Method of reproducing failure code: Start engine, then drive the bucket slowly between the full tilt
and full dump position.

box 2
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
Defective bucket cylinder
level proximity switch F09 Position of bucket Voltage
2
(Internal disconnection or Between (A) and (C) Constant 20 – 30 V
short circuit) Below horizontal Max. 1 V
Between (B) and (C)
Above horizontal 8 – 10 V
Possible causes and carry out troubleshooting.
and standard Defective bucket cylinder full F19 Position of bucket Voltage
value in normal stroke proximity switch
3 Between (A) and (C) Constant 20 – 30 V
state (Internal disconnection or
short circuit) Tilt full stroke 8 – 10 V
Between (B) and (C) Other than tilt full
Max. 1 V
stroke
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
4
(Disconnection or defective Wiring harness between F19 (female) (B) – Resis-
L73 (female) (10) tance
Grounding fault in wiring har- without turning starting switch ON.
5 ness
(Contact with ground circuit) Wiring harness between F09 (female) (B) – Resis-
Min. 1 Mz
L73 (female) (20) and chassis ground tance
40-301 32 WA470, 480-6

Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) SEN04521-01

Possible causes L73 Position of bucket Voltage
and standard
Defective work equipment Between (20) and Below horizontal Max. 1 V
value in normal 6
state controller chassis ground Above horizontal 8 – 10 V
Tilt full stroke 8 – 10 V
Between (10) and
chassis ground Other than tilt full
Max. 1 V
stroke
WA470, 480-6 40-301 33

SEN04521-01 Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
40-301 34 WA470, 480-6

Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree) SEN04521-01
WA470, 480-6 40-301 35

SEN04521-01

©2009 KOMATSU
All Rights Reserved
40-301 36
SEN04522-00
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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
WA470, 480-6 40-302 1

SEN04522-00
Failure code [CA153] (Charge temperature sensor high error)..................................................................... 46

Failure code [CA154] (Charge temperature sensor low error) ...................................................................... 48
Failure code [CA221] (Atmospheric pressure sensor high error).................................................................. 51
Failure code [CA222] (Atmospheric pressure sensor low error) ................................................................... 53
Failure code [CA234] (Engine overspeed) .................................................................................................... 56
Failure code [CA238] (Ne speed sensor power supply error) ....................................................................... 58
40-302 2 WA470, 480-6

SEN04522-00
WA470, 480-6 40-302 3

SEN04522-00 Failure code [AA1ANX] (Air cleaner: Clogging)
Failure code [AA1ANX] (Air cleaner: Clogging) 1
Action code Failure code Air cleaner: Clogging

Trouble
E01 AA1ANX (Machine monitor system)
Contents of
• When the engine is started, the air cleaner clogging sensor circuit is OPEN.
trouble
Action of • Turns the air cleaner clogging caution lamp ON.
Problem that
• The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is
appears on
black.
machine
• The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
Related
information

Defective fuse No. 5, 10 of
fuse box 2
2 Clogged air cleaner The air cleaner may be clogged. Check it directly.
Defective dust indicator troubleshooting.
3
(Internal short circuit) Replace the dust If the condition becomes normal, the trouble
indicator is attributable to defective indicator.
L112 (Male) Resistance
Defective dust indicator relay
Between (1) and (2) 200 – 400 z
(L112)
4 a Prepare with starting switch OFF, then start engine and carry out
(Internal disconnection or
short circuit) troubleshooting.
When dust indicator relay (L112) is replaced with a relay of the
Possible causes same type (5-pin type), if the condition becomes normal, the
and standard exchange relay is defective.
state without turning starting switch ON.
Disconnection in wiring har-
ness Wiring harnesses between L112 (female) Resis-
5 Max. 1 z
(Disconnection or defective (2) – E45 (female) (1) tance
contact in connector) Wiring harnesses between E45 (female) (2) Resis-
Max. 1 z
6 ness
(Contact with ground circuit) Wiring harness between L112 (female) (2) Resis-
Min. 1 Mz
– E45 (female) (1) and chassis ground tance
troubleshooting.
L53 Dust indicator Voltage
7 Defective machine monitor Normal (Air cleaner is
20 – 30 V
Between (3) and normal)
chassis ground Defective (Air cleaner
Max. 1 V
is clogged)
40-302 4 WA470, 480-6

Failure code [AA1ANX] (Air cleaner: Clogging) SEN04522-00
WA470, 480-6 40-302 5

SEN04522-00 Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)
Failure code [AB00L6] (Alternator: Signal disagrees with operating state

of engine) 1
Action code Failure code Alternator: Signal disagrees with operating state of engine
Trouble
E03 AB00L6 (Machine monitor system)
Contents of
• When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
• Turns the charge circuit error caution lamp ON.
Action of
controller
Problem that
appears on • After the engine is started, just turning on the starting switch runs the service meter.
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

troubleshooting.
Alternator Engine Voltage
Defective alternator
1 Wiring harness Running (Throttle:
(Internal trouble) 27.5 – 29.5 V
between terminal R Above 1/2)
(E02) – chassis
ground Holds in position Max. 1 V
Possible causes
and standard a Prepare with starting switch OFF, then turn starting switch ON
value in normal Hot short in wiring harness and carry out troubleshooting.
2
state (Contact with 24V circuit) Wiring harnesses between terminal R (E02)
Voltage Max. 1 V
– L52 (female) (18), – circuit branch end
troubleshooting.
L52 Engine Voltage
3 Defective machine monitor
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
chassis ground
Holds in position Max. 1 V
40-302 6 WA470, 480-6

Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine) SEN04522-00
WA470, 480-6 40-302 7

SEN04522-00 Failure code [AB00MA] (Alternator: Malfunction)
Failure code [AB00MA] (Alternator: Malfunction) 1
Action code Failure code Alternator: Malfunction

Trouble
E03 AB00MA (Machine monitor system)
Contents of
• While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
• Turns the charge circuit failure caution lamp ON.
Action of
controller
• If problem is removed (min. 1 V), system is returned to normal operating state.
Problem that
appears on • Deterioration of battery or insufficient charging
machine
• The input state (voltage) from the alternator can be checked with the monitoring function (Code:
Related
04302, ALTERNATOR R).
information

1 The battery is deteriorated. The battery may be deteriorated. Check it directly.
troubleshooting.
Alternator Engine Voltage
Defective alternator
2 Wiring harness Running (Throttle:
(Internal trouble) 27.5 – 29.5 V
between terminal R Above 1/2)
(E02) – chassis
ground Holds in position Max. 1 V
Possible causes ness without turning starting switch ON.
3
and standard (Disconnection or defective Wiring harnesses between terminal R (E02) Resis-
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
troubleshooting.
L52 Engine Voltage
Running (Throttle:
Between (18) and 27.5 – 29.5 V
Above 1/2)
chassis ground
Holds in position Max. 1 V
40-302 8 WA470, 480-6

Failure code [AB00MA] (Alternator: Malfunction) SEN04522-00
WA470, 480-6 40-302 9

SEN04522-00 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)
Failure code [B@BAZG] (Rotation derating by low engine oil pressure) 1
Action code Failure code Rotation derating by low engine oil pressure
Trouble
E03 B@BAZG (Engine controller system)
Contents of
• While engine was operating, engine oil pressure became lower than operating range.
trouble
Action of • Limit output for travel (Limit injection rate and engine speed)
controller • Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on • Engine output lowers.
machine
• The input state (oil pressure) from the engine oil pressure sensor can be checked with the monitoring
function (Code: 37200 ENG OIL PRESS).
Related
• The input state (voltage) from the engine oil pressure sensor can be checked with the monitoring
information
• Method of reproducing failure code: Start engine.

Engine oil pressure Check the oil pressure.
1
abnormally low (Refer to "Testing and adjusting")
Defective sensor power sup- If failure code [CA187] or [CA227] is displayed, carry out trouble-
2
ply system shooting for it first.
a Prepare with starting switch OFF, then turn starting switch ON or
start engine and carry out troubleshooting.
POIL Voltage
Defective oil pressure sensor
3 Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment.
Disconnection in wiring Wiring harness between EC1 (female) (37) – Resis-
Possible causes Max. 1 z
harness (Disconnection in POIL (female) (1) tance
and standard 4
wiring or defective contact in Wiring harness between EC1 (female) (47) – Resis-
value in normal
connector) Max. 1 z
state POIL (female) (2) tance
Wiring harness between EC1 (female) (13) – Resis-
Max. 1 z
POIL (female) (3) tance
Ground fault in wiring Min. 1 Mz
POIL (female) (1) and chassis ground tance
5 harness (Short circuit with
GND circuit) Wiring harness between EC1 (female) (47) – Resis-
Min. 1 Mz
Min. 1 Mz
6 Defective engine controller EC1 Voltage
Between
Power supply 4.75 – 5.25 V
(37) and (47)
40-302 10 WA470, 480-6

Failure code [B@BAZG] (Rotation derating by low engine oil pressure) SEN04522-00
WA470, 480-6 40-302 11

SEN04522-00 Failure code [B@BAZG] (Rotation derating by low engine oil pressure)
40-302 12 WA470, 480-6

Failure code [B@BAZK] (Engine oil: Low level) SEN04522-00
Failure code [B@BAZK] (Engine oil: Low level) 1
Action code Failure code Engine oil: Low level

Trouble
E01 B@BAZK (Machine monitor system)
• While engine is stopped, the engine oil level sensor circuit was detected to have remained in OPEN
condition for more than 2 seconds.
Contents of
(This error, however, is not detected for 5 minutes from the engine stop)
trouble
• An error being detected at stopping the engine remains as the error after the engine is started again
until the normal condition is recovered.
Action of • Turns the engine oil level caution lamp ON.
Problem that
appears on • The engine oil level is low (The engine may be broken).
machine
• The input state (ON/OFF) from the engine level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-29).
information

1 Low engine oil level The engine oil level may be low. Check it directly.
Defective engine oil level E26 (male) Engine oil level Resistance
2 sensor
(Internal disconnection) Oil level is normal Max. 1 z
Between (1) and
chassis ground Oil level is insuffi-
Min. 1 Mz
Possible causes cient (low level)
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
value in normal ness without turning starting switch ON.
state 3
contact) Max. 1 z
– E26 (female) (1) tance
L54 (female) Engine oil level Resistance
Wiring harness Oil level is normal Max. 1 z
between (11) – chas- Oil level is insuffi-
sis ground Min. 1 Mz
cient (low level)
WA470, 480-6 40-302 13

SEN04522-00 Failure code [B@BCNS] (Coolant: Overheating)
Failure code [B@BCNS] (Coolant: Overheating) 1
Action code Failure code Coolant: Overheating

Trouble
E02 B@BCNS (Engine controller system)
Contents of
• While the engine is run, the engine coolant temperature exceeded the operating range.
trouble
Action of • Limits output and continues operation.
Problem that
machine
• The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: 04104, COOLANT TEMP).
• The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
Related
toring function (Code: 04105, COOLANT TEMP).
information
• if failure code [CA144] (Engine coolant temperature sensor high error) or [CA145] (Engine coolant
temperature sensor high error) is indicated, carry out troubleshooting for it first.

Engine coolant overheat Overheating of engine coolant can be suspected. Check the tem-
1
(When the system is normal) perature to locate and eliminate the cause.
TWTR (male) Temperature Resistance
Defective coolant tempera- 0°C 30 – 37 kz
2 ture sensor
25°C 9.3 – 10.7 kz
(Internal trouble)
Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Possible causes
and standard
Disconnection in wiring har- without turning starting switch ON.
value in normal
state ness Wiring harness between EC1 (female) (15) – Resis-
3 Max. 1 z
(Disconnection or defective TWTR (female) (B) tance
contact in connector) Wiring harness between TWTR (female) (A) Resis-
Max. 1 z
– EC1 (female) (38) tance
EC1 (male) Temperature Resistance
0°C 30 – 37 kz
4 Defective engine controller
25°C 9.3 – 10.7 kz
Between (15) and
50°C 3.2 – 3.8 kz
(38)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
40-302 14 WA470, 480-6

Failure code [B@BCNS] (Coolant: Overheating) SEN04522-00
WA470, 480-6 40-302 15

SEN04522-00 Failure code [B@BCZK] (Coolant: Low level)
Failure code [B@BCZK] (Coolant: Low level) 1
Action code Failure code Coolant: Low level

Trouble
E01 B@BCZK (Machine monitor system)
Contents of
• The coolant level sensor circuit is OPEN (circuit was in this condition for 30 seconds)
trouble
Action of • Turns the coolant level caution lamp ON.
Problem that
appears on • The coolant level is low. The engine overheats (The engine may be broken).
machine
• The input state (ON/OFF) from the coolant level sensor can be checked with the monitoring function
Related
(Code: 40903, D-IN-27).
information

1 Low coolant level The coolant level may be low. Check it directly.
R32 (Male) Sub-tank Resistance
Defective coolant level sen-
2 Below LOW level
sor (Internal short circuit) Max. 1 z
(Abnormal)
Between (1) and (2)
Above LOW level
Min. 1 Mz
(Normal)
and standard Disconnection in wiring har- without turning starting switch ON.
value in normal ness Wiring harness between L54 (female) (10) – Resis-
state 3 Max. 1 z
(Disconnection or defective R32 (female) (1) tance
contact) Wiring harness from R32 (female) (2) and Resis-
Max. 1 z
L54 (female) Sub-tank Resistance
4 Defective machine monitor Below LOW level
Wiring harness Max. 1 z
(Abnormal)
between (10) – chas-
sis ground Above LOW level
Min. 1 Mz
(Normal)
40-302 16 WA470, 480-6

Failure code [B@BCZK] (Coolant: Low level) SEN04522-00
WA470, 480-6 40-302 17

SEN04522-00 Failure code [B@C7NS] (Brake oil: Overheating)
Failure code [B@C7NS] (Brake oil: Overheating) 1
Action code Failure code Brake oil: Overheating

Trouble
E02 B@C7NS (Machine monitor system)
• Brake oil temperature was above 130°C for 5 seconds.
Contents of
• When travel speed was above 35 km/h, brake oil temperature, 125°C and above, was detected con-
trouble
tinuously for 5 seconds.
Problem that
• Brake oil temperature caution lamp lights up.
appears on
• The brake may be damaged.
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).

Brake may overheat because brake was operated improperly during
1 Defective brake operation travel.
• Instruct the operator on the correct way of operating the brake.
Defective rear brake oil tem- Rear brake oil tem-
2 perature sensor (Internal perature
Possible causes
and standard defect) 25°C (Normal tem-
35 – 50 kz
value in normal Between (1) and (2) perature)
state 100°C 3.1 – 4.5 kz
Rear brake oil tem-
L55 Voltage
3 Defective machine monitor perature
Wiring harnesses 25°C (Normal tem-
4.4 – 4.6 V
between (8) – chassis perature)
ground 100°C 2.1 – 2.3 V
40-302 18 WA470, 480-6

Failure code [B@C7NS] (Brake oil: Overheating) SEN04522-00
WA470, 480-6 40-302 19

SEN04522-00 Failure code [b@CENS] (Torque converter oil: Overheating)
Failure code [b@CENS] (Torque converter oil: Overheating) 1
Action code Failure code Torque converter oil: Overheating

Trouble
E02 b@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 120°C.
trouble
Action of • If cause of failure disappears, system resets itself. (120°C and below was detected continuously for 1
controller second.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
• The input state (oil temperature) from the torque converter oil temperature sensor can be checked
with the monitoring function (Code: 40100, TC OIL TEMP).
Related
• The input state (voltage) from the torque converter oil temperature sensor can be checked with the
information
monitoring function (Code: 40101, TC OIL TEMP).

Torque converter oil may overheat due to torque converter stall, etc.
Overheating of torque con-
1 (See Troubleshooting of hydraulic and mechanical system (H-
verter oil
mode).)
Defective torque converter Torque converter oil
TC.T (male) Resistance
2 oil temperature sensor (Inter- temperature
Possible causes
and standard nal defect) 25°C (Normal tem-
35 – 50 kz
state 100°C 3.1 – 4.5 kz
L55 Voltage
3 Defective machine monitor temperature
25°C (Normal tem-
Between (2) and 4.4 – 4.6 V
perature)
chassis ground
100°C 2.1 – 2.3V
40-302 20 WA470, 480-6

Failure code [b@CENS] (Torque converter oil: Overheating) SEN04522-00
WA470, 480-6 40-302 21

SEN04522-00 Failure code [B@CENS] (Torque converter oil: Overheating)
Failure code [B@CENS] (Torque converter oil: Overheating) 1
Action code Failure code Torque converter oil: Overheating

Trouble
E02 B@CENS (Machine monitor system)
Contents of
• The torque converter oil temperature is above 130°C.
trouble
Action of
• If cause of failure disappears, system resets itself. (130°C and below was detected continuously for 1
controller
second.)
Problem that
• The torque converter oil temperature caution lamp is turned ON (If the machine is used as it is, the
appears on
torque converter may be broken).
machine
Related
information

Torque converter oil may overheat due to torque converter stall, etc.
Overheating of torque con-
1 (See Troubleshooting of hydraulic and mechanical system (H-
verter oil
mode).)
2 oil temperature sensor (Inter- temperature
Possible causes
and standard nal defect) 25°C (Normal tem-
35 – 50 kz
state 100°C 3.1 – 4.5 kz
L55 Voltage
25°C (Normal tem-
Between (2) and 4.4 – 4.6 V
perature)
chassis ground
100°C 2.1 – 2.3 V
40-302 22 WA470, 480-6

Failure code [B@CENS] (Torque converter oil: Overheating) SEN04522-00
WA470, 480-6 40-302 23

SEN04522-00 Failure code [B@HANS] (Hydraulic oil: Overheating)
Failure code [B@HANS] (Hydraulic oil: Overheating) 1
Action code Failure code Hydraulic oil: Overheating

Trouble
E02 B@HANS (Machine monitor system)
Contents of
• The hydraulic oil temperature is above 100°C (this level was detected for 10 seconds)
trouble
Problem that
• The hydraulic oil overheat warning is turned ON (If the machine is used as it is, the pump and cylin-
appears on
der seals may be broken).
machine
• The input state (oil temperature) from the hydraulic oil temperature sensor can be checked with the
monitoring function (Code: 04401, HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404, HYD TEMP).

1 Overheating of hydraulic oil The hydraulic oil may be overheating.
Defective hydraulic oil tem- Hydraulic oil tempera-
2 perature sensor ture
Possible causes (Internal trouble) 25°C (Normal tem-
35 – 50 kz
and standard Between (1) and (2) perature)
value in normal 100°C 3.1 – 4.5 kz
state
Hydraulic oil tempera-
L55 Voltage
3 Defective machine monitor ture
Wiring harnesses 25°C (Normal tem-
4.4 – 4.6 V
between (7) – chassis perature)
ground 100°C 2.1 – 2.3 V
40-302 24 WA470, 480-6

Failure code [B@HANS] (Hydraulic oil: Overheating) SEN04522-00
WA470, 480-6 40-302 25

SEN04522-00 Failure code [CA111] (Abnormality in engine controller)
Failure code [CA111] (Abnormality in engine controller) 1
Action code Failure code Abnormality in engine controller

Trouble
E03 CA111 (Engine controller system)
Contents of
• Internal defect occurred in controller.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
• Method of reproducing failure code: Turn starting switch ON.
information

Defective fuse No. 6 of fuse If the fuse is burnt, the circuit probably has a grounding fault.
1
box 1 (See cause 6.)
L171 (male) Resistance
Defective engine control cut Between (1) and (2) 200 – 400 z
2 relay (L171) (Internal discon- a Prepare with starting switch OFF, then turn starting switch ON
nection or short circuit) and carry out troubleshooting.
When engine control cut relay (L171) is replaced with a relay of the
same type, if the condition becomes normal, engine control cut relay
(L171) is defective.
and standard without turning starting switch ON.
value in normal L172 (male) Resistance
state
Defective engine control cut Between (1) and (2) 200 – 400 z
3 relay (L172) (Internal discon- a Prepare with starting switch OFF, then turn starting switch ON
nection or short circuit) and carry out troubleshooting.
When engine control cut relay (L172) is replaced with a relay of the
same type, if the condition becomes normal, engine control cut relay
(L172) is defective.
D11, D12 (male) Diode range Continuity
Defective diode (D11, D12)
4 Between D11 Measure at (2) in
(Internal disconnection)
(1) and (2) diode range.
Continue
Between D12 Measure at (2) in
(1) and (2) diode range.
40-302 26 WA470, 480-6

Failure code [CA111] (Abnormality in engine controller) SEN04522-00

Disconnection in wiring Wiring harness between fuse No. 6 of fuse Resis-
Max. 1 z
harness (Disconnection in box 1 – L171 or L172 (female) (3) tance
5
wiring or defective contact in Wiring harness between L171 (female) (5), Resis-
connector) Max. 1 z
L172 (female) (5) – EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), Resis-
Max. 1 z
(2) – chassis ground tance
Possible causes
and standard
value in normal
state Wiring harness between fuse No. 6 of fuse
Ground fault in wiring Resis-
box 1 – L171, L172 (female) (3) and chassis Min. 1 Mz
6 harness (Short circuit with tance
ground
GND circuit)
Wiring harness between L171 (female) (5),
Resis-
L172 (female) (5) – EC3 (female) (3), (4) and Min. 1 Mz
tance
chassis ground
EC3 Voltage
Between (1), (2) – (3), (4) 20 – 30 V
WA470, 480-6 40-302 27

SEN04522-00 Failure code [CA111] (Abnormality in engine controller)
40-302 28 WA470, 480-6

Failure code [CA115] (Engine Ne or Bkup speed sensor error) SEN04522-00
Failure code [CA115] (Engine Ne or Bkup speed sensor error) 1
Action code Failure code Engine Ne or Bkup speed sensor error

Trouble
Contents of
• Abnormality occurred in Ne and Bkup speed sensor circuits at the same time.
trouble
Action of • Stop the engine.
Problem that
• The engine does not start. (if engine has been stopped.)
appears on
• Engine stops. (if engine has been running.)
machine
Related
information

Defective Ne speed sensor
1 Carry out troubleshooting for failure code [CA689].
system
Defective Bkup speed sensor
2 Carry out troubleshooting for failure code [CA778].
system
Ne speed sensor may be installed defectively. Check it directly.
Defective installation of Ne
Possible causes 3 (Defective installation of sensor itself, internal defect of flywheel,
speed sensor
and standard etc.)
value in normal Bkup speed sensor may be installed defectively. Check it directly.
state Defective installation of Bkup
4 (Defective installation of sensor itself, internal defect of supply
speed sensor
pump, etc.)
Defective sensor connection Ne and Bkup speed sensors may be connected defectively
5
(Improper connection) (improper connection). Check them directly.
If causes 1 – 5 are not the cause of the trouble, the engine control-
6 Defective engine controller ler may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)
WA470, 480-6 40-302 29

SEN04522-00 Failure code [CA122] (Charge pressure sensor high error)
Failure code [CA122] (Charge pressure sensor high error) 1
Action code Failure code Charge pressure sensor high error

Trouble
Contents of
• High voltage is detected in charge pressure sensor (boost pressure sensor) circuit.
trouble
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
Action of
tion.
controller
Problem that
appears on • Engine does not accelerate smoothly.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502 CHG PRESS-A).

Defective power supply sys-
If failure code [CA187] or [CA227] is displayed, carry out trouble-
1 tem of charge pressure sen-
shooting for it first.
sor (boost pressure sensor)
Defective charge pressure PIM Voltage
2 sensor (boost pressure sen- Between (1) and (3) Power supply 4.75 – 5.25 V
sor) (Internal defect)
Charge pressure sensor voltage is measured with wiring harness
connected. Accordingly, if voltage is abnormal, check wiring harness
and controller for another cause of trouble before judgment.
Possible causes without turning starting switch ON.
and standard
value in normal Max. 1 z
state harness (Disconnection in PIM (female) (1) tance
3
connector) Max. 1 z
PIM (female) (2) tance
Max. 1 z
PIM (female) (3) tance
PIM (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
40-302 30 WA470, 480-6

Failure code [CA122] (Charge pressure sensor high error) SEN04522-00

Wiring harness between EC1 (female) (37) –
Resis-
PIM (female) (1) and between EC1 (female) Min. 1 Mz
tance
Short circuit in wiring (47) – PIM (female) (2)
5 harness (with another wiring Wiring harness between EC1 (female) (37) –
Possible causes harness) Resis-
and standard tance
(44) – PIM (female) (3)
value in normal
state Wiring harness between EC1 (female) (47) –
Resis-
tance
(44) – PIM (female) (3)
Between
(37) and (47)
WA470, 480-6 40-302 31

SEN04522-00 Failure code [CA123] (Charge pressure sensor low error)
Failure code [CA123] (Charge pressure sensor low error) 1
Action code Failure code Charge pressure sensor low error

Trouble
Contents of
• Low voltage is detected in charge pressure sensor (boost pressure sensor) circuit.
trouble
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2}), and continues opera-
Action of
tion.
controller
Problem that
appears on • Engine does not accelerate smoothly.
machine
• The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: 36500 CHG PRESS-A).
Related
• The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: 36502 CHG PRESS-A).
Possible causes Cause Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Carry out troubleshooting for failure code [CA122].
state
40-302 32 WA470, 480-6

Failure code [CA123] (Charge pressure sensor low error) SEN04522-00
WA470, 480-6 40-302 33

SEN04522-00 Failure code [CA131] (Throttle sensor high error)
Failure code [CA131] (Throttle sensor high error) 1
Action code Failure code Throttle sensor high error

Trouble
Contents of
• High voltage was detected in the throttle sensor signal circuit.
trouble
Action of • Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem that
appears on • The engine does not reach full throttle.
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD Accelerator pedal Voltage
All range (Power sup-
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal ply)
2
(Internal trouble) When released 0.50 – 0.80 V
Between (2) and (3)
When pressed 3.70 – 4.00 V
Hot short (Short circuit with and carry out troubleshooting.
3 5V, 24V circuit) in wiring har-
Possible causes Wiring harness between EC2 (female) (9) –
ness Voltage Max. 1 V
and standard PD (female) (2) and chassis ground
value in normal
state
Short circuit in wiring har- without turning starting switch ON.
4 ness Wiring harness between EC2 (female) (9) –
(with another wiring harness) PD (female) (2), EC2 (female) (22) – PD Resis-
Min. 1 Mz
tance
(female) (1)
Connecting parts among fuel control dial, engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
5 • 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
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 – 5.25 V
(23) (Power supply)
When released 0.50 – 0.80 V
Between (9) and (23)
40-302 34 WA470, 480-6

Failure code [CA131] (Throttle sensor high error) SEN04522-00
WA470, 480-6 40-302 35

SEN04522-00 Failure code [CA132] (Throttle sensor low error)
Failure code [CA132] (Throttle sensor low error) 1
Action code Failure code Throttle sensor low error

Trouble
Contents of
• Low voltage was detected in the throttle sensor signal circuit.
trouble
Problem that
machine
• The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: 31701, THROTTLE POS).
Related
• The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2186] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD Accelerator pedal Voltage
All range (Power sup-
Between (1) and (3) 4.75 – 5.25 V
Defective accelerator pedal ply)
2
(Internal trouble) When released 0.50 – 0.80 V
Between (2) and (3)
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
3
Possible causes (Short circuit with ground cir- Wiring harness between EC2 (female) (9) – Resis-
and standard cuit) Min. 1 Mz
PD (female) (2) and chassis ground tance
value in normal
state
4 ness Wiring harness between EC2 (female) (9) –
(with another wiring harness) PD (female) (2), PD (female) (23) – PD Resis-
Min. 1 Mz
tance
(female) (3)
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range (Power sup-
4.75 – 5.25 V
(23) ply)
When released 0.50 – 0.80 V
40-302 36 WA470, 480-6

Failure code [CA132] (Throttle sensor low error) SEN04522-00
WA470, 480-6 40-302 37

SEN04522-00 Failure code [CA135] (Engine oil pressure sensor high error)
Failure code [CA135] (Engine oil pressure sensor high error) 1
Action code Failure code Engine oil pressure sensor high error
Trouble
Contents of
• High voltage is detected in engine oil pressure sensor circuit.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on —
machine
Related
information

Defective power supply
If failure code [CA187] or [CA227] is also indicated, carry out trou-
1 system of engine oil pressure
bleshooting for it first.
sensor
POIL Voltage
Defective engine oil pressure
sensor (Internal defect)
and standard
state harness (Disconnection in POIL (female) (1) tance
3
connector) Max. 1 z
Max. 1 z
Min. 1 Mz
Min. 1 Mz
40-302 38 WA470, 480-6

Failure code [CA135] (Engine oil pressure sensor high error) SEN04522-00

Resis-
POIL (female) (1) and between EC1 (female) Min. 1 Mz
tance
Short circuit in wiring (47) – POIL (female) (2)
and standard tance
(13) – POIL (female) (3)
value in normal
Resis-
tance
(13) – POIL (female) (3)
Between
(37) and (47)
WA470, 480-6 40-302 39

SEN04522-00 Failure code [CA141] (Engine oil pressure sensor low error)
Failure code [CA141] (Engine oil pressure sensor low error) 1
Action code Failure code Engine oil pressure sensor low error
Trouble
Contents of
• Low voltage is detected in engine oil pressure sensor circuit.
trouble
Action of
• Sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues operation.
controller
Problem that
appears on —
machine
Related
information

and standard
state
40-302 40 WA470, 480-6

Failure code [CA141] (Engine oil pressure sensor low error) SEN04522-00
WA470, 480-6 40-302 41

SEN04522-00 Failure code [CA144] (Coolant sensor high error)
Failure code [CA144] (Coolant sensor high error) 1
Action code Failure code Coolant sensor high error

Trouble
Contents of
• High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature (at 90°C) and continues operation.
controller
Problem that
• Exhaust smoke becomes white.
appears on
• Overheat prevention function does not function.
machine
Related
information

Defective coolant tempera- 0°C 30 – 37 kz
1 ture sensor
25°C 9.3 – 10.7 kz
(Internal trouble)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
ness Wiring harness between EC1 (female) (15) – Resis-
2 Max. 1 z
(Disconnection or defective TWTR (female) (A) tance
contact in connector) Wiring harness between EC1 (female) (38) – Resis-
Max. 1 z
TWTR (female) (B) tance
value in normal Short circuit in wiring har-
state 3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) – EC1 (female) Resis-
Min. 1 Mz
(With all connectors of wiring harness distance
connected)
Connecting parts among coolant temperature sensor, engine wiring
harness, and engine controller are suspected. Inspect them directly.
connector
EC1 (female) Temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
Between (15) and
50°C 3.2 – 3.8 kz
(38)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
40-302 42 WA470, 480-6

Failure code [CA144] (Coolant sensor high error) SEN04522-00
WA470, 480-6 40-302 43

SEN04522-00 Failure code [CA145] (Coolant sensor low error)
Failure code [CA145] (Coolant sensor low error) 1
Action code Failure code Coolant sensor low error

Trouble
Contents of
• Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
• Fixes engine coolant temperature (at 90°C) and continues operation.
controller
Problem that
appears on
• Overheat prevention function does not function.
machine
Related
information

0°C 30 – 37 kz
Defective coolant tempera- 25°C 9.3 – 10.7 kz
1 ture sensor
(Internal trouble) Between (A) and (B) 50°C 3.2 – 3.8 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Between (B) and
All range Min. 1 Mz
chassis ground
2
(Short circuit with ground cir- Wiring harness between EC1 (female) (15) – Resis-
cuit) Min. 1 Mz
TWTR (female) (A) and chassis ground tance
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
connector
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
40-302 44 WA470, 480-6

Failure code [CA145] (Coolant sensor low error) SEN04522-00
WA470, 480-6 40-302 45

SEN04522-00 Failure code [CA153] (Charge temperature sensor high error)
Failure code [CA153] (Charge temperature sensor high error) 1
Action code Failure code Charge temperature sensor high error

Trouble
Contents of • High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature (boost temperature) at 70°C and continues operation.
controller
Problem that
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501, CHG TEMP).

Defective [temperature sig- TIM (male) Temperature Resistance
nal circuit] of boost pressure 0°C 29 – 36 kz
1
sensor, temperature sensor
(Internal trouble) 25°C 9 – 11 kz
Between (A) and (B)
40°C 4.9 – 5.8 kz
100°C 600 – 700 z
2 Max. 1 z
(Disconnection or defective TIM (female) (A) tance
Max. 1 z
TIM (female) (B) tance
Short circuit in wiring har-
value in normal
3 ness Wiring harness among all pins between EC1
state Resis-
(with another wiring harness) (female) (23) – EC1 (female) (With all con- Min. 1 Mz
tance
Connecting parts among boost pressure sensor/temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
4
connector • Loose connector, broken lock, broken seal
5 Defective engine controller 0°C 29 – 36 kz
Between (23) and 25°C 9 – 11 kz
(47) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z
40-302 46 WA470, 480-6

Failure code [CA153] (Charge temperature sensor high error) SEN04522-00
WA470, 480-6 40-302 47

SEN04522-00 Failure code [CA154] (Charge temperature sensor low error)
Failure code [CA154] (Charge temperature sensor low error) 1
Action code Failure code Charge temperature sensor low error

Trouble
Contents of • Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
• Fixes charge temperature (boost temperature) at 70°C and continues operation.
controller
Problem that
appears on
• Boost temperature-based engine protection function does not function.
machine
• The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: 18500, CHG TEMP).
Related
• The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: 18501, CHG TEMP).

TIM (male) Temperature Resistance
Defective [temperature sig- 0°C 29 – 36 kz
nal circuit] of boost pressure
1 25°C 9 – 11 kz
sensor, temperature sensor Between (A) and (B)
(Internal trouble) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (A) and
All range Min. 1 Mz
chassis ground
2
(Short circuit with ground cir- Wiring harness between EC1 (female) (23) – Resis-
cuit) Min. 1 Mz
TIM (female) (A) and chassis ground tance
Possible causes Short circuit in wiring har- without turning starting switch ON.
and standard 3 ness Wiring harness among all pins between EC1
value in normal (with another wiring harness) (female) (23) – EC1 (female) (With all con- Resis-
Min. 1 Mz
state tance
Connecting parts among boost pressure sensor/temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
4
connector • Loose connector, broken lock, broken seal
0°C 29 – 36 kz
5 Defective engine controller Between (23) and 25°C 9 – 11 kz
(47) 40°C 4.9 – 5.8 kz
100°C 600 – 700 z
Between (23) and
All range Min. 1 Mz
chassis ground
40-302 48 WA470, 480-6

Failure code [CA154] (Charge temperature sensor low error) SEN04522-00
WA470, 480-6 40-302 49

SEN04522-00 Failure code [CA187] (Sensor power supply 2 low error)
Failure code [CA187] (Sensor power supply 2 low error) 1
Action code Failure code Sensor power supply 2 voltage low error
Trouble
Contents of
• Low voltage is detected in sensor power supply 2 (5 V) circuit.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and
continues operation.
Action of
• Charge pressure sensor sets charge pressure to fixed value (400 kPa {4.1 kg/cm2}), and continues
controller
operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa {1.04 kg/cm2}), and limits out-
put to continue operation.
• EGR valve lift sensor limits output and closes EGR valve.
Problem that
machine
Related
information

and standard
state
40-302 50 WA470, 480-6

Failure code [CA221] (Atmospheric pressure sensor high error) SEN04522-00
Failure code [CA221] (Atmospheric pressure sensor high error) 1
Action code Failure code Atmospheric pressure sensor high error

Trouble
Contents of
• High voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and continues operation.
controller
Problem that
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400 AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402 AMBIENT PRESS).

Defective power supply sys-
If failure code [CA187] or [CA227] is displayed, carry out trouble-
1 tem of atmospheric pressure
shooting for it first.
sensor
PAMB Voltage
Defective atmospheric pres-
sure sensor (Internal defect)
and standard
state harness (Disconnection in PAMB (female) (1) tance
3
connector) Max. 1 z
PAMB (female) (2) tance
Max. 1 z
PAMB (female) (3) tance
PAMB (female) (1) and chassis ground tance
Min. 1 Mz
Min. 1 Mz
WA470, 480-6 40-302 51

SEN04522-00 Failure code [CA221] (Atmospheric pressure sensor high error)

Resis-
PAMB (female) (1) and between EC1 Min. 1 Mz
tance
Short circuit in wiring (female) (38) – PAMB (female) (2)
and standard tance
(female) (3) – PAMB (female) (3)
value in normal
state Resis-
tance
(female) (3) – PAMB (female) (3)
Between (37) and (38) 4.75 – 5.25 V
Between (3) and (38) 0.3 – 4.7 V
40-302 52 WA470, 480-6

Failure code [CA222] (Atmospheric pressure sensor low error) SEN04522-00
Failure code [CA222] (Atmospheric pressure sensor low error) 1
Action code Failure code Atmospheric pressure sensor low error

Trouble
Contents of
• Low voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
• Sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}) and continues operation.
controller
Problem that
machine
• The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: 37400 AMBIENT PRESS).
Related
• The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: 37402 AMBIENT PRESS).

and standard
state
WA470, 480-6 40-302 53

SEN04522-00 Failure code [CA227] (Sensor power supply 2 high error)
Failure code [CA227] (Sensor power supply 2 high error) 1
Action code Failure code Sensor power supply 2 high error

Trouble
Contents of
• High voltage is detected in sensor power supply 2 (5 V) circuit.
trouble
• Bkup speed sensor operates with signal from Ne speed sensor.
• Engine oil pressure sensor sets engine oil pressure to default (250 kPa {2.5 kg/cm2}), and continues
operation.
• Atmospheric pressure sensor sets atmospheric pressure to default (52.44 kPa {0.53 kg/cm2}), and
continues operation.
Action of
• Charge pressure sensor (boost pressure sensor) sets charge pressure to fixed value (400 kPa {4.1
controller
kg/cm2}), and continues operation.
• EGR inlet pressure sensor sets EGR inlet pressure to default (102 kPa {1.04 kg/cm2}), and limits out-
put to continue operation.
• EGR valve lift sensor limits output and closes EGR valve.
Problem that
machine
Related
information

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Bkup speed sensor
G connector
system
Disconnect device
Defective sensor (Internal suggested on the Oil pressure sensor POIL connector
2
defect) right. At this time, if Charge pressure
PIM connector
failure code is not sensor
indicated, the device Atmospheric
is defective. PAMB connector
Possible causes pressure sensor
and standard EGR valve lift sensor SEGR connector
value in normal
state
Disconnection in wiring without turning starting switch ON.
harness (Disconnection in Wiring harness between EC1 (female) (37) – Resis-
3 Max. 1 z
wiring or defective contact in each sensor (female) tance
connector) Wiring harness between EC1 (female) (47) – Resis-
Max. 1 z
each sensor (female) tance
Ground fault in wiring
4 harness (Short circuit with Min. 1 Mz
each sensor (female) and chassis ground tance
GND circuit)
Min. 1 Mz
each sensor (female) and chassis ground tance
40-302 54 WA470, 480-6

Failure code [CA227] (Sensor power supply 2 high error) SEN04522-00

Short circuit in wiring without turning starting switch ON.
Possible causes 5 harness (with another wiring Wiring harness between EC1 (female) (37) –
harness) Resis-
and standard each sensor (female) and between EC1 Min. 1 Mz
tance
value in normal (female) (47) – each sensor (female)
state a Prepare with starting switch OFF, then turn starting switch ON
EC1 Voltage
Between (37) and (47) 4.75 – 5.25 V
WA470, 480-6 40-302 55

SEN04522-00 Failure code [CA234] (Engine overspeed)
Failure code [CA234] (Engine overspeed) 1
Action code Failure code Engine overspeed

Trouble
Contents of
• Engine speed exceeded operating range.
trouble
Action of • Reduce fuel injection rate until engine speed lowers in operating range.
Problem that
appears on • Engine speed changes.
machine
Related • Engine speed can be checked by monitoring function (Code: 01002 ENG SPEED).
information • Method of reproducing failure code: Start engine and keep running at high idle.

Possible causes
and standard The method of using the installed machine may be improper, so
2 Usage is improper.
value in normal instruct the operator on how to use the machine properly.
state If causes 1 and 2 are not the cause of the trouble, the engine con-
3 Defective engine controller troller may be defective. (Since trouble is in system, troubleshooting
cannot be carried out.)
40-302 56 WA470, 480-6

Failure code [CA234] (Engine overspeed) SEN04522-00
WA470, 480-6 40-302 57

SEN04522-00 Failure code [CA238] (Ne speed sensor power supply error)
Failure code [CA238] (Ne speed sensor power supply error) 1
Action code Failure code Ne speed sensor power supply error

Trouble
Contents of
• Low voltage is detected in Ne speed sensor power supply (5 V) circuit.
trouble
Action of • Controls with signal from Bkup speed sensor.
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during operations. (When engine Bkup speed sensor is also defective)
machine
Related
information

Disconnect device
Defective Ne speed sensor suggested on the
1
(Internal defect) right. At this time, if
Ne speed sensor NE connector
failure code is not
indicated, the device
is defective.
2 Max. 1 z
wiring or defective contact in NE (female) (1) tance
NE (female) (2) tance
and standard
NE (female) (1) and chassis ground tance
GND circuit)
Min. 1 Mz
harness) Resis-
NE (female) (1) and between EC1 (female) Min. 1 Mz
tance
(48) – NE (female) (2)
EC1 Voltage
Between (16) and (48) 4.75 – 5.25 V
40-302 58 WA470, 480-6

Failure code [CA238] (Ne speed sensor power supply error) SEN04522-00
WA470, 480-6 40-302 59

SEN04522-00

©2008 KOMATSU
All Rights Reserved
40-302 60
SEN04523-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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 [CA342] (Calibration code inconsistency) ................................................................................ 28
Failure code [CA351] (Injectors drive circuit error) ....................................................................................... 29
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
WA470, 480-6 40-303 1

SEN04523-01
Failure code [CA451] (Common rail pressure sensor high error) ................................................................. 44
Failure code [CA452] (Common rail pressure sensor low error)................................................................... 46
Failure code [CA553] (Common rail pressure high error 1) .......................................................................... 47
Failure code [CA554] (Common rail pressure sensor in-range error) ........................................................... 48
Failure code [CA559] (Supply pump pressure very low error) ...................................................................... 49
Failure code [CA689] (Engine Ne speed sensor error) ................................................................................. 53
Failure code [CA731] (Engine Bkup speed sensor phase error)................................................................... 55
Failure code [CA757] (All continuous data lost error) ................................................................................... 55
Failure code [CA778] (Engine Bkup speed sensor error) ............................................................................. 56
Failure code [CA1228] (EGR valve servo error 1) ........................................................................................ 58
Failure code [CA1625] (EGR valve servo error 2) ........................................................................................ 59
Failure code [CA1633] (KOMNET datalink timeout error) ............................................................................. 60
Failure code [CA2185] (Throttle sensor supply voltage high error)............................................................... 62
Failure code [CA2186] (Throttle sensor power supply low error).................................................................. 63
40-303 2 WA470, 480-6

SEN04523-01
WA470, 480-6 40-303 3

SEN04523-01 Failure code [CA263] (Fuel temperature sensor high error)
Failure code [CA263] (Fuel temperature sensor high error) 1
Action code Failure code Fuel temperature sensor high error

Trouble
Contents of
• High voltage is detected in fuel temperature sensor circuit.
trouble
Action of
• Sets fuel temperature to fixed value (90°C), and continues operation.
controller
Problem that
appears on —
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 FUEL TEMP).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201 FUEL TEMP).

TFUEL (male) Fuel temperature Resistance
Defective fuel temperature 0°C 30 – 37 kz

1
sensor (Internal defect) 25°C 9.3 – 10.7 kz
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
Possible causes 2 Max. 1 z
wiring or defective contact in TFUEL (female) (A) tance
and standard connector) Wiring harness between EC1 (female) (47) – Resis-
state TFUEL (female) (B) tance
TFUEL (female) (A) and chassis ground tance
GND circuit)
EC1 (female) Fuel temperature Resistance
0°C 30 – 37 kz
25°C 9.3 – 10.7 kz
4 Defective engine controller Between
50°C 3.2 – 3.8 kz
(30) and (47)
80°C 1.0 – 1.3 kz
95°C 700 – 800 z
40-303 4 WA470, 480-6

Failure code [CA263] (Fuel temperature sensor high error) SEN04523-01
WA470, 480-6 40-303 5

SEN04523-01 Failure code [CA265] (Fuel temperature sensor low error)
Failure code [CA265] (Fuel temperature sensor low error) 1
Action code Failure code Fuel temperature sensor low error

Trouble
Contents of
• Low voltage is detected in fuel temperature sensor circuit.
trouble
Action of • Injection rate by fuel temperature sensor is compensated with coolant temperature sensor (If coolant
controller temperature sensor is abnormal, the controller sets to fixed value (90°C) and continues operation.)
Problem that
appears on —
machine
• The input state (temperature) from the fuel temperature sensor can be checked with the monitoring
function (Code: 04204 FUEL TEMP).
Related
• The input state (voltage) from the fuel temperature sensor can be checked with the monitoring func-
information
tion (Code: 14201 FUEL TEMP).

and standard
value in normal Carry out trouble shooting for failure code [CA263].
state
40-303 6 WA470, 480-6

Failure code [CA265] (Fuel temperature sensor low error) SEN04523-01
WA470, 480-6 40-303 7

SEN04523-01 Failure code [CA271] (PCV1 Short circuit)
Failure code [CA271] (PCV1 Short circuit) 1
Action code Failure code PCV1 short circuit

Trouble
Contents of
• Short circuit was detected in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV1 (male) Resistance
1
PCV1 (Internal short circuit) Between (1) and (2) 2.3 – 5.3 z
Between (1), (2) and
Min. 1 Mz
chassis ground
Grounding fault in wiring
2 harness (Contact with Min. 1 Mz
PCV1 (female) (1) and chassis ground tance
Possible causes ground circuit)
and standard Min. 1 Mz
value in normal
Hot short in wiring harness Wiring harness between EC1 (female) (4) –
3 Voltage Max. 1 V
(Contact with 24 V circuit) PCV1 (female) (1) and chassis ground
Voltage Max. 1 V
PCV1 (female) (2) and chassis ground
EC1 (female) Resistance
Between (4) and (5) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
40-303 8 WA470, 480-6

Failure code [CA271] (PCV1 Short circuit) SEN04523-01
WA470, 480-6 40-303 9

SEN04523-01 Failure code [CA272] (PCV1 Disconnection)
Failure code [CA272] (PCV1 Disconnection) 1
Action code Failure code PCV1 disconnection

Trouble
Contents of
• Disconnection was detected in supply pump PCV1 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV1 PCV1 (male) Resistance
1
(Internal disconnection) Between (1) and (2) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
Disconnection in wiring
2 harness (Disconnection or Max. 1 z
PCV1 (female) (1) tance
Possible causes defective contact of connector)
and standard Max. 1 z
value in normal
state a Prepare with starting switch OFF, then carry out troubleshooting
ground circuit)
Min. 1 Mz
Between (4) and (5) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
40-303 10 WA470, 480-6

Failure code [CA272] (PCV1 Disconnection) SEN04523-01
WA470, 480-6 40-303 11

SEN04523-01 Failure code [CA273] (PCV2 Short circuit)
Failure code [CA273] (PCV2 Short circuit) 1
Action code Failure code PCV2 short circuit

Trouble
Contents of
• Short circuit was detected in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV2 (male) Resistance
1
PCV2 (Internal short circuit) Between (1) and (2) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
Possible causes ground circuit)
value in normal
and carry out troubleshooting
3 Voltage Max. 1 V
(Contact with 24 V circuit) PCV2 (female) (1) and chassis ground
Voltage Max. 1 V
PCV2 (female) (2) and chassis ground
Between (9) and (10) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
40-303 12 WA470, 480-6

Failure code [CA273] (PCV2 Short circuit) SEN04523-01
WA470, 480-6 40-303 13

SEN04523-01 Failure code [CA274] (PCV2 Disconnection)
Failure code [CA274] (PCV2 Disconnection) 1
Action code Failure code PCV2 disconnection

Trouble
Contents of
• Disconnection was detected in supply pump PCV2 circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective supply pump PCV2 without turning starting switch ON.
1
(Internal disconnection) PCV2 (male) Resistance
Between (1) and (2) 2.3 – 5.3 z
2 harness (Disconnection or Max. 1 z
defective contact of connector)
and standard
ground circuit)
Min. 1 Mz
Between (9) and (10) 2.3 – 5.3 z
Min. 1 Mz
chassis ground
40-303 14 WA470, 480-6

Failure code [CA274] (PCV2 Disconnection) SEN04523-01
WA470, 480-6 40-303 15

SEN04523-01 Failure code [CA322] (Injector #1 open/short error)
Failure code [CA322] (Injector #1 open/short error) 1
Action code Failure code Injector #1 open/short error

Trouble
Contents of
• Disconnection or short circuit was detected in injector #1 circuit.
trouble
Action of
controller
Problem that
• Engine output lowers.
appears on
• Speed does not become stable.
machine
Related
information

Defective injector #1 CN1 (male) Resistance
1
(Internal defect) Between (1) and (2) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
2 Max. 1 z
wiring or defective contact in CN1 (female) (1) tance
CN1 (female) (2) tance
and standard
CN1 (female) (1) and chassis ground tance
GND circuit)
Min. 1 Mz
Defective injector or wiring If another failure code for injector abnormality is displayed, carry out
4
harness of another cylinder troubleshooting for it.
Between (45) and (53) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
40-303 16 WA470, 480-6

Failure code [CA322] (Injector #1 open/short error) SEN04523-01
WA470, 480-6 40-303 17


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
and standard
GND circuit)
Min. 1 Mz
4
Between (46) and (60) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
40-303 18 WA470, 480-6

WA470, 480-6 40-303 19


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
and standard
GND circuit)
Min. 1 Mz
4
Between (55) and (52) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
40-303 20 WA470, 480-6

WA470, 480-6 40-303 21


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
and standard
GND circuit)
Min. 1 Mz
4
Between (57) and (59) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
40-303 22 WA470, 480-6

WA470, 480-6 40-303 23


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
and standard
GND circuit)
Min. 1 Mz
4
Between (54) and (51) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
40-303 24 WA470, 480-6

WA470, 480-6 40-303 25


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information

1
Min. 1 Mz
chassis ground
2 Max. 1 z
and standard
GND circuit)
Min. 1 Mz
4
Between (56) and (58) 0.4 – 1.1 z
Min. 1 Mz
chassis ground
40-303 26 WA470, 480-6

WA470, 480-6 40-303 27

SEN04523-01 Failure code [CA342] (Calibration code inconsistency)
Failure code [CA342] (Calibration code inconsistency) 1
Action code Failure code Engine controller data inconsistency

Trouble
Contents of
• Data inconsistency occurred in engine controller.
trouble
Action of
controller
Problem that
• Normal operation is continued; however, the machine may stop during travel or may not start in
appears on
stopped state.
machine
Related
information

and standard
state
40-303 28 WA470, 480-6

Failure code [CA351] (Injectors drive circuit error) SEN04523-01
Failure code [CA351] (Injectors drive circuit error) 1
Action code Failure code Injectors drive circuit error

Trouble
Contents of
• Abnormality occurred in injector drive power supply circuit.
trouble
Action of • Limits output and continues operation (limits common rail pressure).
• Exhaust smoke is black.
Problem that
• There is irregular combustion.
appears on
• Engine output drops.
machine
• The engine does not start.
Related
information

2 If the fuse is broken, the circuit probably has a grounding fault, etc.
box 1
Defective engine control cut- Between (1) and (2) 200 – 400 z
3 out relay (L171) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
connection or short circuit) and carry out troubleshooting.
When engine control cut-out relay (L171) is replaced with a relay of
the same type, if the condition becomes normal, the engine control
cut-out relay 1 is defective.
Possible causes
and standard L172 (male) Resistance
value in normal Defective engine control cut- Between (1) and (2) 200 – 400 z
state 4 out relay (L172) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
cut-out relay 2 is defective.
Disconnection in wiring har- Wiring harness between fuse No. 6 of fuse Resis- Max.
ness box 1 – L171, L172 (female) (3) tance 0.5 z
5
(Disconnection or defective Wiring harness between L171 (female) (5), Resis- Max.
contact in connector) L172 (female) (5) – EC3 (female) (3), (4) tance 0.5 z
Max. 1 z
If causes 1 – 5 are not detected, engine controller may be defective.
6 Defective engine controller (Since trouble is in the system, troubleshooting cannot be carried
out.)
WA470, 480-6 40-303 29

SEN04523-01 Failure code [CA351] (Injectors drive circuit error)
40-303 30 WA470, 480-6

Failure code [CA352] (Sensor power supply 1 low error) SEN04523-01
Failure code [CA352] (Sensor power supply 1 low error) 1
Action code Failure code Sensor power supply 1 low error

Trouble
Contents of
• Low voltage is detected in sensor power supply 1 (5 V) circuit.
trouble
Action of • Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
Problem that
appears on • Engine output drops.
machine
Related
information

and standard
state
WA470, 480-6 40-303 31

SEN04523-01 Failure code [CA386] (Sensor power supply 1 high error)
Failure code [CA386] (Sensor power supply 1 high error) 1
Action code Failure code Sensor power supply 1 high error

Trouble
Contents of
• High voltage is detected in sensor power supply 1 (5 V) circuit.
trouble
Action of • Common rail pressure sensor: Limits output for travel (Limits common rail pressure)
Problem that
machine
Related
information

1 Defect in related system If another failure code is displayed, carry out troubleshooting for it.
Disconnect device
Defective sensor suggested on the
2
(Internal defect) right. At this time, if Common rail
PFUEL
failure code is not pressure sensor
indicated, the device
is defective.
3 Max. 1 z
wiring or defective contact in PFUEL (female) (1) tance
Possible causes connector) Wiring harness between EC1 (female) (47) – Resis-
PFUEL (female) (3) tance
value in normal
state
PFUEL (female) (1) and chassis ground tance
GND circuit)
Min. 1 Mz
harness) Resis-
PFUEL (female) (1) and between EC1 Min. 1 Mz
tance
(female) (47) – PFUEL (female) (3)
EC1 Voltage
Between (33) and (47) 4.75 – 5.25 V
40-303 32 WA470, 480-6

Failure code [CA386] (Sensor power supply 1 high error) SEN04523-01
WA470, 480-6 40-303 33

SEN04523-01 Failure code [CA431] (Idle validation switch error)
Failure code [CA431] (Idle validation switch error) 1
Action code Failure code Idle validation switch error

Trouble
Contents of
• Abnormality occurred in idle validation switch circuit.
trouble
Action of
• Operates at position of throttle sensor.
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: 18300, IVS 1).
Related
information

PD Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1 See Fig. 1 on the next
1
(Internal trouble) Between (6) and (4) Signal 2 page
Disconnection in wiring har- Wiring harness between EC2 (female) (11) – Resis-
Max. 1 z
ness PD (female) (5) tance
2
(Disconnection or defective Wiring harness between EC2 (female) (1) – Resis-
PD (female) (6) tance
Possible causes
PD (female) (4) tance
value in normal
Wiring harness among all pins between EC2
Resis-
(female) (11) – EC2 (female) (PD, too, is dis- Min. 1 Mz
tance
connected.)
Short circuit in wiring har-
3 ness Resis-
(with another wiring harness) tance
connected.)
Between EC2 (female) (11) – EC3 (female) Resis-
Min. 1 Mz
(3) (PD, too, is disconnected.) tance
Between EC2 (female) (1) – EC3 (female) Resis-
Min. 1 Mz
(3) (PD, too, is disconnected.) tance
Connecting parts among accelerator pedal, engine unit wiring har-
connector
40-303 34 WA470, 480-6

Failure code [CA431] (Idle validation switch error) SEN04523-01

and standard
EC2 Signal name Voltage
value in normal 5 Defective engine controller
state Between (11) and
Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
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 ×
when pedal opened)
WA470, 480-6 40-303 35

SEN04523-01 Failure code [CA432] (Idle validation action error)
Failure code [CA432] (Idle validation action error) 1
Action code Failure code Idle validation action error

Trouble
Contents of
• Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
trouble
1. When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor, on
the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to 0%
after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while after
Action of the accelerator pedal is ON.
controller 2. When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on
the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0%
(fix to the low idle).
Problem that
appears on • Engine speed does not rise from low idle.
machine
Related
information

PD Signal name Voltage
Between (5) and (4) Signal 1 See Fig. 1 on the next
1 Defective accelerator pedal
Between (6) and (4) Signal 2 page
(Disconnection or defective PD (female) (1) tance
and standard contact in connector) Wiring harness between EC2 (female) (9) – Resis-
state PD (female) (2) tance
Short circuit in wiring har- Resis-
3 ness tance
connected.)
(with another wiring harness)
Resis-
tance
connected.)
Connecting parts among accelerator pedal, engine unit wiring har-
connector
40-303 36 WA470, 480-6

Failure code [CA432] (Idle validation action error) SEN04523-01

and standard
EC2 Accelelator pedal Voltage
value in normal 5 Defective engine controller
Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 ×
when pedal opened)
B: Voltage when pedal opened + 0.1 ×
when pedal opened)
WA470, 480-6 40-303 37

SEN04523-01 Failure code [CA441] (Battery voltage low error)
Failure code [CA441] (Battery voltage low error) 1
Action code Failure code Battery voltage low error

Trouble
Contents of
• Low voltage (Max. 6 V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
• Engine stops.
appears on
• Starting performance is poor.
machine
Related
information

Loose, corroded battery ter-
1 Inspect battery terminal directly for loose and corrosion.
minal
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and (–) OFF Min. 12 V
terminals START Min. 6.2 V
Defective fuse No. 6 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
3
Possible causes When engine control cut-out relay (L171) is replaced with a relay of
and standard the same type, if the condition becomes normal, the engine control
value in normal cut-out relay (L171) is defective.
state
cut-out relay (L172) is defective.
Disconnection in wiring har- Wiring harness between fuse No. 6 of fuse Resis-
Max. 1 z
ness box 1 – L171 or L172 (female) (3) tance
6
(Disconnection or defective Wiring harness between L171 (female) (5), Resis-
L172 (female) (5) – EC3 (female) (3), (4) tance
Max. 1 z
40-303 38 WA470, 480-6

Failure code [CA441] (Battery voltage low error) SEN04523-01

Wiring harness between fuse No. 6 of fuse
Resis-
Ground fault in wiring harness box 1 – L171, L172 (female) (3) and chassis Min. 1 Mz
7 tance
(Contact with ground circuit) ground
Resis-
L172 (female) (5) – EC (3), (4) and chassis Min. 1 Mz
tance
ground
Wiring harness among pins between EC3
Resis-
(female) (3), (4) – EC3 (female) (1), (2) Min. 1 Mz
tance
Possible causes (With battery terminal disconnected)
Short circuit in wiring harness
and standard 8
(with another wiring harness) Wiring harness among all pins between EC3 Resis-
value in normal (female) (3), (4) – EC2 (female) Min. 1 Mz
tance
state (With battery terminal disconnected)
Resis-
(female) (1), (2) – EC2 (female) Min. 1 Mz
tance
(With battery terminal disconnected)
Connecting parts among fuse No. 6 of fuse box 1, engine unit wiring
connector
10 Defective engine controller EC3 Starting switch Voltage
Between (3), (4) and ON Min. 24 V
(1), (2) START Min. 12 V
WA470, 480-6 40-303 39

SEN04523-01 Failure code [CA441] (Battery voltage low error)
40-303 40 WA470, 480-6

Failure code [CA442] (Battery voltage high error) SEN04523-01
Failure code [CA442] (Battery voltage high error) 1
Action code Failure code Battery voltage high error

Trouble
Contents of
• High voltage (min. 36V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on • Engine may stop.
machine
Related
information

1 Defective battery voltage
Battery Voltage
Between (+) and (–) terminals Less than 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal 2 Defective alternator E02 Engine speed Voltage
state
Between (1) and
Min. medium speed 27.5 – 29.5 V
chassis ground
EC3 Voltage
Between (3), (4) and (1), (2) Less than 32 V
WA470, 480-6 40-303 41

SEN04523-01 Failure code [CA442] (Battery voltage high error)
40-303 42 WA470, 480-6

Failure code [CA449] Common rail pressure high error 2 SEN04523-01
Failure code [CA449] Common rail pressure high error 2 1
Action code Failure code Common rail pressure high error 2

Trouble
Contents of
• There is high pressure error (level 2) in common rail pressure sensor circuit.
trouble
Problem that
machine
• The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: 36400 RAIL PRESS).
Related
• The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: 36402 RAIL PRESS).

and standard
state
WA470, 480-6 40-303 43

SEN04523-01 Failure code [CA451] (Common rail pressure sensor high error)
Failure code [CA451] (Common rail pressure sensor high error) 1
Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
• Common rail pressure sensor circuit is abnormally high.
trouble
Problem that
machine
Related
information

Defective common rail pres- If failure code [CA352] or [CA386] is also indicated, carry out trou-
1
sure sensor power system bleshooting for it first.
PFUEL Voltage
Defective common rail pres- Between (1) and (3) Power supply 4.75 – 5.25 V
2
sure sensor (Internal defect) Between (2) and (3) Signal 0.25 – 4.6 V
Possible causes
and standard
value in normal Disconnection in wiring Wiring harness between EC1 (female) (33) – Resis-
Max. 1 z
state harness (Disconnection in PFUEL (female) (1) tance
3
connector) Max. 1 z
Max. 1 z
Min. 1 Mz
Min. 1 Mz
40-303 44 WA470, 480-6

Failure code [CA451] (Common rail pressure sensor high error) SEN04523-01

Resis-
tance
Short circuit in wiring (female) (25) – PFUEL (female) (2)
and standard tance
value in normal
state Resis-
tance
Between (33) and (47) 4.75 – 5.25 V
Between (25) and (47) 0.25 – 4.6 V
WA470, 480-6 40-303 45

SEN04523-01 Failure code [CA452] (Common rail pressure sensor low error)
Failure code [CA452] (Common rail pressure sensor low error) 1
Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
• Common rail pressure sensor circuit is abnormally low.
trouble
Problem that
machine
Related
information

and standard
state
40-303 46 WA470, 480-6

Failure code [CA553] (Common rail pressure high error 1) SEN04523-01
Failure code [CA553] (Common rail pressure high error 1) 1
Action code Failure code Common rail pressure high error 1

Trouble
Contents of
• There is high pressure error (level 1) in common rail pressure sensor circuit.
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

2 Use of improper fuel Fuel used may be improper. Check it directly. (Viscosity is high)
Defective electrical system of Electrical system of common rail pressure sensor may be defective.
3
Possible causes common rail pressure sensor Carry out troubleshooting for failure code [CA451].
and standard Defective mechanical system
value in normal Mechanical system of common rail pressure sensor may be defec-
4 of common rail pressure sen-
state tive. Check it directly.
sor
Spring damage, seat wear, or ball stuck of overflow valve is sus-
5 Defective overflow valve
pected. Check it directly.
6 Clogged overflow pipe Overflow pipe may be clogged. Check it directly.
7 Defective pressure limiter Pressure limiter may be damaged mechanically. Check it directly.
WA470, 480-6 40-303 47

SEN04523-01 Failure code [CA554] (Common rail pressure sensor in-range error)
Failure code [CA554] (Common rail pressure sensor in-range error) 1
Action code Failure code Common rail pressure sensor in-range error
Trouble
Contents of
• In-range error occurred in common rail pressure sensor circuit.
trouble
Problem that
machine
Related
information

and standard
state
40-303 48 WA470, 480-6

Failure code [CA559] (Supply pump pressure very low error) SEN04523-01
Failure code [CA559] (Supply pump pressure very low error) 1
Action code Failure code Supply pump pressure very low error 1
Trouble
Contents of
• There is no-pressure feed error (level 1) in supply pump.
trouble
Action of • Limits common rail pressure.
Problem that
machine
Related
information

2 Use of improper fuel Fuel used may be improper. Check it directly.
a For more information on troubleshooting, see Note 1. For check
of pressure in fuel low pressure circuit, see Testing and adjusting,
Defect in low pressure “Testing fuel pressure”.
3
circuit parts
Pressure in fuel Min. 0.15 MPa
low-pressure circuit {Min. 1.5 kg/cm2}
4 Clogged fuel filter, strainer a For more information on troubleshooting, see Note 2.
Electrical system of supply pump PCV may be defective. Carry out
Defective electrical system of
5 troubleshooting for failure code [CA271], [CA272], [CA273], or
supply pump PCV
[CA274].
Defective common rail Mechanical system of common rail pressure sensor may be defec-
6
Possible causes pressure sensor tive. Check whether wiring harness is damaged.
and standard a For check of leakage through pressure limiter, see Testing and
value in normal adjusting, “Testing fuel return rate and leakage”.
state 7 Defective pressure limiter
Max. 10 cc/min
Leakage through pressure limiter
(at full stall or relief)
a For check of limited return rate (spill) from injector, see Testing
and adjusting, “Testing fuel return rate and leakage”.
Speed at rated operation Limited return (spill) rate from
(stall load) injector
8 Defective injector 1,600 rpm 960 cc/min

1,700 rpm 1,020 cc/min
1,800 rpm 1,080 cc/min
1,900 rpm 1,140 cc/min
2,000 rpm 1,200 cc/min
If causes 1 – 8 are not the cause of the trouble, supply pump may
9 Defective supply pump
be defective.
<Using check sheet>

While carrying out troubleshooting above, record troubleshooting contents on the “Check sheet for no-pres-
sure feed” attached separately.
WA470, 480-6 40-303 49

SEN04523-01 Failure code [CA559] (Supply pump pressure very low error)
Note 1: When low-pressure circuit is defective, check the following:

1) Fuel level
2) Clogged fuel tank breather
3) Stuck or worn feed pump, clogged filter
4) Leaked or clogged low-pressure fuel pipe
5) Bypass valve malfunction, defective assembly of other parts (See Fig.1.)
6) Clogged fuel filter
7) Fuel in oil pan (fuel leakage in head cover)
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.
40-303 50 WA470, 480-6

Failure code [CA559] (Supply pump pressure very low error) SEN04523-01
Check sheet for no-pressure feed

Machine model WA470-6 Working No.
Model serial No. # Checked on / /
Engine SAA6D125E-5 Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
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
01002 Engine speed High idle (P-mode) rpm 2,170 ± 50

Full stall (P-mode) rpm 1,980 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 107
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 800}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cut-out cylinder Check conditions Unit Good Bad
Cylinder 1 Low idle rpm — — —
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
<by model> 1,600 rpm
Rating or equivalent
cc/min 1,020
12 Return rate from injector cc/min 1,080 Return rate:
cc/min 1,140
cc/min 1,200
WA470, 480-6 40-303 51

SEN04523-01 Failure code [CA559] (Supply pump pressure very low error)
Check sheet for no-pressure feed

Machine model WA480-6 Working No.
Model serial No. # Checked on / /
Engine SAA6D125E-5 Service meter h
Engine serial No. # Worker name
A. Visual check Good Bad

1 Fuel leakage to outside
2 Clogged fuel tank breather
B. Check with machine monitor (Abnormality record, monitoring, cylinder cut-out operation) Good Bad
3 Checking error and failure codes / / / /
Checking monitoring information
Code Display item Check conditions Unit Good Bad
Low idle (P-mode) rpm 800 +50
+50
01002 Engine speed High idle (P-mode) rpm 2,190 ± 50

Full stall (P-mode) rpm 1,850 ± 100
Position of accelerator Low idle % 0
31701
pedal High idle % 100
Common rail pressure
4 36200 Rating or equivalent MPa
command
36400 Common rail fuel pressure Rating or equivalent MPa
Low idle CA — — —
36300 Injection timing command High idle CA — — —
Rating or equivalent CA — — —
kPa Min. 120
36500 Boost pressure Rating or equivalent — —
{mmHg} {Min. 900}
04104 Engine coolant temperature Low idle °C — — —
04204 Fuel temperature Low idle °C — — —
Checking cylinder cut-out operation (Engine speed)
Function Cut-out cylinder Check conditions Unit Good Bad
5 Cylinder 2 Low idle rpm — — —
Cylinder
cut-out
function

C. Checking fuel circuit pressure Check conditions Unit Good Bad
MPa Min. 0.15
6 Pressure in fuel low-pressure circuit High idle
{kg/cm2} {Min. 1.5}
D. Checking strainer, filter Good Bad

7 Visual check of strainer
8 Visual check of gauze filter
9 Visual check of fuel filter
10 Visual check of bypass valve

E. Checking leakage and fuel return rate Check conditions Unit Good Bad
11 Leakage through pressure limiter No load, full stall, or relief cc/min Max. 10
Rating or equivalent Speed:
cc/min 960
cc/min 1,020
12 Return rate from injector cc/min 1,080 Return rate:
cc/min 1,140
cc/min 1,200
40-303 52 WA470, 480-6

Failure code [CA689] (Engine Ne speed sensor error) SEN04523-01
Failure code [CA689] (Engine Ne speed sensor error) 1
Action code Failure code Engine Ne speed sensor error

Trouble
Contents of
• Error was detected in engine Ne speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Bkup speed sensor.
Problem that
• Engine stops during operations. (When engine Bkup speed sensor is also defective)
appears on
• Engine cannot be started during stop. (When engine Bkup speed sensor is also defective)
machine
Related
information

Defective sensor power If failure code [CA238] is displayed, carry out troubleshooting for it
1
supply system first.
Max. 1 z
harness (Disconnection in NE (female) (1) tance
2
connector) Max. 1 z
Max. 1 z
Min. 1 Mz
Possible causes Wiring harness between EC1 (female) (27) – Resis-
Min. 1 Mz
and standard NE (female) (3) and chassis ground tance
Resis-
tance
Short circuit in wiring (48) – NE (female) (2)
harness) Resis-
tance
(27) – NE (female) (3)
Resis-
tance
(27) – NE (female) (3)
Defective installation of
Installation of Ne speed sensor (clearance error) or speed sensor
5 sensor or defective speed
parts (fly wheel) may be defective. Check it directly.
sensor parts
If causes 1 – 5 are not the cause of the trouble, engine Ne speed
Defective engine Ne speed
6 sensor may be defective. (Since trouble is in system, troubleshoot-
sensor
ing cannot be carried out.)
If causes 1 – 6 are not the cause of the trouble, engine controller
7 Defective engine controller may be defective. (Since trouble is in system, troubleshooting can-
not be carried out.)
WA470, 480-6 40-303 53

SEN04523-01 Failure code [CA689] (Engine Ne speed sensor error)
40-303 54 WA470, 480-6

Failure code [CA731] (Engine Bkup speed sensor phase error) SEN04523-01
Failure code [CA731] (Engine Bkup speed sensor phase error) 1
Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
• There is phase error in engine Bkup speed sensor circuit.
trouble
Action of • Controls the engine with signal from engine Ne speed sensor.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during stop. (When engine Ne speed sensor is also defective)
machine
Related
information

Possible causes
Defective engine Ne speed Engine Ne speed sensor may be defective. Carry out troubleshoot-
and standard 1
sensor system ing for failure code [CA689].
value in normal
state Defective engine Bkup Engine Bkup speed sensor may be defective. Carry out trouble-
2
speed sensor system shooting for failure code [CA778].
Failure code [CA757] (All continuous data lost error) 1
Action code Failure code All continuous data lost error

Trouble
Contents of
• All data in engine controller are lost.
trouble
Action of
controller
Problem that
appears on • Operations are continued, but engine may stop during operations or may not start in stopped state.
machine
Related
information

and standard
state
WA470, 480-6 40-303 55

SEN04523-01 Failure code [CA778] (Engine Bkup speed sensor error)
Failure code [CA778] (Engine Bkup speed sensor error) 1
Action code Failure code Engine Bkup speed sensor error

Trouble
Contents of
• Error was detected in engine Bkup speed sensor circuit.
trouble
Action of • Operates the engine with signal from engine Ne speed sensor.
Problem that
• Engine stops during operations. (When engine Ne speed sensor is also defective)
appears on
• Engine cannot be started during stop. (When engine Ne speed sensor is also defective)
machine
Related
information

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
supply system shooting for it first.
Max. 1 z
harness (Disconnection in G (female) (1) tance
2
connector) Max. 1 z
G (female) (2) tance
Max. 1 z
G (female) (3) tance
G (female) (1) and chassis ground tance
Possible causes Min. 1 Mz
and standard
value in normal Min. 1 Mz
state
Resis-
G (female) (1) and between EC1 (female) Min. 1 Mz
tance
Short circuit in wiring (47) – G (female) (2)
harness) Resis-
tance
(26) – G (female) (3)
Resis-
tance
(26) – G (female) (3)
If causes 1 – 4 are not the cause of the trouble, engine Bkup speed
Defective engine Bkup
5 sensor may be defective. (Since trouble is in system, troubleshoot-
speed sensor
ing cannot be carried out.)
40-303 56 WA470, 480-6

Failure code [CA778] (Engine Bkup speed sensor error) SEN04523-01
WA470, 480-6 40-303 57

SEN04523-01 Failure code [CA1228] (EGR valve servo error 1)
Failure code [CA1228] (EGR valve servo error 1) 1
Action code Failure code EGR valve servo error 1

Trouble
Contents of
• There is servo error (level 1) of EGR valve.
trouble
Action of • Performs open control.
Problem that
appears on —
machine
Related
information

a For measurement of EGR valve drive pressure, see Testing and
adjusting, “Measuring EGR valve and bypass valve drive oil pres-
sure”.
Improper EGR valve drive Engine speed EGR valve drive pressure
2
pressure
Low idle Min. 1.18 MPa {12 kg/cm2}
High idle Min. 1.43 MPa {14.6 kg/cm2}
If EGR valve drive pressure is abnormal, check the following.
a For check of engine oil pressure, see Testing and adjusting,
“Testing engine oil pressure”.
Possible causes Engine Engine oil pressure
and standard Defective engine oil pressure
3 Low idle Min. 0.08 MPa {0.8 kg/cm2}
value in normal system (main circuit)
state High idle Min. 0.21 MPa {2.1 kg/cm2}
If engine oil pressure is not normal, carry out troubleshooting (S-
mode) for mechanical system. (S-12 Oil pressure drops)
Defective EGR valve oil Oil pump or relief valve for EGR valve circuit may be defective.
4
pump Check it directly.
Defective EGR valve oil Oil pressure supply piping for EGR valve circuit may be defective.
5
pressure supply piping Check it directly.
Defective EGR valve oil Oil pressure return piping for EGR valve circuit may be defective.
6
pressure return piping Check it directly.
7 Defective EGR valve EGR valve may be damaged mechanically. Check it directly.
40-303 58 WA470, 480-6

Failure code [CA1625] (EGR valve servo error 2) SEN04523-01
Failure code [CA1625] (EGR valve servo error 2) 1
Action code Failure code EGR valve servo error 2

Trouble
Contents of
• There is servo error (level 2) of EGR valve.
trouble
• Limits output and continues operation.
Action of
• Close EGR valve.
controller
Problem that
machine
Related
information

and standard
state
WA470, 480-6 40-303 59

SEN04523-01 Failure code [CA1633] (KOMNET datalink timeout error)
Failure code [CA1633] (KOMNET datalink timeout error) 1
Action code Failure code KOMNET datalink timeout error

Trouble
Contents of • Engine controller detected a communication error in the KOMNET communication circuit used for the
trouble communication between the pump controllers and machine monitor.
• Continues the operation from the default mode.
Action of
controller
Problem that
• KOMNET communication information may not be transmitted correctly to cause incorrect operation
appears on
of machine. (Problem depends on failure occurrence location.)
machine
Related
information

CAN1 (male) Resistance
Defective CAN end point Between (A) and (B) 110 – 140 z
1
resistance a Prepare with starting switch OFF, then carry out troubleshooting
Between (A) and (B) 110 – 140 z
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) – L62 (female) (22), (32) tance
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
Max. 1 z
(47) – CAN1 (female) (A), (B) tance
Max. 1 z
40-303 60 WA470, 480-6

Failure code [CA1633] (KOMNET datalink timeout error) SEN04523-01

Wiring harness between EC2 (female) (46),
Resis-
(47) – L62 (female) (22), (32) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
Ground fault in wiring har- Wiring harness between EC2 (female) (46),
Resis-
ness (47) – L72 (female) (22), (32) and chassis Min. 1 Mz
3 tance
Possible causes (Short circuit with ground cir- ground
and standard cuit) Wiring harness between EC2 (female) (46),
value in normal Resis-
state tance
ground
Resis-
(47) – CAN1 (female) (A), (B) and chassis Min. 1 Mz
tance
ground
Resis-
tance
ground
Defective machine monitor, a If above troubleshootings 1 – 3 have not identified the cause of
transmission controller, work the trouble, failure on the machine monitor, transmission control-
4 equipment controller, engine ler, work equipment controller, engine controller or KOMTRAX
controller or KOMTRAX ter- terminal should be suspected. (Since trouble is in system, trou-
minal bleshooting cannot be carried out.)
WA470, 480-6 40-303 61

SEN04523-01 Failure code [CA2185] (Throttle sensor supply voltage high error)
Failure code [CA2185] (Throttle sensor supply voltage high error) 1
Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
• High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Short circuit in wiring harness Resis-
1 (female) (22) – EC2 (female) (PD, too, is dis- Min. 1 Mz
(with another wiring harness) tance
connected.)
Possible causes
and standard Between EC2 (female) (22) – EC3 (female) Resis-
Min. 1 Mz
value in normal (3) (PD, too, is disconnected.) tance
state Connecting parts among fuel control dial, engine unit wiring har-
connector
(Since trouble is in system, troubleshooting cannot be carried out.)
40-303 62 WA470, 480-6

Failure code [CA2186] (Throttle sensor power supply low error) SEN04523-01
Failure code [CA2186] (Throttle sensor power supply low error) 1
Action code Failure code Throttle sensor power supply voltage low error
Trouble
Contents of
• Low voltage occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Ground fault in wiring harness without turning starting switch ON.
1
(Contact with ground circuit) Wiring harness between EC2 (female) (22) – Resis-
Min. 1 Mz
PD (female) (1) and chassis ground tance
Possible causes Short circuit in wiring harness
2
and standard (with another wiring harness) Wiring harness among all pins between EC2 Resis-
value in normal (female) (9) – EC2 (female) (PD, too, is dis- Min. 1 Mz
tance
state connected.)
connector
WA470, 480-6 40-303 63

SEN04523-01

©2009 KOMATSU
All Rights Reserved
40-303 64
SEN04524-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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 output: Disconnection) ............................................................. 20
Failure code [D160KB] (Backup lamp relay output: Short circuit)................................................................. 22
Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) ............................................ 24
Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) ............................................... 26
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
WA470, 480-6 40-304 1

SEN04524-01
Failure code [D5ZHKA] (Terminal C signal: Disconnection).......................................................................... 41

Failure code [D5ZHKB] (Terminal C signal: Short circuit) ............................................................................. 45
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) .................................................. 48
Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) .......... 53
Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) ................................................. 56
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) ....................................................... 58
Failure code [DAF5KP] (Machine monitor: Low output voltage) ................................................................... 60
Defective communication (Abnormality in target component system)) .................................................. 64
40-304 2 WA470, 480-6

Failure code [CA2249] (Supply pump pressure very low error 2) SEN04524-01
Failure code [CA2249] (Supply pump pressure very low error 2) 1
Action code Failure code Supply pump pressure very low error 2
Trouble
Contents of
• No-pressure feed (2) occurred in common rail circuit.
trouble
Action of • Limits output and continues operation.
Problem that • Starting performance is poor.
appears on • Exhaust smoke is black.
machine • Engine output lowers.
the monitoring function (Code: 36400, RAIL PRESS).
Related
information
function (Code: 36402, RAIL PRESS).
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
WA470, 480-6 40-304 3

SEN04524-01 Failure code [CA2271] (EGR valve lift sensor high error)
Failure code [CA2271] (EGR valve lift sensor high error) 1
Action code Failure code EGR valve lift sensor high error
Trouble
Contents of
• High voltage is detected in EGR valve lift sensor circuit.
trouble
Action of
• Closes EGR valve.
controller
Problem that
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100 BPS VALVE POS).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 BPS VALVE POS).

Defective sensor power If failure code [CA187] or [CA227] is displayed, carry out trouble-
1
supply system shooting for it first.
Defective EGR valve lift SEGR Voltage
2 sensor Between (1) and (2) Power supply 4.75 – 5.25 V
(Internal defect)
and standard Disconnection in wiring Wiring harness between EC1 (female) (37) – Resis-
harness SEGR (female) (1) tance
state 3
(Disconnection or defective Wiring harness between EC1 (female) (47) – Resis-
SEGR (female) (2) tance
Max. 1 z
SEGR (female) (3), (4) tance
Min. 1 Mz
Ground fault in wiring harness SEGR (female) (1) and chassis ground tance
4
Min. 1 Mz
SEGR (female) (2) and chassis ground tance
Min. 1 Mz
SEGR (female) (3), (4) and chassis ground tance
40-304 4 WA470, 480-6

Failure code [CA2271] (EGR valve lift sensor high error) SEN04524-01

without turning staring switch ON.
Resis-
SEGR (female) (1) and EC1 (female) (19) – Min. 1 Mz
tance
SEGR (female) (3), (4)
Short circuit in wiring harness
5
Possible causes (with another wiring harness) Wiring harness between EC1 (female) (37) – Resis-
and standard SEGR (female) (1) and EC1 (female) (19) – Min. 1 Mz
tance
value in normal SEGR (female) (3), (4)
Resis-
SEGR (female) (2) and EC1 (female) (19) – Min. 1 Mz
tance
SEGR (female) (3), (4)
EC1 Voltage
Between (37) and (47) 4.75 – 5.25 V
WA470, 480-6 40-304 5

SEN04524-01 Failure code [CA2272] (EGR valve lift sensor low error)
Failure code [CA2272] (EGR valve lift sensor low error) 1
Action code Failure code EGR valve lift sensor low error
Trouble
Contents of
• Low voltage is detected in EGR valve lift sensor circuit.
trouble
Action of
controller
Problem that
machine
• The input state (position: mm) from the EGR valve lift sensor can be checked with the monitoring
function (Code: 18100 BPS VALVE POS).
Related
• The input state (voltage) from the EGR valve lift sensor can be checked with the monitoring function
information
(Code: 18101 BPS VALVE POS).

and standard
state
40-304 6 WA470, 480-6

Failure code [CA2351] (EGR valve solenoid operation short circuit) SEN04524-01
Failure code [CA2351] (EGR valve solenoid operation short circuit) 1
Action code Failure code EGR valve solenoid operation short circuit error
Trouble
Contents of
• Short circuit was detected in drive circuit of EGR valve solenoid.
trouble
Action of
controller
Problem that
machine
Related
information

Defective EGR valve solenoid without turning starting switch ON.
1
(Internal defect) EGR (male) Resistance
Between (1) and (2) 10 – 21 z
harness Wiring harness between EC1 (female) (22) – Resis-
2 Max. 1 z
(Disconnection or defective EGR (female) (1) tance
Max. 1 z
EGR (female) (2) tance
and standard
value in normal Ground fault in wiring harness Wiring harness between EC1 (female) (22) – Resis-
3 Min. 1 Mz
state (Contact with ground circuit) EGR (female) (1) and chassis ground tance
Min. 1 Mz
EGR (female) (2) and chassis ground tance
4 Voltage Max. 1 V
(Contact with 24 V circuit) EGR (female) (1) and chassis ground
Voltage Max. 1 V
EGR (female) (2) and chassis ground
Between (22) and (11) 10 – 21 z
WA470, 480-6 40-304 7

SEN04524-01 Failure code [CA2351] (EGR valve solenoid operation short circuit)
40-304 8 WA470, 480-6

Failure code [CA2352] (EGR valve solenoid operation disconnect) SEN04524-01
Failure code [CA2352] (EGR valve solenoid operation disconnect) 1
Action code Failure code EGR valve solenoid operation disconnection error
Trouble
Contents of
• Disconnection error was detected in drive circuit of EGR valve solenoid.
trouble
Action of
controller
Problem that
machine
Related
information

and standard
state
WA470, 480-6 40-304 9

SEN04524-01 Failure code [CA2555] (Intake heater relay disconnection error)
Failure code [CA2555] (Intake heater relay disconnection error) 1
Action code Failure code Intake heater relay disconnection error

Trouble
Contents of
• There is disconnection in intake air heater relay.
trouble
Action of
• None in particular.
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
Related • Method of reproducing failure code: Turn the starting switch ON when coolant temperature is –4°C or
information less.

without turning starting switch ON. (Test relay unit).
Between E06 and chassis Resistance
Defective heater relay ground 300 – 600 z
1
(Internal disconnection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
2 Max. 1 z
(Disconnection or defective E06 tance
Possible causes contact in connector) Wiring harness between primary side of Resis-
heater relay – chassis ground tance
value in normal
(with another wiring harness) (female) (40) – EC2 (female) (E06, too, is Resis-
Min. 1 Mz
tance
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
connector
5 Defective engine controller EC2 (female) Resistance
Between (40) and chassis
300 – 600 z
ground
40-304 10 WA470, 480-6

Failure code [CA2555] (Intake heater relay disconnection error) SEN04524-01
WA470, 480-6 40-304 11

SEN04524-01 Failure code [CA2556] (Intake heater relay short circuit error)
Failure code [CA2556] (Intake heater relay short circuit error) 1
Action code Failure code Intake heater relay short circuit error
Trouble
Contents of
• There is short circuit in intake air heater relay.
trouble
Action of
controller
Problem that
• Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
Related • Method of reproducing failure code: Turn the starting switch ON when coolant temperature is –4°C or
information less.

without turning starting switch ON. (Test relay unit).
Between E06 and chassis Resistance
Defective heater relay ground 300 – 600 z
1
(Internal short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
Ground fault in wiring har- without turning starting switch ON.
2 ness
E06 tance
and standard
value in normal
state
(with another wiring harness) (female) (40) – EC2 (female) (E06, too, is Resis-
Min. 1 Mz
tance
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
and engine controller are suspected. Inspect them directly.
connector
5 Defective engine controller EC2 (female) Resistance
Between (40) and
300 – 600 z
chassis ground
40-304 12 WA470, 480-6

Failure code [CA2556] (Intake heater relay short circuit error) SEN04524-01
WA470, 480-6 40-304 13

SEN04524-01 Failure code [D150KA] (Emergency steering relay: Disconnection)
Failure code [D150KA] (Emergency steering relay: Disconnection) 1
Action code Failure code Emergency steering relay: Disconnection

Trouble
E03 D150KA (Transmission controller)
Contents of • Since the emergency steering relay output system is disconnected, signals are not output to the
trouble emergency steering relay.
Action of
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
controller
Problem that • If abnormality is detected in the steering pressure, operation of the automatic emergency steering
appears on becomes unavailable.
machine • Self-check of the emergency steering is ended abnormally.
• The output state (ON/OFF) to the emergency steering relay can be checked with the monitoring
Related
function (Code: 90949, D-OUT-0).
information
• Method of reproducing failure code: Start engine, then operate the steering.

When emergency steering relay (L126) is replaced with a relay of
Defective emergency steer- the same type, if the condition becomes normal, the emergency
1 ing relay (L126) (Internal dis- steering relay is defective.
connection) a Prepare with starting switch OFF, then carry out troubleshooting
Possible causes
and standard Between (1) and (2) 200 – 400 z
ness Wiring harness between L63 (female) (7) – Resis-
2 Max. 1 z
(Disconnection or defective L126 (female) (1) tance
contact in connector) Wiring harness between L126 (female) (2) – Resis-
Max. 1 z
Defective transmission con- without turning starting switch ON.
3
troller L63 (female) Resistance
Between (7) and chassis ground 200 – 400 z
40-304 14 WA470, 480-6

Failure code [D150KA] (Emergency steering relay: Disconnection) SEN04524-01
WA470, 480-6 40-304 15

SEN04524-01 Failure code [D150KB] (Emergency steering relay: Short circuit)
Failure code [D150KB] (Emergency steering relay: Short circuit) 1
Action code Failure code Emergency steering relay: Short circuit

Trouble
E03 D150KB (Transmission controller)
Contents of • Since the emergency steering relay output system is shorted, signals are not output to the emer-
trouble gency steering relay.
Problem that • If abnormality is detected in the steering pressure, operation of the automatic emergency steering
appears on becomes unavailable.
machine • Self-check of the emergency steering is ended abnormally.
Related
information
• Method of reproducing failure code: Start engine and then operate the steering.

the same type, if the condition becomes normal, the emergency
steering relay is defective.
Defective emergency steer-
1 ing relay (L126) (Internal a Prepare with starting switch OFF, then carry out troubleshooting
short circuit) without turning starting switch ON.
Possible causes
value in normal Between (1), (2) and chassis
state Min. 1 Mz
ground
2 ness (Short circuit with GND
circuit) Wiring harness between L63 (female) (7) – Resis-
Min. 1 Mz
3
40-304 16 WA470, 480-6

Failure code [D150KB] (Emergency steering relay: Short circuit) SEN04524-01
WA470, 480-6 40-304 17

SEN04524-01 Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)
Failure code [D150KY] (Emergency steering relay: Short circuit with

power supply line) 1
Action code Failure code Emergency steering relay: Short circuit with power supply line
Trouble
E03 D150KY (Transmission controller)
Contents of • Since the emergency steering relay output system is shorted with the power source, signal output to
trouble the emergency steering relay is continued.
Problem that
• The emergency steering is activated during travel (resulting in seizure of the emergency steering
appears on
motor).
machine
Related
information

the same type, if the condition becomes normal, the emergency
steering relay is defective.
Defective emergency steer-
1 ing relay (L126) (Internal a Prepare with starting switch OFF, then carry out troubleshooting
short circuit) without turning starting switch ON.
Possible causes
state Min. 1 Mz
ground
Hot short in wiring harness and carry out troubleshooting.
2
(Contact with 24V circuit) Wiring harness between L63 (female) (7) –
Voltage Max. 1 V
L126 (female) (1) and chassis ground
3
40-304 18 WA470, 480-6

Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line) SEN04524-01
WA470, 480-6 40-304 19

SEN04524-01 Failure code [D160KA] (Backup lamp relay output: Disconnection)
Failure code [D160KA] (Backup lamp relay output: Disconnection) 1
Action code Failure code Backup lamp relay output: Disconnection

Trouble
• Since the backup lamp relay output system is disconnected, signals are not output to the backup
Contents of lamp relay.
trouble • Since the backup lamp relay output system is shorted with the power source, signal output to the
backup lamp relay is continued.
Action of • Turns the output to the backup lamp relay OFF.
• The backup lamp does not light up (disconnection).
Problem that
• The backup buzzer does not sound (disconnection).
appears on
• The backup lamp remains turned on (hot short).
machine
• The backup buzzer sound does not stop (hot short).
• The output state (ON/OFF) to the backup lamp relay can be checked with the monitoring function
Related (Code: 90951, D-OUT-20).
information • Method of reproducing failure code: Turn the starting switch ON, and set FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).

When backup lamp relay (L117) is replaced with a relay of the same
type, if the condition becomes normal, the backup lamp relay is
Defective backup lamp relay defective.
1
(L117) (Internal short circuit)
Between (1) and (2) 200 – 400 z
and standard
state chassis ground tance
3
Voltage Max. 1 V
FNR (directional)
lever, joystick steer-
Defective transmission con- L63 ing FNR (directional) Voltage
4
troller switch or right FNR
Between (4) and R (Reverse) 20 – 30 V
chassis ground Other than above Max. 1 V
40-304 20 WA470, 480-6

Failure code [D160KA] (Backup lamp relay output: Disconnection) SEN04524-01
WA470, 480-6 40-304 21

SEN04524-01 Failure code [D160KB] (Backup lamp relay output: Short circuit)
Failure code [D160KB] (Backup lamp relay output: Short circuit) 1
Action code Failure code Backup lamp relay output: Short circuit
Trouble
Contents of • Since the backup lamp relay output system is shorted, signals are not output to the backup lamp
trouble relay.
Action of • Turns the output to the backup lamp relay OFF.
Problem that
• The backup lamp does not light up.
appears on
• The backup buzzer does not sound.
machine
• The output state (ON/OFF) to the backup lamp relay can be checked with the monitoring function
information • Method of reproducing failure code: Turn the starting switch ON, and set FNR (directional) lever, joy-
stick steering FNR (directional) switch, or right FNR (directional) switch to R (reverse).

Defective backup lamp relay defective.
1
(L117) (Internal short circuit)
Between (1) and (2) 200 – 400 z
Possible causes
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal 2 ness (Contact with ground
state circuit) Wiring harness between L63 (female) (4) – Resis-
Min. 1 Mz
FNR (directional)
lever, joystick steer-
Defective transmission con- L63 ing FNR (directional) Voltage
3
troller switch or right FNR
40-304 22 WA470, 480-6

Failure code [D160KB] (Backup lamp relay output: Short circuit) SEN04524-01
WA470, 480-6 40-304 23

SEN04524-01 Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)
Failure code [D191KA] (Joystick steering neutral safety relay:

Disconnection) 1
Action code Failure code Joystick steering neural safety relay: Disconnection
Trouble
E01 D191KA (Work equipment controller system)
Contents of • Since the output system of the joystick steering neutral safety relay is disconnected, signals are not
trouble output to the neutral safety relay.
Action of
controller
• While operating joystick steering, engine can be started (Steering moves immediately after engine is
Problem that
started).
appears on
• Starting of the engine is available even when the joystick steering FNR (directional) switch or right
machine
FNR (directional) switch is not set to N (neutral).
• When the neutral position adjustment (initial setting) is not done for the joystick steering, the neutral
safety relay does not work.
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
Related
(Code: 40954, D-OUT-20).
information
• Only for joystick steering
• Method of reproducing failure code: Turn the starting switch ON and operate the joystick steering
(with the engine being stopped).

Defective joystick steering without turning starting switch ON.
1 neutral safety relay (L113)
Between (1) and (2) 200 – 400 z
Possible causes
and standard 2 Max. 1 z
value in normal (Disconnection or defective L113 (female) (1) tance
state contact in connector) Wiring harness between L113 (female) (2) – Resis-
Max. 1 z
Defective work equipment • Operate the joystick steering lever.
3
controller L63 Voltage
20 – 30 V
ground
40-304 24 WA470, 480-6

Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection) SEN04524-01
WA470, 480-6 40-304 25

SEN04524-01 Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)
Failure code [D191KB] (Joystick steering neutral safety relay: Short

circuit) 1
Action code Failure code Joystick steering neural safety relay: Short circuit
Trouble
E01 D191KB (Work equipment controller system)
Contents of • Since the output system of the joystick steering neutral safety relay is shorted, signals are not output
trouble to the neutral safety relay.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
• While operating joystick steering, engine can be started (Steering moves immediately after engine is
Problem that
started).
appears on
• Starting of the engine is available even when the joystick steering FNR (directional) switch or right
machine
FNR (directional) switch is not set to N (neutral).
• As long as the failure code is turned on, the work equipment controller does not output signals to the
joystick steering neutral safety relay.
Related
• The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
information
(Code: 40954, D-OUT-20).

Defective joystick steering L113 (male) Resistance
(Internal short circuit) Between (1) and (2) 200 – 400 z
Between (1), (2) and chassis
Min. 1 Mz
ground
Possible causes
state (Contact with ground circuit) Wiring harness between L63 (female) (37) – Resis-
Min. 1 Mz
3
20 – 30 V
ground
40-304 26 WA470, 480-6

Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit) SEN04524-01
WA470, 480-6 40-304 27

SEN04524-01 Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line)
Failure code [D191KY] (Joystick steering neutral safety relay: Short

circuit with power supply line) 1
Action code Failure code Joystick steering neutral safety relay: Short circuit with power supply
Trouble
E01 D191KY line (Work equipment controller system)
Contents of • Since the output system of the joystick steering neutral safety relay is shorted with the power source,
trouble signals are not output to the neutral safety relay.
Action of • Turns the output to the joystick steering neutral safety relay OFF.
Problem that
appears on • The engine does not start.
machine
• As long as the failure code is turned on, the work equipment controller does not output signals to the
Related joystick steering neutral safety relay.
information • The output state (ON/OFF) to the neutral safety relay can be checked with the monitoring function
(Code: 40954, D-OUT-20).

Min. 1 Mz
ground
Possible causes
2
state (Contact with 24V circuit) Wiring harness between L63 (female) (37) –
Voltage Max. 1 V
3
20 – 30 V
ground
40-304 28 WA470, 480-6

Failure code [D191KY] (Joystick steering neutral safety relay: Short circuit with power supply line) SEN04524-01
WA470, 480-6 40-304 29

SEN04524-01 Failure code [D192KA] (ECSS solenoid: Disconnection)
Failure code [D192KA] (ECSS solenoid: Disconnection) 1
Action code Failure code ECSS solenoid: Disconnection

Trouble
Contents of • Since the ECSS solenoid system is disconnected, no current flows when ECSS solenoid output is
trouble turned ON.
Action of • None in particular.
Problem that
appears on • The ECSS does not operate.
machine
• The output state (ON/OFF) to the ECSS solenoid can be checked with the monitoring function
(Code: 40949, D-OUT-1).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn the starting switch ON, ECSS switch ON and drive the
machine at any gear speed other than 1st speed.

Defective ECSS solenoid without turning starting switch ON.
1
(Internal disconnection) F13 (male) Resistance
Between (1) and (2) 5 – 15 z
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness Wiring harness between L63 (female) (17) – Resis-
value in normal 2 Max. 1 z
(Disconnection or defective F13 (female) (1) tance
state contact in connector) Wiring harness between F13 (female) (2) – Resis-
Max. 1 z
Defective transmission con-
3 L63 (female) Resistance
troller
Wiring harness between (17) –
5 – 15 z
(13)
40-304 30 WA470, 480-6

Failure code [D192KB] (ECSS solenoid: Short circuit) SEN04524-01
Failure code [D192KB] (ECSS solenoid: Short circuit) 1
Action code Failure code ECSS solenoid: Short circuit

Trouble
Contents of • Since the ECSS solenoid system is shorted, abnormal current flowed when ECSS solenoid output is
trouble ON.
Action of • Turns the output to the ECSS solenoid OFF.
Problem that
• The ECSS does not operate.
appears on
• The wiring harness or controller may be burnt out.
machine
(Code: 40949, D-OUT-1).
Related
• Applicable only to ECSS specification machines (if equipped)
information
• Method of reproducing failure code: Turn the starting switch ON, ECSS switch ON and drive the
machine at any gear speed other than 1st speed.

Defective ECSS solenoid F13 (male) Resistance
1
Min. 1 Mz
Possible causes chassis ground
value in normal Grounding fault in wiring har- without turning starting switch ON.
state 2 ness
(Contact with ground circuit) Wiring harness between L63 (female) (17) – Resis-
Min. 1 Mz
F13 (female) (1) and chassis ground tance
Defective transmission con- L63 (female) Resistance
3
troller
(17) – (13) 5 – 15 z
(17), (13) – chassis ground Min. 1 Mz
WA470, 480-6 40-304 31

SEN04524-01 Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)
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
controller
Problem that
appears on • The ECSS keeps operating.
machine
information • Applicable only to ECSS specification machines (if equipped)

Defective ECSS solenoid F13 (male) Resistance
1
Min. 1 Mz
Possible causes ground
state 2
Voltage Max. 1 V
F13 (female) (1) and chassis ground
3
troller
(17) – (13) 5 – 15 z
(17), (13) – chassis ground Min. 1 Mz
40-304 32 WA470, 480-6

Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line) SEN04524-01
WA470, 480-6 40-304 33

SEN04524-01 Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection)
Failure code [D193KA] (Joystick steering solenoid cut-off relay:

Disconnection) 1
Action code Failure code Joystick steering solenoid cut-off relay: Disconnection
Trouble
E03 D193KA (Work equipment controller system)
Contents of • Since the output system of the joystick steering solenoid cut-off relay is disconnected, signals are not
trouble output to the joystick steering solenoid cut-off relay.
• Stops output of signal to the joystick steering right and left solenoids.
Action of • Stops output of signal to the joystick steering cut-off relay.
Problem that
appears on • The operator cannot operate the joystick steering.
machine
• The output state (ON/OFF) to the joystick steering solenoid cut-off relay can be checked with the
monitoring function (Code: 40953, D-OUT-8).
Related
information

1 neutral cut-off relay (L41)
Between (5) and (6) 200 – 400 z
Possible causes
state contact in connector) Wiring harness between L41 (female) (6) – Resis-
Max. 1 z
3
Between (26) and
20 – 30 V
chassis ground
40-304 34 WA470, 480-6

Failure code [D193KA] (Joystick steering solenoid cut-off relay: Disconnection) SEN04524-01
WA470, 480-6 40-304 35

SEN04524-01 Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit)
Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short

circuit) 1
Action code Failure code Joystick steering solenoid cut-off relay: Short circuit
Trouble
E03 D193KB (Work equipment controller system)
Contents of • Since the output system of the joystick steering solenoid cut-off relay is shorted, signals are not out-
trouble put to the joystick steering solenoid cut-off relay.
controller • Turn the centralized warning lamp and alarm buzzer ON.
Problem that
machine
Related
information

1 cut-off relay (L41) (Internal
short circuit) Between (5) and (6) 200 – 400 z
Min. 1 Mz
ground
Possible causes
Min. 1 Mz
3
controller L73 Resistance
Between (26) and
20 – 30 V
chassis ground
40-304 36 WA470, 480-6

Failure code [D193KB] (Joystick steering solenoid cut-off relay: Short circuit) SEN04524-01
WA470, 480-6 40-304 37

SEN04524-01 Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line)
Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short

Action code Failure code Joystick steering solenoid cut-off relay: Short circuit with power sup-
Trouble
E03 D193KY ply line (Work equipment controller system)
Contents of • Since the output system of the joystick steering solenoid cut-off relay is shorted with the power
trouble source, signals are not output to the joystick steering solenoid cut-off relay.
Problem that
machine
Related
information

1 cut-off relay (L41) (Internal
Between (5) (6) and chassis
Min. 1 Mz
ground
Possible causes
Ground fault in wiring har- and carry out troubleshooting.
state (Contact with ground circuit) Wiring harness between L73 (female) (26) – Voltage Max. 1 V
3
Between (26) and
20 – 30 V
chassis ground
40-304 38 WA470, 480-6

Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line) SEN04524-01
WA470, 480-6 40-304 39

SEN04524-01 Failure code [D193KY] (Joystick steering solenoid cut-off relay: Short circuit with power supply line)
40-304 40 WA470, 480-6

Failure code [D5ZHKA] (Terminal C signal: Disconnection) SEN04524-01
Failure code [D5ZHKA] (Terminal C signal: Disconnection) 1
Action code Failure code Terminal C signal: Disconnection

Trouble
E01 D5ZHKA (Transmission controller)
Contents of • Terminal C system is disconnected or shorted with the chassis ground (Engine speed is above 500
trouble rpm and no starting switch terminal C signal has been input.)
Problem that
appears on • Starting performance is poor.
machine
• The input state (ON/OFF) to the transmission controller from starting switch terminal C can be
Related
checked with the monitoring function (Code: 40907, D-IN-16).
information
• Method of reproducing failure code: Set the starting switch to START position

1
a Prepare with starting switch OFF, then turn starting switch ON,
OFF or START and carry out troubleshooting
Defective starting switch S40 Starting switch Resistance
2
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
Disconnection in wiring har- Wiring harness between S40 (female) (3) – Resis-
Max. 1 z
ness W60 (female) (3) tance
3
(Disconnection or defective Wiring harness between W60 (female) (6) – Resis-
Possible causes Wiring harness between L116 (female) (3) – Resis-
value in normal
state
Wiring harness between S40 (female) (3) –
Resis-
W60 (female) (3), – circuit branch end and Min. 1 Mz
tance
Grounding fault in wiring har- chassis ground
4 ness Wiring harness between W60 (female) (6) –
(Contact with ground circuit) L116 (female) (5), – circuit branch end and Resis-
Min. 1 Mz
tance
chassis ground
Wiring harness between L116 (female) (3) –
Resis-
L62 (female) (35), – circuit branch end and Min. 1 Mz
tance
chassis ground
Defective transmission con- L62 Starting switch Voltage
5
troller
Between (35) and START 20 – 30 V
chassis ground OFF, ON Max. 1 V
WA470, 480-6 40-304 41

SEN04524-01 Failure code [D5ZHKA] (Terminal C signal: Disconnection)
40-304 42 WA470, 480-6

Failure code [D5ZHKA] (Terminal C signal: Disconnection) SEN04524-01
WA470, 480-6 40-304 43

SEN04524-01 Failure code [D5ZHKA] (Terminal C signal: Disconnection)
40-304 44 WA470, 480-6

Failure code [D5ZHKB] (Terminal C signal: Short circuit) SEN04524-01
Failure code [D5ZHKB] (Terminal C signal: Short circuit) 1
Action code Failure code Terminal C signal: Short circuit

Trouble
E01 D5ZHKB (Transmission controller)
Contents of • Terminal C system is shorted with the power source (Engine speed is above 500 rpm and starting
trouble switch terminal C signal has been input.).
Action of • Engine start assistance is not working.
Problem that
appears on • Starting performance is poor.
machine
• The input state (ON/OFF) to the transmission controller from starting switch terminal C can be
Related
information

OFF or START and carry out troubleshooting.
1
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
after engine is started and during engine operation.
Possible causes W60 (female) (3), – circuit branch end and Voltage Max. 1 V
and standard chassis ground
value in normal Hot short in wiring harness
2 Wiring harness between W60 (female) (6) –
state (Contact with 24V circuit)
L116 (female) (5), – circuit branch end and Voltage Max. 1 V
chassis ground
chassis ground
3
troller
WA470, 480-6 40-304 45

SEN04524-01 Failure code [D5ZHKB] (Terminal C signal: Short circuit)
40-304 46 WA470, 480-6

Failure code [D5ZHKB] (Terminal C signal: Short circuit) SEN04524-01
WA470, 480-6 40-304 47

SEN04524-01 Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)
Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)1

Action code Failure code Terminal C signal: Disconnection or short circuit
Trouble
E01 D5ZHKZ (Work equipment controller system)
Contents of • Terminal C system is disconnected (Engine speed is above 500 rpm and no starting switch terminal
trouble C signal has been input.)
Problem that • Engine starts when work equipment control lever is not at Neutral (disconnection).
appears on • Relieving of residual pressure on the work equipment becomes unavailable if the engine stopped
machine (hot short).
• The input state (ON/OFF) to the work equipment controller from starting switch terminal C can be
Related
information
• Method of reproducing failure code: Set the starting switch to START position.

1
2
START Max. 1 z
Between (1) and (3)
OFF, ON Min. 1 Mz
Max. 1 z
3
Wiring harness between L116 (female) (3) – Resis-
Max. 1 z
Possible causes
and standard
value in normal Wiring harness between S40 (female) (3) –
Resis-
state W60 (female) (3), – circuit branch end and Min. 1 Mz
tance
Min. 1 Mz
tance
chassis ground
Resis-
tance
chassis ground
W60 (female) (3), – circuit branch end and Voltage Max. 1 V
chassis ground
Hot short in wiring harness
5 Wiring harness between W60 (female) (6) –
(Contact with 24V circuit)
chassis ground
chassis ground
40-304 48 WA470, 480-6

Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) SEN04524-01
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
WA470, 480-6 40-304 49

40-304 50 WA470, 480-6

Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit) SEN04524-01
WA470, 480-6 40-304 51

40-304 52 WA470, 480-6

Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) SEN04524-01
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.)
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.

Defective starting switch S40 Starting switch Voltage
1
Max. 1 z
2
Max. 1 z
Possible causes L52 (female) (2) tance
value in normal without turning starting switch ON.
state
Resis-
W60 (female) (3), – circuit branch end and Min. 1 Mz
tance
Min. 1 Mz
tance
chassis ground
Resis-
tance
chassis ground
4 Defective machine monitor L52 Starting switch Voltage
WA470, 480-6 40-304 53

SEN04524-01 Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state)
40-304 54 WA470, 480-6

Failure code [D5ZHL6] (Terminal C signal: Signal does not match engine running or stopped state) SEN04524-01
WA470, 480-6 40-304 55

SEN04524-01 Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)
Failure code [DA80L4] (Auto grease controller: ON/OFF signals

disagree) 1
Action code Failure code Auto grease controller: ON/OFF signals disagree
Trouble
— DA80L4 (Machine monitor system)
Contents of
• 24V signal has been input to the auto grease sensor A/B circuits at the same time.
trouble
Problem that
• Auto grease does not work.
appears on
• Auto grease lamp goes off.
machine
• The input state (ON/OFF) from the auto grease controller can be checked with the monitoring func-
Related tion (Code: 40900, D-IN-4 and D-IN-5).
information • Applicable only to machines equipped with auto grease function (if equipped)
• Method of reproducing failure code: Turn the starting switch and auto grease start button ON.

1
(Contact with 24V circuit) Wiring harness between L52
Voltage Max. 1 V
(female) (3) – R38 (female) (2)
Defective auto grease con-
2 a Carry out troubleshooting for auto grease system.
troller
Possible causes and carry out troubleshooting.
and standard Auto-grease
L52 Auto grease Voltage
value in normal lamp
state In operation Max. 1 V ON
Between (3) With empty tank 20 – 30 V Flashing (1 Hz)
3 Defective machine monitor and chassis
ground Max. 1 V Flashing (2 Hz)
When abnormal
20 – 30 V OFF
In operation 20 – 30 V ON
Between (12) With empty tank Max. 1 V Flashing (1 Hz)
and chassis
ground Max. 1 V Flashing (2 Hz)
When abnormal
20 – 30 V OFF
40-304 56 WA470, 480-6

Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree) SEN04524-01
WA470, 480-6 40-304 57

SEN04524-01 Failure code [DAF3KK] (Machine monitor: Low source voltage (input))
Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) 1
Action code Failure code Machine monitor: Low source voltage (input)
Trouble
E03 DAF3KK (Machine monitor system)
Contents of • When the voltage of the switch power supply (power supply for operation) is above 17 V, the voltage
trouble of the constant power supply (power supply for the memory) is below 17 V.
Problem that
• The service meter reading is abnormal, the odometer does not advance and failure history data is
appears on
not saved.
machine
Related
information

ness Wiring harness between FS1 (male) (1) – Resis-
1 Max. 1 z
(Disconnection or defective fuse No. 3 of fuse box 1 tance
Possible causes contact) Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
and standard box 1 – L51 (female) (4), (5) tance
Grounding fault in wiring har-
2 ness Wiring harness between fuse No. 3 of fuse
(Contact with ground circuit) box 1 – L51 (female) (4), (5) and chassis Resis-
Min. 1 Mz
tance
ground
Since trouble is in system, troubleshooting cannot be carried out.
(Replace the machine monitor)
40-304 58 WA470, 480-6

Failure code [DAF3KK] (Machine monitor: Low source voltage (input)) SEN04524-01
WA470, 480-6 40-304 59

SEN04524-01 Failure code [DAF5KP] (Machine monitor: Low output voltage)
Failure code [DAF5KP] (Machine monitor: Low output voltage) 1
Action code Failure code Machine monitor: Low output voltage

Trouble
E01 DAF5KP (Machine monitor system)
Contents of • When the voltage of the switch power supply (power supply for operation) is above 17 V, the voltage
trouble of the sensor is below 5 V.
controller • Even if cause of failure disappears, system does not reset itself until it is restarted.
Problem that
appears on • Machine monitor does not display load.
machine
Related • Only for electric lever (if equipped)
information • Method of reproducing failure code: Turn the starting switch ON.

F15 (male) Resistance
Between (C) and (A) 5 kz ± 20%
Between (A), (B), (C) and chas-
Min. 1 Mz
sis ground
Defective lift arm angle sen- a Prepare with starting switch OFF, then turn starting switch ON
1
sor (Internal short circuit) and carry out troubleshooting.
F15 Lift arm cylinder Voltage
Between (C) and (A) Constant 4.85 – 5.15 V
Constant 0.83 – 4.17 V
Possible causes Between (B) and (A) At max. length 3.50 – 4.17 V
and standard
value in normal At min. length 0.83 – 1.88 V
F16 Resistance
Between (A), (B), (C) and
Min. 1 Mz
chassis ground
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
Between (C) and (A) When released 0.50 – 0.90 V
When relieved 3.02 – 3.42 V
40-304 60 WA470, 480-6

Failure code [DAF5KP] (Machine monitor: Low output voltage) SEN04524-01

F17 Resistance
Min. 1 Mz
chassis ground
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
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
Between L51 (female) (16) – F15 (female) Resis-
Grounding fault in wiring har- (C) wiring harness and chassis ground Min. 1 Mz
tance
4 ness
Min. 1 Mz
F16 (female) (B) and chassis ground tance
Min. 1 Mz
5 Defective machine monitor L51 Lift arm cylinder Voltage
Between (16) and
chassis ground
WA470, 480-6 40-304 61

SEN04524-01 Failure code [DAF5KP] (Machine monitor: Low output voltage)
40-304 62 WA470, 480-6

Failure code [DAF5KP] (Machine monitor: Low output voltage) SEN04524-01
WA470, 480-6 40-304 63

Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication
SEN04524-01 (Abnormality in target component system))

Defective communication (Abnormality in target component system)) 1
Action code Failure code CAN communication with machine monitor: Defective communica-
Trouble tion (Abnormality in target component system) (Transmission con-
E03 DAFRKR troller system)
Contents of
• Transmission controller cannot get information from machine monitor.
trouble
Action of
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
controller
Problem that
appears on • The monitor does not display normally.
machine
Related
information

1
value in normal Wiring harness between L62 (female) (22), Resis-
Max. 1 z
Wiring harness between L62 (female) (22), Resis-
Max. 1 z
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
Max. 1 z
Max. 1 z
40-304 64 WA470, 480-6

Failure code [DAFRKR] (CAN communication with machine monitor: Defective communication
(Abnormality in target component system)) SEN04524-01

Resis-
tance
ground
Resis-
tance
ground
Grounding fault in wiring har- Resis-
(32) – EC2 (female) (46), (47) and chassis Min. 1 Mz
3 ness tance
Possible causes ground
(Contact with ground circuit)
and standard Wiring harness between L62 (female) (22),
state tance
ground
Resis-
tance
ground
Resis-
tance
ground
WA470, 480-6 40-304 65

SEN04524-01

©2009 KOMATSU
All Rights Reserved
40-304 66
SEN04525-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Failure code [DAQ0KK] (Transmission controller: Low source voltage) ......................................................... 4
Failure code [DAQ0KT] (Transmission controller: Abnormality in controller).................................................. 6
Failure code [DAQ1KA] (Terminal ACC input: Disconnection)........................................................................ 7
Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)) ....... 10
Disagreement of model selection signals) ............................................................................................. 12
Failure code [DAQRKR] (CAN communication with transmission controller:
Defective communication (Abnormality in target component system)) .................................................. 14
Failure code [DAQRMA] (Transmission controller option setting: Malfunction) ............................................ 16
Defective communication (Abnormality in target component system) ................................................... 18
Failure code [DB90KK] Work equipment controller: Low source voltage (input) .......................................... 20
Failure code [DB90KT] Work equipment controller: Abnormality in controller .............................................. 22
Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)...... 24
Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range ............ 26
Disagreement in model selection signals) ............................................................................................. 29
Failure code [DB9RKR] CAN communication with work equipment controller:
Defective communication (Abnormality in target component system) ................................................... 30
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction) ........................................ 32
WA470, 480-6 40-305 1

SEN04525-01
Failure code [DB9RMC] (CAN communication with transmission controller,

engine controller and machine monitor: Defective operation)................................................................ 33
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time ............................. 36
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time............................. 38
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time .............................. 40
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time .............................. 42
Switch is kept pressed for long time ...................................................................................................... 44
Failure code [DD1BLD] Remote positioner raise/lower set switch (lower):
Switch is kept pressed for long time ...................................................................................................... 46
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time........................... 48
Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time........ 50
Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time ........ 52
Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) ............ 54
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)..................................... 56
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)..................... 58
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree).............................. 60
Switch is kept pressed for long time) ..................................................................................................... 64
40-305 2 WA470, 480-6

SEN04525-01
WA470, 480-6 40-305 3

SEN04525-01 Failure code [DAQ0KK] (Transmission controller: Low source voltage)
Failure code [DAQ0KK] (Transmission controller: Low source voltage) 1
Action code Failure code Transmission controller: Low source voltage

Trouble
E03 DAQ0KK (Transmission controller)
• Voltage of constant power supply (battery direct power supply) of the transmission controller is low.
Contents of
• Voltage of constant power supply (battery direct power supply) is below 18 V and engine speed is
trouble
above 500 rpm.
• Cannot sense the input signals normally.
Action of
• Sets all the controller output to OFF (neutral hold state).
controller
FNR (directional) switch or right FNR (directional) switch is set to N (Neutral).
Problem that
appears on • The machine cannot move (transmission is stuck in Neutral).
machine
Related
information

If the slow-blow fuse is shut down, the circuit probably has a
1 Defective slow-blow fuse
grounding fault, etc. (See cause 4.)
2
Disconnection in wiring har- Wiring harness between emergency steering Resis-
Max. 1 z
ness relay R02 – slow-blow fuse R02 tance
3
(Disconnection or defective Wiring harness between slow-blow fuse R03 Resis-
– fuse No. 5 of fuse box 1 tance
Wiring harness between fuse No. 5 of fuse Resis-
Max. 1 z
box 1 – L63 (female) (1), (11) tance
Possible causes
state Wiring harness between emergency steering
Resis-
relay R02 – slow-blow fuse R02 and chassis Min. 1 Mz
tance
Grounding fault in wiring har- ground
4 ness Wiring harness between slow-blow fuse R03
(Contact with ground circuit) – fuse No. 5 of fuse box 1 and chassis Resis-
Min. 1 Mz
tance
ground
Resis-
box 1 – L63 (female) (1), (11), – circuit Min. 1 Mz
tance
branch end and chassis ground
5 L63 Voltage
troller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)
40-305 4 WA470, 480-6

Failure code [DAQ0KK] (Transmission controller: Low source voltage) SEN04525-01
WA470, 480-6 40-305 5

SEN04525-01 Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)
Failure code [DAQ0KT] (Transmission controller: Abnormality in

controller) 1
Action code Failure code Transmission controller: Abnormality in controller

Trouble
E01 DAQ0KT (Transmission controller)
• The information in the ROM (non-volatile memory) of the transmission controller is abnormal.
Contents of
• The battery direct power is not available immediately after the starting switch is OFF. Thus, the end-
trouble
ing process is not normally executed.
Action of • Sets the internal adjustment values to the default values.
Problem that
appears on • The gear shifting feeling of the transmission may become bad.
machine
Related
information

Possible causes
and standard Since trouble is in system, troubleshooting cannot be carried out.
value in normal Defective transmission con- (If there is no visible trouble on the machine, it is allowed to use the
1
state troller transmission controller without modifying the initial setting or initial
adjustment.)
40-305 6 WA470, 480-6

Failure code [DAQ1KA] (Terminal ACC input: Disconnection) SEN04525-01
Failure code [DAQ1KA] (Terminal ACC input: Disconnection)

Action code Failure code Terminal ACC input: Disconnection
Trouble
E03 DAQ1KA (Transmission controller)
Contents of
• Terminal ACC system is disconnected.
trouble
Action of
controller
Problem that
appears on • When starting switch is turned ON, any item does not light up.
machine
Related
• Method of reproducing failure code: Set the starting switch to ON position.
information

1 If the fuse is burn, the circuit probably has a grounding fault, etc.
box 1
2
ON, START Max. 1 z
Between (1) and (4)
OFF Min. 1 Mz
and standard
Disconnection in wiring har- Wiring harness between battery (–) terminal Resis-
state ness and chassis ground tance
3
(Disconnection or defective Wiring harness between battery (+) terminal Resis-
– R01 – F01 (No.1) tance
Wiring harness between S40 (female) (4) – Resis-
Max. 1 z
4
troller
Between (14) and ON, START 20 – 30 V
chassis ground OFF Max. 1 V
WA470, 480-6 40-305 7

SEN04525-01 Failure code [DAQ1KA] (Terminal ACC input: Disconnection)
Circuit diagram related to engine starting system (C terminal signal)
40-305 8 WA470, 480-6

Failure code [DAQ1KA] (Terminal ACC input: Disconnection) SEN04525-01
WA470, 480-6 40-305 9

SEN04525-01 Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input))
Failure code [DAQ2KK] (Transmission controller load power supply

line: Low source voltage (input)) 1
Action code Failure code Transmission controller load power supply line: Low source voltage
Trouble
E03 DAQ2KK (input) (Transmission controller system)
• The voltage of the 24 V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input is turned OFF, constant power supply (battery direct power
trouble
supply) is above 20 V and solenoid power supply is below 18 V.
• Strain itself not to display failure codes that may be false detected due to low 24 V solenoid source
voltage
Action of
controller
• Even if cause of failure disappears, system does not reset itself until directional lever, joystick steer-
ing FNR (directional) switch or directional selector switch is set to N (Neutral).
Problem that
• The machine cannot move (transmission is stuck in Neutral).
appears on
• When the current fan rotation is reverse, its rotating direction is switched to forward.
machine
Related
information

1
(Disconnection or defective Wiring harness between L63(female) (2), Resis-
(12), (22) – fuse No. 2 of fuse box 2 tance
and standard
2 ness Wiring harness between L63(female) (2),
(Contact with ground circuit) (12), (22) – fuse No. 2 of fuse box 2 and Min. 1 Mz
state tance
chassis ground
3 L63 Voltage
troller
Between (2), (12) (22) and (21),
20 – 30 V
(31), (32), (33)
40-305 10 WA470, 480-6

Failure code [DAQ2KK] (Transmission controller load power supply line: Low source voltage (input)) SEN04525-01
WA470, 480-6 40-305 11

Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection
SEN04525-01 signals)

Disagreement of model selection signals) 1
Action code Failure code Transmission controller model selection: Disagreement of model
Trouble
E03 DAQ9KQ selection signals (Machine monitor system)
Contents of
• The transmission controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
• Does not display failure codes which may be false detected.
Problem that
appears on • Continuing the travel in this condition can damage the transmission.
machine
Related
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting).
state Transmission controller part Confirm the part number of the transmission controller. It must be
2
number error replaced if it is not the specified controller.
40-305 12 WA470, 480-6

Failure code [DAQ9KQ] (Transmission controller model selection: Disagreement of model selection
signals) SEN04525-01
WA470, 480-6 40-305 13

Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication
SEN04525-01 (Abnormality in target component system))
Failure code [DAQRKR] (CAN communication with transmission

controller: Defective communication (Abnormality in target component
system)) 1
Action code Failure code CAN communication with transmission controller: Defective commu-
Trouble nication (Abnormality in target component system) (Machine moni-
E03 DAQRKR tor system)
Contents of
• Machine monitor cannot get information from transmission controller.
trouble
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Action of
controller
Problem that
machine
Related
information

1
Max. 1 z
Max. 1 z
2 Max. 1 z
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
40-305 14 WA470, 480-6

Failure code [DAQRKR] (CAN communication with transmission controller: Defective communication
(Abnormality in target component system)) SEN04525-01

Resis-
tance
ground
Resis-
tance
ground
3 ness tance
ground
Possible causes Wiring harness between L62 (female) (22),
Resis-
and standard (32) – L80 (female) (7), (8) and chassis Min. 1 Mz
tance
value in normal ground
state Wiring harness between L62 (female) (22),
Resis-
tance
ground
Resis-
tance
ground
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of transmission controller
mating of the connector.
WA470, 480-6 40-305 15

SEN04525-01 Failure code [DAQRMA] (Transmission controller option setting: Malfunction)
Failure code [DAQRMA] (Transmission controller option setting:

Malfunction) 1
Action code Failure code Transmission controller option setting: Malfunction

Trouble
E03 DAQRMA (Machine monitor system)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition
trouble done by the transmission controller.
Action of • The transmission controller follows the option setting being recognized by itself.
Problem that
appears on • The option setting does not work normally.
machine
Related
information

Adjust the option setting using the adjustment function of the
Possible causes 1 Defective option setting machine monitor. (See Special functions of machine monitor
and standard (EMMS) in Testing and adjusting.)
value in normal The machine monitor may be defective. (Since trouble is in system,
state 2 Defective machine monitor
troubleshooting cannot be carried out.)
Defective transmission con- The transmission controller may be defective. (Since trouble is in
3
troller system, troubleshooting cannot be carried out.)
40-305 16 WA470, 480-6

Failure code [DAQRMA] (Transmission controller option setting: Malfunction) SEN04525-01
WA470, 480-6 40-305 17

Failure code [DB2RKR] (CAN communication with engine controller: Defective communication
SEN04525-01 (Abnormality in target component system)

Defective communication (Abnormality in target component system) 1
Action code Failure code CAN communication with engine controller: Defective communica-
Trouble tion (Abnormality in target component system) (Transmission con-
E03 DB2RKR troller system)
Contents of • Communication via CAN signal line between the transmission controller and engine controller is
trouble defective.
• Uses CAN information that was sent from engine controller before the occurrence of the error.
• Fixes the recognition value of engine speed to 2,100 rpm.
Action of
• Holds recognized position of accelerator at 80%.
controller
Problem that
machine
Related
information

1
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
Max. 1 z
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
40-305 18 WA470, 480-6

Failure code [DB2RKR] (CAN communication with engine controller: Defective communication
(Abnormality in target component system) SEN04525-01

Resis-
tance
ground
Resis-
tance
ground
3 ness tance
ground
Possible causes Wiring harness between EC2 (female) (46),
Resis-
tance
state Wiring harness between EC2 (female) (46),
Resis-
tance
ground
Resis-
tance
ground
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of engine controller
mating of the connector.
WA470, 480-6 40-305 19

SEN04525-01 Failure code [DB90KK] Work equipment controller: Low source voltage (input)
Failure code [DB90KK] Work equipment controller: Low source voltage

(input) 1
Action code Failure code Work equipment controller: Low source voltage (input)
Trouble
E03 DB90KK (Work equipment controller system)
Contents of • Voltage of work equipment controller UNSW power supply (battery direct power supply) is low.
trouble • Voltage of constant power supply (battery direct power supply) is 18 V or less.
• Does not display failure codes other than this code if voltage of constant power supply (battery direct
power supply) remains under 18 V for more than 2 seconds.
Action of • Even if cause of failure disappears, system does not reset itself until the joystick steering lever and
controller work equipment lever are once set to N (Neutral).
• Cannot operate normally since it cannot sense the input signals properly.
Problem that
appears on • The machine cannot operate normally.
machine
Related
information

If the slow-blow fuse is shut down, the circuit probably has a
grounding fault, etc. (See cause 4.)
2
Disconnection in wiring har- Wiring harness between emergency steering Resis-
Max. 1 z
ness relay R02 – slow-blow fuse R02 tance
3
(Disconnection or defective Wiring harness between slow-blow fuse R03 Resis-
– fuse No. 3 of fuse box 1 tance
Max. 1 z
Possible causes
state Wiring harness between emergency steering
Resis-
relay R02 – slow-blow fuse R02 and chassis Min. 1 Mz
tance
Grounding fault in wiring har- ground
4 ness Wiring harness between slow-blow fuse R03
(Contact with ground circuit) – fuse No. 3 of fuse box 1 and chassis Resis-
Min. 1 Mz
tance
ground
Resis-
box 1 – L73 (female) (1), (11) and chassis Min. 1 Mz
tance
ground
Defective work equipment
5 L73 Voltage
controller
Between (1), (11) and (21), (31),
20 – 30 V
(32), (33)
40-305 20 WA470, 480-6

Failure code [DB90KK] Work equipment controller: Low source voltage (input) SEN04525-01
WA470, 480-6 40-305 21

SEN04525-01 Failure code [DB90KT] Work equipment controller: Abnormality in controller
Failure code [DB90KT] Work equipment controller: Abnormality in

controller 1
Action code Failure code Work equipment controller: Abnormality in controller

Trouble
E01 DB90KT (Work equipment controller system)
Contents of • The information in the ROM (non-volatile memory) of the work equipment controller system is abnor-
trouble mal.
• Sets the internal adjustment values to the default values.
Action of
controller
Problem that
• The machine may false detect errors.
appears on
• Performance degrades since the machine is controlled with improper data.
machine
Related
information

and standard
value in normal Defective work equipment Since trouble is in system, troubleshooting cannot be carried out.
1
state controller Replace the work equipment controller.
40-305 22 WA470, 480-6

Failure code [DB90KT] Work equipment controller: Abnormality in controller SEN04525-01
WA470, 480-6 40-305 23

SEN04525-01 Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input)
Failure code [DB92KK] Work equipment controller load power supply

line: Low source voltage (input) 1
Action code Failure code Work equipment controller load power supply line: Low source volt-
Trouble
E03 DB92KK age (input) (Work equipment controller system)
• The voltage of the 24V solenoid power supply system is low.
Contents of
• Detection conditions: Terminal C input is turned OFF, constant power supply (battery direct power
trouble
supply) is above 20 V and solenoid power supply is below 18 V.
• Cannot supply voltage to the solenoid. (If the voltage is below 18 V, all outputs are turned OFF.)
controller • Even if cause of failure disappears, system does not reset itself until the joystick steering lever and
work equipment lever are once set to N (Neutral).
Problem that
appears on • Work equipment does not move.
machine
Related
information

If the slow blow fuse is shut down, the circuit probably has a ground-
ing fault, etc. (See cause 4.)
2
Disconnection in wiring har- Wiring harness between battery R04 – slow- Resis-
Max. 1 z
ness blow fuse R10 tance
3
(Disconnection or defective Wiring harness between slow-blow fuse Resis-
R06A – fuse No. 5 of fuse box 2 tance
Max. 1 z
Possible causes box 2 – L73 (female) (2), (12), (22) tance
state
Wiring harness between battery relay R04 – Resis-
Min. 1 Mz
slow-blow fuse R10 and chassis ground tance
4 ness Wiring harness between slow-blow fuse
Resis-
(Contact with ground circuit) R06A – fuse No. 5 of fuse box 2 and chassis tance
Min. 1 Mz
ground
Resis-
box 2 – L73 (female) (2), (12), (22) and chas- Min. 1 Mz
tance
sis ground
5 L73 Voltage
controller
Between (2), (12), (22) and (21),
20 – 30 V
(31), (32), (33)
40-305 24 WA470, 480-6

Failure code [DB92KK] Work equipment controller load power supply line: Low source voltage (input) SEN04525-01
WA470, 480-6 40-305 25

SEN04525-01 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range
Failure code [DB95KX] Work equipment controller power supply output:

Out of input signal range 1
Action code Failure code Work equipment controller power supply output: Out of input signal
Trouble
E03 DB95KX range (Work equipment controller system)
Contents of
• Nominal voltage output of 5V sensor power supply system is out of range. (Outside 4.7 – 5.3 V)
trouble
• Cannot sense the input signals normally due to abnormal potentiometer signal.
Action of
controller
Problem that
• The operator cannot operate the work equipment (Machine stops entirely).
appears on
• Following potentiometer error results.
machine
Related
information

Defective joystick steering
lever potentiometer L34 (male) Resistance
1
(Internal disconnection or Between (4) and (1) 4 – 6 kz
short circuit)
Min. 1 Mz
ground
Defective 3-spool valve EPC
lever potentiometer L30 (male) Resistance
2
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kz
short circuit)
Min. 1 Mz
ground
Defective lift arm EPC lever L28 (male) Resistance
Possible causes 3 potentiometer (Internal dis-
connection or short circuit) Between (4) and (1) 2.5 – 3.9 kz
and standard
Min. 1 Mz
state ground
Defective bucket EPC lever
potentiometer L29 (male) Resistance
4
(Internal disconnection or Between (4) and (1) 2.5 – 3.9 kz
short circuit)
Min. 1 Mz
ground
Defective lift arm potentiome- F18 (male) Resistance
5
ter Between (C) and (A) 5 kz ± 20%
Between (A), (C) and chassis
Min. 1 Mz
ground
6 ness
(Contact with ground circuit) Between L71 (female) (22) and chassis Resis-
Min. 1 Mz
ground tance
40-305 26 WA470, 480-6

Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range SEN04525-01

Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Defective work equipment
7
state controller L71 Voltage
Between (22) and (10) 4.85 – 5.15 V
WA470, 480-6 40-305 27

SEN04525-01 Failure code [DB95KX] Work equipment controller power supply output: Out of input signal range
40-305 28 WA470, 480-6

Failure code [DB99KQ] (Work equipment controller model selection: Disagreement in model
selection signals) SEN04525-01

Disagreement in model selection signals) 1
Action code Failure code Work equipment controller model selection: Disagreement in model
Trouble
E03 DB99KQ selection signals (Machine monitor system)
Contents of
• Work equipment controller model is mistaken for another one.
trouble
• Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
controller • Does not display failure codes which may be false detected.
Problem that
appears on • Work equipment does not operate normally.
machine
Related
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor. (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting.)
state Work equipment controller Confirm the part number of the work equipment controller. It must be
2
part number error replaced if it is not the specified controller.
WA470, 480-6 40-305 29

Failure code [DB9RKR] CAN communication with work equipment controller: Defective
SEN04525-01 communication (Abnormality in target component system)
Failure code [DB9RKR] CAN communication with work equipment

controller: Defective communication (Abnormality in target component
system) 1
Action code Failure code Can communication with work equipment controller: Defective com-
Trouble munication (Abnormality in target component system) (Transmis-
E03 DB9RKR sion controller system)
Contents of
• Machine monitor cannot get information from work equipment controller.
trouble
Action of • Uses CAN information that was sent from work equipment controller before the occurrence of the
controller error.
Problem that
machine
Related
information

1
Max. 1 z
state (32) – EC2 (female) (46), (47) tance
Max. 1 z
2 Max. 1 z
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
40-305 30 WA470, 480-6

Failure code [DB9RKR] CAN communication with work equipment controller: Defective
communication (Abnormality in target component system) SEN04525-01

Resis-
tance
ground
Resis-
tance
ground
3 ness tance
ground
Possible causes Wiring harness between L62 (female) (22),
Resis-
tance
Resis-
tance
ground
Resis-
tance
ground
Defective power supply a Power supply circuit or grounding circuit may be defective.
4 circuit of work equipment Confirm that there is no disconnection of the circuit or defective
controller mating of the connector.
WA470, 480-6 40-305 31

SEN04525-01 Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)
Failure code [DB9RMA] (Work equipment controller option setting:

Malfunction) 1
Action code Failure code Work equipment controller option setting: Malfunction
Trouble
E03 DB9RMA (Machine monitor system)
Contents of • Disagreement between the option setting done by the machine monitor and the option recognition
trouble done by the work equipment controller.
Action of • The work equipment controller follows the option setting being recognized by itself.
Problem that
appears on • The optional device does not work normally.
machine
Related
information

Adjust the option setting using the adjustment function of the
Possible causes 1 Defective option setting
machine monitor. (See Testing and adjusting.)
and standard
value in normal Defective work equipment Transmission controller may be defective.
2
state controller (Since trouble is in system, troubleshooting cannot be carried out.)
The machine monitor may be defective.
40-305 32 WA470, 480-6

Failure code [DB9RMC] (CAN communication with transmission controller, engine controller and
machine monitor: Defective operation) SEN04525-01
Failure code [DB9RMC] (CAN communication with transmission

controller, engine controller and machine monitor: Defective operation)1
Action code Failure code CAN communication with transmission controller, engine controller
Trouble and machine monitor: Defective operation (Work equipment control-
E03 DB9RMC ler system)
• Communication via CAN signal line between the work equipment controller – transmission controller,
Contents of
engine controller and machine monitor is defective.
trouble
<Relevant to the transmission controller>
• Judges that the travel speed is at 0 km/h.
• Turns neutral safety relay OFF. (The engine can be started.)
• Uses CAN information that was sent from transmission controller before the occurrence of the error.
Action of
<Relevant to engine controller>
controller
• Judges engine speed is at 1,500 rpm.
• Uses CAN information that was sent from engine controller before the occurrence of the error.
<Relevant to machine monitor>
• Judges that the emergency steering is not in operation.
• Uses CAN information that was sent from machine monitor before the occurrence of the error.
<Relevant to transmission controller>
• The operator may not use semiautomatic digging occasionally or cannot use it entirely.
• Joystick steering does not work (Joystick steering specification)
• Starting becomes available only when the joystick steering is not at neutral.
<Relevant to engine controller>
Problem that • Semiautomatic digging is available. (constant digging speed)
appears on • Defective lift arm positioner and bucket positioner stop position (calculation of pump delivery
machine becomes unavailable.)
• Engine does not pick up smoothly. (swash plate of supply pump remains at MAX.)
<Relevant to machine monitor>
• When the emergency steering is operated, false detection of the power supply error might result.
• If disconnection occurs while the emergency steering is in operation, detection of the power supply
error becomes unavailable.
Related • Method of reproducing failure code: Turn the starting switch ON or start the engine to resume the
information normal operation.

Possible causes CAN1 (male) Resistance
and standard
value in normal 1
state resistance a Prepare with starting switch OFF, then carry out troubleshooting
WA470, 480-6 40-305 33

SEN04525-01 machine monitor: Defective operation)

Max. 1 z
(32) – L56 (female) (3), (8) tance
Max. 1 z
2 Max. 1 z
Max. 1 z
(32) – L80 (female) (7), (8) tance
Max. 1 z
Max. 1 z
Possible causes Resis-
and standard tance
ground
value in normal
Resis-
tance
ground
Ground fault in wiring har- Resis-
3 ness (Contact with ground tance
ground
circuit)
Resis-
tance
ground
Resis-
tance
ground
Resis-
tance
ground
40-305 34 WA470, 480-6

machine monitor: Defective operation) SEN04525-01
WA470, 480-6 40-305 35

SEN04525-01 Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept

pressed for long time 1
Action code Failure code t switch (Panel switch 1): Switch is kept pressed for long time
Trouble
E01 DD15LD (Machine monitor system)
Contents of • The input circuit of the machine monitor mode selector switch 1 “t” (Panel switch 1) is kept CLOSED
trouble for more than continuous 1 minute.
Action of
controller
Problem that
• The operator cannot operate the monitor (cannot enter the service mode).
appears on
• Some characters do not appear on the character display.
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 1 “t” (Panel switch 1) can
Related be checked with the monitoring function (Code: 40901, D-IN-15).
information • The operator may not be able to use the monitoring function because of the t switch trouble.

box 1
Defective t switch (Panel t switch
2 switch 1) (Internal short cir- L07 (male) Resistance
(Panel switch 1)
cuit)
ON Max. 1 z
Possible causes Between (4) and (5)
Other than above Min. 1 Mz
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short in wiring harness and carry out troubleshooting.
3
Voltage Max. 1 V
t switch
(Panel switch 1)
Between (17) and ON 20 – 30 V
40-305 36 WA470, 480-6

Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 37

SEN04525-01 Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept

Action code Failure code U switch (Panel switch 2): Switch is kept pressed for long time
Trouble
Contents of • The input circuit of the machine monitor mode selector switch 2 “U” (Panel switch 2) is kept
trouble CLOSED for more than continuous 1 minute.
Action of
controller
Problem that
• The operator cannot operate the monitor (cannot turn on the service mode).
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 2 “U” (Panel switch 2)
Related can be checked with the monitoring function (Code: 40901, D-IN-14).
information • The operator may not be able to use the monitoring function because of the U switch trouble.

Defective U switch (Panel U switch
1 switch 2) (Internal short cir- L07 (male) Resistance
(Panel switch 2)
cuit)
ON Max. 1 z
Between (5) and (6)
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
U switch
(Panel switch 2)
40-305 38 WA470, 480-6

Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 39

SEN04525-01 Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
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
Contents of • The input circuit of the machine monitor mode selector switch 3 “<” (Panel switch 3) is kept CLOSED
Action of
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 3 “<” (Panel switch 3) can
information • The operator may not be able to use the monitoring function because of the “<” switch trouble.

Defective < switch (Panel < switch
1 switch 3) (Internal short cir- L08 (female) Resistance
(Panel switch 3)
cuit)
ON Max. 1 z
Between (4) and (5)
Possible causes
Min. 1 Mz
< switch
(Panel switch 3)
Between (7) and ON Max. 1 V
40-305 40 WA470, 480-6

Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 41

SEN04525-01 Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time
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
Contents of • The input circuit of the machine monitor mode selector switch 4 “>” (Panel switch 4) is kept CLOSED
Action of
controller
Problem that
• The operator cannot operate the monitor.
appears on
machine
• The input state (ON/OFF) from the machine monitor mode selector switch 4 “>” (Panel switch 4) can
information • The operator may not be able to use the monitoring function because of the > switch trouble.

Defective > switch (Panel > switch
1 switch 4) (Internal short cir- L08 (female) Resistance
(Panel switch 4)
cuit)
ON Max. 1 z
Between (5) and (6)
Possible causes
Min. 1 Mz
> switch
(Panel switch 4)
40-305 42 WA470, 480-6

Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 43

Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for
SEN04525-01 long time

Switch is kept pressed for long time 1
Action code Failure code Remote positioner raise/lower set switch (raise): Switch is kept
Trouble
E01 DD1ALD pressed for long time (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (raise) system is shorted, operator cannot set rais-
trouble ing.
• Stops setting the lift arm raise set position.
Action of • Stops the remote raise stop operation.
controller • Turns the lift arm raise set indicator OFF.
Problem that
• The operator cannot set the lift arm raise set position.
appears on
• Remote positioner raise stop control is not available.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (raise) can be checked
Related
information

Remote positioner
Defective remote positioner S14 (male) Resistance
raise/lower set switch
1 raise/lower set switch (raise)
Raise Max. 1 z
(Internal short circuit) Between (5) and (6)
Possible causes Constant Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
S14 (female) (6) and chassis ground tance
Defective work equipment Remote positioner
3 L72 Voltage
controller raise/lower set switch
Between (13) and Raise Max. 1 V
40-305 44 WA470, 480-6

Failure code [DD1ALD] Remote positioner raise/lower set switch (raise): Switch is kept pressed for
long time SEN04525-01
WA470, 480-6 40-305 45

Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for
SEN04525-01 long time
Failure code [DD1BLD] Remote positioner raise/lower set switch

(lower): Switch is kept pressed for long time 1
Action code Failure code Remote positioner raise/lower set switch (lower): Switch is kept
Trouble
E01 DD1BLD pressed for long time (Work equipment controller system)
Contents of • Since the remote positioner raise/lower set switch (lower) system is shorted, operator cannot set
trouble lowering.
• Stops setting the lift arm lower set position.
Action of • Stops the remote lower stop operation.
controller • Turns the lift arm lower set indicator OFF.
Problem that
• The operator cannot set the lower set position.
appears on
• Remote positioner lower stop control is not available.
machine
• The input state (ON/OFF) from the remote positioner raise/lower set switch (lower) can be checked
Related
information

Remote positioner
Defective remote positioner S14 (male) Resistance
raise/lower set switch
1 raise/lower set switch
Lower Max. 1 z
chassis ground
and standard
state 2 ness
Min. 1 Mz
3 L72 Voltage
controller raise/lower set switch
Between (3) and Lower Max. 1 V
40-305 46 WA470, 480-6

Failure code [DD1BLD] Remote positioner raise/lower set switch (lower): Switch is kept pressed for
long time SEN04525-01
WA470, 480-6 40-305 47

SEN04525-01 Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept

Action code Failure code Load meter subtotal switch: Switch is kept pressed for long time
Trouble
E01 DD1CLD (Machine monitor system)
Contents of • Since the load meter subtotal switch system is shorted, the load meter subtotal switch does not func-
trouble tion.
Action of
controller
Problem that
• The total amount of load cannot be set to 0 on the screen.
appears on
• Printer (if equipped) is not available.
machine
• The input state (ON/OFF) from the load meter subtotal switch can be checked with the monitoring
Related function (Code: 40904, D-IN-32).
information • Only for load meter (if equipped)

Load meter subtotal
Defective load meter subtotal switch
1
switch (Internal short circuit) ON Max. 1 z
Between (3) and (4)
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Load meter subtotal
switch
chassis ground OFF 20 – 30 V
40-305 48 WA470, 480-6

Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 49

SEN04525-01 Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time
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
controller
Problem that
• The working object cannot be changed.
appears on
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).

Load meter mode
Defective load meter mode S31 (male) Resistance
selector switch (A/B)
1 selector switch (A/B) (Inter-
ON Max. 1 z
nal short circuit) Between (5) and (6)
OFF Min. 1 Mz
chassis ground
and standard
state Hot short in wiring harness and carry out troubleshooting.
2
Voltage Max. 1 V
S31 (female) (6) and chassis ground
Load meter mode
selector switch (A/B)
40-305 50 WA470, 480-6

Failure code [DD1FLD] Load meter mode selector switch (A/B): Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 51

SEN04525-01 Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time
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
controller
Problem that
• The operator cannot make settings of load meter addition mode.
appears on
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).

box 1
Load meter mode
Defective load meter mode S31 (male) Resistance
selector switch (+/–)
2 selector switch (+/–) (Internal
ON Max. 1 z
short circuit) Between (4) and (5)
OFF Min. 1 Mz
Possible causes
and standard Constant Min. 1 Mz
chassis ground
value in normal
3
Voltage Max. 1 V
Load meter mode
selector switch (+/–)
40-305 52 WA470, 480-6

Failure code [DD1GLD] Load meter mode selector switch (+/–): Switch is kept pressed for long time SEN04525-01
WA470, 480-6 40-305 53

SEN04525-01 Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time)
Failure code [DD1HLD] (Load meter display selector switch: Switch is

kept pressed for long time) 1
Action code Failure code Load meter display selector switch: Switch is kept pressed for long
Trouble
E01 DD1HLD time (Machine monitor system)
Contents of • Since the load meter display selector switch system is shorted, the load meter display selector switch
trouble does not function.
Action of
controller
Problem that
• Unable to display cumulative data.
appears on
machine
• The input state (ON/OFF) from the load meter display selector switch can be checked with the moni-
Related toring function (Code: 40902, D-IN-23).

box 1
Load meter display
Defective load meter display S31 (male) Resistance
selector switch
2 selector switch (Internal
ON Max. 1 z
OFF Min. 1 Mz
Possible causes
chassis ground
value in normal
3 ness
Min. 1 Mz
Load meter display
selector switch
40-305 54 WA470, 480-6

Failure code [DD1HLD] (Load meter display selector switch: Switch is kept pressed for long time) SEN04525-01
WA470, 480-6 40-305 55

SEN04525-01 Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)
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
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

box 2
S16 (male) Fan reverse switch Resistance
Defective fan reverse switch
2 ON Max. 1 z
OFF Min. 1 Mz
Possible causes
chassis ground
value in normal
3
Voltage 20 – 30 V
Defective transmission L61 Fan reverse switch Voltage
4
controller
40-305 56 WA470, 480-6

Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time) SEN04525-01
WA470, 480-6 40-305 57

SEN04525-01 Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time)
Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept

pressed for long time) 1
Action code Failure code Fan automatic reverse switch: Switch is kept pressed for long time
Trouble
E01 DD1NL4 (Transmission controller system)
Contents of • Since the fan automatic reverse switch system is shorted with the power source, the fan automatic
trouble reverse switch function becomes unavailable.
Action of
• The automatic reverse switch is OFF.
controller
Problem that
appears on • Automatic reversing of the fan becomes unavailable.
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

box 2
Fan automatic reverse
Defective fan automatic S16 (male) Resistance
switch
2 reverse switch (Internal short
ON Max. 1 z
circuit) Between (3) and (4)
OFF Min. 1 Mz
Possible causes
chassis ground
value in normal
3
Voltage 20 – 30 V
Defective transmission Fan automatic reverse
4 L61 Voltage
controller switch
40-305 58 WA470, 480-6

Failure code [DD1NL4] (Fan automatic reverse switch: Switch is kept pressed for long time) SEN04525-01
WA470, 480-6 40-305 59

SEN04525-01 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF

signals disagree) 1
Action code Failure code Parking brake switch (Neutralizer): ON/OFF signals disagree
Trouble
E03 DDB6L4 (Transmission controller system)
• Controller outputs a failure signal when the following conditions are all met.
Contents of 1) Parking brake switch signal ON (neutralizer signal OPEN)
trouble 2) Parking brake released (by CAN communication from the machine monitor)
3) Hydraulic oil temperature above 25°C
Problem that
• Forward and reverse travel of the machine become unavailable. Or the parking brake indicator
appears on
remains unlighted.
machine
• The input state (ON/OFF) from the parking indicator switch to the machine monitor can be checked
• The input state (ON/OFF) from the parking brake switch can be checked with the monitoring function
(Code: 40907, D-IN-23).
• If failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) is indicated,
Related carry out troubleshooting for it first.
information • If failure code [DAFRKR] (CAN communication with machine monitor: Defective communication
(Abnormality in target component system)) is indicated, carry out troubleshooting for it first.
• Above is sometimes detected if the emergency parking brake switch is set to ON (release side) when
the parking brake switch is turned ON (parking side).
• Method of reproducing failure code: Turn the starting switch ON and turn the parking brake switch
ON.

box 2
Parking brake oil
PB.SW (male) Resistance
pressure
Defective parking brake indi- When parking brake is
2 cator switch released, Min. 0.61 Max. 1 z
(Internal disconnection) MPa {Min. 6.2 kg/cm2}
Possible causes
Between (1) and (2) When parking brake
and standard
value in normal applied, Max. 0.34
Min. 1 Mz
state MPa {Max. 3.5 kg/
cm2}
L01 (male) Parking brake switch Resistance
Defective parking brake ON Min. 1 Mz
3 switch (Internal disconnec- Between (3) and (4)
OFF Max. 1 z
tion)
ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (3) and (6) Constant Min. 1 Mz
40-305 60 WA470, 480-6

Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) SEN04525-01

Disconnection in wiring har- Wiring harness between L54 (female) (1) – Resis-
Max. 1 z
ness PB.SW (female) (1) tance
4
(Disconnection or defective Wiring harness between PB.SW (female) (2) Resis-
contact) Max. 1 z
Possible causes
value in normal
L62 Parking brake switch Voltage
Defective transmission con- ON Max. 1 V
5
troller
Between (6) and Turn on the starting
chassis ground switch and turn on the
20 – 30 V
parking brake switch,
then turn it off.
WA470, 480-6 40-305 61

SEN04525-01 Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)
40-305 62 WA470, 480-6

Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree) SEN04525-01
WA470, 480-6 40-305 63

Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long
SEN04525-01 time)

Switch is kept pressed for long time) 1
Action code Failure code Remote positioner bucket angle set switch: Switch is kept pressed
Trouble
E01 DDD1LD for long time (Work equipment controller system).
• Unable to set the bucket to a specified angle due to ground fault in the remote positioner bucket
Contents of
angle set switch system.
trouble
• Detects continuous operation for 30 seconds and longer.
Action of • Judges that remote positioner bucket angle set switch is turned ON.
• Remote positioner raise set: Setting is changed to upward by 1° (degree) and the monitor displays
Problem that the changed angle.
appears on • Remote lower set: Setting is changed to downward by 1° (degree) and the monitor displays the
machine changed angle.
• Change of setting to upward or downward becomes unavailable.
• The input state (ON/OFF) from the remote positioner bucket angle set switch can be checked with
the monitoring function (Code: 40911, D-IN-10, D-IN-11).
Related
• Only for electric lever (if equipped)
information
• Method of reproducing failure code: Turn the starting switch and remote positioner bucket angle set
switch ON

Remote positioner
S33 (male) bucket angle set Resistance
switch
Defective remote positioner
1 bucket angle set switch Downward ON Max. 1 z
Between (4) and (5)
(Internal short circuit) OFF Min. 1 Mz
Upward ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (4), (5), (6)
Constant Min. 1 Mz
and chassis ground
Possible causes
and standard
value in normal Grounding fault in wiring har-
state Wiring harness between L73 (female) (30) – Resis-
2 ness Min. 1 Mz
Min. 1 Mz
Remote positioner
L73 bucket angle set Voltage
Defective work equipment switch
3
controller Downward ON Max. 1 V
Between (40) and
Between (30) and Upward ON Max. 1 V
40-305 64 WA470, 480-6

Failure code [DDD1LD] (Remote positioner bucket angle set switch: Switch is kept pressed for long
time) SEN04525-01
WA470, 480-6 40-305 65

SEN04525-01

©2009 KOMATSU
All Rights Reserved
40-305 66
SEN04526-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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 signal: Disconnected) .................................................... 20
Failure code [DDS5KB] (Steering pressure switch signal: 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
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)...................................................... 36
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)......................................................... 40
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)............................................ 42
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) .............................................. 44
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) ................................ 46
Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)............................................... 48
Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) ............................. 50
WA470, 480-6 40-306 1

SEN04526-01
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) ..................... 52
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) ..................................................... 54
Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)....................................... 56
40-306 2 WA470, 480-6

SEN04526-01
WA470, 480-6 40-306 3

SEN04526-01 Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)1

Action code Failure code Emergency steering drive switch: Malfunction
Trouble
E01 DDE5MA (Machine monitor system)
Contents of • When engine is stopped, steering pump pressure is detected because of ground fault in the emer-
trouble gency steering drive switch system.
Action of
controller
Problem that
appears on —
machine
• The input state (ON/OFF) from the emergency steering motor can be checked with the monitoring
Related
information

troubleshooting.
• Relieve the steering circuit.
Defective emergency steer- Steering relief oil

R37 (male) Resistance
1 ing drive switch pressure
(Internal trouble) Low Min. 1 Mz
Between (1) and (2)
Normal Max. 1 z
chassis ground
and standard
state 2 ness
Min. 1 Mz
R37 (female) (2) and chassis ground tance
troubleshooting.
• Relieve the steering circuit
3 Defective machine monitor Steering relief oil
L54 Voltage
pressure
Between (3) and Low 20 – 30 V
chassis ground Normal Max. 1 V
40-306 4 WA470, 480-6

Failure code [DDE5MA] (Emergency steering drive switch: Malfunction) SEN04526-01
WA470, 480-6 40-306 5

SEN04526-01 Failure code [DDK3KA] (Right FNR switch: Disconnection)
Failure code [DDK3KA] (Right FNR switch: Disconnection) 1
Action code Failure code Right FNR switch: Disconnection

Trouble
E03 DDK3KA (Transmission controller system)
Contents of • Since the right FNR (directional) switch input signal system is disconnected or shorted, the right FNR
trouble (directional) switch signal is not recognized.
• Sets to neutral.
controller • Even if cause of failure disappears, system does not reset itself until the right FNR (directional)
switch is set to N (Neutral).
Problem that • Machine travel with the right FNR (directional) switch becomes unavailable.
appears on • Travel with FNR (directional) lever is available.
machine • Shift lever position pilot lamp goes off.
• The input signals (ON/OFF) from the right FNR (directional) switch or joystick steering FNR (direc-
tional) switch can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-
Related 19).
information • Only for right FNR (directional) switch (if equipped)
• Method of reproducing failure code: Turn the starting switch ON, turn the directional selector ON/
OFF switch ON, then operate the FNR (directional) switch.

1
Right FNR
F (Forward) Max. 1 z
Between (1) and (2)
Defective right FNR (direc- Other than above Min. 1 Mz
tional) switch
2 N (Neutral) Max. 1 z
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 Mz
Possible causes R (Reverse) Max. 1 z
and standard Between (1) and (4)
value in normal
state Between (1), (2), (3),
(4) and chassis Constant Min. 1 Mz
ground
Max. 1 z
Disconnection in wiring har- box 2 – L12 (female) (1) tance
3 Max. 1 z
Max. 1 z
Max. 1 z
40-306 6 WA470, 480-6

Failure code [DDK3KA] (Right FNR switch: Disconnection) SEN04526-01

Min. 1 Mz
box 2 – L12 (female) (1) and chassis ground tance
4 ness Min. 1 Mz
Min. 1 Mz
and standard
state and carry out troubleshooting.
• Turn on the directional selector ON/OFF switch
Right FNR
L62 Voltage
Defective transmission con- Between (25) and F (Forward) 20 – 30 V
5
troller chassis ground Other than above Max. 1 V
Between (15) and N (Neutral) 20 – 30 V
WA470, 480-6 40-306 7

SEN04526-01 Failure code [DDK3KA] (Right FNR switch: Disconnection)
40-306 8 WA470, 480-6

Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) SEN04526-01
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) 1
Action code Failure code Joystick steering FNR switch: Disconnection

Trouble
Contents of • Since the input signal system of the joystick steering FNR (directional) switch is disconnected or
trouble shorted, joystick steering FNR (directional) switch signals are not input.
controller • Even if cause of failure disappears, system does not reset itself until the joystick steering FNR (direc-
tional) switch is set to N (Neutral).
Problem that • Machine travel with the joystick steering FNR (directional) switch becomes unavailable.
appears on • Travel with FNR (directional) lever is available.
• The input signals (ON/OFF) from the right FNR (directional) switch or joystick steering FNR (direc-
tional) switch can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-
Related 19).
information • Only for joystick steering (if equipped)
• Method of reproducing failure code: Turn the starting switch ON, turn the joystick ON/OFF switch
ON, then operate the joystick steering FNR (directional) switch.

Defective fuse No.2 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
1
Joystick steering FNR
F (Forward) Max. 1 z
Between (1) and (2)
Defective joystick steering Other than above Min. 1 Mz
FNR (directional) switch
2 N (Neutral) Max. 1 z
(Internal disconnection or Between (1) and (3)
short circuit) Other than above Min. 1 Mz
Possible causes R (Reverse) Max. 1 z
and standard Between (1) and (4)
value in normal
state Between (1), (2), (3),
(4) and chassis Constant Min. 1 Mz
ground
Max. 1 z
Disconnection in wiring har- box 2 – L37 (female) (1) tance
3 Max. 1 z
Max. 1 z
Max. 1 z
WA470, 480-6 40-306 9

SEN04526-01 Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)

Min. 1 Mz
4 ness Min. 1 Mz
Min. 1 Mz
and standard
• Turn on joystick ON/OFF switch
Joystick steering FNR
L62 Voltage
Defective transmission con- Between (25) and F (Forward) 20 – 30 V
5
troller chassis ground Other than above Max. 1 V
40-306 10 WA470, 480-6

Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection) SEN04526-01
WA470, 480-6 40-306 11

SEN04526-01 Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF

signals disagree) 1
Action code Failure code Joystick steering shift-up/down switch: ON/OFF signals disagree
Trouble
E01 DDK5L4 (Transmission controller system)
Contents of • Since the joystick steering shift up and down switch system is shorted with the power source, multi-
trouble ple signals are input.
Action of • Turns off the shift-up/down function of the joystick steering.
controller • If cause of failure disappears, system resets itself.
Problem that
appears on • Shift up or down from the joystick steering is disabled.
machine
• The input signals (ON/OFF) from the joystick steering shift-up/down switch can be checked with the
Related monitoring function (Code: 40906, D-IN-12 or D-IN-13).
information • Method of reproducing failure code: Turn the starting switch ON, turn the joystick ON/OFF switch
ON, then turn the joystick steering shift-up/down switch ON.

Joystick steering
shift-up/down switch
Shift down ON Min. 1 Mz
Between (1) and (5)
Shift down OFF Max. 1 z
Defective joystick steering Shift down ON Max. 1 z

Between (1) and (6)
1 shift-up/down switch Shift down OFF Min. 1 Mz
(Internal short circuit) Shift up ON Min. 1 Mz
Between (1) and (7)
Shift up OFF Max. 1 z
Shift up ON Max. 1 z
Between (1) and (8)
Shift up OFF Min. 1 Mz
Possible causes Between (5), (6), (7),
and standard (8) and chassis Constant Min. 1 Mz
2 ness Min. 1 Mz
Min. 1 Mz
• Turn on joystick ON/OFF switch.
Joystick steering
L63 Resistance
Defective transmission con- shift-up/down switch
3
troller Shift down ON Max. 1 z
Between (19) and
chassis ground Shift down OFF Min. 1 Mz
Between (9) and Shift up ON Max. 1 z
chassis ground Shift up OFF Min. 1 Mz
40-306 12 WA470, 480-6

Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree) SEN04526-01
WA470, 480-6 40-306 13

SEN04526-01 Failure code [DDK6KA] (FNR lever switch: Disconnection)
Failure code [DDK6KA] (FNR lever switch: Disconnection) 1
Action code Failure code FNR lever switch: Disconnection

Trouble
Contents of • Since the FNR (directional) lever switch signal system is disconnected or shorted, all the lever sig-
trouble nals are not input.
• When the joystick steering ON/OFF switch is set to OFF, set it to Neutral.
• When the ON-OFF switch of right FNR switch or joystick steering ON/OFF switch is set to ON:
1) The controller operation follows the right FNR (directional) switch or joystick steering FNR (direc-
Action of tional) switch.
controller 2) The controller assumes that FNR (directional) lever switch is set to Neutral.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
Problem that • Machine travel with the FNR (directional) lever switch is unavailable.
appears on • Travel is available with right FNR (directional) switch or joystick steering FNR (directional) switch.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: 40907, D-IN-20, D-IN-21 or D-IN-22).
information
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever.

1
FNR (directional)
L04 Voltage
lever
Between (1) and (10) Constant 20 – 30 V
Defective FNR (directional)
2 lever switch (Internal discon- Between (3) and (10) N (Neutral) 20 – 30 V
nection or short circuit) Other than above Max. 1 V
F (Forward) 20 – 30 V
Possible causes Other than above Max. 1 V
and standard R (Reverse) 20 – 30 V
value in normal Between (4) and (10)
state Other than above Max. 1 V
Max. 1 z
box 2 – L04 (female) (1) tance
Max. 1 z
ness L04 (female) (4) tance
3
(Disconnection or defective Wiring harness between L62 (female) (26) – Resis-
Max. 1 z
Max. 1 z
40-306 14 WA470, 480-6

Failure code [DDK6KA] (FNR lever switch: Disconnection) SEN04526-01

Min. 1 Mz
4 ness Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
and standard L04 (female) (2) and chassis ground tance
FNR (directional)
L62 Voltage
lever
5 chassis ground Other than above Max. 1 V
troller
Between (36) and F (Forward) 20 – 30 V
WA470, 480-6 40-306 15

SEN04526-01 Failure code [DDK6KA] (FNR lever switch: Disconnection)
40-306 16 WA470, 480-6

Failure code [DDK6KA] (FNR lever switch: Disconnection) SEN04526-01
WA470, 480-6 40-306 17

SEN04526-01 Failure code [DDK6KB] (FNR lever switch: Short circuit)
Failure code [DDK6KB] (FNR lever switch: Short circuit) 1
Action code Failure code FNR lever switch: Short circuit

Trouble
E03 DDK6KB (Transmission controller system)
Contents of • Since the FNR (directional) lever switch signal system is shorted with power source, multiple FNR
trouble (directional) lever switch signals are input.
• As the ON-OFF switch of right FNR switch or joystick steering ON/OFF switch is switched ON o
Action of
OFF o ON, the controller operation follows the right FNR (directional) switch or joystick steering
controller
switch.
• Even if cause of failure disappears, system does not reset itself until FNR (directional) lever is set to
N (Neutral).
• Machine travel with the FNR (directional) lever switch is unavailable.
Problem that
• Multiple shift lever position pilot lamps light up.
appears on
• Travel is enabled by using right FNR (directional) switch or joystick steering FNR (directional) switch
machine
after setting the shift to neutral.
• The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related function (Code: 40907, D-IN-20, D-IN-21 or D-IN-22).
information • Only for steering wheel (Standard)
• Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever.

FNR (directional)
L04 Voltage
lever
Defective FNR (directional)
1 lever switch (Internal short F (Forward) 20 – 30 V
circuit) Other than above Max. 1 V
N (Neutral) 20 – 30 V
Other than above Max. 1 V
and standard Wiring harness between L62 (female) (16) –
value in normal Voltage Max. 1 V
Hot short in wiring harness L04 (female) (4)
state 2
Voltage Max. 1 V
L04 (female) (3)
Voltage Max. 1 V
L04 (female) (2)
FNR (directional)
L62 Voltage
lever
3 chassis ground Other than above Max. 1 V
troller
Between (36) and F (Forward) 20 – 30 V
40-306 18 WA470, 480-6

Failure code [DDK6KB] (FNR lever switch: Short circuit) SEN04526-01
WA470, 480-6 40-306 19

SEN04526-01 Failure code [DDS5KA] (Steering pressure switch signal: Disconnected)
Failure code [DDS5KA] (Steering pressure switch signal: Disconnected)

Action code Failure code Steering pressure switch signal: Disconnected
Trouble
E03 DDS5KA (Transmission controller system)
Contents of
• Both N.C and N.O signals of the steering pressure switch are open simultaneously.
trouble
Action of • Turns electric emergency motor relay output OFF.
Problem that • The auto emergency steering does not operate (However, the emergency steering can be operated
appears on manually).
machine • Self-check of the emergency steering does not work.
Related • State of steering pressure switch can be checked with monitoring function. (Code: 40905, D-IN-0 or
information D-IN-1).

Resis-
Engine stopped Max. 1 z
tance
Between R36 (male) Open to atmosphere Resis-
Max. 1 z
(2) – (1) (Reference) tance
Defective steering pressure
Resis-
1 switch (Internal disconnec- Engine started Min. 1 Mz
tance
tion)
Resis-
Engine stopped Min. 1 Mz
tance
Min. 1 Mz
Resis-
Engine started Max. 1 z
Possible causes tance
state
Max. 1 z
R36 (female) (2) tance
Wiring harness discontinuity
2 (Disconnection or defective Max. 1 z
contact)
Wiring harness between R36 (female) (1) – Resis-
Max. 1 z
Max. 1 z
Defective transmission and Between L61 (17) – Engine stopped Voltage Max. 1 V
3 chassis ground
fan pump motor controller Engine started Voltage 20 – 30 V
Between L61 (23) – Engine stopped Voltage 20 – 30 V
chassis ground Engine started Voltage Max. 1 V
40-306 20 WA470, 480-6

Failure code [DDS5KA] (Steering pressure switch signal: Disconnected) SEN04526-01
WA470, 480-6 40-306 21

SEN04526-01 Failure code [DDS5KB] (Steering pressure switch signal: Short circuit)
Failure code [DDS5KB] (Steering pressure switch signal: Short circuit)

Action code Failure code Steering pressure switch signal: Short circuit
Trouble
E03 DDS5KB (Transmission controller system)
Contents of
• Both N.C and N.O signals of the steering pressure switch is closed simultaneously.
trouble
Action of • Turns electric emergency motor relay output OFF.
Problem that • The auto emergency steering does not operate (However, the emergency steering can be operated
appears on manually).
machine • Self-check of the emergency steering does not work.
Related • State of steering pressure switch can be checked with monitoring function. (Code: 40905, D-IN-0 or

Resis-
tance
Max. 1 z
Defective steering pressure
Resis-
1 switch (Internal disconnec- Engine started Min. 1 Mz
tance
tion)
Resis-
Engine stopped Min. 1 Mz
tance
Min. 1 Mz
Possible causes (2) – (1) (Reference) tance
and standard Resis-
value in normal Engine started Max. 1 z
tance
state
2 ness Min. 1 Mz
Min. 1 Mz
Defective transmission and Between L61 (17) – Engine stopped Voltage Max. 1 V
3 chassis ground
fan pump motor controller Engine started Voltage 20 – 30 V
Between L61 (23) – Engine stopped Voltage 20 – 30 V
chassis ground Engine started Voltage Max. 1 V
40-306 22 WA470, 480-6

Failure code [DDS5KB] (Steering pressure switch signal: Short circuit) SEN04526-01
WA470, 480-6 40-306 23

SEN04526-01 Failure code [DDS5L6] (Steering: Low oil pressure)
Failure code [DDS5L6] (Steering: Low oil pressure)

Action code Failure code Steering: Low oil pressure
Trouble
E03 DDS5L6 (Machine monitor system)
Contents of
• Steering pump pressure is lower than normal range.
trouble
Action of • Judges the steering pump pressure is absent.
Problem that
appears on • Response to turning operation is low.
machine
• The input state (oil pressure) from the steering pump pressure sensor can be checked with the mon-
itoring function (Code: 95300, S/T OIL PRESS).
Related
• The input state (voltage) from the steering pump pressure sensor can be checked with the monitor-
information
ing function (Code: 95301, S/T OIL PRESS).

Possible causes
Referring to [H-9] (Response to turning operation is low) in troubleshooting for hydraulic and
and standard 1
mechanical system (H mode), perform troubleshooting.
value in normal
state If no abnormality is detected by above troubleshooting, perform troubleshooting for [DHT8KA] and
[DHT8KB].
40-306 24 WA470, 480-6

Failure code [DDS5L6] (Steering: Low oil pressure) SEN04526-01
WA470, 480-6 40-306 25

SEN04526-01 Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals

disagree) 1
Action code Failure code Shift mode selector switch: ON/OFF signals disagree
Trouble
E01 DDT0L4 (Transmission controller system)
Contents of • The signals input from the transmission manual/auto shift selector switch are combined in an impos-
trouble sible manner.
Action of • Selects the manual shift mode.
Problem that
• The position of the transmission manual/auto shift selector switch does not match the shift mode dur-
appears on
ing auto shift.
machine
• The input state (H/L) from the transmission manual/auto shift selector switch can be checked with
Related the monitoring function (Code: 40905, D-IN-4 or D-IN-5).
information • The operator can check the current shift mode with the automatic shift pilot lamp.

S22 (male) Shift mode Resistance
Manual shift Min. 1 Mz
Between (1) and (2) Auto (L) Max. 1 z
Defective transmission man- Auto (H) Min. 1 Mz
1 ual/auto shift selector switch
Manual shift Min. 1 Mz
(Internal defect)
Between (1) and (4) Auto (L) Min. 1 Mz
Auto (H) Max. 1 z
Manual shift Max. 1 z
Between (3) and (4) Auto (L) Min. 1 Mz
Auto (H) Max. 1 z
2
Possible causes (Disconnection or defective Wiring harness between L61 (female) (24) – Resis-
and standard contact in connector) Max. 1 z
S22 (female) (2) tance
value in normal
3 ness
Min. 1 Mz
4
Voltage Max. 1 V
L61 Shift mode Voltage
Manual shift Max. 1 V
Defective transmission con- Between (18) and
5 Auto (L) Max. 1 V
troller chassis ground
Auto (H) 20 – 30 V
Manual shift Max. 1 V
Between (24) and
Auto (L) 20 – 30 V
chassis ground
Auto (H) Max. 1 V
40-306 26 WA470, 480-6

Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree) SEN04526-01
WA470, 480-6 40-306 27

SEN04526-01 Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time)
Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept

Action code Failure code The transmission cut-off set switch: Switch is kept pressed for long
Trouble
E01 DDT4LD time (transmission controller system)
Contents of • Since the transmission cut-off set switch system is shorted, normal transmission cut-off becomes
trouble unavailable.
Action of
controller
Problem that
appears on • The transmission is cut off at an unintended position.
machine
• The input state (ON/OFF) from the transmission cut-off set switch can be checked with the monitor-
Related
ing function (Code: 40906, D-IN-9).
information

Transmission cut-off
Defective transmission cut- S05 (male) Resistance
set switch
1 off set switch
ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Defective transmission con- Transmission cut-off
troller set switch
Between (5) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
40-306 28 WA470, 480-6

Failure code [DDT4LD] (Transmission cut-off set switch: Switch is kept pressed for long time) SEN04526-01
WA470, 480-6 40-306 29

SEN04526-01 Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for

long time) 1
Action code Failure code Kick-down switch: Switch is kept pressed for long time
Trouble
E01 DDW9LD (Transmission controller system)
Contents of
• Since the kick-down switch system is shorted, kick-down becomes unavailable.
trouble
• Implements kick-down once at occurrence of the ground fault. After that, kick-down control is not
Action of
executed.
controller
• If cause of failure disappears, system resets itself.
Problem that
• When ground fault occurs, turns the kick-down ON once.
appears on
• No kick down is executed after that.
machine
• The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
Related
(Code: 40908, D-IN-30).
information

L14 (male) Kick-down switch Resistance
Defective kick-down switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Defective transmission con- L62 Kick-down switch Voltage
3
troller
40-306 30 WA470, 480-6

Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time) SEN04526-01
WA470, 480-6 40-306 31

SEN04526-01 Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
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.
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

L04 (male) Hold switch Resistance
Defective hold switch
1 ON Max. 1 z
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Defective transmission con- L62 Hold switch Voltage
3
troller
40-306 32 WA470, 480-6

Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time) SEN04526-01
WA470, 480-6 40-306 33

SEN04526-01 Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept

Action code Failure code Load meter cancel switch: Switch is kept pressed for long time
Trouble
E01 DDY0LD (Machine monitor system)
Contents of
• The load meter cancel switch is shorted and load meter cancel switch does not function.
trouble
Action of
controller
Problem that
appears on • Cancellation of calculated load becomes unavailable.
machine
• The input state (ON/OFF) from the load meter cancel switch can be checked with the monitoring
Related function (Code: 40904, D-IN-33).
information • Only for load meter (if equipped).

Load meter cancel
Defective load meter cancel switch
1
switch (Internal short circuit) ON Max. 1 z
Between (1) and (2)
OFF Min. 1 Mz
chassis ground
and standard
state 2 ness
Min. 1 Mz
Load meter cancel
switch
40-306 34 WA470, 480-6

Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time) SEN04526-01
WA470, 480-6 40-306 35

SEN04526-01 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)
Failure code [DF10KA] (Transmission shift lever switch: Disconnected) 1

Action code Failure code Transmission shift lever switch: Disconnected
Trouble
E01 DF10KA (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is disconnected or shorted, the signal is
trouble not input.
Action of • Fixes to the shift range before the abnormality occurred.
Problem that
• The transmission is not set to the selected gear speed.
appears on
• Shift indicator displays the shift range before the abnormality occurred
machine
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40906, D-IN-8, D-IN-9, D-IN-10 or D-IN-11)
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever.

L04 Shift range Voltage
1st (1st speed) 20 – 30 V
Defective transmission shift Other than above Max. 1 V
1 lever switch
2nd (2nd speed) 20 – 30 V
(Internal disconnection) Between (6) and (10)
3rd (3rd speed) 20 – 30 V
Possible causes 4th (4th speed) 20 – 30 V
and standard Other than above Max. 1 V
value in normal
Max. 1 z
Max. 1 z
Disconnection in wiring har- L04 (female) (5) tance
2 Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
40-306 36 WA470, 480-6

Failure code [DF10KA] (Transmission shift lever switch: Disconnected) SEN04526-01

Min. 1 Mz
Grounding fault in wiring har- L04 (female) (5) and chassis ground Min. 1 Mz
tance
3 ness
Min. 1 Mz
Min. 1 Mz
value in normal
Between (10) and 1st (1st speed) 20 – 30 V
Defective transmission con- 2nd (2nd speed) 20 – 30 V
4 Between (20) and
troller
Between (30) and 3rd (3rd speed) 20 – 30 V
Between (40) and 4th (4th speed) 20 – 30 V
WA470, 480-6 40-306 37

SEN04526-01 Failure code [DF10KA] (Transmission shift lever switch: Disconnected)
40-306 38 WA470, 480-6

Failure code [DF10KA] (Transmission shift lever switch: Disconnected) SEN04526-01
WA470, 480-6 40-306 39

SEN04526-01 Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
Failure code [DF10KB] (Transmission shift lever switch: Short circuit) 1
Action code Failure code Transmission shift lever switch: Short circuit
Trouble
E01 DF10KB (Transmission controller system)
Contents of • Since the transmission shift lever switch input signal system is shorted with the power source, multi-
trouble ple transmission shift lever switch signals are input.
Action of • Uses the shift range input to the higher gear speed
Problem that • Specified gear speed is not available (1st speed or 2nd speed not selectable from the transmission
appears on shift lever).
machine • Shift indicator indicates the shift range input to the higher gear speed.
• The input state (ON/OFF) from each shift switch can be checked with the monitoring function (Code:
Related
40906, D-IN-8, D-IN-9, D-IN-10 or D-IN-11)
information
• Method of reproducing failure code: Turn the starting switch ON and operate shift lever.

1st (1st speed) 20 – 30 V
Defective transmission shift
1 lever switch 2nd (2nd speed) 20 – 30 V
(Internal short circuit) Other than above Max. 1 V
3rd (3rd speed) 20 – 30 V
4th (4th speed) 20 – 30 V
Possible causes Voltage Max. 1 V
and standard
value in normal Hot short in wiring harness Wiring harness between L63 (female) (20) –
2 Voltage Max. 1 V
state (Contact with 24V circuit) L04 (female) (6) and chassis ground
Voltage Max. 1 V
Voltage Max. 1 V
Between (10) and 1st (1st speed) 20 – 30 V
Defective transmission con- 2nd (2nd speed) 20 – 30 V
3 Between (20) and
troller
Between (30) and 3rd (3rd speed) 20 – 30 V
Between (40) and 4th (4th speed) 20 – 30 V
40-306 40 WA470, 480-6

Failure code [DF10KB] (Transmission shift lever switch: Short circuit) SEN04526-01
WA470, 480-6 40-306 41

SEN04526-01 Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)
Failure code [DGF1KA] (Transmission oil temperature sensor:

Disconnected) 1
Action code Failure code Transmission oil temperature sensor: Disconnected

Trouble
E01 DGF1KA (Transmission controller system)
• Since the transmission oil temperature sensor signal system is disconnected, the signal level is
Contents of
higher than normal range (Transmission oil temperature sensor signal voltage: Min. 4.56 V (Max.
trouble
15°C)) and the torque converter oil temperature sensor signal voltage: Min. 3.7 V (Max. 5.5°C).
Action of • Cannot judge the transmission oil temperature normally.
Problem that
appears on • Gear shifting shocks can result.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600 T/M OIL TEMP).
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
itoring function (Code: 93601, T/M OIL TEMP).
Related
information

Defective transmission oil Transmission oil
temperature sensor (Internal TM.T (male) Resistance
1 temperature
disconnection or short cir-
cuit) 25°C
35 – 50 kz
Between (1) and (2) (Normal temperature)
100°C 3.1 – 4.5 kz
and standard Disconnection in wiring
harness Wiring harness between L61 (female) (9) – Resis-
state (Disconnection or defective TM.T (female) (1) tance
contact in connector) Wiring harness between TM.T (female) (2) – Resis-
Max. 1 z
Transmission oil
Defective transmission L61 (female) Resistance
3 temperature
controller
25°C
Between (9) and 35 – 50 kz
(Normal temperature)
chassis ground
100°C 3.1 – 4.5 kz
40-306 42 WA470, 480-6

Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected) SEN04526-01
WA470, 480-6 40-306 43

SEN04526-01 Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
Failure code [DGF1KB] (Transmission oil temperature sensor: Short

circuit) 1
Action code Failure code Transmission oil temperature sensor: Short circuit
Trouble
E01 DGF1KB (Transmission controller system)
Contents of • Due to grounding fault in transmission oil temperature sensor signal system, the signal level is lower
trouble than normal range (Transmission oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of • Cannot judge the transmission oil temperature normally.
Problem that
appears on • Gear shifting shocks can result.
machine
• The input state (oil temperature) from the transmission oil temperature sensor can be checked with
the monitoring function (Code: 93600, T/M OIL TEMP).
Related
• The input state (voltage) from the transmission oil temperature sensor can be checked with the mon-
information
itoring function (Code: 93601, T/M OIL TEMP).

Defective transmission oil Transmission oil
TM.T (male) Resistance
1 temperature sensor (Internal temperature
short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
and standard Grounding fault in wiring without turning starting switch ON.
value in normal 2 harness
Min. 1 Mz
TM.T (female) (1) and chassis ground tance
Transmission oil
3 temperature
controller
25°C
chassis ground
100°C 3.1 – 4.5 kz
40-306 44 WA470, 480-6

Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit) SEN04526-01
WA470, 480-6 40-306 45

SEN04526-01 Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input

signal range) 1
Action code Failure code Hydraulic oil temperature sensor: Out of input signal range
Trouble
E01 DGH2KX (Machine monitor system)
Contents of • Due to grounding fault in hydraulic oil temperature sensor signal system, the signal level is lower
trouble than normal range (Hydraulic oil temperature sensor signal voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on • The hydraulic oil temperature gauge reads MAX position.
machine
monitoring function (Code: 04401, HYD TEMP).
Related
• The input state (voltage) from the hydraulic oil temperature sensor can be checked with the monitor-
information
ing function (Code: 04404, HYD TEMP).

Defective hydraulic oil Hydraulic oil
1 temperature sensor temperature
(Internal short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Min. 1 Mz
Hydraulic oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
40-306 46 WA470, 480-6

Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range) SEN04526-01
WA470, 480-6 40-306 47

SEN04526-01 Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)
Failure code [DGR2KA] (Rear brake oil temperature sensor:

Disconnected) 1
Action code Failure code Rear brake oil temperature sensor: Disconnected
Trouble
E01 DGR2KA (Machine monitor system)
Contents of
• Disconnection in the rear brake oil temperature sensor signal system
trouble
Action of
controller
Problem that
appears on —
machine
Related
information

Defective rear brake oil Rear brake oil
disconnection) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
state (Disconnection or defective R60 (female) (1) tance
contact in connector) Wiring harness between R60 (female) (2) – Resis-
Max. 1 z
Rear brake oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
40-306 48 WA470, 480-6

Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected) SEN04526-01
WA470, 480-6 40-306 49

SEN04526-01 Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
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
controller
Problem that
appears on —
machine
Related
information

Defective rear brake oil Rear brake oil
short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
Min. 1 Mz
Rear brake oil
25°C
chassis ground
100°C 3.1 – 4.5 kz
40-306 50 WA470, 480-6

Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range) SEN04526-01
WA470, 480-6 40-306 51

SEN04526-01 Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range)
Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of

input signal range) 1
Action code Failure code Torque converter oil temperature sensor: Out of input signal range
Trouble
E01 DGT1KX (Machine monitor system)
Contents of • Due to grounding fault in the torque converter oil temperature sensor signal system, the signal level
trouble is lower than normal range (Transmission oil temperature signal voltage: Max. 0.97 V (Min. 150°C))
Action of
controller
Problem that
appears on • The torque converter oil temperature gauge reads MAX position.
machine
Related
information

1 oil temperature sensor temperature
(Internal short circuit) 25°C
35 – 50 kz
100°C 3.1 – 4.5 kz
Possible causes
(Contact with ground circuit) Max. 1 z
TC.T (female) (1) and chassis ground tance
25°C
chassis ground
100°C 3.1 – 4.5 kz
40-306 52 WA470, 480-6

Failure code [DGT1KX] (Torque converter oil temperature sensor: Out of input signal range) SEN04526-01
WA470, 480-6 40-306 53

SEN04526-01 Failure code [DH21KA] (Loader pump pressure sensor: Disconnection)
Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) 1

Action code Failure code Loader pump pressure sensor: Disconnection
Trouble
E01 DH21KA (Transmission controller system)
• Loader pump pressure signal voltage is lower than normal range because of disconnection or
Contents of
ground fault in loader pump pressure sensor system.
trouble
(Work equipment pump pressure sensor signal voltage: Max. 0.3 V)
Action of • Lets loader pump pressure to be 0 MPa {0 kg/cm2} and continues operation.
Problem that
appears on • When oil is relieved, cut-off operation is not turned ON.
machine
• Input state (Oil pressure) from loader pump pressure sensor can be checked with monitoring function
(Code: 95200, PUMP PRESS).
Related
• Input state (Voltage) from loader pump pressure sensor can be checked with monitoring function
information
• Method of reproducing failure code: Start engine + Tilt bucket to relieve oil).

a Prepare with starting switch OFF, then turn starting switch START
Loader pump
F12 Voltage
pressure
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)
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.
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
3 harness Min. 1 Mz
F12 (female) (C) and chassis ground tance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, tilt bucket,
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
40-306 54 WA470, 480-6

Failure code [DH21KA] (Loader pump pressure sensor: Disconnection) SEN04526-01
WA470, 480-6 40-306 55

SEN04526-01 Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short)
Failure code [DH21KB] (Loader pump pressure sensor: Power supply

line short) 1
Action code Failure code Loader pump pressure sensor: Power supply line short
Trouble
E01 DH21KB (Transmission controller system)
Contents of • Loader pump pressure signal is higher than normal range because of hot short in loader pump pres-
trouble sure sensor system. (Loader pump pressure sensor signal voltage: Min. 4.7 V)
Action of • Lets loader pump pressure to be 0 MPa {0 kg/cm2} and continues operation.
Problem that
appears on • When oil is relieved, cut-off operation is not turned ON.
machine
• Input state (Oil pressure) from loader pump pressure sensor can be checked with monitoring function
Related
• Input state (Voltage) from loader pump pressure sensor can be checked with monitoring function
information
• Method of reproducing failure code: Start engine + Tilt bucket to relieve oil).

a Prepare with starting switch OFF, then turn starting switch START
Loader pump
F12 Voltage
pressure
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)
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
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,
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
40-306 56 WA470, 480-6

Failure code [DH21KB] (Loader pump pressure sensor: Power supply line short) SEN04526-01
WA470, 480-6 40-306 57

SEN04526-01

©2009 KOMATSU
All Rights Reserved
40-306 58
SEN04527-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)...................... 2
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)......................... 4
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) ........................... 6
Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) ..................................................... 8
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)....................................................... 10
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) ...................................... 12
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)...... 15
Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) ....................... 18
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) ....................................... 21
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)....... 24
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)....................................... 27
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) ...... 30
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) ........................ 33
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) ........................................ 36
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) ....... 39
WA470, 480-6 40-307 1

SEN04527-01 Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range)
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
controller
Problem that
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

Check that the failure code does not display when the lift arm cylin-
der bottom pressure sensor is replaced.
a Prepare with starting switch OFF, then start engine, raise the lift
Defective lift arm cylinder arm and carry out troubleshooting.
bottom pressure sensor F16 Lift arm Voltage
1
Between (B) and (A) Constant 4.85 – 5.15 V
short circuit)
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm bottom relief 3.02 – 3.42 V
and standard
Disconnection in wiring Wiring harness between L51 (female) (16) – Resis-
state harness F16 (female) (B) tance
2
(Disconnection in wiring Wiring harness between L55 (female) (9) – Resis-
harness or defective contact) Max. 1 z
F16 (female) (C) tance
Wiring harness between F16 (female) (A) – Resis-
Max. 1 z
Grounding fault in wiring Resis-
F16 (female) (B), – circuit branch end and Min. 1 Mz
3 harness tance
chassis ground
Resis-
F16 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground
40-307 2 WA470, 480-6

Failure code [DHPCKX] (Lift arm cylinder bottom pressure sensor: Out of input signal range) SEN04527-01

Hot short in wiring harness F16 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24V circuit) chassis ground
Possible causes F16 (female) (C), – circuit branch end and Voltage Max. 1 V
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Between L55 (9) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm bottom relief 3.02 – 3.42 V
WA470, 480-6 40-307 3

SEN04527-01 Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range)
Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of
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
controller
Problem that
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

Check that the failure code does not display when the lift arm cylin-
der bottom pressure sensor is replaced.
a Prepare with starting switch OFF, then start engine, lower the lift
Defective lift arm cylinder arm and carry out troubleshooting.
head pressure sensor F17 Lift arm Voltage
1
short circuit)
Between (C) and (A) Neutral 0.50 – 0.90 V
Lift arm head relief 3.02 – 3.42 V
and standard
state harness F17 (female) (B) tance
2
F17 (female) (C) tance
Wiring harness between F17 (female) (A) – Resis-
Max. 1 z
F17 (female) (B), – circuit branch end and Min. 1 Mz
3 harness tance
chassis ground
Resis-
F17 (female) (C), – circuit branch end and Min. 1 Mz
tance
chassis ground
40-307 4 WA470, 480-6

Failure code [DHPDKX] (Lift arm cylinder head pressure sensor: Out of input signal range) SEN04527-01

Hot short in wiring harness F17 (female) (B), – circuit branch end and Voltage Max. 1 V
4
(Contact with 24V circuit) chassis ground
Possible causes F17 (female) (C), – circuit branch end and Voltage Max. 1 V
value in normal a Prepare with starting switch OFF, then start engine, raise the lift
state arm and carry out troubleshooting.
L51, L55 Lift arm Voltage
Between L51 (16)
5 Defective machine monitor Constant 4.85 – 5.15 V
and chassis ground
Between L55 (4) and
Neutral 0.50 – 0.90 V
chassis ground
Lift arm head relief 3.02 – 3.42 V
WA470, 480-6 40-307 5

SEN04527-01 Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)
Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of

Action code Failure code Transmission cut-off pressure sensor: Out of input signal range
Trouble
E01 DHT1KX (Transmission controller system)
Contents of • Due to grounding fault in transmission cut-off (left brake) pressure sensor signal system, the signal
trouble level is lower than normal range.
• Turns off the transmission cut-off function
• Does not allow changing the transmission cut-off set.
Action of
controller
steering FNR (directional) switch or right FNR (directional) switch is set to N (Neutral). Or the trans-
mission cut-off switch must be turned off.
Problem that
• The transmission cut-off indicator goes off.
appears on
• The transmission cut-off does not work.
machine
• Input voltage of the transmission cut-off pressure sensor is max. 0.3 V
• The input state (oil pressure) from the transmission cut-off pressure sensor can be checked with the
Related monitoring function (Code: 41201, T/M CUT OFF P).
information • The input state (voltage) from the transmission cut-off pressure sensor can be checked with the mon-
itoring function (Code: 41202, T/M CUT OFF P).
• Method of reproducing failure code: Turn the starting switch and the transmission cut-off switch ON.

• Transmission cut-off switch is ON.
R73 Brake Voltage
When brake is
0.9 – 1.1 V
Defective transmission released
1 cut-off pressure sensor When the left brake
(Internal short circuit) pedal is pressed 1.1 – 5.1 V
Between (C) and (A) down
When the right brake
Possible causes pedal is pressed 1.1 – 5.1 V
and standard down
value in normal Other than above 0.9 – 5.1 V
Grounding fault in wiring without turning starting switch ON.
2 harness
Min. 1 Mz
R73 (female) (C) and chassis ground tance
Max. 1 z
ness R73 (female) (B) tance
3
R73 (female) (C) tance
Wiring harness between R73 (female) (A) – Resis-
Max. 1 z
R22 tance
40-307 6 WA470, 480-6

Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range) SEN04527-01

L61 Brake Voltage
When brake is
Possible causes 0.9 – 1.1 V
released
and standard
value in normal Defective transmission When the left brake
4
state controller pedal is pressed 1.1 – 5.1 V
Between (19) and down
chassis ground
When the right brake
pedal is pressed 1.1 – 5.1 V
down
Other than above 0.9 – 5.1 V
WA470, 480-6 40-307 7

SEN04527-01 Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)
Failure code [DHT8KA] (Steering pump pressure sensor:

Disconnection) 1
Action code Failure code Steering pump pressure sensor: Disconnection

Trouble
E01 DHT8KA (Transmission controller system)
Contents of • Due to disconnection or ground fault in steering pump pressure sensor system, the signal level is
trouble lower than normal range. (Steering pump pressure sensor signal voltage: Max. 0.3 V)
Problem that
appears on • Engine does not pick up smoothly at low speed.
machine
Related
information

troubleshooting.
Steering pump
R86 Voltage
pressure
Defective steering pump Constant 0.50 – 4.50 V
1 pressure sensor (Internal When steering is in
disconnection or short circuit) 0.50 – 0.90 V
Between (C) and (A) neutral
When steering is
3.02 – 3.42 V
relieved
ingly, if voltage is abnormal, check wiring harness and controller,
too, for another cause of trouble, and then judge.
Possible causes
Disconnection in wiring a Prepare with starting switch OFF, then carry out troubleshooting
and standard
harness without turning starting switch ON.
value in normal 2
state (Disconnection or defective Wiring harness between L61 (female) (3) – Resis-
R86 (female) (C) tance
3 harness
Min. 1 Mz
troubleshooting.
Steering pump
L61 Voltage
pressure
Defective transmission
4 Constant 0.50 – 4.50 V
controller
When steering is in
Between (3) and 0.50 – 0.90 V
neutral
chassis ground
When steering is
3.02 – 3.42 V
relieved
40-307 8 WA470, 480-6

Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection) SEN04527-01
WA470, 480-6 40-307 9

SEN04527-01 Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)
Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) 1
Action code Failure code Steering pump pressure sensor: Short circuit
Trouble
E01 DHT8KB (Transmission controller system)
Contents of • Due to hot short circuit in the steering pump pressure sensor signal system, the signal level is higher
trouble than normal range. (Steering pump pressure sensor signal voltage: Min. 4.7 V)
Problem that
appears on • Engine does not pick up smoothly at low speed.
machine
Related
information

troubleshooting.
Steering pump
R86 Voltage
pressure
Defective steering pump oil
pressure sensor
1 When steering is in
(Internal disconnection or 0.50 – 0.90 V
short circuit) Between (C) and (A) neutral
When steering is
3.02 – 3.42 V
relieved
Possible causes
ingly, if voltage is abnormal, check wiring harness and controller,
and standard
too, for another cause of trouble, and then judge.
value in normal
Hot short in wiring harness without turning starting switch ON.
2
(Contact with 24 V circuit) Wiring harness between L61 (female) (3) – Resis-
Min. 1 Mz
troubleshooting.
Steering pump
L61 Voltage
pressure
3 Constant 0.50 – 4.50 V
controller
When steering is in
Between (3) and 0.50 – 0.90 V
neutral
chassis ground
When steering is
3.02 – 3.42 V
relieved
40-307 10 WA470, 480-6

Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit) SEN04527-01
WA470, 480-6 40-307 11

SEN04527-01 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Lift arm EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK59KA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range (Lift arm EPC lever potentiometer (Main) signal voltage:
trouble
Max. 0.3 V).
• If the lift arm EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
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
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever • Work equipment lock lever: Free
potentiometer L28 Lift arm EPC lever Voltage
1
short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes Lever in neutral 2.40 – 2.60 V
and standard Raise operation
value in normal 3.69 – 4.09 V
(Before detent)
state
Raise operation
Between (3) and (1) 3.91 – 4.31 V
(Detent position)
Lower operation
0.91 – 1.31 V
(Before detent)
Float operation 0.69 – 1.09 V
Max. 1 z
harness L28 (female) (3) tance
2
Max. 1 z
40-307 12 WA470, 480-6

Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection) SEN04527-01

Grounding fault in wiring Wiring harness between L71 (female) (19) – Resis-
Min. 1 Mz
3 harness L28 (female) (3) and chassis ground tance
(Contact with ground circuit) Wiring harness between L71 (female) (22) –
Resis-
tance
chassis ground
Possible causes
• Work equipment lock lever: Free
and standard
value in normal L71 Lift arm EPC lever Voltage
(10)
Defective work equipment Lever at neutral 2.40 – 2.60 V
4
controller Raise operation
3.69 – 4.09 V
(Before detent)
Between (19) and Raise operation
3.91 – 4.31 V
(10) (Detent position)
Lower operation
0.91 – 1.31 V
(Before detent)
WA470, 480-6 40-307 13

SEN04527-01 Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
40-307 14 WA470, 480-6

Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) SEN04527-01
Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short
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.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever
1 potentiometer L28 Lift arm EPC lever Voltage
(Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
and standard Lever at neutral 2.40 – 2.60 V
value in normal Raise operation
3.69 – 4.09 V
state (Before detent)
Raise operation
Between (3) and (1) 3.91 – 4.31 V
(Detent position)
Lower operation
0.91 – 1.31 V
(Before detent)
Hot short in wiring harness Voltage Max. 1 V
2 L28 (female) (3) and chassis ground
chassis ground
WA470, 480-6 40-307 15

SEN04527-01 Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)

L71 Lift arm EPC lever Voltage
Between (22) and
Possible causes Constant 4.85 – 5.15 V
(10)
and standard
value in normal 3
state controller Raise operation
3.69 – 4.09 V
(Before detent)
3.91 – 4.31 V
Lower operation
0.91 – 1.31 V
(Before detent)
40-307 16 WA470, 480-6

Failure code [DK59KY] (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line) SEN04527-01
WA470, 480-6 40-307 17

SEN04527-01 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
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
• 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.
Related
information
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes Lever at neutral 2.40 – 2.60 V
and standard Defective lift arm EPC lever
Raise operation
value in normal potentiometer 3.69 – 4.09 V
1 (Before detent)
short circuit) Raise operation
Between (3) and (1) 3.91 – 4.31 V
(Detent position)
Lower operation
0.69 – 1.09 V
(Before detent)
Lever at neutral 2.40 – 2.60 V
Raise operation
0.91 – 1.31 V
(Before detent)
Raise operation
Between (2) and (1) 0.69 – 1.09 V
(Detent position)
Lower operation
3.69 – 4.09 V
(Before detent)
40-307 18 WA470, 480-6

Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree) SEN04527-01

Max. 1 z
Disconnection in wiring L28 (female) (2) tance
2 Max. 1 z
(Disconnection in wiring L28 (female) (3) tance
harness or defective contact) Wiring harness between L71 (female) (22) – Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Grounding fault in wiring L28 (female) (2) and chassis ground tance
3 harness Wiring harness between L71 (female) (19) – Resis-
(Contact with ground circuit) L28 (female) (3) and chassis ground Min. 1 Mz
tance
Resis-
tance
chassis ground
Voltage Max. 1 V
Possible causes 4 Wiring harness between L71 (female) (19) –
(Contact with 24V circuit) Voltage Max. 1 V
and standard L28 (female) (3) and chassis ground
value in normal
state
chassis ground
Between (22) and
(10)
Raise operation
0.91 – 1.31 V
(Before detent)
0.69 – 1.09 V
Defective work equipment (10) (Detent position)
5
controller Float operation 3.69 – 4.09 V
Lower operation
3.91 – 4.31 V
(Before detent)
Raise operation
3.69 – 4.09 V
(Before detent)
3.91 – 4.31 V
Lower operation
0.91 – 1.31 V
(Before detent)
WA470, 480-6 40-307 19

SEN04527-01 Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
40-307 20 WA470, 480-6

Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) SEN04527-01
Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Lift arm EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5AKA (Work equipment controller system)
• Due to disconnection or grounding fault in the lift arm EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Lift arm EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 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
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever • Work equipment lock lever: Free
potentiometer L28 Lift arm EPC lever Voltage
1
short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
and standard Raise operation
value in normal 0.91 – 1.31 V
(Before detent)
state
Raise operation
Between (2) and (1) 0.69 – 1.09 V
(Detent position)
Lower operation
3.69 – 4.09 V
(Before detent)
Max. 1 z
2
Max. 1 z
WA470, 480-6 40-307 21

SEN04527-01 Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)

Min. 1 Mz
Resis-
tance
chassis ground
Possible causes
and standard
value in normal L71 Lift arm EPC lever Voltage
(10)
4
controller Raise operation
0.91 – 1.31 V
(Before detent)
0.69 – 1.09 V
Lower operation
3.69 – 4.09 V
(Before detent)
40-307 22 WA470, 480-6

Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection) SEN04527-01
WA470, 480-6 40-307 23

SEN04527-01 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)
Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short
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.
(Neutral).
Problem that
appears on —
machine
Related
information
• Method of reproducing failure code: Turn the starting switch ON and operate lift arm lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective lift arm EPC lever
1 potentiometer L28 Lift arm EPC lever Voltage
(Internal short circuit) Between (4) and (1) Constant 4.85 – 5.15 V
Possible causes
value in normal Raise operation
0.91 – 1.31 V
state (Before detent)
Raise operation
Between (2) and (1) 0.69 – 1.09 V
(Detent position)
Lower operation
3.69 – 4.09 V
(Before detent)
chassis ground
40-307 24 WA470, 480-6

Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line) SEN04527-01

Between (22) and
Possible causes Constant 4.85 – 5.15 V
(10)
and standard
value in normal 3
state controller Raise operation
0.91 – 1.31 V
(Before detent)
0.69 – 1.09 V
Lower operation
3.69 – 4.09 V
(Before detent)
WA470, 480-6 40-307 25

SEN04527-01 Failure code [DK5AKY] (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)
40-307 26 WA470, 480-6

Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) SEN04527-01
Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main):

Disconnection) 1
Action code Failure code Bucket EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5BKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Main) system, the
Contents of
signal voltage is lower than normal range (Bucket EPC lever potentiometer (Main) signal voltage:
trouble
Max. 0.3 V)
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns on the centralized warning lamp and the alarm buzzer ON.
controller • Even if cause of failure disappears, system does not reset itself until bucket EPC lever is set to N
(Neutral).
Problem that
appears on —
machine
• The input state (voltage) from the bucket EPC lever potentiometer (Main) can be checked with the
monitoring function (Code: 42002, BUCKET POT1).
Related
• The input state (voltage) from the bucket EPC lever potentiometer (Sub) can be checked with the
information
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Defective bucket EPC lever and carry out troubleshooting.
potentiometer • Work equipment lock lever: Free
1
L29 Bucket EPC lever Voltage
short circuit)
Possible causes Between (4) and (1) Constant 4.85 – 5.15 V
value in normal
Tilt operation
state 3.69 – 4.09 V
(Before detent)
Between (3) and (1)
Tilt operation
3.91 – 4.31 V
(Detent position)
Full dump operation 0.69 – 1.09 V
Max. 1 z
2
Max. 1 z
WA470, 480-6 40-307 27

SEN04527-01 Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)

Min. 1 Mz
Resis-
tance
chassis ground
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
Defective work equipment (10)
4
controller Lever at neutral 2.40 – 2.60 V
Tilt operation
3.69 – 4.09 V
(Before detent)
Tilt operation
3.91 – 4.31 V
(Detent position)
40-307 28 WA470, 480-6

Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection) SEN04527-01
WA470, 480-6 40-307 29

SEN04527-01 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)
Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short

Action code Failure code Bucket EPC lever potentiometer (Main): Short circuit with the power
Trouble
E03 DK5BKY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the bucket EPC lever potentiometer (Main) system, the signal voltage is
trouble higher than normal range (Bucket EPC lever potentiometer (Main) signal voltage: Min. 4.7 V)
• If the bucket EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Action of • Turns on the centralized warning lamp and the alarm buzzer ON.
(Neutral).
Problem that
appears on —
machine
Related
information
• Method of reproducing failure code: Turn the starting switch ON and operate bucket lever.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer (Internal short • Work equipment lock lever: Free
circuit) L29 Bucket EPC lever Voltage
Possible causes
and standard
value in normal Lever at neutral 2.40 – 2.60 V
state Tilt operation
3.69 – 4.09 V
(Before detent)
Between (3) and (1)
Tilt operation
3.91 – 4.31 V
(Detent position)
chassis ground
40-307 30 WA470, 480-6

Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line) SEN04527-01

Possible causes Between (22) and
and standard Constant 4.85 – 5.15 V
value in normal 3
state controller Lever at neutral 2.40 – 2.60 V
Tilt operation
3.69 – 4.09 V
(Before detent)
Tilt operation
3.91 – 4.31 V
(Detent position)
WA470, 480-6 40-307 31

SEN04527-01 Failure code [DK5BKY] (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)
40-307 32 WA470, 480-6

Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) SEN04527-01
Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog

signals disagree) 1
Action code Failure code Bucket EPC lever potentiometer (Main): Analog signals disagree
Trouble
E03 DK5BL8 (Work equipment controller system)
• Bucket EPC lever potentiometer (Main & Sub) input signals disagree with each other. (Bucket EPC
Contents of
lever potentiometer signal voltage (sum of Main and Sub): Max. 4.7 V) or (Bucket EPC lever potenti-
trouble
ometer signal voltage (sum of Main and Sub): Min. 5.3 V)
Action of
trality ±5%.
controller
• Even if cause of failure disappears, system does not reset itself until bucket 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, bucket does not move.
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
Possible causes
and standard Defective bucket EPC lever Between (4) and (1) Constant 4.85 – 5.15 V
value in normal potentiometer
1 Lever at neutral 2.40 – 2.60 V
short circuit) Tilt operation
3.69 – 4.09 V
(Before detent)
Between (3) and (1)
Tilt operation
3.91 – 4.31 V
(Detent position)
Tilt operation
0.91 – 1.31 V
(Before detent)
Between (2) and (1)
Tilt operation
0.69 – 1.09 V
(Detent position)
WA470, 480-6 40-307 33

SEN04527-01 Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)

Max. 1 z
2 Max. 1 z
(Disconnection in wiring L29 (female) (3) tance
Max. 1 z
Max. 1 z
Min. 1 Mz
Grounding fault in wiring L29 (female) (2) and chassis ground tance
3 harness Wiring harness between L71 (female) (7) – Resis-
(Contact with ground circuit) L29 (female) (3) and chassis ground Min. 1 Mz
tance
Resis-
tance
chassis ground
Possible causes Wiring harness between L71 (female) (1) –
and standard Voltage Max. 1 V
value in normal Hot short in wiring harness
4 Wiring harness between L71 (female) (7) –
state (Contact with 24V circuit) Voltage Max. 1 V
chassis ground
Between (22) and
(10)
Tilt operation
3.69 – 4.09 V
Defective work equipment (Before detent)
5 Between (7) and (10)
controller Tilt operation
3.91 – 4.31 V
(Detent position)
Tilt operation
0.91 – 1.31 V
(Before detent)
Tilt operation
0.69 – 1.09 V
(Detent position)
40-307 34 WA470, 480-6

Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree) SEN04527-01
WA470, 480-6 40-307 35

SEN04527-01 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)
Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub):

Disconnection) 1
Action code Failure code Bucket EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5CKA (Work equipment controller system)
• Due to disconnection or grounding fault in the bucket EPC lever potentiometer (Sub) system, the sig-
Contents of
nal voltage is lower than normal range (Bucket EPC lever potentiometer (Sub) signal voltage: Max.
trouble
0.3 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
potentiometer • Work equipment lock lever: Free
1
short circuit)
Tilt operation
0.91 – 1.31 V
(Before detent)
Possible causes Between (2) and (1)
and standard Tilt operation
0.69 – 1.09 V
value in normal (Detent position)
state Full dump operation 3.91 – 4.31 V
Max. 1 z
2
Max. 1 z
Min. 1 Mz
Resis-
tance
chassis ground
40-307 36 WA470, 480-6

Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection) SEN04527-01

value in normal 4
Tilt operation
0.91 – 1.31 V
(Before detent)
Tilt operation
0.69 – 1.09 V
(Detent position)
WA470, 480-6 40-307 37

SEN04527-01 Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)
40-307 38 WA470, 480-6

Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) SEN04527-01
Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short

Action code Failure code Bucket EPC lever potentiometer (Sub): Short circuit with the power
Trouble
E03 DK5CKY supply line (Work equipment controller system)
Contents of • Due to hot short circuit in the bucket EPC lever potentiometer (Sub) system, the signal voltage is
trouble higher than normal range (Bucket EPC lever potentiometer (Sub) signal voltage: Min. 4.7 V).
• If the bucket EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
(Neutral).
Problem that
appears on —
machine
Related
information

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3), (4) and
Min. 1 Mz
chassis ground
1 potentiometer (Internal short • Work equipment lock lever: Free
circuit) L29 Bucket EPC lever Voltage
Possible causes
and standard
value in normal Lever at neutral 2.40 – 2.60 V
state Tilt operation
0.91 – 1.31 V
(Before detent)
Between (2) and (1)
Tilt operation
0.69 – 1.09 V
(Detent position)
chassis ground
WA470, 480-6 40-307 39

SEN04527-01 Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)

value in normal 3
Tilt operation
0.91 – 1.31 V
(Before detent)
Tilt operation
0.69 – 1.09 V
(Detent position)
40-307 40 WA470, 480-6

Failure code [DK5CKY] (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line) SEN04527-01
WA470, 480-6 40-307 41

SEN04527-01

©2009 KOMATSU
All Rights Reserved
40-307 42
SEN04528-01
WHEEL LOADER 1HOP MANUAL
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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 [DLF1KA] (Transmission input speed sensor: Disconnection) ................................................. 22
Failure code [DLF1LC] (Transmission input speed sensor: Short circuit)..................................................... 23
Failure code [DLM3KA] (Fan speed sensor: Disconnection) ........................................................................ 24
Failure code [DLM3LC] (Fan speed sensor: Short circuit)............................................................................ 26
Failure code [DLT3KA] (Transmission output speed sensor: Disconnection) ............................................... 28
Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range)............................... 30
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit).................................................. 32
Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)..................................... 34
Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) .................................... 36
Failure code [DV00KB] (Alarm buzzer: Short circuit).................................................................................... 38
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) ........................................................ 40
WA470, 480-6 40-308 1

SEN04528-01
Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) ............................................................ 42
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) ........................ 44
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) ....................................................... 46
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) ........................................................... 47
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) ....................... 48
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection).............................................................. 50
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) ................................................................. 51
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) ............................. 52
40-308 2 WA470, 480-6

Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) SEN04528-01
Failure code [DK5FKA] (Joystick steering EPC lever potentiometer

(Main): Disconnection) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Disconnection
Trouble
E03 DK5FKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer (Main) sys-
Contents of
tem, the signal voltage is lower than normal range (Joystick steering EPC lever potentiometer (Main)
trouble
signal voltage: Max. 0.3 V)
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
controller • Even if cause of failure disappears, system does not reset itself until the joystick steering EPC lever
is set to N (Neutral).
Problem that
appears on —
machine
• When the joystick steering ON/OFF switch is set to OFF, this failure code is not displayed.
• The input state (voltage) from the joystick steering EPC lever potentiometer (Main) can be checked
Related with the monitoring function (Code: 42004, J/S POT1).
information • The input state (voltage) from the joystick steering EPC lever potentiometer (Sub) can be checked
with the monitoring function (Code: 42005, J/S POT2).
• Method of reproducing failure code: Turn the starting switch ON and operate joystick steering lever.

JS3 (male) Resistance
Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
EPC lever potentiometer a Prepare with starting switch OFF, then turn starting switch ON
1 and carry out troubleshooting.
short circuit) Joystick steering EPC
JS3 Voltage
lever
Possible causes
and standard Between (3) and (1) Left turning 1.14 – 1.54 V
value in normal Right turning 3.46 – 3.86 V
state
Max. 1 z
harness JS3 (female) (3) tance
2
JS3 (female) (4) tance
Wiring harness between JS3 (female) (1) – Resis-
Max. 1 z
3 harness Min. 1 Mz
JS3 (female) (3) and chassis ground tance
Min. 1 Mz
WA470, 480-6 40-308 3

SEN04528-01 Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)

Possible causes Joystick steering EPC

L71 Voltage
and standard lever
value in normal Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
state controller (10)
Between (9) and (10) Left turning 1.14 – 1.54 V
Right turning 3.46 – 3.86 V
40-308 4 WA470, 480-6

Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection) SEN04528-01
WA470, 480-6 40-308 5

Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power
SEN04528-01 supply line)
Failure code [DK5FKY] (Joystick steering EPC lever potentiometer

(Main): Short circuit with power supply line) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Short circuit with
Trouble
E03 DK5FKY the power supply line (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Main) system, the signal
Contents of
voltage is higher than normal range. (Joystick steering EPC lever potentiometer (Main) signal volt-
trouble
age: Max. 4.7 V)
• If the joystick steering EPC lever potentiometer (Sub) is normal, the Sub potentiometer is in control.
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
Defective joystick steering a Prepare with starting switch OFF, then turn starting switch ON
1 EPC lever potentiometer and carry out troubleshooting.
(Internal short circuit)
JS3 Voltage
lever
Possible causes Between (3) and (1) Left turning 1.14 – 1.54 V
and standard
Hot short in wiring harness Wiring harness between L71 (female) (9) –
2 Voltage Max. 1 V
(Contact with 24V circuit) JS3 (female) (3) and chassis ground
Voltage Max. 1 V
JS3 (female) (4) and chassis ground
L71 Voltage
lever
3 (22) – (10) Constant 4.85 – 5.15 V
controller
40-308 6 WA470, 480-6

Failure code [DK5FKY] (Joystick steering EPC lever potentiometer (Main): Short circuit with power
supply line) SEN04528-01
WA470, 480-6 40-308 7

SEN04528-01 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
Failure code [DK5GKA] (Joystick steering EPC lever potentiometer

(Sub): Disconnection) 1
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Disconnection
Trouble
E03 DK5GKA (Work equipment controller system)
• Due to disconnection or grounding fault in the joystick steering EPC lever potentiometer (Sub) sys-
Contents of
tem, the signal voltage is lower than normal range (Joystick steering EPC lever potentiometer (Sub)
trouble
signal voltage: Max. 0.3 V)
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Action of
controller
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
JS3 Voltage
lever
Possible causes
state
Max. 1 z
harness JS3 (female) (2) tance
2
Max. 1 z
3 harness Min. 1 Mz
Min. 1 Mz
40-308 8 WA470, 480-6

Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection) SEN04528-01

Possible causes Joystick steering EPC

L71 Voltage
and standard lever
value in normal Defective work equipment Between (22) and
4 Constant 4.85 – 5.15 V
state controller (10)
WA470, 480-6 40-308 9

SEN04528-01 Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
40-308 10 WA470, 480-6

Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power
supply line) SEN04528-01
Failure code [DK5GKY] (Joystick steering EPC lever potentiometer

(Sub): Short circuit with power supply line) 1
Action code Failure code Joystick steering EPC lever potentiometer (Sub): Short circuit with
Trouble
E03 DK5GKY power supply line (Work equipment controller system)
• Due to hot short circuit in the joystick steering EPC lever potentiometer (Sub) system, the signal volt-
Contents of
age is higher than normal range. (Joystick steering EPC lever potentiometer (Sub) signal voltage:
trouble
Min. 4.7 V)
• If the joystick steering EPC lever potentiometer (Main) is normal, the Main potentiometer is in control.
Problem that
appears on —
machine

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
JS3 Voltage
lever
Possible causes Between (2) and (1) Left turning 3.46 – 3.86 V
and standard Right turning 1.14 – 1.54 V
value in normal
state
2 Voltage Max. 1 V
(Contact with 24V circuit) JS3 (female) (2) and chassis ground
Voltage Max. 1 V
L71 Voltage
lever
Defective work equipment Between (22) and
3 Constant 4.85 – 5.15 V
controller (10)
WA470, 480-6 40-308 11

Failure code [DK5GKY] (Joystick steering EPC lever potentiometer (Sub): Short circuit with power
SEN04528-01 supply line)
40-308 12 WA470, 480-6

Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) SEN04528-01
Failure code [DK5FL8] (Joystick steering EPC lever potentiometer

(Main): Analog signals disagree) 1
Action code Failure code Joystick steering EPC lever potentiometer (Main): Analog signals
Trouble
E03 DK5FL8 disagree (Work equipment controller system)
• Joystick steering EPC lever potentiometer (Main & Sub) input signals disagree with each other. (Joy-
Contents of
stick steering EPC lever potentiometer signal voltage (both Main and Sub): Max. 4.7 V) or (Joystick
trouble
steering EPC lever potentiometer signal voltage (both Main and Sub): Min 5.3 V)
Action of
trality ±5%.
controller
• Even if cause of failure disappears, system does not reset itself until the joystick steering EPC lever
Problem that • If either Main or Sub potentiometer is abnormal, machine operates normally after the joystick steer-
appears on ing EPC lever is set to neutral.
machine • If both Main and Sub potentiometers are abnormal, steering cylinder does not move.

Between (1) and (4) 3.2 ± 0.64 kz
Between (1), (2), (3) or (4) and
Min. 1 Mz
chassis ground
Defective joystick steering and carry out troubleshooting.
EPC lever potentiometer Joystick steering EPC
1 JS3 Voltage
(Internal disconnection or lever
short circuit)

state
Max. 1 z
Disconnection in wiring JS3 (female) (2) tance
2 Max. 1 z
(Disconnection in wiring JS3 (female) (3) tance
Max. 1 z
Max. 1 z
WA470, 480-6 40-308 13

SEN04528-01 Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)

Grounding fault in wiring Min. 1 Mz
3 harness
Min. 1 Mz
Min. 1 Mz
Voltage Max. 1 V
Hot short in wiring harness JS3 (female) (2) and chassis ground
4
Possible causes (Contact with 24V circuit) Wiring harness between L71 (female) (9) –
Voltage Max. 1 V
and standard JS3 (female) (3) and chassis ground
value in normal Wiring harness between L71 (female) (22) –
state Voltage Max. 1 V
L71 Voltage
lever
Between (22) and
(10)
5 Lever at neutral 2.40 – 2.60 V
controller
40-308 14 WA470, 480-6

Failure code [DK5FL8] (Joystick steering EPC lever potentiometer (Main): Analog signals disagree) SEN04528-01
WA470, 480-6 40-308 15

SEN04528-01 Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)
Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) 1
Action code Failure code Lift arm angle sensor: Disconnection

Trouble
E01 DKA0KA (Work equipment controller system)
Contents of • Due to disconnection or ground fault in lift arm angle sensor system, the signal voltage is lower than
trouble normal range (Lift arm angle sensor signal: Max. 0.3 V).
• Judges that lift arm is at the lowest position.
• Resets the remote positioner function.
• Resets semi-auto digging function.
Action of • No PC control while the lift arm is rising.
controller • When the remote positioner down setting is ON, turns OFF the lift arm float detent, and when the
remote positioner down setting is OFF, usually operates the lift arm float detent.
• Turns the lift arm up detent OFF.
Problem that • Remote positioner malfunction (operation is not stopped).
appears on • Malfunctioning in semi-auto digging operation (operation is stopped).
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).
• The input state (voltage) from the lift arm angle sensor can be checked with the monitoring function
Related
information
• If failure code [DAF5KP] (Machine monitor: Low output voltage) is displayed, carry out troubleshoot-
ing for it first.

Between (A) and (C) 5 kz ± 20%
Min. 1 Mz
chassis ground
Defective lift arm angle sen-
1 sor (Internal disconnection or a Prepare with starting switch OFF, then start engine and carry out
short circuit) troubleshooting.
F18 Lift arm position Voltage
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
state
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-
Wiring harness between F18 (female) (C) – Resis-
Max. 1 z
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
40-308 16 WA470, 480-6

Failure code [DKA0KA] (Lift arm angle sensor: Disconnection) SEN04528-01

Possible causes troubleshooting.
and standard L71 Lift arm position Voltage
value in normal Defective work equipment
4
state controller Constant 0.83 – 4.17 V
Between (8) and
Up stroke end 3.50 – 4.17 V
chassis ground
Lower stroke end 0.83 – 1.88 V
WA470, 480-6 40-308 17

SEN04528-01 Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
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.
• 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
• 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.
Related
information

Min. 1 Mz
chassis ground
Defective lift arm angle a Prepare with starting switch OFF, then start engine and carry out
1
sensor (Internal short circuit) troubleshooting.
F18 Lift arm position Voltage
Possible causes
Between (B) and (A) Up stroke end 3.50 – 4.17 V
and standard
value in normal Lower stroke end 0.83 – 1.88 V
Wiring harness between F18 (female) (B) –
Wiring harness between F18 (female) (C) –
chassis ground
troubleshooting.
Defective work equipment L71 Lift arm position Voltage

3
controller Constant 0.83 – 4.17 V
Between (8) and
chassis ground
40-308 18 WA470, 480-6

Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line) SEN04528-01
WA470, 480-6 40-308 19

SEN04528-01 Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)
Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) 1
Action code Failure code Lift arm angle sensor: Double meshing
Trouble
E01 DKA0L0 (Work equipment controller system)
Contents of • Due to lift arm angle sensor dislocation, lift arm angle is not detectable correctly. (Lift arm angle
trouble upper limit +5° and above or lift arm angle lower limit +5° or above)
• 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
Problem that • Remote positioner malfunction (operation is not stopped).
appears on • Malfunctioning in semiautomatic digging operation (operation is stopped).
• This failure code is sometimes displayed if the initial setting of the lift arm angle sensor was not
appropriate.
Related
information
• Method of reproducing failure code: Start engine and set the lift arm to up or down stroke end.

Defective lift arm angle sen- a Adjustment of lift arm angle sensor may be defective. Check it
1
sor adjustment directly (see Testing and adjusting).
Min. 1 Mz
chassis ground
Defective lift arm angle a Prepare with starting switch OFF, then start engine and carry out
2
Possible causes sensor (Internal short circuit) troubleshooting.
and standard
value in normal F18 Lift arm position Voltage
state Between (C) and (A) Constant 4.85 – 5.15 V
Between (B) and (A) Up stroke end 3.50 – 4.17 V
troubleshooting.
Defective work equipment L71 Lift arm position Voltage

3
controller Constant 0.83 – 4.17 V
Between (8) and
chassis ground
40-308 20 WA470, 480-6

Failure code [DKA0L0] (Lift arm angle sensor: Double meshing) SEN04528-01
WA470, 480-6 40-308 21

SEN04528-01 Failure code [DLF1KA] (Transmission input speed sensor: Disconnection)
Failure code [DLF1KA] (Transmission input speed sensor:

Disconnection)
Action code Failure code Transmission input speed sensor: Disconnection
Trouble
E01 DLF1KA (Transmission controller system)
• Due to disconnection or hot short circuit in the transmission input speed sensor system, the signal
voltage is higher than normal range
Contents of
• This failure code is displayed under following condition.
trouble
1) Input voltage is Min. 1.5 V.
2) There is no record of pulse input.
• Set transmission in manual shift mode.
Action of • Resets lockup clutch (if equipped).
controller • Holds travel speed value which is of before occurrence of failure.
Problem that • Transmission is not set in auto-shift mode (but set in manual shift mode).
appears on • Clutch is not locked up.
machine • Gear shift shocks are made.
Related • The input state (speed) from the transmission input speed sensor can be checked with the monitor-
information ing function (Code: 31200 T/M SPEED IN).
Defective transmission input a Prepare with starting switch OFF, then carry out troubleshooting
speed sensor without turning starting switch ON.
1
(Internal disconnection or REV INP (male) Resistance
short circuit) Between (1) and (2) 500 – 1,000 z
(Disconnection in wiring REV INP (female) (2) tance
and standard harness or defective contact) Wiring harness between L62 (female) (40) – Resis-
state REV INP (female) (1) tance
3
(Contact with 24 V circuit) Wiring harness between L62 (female) (40) –
Voltage Max. 1 V
REV INP (female) (1) and chassis ground
Defective transmission without turning starting switch ON.
4
Between (39) and (40) 500 – 1,000 z
40-308 22 WA470, 480-6

Failure code [DLF1LC] (Transmission input speed sensor: Short circuit) SEN04528-01
Failure code [DLF1LC] (Transmission input speed sensor: Short circuit)1

Action code Failure code Transmission input speed sensor: Short circuit
Trouble
E01 DLF1LC (Transmission controller system)
• Due to grounding fault in the transmission input speed sensor, the transmission input speed sensor
signal voltage is lower than normal range.
• After clutch pressure is held, when engine speed is 500 rpm or above in following condition, this fail-
ure code is displayed ([A] or [B]).
[A]
1) Input speed obtained from output speed sensor and reduction ratio is 200 rpm or above.
Contents of
2) There is no input speed sensor pulse.
trouble
3) Disconnection is not detected in input speed sensor.
[B]
1) Difference between output speed obtained from input speed sensor and reduction ratio and
value of output speed sensor is 200 rpm or above.
2) There are input speed sensor pulses.
3) There are output speed sensor pulses.
• Set transmission in manual shift mode.
Action of • Resets lockup clutch (if equipped).
controller • Holds travel speed value which is of before occurrence of failure.
Problem that • Transmission is not set in auto-shift mode (but set in manual shift mode).
appears on • Clutch is not locked up.
machine • Gear shift shocks are made.
Related • The input state (speed) from the transmission input speed sensor can be checked with the monitor-
information ing function (Code: 31200, T/M SPEED IN).

Defective transmission input REV INP (male) Resistance
1 speed sensor
(Internal short circuit) Between (1) and (2) 500 – 1,000 z
chassis ground
and standard
state
2 harness
Min. 1 Mz
REV INP (female) (1) and chassis ground tance
3
Between (39) and (40) 500 – 1,000 z
WA470, 480-6 40-308 23

SEN04528-01 Failure code [DLM3KA] (Fan speed sensor: Disconnection)
Failure code [DLM3KA] (Fan speed sensor: Disconnection) 1
Action code Failure code Fan speed sensor: Disconnection

Trouble
E01 DLM3KA (Transmission controller system)
• Fan speed sensor signal voltage is higher than normal range because of disconnection or hot short
in fan speed sensor system.
Contents of
trouble
1) Input voltage is Min. 1.5 V.
2) There is no record of pulse input.
Action of
• Stops fan speed feedback control and starts open control.
controller
Problem that
appears on • Fan speed is not accurate.
machine
Related • Input state (rotation speed) from fan speed sensor can be checked with the monitoring function
information (Code: 10007 FAN SPEED).

Defective adjustment of fan a Fan speed sensor may be adjusted defectively. Check it directly
1
speed sensor (see Testing and adjusting, “Adjusting fan speed sensor”).
Defective fan speed sensor without turning starting switch ON.
2
(Internal disconnection) G12 (male) Resistance
Between (1) and (2) 500 – 1,000 z
Possible causes
(Disconnection in wiring G12 (female) (1) tance
value in normal
state Max. 1 z
G12 (female) (2) tance
4
(Contact with 24 V circuit) Wiring harness between L62 (female) (30) –
Voltage Max. 1 V
G12 (female) (1) and chassis ground
5
Between (29) and (30) 500 – 1,000 z
40-308 24 WA470, 480-6

Failure code [DLM3KA] (Fan speed sensor: Disconnection) SEN04528-01
WA470, 480-6 40-308 25

SEN04528-01 Failure code [DLM3LC] (Fan speed sensor: Short circuit)
Failure code [DLM3LC] (Fan speed sensor: Short circuit) 1
Action code Failure code Fan speed sensor: Short circuit

Trouble
E01 DLM3LC (Transmission controller system)
• Fan speed sensor pulse signal is not output because of ground fault in fan speed sensor system.
Contents of
1) Disconnection is not detected in fan speed sensor.
trouble
2) Engine speed is 500 rpm or higher.
3) Fan reverse control is not applied.
Action of
• Stops fan speed feedback control and starts open control.
controller
Problem that
appears on • Fan speed is not accurate.
machine
Related • Input state (rotation speed) from fan speed sensor can be checked with the monitoring function
information (Code: 10007 FAN SPEED).

Defective adjustment of fan a Fan speed sensor may be adjusted defectively. Check it directly
1
speed sensor (see “Testing and adjusting”, “Adjusting fan speed sensor”).
Defective fan speed sensor G12 (male) Resistance
2
Possible causes
chassis ground
value in normal
3 harness
Min. 1 Mz
G12 (female) (1) and chassis ground tance
4
Between (29) and (30) 500 – 1,000 z
40-308 26 WA470, 480-6

Failure code [DLM3LC] (Fan speed sensor: Short circuit) SEN04528-01
WA470, 480-6 40-308 27

SEN04528-01 Failure code [DLT3KA] (Transmission output speed sensor: Disconnection)
Failure code [DLT3KA] (Transmission output speed sensor:

Disconnection) 1
Action code Failure code Transmission output speed sensor: Disconnection (Transmission
Trouble
E03 DLT3KA controller system)
• Due to disconnection in the transmission output speed sensor system, the signal voltage is outside
the lower limit.
Contents of
• This failure code appears under the following conditions.
trouble
1) Disconnection detection input voltage is max. 1.5 V
2) Pulse has not been input
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
• When the manual shift mode is turned on, normal control is carried out.
Action of
• Releases the lockup clutch (if equipped).
controller
• When the 1st speed is set, the controller constantly turns on the torque derating function.
• Maintains the travel speed that had been set prior to the failure.
• The auto-shift mode is not turned on (the manual shift mode is selected)
• Lockup becomes unavailable.
Problem that • Travel speed derating function is unavailable.
appears on • Transmission protection function is unavailable.
machine • When the 1st speed is set, digging torque is reduced.
• Gear shifting shocks are made.
• The auto-shift pilot lamp goes off.
• The input state (speed) from the transmission output speed sensor can be checked with the monitor-
Related
ing function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and move the machine

Defective adjustment of a The transmission output speed sensor adjustment may be defec-
1 transmission output speed tive. Check it directly (see Testing and adjusting, Adjusting trans-
sensor mission speed sensor).
Defective transmission output without turning starting switch ON.
2 speed sensor
REV OUT (male) Resistance
Possible causes Between (1) and (2) 500 – 1,000 z
value in normal Disconnection in wiring without turning starting switch ON.
state harness Wiring harness between L62 (female) (20) – Resis-
3 Max. 1 z
(Disconnection in wiring har- REV OUT (female) (2) tance
ness or defective contact) Wiring harness between L62 (female) (29) – Resis-
Max. 1 z
REV OUT (female) (1) tance
4
controller L62 (female) Resistance
Between (20) and (29) 500 – 1,000 z
40-308 28 WA470, 480-6

Failure code [DLT3KA] (Transmission output speed sensor: Disconnection) SEN04528-01
WA470, 480-6 40-308 29

SEN04528-01 Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range)
Failure code [DLT3LC] (Transmission output speed sensor: Out of input

signal range) 1
Action code Failure code Transmission output speed sensor: Out of input signal range (Trans-
Trouble
E03 DLT3LC mission controller system)
• Due to ground fault in the transmission output speed sensor system, the signal voltage is lower than
the normal range.
• Failure detection condition
1) If the current travel speed – 15 km/h or above – were changed (reduced) by 5 km/h or more and
Contents of the pulse is 10 msec or above, the travel speed immediately preceding the change is maintained.
trouble (If pulse update of the transmission output speed sensor is continued 50 msec or more and the
travel speed pulse input voltage below 1.5 V is detected 5 times or more, the currently held pre-
ceding travel speed is canceled.)
2) When the output is not set to N, an error is turned on if the immediately preceding travel speed is
held for more than 10 seconds.
• In the auto-shift mode, changes the shift mode to the manual mode.
• In the auto-shift mode, changes the mode for transmitting signal to the machine monitor to the man-
ual mode.
Action of • When the manual shift mode is turned on, normal control is carried out.
controller • Controls the operation by determining the output speed from the input speed and the gear speed
reduction ratio.
• Resets the torque converter lockup.
• The auto-shift mode is not turned on (the manual shift mode is selected).
• Torque converter lockup becomes unavailable.
Problem that
• Travel speed derating function is unavailable.
appears on
• Transmission protection function is unavailable.
machine
• When the 1st speed is set, digging torque goes low.
• Gear shifting shocks are made.
• The input state (speed) from the transmission output speed sensor can be checked with the monitor-
Related
ing function (Code: 31400, T/M SPEED OUT).
information
• Method of reproducing failure code: Start engine and move the machine

Defective adjustment of a The transmission output speed sensor adjustment may be defec-
1 transmission output speed tive. Check it directly (see Testing and adjusting, Adjusting trans-
sensor mission speed sensor).
Defective transmission output REV OUT (male) Resistance
2 speed sensor
Possible causes Between (1), (2) and
Min. 1 Mz
state Grounding fault in wiring without turning starting switch ON.
3 harness
Min. 1 Mz
REV OUT (female) (2) and chassis ground tance
Defective transmission L62 Resistance
4
controller Between (20) and (29) 500 – 1,000 z
Min. 1 Mz
chassis ground
40-308 30 WA470, 480-6

Failure code [DLT3LC] (Transmission output speed sensor: Out of input signal range) SEN04528-01
WA470, 480-6 40-308 31

SEN04528-01 Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
Failure code [DT20KB] (Transmission cut-off indicator lamp: Short

circuit) 1
Action code Failure code Transmission cut-off indicator lamp: Short circuit
Trouble
E01 DT20KB (Transmission controller system)
Contents of • Since the transmission cut-off indicator lamp system is shorted, output signals are not entered to the
trouble indicator lamp.
Action of • Turns off the transmission cut-off indicator lamp.
Problem that
appears on • Transmission cut-off indicator lamp does not light up.
machine
Related
• Method of reproducing failure code: Start engine and turn transmission cut-off switch ON.
information

Defective transmission cut-off S03 (male) Resistance
1 indicator lamp (LED)
(Internal short circuit) Between (2) and (1) Min. 1 Mz (No continuity)
Min. 1 Mz
ground
Possible causes
state (Contact with ground circuit) Wiring harness between L63 (female) (8) – Resis- Min.
S03 (female) (1) and chassis ground tance 1 Mz
Defective transmission Transmission cut-off
3 L63 Voltage
controller switch
40-308 32 WA470, 480-6

Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit) SEN04528-01
WA470, 480-6 40-308 33

SEN04528-01 Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)
Failure code [DUM1KB] (Remote positioner raise set indicator lamp:

Short circuit) 1
Action code Failure code Remote positioner raise set indicator lamp: Short circuit
Trouble
— DUM1KB (Work equipment controller system)
Contents of • Since the remote positioner raise set indicator lamp system is shorted, output signals are not entered
trouble to the indicator lamp.
Action of • Turns off the remote positioner raise set indicator output.
Problem that
appears on • Remote positioner raise set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner raise set indicator lamp can be checked with the
Related
information

• See Testing and adjusting, Diode inspection procedure.
1 raise set indicator lamp S14 (male) Resistance
(LED) (Internal short circuit) Between (2) and (1) Min. 1 Mz (No continuity)
Min. 1 Mz
value in normal Grounding fault in wiring without turning starting switch ON.
state 2 harness
Min. 1 Mz
3 L73 Voltage
controller raise
Between (8) and When used 20 – 30 V
chassis ground When not used. Max. 1 V
40-308 34 WA470, 480-6

Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit) SEN04528-01
WA470, 480-6 40-308 35

SEN04528-01 Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)
Failure code [DUM2KB] (Remote positioner lower set indicator lamp:

Short circuit) 1
Action code Failure code Remote positioner lower set indicator lamp: Short circuit
Trouble
— DUM2KB (Work equipment controller system)
Contents of • Since the remote positioner lower set indicator lamp system is shorted, output signals are not
trouble entered to the indicator lamp.
Action of • Turns off the remote positioner lower set indicator output.
Problem that
appears on • Remote positioner lower set indicator lamp does not light up.
machine
• The output state (ON/OFF) to the remote positioner lower set indicator lamp can be checked with the
Related
information

• See Testing and adjusting, Diode inspection procedure.
1 lower set indicator lamp S14 (male) Resistance
(LED) (Internal short circuit) Between (2) and (3) Min. 1 Mz (No continuity)
Min. 1 Mz
state 2 harness
Min. 1 Mz
3 L73 Voltage
controller lower
Between (18) and When used 20 – 30 V
chassis ground When not used. Max. 1 V
40-308 36 WA470, 480-6

Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit) SEN04528-01
WA470, 480-6 40-308 37

SEN04528-01 Failure code [DV00KB] (Alarm buzzer: Short circuit)
Failure code [DV00KB] (Alarm buzzer: Short circuit) 1
Action code Failure code Alarm buzzer: Short circuit

Trouble
E01 DV00KB (Machine monitor system)
Contents of
• The alarm buzzer output circuit is shorted with the power source.
trouble
Action of • Stops alarm buzzer output.
Problem that
appears on • Alarm buzzer does not sound.
machine
• The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function (Code:
Related
40952, D-OUT-0).
information

1
Voltage Max. 1 V
Possible causes
and standard
• Remove the buzzer, then connect +24 V to L20 (male) (1) and
value in normal
Defective alarm buzzer GND to L20 (male) (2).
state 2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
• When above 1) and 2) are normal, failure on the machine monitor
can be suspected.
40-308 38 WA470, 480-6

Failure code [DV00KB] (Alarm buzzer: Short circuit) SEN04528-01
WA470, 480-6 40-308 39

SEN04528-01 Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)
Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) 1
Action code Failure code Lift arm raise EPC solenoid: Disconnection
Trouble
E03 DW4PKA (Work equipment controller system)
Contents of • Since the lift arm raise EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm raise EPC solenoid output is ON.
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

Defective lift arm raise EPC without turning starting switch ON.
1 solenoid (Internal disconnec-
CN-4 (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
state (Disconnection in wiring CN-4 (female) (1) tance
Max. 1 z
CN-4 (female) (2) tance
Defective work equipment without turning starting switch ON.
3
Between (6) and (3) 5 – 15 z
40-308 40 WA470, 480-6

Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection) SEN04528-01
WA470, 480-6 40-308 41

SEN04528-01 Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)
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.
Problem that
appears on • Lift arm does not rise.
machine
Related
information
• Method of reproducing failure code: Engine started + lift arm raise

Defective lift arm raise EPC CN-4 (male) Resistance
1
solenoid (Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
CN-4 (female) (1) and chassis ground tance
Defective work equipment L73 (female) Resistance
3
controller Between (6) and (3) 5 – 15 z
Min. 1 Mz
chassis ground
40-308 42 WA470, 480-6

Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit) SEN04528-01
WA470, 480-6 40-308 43

SEN04528-01 Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)
Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with
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.
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 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

Defective lift arm raise EPC CN-4 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
CN-4 (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40-308 44 WA470, 480-6

Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line) SEN04528-01
WA470, 480-6 40-308 45

SEN04528-01 Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)
Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection) 1
Action code Failure code Lift arm lower EPC solenoid: Disconnection
Trouble
E03 DW4QKA (Work equipment controller system)
Contents of • Since the lift arm lower EPC solenoid output signal system is disconnected, no current flows when
trouble the lift arm lower EPC solenoid output is ON.
Action of
• Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF
controller
once.
Problem that
appears on • Lift arm does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Defective lift arm lower EPC without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (16) and (3) 5 – 15 z
40-308 46 WA470, 480-6

Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit) SEN04528-01
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.
Problem that
appears on • Lift arm does not lower.
machine
Related
information
• Method of reproducing failure code: Start engine and lower the lift arm.

Defective lift arm lower EPC CN-2 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA470, 480-6 40-308 47

SEN04528-01 Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line)
Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with
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.
Problem that
appears on
• The lift arm lower EPC solenoid may be burnt out.
machine
Related
information

Defective lift arm lower EPC CN-2 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
40-308 48 WA470, 480-6

Failure code [DW4QKY] (Lift arm lower EPC solenoid: Short circuit with power supply line) SEN04528-01
WA470, 480-6 40-308 49

SEN04528-01 Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection) 1
Action code Failure code Bucket tilt EPC solenoid: Disconnection

Trouble
E03 DW4RKA (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid output signal output signal system is disconnected, no current
trouble flows when the bucket tilt EPC solenoid output is ON.
Problem that
appears on • Bucket does not tilt.
machine
Related
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Defective bucket tilt EPC without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (5) and (13) 5 – 15 z
40-308 50 WA470, 480-6

Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) SEN04528-01
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit) 1
Action code Failure code Bucket tilt EPC solenoid: Short circuit
Trouble
E03 DW4RKB (Work equipment controller system)
Contents of • Since the bucket tilt EPC solenoid signal system is shorted, abnormal current flows when the bucket
trouble tilt EPC solenoid output is ON.
• Stops outputting the signal to the bucket tilt EPC solenoid.
Action of • Stops outputting the signal to the bucket tilt detent.
Problem that
appears on • Bucket does not tilt.
machine
Related
information
• Method of reproducing failure code: Start engine and tilt the bucket.

Defective bucket tilt EPC CN-1 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA470, 480-6 40-308 51

SEN04528-01 Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with
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.
Problem that
appears on
• The bucket tilt EPC solenoid may be burnt out.
machine
Related
information

Defective bucket tilt EPC CN-1 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
40-308 52 WA470, 480-6

Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line) SEN04528-01
WA470, 480-6 40-308 53

SEN04528-01

©2009 KOMATSU
All Rights Reserved
40-308 54
SEN04529-00
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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).......................... 6
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) .................................................................... 8
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) ........................................................................ 9
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) .................................. 10
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)........................................ 12
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) ........................................... 14
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) ....... 16
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)......................................... 18
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) ............................................ 20
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) ........ 22
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection).......................................... 24
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) ............................................. 26
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) ......... 28
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection).............................................. 30
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) ................................................. 32
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source).................... 34
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) .............................................................. 36
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) .................................................................. 37
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) .............................. 38
WA470, 480-6 40-309 1

SEN04529-00
Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection) ................................................... 40

Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)....................................................... 42
Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection) ................................................ 44
Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit) .................................................... 46
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)................................................................ 48
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) ................................................................... 50
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) ............................... 52
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) ............................................................ 54
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)................................................................ 56
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) ........................... 58
40-309 2 WA470, 480-6

Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) SEN04529-00
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection) 1
Action code Failure code Bucket dump EPC solenoid: Disconnection

Trouble
E03 DW4SKA (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid output signal system is disconnected, no current flows when
trouble the bucket dump EPC solenoid output is ON.
Problem that
appears on • Bucket does not dump.
machine
Related
information
• Method of reproducing failure code: Start engine and dump the bucket.

Defective bucket dump EPC without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (15) and (13) 5 – 15 z
WA470, 480-6 40-309 3

SEN04529-00 Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) 1
Action code Failure code Bucket dump EPC solenoid: Short circuit
Trouble
E03 DW4SKB (Work equipment controller system)
Contents of • Since the bucket dump EPC solenoid signal system is shorted, abnormal current flows when the
trouble bucket dump EPC solenoid output is ON.
• Stops outputting the signal to the bucket dump EPC solenoid.
Action of
controller
Problem that
• Bucket does not dump.
appears on
machine
Related
information
• Method of reproducing failure code: Start engine and dump the bucket.

Defective bucket dump EPC CN-3 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
40-309 4 WA470, 480-6

Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 5

SEN04529-00 Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with
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.
• Stops outputting the signal to the lift arm raise/lower, bucket dump/dump, 3-spool valve (attachment)
Problem that
appears on
• The bucket dump EPC solenoid may be burnt out.
machine
Related
information

Defective bucket dump EPC CN-3 (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
40-309 6 WA470, 480-6

Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 7

SEN04529-00 Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection) 1
Action code Failure code Fan reverse solenoid: Disconnection

Trouble
E01 DW7BKA (Transmission controller system)
Contents of • Since the fan reverse solenoid system is disconnected, no current flows when the fan reverse sole-
trouble noid output is ON.
Action of • Disables the automatic fan reverse function (OPT).
Problem that
• The automatic fan reverse function is disabled in the case of automatic fan reverse function (OPT)
appears on
specification.
machine
• The output state (ON/OFF) to the fan reverse solenoid can be checked with the monitoring function
Related
(Code: 40949, D-OUT-4).
information

Defective fan reverse solenoid without turning starting switch ON.
1
(Internal disconnection) G11 (male) Resistance
Between (1) and (2) 35 – 45 z
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L63 (female) (28) – Resis-
(Disconnection or defective G11 (female) (1) tance
state contact in connector) Wiring harness between G11 (female) (2) – Resis-
Max. 1 z
controller
Between (28) and
35 – 45 z
chassis ground
40-309 8 WA470, 480-6

Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) SEN04529-00
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit) 1
Action code Failure code Fan reverse solenoid: Short circuit

Trouble
E01 DW7BKB (Transmission controller system)
Contents of • Since the fan reverse solenoid system is shorted, abnormal current flows when the fan reverse sole-
trouble noid output is turned on.
• Turns the output to the fan reverse solenoid OFF.
Action of
• Disables the automatic fan reverse function (OPT).
controller
Problem that • The fan cannot turn in reverse by operating the fan reverse switch.
appears on • The automatic fan reverse function is disabled in the case of automatic fan reverse function (OPT)
machine specification.
Related
(Code: 40949, D-OUT-4).
information

Defective fan reverse solenoid G11 (male) Resistance
1
Min. 1 Mz
state 2 harness
Min. 1 Mz
G11 (female) (1) and chassis ground tance
controller
Between (28) and
35 – 45 z
chassis ground
WA470, 480-6 40-309 9

SEN04529-00 Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
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).
• 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.
Related
(Code: 40949, D-OUT-4).
information

Defective fan reverse solenoid G11 (male) Resistance
1
Min. 1 Mz
state 2
Voltage Max. 1 V
G11 (female) (1) and chassis ground
controller
Between (28) and
35 – 45 z
chassis ground
40-309 10 WA470, 480-6

Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 11

SEN04529-00 Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)
Failure code [DWM1KA] (Work equipment neutral lock solenoid:

Disconnection) 1
Action code Failure code Work equipment neutral lock solenoid: Disconnection
Trouble
E01 DWM1KA (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is disconnected, no current flows when the
trouble work equipment neutral lock solenoid output is ON.
• Stops outputting the signal to the work equipment solenoid according to an input signal from the work
Action of
equipment lock lever.
controller
Problem that
• Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on
ment lock lever.
machine
• The output state (ON/OFF) to the work equipment neutral lock solenoid can be checked with the
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position.

1 neutral lock solenoid
Between (1) and (2) 35 – 45 z
state (Disconnection in wiring F26 (female) (1) tance
harness or defective contact) Wiring harness between F26 (female) (2) – Resis-
Max. 1 z
3
40-309 12 WA470, 480-6

Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 13

SEN04529-00 Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short

circuit) 1
Action code Failure code Work equipment neutral lock solenoid: Short circuit
Trouble
E01 DWM1KB (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted, abnormal current flows when the
trouble work equipment neutral lock solenoid output is turned on.
• Turns off the output to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment solenoid according to an input signal from the work
controller equipment lock lever.
Problem that • Each work equipment solenoid lock normally works according to an input signal from the work equip-
appears on ment lock lever.
machine • The wiring harness or controller may be burnt out.
Related monitoring function (Code: 40952, D-OUT-0).
information • Method of reproducing failure code: Turn the starting switch ON and move the work equipment lock
lever to the LOCK position

Defective work equipment F26 (male) Resistance
Min. 1 Mz
chassis ground
Possible causes F27 (male) Diode range Continuity
Defective diode (F27)
and standard 2 Measured from (2)
(Internal short circuit) Between (2) and (1) Continue
value in normal side
state
Measured from (1)
Between (1) and (2) Continuity absent
side
3 harness
Min. 1 Mz
F26 (female) (1) and chassis ground tance
4
40-309 14 WA470, 480-6

Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 15

SEN04529-00 Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line)
Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short

Action code Failure code Work equipment neutral lock solenoid: Short circuit with power sup-
Trouble
E01 DWM1KY ply line (Work equipment controller system)
Contents of • Since the work equipment neutral lock solenoid system is shorted with power source, abnormal volt-
trouble age is applied when the work equipment neutral lock solenoid output is OFF.
• Turns off the output to the work equipment neutral lock solenoid.
Action of • Stops outputting the signal to the work equipment solenoid according to an input signal from the work
controller equipment lock lever.
Problem that
appears on • All work equipments do not move.
machine
• Removing (disconnecting) the connector of the work equipment neutral lock solenoid enables oper-
ating the work equipment.
Related
information

Defective work equipment F26 (male) Resistance
Min. 1 Mz
chassis ground
Possible causes F27 (male) Diode range Continuity
Defective diode (F27)
and standard 2 Measured from (2)
(Internal short circuit) Between (2) and (1) Continue
value in normal side
state
Measured from (1)
Between (1) and (2) No continuity
side
3
Voltage Max. 1 V
F26 (female) (1) and chassis ground
4
40-309 16 WA470, 480-6

Failure code [DWM1KY] (Work equipment neutral lock solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 17

SEN04529-00 Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid:

Disconnection) 1
Action code Failure code Lift arm raise magnet detent solenoid: Disconnection
Trouble
E01 DWN6KA (Work equipment controller system)
Contents of • Since the lift arm raise magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm raise magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm raise magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner raise stop lamp.
controller
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

Defective lift arm raise magnet without turning starting switch ON.
1 detent solenoid
L26E (male) Resistance
Between (1) and (2) 35 – 45 z
Possible causes
(Disconnection or defective L26E (female) (1) tance
value in normal
contact) Wiring harness between L26E (female) (2) – Resis-
state Max. 1 z
Defective work equipment L73 Lift arm lever Voltage
3
controller Neutral Max. 1 V
Between (17) and
chassis ground Raise detent
20 – 30 V
operation
40-309 18 WA470, 480-6

Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 19

SEN04529-00 Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)
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
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
Related
information
• Method of reproducing failure code: Engine started + lift arm raise detent

Defective lift arm raise magnet L26E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
L26E (female) (1) and chassis ground tance
3
Between (17) and
20 – 30 V
operation
40-309 20 WA470, 480-6

Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 21

SEN04529-00 Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line)
Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short
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
• 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).
Related
information

Defective lift arm raise magnet L26E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
L26E (female) (1) and chassis ground
3
Between (17) and
20 – 30 V
operation
40-309 22 WA470, 480-6

Failure code [DWN6KY] (Lift arm raise magnet detent solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 23

SEN04529-00 Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)
Failure code [DWN7KA] (Lift arm float magnet detent solenoid:

Disconnection) 1
Action code Failure code Lift arm float magnet detent solenoid: Disconnection
Trouble
Contents of • Since the lift arm float magnet detent solenoid power supply system is disconnected, no current
trouble flows when the lift arm float magnet detent solenoid output is ON.
• Keeps normal output condition to the lift arm float magnet detent solenoid.
Action of
• Stops outputting the signal to the remote positioner lower stop lamp.
controller
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
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Defective lift arm float magnet without turning starting switch ON.
1 detent solenoid
Between (1) and (2) 35 – 45 z
Possible causes Disconnection in wiring without turning starting switch ON.
and standard harness Wiring harness between L73 (female) (27) – Resis-
2 Max. 1 z
state contact) Wiring harness between L27 (female) (2) – Resis-
Max. 1 z
3
controller
Between (27) and Neutral Max. 1 V
chassis ground Float detent operation 20 – 30 V
40-309 24 WA470, 480-6

Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 25

SEN04529-00 Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)
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
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
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
Related
information
• Method of reproducing failure code: Start engine and perform lift arm float detent operation.

Defective lift arm float magnet L27 (male) Resistance
1 detent solenoid
Min. 1 Mz
state 2 harness
Min. 1 Mz
3
controller
40-309 26 WA470, 480-6

Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 27

SEN04529-00 Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line)
Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short
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
• 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
Related
information

Defective lift arm float magnet L27 (male) Resistance
1 detent solenoid
Min. 1 Mz
state 2
Voltage Max. 1 V
3
controller
40-309 28 WA470, 480-6

Failure code [DWN7KY] (Lift arm float magnet detent solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 29

SEN04529-00 Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid:

Disconnection) 1
Action code Failure code Bucket tilt magnet detent solenoid: Disconnection
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power supply system is disconnected, no current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Keeps normal output condition to the bucket tilt magnet detent solenoid.
Problem that
• Bucket leveler does not work.
appears on
• Holding the bucket at the tilt detent position becomes unavailable.
machine
• The output state (ON/OFF) to the bucket tilt magnet detent solenoid can be checked with the moni-
Related
toring function (Code: 40952, D-OUT-3).
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Defective bucket tilt magnet without turning starting switch ON.
1 detent solenoid
L25E (male) Resistance
Between (1) and (2) 35 – 45 z
Possible causes
(Disconnection or defective L25E (female) (1) tance
value in normal
contact) Wiring harness between L25E (female) (2) – Resis-
state Max. 1 z
Defective work equipment L73 Bucket lever Voltage
3
Between (37) and
chassis ground Bucket detent
20 – 30 V
operation
40-309 30 WA470, 480-6

Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 31

SEN04529-00 Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short

circuit) 1
Action code Failure code Bucket tilt magnet detent solenoid: Short circuit
Trouble
Contents of • Since the bucket tilt magnet detent solenoid power supply system is shorted, abnormal current flows
trouble when the bucket tilt magnet detent solenoid output is ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
Problem that
• Bucket leveler does not work.
appears on
• Holding the bucket at the tilt detent position becomes unavailable.
machine
Related
information
• Method of reproducing failure code: Engine started + bucket tilt detent

Defective bucket tilt magnet L25E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
L25E (female) (1) and chassis ground tance
3
Between (37) and
20 – 30 V
operation
40-309 32 WA470, 480-6

Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 33

SEN04529-00 Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source)
Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted

with the power source) 1
Action code Failure code Bucket tilt magnet detent solenoid: Shorted with the power source
Trouble
E01 DWN8KY (Work equipment controller system)
Contents of • Since the bucket tilt magnet detent solenoid power supply system is shorted with the power source,
trouble abnormal voltage is applied when the bucket tilt magnet detent solenoid output is ON.
Action of • Stops outputting the signal to the bucket tilt magnet detent solenoid.
• If you perform bucket tilt detent operation, detent condition is not automatically released (can be
Problem that
manually released).
appears on
• If you do not perform bucket detent operation, return of the bucket lever to neutral is affected by the
machine
Related
information

Defective bucket tilt magnet L25E (male) Resistance
1 detent solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
L25E (female) (1) and chassis ground
3
Between (37) and
20 – 30 V
operation
40-309 34 WA470, 480-6

Failure code [DWN8KY] (Bucket tilt magnet detent solenoid: Shorted with the power source) SEN04529-00
WA470, 480-6 40-309 35

SEN04529-00 Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection) 1
Action code Failure code Fan pump EPC solenoid: Disconnection

Trouble
E01 DX16KA (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is disconnected, no current flows when the fan pump EPC
trouble solenoid output is ON.
Action of
controller
Problem that
appears on • The fan speed is set to the maximum.
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

Defective fan pump EPC without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 10 z
Max. 1 z
3
Between (36) and (23) 5 – 10 z
40-309 36 WA470, 480-6

Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) SEN04529-00
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit) 1
Action code Failure code Fan pump EPC solenoid: Short circuit
Trouble
E01 DX16KB (Transmission controller system)
Contents of • Since the fan pump EPC solenoid system is shorted, abnormal current flows when the fan pump
trouble EPC solenoid output is ON.
Action of • Turns the output to the fan pump EPC solenoid OFF.
Problem that
appears on • The fan speed is set to the maximum.
machine
Related
(Code: 41400 FAN EPC DIR).
information

Defective fan pump EPC R29 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
WA470, 480-6 40-309 37

SEN04529-00 Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with
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.
Problem that
appears on • The fan speed is minimized.
machine
Related
(Code: 41400, FAN EPC DIR).
information

Defective fan pump EPC R29 (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
R29 (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40-309 38 WA470, 480-6

Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 39

SEN04529-00 Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection)
Failure code [DXA1KA] (Loader pump PC-EPC solenoid:

Disconnection) 1
Action code Failure code Loader pump PC-EPC solenoid: Disconnection

Trouble
E01 DXA1KA (Transmission controller system)
Contents of • Since the loader pump PC-EPC solenoid system is disconnected, no current flows when the loader
trouble pump PC-EPC solenoid output is ON.
Action of • Keeps normal output condition to the loader pump PC-EPC solenoid.
• Fuel consumption may become poor when engine speed is low.
Problem that
• The engine may stop.
appears on
• Engine acceleration performance is deteriorated.
machine
• The lift arm may increase speed suddenly.
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 95100 PUMP EPC DIR).
information

Defective loader pump PC- without turning starting switch ON.
1 EPC solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (23) and (27) 5 – 15 z
40-309 40 WA470, 480-6

Failure code [DXA1KA] (Loader pump PC-EPC solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 41

SEN04529-00 Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit)
Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit) 1
Action code Failure code Loader pump PC-EPC solenoid: Short circuit
Trouble
E01 DXA1KB (Transmission controller system)
Contents of • Since the loader pump PC-EPC solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when the loader pump PC-EPC solenoid output was ON.
Action of • Stops outputting the signal to the loader pump PC-EPC solenoid.
Problem that
appears on
• The lift arm may increase speed suddenly.
machine
• The output state (current) to the loader pump PC-EPC solenoid can be checked with the monitoring
Related
function (Code: 95100 PUMP EPC DIR).
information

Defective loader pump R71 (male) Resistance
1 PC-EPC solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
troller Between (23) and (27) 5 – 15 z
Min. 1 Mz
chassis ground
40-309 42 WA470, 480-6

Failure code [DXA1KB] (Loader pump PC-EPC solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 43

SEN04529-00 Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection)
Failure code [DXANKA] (Steering pump PC-EPC solenoid:

Disconnection) 1
Action code Failure code Steering pump PC-EPC solenoid: Disconnection

Trouble
E01 DXANKA (Transmission controller system)
Contents of • Since the steering pump PC-EPC solenoid system is disconnected, no current flows when the steer-
trouble ing pump PC-EPC solenoid output is ON.
Action of • Keeps normal output condition to the steering pump PC-EPC solenoid.
Problem that
• The engine may stop.
appears on
machine
• The turn may increase speed suddenly.
• The output state (current) to the steering pump PC-EPC solenoid can be checked with the monitor-
Related
ing function (Code: 95600 ST EPC DIR).
information

Defective steering pump PC- without turning starting switch ON.
1 EPC solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (23) and (38) 5 – 15 z
40-309 44 WA470, 480-6

Failure code [DXANKA] (Steering pump PC-EPC solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 45

SEN04529-00 Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit)
Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit)1

Action code Failure code Steering pump PC-EPC solenoid: Short circuit
Trouble
E01 DXANKB (Transmission controller system)
Contents of • Since the steering pump PC-EPC solenoid system was shorted with the chassis ground, abnormal
trouble current flowed when the steering pump PC-EPC solenoid output was ON.
Action of • Stops outputting the signal to the steering pump PC-EPC solenoid.
Problem that
appears on
• The turn may increase speed suddenly.
machine
• The output state (current) to the steering pump PC-EPC solenoid can be checked with the monitor-
Related
ing function (Code: 95600 ST EPC DIR).
information

Defective steering pump R96 (male) Resistance
1 PC-EPC solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
troller Between (23) and (38) 5 – 15 z
Min. 1 Mz
chassis ground
40-309 46 WA470, 480-6

Failure code [DXANKB] (Steering pump PC-EPC solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 47

SEN04529-00 Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) 1
Action code Failure code Lockup ECMV solenoid: Disconnection

Trouble
E01 DXH1KA (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is disconnected, no current flows when the lockup solenoid
trouble output is ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on
machine
• The output state (current) to the lockup ECMV solenoid can be checked with the monitoring function
Related (Code: 31609 ECMV LU DIR).
information • Method of reproducing failure code: Start engine, turn the torque convertor lockup switch ON, and
drive the machine.

Defective lockup ECMV sole- without turning starting switch ON.
1
noid (Internal disconnection) LC.PS (male) Resistance
Between (1) and (2) 5 – 15 z
state (Disconnection or defective LC.PS (female) (2) tance
contact of connector) Wiring harness between L63 (female) (35) – Resis-
Max. 1 z
LC.PS (female) (1) tance
3
Between (23) and (35) 5 – 15 z
40-309 48 WA470, 480-6

Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 49

SEN04529-00 Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) 1
Action code Failure code Lockup ECMV solenoid: Short circuit

Trouble
E01 DXH1KB (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system is short with the chassis ground, abnormal current flowed
trouble when the lockup solenoid output was ON.
• Stops outputting the signal to the lockup ECMV solenoid.
Action of
• Determines that the lockup fill switch is OFF.
controller
Problem that
appears on • Torque converter lockup is not turned on.
machine
Related
(Code: 31609 ECMV LU DIR).
information
• Method of reproducing failure code: Engine started + torque convertor lockup switch ON + Travel

Defective lockup ECMV sole- LC.PS (male) Resistance
1
noid (Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
(Contact with ground circuit) Max. 1 z
LC.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
40-309 50 WA470, 480-6

Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 51

SEN04529-00 Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with

Action code Failure code Lockup ECMV solenoid: Short circuit with power supply line
Trouble
E03 DXH1KY (Transmission controller system)
Contents of • Since the lockup ECMV solenoid system was shorted with the power source, abnormal voltage was
trouble applied when the lockup ECMV solenoid output was OFF.
• Keeps the transmission in neutral.
• Releases the transmission from neutral if you move the FNR (directional) lever, joystick steering
Action of FNR (directional) switch, or right FNR (directional) switch to N (neutral).
• 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 • Neutral is held until the FNR (directional) lever, joystick steering FNR (directional) switch, or right
appears on FNR (directional) switch is set to N (neutral).
machine • The lockup clutch is always in the meshed state.
Related
(Code: 31609 ECMV LU DIR).
information

Defective lockup ECMV sole- LC.PS (male) Resistance
1
noid (Internal short circuit) Between (1) and (2) 5 – 15 z
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L63 (female) (35) –
Voltage Max. 1 V
LC.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40-309 52 WA470, 480-6

Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 53

SEN04529-00 Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) 1
Action code Failure code 1st clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 1st clutch ECMV solenoid system is disconnected, no current flows when 1st clutch ECMV
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st).
machine
• The output state (current value) to the 1st (1st speed) clutch ECMV solenoid can be checked with the
monitoring function (Code: 31602, ECMV 1 DIR).
Related
• Method of reproducing failure code: Turn on the starting switch, set the transmission auto-shift/man-
information
ual shift selector switch in the MANUAL position and select 1st using the shift down switch or move
the gear shift lever to 1st.

Defective 1st clutch ECMV without turning starting switch ON.
1.PS (male) Resistance
tion)
Between (1) and (2) 5 – 15 z
state (Disconnection or defective 1.PS (female) (2) tance
Max. 1 z
1.PS (female) (1) tance
3
Between (25) and (13) 5 – 15 z
40-309 54 WA470, 480-6

Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection) SEN04529-00
WA470, 480-6 40-309 55

SEN04529-00 Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) 1
Action code Failure code 1st clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 1st ECMV solenoid system is shorted, abnormal current flows when 1st clutch ECMV sole-
trouble noid output is ON.
• Stops outputting the signal to the 1st clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 1st (The machine can travel in any gear speed other than 1st).
machine
Related
information
ual shift selector switch in the MANUAL position and select 1st using the shift down switch or move
the gearshift lever to 1st.

Defective 1st clutch ECMV 1.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
1.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
40-309 56 WA470, 480-6

Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit) SEN04529-00
WA470, 480-6 40-309 57

SEN04529-00 Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with
Action code Failure code 1st clutch ECMV solenoid: Short circuit with power supply line
Trouble
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).
Problem that
appears on • The transmission does not shift into 2nd, 3rd, nor 4th (the machine can travel at 1st).
machine
Related
information

Defective 1st clutch ECMV 1.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
1.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40-309 58 WA470, 480-6

Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line) SEN04529-00
WA470, 480-6 40-309 59

SEN04529-00

©2008 KOMATSU
All Rights Reserved
40-309 60
SEN04530-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

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
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
WA470, 480-6 40-310 1

SEN04530-01
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
40-310 2 WA470, 480-6

SEN04530-01
WA470, 480-6 40-310 3

SEN04530-01 Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) 1
Action code Failure code 2nd clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the 2nd clutch ECMV solenoid system is disconnected, no current flows when 2nd clutch
trouble ECMV solenoid output is ON.
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current value) to the 2nd (2nd speed) clutch ECMV solenoid can be checked with
the monitoring function (Code: 31603, ECMV 2 DIR).
Related
information
ual shift selector switch in the MANUAL position, and select 2nd using the shift down switch or mov-
ing the gear shift lever to 2nd.

Defective 2nd clutch ECMV without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (6) and (3) 5 – 15 z
40-310 4 WA470, 480-6

Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 5

SEN04530-01 Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) 1
Action code Failure code 2nd clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 2nd clutch ECMV solenoid system is shorted, abnormal current flows when 2nd clutch
• Stops outputting the signal to the 2nd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 2nd (The machine can travel in any gear speed other than 2nd.)
machine
• The output state (current value) to the 2nd (2nd speed) clutch ECMV solenoid can be checked with
the monitoring function (Code: 31603, ECMV 2 DIR).
Related
information
ual shift selector switch in the MANUAL position, and select 2nd using the shift down switch or mov-
ing the gear shift lever to 2nd.

Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
40-310 6 WA470, 480-6

Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 7

SEN04530-01 Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with
Action code Failure code 2nd clutch ECMV solenoid: Short circuit with power supply line
Trouble
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.
Action of speed clutch output is OFF (other than 2nd speed).
• 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

Defective 2nd clutch ECMV 2.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
state (Contact with 24 V circuit) Wiring harness between L63 (female) (6) –
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
40-310 8 WA470, 480-6

Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 9

SEN04530-01 Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) 1
Action code Failure code 3rd clutch ECMV solenoid: Disconnection

Trouble
Contents of • Since the 3rd clutch ECMV solenoid system is disconnected, no current flows when 3rd clutch ECMV
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information
ual shift selector switch to the MANUAL position, and select 3rd using the shift down switch or mov-
ing the gear shift lever to 3rd.

Defective 3rd clutch ECMV without turning starting switch ON.
tion)
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (16) and (3) 5 – 15 z
40-310 10 WA470, 480-6

Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 11

SEN04530-01 Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) 1
Action code Failure code 3rd clutch ECMV solenoid: Short circuit
Trouble
Contents of • Since the 3rd clutch ECMV solenoid system is shorted, abnormal current flows when 3rd clutch
• Stops outputting the signal to the 3rd clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 3rd (The machine can travel in any gear speed other than 3rd.)
machine
Related
information
ual shift selector switch to the MANUAL position, and select 3rd using the shift down switch or mov-
ing the gear shift lever to 3rd.

Defective 3rd clutch ECMV 3.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
40-310 12 WA470, 480-6

Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 13

SEN04530-01 Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with
Action code Failure code 3rd clutch ECMV solenoid: Short circuit with power supply line
Trouble
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.
Action of speed clutch output is OFF (other than 3rd speed).
Problem that
appears on • The transmission does not shift into 1st, 2nd or 4th (the machine can travel at 3rd).
machine
Related
information

Defective 3rd clutch ECMV 3.PS (male) Resistance
1 solenoid
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
40-310 14 WA470, 480-6

Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 15

SEN04530-01 Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) 1
Action code Failure code R clutch ECMV solenoid: Disconnection

Trouble
Contents of • When the R (Reverse) clutch ECMV solenoid system is disconnected, no current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel at F (Forward)).
machine
• The output state (current value) to the R (reverse) clutch ECMV solenoid can be checked with the
Related monitoring function (Code: 31606, ECMV R DIR).
information • Method of reproducing failure code: Turn the starting switch ON and set FNR (directional) lever, joy-
stick steering FNR (directional) switch or right FNR (directional) switch to R (reverse).

Defective R (Reverse) clutch without turning starting switch ON.
1 ECMV solenoid
R.PS (male) Resistance
Between (1) and (2) 5 – 15 z
state (Disconnection or defective R.PS (female) (2) tance
Max. 1 z
R.PS (female) (1) tance
3
Between (15) and (13) 5 – 15 z
40-310 16 WA470, 480-6

Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 17

SEN04530-01 Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) 1
Action code Failure code R clutch ECMV solenoid: Short circuit

Trouble
Contents of • Since the R (Reverse) clutch ECMV solenoid system is shorted, abnormal current flows when R
trouble (Reverse) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the R (Reverse) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the R (Reverse) position (the machine can travel at F (Forward)).
machine
Related monitoring function (Code: 31606, ECMV R DIR).
stick steering FNR (directional) switch or right FNR (directional) switch to R (reverse).

Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
R.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
40-310 18 WA470, 480-6

Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 19

SEN04530-01 Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with

Action code Failure code R clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the R (Reverse) ECMV solenoid system is shorted with the power source, abnormal voltage is
trouble applied when the R (Reverse) ECMV solenoid output is OFF.
• Outputs the signal to the R (Reverse) clutch ECMV solenoid when the directional lever or directional
switch is in R (Reverse).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or F (Forward).
Problem that
appears on • The machine can travel in the R (Reverse) position alone.
machine
Related
monitoring function (Code: 31606, ECMV R DIR).
information

Defective R (Reverse) clutch R.PS (male) Resistance
1 ECMV solenoid (Internal
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
R.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40-310 20 WA470, 480-6

Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 21

SEN04530-01 Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) 1
Action code Failure code F clutch ECMV solenoid: Disconnection

Trouble
Contents of • Since the F (Forward) clutch ECMV solenoid system is disconnected, no current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel at R (Reverse)).
machine
• The output state (current value) to the F (Forward) clutch ECMV solenoid can be checked with the
Related monitoring function (Code: 31608, ECMV F DIR).
stick steering FNR (directional) switch, or right FNR (directional) switch to F (forward).

Defective F (Forward) clutch without turning starting switch ON.
1 ECMV solenoid (Internal dis-
F.PS (male) Resistance
connection)
Between (1) and (2) 5 – 15 z
state (Disconnection or defective F.PS (female) (2) tance
Max. 1 z
F.PS (female) (1) tance
3
Between (5) and (3) 5 – 15 z
40-310 22 WA470, 480-6

Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 23

SEN04530-01 Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) 1
Action code Failure code F clutch ECMV solenoid: Short circuit

Trouble
Contents of • When the F (Forward) clutch ECMV solenoid system is shorted, abnormal current flows when F (For-
trouble ward) clutch ECMV solenoid output is ON.
• Stops outputting the signal to the F (Forward) clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission cannot be set in the F (Forward) position (the machine can travel at R (Reverse)).
machine
Related monitoring function (Code: 31608, ECMV F DIR).
stick steering FNR (directional) switch, or right FNR (directional) switch to F (forward).

Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
F.PS (female) (1) and chassis ground tance
3
Min. 1 Mz
chassis ground
40-310 24 WA470, 480-6

Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 25

SEN04530-01 Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with

Action code Failure code F clutch ECMV solenoid: Short circuit with power supply line
Trouble
Contents of • Since the F (Forward) ECMV solenoid system is shorted with the power source, abnormal voltage is
trouble applied when the F (Forward) ECMV solenoid output is OFF.
• Outputs the signal to the F (Forward) clutch ECMV solenoid when the directional lever or directional
switch is in F (Forward).
Action of • Sets the transmission in N (Neutral) when the gear shift lever is in N (Neutral) or R (Reverse).
Problem that
appears on • The machine can travel in the F (Forward) position alone.
machine
Related
monitoring function (Code: 31608, ECMV F DIR).
information

Defective F (Forward) clutch F.PS (male) Resistance
1 ECMV solenoid (Internal
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
F.PS (female) (1) and chassis ground
3
Min. 1 Mz
chassis ground
40-310 26 WA470, 480-6

Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 27

SEN04530-01 Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) 1
Action code Failure code 4th clutch ECMV solenoid: Disconnection

Trouble
E03 DXHHKA (Transmission controller system)
Contents of • Since the 4th clutch ECMV solenoid system is disconnected, no current flows when 4th clutch ECMV
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
• Method of reproducing failure code: Turn the starting switch ON, set the transmission auto-shift/man-
information
ual shift selector switch in the MANUAL position, and select 4th using the shift down switch or mov-
ing the gear shift lever to 4th.

Defective 4th clutch ECMV without turning starting switch ON.
1 solenoid
Between (1) and (2) 5 – 15 z
Max. 1 z
3
Between (26) and (13) 5 – 15 z
40-310 28 WA470, 480-6

Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 29

SEN04530-01 Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) 1
Action code Failure code 4th clutch ECMV solenoid: Short circuit
Trouble
E03 DXHHKB (Transmission controller system)
Contents of • Since the 4th clutch ECMV solenoid system is shorted, abnormal current flows when 4th clutch
• Stops outputting the signal to the 4th clutch ECMV solenoid.
Action of
controller
Problem that
appears on • The transmission does not shift into 4th (The machine can travel in any gear speed other than 4th.)
machine
Related
• Method of reproducing failure code: Turn the starting switch ON, set the transmission manual/auto
information
shift selector switch in the MANUAL position, and select 4th using the shift down switch or moving
the gear shift lever to 4th.

Defective 4th clutch ECMV 4.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
Min. 1 Mz
3
Min. 1 Mz
chassis ground
40-310 30 WA470, 480-6

Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 31

SEN04530-01 Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with
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.
Action of speed clutch output is OFF (other than 4th speed).
Problem that
appears on • The transmission does not shift into 1st, 2nd or 3rd (the machine can travel at 4th).
machine
Related
information

Defective 4th clutch ECMV 4.PS (male) Resistance
1
Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal 2
Voltage Max. 1 V
3
Min. 1 Mz
chassis ground
40-310 32 WA470, 480-6

Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 33

SEN04530-01 Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
Failure code [DXHLKA] (Joystick steering right EPC solenoid:

Disconnection) 1
Action code Failure code Joystick steering right EPC solenoid: Disconnection
Trouble
E03 DXHLKA (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering right EPC solenoid output is ON.
• Stops outputting the signal to the joystick steering right and left EPC solenoids.
Action of • Stops outputting the signal to the joystick steering solenoid cut-off relay.
Problem that
• Steering control with the joystick steering becomes unavailable (steering control from the handle
appears on
mode is available).
machine
• The output state (current value) to the joystick steering right EPC solenoid can be checked with the
monitoring function (Code: 41904, J/S EPC DIR RH).
Related
information
• When the failure code (D193KA, D193KB or D193KY) for the joystick steering solenoid cut-off relay
system is displayed at the same time, carry out troubleshooting for it first.
• Method of reproducing failure code: Start engine and steer to the right using the joystick steering.

1 right EPC solenoid
Between (1) and (2) 5 – 15 z
Defective joystick steering Between (5) and (6) 200 – 400 z
2 cut-off relay (L41) a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection) and carry out troubleshooting.
When joystick steering cut-off relay (L41) is replaced with a relay of
Possible causes the same type, if the condition becomes normal, the joystick steer-
and standard ing cut-off relay is defective.
Max. 1 z
3
Max. 1 z
Defective work equipment Joystick steering
4 L73 Voltage
controller lever
(23) Full right steering 5 – 10 V
40-310 34 WA470, 480-6

Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 35

SEN04530-01 Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short

circuit) 1
Action code Failure code Joystick steering right EPC solenoid: Short circuit
Trouble
E03 DXHLKB (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is shorted, abnormal current flows when the
trouble joystick steering right EPC solenoid output is ON.
Problem that
appears on
mode is available).
machine
Related
information
• Method of reproducing failure code: Start engine and steer to the right using the joystick steering.

Min. 1 Mz
chassis ground
Possible causes 2 cut-off relay (L41) a Prepare with starting switch OFF, then turn starting switch ON
and standard (Internal disconnection) and carry out troubleshooting.
value in normal
state
the same type, if the condition becomes normal, the joystick steer-
ing cut-off relay is defective.
3 harness
Min. 1 Mz
4
Min. 1 Mz
chassis ground
40-310 36 WA470, 480-6

Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 37

SEN04530-01 Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line)
Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short

Action code Failure code Joystick steering right EPC solenoid: Short circuit with power supply
Trouble
E03 DXHLKY line (Work equipment controller system)
Contents of • Since the joystick steering right EPC solenoid system is shorted with the power source, abnormal
trouble voltage is applied when the joystick steering right EPC solenoid output is OFF.
Problem that
appears on
mode is available).
machine
Related
information

Min. 1 Mz
chassis ground
value in normal
state
3
Voltage Max. 1 V
4
Min. 1 Mz
chassis ground
40-310 38 WA470, 480-6

Failure code [DXHLKY] (Joystick steering right EPC solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 39

SEN04530-01 Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
Failure code [DXHMKA] (Joystick steering left EPC solenoid:

Disconnection) 1
Action code Failure code Joystick steering left EPC solenoid: Disconnection
Trouble
E03 DXHMKA (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is disconnected, no current flows when the joy-
trouble stick steering left EPC solenoid output is ON.
Problem that
appears on
mode is available).
machine
• The output state (current) to the joystick steering left EPC solenoid can be checked with the monitor-
Related
ing function (Code: 41905, J/S EPC DIR LH).
information
• Method of reproducing failure code: Start the engine and steer to the left using the joystick steering.

1 left EPC solenoid
Between (1) and (2) 5 – 15 z
2 cut-off relay (L41) a Prepare with starting switch OFF, then turn starting switch ON
(Internal disconnection) and carry out troubleshooting.
Possible causes When joystick steering cut-off relay (L41) is replaced with a relay of
and standard the same type, if the condition becomes normal, the joystick steer-
value in normal ing cut-off relay is defective.
state
Max. 1 z
3
Max. 1 z
4
Between (38) and (23) 5 – 15 z
40-310 40 WA470, 480-6

Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection) SEN04530-01
WA470, 480-6 40-310 41

SEN04530-01 Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short

circuit) 1
Action code Failure code Joystick steering left EPC solenoid: Short circuit
Trouble
E03 DXHMKB (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is shorted, abnormal current flows when the joy-
trouble stick steering left EPC solenoid output is ON.
Problem that
appears on
mode is available).
machine
Related
information
• Method of reproducing failure code: Start the engine and steer to the left using the joystick steering.

1 left EPC solenoid
Min. 1 Mz
chassis ground
value in normal
state
3 harness
Min. 1 Mz
4
Min. 1 Mz
chassis ground
40-310 42 WA470, 480-6

Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit) SEN04530-01
WA470, 480-6 40-310 43

SEN04530-01 Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line)
Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short

Action code Failure code Joystick steering left EPC solenoid: Short circuit with power supply
Trouble
E03 DXHMKY line (Work equipment controller system)
Contents of • Since the joystick steering left EPC solenoid system is shorted with the power source, abnormal volt-
trouble age is applied when the joystick steering left EPC solenoid output is OFF.
Problem that
appears on
mode is available).
machine
Related
information

1 left EPC solenoid
Min. 1 Mz
chassis ground
value in normal
state
3
Voltage Max. 1 V
4
Min. 1 Mz
chassis ground
40-310 44 WA470, 480-6

Failure code [DXHMKY] (Joystick steering left EPC solenoid: Short circuit with power supply line) SEN04530-01
WA470, 480-6 40-310 45

SEN04530-01 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)
Failure code [DY30MA] Motor-driven emergency steering pump failure

(During operation of machine) 1
Action code Failure code Motor-driven emergency steering pump failure

Trouble
E01 DY30MA (During operation of machine) (Transmission controller system)
Contents of • While transmission controller does not output emergency steering operation command, emergency
trouble steering operating signal (CAN communication) is received from monitor.
Action of
• If trouble disappears, system resets itself after starting switch is turned OFF.
controller
Problem that • The motor-driven emergency steering motor (pump) operates although the motor-driven emergency
appears on steering switch is not operated. If motor is operated for long time, it will burn.
machine • The emergency steering operation indicator comes on.
Related • Check operation of the emergency steering with the monitoring function (Code: 40903 D-IN-30).
information • Check steering pressure drop with the monitoring function (Code: 40905 D-IN-0, D-IN-1).

Between L105 (male) Resis-
Defective emergency steer- Relay: OFF Min. 1 Mz
(11) and (12) tance
1 ing relay (L126) (Power and
signal lines short-circuited) a Prepare with starting switch OFF, then carry out troubleshooting
Resis- 200 –
Between L105 (male) (9) – (10)
tance 400 z
Defective emergency steer- a Prepare with starting switch OFF, then carry out troubleshooting
ing relay (For driving emer- without turning starting switch ON.
2 gency steering motor)
Possible causes (Power and signal lines Between disconnected relay terminals Resis-
Min. 1 Mz
and standard short-circuited) (3) and (5) tance
value in normal
Voltage Max. 1 V
3 Wiring harness between L105 (female) (12)
(Contact with 24V circuit) Voltage Max. 1 V
– R13 terminal and chassis ground
Wiring harness between emergency steering
relay – emergency steering motor and chas- Voltage Max. 1 V
sis ground
Wiring harness discontinuity without turning starting switch ON.
4 (Disconnection or defective
contact) Max. 1 z
40-310 46 WA470, 480-6

Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine) SEN04530-01

Emergency steering: Resis-
Max. 1 z
Stopped tance
At open to atmo- Resis-
5
Defective emergency steer- Max. 1 z
Possible causes ing pressure switch sphere (for reference) tance
Between R37 (male)
and standard Emergency steering:
(2) and (1)
value in normal Operating (High pres-
state Resis-
sure) (Operate in Min. 1 Mz
tance
manual mode switch
ON.)
Defective transmission and without turning starting switch ON.
6
fan pump motor controller Between L63 (female) (7) and chassis Resis- 200 –
ground tance 400 z
WA470, 480-6 40-310 47

SEN04530-01 Failure code [DY30MA] Motor-driven emergency steering pump failure (During operation of machine)
40-310 48 WA470, 480-6

Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode) SEN04530-01
Failure code [DY30MC] Motor-driven emergency steering pump failure

(Malfunction in manual mode) 1
Action code Failure code Motor-driven emergency steering pump failure

Trouble
E03 DY30MC (Malfunction in manual mode) (Transmission controller system)
Contents of • While transmission controller outputs emergency steering operation command, emergency steering
trouble operating signal (CAN communication) is not received from monitor.
Action of
• If trouble disappears, system resets itself after starting switch is turned OFF.
controller
Problem that
• The motor-driven emergency steering motor (pump) does not operate although the motor-driven
appears on
emergency steering switch is operated.
machine
Related • Check operation of the emergency steering with the monitoring function (Code: 40903 D-IN-30).
information • Check steering pressure drop with the monitoring function (Code: 40905 D-IN-0, D-IN-1).

1) Keep engine START for 10 seconds or longer and turn starting
switch OFF.
2) Replace L126 relay with another relay of the same type.
3) Turn starting switch ON (for self-check).
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
Resis- 200 –
Between L105 (male) (9) and (10)
Possible causes tance 400 z
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
Wiring harness ground fault without turning starting switch ON.
3
Min. 1 Mz
WA470, 480-6 40-310 49

SEN04530-01 Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode)

Emergency steering: Resis-
Max. 1 z
Stopped tance
Defective emergency steer- At open to atmo- Resis-
4
ing pressure switch Max. 1 z
Between R37 (male) sphere (for reference) tance
(2) and (1) Emergency steering:
Operating (High pres- Resis-
Min. 1 Mz
sure) (Operate in tance
Possible causes manual mode.)
value in normal and carry out troubleshooting.
state
Emergency steering:
Voltage Max. 1 V
Stopped
Defective emergency steer- Between emergency
5
ing motor steering motor (+) ter- Emergency steering:
minal and chassis Operating (High pres-
ground sure) (Operate in Voltage 20 – 30 V
manual mode switch
ON.)
Defective transmission and without turning starting switch ON.
6
fan pump motor controller Between L63 (female) (7) and chassis Resis- 200 –
ground tance 400 z
40-310 50 WA470, 480-6

Failure code [DY30MC] Motor-driven emergency steering pump failure (Malfunction in manual mode) SEN04530-01
WA470, 480-6 40-310 51

SEN04530-01 Failure code [DY30ME] Emergency steering: Operating for more than 1 minute
Failure code [DY30ME] Emergency steering: Operating for more than 1

minute 1
Action code Failure code Emergency steering: Operating for more than 1 minute
Trouble
E02 DY30ME (Machine monitor system)
Contents of
• Emergency steering operation detecting circuit is kept "OPEN" for more than 1 minute.
trouble
Action of
• Alarm activated.
controller
• With 1-minute emergency steering operation alarm is activated ON (Emergency steering motor may
Problem that
be malfunctioning or may have burned).
appears on
• While emergency steering motor is not operating, indicator lights up.
machine
• Emergency steering operates continuously.
Related
• Check operating condition of emergency steering with monitoring function (Code: 40903 D-IN-30).
information

Defective emergency steer- without turning starting switch ON.
1
ing relay (L126) L105 (male) Resistance
Between (9) and (10) 200 – 400 z
Defective emergency steer- without turning starting switch ON.
2 ing relay (for driving emer-
Resistance
gency steering motor) Between relay contacts
Min. 1 Mz
Defective disconnection in without turning starting switch ON.
wiring harness (Disconnec- Wiring harness between L54 (female) (3) – Resis-
and standard tion in wiring or defective R37 (female) (2) tance
value in normal contact in connector) Wiring harness between R37 (female) (1) – Resis-
Max. 1 z
state machine tance
Min. 1 Mz
4 harness (Contact with GND
circuit) Wiring harness between L61 (female) (23) – Resis-
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
terminal R13 and chassis ground tance
40-310 52 WA470, 480-6

Failure code [DY30ME] Emergency steering: Operating for more than 1 minute SEN04530-01

When emergency Resis-
Max. 1 z
steering stopped tance
Open to atmosphere Resis-
5
Defective emergency steer- Max. 1 z
ing pressure switch (Reference) tance
Between R37 (male)
(2) – (1) When emergency
steering operated
Resis-
(High pressure) Min. 1 Mz
tance
(Manual operation
switch ON)
Resis-
tance
Max. 1 z
Possible causes Defective steering pressure Resis-
6 Engine operated Min. 1 Mz
and standard switch tance
state Engine stopped Min. 1 Mz
tance
Min. 1 Mz
Resis-
Engine operated Max. 1 z
tance
Defective emergency steer- Emergency steering Resis-
7 Max. 1 z
ing check switch Between S19 (male) switch ON tance
(4) – (3) Emergency steering Resis-
Min. 1 Mz
switch OFF tance
Emergency steering
Voltage Max. 1 V
stopped
Between L54 (3) – Emergency steering
ground operated (High pres-
Voltage 20 – 30 V
sure) (Manual opera-
tion switch ON)
WA470, 480-6 40-310 53

SEN04530-01 Failure code [DY30ME] Emergency steering: Operating for more than 1 minute
40-310 54 WA470, 480-6

Failure code [DY30ME] Emergency steering: Operating for more than 1 minute SEN04530-01
WA470, 480-6 40-310 55

SEN04530-01

©2009 KOMATSU
All Rights Reserved
40-310 56
SEN04531-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
400 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
E-13 The KOMTRAX system does not work properly................................................................................... 54
E-14 When kick-down switch is turned ON, kick-down operation does not start .......................................... 56
E-15 When hold switch is pressed, holding operation does not start ........................................................... 58
E-16 Transmission is kept in neutral, or brake drags when directional lever is operated while parking
brake is applied .................................................................................................................................... 60
E-17 Transmission cut-off mode cannot be set or reset ............................................................................... 62
E-18 Transmission cut-off set cannot be reset.............................................................................................. 64
WA470, 480-6 40-400 1

400 Troubleshooting of electrical system (E-mode)
SEN04531-01
E-19 FNR switch mode cannot be set or reset ............................................................................................. 66

E-20 Fan reverse function cannot be used or reset ...................................................................................... 68
E-21 Discharge from loader pump does not rise from minimum level .......................................................... 70
E-22 ECSS function cannot be used or reset ............................................................................................... 72
E-23 When parking brake is turned ON, parking brake indicator lamp does not light up.............................. 74
E-24 When emergency brake operates, brake oil pressure caution lamp does not operate ........................ 78
E-25 Air cleaner clogging indicator lamp does not light up ........................................................................... 80
E-26 Radiator coolant level caution lamp does not light up .......................................................................... 82
not light up............................................................................................................................................ 83
caution lamp does not light up.............................................................................................................. 84
E-29 Steering oil pressure caution lamp does not light up ............................................................................ 86
E-30 Abnormality in t switch (panel switch 1) input ..................................................................................... 88
E-31 Abnormality in U switch (panel switch 1) input .................................................................................... 90
E-32 Abnormality in < switch (panel switch 2) input...................................................................................... 92
E-33 Abnormality in > switch (panel switch 2) input...................................................................................... 94
40-400 2 WA470, 480-6

Installing positions of fuses SEN04531-01
Installing positions of fuses 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
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, 480-6 40-400 3

SEN04531-01 Installing positions of fuses
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
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
Slow blow fuse

Slow-blow Capacity of
Type of power supply Destination of power
fuse No. fuse
Spare 1, engine controller (A) circuit, transmission controller (B)
Constant power circuit, work equipment controller (B) circuit (if equipped), room
1 50 A
supply lamp circuit, machine monitor (B) circuit, KOMTRAX (B) circuit (if
equipped), hazard lamp circuit and starting switch circuit
Main lamp circuit, machine monitor (B) circuit, load meter printer
(if equipped) circuit, air conditioner (B) circuit, air conditioner (A)
circuit, wiper and washer circuit, rear lamp and brake lamp cir-
2 50 A cuit, work equipment positioner circuit, work equipment controller
(A) circuit (if equipped), emergency steering circuit (if equipped),
parking brake circuit, transmission controller (A) circuit and horn
circuit
Switch power supply
Rear glass heater circuit, air suspension seat, yellow rotary lamp
circuit (if equipped), turn signal lamp circuit, car radio circuit, 12V
3 50 A
converter circuit, rear working lamp circuit and front working lamp
circuit
4 120 A Charging circuit
5 120 A Heater relay circuit
40-400 4 WA470, 480-6

Installing positions of fuses SEN04531-01
Locations and numbers of fuse boxes and slow blow fuse
WA470, 480-6 40-400 5

SEN04531-01 Information in troubleshooting table
Information in troubleshooting table 1
a The following information is summarized in the troubleshooting table and the related electrical circuit
diagram. Before carrying out troubleshooting, understand that information fully.
Trouble Problem that appears on machine
Related
Information related to detected trouble or troubleshooting
information
<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 (–)
leads as shown below unless especially specified.
4
• 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.
This is the excerpted circuit diagram related to troubleshooting

• Connector No.: Indicates (Model – No. of pins) (Color).
• “Connector No. and pin No.” from each branching/merging point: indicate
the ends of branch or source of merging within the parts of the same wir-
ing harness
• Arrow (io): Roughly indicates mounting place on machine.
40-400 6 WA470, 480-6

Information in troubleshooting table SEN04531-01
WA470, 480-6 40-400 7

SEN04531-01 E-1 Engine does not start
E-1 Engine does not start 1
Contents of
• The engine does not start.
trouble
• The engine does not start, because the starting motor does not run due to troubles in the starting
motor system and starting switch terminal C signal system.
• Check that No. 1 fuse of fuse box 1 is normal.
(If it is broken, check the related wiring harness for grounding fault.)
• 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 • The input state (ON/OFF) to the transmission controller from starting switch terminal C can be
• The input state (ON/OFF) to the work equipment controller from the starting switch terminal C can be
• If failure codes D5ZHKA, D5ZHKB, D5ZHKZ, D5ZHL6, DB2RKR, DDK3KA, DDK4KA, DDK6KA,
DDK6KB, and DB2RKR are indicated, curry out troubleshooting for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
Defective battery relay The battery relay can be judged normal if operating sounds are audible
2 (Internal disconnection or when the starting switch is operated.
short circuit) • Starting switch operation in the order of OFF o ON o OFF
Defective fuse No. 1 of If the fuse is burnt, the circuit probably has a grounding fault, etc. (See
3
fuse box 1 cause 15.)
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch START and carry out troubleshooting.
Starting motor Voltage
Between terminals B and
Power supply input 20 – 30 V
E
Defective starting motor
4 Between terminal R E01
(Internal trouble) Battery input Max. 1 V
and terminal E
Between terminal C E01
Starting input 20 – 30 V
Possible and terminal E
causes and If the starting motor does not run even if power supply input, battery
standard value input and starting input is normal, the starting motor is defective.
in normal state
a Prepare with starting switch OFF, then turn starting switch ON and
Defective alternator carry out troubleshooting.
5
(Internal trouble) Wiring harness between alternator terminal R (1)
Voltage Max. 1 V
– chassis ground
a Prepare with starting switch OFF, then carry out troubleshooting with
starting switch OFF and START each.
Defective starting switch S40 (male) Position of switch Resistance
6
OFF Min. 1 Mz
Between (1) and (3)
START Max. 1 z
carry out troubleshooting.
Defective FNR (direc- FNR (directional)
tional) lever switch L04 Voltage
7 lever
short circuit)
N (Neutral). 20 – 30 V
40-400 8 WA470, 480-6

E-1 Engine does not start SEN04531-01

a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective joystick steering Joystick steering FNR

FNR (directional) switch (directional) switch
8
(Internal disconnection or N (Neutral). Max. 1 z
Constant Min. 1 Mz
chassis ground
Right FNR (direc-
tional) switch
Defective right FNR (direc-
tional) switch N (Neutral). Max. 1 z
9 Between (1) and (3)
(Internal disconnection or Other than above Min. 1 Mz
short circuit)
Constant Min. 1 Mz
chassis ground
D04 (male) Diode range Continuity
Measure at (2) in
Defective diodes (D04, Between (2) and (1) Continue
diode range.
10 D05) (Internal disconnec-
tion) a Prepare with starting switch OFF, then carry out troubleshooting with-
D05 (male) Diode range Continuity
Measure at (2) in
Between (2) and (1) Continue
Possible diode range.
causes and a Prepare with starting switch OFF, then carry out troubleshooting with-
standard value out turning starting switch ON.
in normal state
Defective joystick safety Between (1) and (2) 200 – 400 z
11 relay (L113) a Prepare with starting switch OFF, then turn starting switch to START
(Internal trouble) and carry out troubleshooting.
When joystick safety relay (L113) is replaced with a relay of the same
type, if the condition becomes normal, the joystick safety relay is defec-
tive.
Defective neutral safety Between (1) and (2) 200 – 400 z
12 relay (L116) a Prepare with starting switch OFF, then turn starting switch to START
When neutral safety relay (L116) is replaced with a relay of the same
type, if the condition becomes normal, the neutral safety relay is defec-
tive.
L171 (male), L172 (male) Resistance
Defective engine control Between (1) and (2) 200 – 400 z
13 cut-out relays (L171, a Prepare with starting switch OFF, then turn starting switch to START
L172) (Internal defect) and carry out troubleshooting.
When engine control cut-out relay (L171, L172) is replaced with a relay
of the same type, if the condition becomes normal, the engine control
cut-out relay is defective.
WA470, 480-6 40-400 9


W60 (male) Resistance
Defective KOMTRAX Between (1) and (2) 200 – 400 z
14 engine cut-out relay (W60) a Prepare with starting switch OFF, then turn starting switch to START
When KOMTRAX engine cut-out relay (W60) is replaced with a relay of
the same type, if the condition becomes normal, the KOMTRAX engine
cut-out relay is defective.
Wiring harness between battery relay R04 – Resis-
Max. 1 z
starting motor terminal B tance
Wiring harness between starting motor terminal Resis-
Max. 1 z
E – chassis ground tance
Wiring harness between S40 (female) (3) – W60 Resis-
Max. 1 z
(female) (3) tance
Wiring harness between W60 (female) (6) – Resis-
Max. 1 z
Max. 1 z
(female) (1) tance
Possible Wiring harness between W60 (female) (2) – L80 Resis-
Max. 1 z
causes and (female) (20) tance
standard value Wiring harness between L116 (female) (3) – Resis-
in normal state Max. 1 z
Wiring harness between L04 (female) (3) – L116 Resis-
Disconnection in wiring Max. 1 z
(female) (1) tance
harness
15 (Disconnection in wiring Max. 1 z
harness or defective con-
tact) Wiring harness between L113 (female) (3) – D05 Resis-
Max. 1 z
(female) (2) tance
Wiring harness between D05 (female) (1) – E01 Resis-
Max. 1 z
(female) (1) tance
Max. 1 z
Max. 1 z
Wiring harness between S40 (female) (2) – L171 Resis-
Max. 1 z
(male) (1), L172 (male) (1) tance
Wiring harness between L171 (male) (2), L172 Resis-
Max. 1 z
(male) (2) – EC2 (female) (33) tance
Wiring harness between fuse No. 6 of fuse box 1 Resis-
Max. 1 z
– L171 (male) (3), L172 (male) (3) tance
Wiring harness between L171 (male) (4), L172 Resis-
Max. 1 z
(male) (4) – EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), (2) – Resis-
Max. 1 z
40-400 10 WA470, 480-6


Wiring harness between battery relay R04 –
Resis-
starting motor terminal B (E30) and chassis Min. 1 Mz
tance
ground
Wiring harness between S40 (male) (3) – W60
Resis-
(female) (3), – circuit branch end and chassis Min. 1 Mz
tance
ground
Wiring harness between W60 (female) (6) – Resis-
Min. 1 Mz
Min. 1 Mz
(female) (1) and chassis ground tance
Min. 1 Mz
Ground fault in wiring har- L113 (female) (6) and chassis ground tance
ness Wiring harness between L04 (female) (3) – L116 Resis-
16 Min. 1 Mz
(Contact with ground cir- (female) (1) and chassis ground tance
cuit) Wiring harness between L113 (female) (3) – D05 Resis-
Min. 1 Mz
Wiring harness between D05 (female) (1) – E01 Resis-
Min. 1 Mz
Possible Wiring harness between L63 (female) (37) – Resis-

Min. 1 Mz
causes and L113 (female) (1) and chassis ground tance
standard value Wiring harness between S40 (female) (2) – L171 Resis-
Min. 1 Mz
in normal state (male) (1) and chassis ground tance
Wiring harness between fuse No. 6 of fuse box 1
Resis-
– L171 (male) (3), L172 (male) (3) and chassis Min. 1 Mz
tance
ground
Wiring harness between L171 (male) (4), L172
Resis-
(male) (4) – EC3 (female) (3), (4) and chassis Min. 1 Mz
tance
ground
Hot short in wiring harness Wiring harness between alternator terminal R

17
(Contact with 24V circuit) E02 – E01 (female) (2), – circuit branch end and
chassis ground (Note: if hot short occurs across Voltage Max. 1 V
them, the charging lamp will be lighted as the
starting switch is ON.
L62 FNR lever Voltage
Defective transmission Between (27) and Neutral 20 – 30 V

18 chassis ground
controller Other than above Max. 1 V
L63 Joystick control lever Voltage
Between (37) and Neutral 20 – 30 V
WA470, 480-6 40-400 11

40-400 12 WA470, 480-6

WA470, 480-6 40-400 13

SEN04531-01 E-2 Wiper does not operate
E-2 Wiper does not operate 1
Contents of
(1) Front wiper does not operate.
trouble
Related
• The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
information

Defective fuse No. 7 of fuse If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
C12 Front wiper switch Voltage
Between (6) and
Constant 20 – 30 V
chassis ground
Defective front wiper motor Between (2) and
2 Lo 20 – 30 V
(Internal defect) chassis ground
Between (1) and
Hi 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C12 (5) and chassis ground until wiper motor
stops.
L31 Front wiper switch Voltage
Possible Between (3) and
causes and chassis ground
standard value Defective wiper timer (relay) Between (4) and
in normal state 3 INT 20 – 30 V
(Internal defect) chassis ground
Between (2) and
Washer side 20 – 30 V
chassis ground
INT (If wiper switch is
Between (5) and Repeat 20 to 30 V o
set in INT, voltage is
chassis ground 0V
output intermittently.)
L21 Voltage
Between (7) and chassis ground 20 – 30 V
Defective front wiper switch
4 L22 Front wiper switch Resistance
(Internal defect)
Between (7) and (5) Lo Max. 1 z
Between (7) and (4) Hi Max. 1 z
Between (7) and (2) INT Max. 1 z
Between (3) and (5) INT Max. 1 z
40-400 14 WA470, 480-6

E-2 Wiper does not operate SEN04531-01

Max. 1 z
Disconnection in wiring harness
5 (Disconnection or defective Max. 1 z
C12 (female) (2) tance
contact in connector)
Max. 1 z
fuse No. 7 of fuse box 2, – circuit branch end tance
Max. 1 z
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Wiring harness between L21 (female) (3) –
Resis-
tance
chassis ground
C12 (female) (2), – circuit branch end and Min. 1 Mz
6 harness tance
chassis ground
Resis-
fuse No. 7 of fuse box 2, – circuit branch end Min. 1 Mz
tance
and chassis ground
Resis-
tance
chassis ground
WA470, 480-6 40-400 15

SEN04531-01 E-2 Wiper does not operate
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

C15 Rear wiper switch Voltage
Between (1) and
Defective rear wiper motor chassis ground
1
(Internal trouble) Between (2) and
ON 20 – 30 V
chassis ground
• If wiper switch is turned OFF while wiper is operating, voltage is
applied between C15 (1) and chassis ground until wiper motor
stops.
L21 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal trouble)
L21 Rear wiper switch Resistance
Possible Between (7) and (9) ON Max. 1 z
causes and Between (8) and (9) OFF Max. 1 z
standard value
in normal state Other than above Min. 1 Mz
Max. 1 z
Disconnection in wiring C15 (female) (1) tance
3 Max. 1 z
(Disconnection or defective C15 (female) (3) tance
Max. 1 z
Wiring harness between C15 (female) (4) – Resis-
Max. 1 z
Resis-
Ground fault in wiring harness chassis ground tance
4
Min. 1 Mz
C15 (female) (3) and chassis ground tance
Min. 1 Mz
C15 (female) (2) and chassis ground tance
40-400 16 WA470, 480-6

E-2 Wiper does not operate SEN04531-01
WA470, 480-6 40-400 17

SEN04531-01 E-3 Windshield washer does not operate
E-3 Windshield washer does not operate 1
Contents of
Windshield washer does not operate.
trouble
• Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information • Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for “E-2 Wiper does not operate” first.)

Defective front washer motor and carry out troubleshooting.
1
(Internal defect) R43 Voltage
Defective rear washer motor and carry out troubleshooting.
2
(Internal defect) R45 Voltage
L21 Voltage
Defective front wiper switch without turning starting switch ON.
3
(Internal defect) Washer switch for
front wiper
ON Max. 1 z
Between (7) and (6)
OFF Min. 1 Mz
Possible Between (7), (6) and

Constant Min. 1 Mz
standard value a Prepare with starting switch OFF, then turn starting switch ON
in normal state and carry out troubleshooting.
L21 Voltage
Defective rear wiper switch without turning starting switch ON.
4
(Internal defect) Washer switch for
rear wiper
ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Washer switch for
L31 Voltage
front wiper
Defective wiper timer (relay) Between (3) and
5 Constant 20 – 30 V
(for only front wiper) chassis ground
Between (2) and
ON 20 – 30 V
chassis ground
Between (5) and
0.2 – 0.8 sec after ON 20 – 30 V
chassis ground
40-400 18 WA470, 480-6

E-3 Windshield washer does not operate SEN04531-01

Max. 1 z
Disconnection in wiring R43 (female) (1), – L31 (female) (2) tance
harness Wiring harness between L21(female) (7) – Resis-
6 Max. 1 z
(Disconnection or defective fuse No. 7 of fuse box 2 tance
Max. 1 z
Possible Wiring harness between R43 (female) (2), Resis-
causes and Max. 1 z
R45 (female) (2) – chassis ground tance
standard value
in normal state
Resis-
R43 (female) (1), – L31 (female) (2), – circuit Min. 1 Mz
tance
Ground fault in wiring harness
7
fuse No. 7 of fuse box 2, – circuit branch end Min. 1 Mz
tance
and chassis ground
Resis-
R45 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
WA470, 480-6 40-400 19

SEN04531-01 E-3 Windshield washer does not operate
40-400 20 WA470, 480-6

E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off SEN04531-01
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
• The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be

1
L02 (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
2 (Internal disconnection or
short circuit) OFF Min. 1 Mz
Possible Between (1) and (2) SMALL Min. 1 Mz
causes and
HEAD Max. 1 z
standard value
in normal state Between (1), (2), (5)
Constant Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
connector contact) Max. 1 z
4
(Contact with ground circuit) Wiring harness between fuse No. 11 of fuse Resis-
box 2 – L02 (female) (1), – circuit branch end Min. 1 Mz
tance
and chassis ground
WA470, 480-6 40-400 21

SEN04531-01 E-4 Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
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
information

Defective fuses No. 15 and If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
No. 14 of fuse box 2 (See cause 6.)
Between (1) and (2) 200 – 400 z
Defective headlamp relay
2 a Prepare with starting switch OFF, then turn starting switch ON
(L131)
When headlamp relay (L131) is replaced with a relay of the same
type, if the condition becomes normal, the headlamp relay is defec-
tive.
Possible without turning starting switch ON.
causes and L02 (male) Headlamp switch Resistance
standard value Defective lamp switch OFF Min. 1 Mz
in normal state 3 (Internal disconnection or
short circuit) Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Constant Min. 1 Mz
chassis ground
L02 (male) Dimmer switch Resistance
Defective dimmer switch Low Min. 1 Mz

Between (6) and (3)
4 (Internal disconnection or High Max. 1 z
short circuit) Low Max. 1 z
Between (6) and (4)
High Min. 1 Mz
Between (3), (4), (6)
Constant Min. 1 Mz
and chassis ground
40-400 22 WA470, 480-6


Max. 1 z
Max. 1 z
Disconnection in wiring har- chassis ground tance
ness Wiring harness between fuse No. 11 of fuse Resis-
5 Max. 1 z
(Disconnection or defective box 2 – L131 (female) (3) tance
contact in connector) Wiring harness between L131(female) (5) – Resis-
Max. 1 z
fuses No. 15, No. 14 of fuse box 2 tance
Max. 1 z
box 2 – left HEAD (female) (B) tance
Max. 1 z
box 2 – right HEAD (female) (B) tance
Resis-
tance
chassis ground
Possible
Wiring harness between L131(female) (5) –
causes and Resis-
Ground fault in wiring harness fuses No. 15, No. 14 of fuse box 2 and chas- Min. 1 Mz
standard value 6 tance
(Contact with ground circuit) sis ground
in normal state
Resis-
box 2 – left HEAD (female) (B) and chassis Min. 1 Mz
tance
ground
Resis-
box 2 – right HEAD (female) (B) and chassis Min. 1 Mz
tance
ground
• Headlamp switch is OFF
chassis ground
7 fuses No. 15, No. 14 of fuse box 2 and chas- Voltage Max. 1 V
sis ground
box 2 – left HEAD (female) (B) and chassis Voltage Max. 1 V
ground
box 2 – right HEAD (female) (B) and chassis Voltage Max. 1 V
ground
WA470, 480-6 40-400 23

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
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.

Between (6) and (3)
Possible short circuit) Low Max. 1 z
causes and Between (6) and (4)
High Min. 1 Mz
standard value
in normal state Between (3), (4), (6)
Constant Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between HEAD (female) (A) Resis-
– L02 (female) (4) tance
Ground fault in wiring harness without turning starting switch ON.
4
(Contact with ground circuit) Wiring harness between HEAD (female) (A) Resis-
Min. 1 Mz
– L02 (female) (4) and chassis ground tance
40-400 24 WA470, 480-6

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
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb

Between (6) and (3)
short circuit) Low Max. 1 z
Possible Between (6) and (4)
causes and High Min. 1 Mz
standard value Between (3), (4), (6)
in normal state Constant Min. 1 Mz
and chassis ground
3
(Disconnection or defective Wiring harness between HEAD (female) (C) Resis-
– L02 (female) (3) tance
4
(Contact with ground circuit) Wiring harness between HEAD (female) (C) Resis-
– L02 (female) (3), – circuit branch end and Min. 1 Mz
tance
chassis ground
WA470, 480-6 40-400 25

Contents of (5) Clearance lamp does not light up or go off.

trouble (6) Tail lamp does not light up or go off.
• Defective switch, lamp, or wiring harness of the clearance lamp or tail lamp system.
Related • When the headlamp and turn signal lamp light up.
information • The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuses No. 13 and If the fuse is burnt, the circuit probably has a grounding fault, etc.
2
No. 12 of fuse box 2 (See cause 5.)
L02 (male) Headlamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (1) and (5)
SMALL or HEAD Max. 1 z
Between (1) and (2) SMALL Min. 1 Mz
HEAD Max. 1 z
Between (1), (2), (5)
Constant Min. 1 Mz
and chassis ground
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and without turning starting switch ON.
standard value
in normal state Disconnection in wiring Max. 1 z
fuses No. 13, No. 12 of fuse box 2 tance
harness
4 Wiring harness between fuse No. 12 of fuse
(Disconnection or defective Resis-
contact in connector) box 2 – right COMBI (female) (A), – R31 Max. 1 z
tance
(female) (4)
Max. 1 z
box 2 – left COMBI (female) (A) tance
Resis-
fuses No. 13, No. 12 of fuse box 2 and chas- Min. 1 Mz
tance
sis ground
5
(Contact with ground circuit) Wiring harness between fuse No. 12 of fuse Resis-
box 2 – right COMBI (female) (A), – R31 Min. 1 Mz
tance
(female) (4) and chassis ground
Resis-
box 2 – left COMBI (female) (A) and chassis Min. 1 Mz
tance
ground
40-400 26 WA470, 480-6


• Headlamp switch is OFF
Possible fuses No. 13, No. 12 of fuse box 2, – circuit Voltage Max. 1 V
causes and branch end and chassis ground
standard value Hot short in wiring harness
6 Wiring harness between fuse No. 12 of fuse
in normal state (Contact with 24V circuit)
box 2 – right COMBI (female) (A), – R31
Voltage Max. 1 V
(female) (4), – circuit branch end and chas-
sis ground
box 2 – left COMBI (female) (A), – circuit Voltage Max. 1 V
WA470, 480-6 40-400 27

40-400 28 WA470, 480-6

E-5 Working lamp does not light up or go off SEN04531-01
E-5 Working lamp does not light up or go off 1
Contents of
(1) Front working lamp does not light up or go off.
trouble
Related • The switch, lamp, or wiring harness of the front working lamp system is defective.
information • When the rear working lamp lights up (goes off).

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
2
Between (1) and (2) 200 – 400 z
Defective front working lamp
relay (L127)
When front working lamp relay (L127) is replaced with a relay of the
same type, if the condition becomes normal, the front working lamp
relay is defective.
Possible Front working lamp
Defective front working lamp S01 (male) Resistance
causes and switch
4 switch (Internal disconnection
standard value ON Max. 1 z
in normal state or short circuit) Between (5) and (6)
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Max. 1 z
box 1 – S01 (female) (6) tance
Max. 1 z
5 Max. 1 z
(Disconnection or defective chassis ground tance
contact in connector) Wiring harness between fuse No. 8 of fuse Resis-
Max. 1 z
Max. 1 z
C04 (female) (1), – C05 (female) (1) tance
Wiring harness between C04 (female) (2), Resis-
Max. 1 z
C05 (female) (2) – chassis ground tance
WA470, 480-6 40-400 29

SEN04531-01 E-5 Working lamp does not light up or go off

Min. 1 Mz
box 1 – S01 (female) (6) and chassis ground tance
Min. 1 Mz
Ground fault in wiring harness L127 (female) (1) and chassis ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 8 of fuse
Resis-
box 1 – L127 (female) (3) and chassis Min. 1 Mz
tance
ground
Resis-
Possible C04 (female) (1), – C05 (female) (1), – circuit Min. 1 Mz
tance
causes and branch end and chassis ground
• Front working lamp switch turned off.
Voltage Max. 1 V
box 1 – S01 (female) (6) and chassis ground
box 1 – L127 (female) (3) and chassis Voltage Max. 1 V
ground
C04 (female) (1), – C05 (female) (1), – circuit Voltage Max. 1 V
40-400 30 WA470, 480-6

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)

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) and (2) 200 – 400 z
Defective rear working lamp
relay (L128)
When rear working lamp relay (L128) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
Defective rear working lamp Rear working lamp

Possible S02 (male) Resistance
switch switch
causes and 4
standard value (Internal disconnection or ON Max. 1 z
in normal state OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Max. 1 z
box 1 – S02 (female) (6) tance
Max. 1 z
harness Max. 1 z
5 chassis ground tance
(Disconnection or defective
contact in connector) Wiring harness between fuse No. 9 of fuse Resis-
Max. 1 z
Resis-
G04 (female) (2), – G05 (female) (2), – cir- Max. 1 z
tance
cuit branch end
Wiring harness between G04 (female) (1), Resis-
Max. 1 z
G05 (female) (1) – chassis ground tance
WA470, 480-6 40-400 31

SEN04531-01 E-5 Working lamp does not light up or go off

Max. 1 z
box 1 – S02 (female) (6) and chassis ground tance
Max. 1 z
Ground fault in wiring harness L128 (female) (1) and chassis ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 9 of fuse
Resis-
box 1 – L128 (female) (3) and chassis Max. 1 z
tance
ground
Resis-
Possible G04 (female) (2), – G05 (female) (2), – cir- Max. 1 z
tance
causes and cuit branch end and chassis ground
• Front working lamp switch turned off
Voltage Max. 1 V
box 1 – S02 (female) (6) and chassis ground
box 1 – L128 (female) (3) and chassis Voltage Max. 1 V
ground
G04 (female) (2), – G05 (female) (2), – cir- Voltage Max. 1 V
cuit branch end and chassis ground
40-400 32 WA470, 480-6

WA470, 480-6 40-400 33

SEN04531-01 E-6 Turn signal lamp and hazard lamp do not light up or go off
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).

Defective No. 11 and No. 2 If the fuse is burnt, the circuit probably has a grounding fault, etc.
1
fuses of fuse box 1 (See cause 6.)
Between (1) and (2) 200 – 400 z
2 Defective hazard relay (L111)
Possible When hazard relay (L111) is replaced with a relay of the same type,
causes and if the condition becomes normal, the hazard relay is defective.
L19 Voltage
Between (3) and (1) 20 – 30 V
Defective flasher unit 20 – 30 V and 0 V are indicated
Between (4) and (1)
3 (Internal disconnection or repeatedly.
short circuit) a Prepare with starting switch OFF, then carry out troubleshooting
Min. 1 Mz
chassis ground
40-400 34 WA470, 480-6

E-6 Turn signal lamp and hazard lamp do not light up or go off SEN04531-01

Turn signal lamp and
hazard lamp switches
Turn signal lamp
Min. 1 Mz
lever: Left
Turn signal lamp
Min. 1 Mz
lever: Neutral
Between (2) and (3)
Turn signal lamp
Max. 1 z
lever: Right
Hazard lamp switch:
Max. 1 z
ON
Turn signal lamp
Defective turn signal lamp and Max. 1 z
lever: Left
hazard lamp switches (Inter-
4 Turn signal lamp
nal disconnection or short cir- Min. 1 Mz
cuit) lever: Neutral
Between (2) and (4)
Turn signal lamp
Min. 1 Mz
lever: Right
Hazard lamp switch:
Max. 1 z
ON
Hazard lamp switch:
Max. 1 z
ON
Between (1) and (5)
Possible Hazard lamp switch:
Min. 1 Mz
causes and OFF
standard value Between (1), (2), (3),
in normal state (4) or (5) and chassis Constant Min. 1 Mz
ground
Max. 1 z
ness L19 (female) (3) tance
5
Max. 1 z
Ground fault in wiring harness Wiring harness between L111 (female) (3) – Resis-
6 Min. 1 Mz
(Contact with ground circuit) L19 (female) (3) and chassis ground tance
Min. 1 Mz
7 Voltage Max. 1 V
(Contact with 24V circuit) L19 (female) (3) and chassis ground
Voltage Max. 1 V
WA470, 480-6 40-400 35

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).

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
Turn signal lamp and
hazard lamp switches
Turn signal lamp
Min. 1 Mz
lever: Left
Turn signal lamp
Min. 1 Mz
lever: Neutral
Between (2) and (3)
Turn signal lamp
Max. 1 z
lever: Right
Defective turn signal lamp and Hazard lamp switch:
Max. 1 z
hazard lamp switches (Inter- ON
2
nal disconnection or short cir- Turn signal lamp
cuit) Max. 1 z
lever: Left
Turn signal lamp
Min. 1 Mz
lever: Neutral
Between (2) and (4)
Turn signal lamp
Min. 1 Mz
lever: Right
Hazard lamp switch:
Max. 1 z
ON
Possible
causes and Between (2), (3), (4)
Constant Min. 1 Mz
standard value and chassis ground
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Max. 1 z
R31 (female) (1), – right COMBI (female) (C) tance
Max. 1 z
Disconnection in wiring har- R30 (female) (1), – left COMBI (female) (C) tance
ness Wiring harness between R30 (female) (4) – Resis-
3 Max. 1 z
(Disconnection or defective chassis ground tance
contact in connector) Wiring harness between R31 (female) (4) – Resis-
Max. 1 z
Wiring harness between right COMBI Resis-
Max. 1 z
(female) (B) – chassis ground tance
Wiring harness between left COMBI (female) Resis-
Max. 1 z
(B) – chassis ground tance
Resis-
Ground fault in wiring harness R31 (female) (1), – right COMBI (female) Min. 1 Mz
4 tance
(Contact with ground circuit) (C), – circuit branch end and chassis ground
Resis-
R30 (female) (1), – left COMBI (female) (C), Min. 1 Mz
tance
– circuit branch end and chassis ground
40-400 36 WA470, 480-6


Possible
causes and Wiring harness between L03 (female) (3) –
standard value Hot short in wiring harness R31 (female) (1), – right COMBI (female) Voltage Max. 1 V
5
in normal state (Contact with 24V circuit) (C), – circuit branch end and chassis ground
R30 (female) (1), – left COMBI (female) (C), Voltage Max. 1 V
WA470, 480-6 40-400 37

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.

1
Between (1) and (2) 200 – 400 z
2 Defective hazard relay (L111)
When hazard relay (L111) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
L03 (male) Hazard lamp switch Resistance
Between (2) and (3), ON Max. 1 z
Defective hazard lamp switch (4) OFF Min. 1 Mz
short circuit) ON Max. 1 z
Between (1) and (5)
OFF Min. 1 Mz
Between (1), (2), (3),
(4) or (5) and chassis Constant Min. 1 Mz
ground
Possible
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
in normal state Wiring harness between fuse No. 2 of fuse Resis-
Disconnection in wiring Max. 1 z
harness box 1 – L111 (female) (1), (5) tance
4
Max. 1 z
Ground fault in wiring harness Resis-
5 box 1 – L111 (female) (1), (5) and chassis Min. 1 Mz
(Contact with ground circuit) tance
ground
Min. 1 Mz
• When hot short resulted on the wiring harnesses of the following
two circuits
6
(Contact with 24V circuit) R31 (female) (1), – right COMBI (female) Voltage Max. 1 V
(C), – circuit branch end and chassis ground
R30 (female) (1), – left COMBI (female) (C), Voltage Max. 1 V
40-400 38 WA470, 480-6

WA470, 480-6 40-400 39

SEN04531-01 E-7 Brake lamp does not light or it keeps lighting up
E-7 Brake lamp does not light or it keeps lighting up 1
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
• The lamp or wiring harness of the brake lamp system is abnormal.
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
2
Defective brake lamp relay
Between (1) and (2) 200 – 400 z
(L118)
short circuit) and carry out troubleshooting.
When brake lamp relay (L118) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
Defective brake lamp switch L09 (male) Brake pedal Resistance

4 (Internal disconnection or Press Max. 1 z
Released Min. 1 Mz
Possible Between (1), (2) and
Constant Min. 1 Mz
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state without turning starting switch ON.
Max. 1 z
box 2 – L118 (female) (3), – L09 (female) (1) tance
Max. 1 z
5
Max. 1 z
R30 (female) (5), – R31 (female) (5) tance
Wiring harness between R30 (female) (4), Resis-
Max. 1 z
R31 (female) (4) – chassis ground tance
Resis-
box 2 – L118 (female) (3), – L09 (female) (1), Min. 1 Mz
tance
Ground fault in wiring harness – circuit branch end and chassis ground
6
Min. 1 Mz
Resis-
R30 (female) (5), – R31 (female) (5) and Min. 1 Mz
tance
chassis ground
40-400 40 WA470, 480-6

E-7 Brake lamp does not light or it keeps lighting up SEN04531-01

Possible and carry out troubleshooting.
standard value Hot short in wiring harness Voltage Max. 1 V
R30 (female) (5), – R31 (female) (5) and Voltage Max. 1 V
chassis ground
WA470, 480-6 40-400 41

SEN04531-01 E-8 Backup lamp does not light or it keeps lighting up
E-8 Backup lamp does not light or it keeps lighting up 1
Contents of
Backup lamp does not light or it keeps lighting up.
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related
(If disconnection or short circuit occurs in the primary side of the back lamp relay, failure code
information
[D160KA] or [D160KB] is indicated. Carry out troubleshooting for it first.)

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L117) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
defective.
Max. 1 z
Max. 1 z
R30 (female) (2), – R31 (female) (2) tance
Possible
standard value Disconnection in wiring L117 (female) (1) Resis-
Max. 1 z
in normal state harness • As a failure is detected, failure code tance
4
(Disconnection or defective [D160KA] is indicated.
contact in connector) Wiring harness between L117 (female) (2) –
chassis ground Resis-
Max. 1 z
• As a failure is detected, failure code tance
[D160KA] is indicated
Max. 1 z
Max. 1 z
Resis-
box 2 – L117 (female) (3), – circuit branch Min. 1 Mz
tance
end and chassis ground
Ground fault in wiring harness Wiring harness between L117 (female) (5) –
5 Resis-
(Contact with ground circuit) R30 (female) (2), – R31 (female) (2), – circuit Min. 1 Mz
tance
L117 (female) (1) and chassis ground Resis-
Min. 1 Mz
[D160KB] is displayed
40-400 42 WA470, 480-6

E-8 Backup lamp does not light or it keeps lighting up SEN04531-01

Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting.
standard value Hot short in wiring harness
R30 (female) (2), – R31 (female) (2), – circuit Voltage Max. 1 V
WA470, 480-6 40-400 43

SEN04531-01 E-9 Backup buzzer does not sound or it keeps sounding
E-9 Backup buzzer does not sound or it keeps sounding 1
Contents of
Backup buzzer does not sound or it keeps sounding.
trouble
• The transmission controller monitors the primary circuit of the backup lamp relay for a trouble.
Related (If disconnection or ground fault occurs in the primary side of the back lamp relay, failure code
information [D160KA] or [D160KB] is indicated. In such case, give precedence to the troubleshooting of the fail-
ure indicated with the code.)

Defective backup buzzer
1 (Internal disconnection or G10 Gear shift lever Voltage
short circuit) R 20 – 30 V
Between (1) and (2)
Other than R Max. 1 V
2
Defective backup lamp relay Between (1) and (2) 200 – 400 z
3 (L101) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
defective.
causes and
standard value Max. 1 z
in normal state
Max. 1 z
G10 (female) (1) tance
Disconnection in wiring Wiring harness between L63 (female) (4) –
harness L117 (female) (1) Resis-
4
(Disconnection or defective Max. 1 z
contact in connector) [D160KA] is indicated.
chassis ground Resis-
Max. 1 z
[D160KA] is indicated.
Wiring harness between G10 (female) (2) – Resis-
Max. 1 z
Resis-
Ground fault in wiring harness box 2 – L117 (female) (3) and chassis Min. 1 Mz
5 tance
(Contact with ground circuit) ground
Resis-
G10 (female) (1), – circuit branch end and Min. 1 Mz
tance
chassis ground
40-400 44 WA470, 480-6

E-9 Backup buzzer does not sound or it keeps sounding SEN04531-01

L117 (female) (1), – circuit branch end and
Ground fault in wiring harness Resis-
5 chassis ground Min. 1 Mz
Possible (Contact with ground circuit) tance
• As a failure is detected, failure code
causes and [D160KB] is indicated
standard value
in normal state a Prepare with starting switch OFF, then turn starting switch ON
G10 (female) (1), – circuit branch end and Voltage Max. 1 V
chassis ground
WA470, 480-6 40-400 45

SEN04531-01 E-10 Horn does not sound or it keeps sounding
E-10 Horn does not sound or it keeps sounding 1
Contents of
Horn does not sound or it keeps sounding (Steering wheel specification).
trouble
Related
• The relay, switch, horn, or wiring harness of the horn system is abnormal.
information

1
Defective horn relay (L119)
Between (1) and (2) 200 – 400 z
short circuit) a Prepare with starting switch OFF, then turn starting switch ON
When horn relay (L119) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective steering wheel horn
switch Steering wheel horn
3 L05 (male) Resistance
(Internal disconnection or switch
short circuit) Between (1) and ON Max. 1 z
chassis ground OFF Min. 1 Mz
Defective joystick lever horn
switch Joystick lever horn
4 L37 (male) Resistance
(Internal disconnection or switch
Possible short circuit) ON Max. 1 z
causes and Between (9) and (10)
standard value OFF Min. 1 Mz
in normal state a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Disconnect connector and mea-
sure on female side)
Defective horn F03, F05 Horn switch Voltage
5 (Internal disconnection or ON Max. 1 V
Between F03 (2) and
short circuit)
(1) OFF 20 – 30 V
Between F05 (2) and ON Max. 1 V
(1) OFF 20 – 30 V
Max. 1 z
Max. 1 z
Disconnection in wiring L05 (female) (1), – L37 (female) (9) tance
6 Max. 1 z
(Disconnection or defective F03 (female) (2), – F05 (female) (2) tance
contact in connector) Wiring harness between F03 (female) (1) – Resis-
Max. 1 z
F05 (female) (1) – chassis ground tance
Wiring harness between steering wheel horn Resis-
Max. 1 z
switch – chassis ground tance
Max. 1 z
40-400 46 WA470, 480-6

E-10 Horn does not sound or it keeps sounding SEN04531-01

Possible
causes and Wiring harness between fuse No. 1 of fuse
Resis-
standard value Ground fault in wiring harness box 2 – L119 (female) (1), (3), – circuit Min. 1 Mz
7 tance
in normal state (Contact with ground circuit) branch end and chassis ground
Resis-
F03 (female) (2), – F05 (female) (2), – circuit Min. 1 Mz
tance
WA470, 480-6 40-400 47

SEN04531-01 E-11 Alarm buzzer does not sound or it keeps sounding
E-11 Alarm buzzer does not sound or it keeps sounding 1
Contents of
• Alarm buzzer does not sound or it keeps sounding.
trouble
• Disconnection or ground fault in alarm buzzer output circuit
Related • The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: 40952, D-OUT-0).
• If failure code [DV00KB] (Alarm buzzer: Short circuit) is indicated, carry out troubleshooting for it first.

1
• Remove the buzzer then connect +24 V to L20 (male) (1) and
Defective alarm buzzer GND to L20 (male) (2).
2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Disconnection in wiring har- without turning starting switch ON.
standard value ness Wiring harness between fuse No. 10 of fuse Resis-
in normal state 3 Max. 1 z
(Disconnection or defective box 2 – L20 (female) (1) tance
Max. 1 z
Ground fault in wiring harness Resis- Min.
4 box 2 – L20 (female) (1), – circuit branch end
(Contact with ground circuit) tance 1 Mz
and chassis ground
Wiring harness between L20 (female) (2) – Resis- Min.
L51 (female) (14) and chassis ground tance 1 Mz
• When above 1 – 4 are normal, failure on the machine monitor can
be suspected.
40-400 48 WA470, 480-6

E-11 Alarm buzzer does not sound or it keeps sounding SEN04531-01
WA470, 480-6 40-400 49

SEN04531-01 E-12 Air conditioner does not operate or stop
E-12 Air conditioner does not operate or stop 1
Contents of
Air conditioner does not operate or stop.
trouble
• The following is troubleshooting applicable only to the power supply and GND circuit between the air
Related
conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual
information
for the air conditioner.

Defective No. 8 and No. 9
fuses of fuse box 2 or defec-
If the fuse is burnt, the circuit probably has a grounding fault, etc.
1 tive 5 A and 15 A fuses of the
(See cause 2.)
main circuit in the air condi-
tioner unit.
• When fuse No. 8 of fuse box 2 is blown
box 2 – 5A fuse of air conditioner main circuit, Resis- Min.
– 15A fuse in the air conditioner and chassis tance 1 Mz
ground
• When fuse No. 9 of fuse box 2 is broken
Resis- Min.
box 2 – compressor clutch relay and chassis
Grounding fault in power tance 1 Mz
ground
2 supply wiring harness
(Contact with ground circuit) a Prepare with starting switch OFF, then carry out troubleshooting
causes and • When 5A fuse of the air conditioner unit main circuit is broken
standard value Wiring harness between 5A fuse of air condi-
in normal state tioner unit main circuit – C48 (female) (7), – Resis- Min.
pressure switch, – blower OFF relay primary tance 1 Mz
side and chassis ground
• When 15A fuse of the air conditioner unit is broken
Wiring harness between 15A fuse of air con-
Resis- Min.
ditioner unit – blower OFF relay and chassis
tance 1 Mz
ground
C48 Starting switch Voltage
Defective A/C control panel ON 20 – 30 V

Between (7) and (1)
power supply and disconnec- OFF Max. 1 V
3 tion of GND wring harness a Prepare with starting switch OFF, then carry out troubleshooting
(disconnection or defective without turning starting switch ON.
contact in connector)
Max. 1 z
box 2 – C48 (female) (7) tance
Wiring harness between C48 (female) (1) – Resis-
Max. 1 z
40-400 50 WA470, 480-6

E-12 Air conditioner does not operate or stop SEN04531-01

Blower OFF relay,
Starting switch Voltage
pressure switch
Blower OFF relay ON 20 – 30 V
(15A fuse line) and
Blower OFF relay (5A ON 20 – 30 V

fuse line of main cir-
cuit) and chassis OFF Max. 1 V
ground
Pressure switch ON 20 – 30 V
Possible
Disconnection in wiring har- (5A fuse line of main
causes and
ness of relay power supply circuit) and chassis OFF Max. 1 V
standard value 4
(Disconnection or defective ground
in normal state
contact in connector) a Prepare with starting switch OFF, then carry out troubleshooting
Resis-
box 2 – blower OFF relay (on the 15A fuse Max. 1 z
tance
line)
Resis-
box 2 – blower OFF relay (on the 5A fuse line Max. 1 z
tance
of main circuit)
Resis-
box 2 – pressure switch (on the 5A fuse line Max. 1 z
tance
of main circuit)
Wiring harness between pressure switch – Resis-
Max. 1 z
compressor clutch relay tance
WA470, 480-6 40-400 51

SEN04531-01 E-12 Air conditioner does not operate or stop
40-400 52 WA470, 480-6

E-12 Air conditioner does not operate or stop SEN04531-01
WA470, 480-6 40-400 53

SEN04531-01 E-13 The KOMTRAX system does not work properly
E-13 The KOMTRAX system does not work properly 1
Trouble • The KOMTRAX system does not work properly.

• If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
• A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.

1 Defective power supply L80 Signal Voltage
Between (39), (40) – Constant power
20 – 30 V
(37) and (38) supply
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED (1) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Between (36) and
Starting switch ACC 20 – 30 V
(37), (38)
Between (28) – (37),
Alternator R 20 – 30 V
(38)
L80 Signal Voltage
Starting switch C Max. 1 V
and standard Defective starting switch C (37), (38)
value in normal 3
signal a Prepare with starting switch OFF, then turn starting switch START
L80 Signal Voltage
Between (27) and
Starting switch C 20 – 30 V
(37), (38)
a Turn the starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
4
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 – 80 z
5 Number of unsent mails LED (7) Normal state
7 segments 0–9
Defective GPS positioning Dot ON
6
status
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
40-400 54 WA470, 480-6

E-13 The KOMTRAX system does not work properly SEN04531-01
Lamp display section of KOMTRAX terminal L80 connector
CPU LED
1. LED-C1 (R signal and ACC signal status)
2. LED-C2 (engine control signal status)
3. LED-C3 (S-NET, C signal status)
4. LED-C4 (CAN status)
5. LED-C5 (download writing condition)
6. LED-C6 (download writing condition)
7 segments and dot for CPU

7. 7 segments (number of mails not yet sent)
8. Dot (GPS positioning in progress)
WA470, 480-6 40-400 55

SEN04531-01 E-14 When kick-down switch is turned ON, kick-down operation does not start
E-14 When kick-down switch is turned ON, kick-down operation does

not start 1
Contents of
• When kick-down switch is turned ON, kick-down operation does not start.
trouble
• The kick-down system is disconnected or shorted with the power source.
Related • The input state (ON/OFF) from the kick-down switch can be checked with the monitoring function
information (Code: 40905, D-IN-6).
• If failure code [DDW9LD] is displayed, carry out troubleshooting for it first.

L14 (male) Kick-down switch Resistance
1 ON Max. 1 z
OFF Min. 1 Mz
Between (1) or (2) and
Constant Min. 1 Mz
chassis ground
Disconnection in wiring har- out turning starting switch ON.
Possible causes
ness Wiring harness between L62 (female) (2) – L14
and standard 2 Resistance Max. 1 z
(Disconnection or defective (female) (1)
value in normal
contact of connector) Wiring harness between L14 (female) (2) –
state Resistance Max. 1 z
chassis ground
Hot short in wiring harness carry out troubleshooting.
3
(Contact with 24V circuit) Wiring harness between L62 (female) (2) – L14
Voltage Max. 1 V
4 L62 Kick-down switch Voltage
troller
Between (2) and chas- ON Max. 1V
sis ground OFF 20 – 30 V
40-400 56 WA470, 480-6

E-14 When kick-down switch is turned ON, kick-down operation does not start SEN04531-01
WA470, 480-6 40-400 57

SEN04531-01 E-15 When hold switch is pressed, holding operation does not start
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.

Defective hold switch L14 (male) Hold switch Resistance
1 (Internal disconnection or ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting with-
Possible causes
ness out turning starting switch ON.
and standard 2
(Disconnection or defective Wiring harness between L62 (female) (38) – L14
value in normal
contact of connector) Resistance Max. 1 z
state (female) (3)
3
Voltage Max. 1 V
4 L62 Hold switch Voltage
troller
40-400 58 WA470, 480-6

E-15 When hold switch is pressed, holding operation does not start SEN04531-01
WA470, 480-6 40-400 59

SEN04531-01 brake is applied
E-16 Transmission is kept in neutral, or brake drags when directional

lever is operated while parking brake is applied 1
Contents of • Transmission is kept in neutral, or brake drags when directional lever is operated while parking brake
trouble is applied.
• The neutralizer signal (parking brake signal) system is abnormal.
Related
• The input state (ON/OFF) from the neutralizer (parking brake) switch can be checked with the monitor-
information
ing function (Code: 40907, D-IN-23).

Defective fuse (3) of fuse If the fuse is broken, the circuit probably has a grounding fault, short cir-
1
box 2 cuit, etc. (See cause 6.)
Defective parking brake L01 (male) Parking brake switch Resistance
2
switch (Internal defect) ON Max. 1 z
Between (5) and (6)
OFF Min. 1 Mz
Between (3) and (6) Constant Min. 1 Mz
PB.PS Resistance
Defective parking brake Between (male) (1) and (2) 10 – 40 z
3
solenoid (Internal defect) Between (female) (2) and chassis
Max. 1 z
ground
Between (male) (1) or (2) and
Min. 1 Mz
chassis ground
Possible causes ness out turning starting switch ON.
4
and standard (Disconnection or defective Wiring harness between L62 (female) (6) and
Resistance Max. 1 z
value in normal contact of connector) L01 (female) (2)
state a Prepare with starting switch OFF, then turn starting switch ON and
5 Wiring harness between L62 (female) (6) – L01
(female) (3) or PB.PS (female) (1) and chassis Voltage Max. 1 V
ground
Grounding fault in wiring out turning starting switch ON.
6 harness (Contact with Wiring harness between L62 (female) (6) – L01
ground circuit) (female) (3) or PB.PS (female) (1) and chassis Resistance Min. 1 Mz
ground
L62 Parking brake switch Voltage
OFF o ON
Max. 1 V
Defective transmission con- (Not opened)
7
troller Kept in OFF
Between (6) and chas- Max. 1 V
(Not opened)
sis ground
ON o OFF (Opened) 20 – 30 V
Kept in ON
Max. 1 V
(Not opened)
40-400 60 WA470, 480-6

brake is applied SEN04531-01
WA470, 480-6 40-400 61

SEN04531-01 E-17 Transmission cut-off mode cannot be set or reset
E-17 Transmission cut-off mode cannot be set or reset 1
Contents of
• Transmission cut-off mode cannot be set or reset.
trouble
• The transmission cut-off switch system is abnormal.
Related
• The input state (ON/OFF) from the transmission cut-off switch can be checked with the monitoring
information

Defective transmission cut- Transmission cut-off
S03 (male) Resistance
off switch switch
1
(Internal disconnection or ON Max. 1 z
Between (5) and (6)
Constant Min. 1 Mz
chassis ground
2
(Disconnection or defective Wiring harness between L61 (female) (11) and
Possible causes Resistance Max. 1 z
contact of connector) S03 (female) (5)
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON and
Short circuit with power carry out troubleshooting.
state 3 source (Contact with 24V
Between L61 (female) (11) – S03 (female) (5)
circuit) in wiring harness Voltage Max. 1 V
wiring harness and chassis ground
4 harness (Contact with
ground circuit) Resistance Min. 1 Mz
5 L61 Voltage
troller switch
40-400 62 WA470, 480-6

E-17 Transmission cut-off mode cannot be set or reset SEN04531-01
WA470, 480-6 40-400 63

SEN04531-01 E-18 Transmission cut-off set cannot be reset
E-18 Transmission cut-off set cannot be reset 1
Contents of
• Transmission cut-off set cannot be reset.
trouble
• The transmission cut-off set switch is disconnected or shorted with the power source.
Related • The input state (ON/OFF) from the switch can be checked with the monitoring function (Code: 40905,
• If failure code [DDT4LD] is displayed, carry out troubleshooting for it first.

Defective transmission cut- Transmission cut-off
S05 (male) Resistance
off switch set switch
1
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
2
(Disconnection or defective Wiring harness between L61 (female) (5) – S05
Possible causes contact of connector) Resistance Max. 1 z
(female) (5)
and standard
value in normal a Prepare with starting switch OFF, then turn starting switch ON and
state Hot short in wiring harness carry out troubleshooting.
3
(Contact with 24V circuit) Wiring harness between L61 (female) (5) – S05
Voltage Max. 1 V
Wiring harness between L61 (female) (5) – S05
5 L61 Voltage
troller set switch
Between (5) and chas- ON Max. 1 V
40-400 64 WA470, 480-6

E-18 Transmission cut-off set cannot be reset SEN04531-01
WA470, 480-6 40-400 65

SEN04531-01 E-19 FNR switch mode cannot be set or reset
E-19 FNR switch mode cannot be set or reset 1
Contents of
• FNR switch mode cannot be set or reset.
trouble
• The FNR switch mode selector switch system is abnormal.
(The FNR switch mode is not set (grounding fault), or the steering wheel mode is not set (disconnec-
Related tion).)
information • The state (ON/OFF) of the FNR switch mode selector switch can be checked with the monitoring func-
tion (Code: 40906, D-IN-15).
• Installation of the right FNR switch can be checked in the service mode of the monitor.

Defective FNR switch mode FNR switch mode
S04 (female) Resistance
selector switch selector switch
1
Between (5) and (6)
Constant Min. 1 Mz
chassis ground
Wiring harness between L63 (female) (39) and
ness Resistance Max. 1 z
2 S04 (female) (5)
(Disconnection or defective
Possible causes a Prepare with starting switch OFF, then turn starting switch ON and
contact of connector)
and standard carry out troubleshooting.
value in normal Between S04 (female) (6) and chassis ground Voltage 20 – 30 V
3 source (Contact with 24V
Defective transmission con- FNR switch mode
5 L63 Voltage
troller selector switch
40-400 66 WA470, 480-6

E-19 FNR switch mode cannot be set or reset SEN04531-01
WA470, 480-6 40-400 67

SEN04531-01 E-20 Fan reverse function cannot be used or reset
E-20 Fan reverse function cannot be used or reset 1
Contents of
• Fan reverse function cannot be used or reset.
trouble
• The fan reverse switch system is disconnected, shorted with the chassis ground, or shorted with the
power source.
Related
(The fan reverse operation cannot be turned ON (Disconnection or grounding fault). The fan reverse
information
operation cannot be turned OFF (Short circuit with power source).)
• If failure code [DW7BKA] or [DW7BKB] is displayed, carry out troubleshooting for it first.

1
S16 (male) Fan reverse switch Resistance
2 ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
Disconnection in wiring har- Wiring harness between L61 (female) (7) – S16
Resistance Max. 1 z
ness (Disconnection or (female) (6)
Possible causes 3
defective contact of con- a Prepare with starting switch OFF, then turn starting switch ON and
and standard
nector) carry out troubleshooting.
value in normal
state Wiring harness between S16 (female) (6) and
Voltage 20 – 30 V
chassis ground.
4 source (Contact with 24V
Between L61 (female) (7) – S16 (female) (6) wir-
ing harness and chassis ground
Between L61 (female) (7) – S16 (female) (6) wir-
ing harness and chassis ground
6 L61 Fan reverse switch Voltage
troller
Between (7) and chas- ON 20 – 30 V
sis ground OFF Max. 1 V
40-400 68 WA470, 480-6

E-20 Fan reverse function cannot be used or reset SEN04531-01
WA470, 480-6 40-400 69

SEN04531-01 E-21 Discharge from loader pump does not rise from minimum level
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).

Possible causes 1 source (Contact with 24V
Between L63 (female) (27) – R71 (female) (2)
and standard circuit) in wiring harness Voltage Max. 1 V
value in normal
state
Defective transmission con- out turning starting switch ON.
2
Wiring harness between (27) – (23) 5 – 10 z
40-400 70 WA470, 480-6

E-21 Discharge from loader pump does not rise from minimum level SEN04531-01
WA470, 480-6 40-400 71

SEN04531-01 E-22 ECSS function cannot be used or reset
E-22 ECSS function cannot be used or reset 1
Contents of
• ECSS function cannot be used or reset.
trouble
• The ECSS switch system is abnormal.
Related (The ECSS function cannot be used (grounding fault) or reset (short circuit with power source).)
information • The input state (ON/OFF) from the ECSS switch can be checked with the monitoring function (Code:
40905, D-IN-7).

1
Defective ECSS switch S07 (female) ECSS switch Resistance
2 (Internal disconnection or ON Max. 1 z
OFF Min. 1 Mz
Constant Min. 1 Mz
chassis ground
a Prepare with starting switch OFF, then start engine and carry out trou-
bleshooting.
ECSS cut-off pressure
Defective ECSS cut-off switch
pressure switch (Internal OFF
3 Min. 1 Mz
disconnection or short cir- (Other than below)
Between (1) and (2)
cuit) ON (Work equipment
Max. 1 z
lever at LOWER)
Constant Min. 1 Mz
chassis ground
Possible causes
and standard
value in normal Disconnection in wiring har- Wiring harness between L61 (female) (6) – F14 Resistance Max. 1 z
state ness (Disconnection or (female) (1)
4
defective contact of con- Wiring harness between F14 (female) (2) – S07
Resistance Max. 1 z
nector) (female) (5)
Wiring harness between S07 (female) (2) and
Resistance Max. 1 z
chassis ground
Short circuit with power
Wiring harness between L61 (female) (6) – F14
5 source (Contact with 24V Voltage Max. 1 V
(female) (1) wiring harness and chassis ground
circuit) in wiring harness
Between F14 (female) (2) – S07 (female) (5)
Voltage Max. 1 V
Wiring harness between L61 (female) (6) – F14
6 harness (Contact with Resistance Min. 1 Mz
(female) (1) wiring harness and chassis ground
ground circuit)
Between F14 (female) (2) – S07 (female) (5) or
Resistance Min. 1 Mz
(6) wiring harness and chassis ground
7 L61 ECSS switch Voltage
troller
Between (6) and chas- ON Max. 1 V
40-400 72 WA470, 480-6

E-22 ECSS function cannot be used or reset SEN04531-01
WA470, 480-6 40-400 73

SEN04531-01 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up
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
• The input signal (ON/OFF) (neutralizer signal) from the parking brake switch can be checked with the
monitoring function (Code: 40907, D-IN-23).

1 Defective parking brake Check the parking brake directly (See Testing and adjusting).
Parking brake oil
PB.PS (male) Resistance
pressure
Defective parking brake
Min. 0.6 MPa
2 indicator switch (Internal Max. 1 z
{6.1 kg/cm2}
Max. 0.34 MPa
Min. 1 Mz
{3.5 kg/cm2}
Constant Min. 1 Mz
chassis ground
3 harness (Contact with Resistance Max. 1 z
PB.PS (female) (1)
ground circuit)
Between PB.PS (female) (1) – L54 (female) (1)
Possible causes
and standard
value in normal L01 (male) Parking brake switch Resistance
state Defective parking brake ON Max. 1 z
Between (5) and (6)
4 switch (Internal short cir- OFF Min. 1 Mz
cuit) ON Min. 1 Mz
Between (3) and (4)
OFF Max. 1 z
Constant Min. 1 Mz
chassis ground
Defective parking brake PB.PS Resistance
5 solenoid (Internal short cir-
Between (male) (1) and (2) 10 – 40 z
cuit)
Between (female) (2) and chassis ground Max. 1 z
Between (male) (1) or (2) and chassis ground Min. 1 Mz
Defective emergency brake R52 (male) Brake oil pressure Resistance
6 pressure switch (Internal Min.4.41 MPa
Max. 1 z
short circuit) {45 kg/cm2}
Between (1) and (2)
Max.3.6 MPa
Min. 1 Mz
{37 kg/cm2}
40-400 74 WA470, 480-6

E-23 When parking brake is turned ON, parking brake indicator lamp does not light up SEN04531-01

bleshooting.
Possible causes
Parking brake oil
and standard L54 Voltage
pressure
value in normal 7 Defective machine monitor
state Min. 0.6 MPa
Max. 1 V
Between (1) and {6.1 kg/cm2}
chassis ground Max. 0.34 MPa
20 – 30 V
{3.5 kg/cm2}
WA470, 480-6 40-400 75

SEN04531-01 E-23 When parking brake is turned ON, parking brake indicator lamp does not light up
40-400 76 WA470, 480-6

E-23 When parking brake is turned ON, parking brake indicator lamp does not light up SEN04531-01
WA470, 480-6 40-400 77

SEN04531-01 E-24 When emergency brake operates, brake oil pressure caution lamp does not operate
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).

bleshooting.
R54 (male) Brake oil pressure Resistance
Defective brake accumula- Min. 5.88 MPa
Max. 1 z
1 tor pressure switch (Internal {60 kg/cm2}
Between (1) and (2)
short circuit) Max. 3.9 MPa
Min. 1 Mz
{40 kg/cm2}
chassis ground
and standard
value in normal Grounding fault in wiring out turning starting switch ON.
state 2 harness (Contact with
Between L53 (female) (7) – L102 (female) (9)
L53 (female) Brake oil pressure Resistance
3 Defective machine monitor Min. 5.88 MPa
Wiring harness Max. 1 z
{60 kg/cm2}
between (7) and
chassis ground Max. 3.9 MPa
Min. 1 Mz
{40 kg/cm2}
40-400 78 WA470, 480-6

E-24 When emergency brake operates, brake oil pressure caution lamp does not operate SEN04531-01
WA470, 480-6 40-400 79

SEN04531-01 E-25 Air cleaner clogging indicator lamp does not light up
E-25 Air cleaner clogging indicator lamp does not light up 1
Contents of
• Air cleaner clogging indicator lamp does not light up.
trouble
• The dust indicator circuit is abnormal.
• When the air cleaner is clogged, the sensor circuit is CLOSED (and the air cleaner is not judged
Related
clogged).
information
• The input signal (ON/OFF) from the dust indicator can be checked with the monitoring function (Code:
40902, D-IN-20).

1 Defective dust indicator Check the dust indicator visually.
Defective dust indicator out turning starting switch ON.
2 relay (Internal disconnec-
tion)
Between (1) and (2) 200 – 400 z
Possible causes
ness (Disconnection or Wiring harness between L53 (female) (3) – L112
value in normal defective contact of con- (female) (4)
state nector) a Wiring harness between L112 (female) (3)
Resistance Max. 1 z
and chassis ground
bleshooting.
L53 Dust indicator Voltage
4 Defective machine monitor Normal (Air cleaner is
Max. 1 V
Between (3) and not clogged)
chassis ground Defective (Air cleaner
20 – 30 V
is clogged)
40-400 80 WA470, 480-6

E-25 Air cleaner clogging indicator lamp does not light up SEN04531-01
WA470, 480-6 40-400 81

SEN04531-01 E-26 Radiator coolant level caution lamp does not light up
E-26 Radiator coolant level caution lamp does not light up 1
Contents of
• Radiator coolant level caution lamp does not light up.
trouble
• The coolant level sensor circuit is shorted or shorted with the chassis ground.
• When the radiator coolant level is low, the radiator coolant level caution lamp does not light up (the
Related
engine may be broken).
information
• The input signal (ON/OFF) from the coolant level sensor can be checked with the monitoring function
(Code: 40903, D-IN-27).

R32 (male) Sub-tank Resistance
Below LOW level
Defective coolant level sen- Min. 1 Mz
1 (Abnormal)
sor (Internal short circuit) Between (1) and (2)
Above LOW level
Max. 1 z
(Normal)
chassis ground
and standard
value in normal Grounding fault in wiring out turning starting switch ON.
state 2 harness (Contact with
Between L54 (female) (10) – R32 (female) (1)
L54 (female) Sub-tank Resistance
3 Defective machine monitor Below LOW level
Wiring harness Min. 1 Mz
(Abnormal)
between (10) and
Above LOW level
chassis ground Max. 1 z
(Normal)
40-400 82 WA470, 480-6

not light up SEN04531-01
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.
monitoring function (Code: 04401 HYD TEMP).

Defective hydraulic oil tem- Hydraulic oil
1 perature sensor (Internal temperature
defect) Normal temperature
35 – 50 kz
Between (1) and (2) (25°C)
100°C 3.1 – 4.5 kz
Possible causes
and standard Grounding fault in wiring out turning starting switch ON.
value in normal 2 harness (Contact with
Wiring harness between L55 (female) (7) – R47
state ground circuit) Resistance Max. 1 z
(female) (1)
Hydraulic oil
Wiring harness Normal temperature
35 – 50 kz
between (7) and (25°C)
chassis ground 100°C 3.1 – 4.5 kz
WA470, 480-6 40-400 83

SEN04531-01 caution lamp does not light up
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.

TC-T (male) Resistance
1 oil temperature sensor temperature
(Internal defect) Normal temperature
35 – 50 kz
Between (1) and (2) (25°C)
100°C 3.1 – 4.5 kz
Possible causes
TC-T (female) (1)
Wiring harness Normal temperature
35 – 50 kz
between (2) and (25°C)
chassis ground 100°C 3.1 – 4.5 kz
40-400 84 WA470, 480-6

caution lamp does not light up SEN04531-01
WA470, 480-6 40-400 85

SEN04531-01 E-29 Steering oil pressure caution lamp does not light up
E-29 Steering oil pressure caution lamp does not light up 1
Contents of
• Steering oil pressure caution lamp does not light up.
trouble
• The steering oil pressure sensor circuit is disconnected.
Related • While the steering oil pressure lowers, the steering oil pressure switch circuit is kept OPEN.
information • The input state (ON/OFF) from the steering oil pressure switch can be checked with the monitoring
function (Code: 40904. D-IN-39).

bleshooting.
Defective steering oil pres- R36 (male) Engine Resistance
1 sure switch (Internal dis- Stopped Max. 1 z
connection) Running Min. 1 Mz
Between (1) and (2)
Open to atmosphere
Max. 1 z
(Reference)
Possible causes
R36 (female) (2)
bleshooting.
L54 (female) Engine Resistance
3 Defective machine monitor Stopped Max. 1 z
Wiring harness
Running Min. 1 Mz
between (16) and
Open to atmosphere
chassis ground Max. 1 z
(Reference)
40-400 86 WA470, 480-6

E-29 Steering oil pressure caution lamp does not light up SEN04531-01
WA470, 480-6 40-400 87

SEN04531-01 E-30 Abnormality in t switch (panel switch 1) input
E-30 Abnormality in t switch (panel switch 1) input 1
Contents of
• Abnormality in t switch (panel switch 1) input
trouble
• The t switch (panel switch 1) circuit is disconnected or shorted with the chassis ground.
• While the t switch (panel switch 1) is turned ON, the input circuit is kept OPEN (the switch is kept
Related OFF).
information • The operator cannot operate the monitor (cannot enter the service mode and monitoring function).
• The input state (ON/OFF) from the t switch (panel switch 1) can be checked with the monitoring func-
tion (Code: 40901. D-IN-15).

1
Defective t switch (panel L07 (female) t switch (Panel switch 1) Resistance
2 switch 1) (Internal discon- ON Max. 1 z
nection or short circuit) Between (4) and (5)
Constant Min. 1 Mz
chassis ground
Possible causes
defective contact of con- (female) (4)
value in normal
nector) Wiring harness between L51 (female) (4) or (5)
– L07 (female) (5)
Wiring harness between L52 (female) (17) – L07
ground circuit)
Wiring harness between L51 (female) (4) or (5)
– L07 (female) (5) and chassis ground
5 Defective monitor panel L52 t switch (Panel switch 1) Voltage
40-400 88 WA470, 480-6

E-30 Abnormality in t switch (panel switch 1) input SEN04531-01
WA470, 480-6 40-400 89

SEN04531-01 E-31 Abnormality in U switch (panel switch 1) input
E-31 Abnormality in U switch (panel switch 1) input 1
Contents of
• Abnormality in U switch (panel switch 1) input
trouble
• The U switch (panel switch 1) circuit is disconnected or shorted with the chassis ground.
• While the U switch (panel switch 1) is turned ON, the input circuit is kept OPEN (the switch is kept
Related OFF).
information • The operator cannot operate the monitor (cannot enter the monitoring function).
• The input state (ON/OFF) from the U switch (panel switch 1) can be checked with the monitoring
function (Code: 40901. D-IN-14).

1
Defective U switch (panel L07 (female) U switch (Panel switch 1) Resistance
2 switch 1) (Internal discon- ON Max. 1 z
nection or short circuit) Between (5) and (5)
Constant Min. 1 Mz
chassis ground
Possible causes
defective contact of con- (female) (6)
value in normal
nector) Wiring harness between L51 (female) (4) or (5)
– L07 (female) (5)
Wiring harness between L52 (female) (8) – L07
ground circuit)
Wiring harness between L51 (female) (4) or (5)
– L07 (female) (5) and chassis ground
5 Defective monitor panel L52 U switch (Panel switch 1) Voltage
Between (8) and chas- ON 20 – 30 V
sis ground Other than above Max. 1 V
40-400 90 WA470, 480-6

E-31 Abnormality in U switch (panel switch 1) input SEN04531-01
WA470, 480-6 40-400 91

SEN04531-01 E-32 Abnormality in < switch (panel switch 2) input
E-32 Abnormality in < switch (panel switch 2) input 1
Contents of
• Abnormality in < switch (panel switch 2) input
trouble
• The < switch (panel switch 2) circuit is disconnected or shorted with the chassis ground.
• While the < switch (panel switch 2) is turned ON, the input circuit is kept OPEN (the switch is kept
Related OFF).
• The input state (ON/OFF) from the < switch (panel switch 2) can be checked with the monitoring func-
tion (Code: 40904. D-IN-38).

Defective < switch (panel out turning starting switch ON.
1 switch 2) (Internal discon- L08 (female) < switch (Panel switch 2) Resistance
nection or short circuit) ON
Between (4) and (5)
ness (Disconnection or out turning starting switch ON.
Possible causes 2
defective contact of con- Wiring harness between L54 (female) (7) – L08
and standard
nector) Resistance Max. 1 z
(female) (4)
value in normal
3
Voltage Max. 1 V
4 Defective monitor panel L54 < switch (Panel switch 2) Voltage
Between (7) and ON Max. 1V
40-400 92 WA470, 480-6

E-32 Abnormality in < switch (panel switch 2) input SEN04531-01
WA470, 480-6 40-400 93

SEN04531-01 E-33 Abnormality in > switch (panel switch 2) input
E-33 Abnormality in > switch (panel switch 2) input 1
Contents of
• Abnormality in > switch (panel switch 2) input
trouble
• The > switch (panel switch 2) circuit is disconnected or shorted with the chassis ground.
• While the > switch (panel switch 2) is turned ON, the input circuit is kept OPEN (the switch is kept
Related OFF).
• The input state (ON/OFF) from the > switch (panel switch 2) can be checked with the monitoring func-
tion (Code: 40904. D-IN-37).

Defective > switch (panel out turning starting switch ON.
1 switch 2) (Internal discon- L08 (female) > switch (Panel switch 2) Resistance
nection or short circuit) ON Max. 1 z
Between (5) and (6)
ness (Disconnection or out turning starting switch ON.
Possible causes 2
defective contact of con- Wiring harness between L54 (female) (15) – L08
and standard
nector) Resistance Max. 1 z
(female) (6)
value in normal
3
Voltage Max. 1 V
4 Defective monitor panel L54 > switch (Panel switch 2) Voltage
Between (15) and ON Max. 1V
40-400 94 WA470, 480-6

E-33 Abnormality in > switch (panel switch 2) input SEN04531-01
WA470, 480-6 40-400 95

SEN04531-01

©2009 KOMATSU
All Rights Reserved
40-400 96
SEN04532-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
500 Troubleshooting of hydraulic and

mechanical system (H-mode)
Method of using troubleshooting chart .....................................................................................................................3
Table of failure 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
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
WA470, 480-6 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04532-01
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
40-500 2 WA470, 480-6

Method of using troubleshooting chart SEN04532-01
Method of using troubleshooting chart 1
This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable cause. troubleshooting, put a check against the item.
Keeping the content of the questions in mind, a When carrying out the troubleshooting,
read the matrix and proceed with Step 2 and check the easier items first. It is not neces-
Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Ask the operator and check the following points. Remedys
No.
q Did the problem suddenly occur? Diagnosis
o Related equipment broken Steering does not turn in both directions (left
1
q Was the steering wheel heavy before? and right)
o Wear of related parts, defective seal Steering turns only in one direction (left or
2
right)
Step 2. Checks before troubleshooting Steering is heavy when turned in both direc-
q Before measuring the oil pressure or starting 3
tions (left and right)
the troubleshooting, confirm the checks before Steering wheel is heavy in one direction (left
starting items, check for leakage of oil, or for 4
or right)
loose bolts. This will prevent wasting time
5 Work equipment moves
when troubleshooting. The items given under
“Checks before troubleshooting” are checks
that are particularly important to make about 2. Find the matching cause in the Cause column.
the condition of the machine before starting the In the same way as in Step 2), if a problem is
actual troubleshooting. found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diag-
Example: Checks before starting troubleshoot- nosis item 2 in the same diagram below the
ing cause is (c) or (e).)
q Is oil level and type of oil in hydraulic tank cor- When there is one Q mark:
rect? Carry out troubleshooting for the other items
q Is there any oil leakage from steering valve or marked with Q in the same Cause column to
demand valve? check if the problem occurs, then make
q Is steering linkage adjusted properly? repairs.
When there are two Q marks:
Go to Step 3) to narrow down the cause.
3. Operate the machine and carry out trouble-

shooting of the items not checked in Step 1.
WA470, 480-6 40-500 3

SEN04532-01 Method of using troubleshooting chart
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. Find the matching cause in the Cause column. 7. Remedy

In the same way as in Step 2), if a problem is After narrowing down the common causes,
found, the Q marks on the same line for the take the action given in the remedy line.
troubleshooting item are the causes. (In Diag- Marks and remedies in remedy line
nosis item 5 in the diagram below the cause is ×: Replace E: Repair A: Adjust C: Clean
(b) or (e).)
5. Narrow down the causes.

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1) and Step 3).
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are (c) or (e), and the causes
in Diagnosis item 5 are (b) or (e), so
Cause (e) is the common cause.)
40-500 4 WA470, 480-6

WA470, 480-6 40-500 5

SEN04532-01 Table of failure and causes
Table of failure and causes 1
Clogging of torque converter charging pump strainer

Clogging or air intake on torque converter charging
Drop of transmission main relief valve set pressure

Defective operation of torque converter relief valve
Clogged or broken torque converter oil cooler
Parts that may case failures
Defective torque converter charging pump

Internal breakage of torque converter
Clogging of last chance filter

Defective regulator valve
The PTO is defective
pump suction side

Defective engine
Problem
Machine does not start Q Q Q Q Q Q Q Q

Torque converter lockup is not switched off (engine stalls) [Lockup clutch specification (if
equipped)]
Power train
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
Steering response is poor [Joystick steering specification (if equipped)] Q

Steering is heavy
Steering wheel shakes or makes large shocks
Steering wheel shakes or makes large shocks [Joystick steering specification (if equipped)]
Wheel brake does not work or braking force is low
Brake
Wheel brake does not reset or drag

Parking brake does not work or braking force is low
The parking brake is not released or it drags (including emergency release system)
Lift arm does not rise Q
Lift arm speed is low or rising force of lift arm is insufficient
When lift arm rises, its speed lowers at specific height
The lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drift of lift arm is large
Lift arm shakes during operation
Bucket does not tilt Q
Work equipment
Bucket speed is low or tilt-back force is insufficient

Bucket speed goes low during tilt-back operation
Bucket cannot be held with bucket cylinder
Hydraulic drift of bucket is large
Bucket shakes during travel with load (Work equipment valve is in HOLD)
Lift arm and bucket control levers do not move smoothly and they are heavy
Large engine speed reduction or engine stall occurs during work equipment control Q
Large shock is made when work equipment starts and stops
When work equipment is relieved singly, other work equipment moves
ECSS does not operate, allowing pitching or bouncing to occur
40-500 6 WA470, 480-6

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
WA470, 480-6
Defective clutch piston
The relevant clutch piston seal is defective
Q Q
Q Q Q
Q Q
Q Q
Defective seal of relevant clutch shaft
Table of failure and causes
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
Defective fan pump

Q Q
Q Q
Q Q
Q Q
Clogging or air intake on fan pump suction side

Air in wheel brake circuit
Q
Q Q Q Q
Defective brake valve
40-500
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
SEN04532-01
SEN04532-01 Table of failure and causes
Defective operation of check valve (between last chance filter

Gas leakage from accumulator, defective seal of piston
Damages on parking brake switch line wiring harness
Defective operation of parking brake solenoid valve

Defective parking brake emergency release valve
Parts that may case failures
Defective accumulator charge valve
Defective parking brake spring

and parking brake solenoid)
Problem
Machine does not start Q Q Q

Torque converter lockup is not switched off (engine stalls) [Lockup clutch specification (if equipped)]
Power train
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
Steering response is poor [Joystick steering specification (if equipped)] Q

Steering is heavy Q
Steering wheel shakes or makes large shocks Q
Steering wheel shakes or makes large shocks [Joystick steering specification (if equipped)] Q
Wheel brake does not work or braking force is low Q Q
Brake
Wheel brake does not reset or drag

Parking brake does not work or braking force is low Q Q Q
Parking brake cannot be reset or it drags Q Q Q
Lift arm does not rise Q
Lift arm speed is low or rising force of lift arm is insufficient Q
When lift arm rises, its speed lowers at specific height
The lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drift of lift arm is large
Lift arm shakes during operation
Bucket does not tilt Q
Work equipment
Bucket speed is low or tilt-back force is insufficient Q

Bucket speed lowers during tilt-back operation Q
Bucket cannot be held with bucket cylinder
Hydraulic drift of bucket is large
Bucket shakes while machine is traveling with load (Work equipment valve is in HOLD)
Lift arm and bucket control levers do not move smoothly and are heavy
Engine speed lowers remarkably or engine stalls during work equipment control
Large shock is made when work equipment starts and stops
When work equipment is relieved singly, other work equipment moves
ECSS. does not operate, and pitching or bouncing occurs Q
40-500 8 WA470, 480-6

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
WA470, 480-6
Q
Q
Q
Q
Q
Q
Q
Q
Q
Clogging or air intake on work equipment pump suction side
Q
Defective work equipment controller
Table of failure and causes
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
Defective safety-suction valve on bucket head side of work
Q
Q
equipment valve
Defective safety-suction valve on bucket bottom side of work
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
40-500
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
SEN04532-01
SEN04532-01 H-1 The machine does not start
H-1 The machine does not start 1
Ask the operator about the following ques- Causes

tions.
Parking brake emergency

q Has the machine come not to start sud-
Torque converter
Torque converter
Main relief valve

charging pump
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?
Testing before troubleshooting

q Does the machine monitor function nor- a b c d e f g h i j k l m n o p q
mally?
(between last chance filter and parking brake solenoid)

q Is any failure code of the electrical system
Defective operation of parking brake solenoid valve

displayed on the machine monitor?
q Are the transmission oil level and the oil type
Defective operation of spool of parking brake

appropriate?

q Did you smell deteriorated or burnt transmis-

Drop of main relief valve set pressure

Clogging or air intake on suction side
sion oil?
Defective operation of check valve

Wear or seizure of relevant clutch
q Haven't the transmission filter and strainer The charging pump is defective
been clogged?
emergency release valve

q Can you find any damage or oil leak from
the appearance?
Clogging of strainer
q Has the drive shaft been broken?

q Have the wheel brake and the parking brake
been locked?
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).”
40-500 10 WA470, 480-6

H-1 The machine does not start SEN04532-01
* Defective clutch and ECMV specifying method (Check by

failure code)
a For the checking method of failure code display, see the
paragraph of “Special functions of machine monitor (EMMS)”
of section Testing and adjusting.
a When replacing the ECMV for troubleshooting, remove mud
and dust around the ECMV completely and clean it, and then Causes
tighten the mounting bolt with the specified torque. Transmission ECMV
a For the following diagnoses, start the engine and select the a b c d e f g h i j k l
manual mode:
Clutch
Table of Applicable Clutches
F R 1st 2nd 3rd 4th
q
Wear or seizure of 2nd clutch disc or wear of piston seal

In the automatic mode
Wear or seizure of 3rd clutch disc or wear of piston seal

Wear or seizure of 4th clutch disc or wear of piston seal
Wear or seizure of 1st clutch disc or wear of piston seal
N
Wear or seizure of R clutch disc or wear of piston seal

Wear or seizure of F clutch disc or wear of piston seal
In the manual mode Q Q Q Q
Defective operation of 2nd clutch ECMV (Fill switch)

Defective operation of 3rd clutch ECMV (Fill switch)
Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
Defective operation of R clutch ECMV (Fill switch)
Defective operation of F clutch ECMV (Fill switch)
F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q
a When the gear speed is N in the manual mode, the clutch of

the gear speed (Marked with Q), to which the gear shift lever
is set, is ON.
q Even if the gear shift lever is used when the gear speed is N,
the clutch position can not be changed.
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, 480-6 40-500 11

H-2 Torque converter lockup is not switched off (engine stalls) [Machine with lockup clutch (if
SEN04532-01 equipped)]
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
Defective operation of lockup clutch ECMV
Wear or seizure of lockup clutch disc

Remedy
No. x x
Diagnosis
1 Lockup oil pressure does not drop to 0 Q
2 Lockup cannot be turned off even when the lockup oil pressure is 0 Q
40-500 12 WA470, 480-6

H-3 Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)] SEN04532-01
H-3 Torque converter lockup is not switched on [Machine with lockup

clutch (if equipped)] 1
Ask the operator about the following: Cause

q Has the lockup come not to turn on suddenly? a b c d e f g
o Seizure or breakage inside torque converter
Drop of transmission main relief valve set pressure

q Did any abnormal noise occur at the time? o Breakage of parts
Defective operation of lockup clutch ECMV

Checks before troubleshooting
q Is the oil level of transmission case appropriate?
Defective seal of lockup clutch piston

Wear or seizure of lockup clutch disc
q Is there any external oil leakage?
Defective seal of lockup clutch shaft

Check of abnormality

Crack on lockup clutch case
q Main relief oil pressure
q Lockup oil pressure
q Travel speed
Remedy E
No. x x x x C x
Diagnosis x
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 Q
WA470, 480-6 40-500 13

H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the
SEN04532-01 gear is not shifted
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
Main relief valve

charging pump
o Breakage of related equipment
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
Checking for abnormalities

a b c d e f g h i j k l m n o p q r
q Execute digging and measure traveling speeds on a
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
Breakage of oil cooler and pipe (After torque converter outlet)

q Is any failure code of the electrical system displayed
Clogging of oil cooler and pipe (After torque converter outlet)

on the machine monitor?
q Are the transmission oil level and the oil type appropri-
ate?

q Haven't the transmission filter and strainer been
clogged?
(Mixing of hydraulic oil in transmission case)

Clogging or air intake on pump suction side

q Is any external oil leak found on the mating faces of

pipes and valves around the torque converter and the


transmission?

q Isn't the wheel brake or the parking brake being
The charging pump is defective
Oil leak inside torque converter

dragged?

q Are the tire air pressure and the tread shape appropri-
ate?
Clogging of breather
q Is the operating method correct?
Note Engine degradation

NOTE: When the inspection result was “Engine degrada-

tion,” proceed to Troubleshooting of engine (S
mode).
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.)
40-500 14 WA470, 480-6

H-4 The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and the
gear is not shifted SEN04532-01

failure code)
Causes
and dust around the ECMV completely and clean it, and then
Transmission ECMV
tighten the mounting bolt with the specified torque.
manual mode:
Clutch
F R 1st 2nd 3rd 4th
q


N


F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA470, 480-6 40-500 15

SEN04532-01 H-5 Shocks are large at the times of starting and shifting gear
H-5 Shocks are large at the times of starting and shifting gear 1

q Did shocks become large suddenly?
Torque converter
Main relief valve

charging pump
Parking brake
Transmission
Sensors
ECMV
q Did shocks become large gradually?
Testing before troubleshooting a b c d e f g h i j k l

q Did any of the following abnormal phenomena occur at the same
Defective return (Release) of relevant clutch piston

time?: The traveling speed is slow, the braking is weak, the uphill
travelling power is weak, the gear is not shifted. o Execute H-4


Defective operation of relevant ECMV a
Defect of transmission controller system
Defective operation of main relief valve

q Is any failure code of the electrical system displayed on the
machine monitor?

q Are the transmission oil level and the oil type appropriate?

q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipes and
valves around the torque converter and the transmission?
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 “Troubleshooting of transmission controller system” of Troubleshooting by
failure code (Display of code).
***: Proceed to the paragraph of “Troubleshooting by failure code (Display of code), code [DGF1KA] and
code [DGF1KB]”.
40-500 16 WA470, 480-6

H-5 Shocks are large at the times of starting and shifting gear SEN04532-01

failure code)
Causes
Transmission ECMV
manual mode:
Clutch
F R 1st 2nd 3rd 4th
q


N


F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA470, 480-6 40-500 17

SEN04532-01 H-6 Time lag is large at the times of starting and shifting gear
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
Torque converter
Main relief valve

charging pump
Parking brake
Transmission
Sensor
q Has the time lag become large gradually?
ECMV
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

power is weak, the gear is not shifted. o Execute H-4

Defective operation of relevant ECMV a

q Is any failure code of the electrical system displayed on the machine
monitor?

q Are the transmission oil level and the oil type appropriate?

q Haven't the transmission filter and strainer been clogged?
q Is any external oil leak found on the mating faces of pipings and valves
around the torque converter and the transmission?
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 “Troubleshooting by failure code (Display of code), code [DGF1KA] and
code [DGF1KB]”.
40-500 18 WA470, 480-6

H-6 Time lag is large at the times of starting and shifting gear SEN04532-01

failure code)
Causes
Transmission ECMV
manual mode:
Clutch
F R 1st 2nd 3rd 4th
q


N


F1 q q
F2 q q
Gear Speed
F3 q q
F4 q q
R1 q q
R2 q q
R3 q q
R4 q q

is set, is ON.
Remedy Failure
Diagnosis code
1
2
ECMV
clutch ECMV
ECMV
ECMV
WA470, 480-6 40-500 19

SEN04532-01 H-7 The torque converter oil temperature is high
H-7 The torque converter oil temperature is high 1

q Does the oil temperature rise when the torque converter
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
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
Defective seal of work equipment and steering

q Measure the torque converter oil temperature to find if
(Mixing of hydraulic oil in transmission case)

the oil temperature is really high.
o The torque converter oil temperature gauge is defective


Breakage of oil cooler and pipe
Oil leak inside torque converter

Clogging of oil cooler and pipe
(After torque converter outlet)
(After torque converter outlet)

q Are the coolant level in the radiator and the fan belt ten-
system hydraulic pump shaft

sion appropriate?
q Are the oil level in the transmission and the oil type
Clogging of breather
appropriate?
Note Engine degradation

q Haven't the transmission filter and strainer been
clogged?
NOTE:When the inspection result was “Engine degradation,”
proceed to Troubleshooting of engine (S mode).
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.)
40-500 20 WA470, 480-6

H-8 Steering does not turn SEN04532-01
H-8 Steering does not turn 1

Did the problem suddenly start? o Breakage of related equipment
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
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?
Defect in steering cylinder (defective piston seal)

Defective actuation of steering spool

Malfunction of flow control spool

Defective brake pump
Defective stop valve

Remedy E EEEEEEE
No. E x x
Diagnosis x x x x x x x x
1 Steering does not turn in both directions (left and right) Q Q Q Q Q Q Q Q Q
2 Steering turns only in one direction (left or right) Q Q
3 Steering is heavy when turned in both directions (left and right) Q Q Q Q
4 Steering wheel is heavy in one direction (left or right) Q
5 Work equipment moves 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 fan pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in both
9 Q Q Q Q Q Q Q Q Q
When steering relief directions (left and right)
pressure is measured Oil pressure is low or there is no oil pressure in one
10 Q Q
direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be low or
11 Q Q Q Q Q
there is no oil pressure
12 When Orbit-roll basic Oil pressure is low Q Q Q Q
13 pressure is measured There is no oil pressure Q Q Q
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, 480-6 40-500 21

SEN04532-01 H-9 Steering does not turn [Machine with joystick steering (if equipped)]
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
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?

q Is the steering shaft broken?
a b c d e f g h i j k l m
q Is the steering stop valve properly adjusted?

q Has the lock bar been removed from the frame?
q Is the connect of the connector of joystick steering ON/OFF
switch correct?

Air sucked in at suction end of pump


Malfunction of stop valve
Defective fan pump
Clogged line filter
Remedy E EEEE C EEE
No. E 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
11 Abnormal noise comes from around fan pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in
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
40-500 22 WA470, 480-6

H-10 Steering response is poor SEN04532-01
H-10 Steering response is poor 1

q Did the problem suddenly start? Causes
Hydraulic cylinder
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
where?
q Did the problem gradually appear?
o Wear of related parts, defective seal

a b c d e f g h i j k l



Defective main relief valve
Defective steering spool


Remedy E EEEEEEEE E
No. E x
Diagnosis x x x x x x x x x x
Turning, response of steering wheel is poor in both directions (left and
1 Q Q Q Q Q Q Q Q Q Q
right)
2 Turning, response of steering wheel is poor in one direction (left or right) Q Q
3 Steering wheel is heavy in both directions (left and right) Q Q Q
5 Work equipment moves Q Q Q Q Q Q Q Q Q
6 Work equipment does not move Q Q Q
8 Abnormal noise comes from around steering pump or hydraulic tank Q Q
Oil pressure is low or there is no oil pressure in
9 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
10 Q Q
one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be
11 Q Q Q Q
When Orbit-roll basic pressure is measured, oil pressure is found to be
12 Q Q Q
When steering pump servo assembly is replaced, oil pressure is found to
13 Q
be normal
WA470, 480-6 40-500 23

SEN04532-01 H-11 Turning, response of steering is poor [machine with joystick steering (if equipped)]
H-11 Turning, response of steering is poor [machine with joystick

steering (if equipped)] 1
Hydraulic cylinder
q Did the problem suddenly start?
Joystick steering
Steering pump
solenoid valve
Steering valve
Charge valve
Stop valve
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





Defective fan pump
Remedy EClogged line filter

EEEE C EEEE E
No. E x x
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
8 Abnormal noise comes from around hydraulic tank Q Q
Oil pressure is low or there is no oil pressure
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.
40-500 24 WA470, 480-6

H-12 Steering is heavy SEN04532-01
H-12 Steering is heavy 1
Check of abnormality Causes

Is the steering difficult to turn? o See H-8 or H-9
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.

a b c d e f
q Did the problem suddenly start? o Breakage of related equipment broken
Defective actuation of steering wheel or steering shaft

q Was there previously any symptom that may lead to heavy steering?
o Wear of steering related parts, defective seal

q Is the tire inflation pressure correct?


Defective fan pump
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
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, 480-6 40-500 25

SEN04532-01 H-13 When machine turns, it shakes or makes large shocks
H-13 When machine turns, it shakes or makes large shocks 1

q Is the steering difficult to turn? o See H-8 Causes
q Is there any abnormal noise from around the steering equipment?
Hydraulic pump
Steering valve
Charge valve
Stop valve
Orbit-roll
Cylinder
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 fan pump
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)
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
40-500 26 WA470, 480-6

H-14 When machine turns, it shakes or makes large shocks [machine with joystick steering (if
equipped)] SEN04532-01
H-14 When machine turns, it shakes or makes large shocks [machine

with joystick steering (if equipped)] 1
Checking for abnormalities Causes

Is the steering difficult to turn? o See H-9
Joystick steering solenoid valve

q
q Is there any abnormal noise from around the steering equipment
Hydraulic pump
Steering valve
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
Malfunction of the joystick steering solenoid valve


Malfunction of stop valve
Defective fan pump
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
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)
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, 480-6 40-500 27

SEN04532-01 H-15 The wheel brake does not work or does not work well
H-15 The wheel brake does not work or does not work well 1

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

q Is the hydraulic oil level appropriate? a b c d e f g h i j
Defective seal of accumulator piston, insufficient gas pressure

q Is the play of brake pedal appropriate?
q Oil leak from brake tube and connector and deformation of tube
Metal contact due to complete wear of brake disc in axle

q Tire air pressure and state of tire tread

q Test the effectiveness of the brake referring to “Measuring brake perfor-
mance” in “Testing and adjusting” to check whether the abnormality actu-
Defective operation of brake piston in axle
Wear or abnormality of brake disc in axle

ally occurs or is a matter of operator's sense
Defective seal of brake piston in axle

Defective operation of charge valve
The brake in axle is defective
Mixing of air in brake circuit

Defective brake valve
Defective fan pump
Remedy E E E E E E E E E
No. E
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
40-500 28 WA470, 480-6

H-16 The wheel brake is not released or it drags SEN04532-01
H-16 The wheel brake is not released or it drags 1
Testing before troubleshooting Causes
Wheel brake
q Has the brake pedal returned completely?
Brake valve
q Is the parking brake released completely?

q Abnormal heat of brake
a b c
q Does the machine travel smoothly by inertia on a level ground?
Defect inside brake valve (Sticking of piston)
Defective operation of brake piston in axle

Abnormal lining of brake in axle
Remedy E E E
No.
Diagnosis x x x
1 The brake pedal is released, but the brake is still applied Q Q Q
When the brake pedal is released, oil is drained from the air bleeder, the circuit pressure drops and the
2 Q
brake is released
The four wheels are jacked up, the axle is placed on a table, the engine is stopped, the parking brake is
3 Q Q
released and the tires are rotated by hand but a specific tire hardly rotates
WA470, 480-6 40-500 29

SEN04532-01 H-17 The parking brake does not work or does not work well
H-17 The parking brake does not work or does not work well 1

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?
Checks before troubleshooting a b c d e

q Isn't the parking brake emergency release switch turned ON?
Defective parking brake emergency release valve

q Hasn't the mechanical release of parking brake performed?

Defective parking brake solenoid valve
Defective parking brake spring
Wear of parking brake disc

Remedy E E
No. x x x
Diagnosis x x
1 The parking brake is not applied even if the engine stops Q Q Q
2 When wear of parking brake disc is checked, the disc thickness is lower than standard value Q
With the parking brake switch ON, there is no oil pressure
3 When the parking brake inlet pressure (Normal) Q Q
is measured
4 With the parking brake switch ON, there is oil pressure Q Q Q
With the parking brake switch ON, there is no oil pressure
5 When the parking brake solenoid valve (Normal) Q Q
output pressure is measured
6 With the parking brake switch ON, there is oil pressure Q
40-500 30 WA470, 480-6

H-18 The parking brake is not released or it drags (including emergency release system) SEN04532-01
H-18 The parking brake is not released or it drags (including emergency

release system) 1
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
Insufficient oil level due to defect of transmission valve

Damages on parking brake switch line wiring harness
Pinching due to peeling of parking brake disc
Defect inside parking brake solenoid valve
Remedy E E EE
No. E
Diagnosis x x x x
1 When the parking brake switch is off, the parking brake is not released Q Q Q Q Q
2 When the parking brake switch is off, the brake is not applied even if the engine stops Q
3 When the parking brake switch is on, the parking brake does not work well Q Q
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, 480-6 40-500 31

SEN04532-01 H-19 Lift arm does not rise
H-19 Lift arm does not rise 1
Ask the operator about the following. Causes

q Did the lift arm stop suddenly?
Work equipment valve

o Seizure or breakage of each component
Did abnormal sound come out when the lift arm stopped? (From
Tank – Pump
PPC valve
Cylinder
what part)
q Has the speed lowered? o Wear of parts and fatigue of springs

q Is the oil level in the hydraulic tank proper?
q Is the stroke of the lift arm control lever proper?
q Is the engine speed proper? a b c d e f g h i j k l
Malfunction of lift arm pressure compensation valve

Internal breakage of valve body (lift arm spool)
Damaged lift arm cylinder piston seal

Malfunction of main relief valve

Malfunction of unload valve
Malfunction of relief valve
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
40-500 32 WA470, 480-6

H-20 Lift arm speed is low or rising force of lift arm is insufficient SEN04532-01
H-20 Lift arm speed is low or rising force of lift arm is insufficient 1

q Is the stroke of the lift arm control lever proper?

q Is the engine speed proper?
q Is the work equipment linkage bushing normal (Is abnormal
Bypass valve
Tank – Pump
PPC valve
Cylinder
sound made)?

q The troubles of the rising force and rising speed are
strongly related to each other. The rising speed lowers first.
Measure the lift arm rising speed while it is loaded and
check abnormality with the standard values table. a b c d e f g h i j k l m n o
Internal wear or breakage of valve body (lift arm spool)

Malfunction of bucket pressure compensation valve
Damaged lift arm cylinder piston seal

Malfunction of back pressure valve
Malfunction of ECSS charge valve

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
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
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, 480-6 40-500 33

SEN04532-01 H-21 When rising, the lift arm comes to move slowly at specific height
H-21 When rising, the lift arm comes to move slowly at specific height 1

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.”

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder head side of work equipment valve
q Oil leakage from seal of lift arm cylinder piston
q Defective stroke of lift arm EPC lever (if equipped)
H-23 Hydraulic drift of the lift arm is large 1

q Have hydraulic drifts come to be large suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to be large gradually? o Wear of parts
q Is the lift arm spool at the neutral position? o The spool detent is defective.
q Check the hydraulic drift of the lift arm with the standard values table.
Cause
q Oil leakage in lift arm cylinder
q Imperfect fitting of lift arm spool
H-24 The lift arm wobbles during operation 1
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the HOLD position.
Diagnosis and Cause
Check at first the hydraulic drift and if the lift arm cylinder can lift the machine.
1. When the hydraulic drift is more than the standard value, see “H-23 Hydraulic drifts of the lift arm is
large.”
2. When the lift arm cylinder cannot lift the machine, see “H-22. The lift arm cylinder cannot hold down the
bucket (bucket floats).”
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vac-
uum generated inside the cylinder.
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder head side is defective.
40-500 34 WA470, 480-6

H-25 Bucket does not tilt back SEN04532-01
H-25 Bucket does not tilt back 1
Ask the operator about the following. Causes

q Did the bucket stop suddenly?

o Seizure or breakage of each component
Did abnormal sound come out when the lift arm stopped?
Tank – Pump
PPC valve
Cylinder
(From what part)
q Has the speed lowered?
o Wear of parts and fatigue of springs

q Is the oil level in the hydraulic tank proper?
q Is the stroke of the bucket control lever proper? a b c d e f g h i j k l m n
Malfunction of bucket bottom suction valve (suction safety valve)

Malfunction of bucket bottom safety valve (suction safety valve)
q Has the machine monitor displayed any failure code?
o See Troubleshooting by Failure Code (Display of code)

Internal breakage of valve body (bucket spool)
Damaged bucket cylinder piston seal


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
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, 480-6 40-500 35

SEN04532-01 H-26 Bucket speed is low or tilting back force is insufficient
H-26 Bucket speed is low or tilting back force is insufficient 1

q Is the stroke of the bucket control lever proper?

q Is the work equipment linkage bushing normal (Is abnor-
Tank – Pump
PPC valve
Cylinder
mal sound made)?

q Check by actual operation that the tilting back force is
insufficient.
q Measure the operating speed of the bucket and check it
with the standard values table. a b c d e f g h i j k l m n o p
Malfunction of bucket bottom suction valve (suction safety valve)

Malfunction of bucket bottom safety valve (suction safety valve)
Malfunction and defective adjustment of main relief valve

Internal breakage of valve body (bucket spool)

Damaged bucket cylinder piston seal

Malfunction of ECSS charge valve
Malfunction back pressure valve

Defective fan pump
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
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.
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
40-500 36 WA470, 480-6

H-27 The bucket comes to operate slowly in the midst of tilting-back SEN04532-01
H-27 The bucket comes to operate slowly in the midst of tilting-back 1

q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see “H-26 Bucket speed is low or tilting back
force is insufficient.”
H-28 The bucket cylinder cannot hold down the bucket 1
See “H-26. The bucket moves slowly or the tilting back force is insufficient.”
q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of suction safety valve on the bucket cylinder head side of work equipment valve
q Oil leak from bucket cylinder piston seal
q Defective stroke of bucket EPC lever (if equipped)
H-29 Hydraulic drift of the bucket is large 1

q Have hydraulic drifts come to be large suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to be large gradually? o Wear of parts
q Is the bucket spool at the neutral position? o The spool detent is defective
q Refer to the standard value table and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of suction safety valve on the bottom side
q Improper oil tight of bucket spool
H-30 The bucket wobbles during travel with cargo (The work equipment
valve is set to “HOLD”) 1

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, 480-6 40-500 37

SEN04532-01 H-31 Lift arm and bucket control levers do not move smoothly and are heavy
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
Improper roundness between PPC valve body and spool

Improper clearance between PPC valve body and spool
Foreign matter pinched in PPC valve spool

The PPC valve spool is bent
Remedy EE C
No. x
Diagnosis x x E
1 When the machine is loaded and the oil pressure rises, the levers come not to move smoothly Q Q
2 The levers come not to move smoothly as the oil temperature rises Q Q
The levers totally come not to move smoothly during operation irrespective of oil pressure and oil tem-
3 Q Q
perature
40-500 38 WA470, 480-6

H-32 During operation of the machine, engine speed lowers remarkably or engine stalls SEN04532-01
H-32 During operation of the machine, engine speed lowers remarkably

or engine stalls 1

Is the working equipment main relief pressure normal?
Cause
q Defective work equipment pump servo
q Defective working equipment pump unit
q Defective working equipment pump servo EPC input voltage
q Defective engine system
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)
H-34 When work equipment circuit is relieved singly, other work

equipment moves 1
Cause
q Pressure is not released properly from main spool of moving equipment o Replace main spool
WA470, 480-6 40-500 39

SEN04532-01 H-35 ECSS does not operate, and pitching, bouncing occur
H-35 ECSS does not operate, and pitching, bouncing occur 1

Did pitching, bouncing occur suddenly? o Breakage of related equipment
Solenoid valve
q
Accumulator
Controller
Sensor
q Has pitching, bouncing occurred gradually? o Wear of related equipment, defective seal

q Is the state of ECSS switch proper? a b c d
Defective transmission output shaft speed sensor

Defective operation of work equipment controller
Gas leakage from accumulator, defective seal
Defective ECSS solenoid valve
Remedy A
No. x x x
Diagnosis x
1 The ECSS actuation speed (5 km/h) largely fluctuates Q Q
2 The ECSS does not operate under no load Q Q
3 When the ECSS operates under load, the lift arm lowers the maximum distance (30 cm or more) Q
4 The ECSS does not operate at all Q Q Q Q
40-500 40 WA470, 480-6

H-35 ECSS does not operate, and pitching, bouncing occur SEN04532-01
WA470, 480-6 40-500 41

SEN04532-01

©2009 KOMATSU
All Rights Reserved
40-500 42
SEN04533-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
600 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
S-16 Vibration is excessive ........................................................................................................................... 26
WA470, 480-6 40-600 1

SEN04533-01
40-600 2 WA470, 480-6

Method of using troubleshooting chart 1
The troubleshooting chart consists of “questions”, “check items”, “causes”, and “troubleshooting” blocks.
The “questions” and “check items” narrow down the causes to highly probable “causes” by simple inspection
or from symptoms without using a diagnostic tool.
Then, the final verifications of “causes” are carried out by checking the narrowed down “causes” in the order
of their probability with diagnostic tools or by direct inspection following the “troubleshooting” procedure.
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.
This troubleshooting chart marks the content of the

questions and check items with E, Q or w accord-
ing to their closer relationship with the causes.
E : A cause that can be referred to in relation to
the question or check item.
Q : A cause that is related to the question or check
item.
w : A cause particularly probable among those
marked with Q above.
a Count the priority level of each marking as w >
Q when determining the cause.
Don't count E when determining the cause.
The item with this marking may be counted,
however, if no difference is present than this
and the cause cannot be determined.
WA470, 480-6 40-600 3

SEN04533-01 Method of using troubleshooting chart
<Example of troubleshooting> Exhaust smoke is black (incomplete combustion)

Let us now assume that a defect, “Color of exhaust smoke is black” occurs, the [questions] and [check items]
are implemented, and the following 3 symptoms corresponds: [Color of exhaust gas gradually became
black.], [Power was lost gradually.] and [Red dust indicator is displayed.].
40-600 4 WA470, 480-6

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, 480-6 40-600 5

SEN04533-01 S-1 Starting performance is poor.
S-1 Starting performance is poor. 1
General causes why starting performance is poor Cause
Cracked EGR cooler (Coolant in exhaust piping)

q Defective electrical system
q Insufficient supply of fuel
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
q Insufficient intake of air
Defective alternator (generator section)

Defective alternator (regulator section)
q Improper selection of fuel
Stuck, seized supply pump plunger
Defective intake air heater system

q Coolant in exhaust piping
Defective or deteriorated battery

Clogged feed pump gauze filter
a The common rail fuel injection system (CRI) recog-
Clogged air cleaner element
Clogged fuel filter, element

nizes the fuel injection timing electrically. Accordingly,
Worn piston ring, cylinder

even if the starting operation is carried out, the engine
may not start until the crankshaft revolves 2 turns at
Defective injector
maximum. This phenomenon does not indicate a trou-
ble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E E E
Became worse gradually Q Q w w Q Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q Q

Replacement of filters has not been carried out according to Operation and Main-
w w w Q Q
tenance Manual
Engine oil must be added more frequently w
When engine is preheated or when temperature is low, preheating monitor does
w
not indicate normally
During operation, charge level monitor indicates abnormal charge w w
Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q Q
Starting motor cranks engine slowly Q w
If air bleeding plug of fuel filter is removed, fuel does
w w
While engine is cranked not flow out
with starting motor If spill hose from injector is disconnected, little fuel
Check items
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
Inspect air cleaner directly q

When EGR cooler outlet gas pipe is removed, coolant mixed with antifreeze
q
flows out (*1)
When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Inspect gauze filter of feed pump directly q

Carry out troubleshooting by failure code “Loss of pressure feed from supply
q
pump (*2)”
When a cylinder is cut out for reduced cylinder mode operation, engine speed
q
does not change with some cylinders
When starting switch is turned to HEAT, intake air heater mount does not become
q
warm
Is voltage 20 – 30 V between alternator terminal R and terminal E Yes q
with engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are
q
low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
40-600 6 WA470, 480-6

S-1 Starting performance is poor. SEN04533-01
*1: EGR cooler outlet gas piping

Loosen 4 mounting bolts (1) of gas piping to EGR cooler outlet and check the flowout of coolant.
Condensed water from cooled exhaust gas may come out in small quantity but it poses no problem if col-
orless and transparent.
*2: Troubleshooting by failure code (Display of code), Code [CA559], and Code [CA2249]
WA470, 480-6 40-600 7

SEN04533-01 S-2 Engine does not start
S-2 Engine does not start 1
a) Engine does not crank Cause
Cracked EGR cooler (coolant mixing in the exhaust)

General causes why engine does not turn
Seizure inside engine
Defective starting motor (Safety relay section)

q
o See the troubleshooting for “S-4 Engine stops during opera-
Defective starting motor (Motor section)

tions”.
Defective battery terminal connection

q Coolant mixing inside cylinder causing water hammer
Defective wiring of starting circuit

q Electrical system is not normal

q Defective drive unit on applicable machine side
Damaged flywheel ring gear

o Carry out troubleshooting on applicable machine side
Defective starting switch

Defective battery relay
Check recent repair history
Questions
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
Speed of rotation is low Q w

When starting switch is set Makes grating noise w w
to START, the starting pin-
ion comes out, but Soon disengages pinion again w
Makes rattling noise and does not turn w Q Q w
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
There is no voltage (20 – 30 V) between battery relay

q
terminal B and terminal E
Turn the starting switch When terminal B and terminal C of starting switch are
q
OFF, connect the cord, then connected, engine starts
turn starting switch ON and When the safety relay outlet terminal B and terminal C
carry out troubleshooting q
are connected, engine starts
When the safety relay outlet terminal B and terminal C
q
are connected, engine does not start
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
40-600 8 WA470, 480-6

S-2 Engine does not start SEN04533-01

WA470, 480-6 40-600 9

SEN04533-01 S-2 Engine does not start
b) Engine turns but no exhaust smoke comes out Cause
Defective operation of overflow valve (not closing)

General causes why engine turns but no exhaust smoke
comes out
Clogged air breather hole in fuel tank cap

q Fuel is not being supplied
Seizure or abnormal wear of feed pump
Wrong connection of supply pump PCV

q Supply of fuel extremely small
Stuck or seized supply pump plunger

Leakage, clogging, air in fuel piping
Defective operation of flow damper

q Improper selection of fuel (particularly in winter)
Broken supply pump shaft, key
Defective supply pump PCV

Clogged fuel filter element
Insufficient fuel in tank
Defective fuel injector

Improper fuel used
Degree of machine
Questions
Machine operated for long period EEE

operation
Exhaust smoke suddenly stops coming out (when starting again) w Q w w w EE
Replacement of filters has not been carried out according to Operation
w w E Q
& Maintenance Manual
Fuel tank is found to be empty w
Clogged air breather hole in fuel tank cap Q w
Rust and water are detected when fuel tank is drained Q Q Q Q Q
When fuel filter is removed, no fuel is inside the fuel filter w w
Leakage from fuel piping w
Check items
No response or heavy resistance felt when operating priming pump w Q Q

and the air breathing plug is removed from
Q Q w Q
When engine is cranked the fuel filter, fuel fails to discharge
with starting motor, Spill flow drops, when spill hose is separated
Q w w w w Q
from injector
Air is discharged when the air is bled from the fuel system q
Inspect the fuel filter directly q
Troubleshooting
Inspect fuel feed pump gauze filter directly q

Inspect feed pump directly q
Carry out troubleshoot by “Rail Press Very Low Error (*1)” q q q q
Carry out troubleshoot by “PCV1 Error (*2) or PCV2 Error (*3)” q
Inspect overflow valve directly q
Engine can start when operated in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Add
Remedy
40-600 10 WA470, 480-6

S-2 Engine does not start SEN04533-01
c) Exhaust smoke comes out but engine does not start Cause
Defective coolant temperature sensor or defective wiring harness

(Fuel is being injected)
General causes why exhaust smoke comes out but engine

does not start
q Rotating force is short due to defective electrical system
Wear of valve system (valve, rocker lever, etc.)

q Supply of fuel small
q Small air intake
Clogged injection nozzle, defective spray


Defective intake air heater system

Worn piston ring, cylinder liner
Clogged fuel filter, strainer

Improper fuel used
Degree of machine
Machine operated for long period E E E E
operation
w w Q
Questions
Suddenly failed to start

Non-specified fuel is being used Q Q
Replacement of filters has not been carried out according to Operation & Maintenance
w w w
Manual
Engine oil replenishment increasing w
Preheat monitor not indicating normal operation during preheating or at low temper-
w
ature
Dust indicator turned red w
Clogged air breather hole in fuel tank cap Q
Rust and water are detected when fuel tank is drained w w
When fuel filter is removed, no fuel is inside the fuel filter w
Starting motor cranks engine slowly w
When engine is cranked, abnormal noise is heard from around cylinder head w
Check items
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

Inspect valve system directly q
When compression pressure is measured, the oil pressure is low q
Troubleshooting
Inspect the fuel filter, strainer 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
WA470, 480-6 40-600 11

SEN04533-01 S-3 Engine does not pick up smoothly
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Cause

Defective operation of flow damper (excessive injector leakage)

q Fuel injection condition not normal
q Controller in derate control mode
(Controlling injection capacity (output) due to an error in

the electrical system)
Clogged injection nozzle, defective spray

Seizure or interference of turbocharger

q EGR valve is stuck in open state

(Shortage of air intake due to excessive EGR gas)


Improper valve clearance
Stuck EGR valve
Degree of machine
Machine operated for long period E E E E E E
operation
Questions
Engine pick-up suddenly became poor Q w Q Q Q

Non-specified fuel is being used w w w w
Replacement of filters has not been carried out according to Operation & Maintenance
w w w
Manual
Engine oil replenishment increasing w
Clogged air breather hole in fuel tank cap w
Q w
Blue under light load w
Color of exhaust gas
Check items
Black w Q w 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

Carry out troubleshooting by “EGR Valve Servo Error (*1)” q
When compression pressure is measured, the oil pressure is low q q
Troubleshooting
Inspect valve clearance directly q

When turbocharger is rotated by hand, it is found to be heavy q
Speed of some cylinders does not change when operated in reduced cylinder mode q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
40-600 12 WA470, 480-6

S-4 Engine stops during operation SEN04533-01
S-4 Engine stops during operation 1
General causes why engine stops during operations Cause

q Seizure inside engine
Broken auxiliary equipment (pump, compressor, etc.)

Breakage of valve system (valve, rocker lever, etc.)
q Overheating
q Defective drive unit on applicable machine side:

o Carry out troubleshooting on applicable machine
Broken, seized piston or connecting rod

side.
Broken, seized crankshaft metal
Leakage, clogging in fuel piping
Broken supply pump shaft, key

Broken, seized feed pump

Broken, seized gear train
Defective power train

Degree of machine
Machine operated for long period E E
operation
Abnormal noise was heard and engine stopped sud-
w w w w Q w Q w w
denly
Questions
Condition when Engine overheated and stopped w Q Q

engine stopped
Engine stopped slowly w Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation &
w w
Maintenance Manual
Fuel level monitor indicates low fuel level w
Fuel tank is found to be empty w
w w Q Q
Check items
Metal particles are found when oil pan is drained

Does not turn at all w w
When engine is Turns in opposite direction w
cranked manually Moves by the amount of gear backlash w w
Supply pump shaft does not turn w
Engine rotates, but stops when loaded on the machine side w

Carry out troubleshooting
Inspect piston and connecting rod directly. q

q
Troubleshooting
Inspect crankshaft metal directly

in the H-mode.
Inspect gear train directly q

Inspect feed pump directly q
Carry out troubleshooting by “Rail Press Very Low Error (*1)” q q
Engine rotates when auxiliary equipment (pump, compressor) is removed q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Add
Remedy
WA470, 480-6 40-600 13

SEN04533-01 S-5 Engine does not rotate smoothly
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly: Causes

q Air in fuel system
Defective operation of flow damper (Excessive leakage from injector)

q Defective speed sensor (Error at degree that it is not indicated)
q Defective EGR valve
Clogged injector, defective spray (dirt in injector)
Defective Bkup speed sensor or wiring harness

Defective Ne speed sensor or wiring harness
Leaking or clogged fuel piping, entry of air
Defective operation of EGR valve

Low idle speed is set too low.
Clogged fuel filter or strainer

Confirm recent repair history.
Degree of use of machine Operated for long period E E E
Occurs at a certain speed range Q Q Q Q
Questions
Occurs at low idle. w Q Q Q Q Q Q Q

Condition of hunting
Occurs even when speed is raised Q Q Q Q
Occurs on slopes w Q Q
Replacement of filters has not been carried out according to Operation and Main-
w w
tenance Manual.
When fuel tank is inspected, it is found to be empty. w
Air breather hole in fuel tank cap is clogged. w
Check items
Rust or water are observed when fuel tank is drained. Q Q

Fuel is leaking from fuel piping. w
When priming pump is operated, it makes no reaction or it is heavy. w Q Q
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
Inspect feed pump gauze filter directly

Inspect fuel filter and strainer directly. q
When a specific cylinder is cut out for reduced cylinder mode operation, engine
q q
speed does not change.
Carry out troubleshooting by failure code “Abnormal engine Ne speed sensor
q
(*2)”
Carry out troubleshooting by failure code “Abnormal engine Bkup speed sensor
q
(*3)”
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Clean
Clean
Clean
Refill
Remedy
*1: Failure codes [CA1228] and [CA1625]

*2: Failure code [CA689]
*3: Failure code [CA778]
40-600 14 WA470, 480-6

S-6 Engine lacks output (or lacks power) SEN04533-01
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Cause

Defective fuel temperature sensor or defective wiring harness

Defective charge pressure sensor or defective wiring harness
Defective mounting of charge pressure sensor (air leak)

q Overheating
Defective drive of injector (signal or solenoid)

o See the troubleshooting for “S-14 Coolant

Clogged fuel injector, defective injection

temperature too high (Overheat)”

Leakage, clogging in fuel piping

(Controlling injection capacity (output) due to an
Air leakage from air intake pipe

error in the electrical system)

Confirm recent repair history
Degree of use of machine Operated for long period E E E E E
Suddenly Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q Q
Replacement of filters not carried out according to Operation & Maintenance
w
Manual
Engine oil must be added more frequently Q Q Q
Dust indicator is red (with indicator installed) w
Output reduces after a break w
Black w w
When exhaust manifold is touched immediately after starting engine, tempera-
w
ture of some cylinders is low
Check items
When engine is cranked, interfering noise is heard from around turbocharger w

High idle speed of engine is low Q
High idle speed under no load is normal, but speed suddenly drops when load
w w Q
is applied
Engine does not pick up smoothly, and combustion is irregular w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q
Inspect intake air piping directly q
When boost pressure is measured, the oil pressure is low q q q
Troubleshooting

Inspect fuel filter, strainer directly q
Check the mount of boost pressure sensor directly q
Carry out troubleshooting by “Chg Air Press Sensor Error (*2)” q
Carry out troubleshooting by “Fuel Temp Press Sensor Error (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Clean
Remedy
WA470, 480-6 40-600 15

SEN04533-01 S-7 Exhaust smoke is black (Incomplete combustion)
S-7 Exhaust smoke is black (Incomplete combustion) 1
General causes why exhaust smoke is black Cause


Air leakage between turbocharger and cylinder head
Clogged fuel spill piping (on the cylinder head side)

q Overheating
o See the troubleshooting for “S-14 Coolant tem-
perature too high (Overheat)”
Defective contact of valve or valve seat


(Controlling injection capacity (output) due to an
error in the electrical system)

q EGR valve is stuck in open state
Improper injection pressure

(Shortage of air intake due to excessive EGR gas)
Abnormal wear of injector

Crushed, clogged muffler
Improper injection timing

Clogged, seized injector
q Clogged EGR gas pressure piping
(Entry of exhaust gas in intake air at acceleration
Stuck EGR valve

and deceleration)

Degree of machine
Machine operated for long period E E E E E
operation
Suddenly became black w Q Q Q
Questions
Color of exhaust gas Gradually became black w Q Q Q

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Leakage of air between turbocharger and cylinder head, loose clamp w
Operated in low-temperature mode during normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, tem-
Q w
perature of some cylinders is low
Check items

Torque converter stall or high pump relief speed (excessive fuel injection) Q Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly, and combustion is irregular Q Q Q Q Q Q w
Spill flow is excessive when spill hose is separated from injector w
Carry out troubleshooting by “EGR Valve Servo Error (*1)” q
Troubleshooting

When muffler is removed, exhaust color returns to normal q
Carry out troubleshooting by “Rail Press Very Low Error (*2)” q q
Speed of some cylinders does not change when operated in reduced cylinder mode q
Inspect fuel spill piping (on the cylinder head side) directly q
Carry out troubleshooting by “Coolant Temp Sensor Error (*3)” q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Adjust
Clean
Remedy
40-600 16 WA470, 480-6

S-8 Oil is consumed much (or exhaust gas color is blue) SEN04533-01
S-8 Oil is consumed much (or exhaust gas color is blue) 1
General causes why oil consumption is excessive Cause

q Abnormal oil combustion
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
Leakage from oil pan, cylinder head, etc.

and longer inhibited)
q Oil leakage to outside
Clogged breather or breather hose

Dust sucked in from intake system
Worn, damaged rear seal surface

Oil leakage from EGR valve stem
q Wear of lubricating system
Leakage from oil drain plug

Wear of seal at blower end
Worn seal at turbine end
Leakage from oil cooler
Leakage from oil piping

Leakage from oil filter
Broken piston ring
Broken oil cooler

Degree of machine
Questions
Machine operated for long period EEEE E

operation
Oil consumption suddenly increased w Q
Engine oil must be added more frequently Q w Q
Engine oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
Pipe clamps for intake system are loose w
Inside of turbocharger air intake outlet pipe is contaminated with oil w
Inside of turbocharger exhaust outlet pipe is contaminated with oil Q w
Check items
There is oil in the coolant w

Oil level in clutch or damper chambers on increasing w
Color of exhaust gas blue under light load Q w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is contaminated abnormally q
q q
Troubleshooting
Excessive play of turbocharger shaft

When EGR valve is removed, exhaust port is contaminated with oil q
Inspect breather, breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA470, 480-6 40-600 17

SEN04533-01 S-9 Engine oil becomes contaminated quickly
S-9 Engine oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Cause

q Entry of exhaust gas due to internal wear
Clogged lubricating drain tube of turbocharger

q Clogging of lubrication route
Defective seal at turbocharger turbine end

q Improper fuel is being used
q Improper oil is being used
q Operated under excessive load
Clogged breather, breather hose

Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is black

Worn EGR valve guide
Clogged oil cooler

Clogged oil filter
Degree of machine
Machine operated for long period EEEE
Questions
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
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

When EGR valve is removed, exhaust port is contaminated with oil q
Troubleshooting

(See S-7)
Inspect breather, breather hose directly q

Inspect oil cooler directly q
Inspect oil filter directly q
There is catching or breakage to the oil filter safety valve spring q
Inspect turbocharger lubricating drain tube directly q
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
—
Remedy
40-600 18 WA470, 480-6

S-10 Fuel consumption is excessive SEN04533-01
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Cause

q Leakage of fuel

q Fuel injection condition (fuel pressure and injection timing) not nor-
mal
q Excessive fuel injection
Fuel leakage from fuel filter, piping, etc.
Defective common rail fuel pressure

Leakage of fuel inside head cover
Defective supply pump plunger

Defective feed pump oil seal
Defective injector operation

Defective injector spray
Questions
Degree of machine operation Machine operated for long period EE E

More than other machines of same model Q Q Q Q
Condition of fuel
Gradually increased Q Q
consumption
Suddenly increased Q Q
Fuel leakage to outside w
There is irregular combustion w
Oil increasing of smelling of diesel oil w w
w
Check items
Low idle speed is too high Q

Torque converter stall or hydraulic pump relief speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

q
Troubleshooting
Inspect feed pump oil seal directly

Speed of some cylinders does not change when operated in reduced cylinder mode q
Spill flow is excessive when spill hose is separated from injector q
Carry out troubleshooting by “Coolant Temp Sensor Error (*2)” q
Check by the monitoring function q q
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Remedy
WA470, 480-6 40-600 19

SEN04533-01 S-11 Coolant contains oil (blows back or reduces)
S-11 Coolant contains oil (blows back or reduces) 1
General causes why oil in coolant Cause

q Internal leakage of lubricating system
Hole drilled by damages or pitching of cylinder liner O-ring

q Internal leakage of cooling system
Broken hydraulic oil cooler, power train oil cooler

Insufficient protrusion of cylinder liner
Broken cylinder head, head gasket
Internal cracks in cylinder block
Broken oil cooler core, O-ring

Questions
Degree of machine operation Machine operated for long period E E

Suddenly increased Q Q Q
Oil level
Hard water is being used as coolant Q Q
Oil level has risen, oil is milky Q Q w
w w
Check items
Excessive air bubbles inside radiator, coolant spurts back

Hydraulic oil or power train oil is milky w
When hydraulic oil or power train oil is drained, water is discharged w
q
troubleshooting
Pressure-tightness test of cylinder head shows there is leakage in the H-mode.
Troubleshooting
Carry out
Inspect cylinder block, liner directly q q

Inspect cylinder liner directly q
Pressure-tightness test of cylinder head shows there is leakage q

Replace
Replace
Replace
Replace
Replace
Remedy
40-600 20 WA470, 480-6

S-12 Oil pressure drops SEN04533-01
S-12 Oil pressure drops 1
General causes why oil pressure drops Cause

q Leakage, clogging, wear of lubrication system
Defective hydraulic sensor or defective wiring harness

Defective oil level sensor or defective wiring harness
q Hydraulic control is not normal
Leakage, crushing or clogging of hydraulic piping

q Selection of oil by the temperature etc. specified in the
“Operation and Maintenance Manual” is not observed.
Clogging or breakage of pipe inside oil pan

q Oil deteriorated by overheating
Leakage from EGR hydraulic piping

Clogged strainer inside oil pan
Defective oil pump relief valve
Defective EGR oil pump

Wear of metal journal
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Water, fuel in oil
Degree of machine
Machine operated for long period E E E E
Questions
operation
Oil pressure monitor indicates low pressure level Q w
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
Indicates a drop of oil pressure during low and high
Q w w w Q Q Q
Oil pressure monitor idle
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 w w
Oil pan oil level is in short w
w w
Check items
Leakage or crushing with external hydraulic piping

Oil is cloudy white or smells of diesel oil w
Metal particles are found when oil pan is drained w
Metal particles are found when oil is drained from oil filter w Q Q
Metal particles are detected in oil filter q

Inspect oil pan strainer, pipe directly q q
Oil pump rotation is heavy, there is play q
Troubleshooting
Oil pump relief valve, spring is fatigued or damaged q

See S-13
Inspect oil filter directly q

Relief valve of EGR oil pump is damaged or has oil leak q
Inspect EGR hydraulic piping directly q
Carry out troubleshooting by “Eng Oil Press Sensor Error (*1)” q
Replacing the oil level sensor will cause the oil pressure monitor to be dis-
q
played normally.
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
—
Remedy
WA470, 480-6 40-600 21

SEN04533-01 S-13 Oil level rises (Water, fuel in oil)
S-13 Oil level rises (Water, fuel in oil) 1
General causes why oil level rises Cause

q Coolant mixing in the oil (oil turns cloudy)
Clogging of water pump drain hole (breather hole) or defective seal

q Fuel in oil (smells diluted diesel fuel)
a If oil mixes with the coolant, carry out troubleshooting by “S-11
Defective seal of auxiliary equipment (pump or compressor)

Coolant contains oil”
Cracked EGR cooler (mixing of coolant)

Leakage of fuel inside head cover
Worn, damaged rear seal surface

Internal cracks in cylinder block
Broken oil cooler core, O-ring
Defective thermostat sheet

Defect inside supply pump
Questions
Degree of machine operation Machine operated for long period EE E E

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q w
There is oil in the coolant Q Q Q w
Engine oil smells of diesel fuel w w
Oil is milky Q Q w
After starting engine, drops of water come from muffler Q Q
Leave radiator cap open. When engine is run at idle, an abnormal number of bub-
w Q
bles appear or water spurts back
Check items
Exhaust gas is white Q Q

Clogged water pump drain hole (breather hole) w
Water comes out when water pump drain hole (breather hole) is cleaned w
Oil level in clutch or damper chambers on applicable machine side decreasing w
Hydraulic tank oil level is decreasing w
Removing EGR cooler outlet gas piping causes coolant containing antifreeze to
q
flow out (*1)
q
Troubleshooting
Remove head cover and inspect directly

Inspect cylinder block, liner directly q q
Inspect rear oil seal directly q
Pressure-tightness test of cylinder head shows there is leakage q
Remove water pump and inspect directly q
Remove thermostat cover and inspect directly q
Remove supply pump and inspect directly q
Inspect the seal of auxiliary machine directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
40-600 22 WA470, 480-6

S-13 Oil level rises (Water, fuel in oil) SEN04533-01

WA470, 480-6 40-600 23

SEN04533-01 S-14 Coolant temperature rises too high (Overheating)
S-14 Coolant temperature rises too high (Overheating) 1
General causes why coolant temperature becomes too Cause

high

q Lack of cooling air (deformation, damages of fan)
q Drop in heat dissipation efficiency
q Defect in the coolant circulation system
q Power train oil temperature on applicable machine
side is rising:
Defective radiator cap (pressure valve)

o Carry out troubleshooting on applicable machine
Slipping of fan belt, wear of fan pulley

Water leakage to outside EGR cooler
Defective coolant temperature gauge

Rise of power train oil temperature

Defective operation of thermostat
side
Clogged, crushed radiator fins

Clogged, broken oil cooler
Clogged radiator core

Broken water pump
Lack of coolant
Degree of machine
Machine operated for long period E E E E E
Questions
operation
Suddenly increased Q Q w Q
Condition of overheating
Always tends to overheat Q w w Q
Rises quickly Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates low level 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
Check items
When light bulb is held behind radiator, no light passes through w

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
w
temperature gauge
Inspect coolant leakage from EGR cooler directly q

Carry out troubleshooting in the H-mode.

Inspect cylinder liner directly q
Inspect oil cooler directly q
Troubleshooting
Temperature difference between top and bottom radiator tanks is excessive q

When function test is carried out on thermostat, it does not open even at crack-
q
ing temperature
Temperature difference between top and bottom radiator tanks is slight q
Inspect radiator core directly q
When function test is carried out on the radiator cap, cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
40-600 24 WA470, 480-6

S-15 Abnormal noise is made SEN04533-01
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Cause

q Abnormality due to defective parts
Defective fuel injection timing (abnormal low coolant temperature sensor)

q Abnormal combustion
q Air sucked in from intake system
a Judge if noise is from inside or outside before proceed-
ing with troubleshooting
a When engine is not fully warmed up, engine noise rises
Air leakage between turbocharger and cylinder head

slightly because of operation in the low temperature
Defect inside muffler (dividing board out of position)

Breakage of valve system (valve, rocker lever, etc.)
mode. This is not abnormal, however.
a When engine is accelerated, it enters acceleration mode,
Cracks or gas leakage from EGR gas piping
Deformed fan, loose fan belt or interference

Excessive wear of piston ring, cylinder liner
where engine noise remains slightly higher for about 5

seconds maximum. This is not abnormal, however.
Missing, seized gear train bushing

Improper gear train backlash
Dirt caught in the injector

Clogged, seized injector
Degree of machine operation Machine operated for long period E
Questions
Condition of abnormal noise
Suddenly increased Q Q Q Q
Non-specified fuel is being used Q
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 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

w Q
Black Q w Q
Engine pickup is poor and combustion is abnormal w
Abnormal noise is loud when accelerating engine Q Q Q Q

Inspect EGR gas piping directly q
Troubleshooting
When muffler is removed, abnormal noise disappears q

Inspect gear train directly q q
Inspect fan and fan belt directly q
Abnormal noise is emitted only when starting engine q
Check by the realtime monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Adjust
Remedy
WA470, 480-6 40-600 25

SEN04533-01 S-16 Vibration is excessive
S-16 Vibration is excessive 1
General causes why vibration is excessive Cause

q Defective parts (abnormal wear, breakage, etc.)
Breakage of damper or power train output shaft

Loose engine mounting bolts, broken cushion
q Alignment with applicable machine side is not normal
Stuck valve system (valve, rocker lever, etc.)

q Abnormal combustion
Wear of front support spigot joint portion

a If there is abnormal noise together with the vibration, carry out trou-
Worn main metal, connecting rod metal

bleshooting also for “S-15 Abnormal noise is made”.
Center of engine and power train

Improper gear train backlash

Worn camshaft bushing
Questions
Degree of machine operation Machine operated for long period E E E E

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q Q
Metal particles are found when oil is drained in oil filter w w
Metal particles are found when oil pan is drained w w
Q Q
Check items
Oil pressure is low at low idle

Vibration occurs at mid-range speed Q Q
Vibration follows engine speed Q Q Q Q Q
Exhaust smoke color is black w

Inspect main metal, connecting rod metal directly q
q
Troubleshooting
Inspect gear train directly

Inspect camshaft bushing directly q
Check by the realtime monitoring function q
Inspect engine mount bolt, cushion directly. q
When face runout and radial runout are inspected, they are found to be incorrect q
Inspect front support spigot directly q
Inspect inside of output shaft or damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Remedy
40-600 26 WA470, 480-6

S-16 Vibration is excessive SEN04533-01
WA470, 480-6 40-600 27

SEN04533-01

©2009 KOMATSU
All Rights Reserved
40-600 28
SEN04534-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
50 Disassembly and
assembly 1
100 General information on disassembly
and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tools list .............................................................................................................................................. 7
Sketches of special tools .............................................................................................................................. 12
WA470-6, WA480-6 1-100 1

100 General information on disassembly and assembly
SEN04534-01 How to read this manual
How to read this manual 1

(Rev. 2009.01)
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In “Removal” section, the work procedures,
r e m o v a l o r i n s ta l l a t i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2]••• etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in “Removal” section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this “Installation” section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
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
5 : Amount of oil or coolant to be replenished
Sketches of special tools

q Various special tools are illustrated for the local
manufacture.
1-100 2 WA470-6, WA480-6

How to read this manual SEN04534-01
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In “Disassembly” section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, ••• X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2]••• etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in “Disas-
tuted and should always be used. sembly” section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In “Assembly” section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2]••• etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in “Assem-
any modification. bly” section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of “Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools”.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
Sketches of special tools
q Various special tools are illustrated for the local
manufacture.
WA470-6, WA480-6 1-100 3

SEN04534-01 Coating materials list
Coating materials list 1

(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
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
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
1-100 4 WA470-6, WA480-6

Coating materials list SEN04534-01
Cate- Komatsu
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
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
— 09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

Seizure
LC-G pound with metallic super-fine-grain, etc.

NEVER- — — Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
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 1-100 5

SEN04534-01 Coating materials list
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
Grease
resistance and long life, can be packed into the

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
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
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
1-100 6 WA470-6, WA480-6

Special tools list SEN04534-01
Special tools list 1
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
Removal and instal- 1 795-630-5500 Standard puller t 1

lation of fuel supply A1 2 01010-81090 Bolt t 1 Separation of gear and shaft
pump assembly 3 01643-31032 Washer t 1
Removal and instal-
lation of cylinder A2 790-331-1110 Wrench q 1 Tightening of cylinder head bolt
head assembly
Seal puller assem-
A3 795-931-1100 q 1 Removal of engine front oil seal
bly
Removal and instal-
lation of engine 1 795T-521-1140 Push tool t 1 Q
front oil seal A4 2 01010-61650 Bolt t 3 Installation of engine front oil seal
3 01643-31645 Washer t 9
Seal puller
A5 795-931-1100 q 1 Removal of engine rear oil seal
assembly
1 795T-421-1340 Push tool t 1 Q
For standard
A6 2 01010-61635 Bolt t 3
seal
3 01643-31645 Washer t 3
Removal and instal-
lation of engine rear 1 795-931-1220 Push tool t 1 Installation of
oil seal A7 2 01010-61645 Bolt t 3 engine rear oil
3 01643-31645 Washer t 3 seal
For sleeved seal
1 795T-421-1320 Push tool t 1 Q
A8 2 01010-61645 Bolt t 3
3 01643-31645 Washer t 9
Removal and instal-
793T-607-1250 Bracket t 1 R Q
lation of parking
brake disc and
plate 1 01051-62240 Bolt t 1 Removal and installation of ring
Disassembly and
assembly of trans- B 01643-32260 Washer t 1
mission assembly
793T-607-1260 Plate t 1 N Q
Disassembly and 01016-52045 Bolt t 1 Separation of transfer shaft 1 and
assembly of trans- 2
01016-51690 Bolt t 1 inner race
mission assembly
01010-81245 Bolt t 4
WA470-6, WA480-6 1-100 7

SEN04534-01 Special tools list
New/Remodel
Necessity
Symbol
Sketch
Q'ty
3 793T-607-1270 Plate t 1 N Q Removal and installation of PTO

4 790-102-1891 Nut wrench t 1 gear nut
793T-607-1220 Lifting tool t 1 Q Removal and installation of F and
5
793-607-1230 Pin t 1 1st clutch pack assembly
793T-607-1280 Lifting tool t 2 R Q
01016-31245 Bolt t 4
01580-11210 Nut t 4
01017-32050 Bolt t 2 Removal and installation of R and
6 2nd clutch pack assembly and 3rd
01643-32060 Washer t 4 and 4th clutch pack assembly
01580-12016 Nut t 4
793T-607-1290 Bar t 1 R Q
04530-11628 Eye bolt t 1
Disassembly and 793T-607-1310 Plate t 1 N Q
assembly of trans-
mission assembly 793T-607-1320 Push tool t 1 N Q
t Separation of transfer shaft 2 and
7 2989-01-1220 Bolt 1
transfer gear 2
01643-33080 Washer t 2
01017-31420 Bolt t 8
793T-607-1330 Bracket t 1 N Q
793T-607-1340 Plate t 1 N Q
8 Positioning of transfer gear 2
01010-80820 Bolt t 2
01643-30823 Washer t 2
793T-607-1350 Bolt t 1 N Q
9 Installation of transfer shaft 2
04530-11018 Eye bolt t 1
793T-607-1360 Sleeve t 1 R Q
B Installation of spacer to transfer
10 01017-52030 Bolt t 1
gear 1
01643-32060 Washer t 1
790-501-5000 Unit repair stand q 1
q Fixing of torque converter assem-
Disassembly and 11 790-901-2110 Bracket 1
bly
assembly of torque 790-901-4240 Plate q 1
converter assembly
t 1 Removal and installation of stator
12 792-213-1110 Wrench
shaft locknut (lockup specification)
t 1 Installation of seal ring to 3rd pis-

13 793-415-1170 Seal holder
ton
14 793T-607-1370 Seal holder t 1 R Q Installation of seal ring to 4th pis-

ton
15 796T-667-1120 Push tool t 1 Q Press fitting of R and 4th clutch

bearings
16 799-301-1500 Oil leak tester kit t 1 Confirmation of clutch operation
Disassembly and 17 793T-607-1380 Seal holder t 1 R Q Installation of seal ring to 1st and
2nd pistons
assembly of clutch
pack assembly 18 796T-467-2160 Push tool t 1 Q Press fitting of 2nd clutch ball
bearing and F clutch bearing
19 792T-446-1150 Push tool t 1 Q Press fitting of 2nd clutch inner

race
20 793T-607-1390 Seal holder t 1 R Q Installation of seal ring to F and R

pistons
21 796T-467-2160 Push tool t 1 Q Press fitting of spacer to top of F

and R gears
22 795-102-2730 Collar t 1 Press fitting of 1st clutch bearing
1-100 8 WA470-6, WA480-6

New/Remodel
Necessity
Symbol
Sketch
Q'ty
q 1 Press fitting of outer race to F and

23 790-201-2660 Plate
1st clutch shaft cage
q 1 Press fitting of transfer shaft 1

24 792-135-3360 Plate
bearing to case
25 792-822-1430 Plate q 1 Press fitting of transfer gear 2
26 790-201-2860 Spacer q 1 outer race to case
q 1 Press fitting of outer race to trans-

27 792-822-1430 Plate
fer gear 2 cage
28 792T-227-1110 Push tool t 1 Q Press fitting of bearing to transfer
29 796-765-1110 Push tool t 1 shaft 2
30 790-201-2680 Plate q 1 Press fitting of outer race on out-

31 794T-425-1110 Push tool t 1 Q put shaft rear side
32 793T-607-1410 Push tool t 1 R Q Press fitting of output shaft bear-

ing (small)
33 791T-630-2410 Push tool t 1 Q Press fitting of output shaft bear-

ing (large)
q 1 Press fitting of outer race on out-

Disassembly and 34 792-822-1430 Plate
put shaft front side
assembly of trans-
mission assembly q 1 Press fitting of input shaft bearing
35 796-630-1110 Plate
to case
q 1 Press fitting of input gear inner

36 795-102-2730 Collar
race
37 793T-607-1420 Push tool t 1 R Q Press fitting of input shaft inner

race
B Press fitting of each clutch pack
38 792-822-1430 Plate q 1
outer race to case
q 1 Press fitting of outer race to PTO

39 791-100-1260 Sleeve
cage
40 790-445-3810 Push tool t 1 Press fitting of PTO bearing
q 1 Press fitting of input shaft portion

41 790-201-2860 Spacer
cover
790-101-5401 Push tool kit q 1
790-101-5421 • Grip 1 Press fitting of input shaft portion
42
790-101-5441 • Plate 1 spacer
01010-51240 • Bolt 1
q 1 Press fitting of input shaft bearing

43 790-434-1470 Push tool
(large)
q 1 Press fitting of bearing to case

44 790-201-2670 Plate
(standard specification)
q 1 Press fitting of bearing to boss

45 790-201-2750 Spacer
(standard specification)
q 1 Press fitting of bearing to PTO

46 790-201-2690 Plate
Disassembly and drive gear (standard specification)
assembly of torque 47 790-201-2220 Plate q 1 Press fitting of stator shaft to bear-
converter assembly ing (standard specification and
48 791-830-1770 Push tool q 1 lockup specification)
q 1 Press fitting of bearing to housing

49 790-201-2750 Spacer
(lockup specification)
q 1 Press fitting of bearing to guide

50 790-201-2680 Plate
(lockup specification)
WA470-6, WA480-6 1-100 9

SEN04534-01 Special tools list
New/Remodel
Necessity
Symbol
Sketch
Q'ty
793T-607-1430 Push tool t 1 R Q

790-101-5421 Grip t 1 Press fitting of oil seal and dust
51 seal on output shaft front side
01010-51240 Bolt t 1
Disassembly and 52 793T-607-1140 Spacer t 1 Q Press fitting of dust seal on output

shaft front side
assembly of trans- B
mission assembly 793T-607-1440 Push tool t 1 R Q
t 1 Press fitting of oil seal and dust
53 790-101-5421 Grip seal on output shaft rear side
01010-51240 Bolt t 1
54 793T-607-1450 Spacer t 1 R Q Press fitting of dust seal on output

shaft rear side
1 793T-622-1330 Push tool t 1 Q
D7 2 793T-622-1340 Spacer t 1 Q Press fitting of oil seal and bearing
3 793T-622-1350 Push tool t 1 Q
1 790-201-2320 Plate t 1
Disassembly and
D8 2 790-201-2770 Spacer t 1 Press fitting of bearing
assembly of axle
housing assembly 3 790-201-2760 Spacer t 1
1 793T-622-1370 Support t 2 Q
D9 2 793T-622-1380 Support t 2 Q Support of oil seal
3 01016-30860 Bolt t 6
D10 793T-622-1510 Holder t 1 Q Selection of shim
1 790-501-5000 Unit repair stand q 1
D1 2 790-901-2110 Bracket q 1 Fixation of differential assembly
3 790T-901-3440 Plate q 1 Q
1 793T-622-1310 Push tool t 1 Q
D2 2 790-101-5421 Grip t 1
3 01010-51240 Bolt t 1
1 793T-622-1310 Push tool t 1 Q
2 793T-622-1320 Spacer t 1 Q Assembly of pinion gear and cage
D3
3 790-101-5421 Grip t 1 assembly
4 01010-51240 Bolt t 1
Disassembly and
D4 793T-622-1360 Push tool t 1 Q
assembly of differ-
ential assembly 1 796-765-1110 Push tool t 1
D5
2 790-201-2750 Spacer t 1
790-301-1720 Adapter t 1
1
07002-12034 O-ring t 1
D6 2 799-101-5002 Hydraulic tester t 1 Check for brake oil leakage
3 793-605-1001 Brake tester t 1
4 790-101-1102 Hydraulic pump t 1
1 796-751-1510 Wrench t 1 For measurement of
D11 differential torque of
2 01010-50620 Bolt t 2 differential
D12 799-301-1500 Oil leak tester kit t 1 Confirming operation of piston
1 790-101-2300 Push puller t 1
2 793-520-2370 Push tool t 1
Removal and instal- 3 793-520-2350 Push tool t 1
Removal, installation of upper
lation of center E1 4 793-520-2540 Guide t 1
hinge pin
hinge pin 5 793-520-2360 Bar t 2
7 790-101-2102 Puller (30 tons) t 1
1-100 10 WA470-6, WA480-6

New/Remodel
Necessity
Symbol
Sketch
Q'ty
1 790-502-1003 Repair stand t 1 Disassembly, assembly of hydrau-

F1
2 790-101-1102 Hydraulic pump t 1 lic cylinder assembly
Socket (Width
F2 790-302-1280 t 1 For steering cylinder piston nut
across flats: 55 mm)
1 790-330-1100 Wrench assembly t 1
F3 For steering cylinder head
1 790-102-4300 Wrench assembly t 1 For lift arm and bucket cylinder
F4
2 790-102-4310 Pin t 1 pistons
1 790-720-1000 Expander t 1
2 796-720-1650 Ring t 1
3 07281-01029 Clamp t 1
F5 4 796-720-1680 Ring t 1 For assembly of piston ring
5 07281-01589 Clamp t 1
Disassembly and 6 796-720-1690 Ring t 1
assembly of
7 07281-01919 Clamp t 1
hydraulic cylinder
assembly 1 790-201-1500 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1
F6 4 790-201-1570 • Plate 1 For cylinder head dust seal
5 790-201-1990 Plate t 1
6 790-201-1660 • Plate 1
7 790-201-1670 • Plate 1
1 790-201-1702 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-50816 • Bolt 1
F7 4 790-201-1761 • Push tool 1 For cylinder head bushing
5 790-201-1930 • Push tool 1
6 790-201-1851 • Push tool 1
7 790-201-1861 • Push tool 1
1 793-498-1120 Clear plate t 2
Removal and instal- X2 2 793-498-1130 Plate t 2
lation of operator’s
cab glass (stuck 3 793-498-1110 Magnet t 2 Installation of operator’s cab glass
glass) Lifter
X3 793-498-1210 t 2
(Suction cups)
WA470-6, WA480-6 1-100 11

SEN04534-01 Sketches of special tools
Sketches of special tools 1

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A4-1 Push tool
A6-1 Push tool
1-100 12 WA470-6, WA480-6

Sketches of special tools SEN04534-01
A8-1 Push tool
B1 Bracket
WA470-6, WA480-6 1-100 13

B2 Plate
B3 Plate
1-100 14 WA470-6, WA480-6

B5 Lifting tool
B6 Lifting tool
WA470-6, WA480-6 1-100 15

B6 Bar
B7 Plate
1-100 16 WA470-6, WA480-6

B7 Push tool
B8 Bracket
WA470-6, WA480-6 1-100 17

B8 Plate
B9 Bolt
1-100 18 WA470-6, WA480-6

B10 Sleeve
B14 Seal holder
WA470-6, WA480-6 1-100 19

B5 Push tool
B17 Seal holder
1-100 20 WA470-6, WA480-6

B18 Push tool
B19 Push tool
WA470-6, WA480-6 1-100 21

B20 Seal holder
B21 Push tool
1-100 22 WA470-6, WA480-6

B28 Push tool
B31 Push tool
WA470-6, WA480-6 1-100 23

B32 Push tool
B33 Push tool
1-100 24 WA470-6, WA480-6

B37 Push tool
B51 Push tool
WA470-6, WA480-6 1-100 25

B52 Spacer
B53 Push tool
1-100 26 WA470-6, WA480-6

B54 Spacer
D1-3 Plate
WA470-6, WA480-6 1-100 27

D2-1, D3-1 Push tool
D3-2 Spacer
1-100 28 WA470-6, WA480-6

D4 Push tool
D7-1 Push tool
WA470-6, WA480-6 1-100 29

D7-2 Spacer
D7-3 Push tool
1-100 30 WA470-6, WA480-6

D9-1 Support
D9-2 Support
WA470-6, WA480-6 1-100 31

D10 Holder
1-100 32 WA470-6, WA480-6

WA470-6, WA480-6 1-100 33

SEN04534-01

©2009 KOMATSU
All Rights Reserved
1-100 34
SEN04535-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
50 Disassembly and assembly

Removal and installation of engine assembly ................................................................................................. 2
Removal and installation of engine hood assembly ........................................................................................ 6
Removal and installation of radiator assembly ............................................................................................... 9
Removal and installation of aftercooler assembly......................................................................................... 12
Removal and installation of oil cooler assembly ........................................................................................... 14
Removal and installation of cooling fan and drive motor assembly .............................................................. 16
Removal and installation of fuel supply pump assembly .............................................................................. 20
Removal and installation of fuel injector assembly ....................................................................................... 26
Removal and installation of cylinder head assembly .................................................................................... 32
Removal and installation of engine front oil seal........................................................................................... 40
Removal and Installation of engine rear oil seal ........................................................................................... 43
Removal and installation of fuel tank assembly ............................................................................................ 48
WA470-6, WA480-6 50-200 1

SEN04535-01 Removal and installation of engine assembly
Removal and installation of 6. Disconnect fuel hose (1).

engine assembly 1
Removal
k Install the lock bar on the frame, apply the
parking brake and put chocks under the
tires.
k Disconnect the cable from the negative (–)
terminal of the battery.
1. Drain coolant.
6 Coolant: 61 l
7. Remove clamp (2) for the hose between the

2. Drain hydraulic oil. torque converter and oil cooler and clamps (3)
6 Hydraulic oil: 173 l for the air conditioner hose.
3. Remove the hood assembly, referencing to

"Removal and installation of engine hood
assembly."
4. Remove the hydraulic tank, referencing to

"Removal and installation of hydraulic tank."
5. Set jack [1] at the bottom of the transmission.

a This is necessary to prevent falling off of
the transmission side when the engine will
be separated.
8. Disconnect fuel hoses (4) and (5).
50-200 2 WA470-6, WA480-6

Removal and installation of engine assembly SEN04535-01
9. Disconnect air conditioner compressor top 14. Remove plate (12) on the bottom oil cooler.
connector E10 (6).
10. Remove air conditioner compressor assembly

(7) and slide it toward the right side frame. [*1]
15. Remove clamp (13) and disconnect heater

hose (14).
16. Loosen the clamp and disconnect radiator

11. Remove engine oil drain tube (8) from fuel hose (15). [*2]
tank.
17. Remove the clamp and disconnect battery

12. Loosen the clamps and disconnect aftercooler relay wiring E07A (16).
hoses (9) and (10) on the engine side. [*2]
18. Disconnect connector ER4 (17).
13. Loosen the clamp and disconnect radiator
cooler hose (11) on the radiator side. [*2]
WA470-6, WA480-6 50-200 3

SEN04535-01 Removal and installation of engine 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), ER1 23. Temporarily lift engine assembly (25).
(21) and ER3 (22), and then remove the
clamp.
a The connectors are arranged in the order
of ER2, ER1 and ER3 from the top.
24. Remove mounting bolts (26) for the right and

left side engine front mounts. [*3]
21. Remove 2 air conditioner hose clamps (23),

and then remove bracket (24).
50-200 4 WA470-6, WA480-6

Removal and installation of engine assembly SEN04535-01
25. Remove 12 torque converter housing mount- Installation

ing bolts (27). [*4] q Carry out installation in reverse order of
removal.
[*1]
a Adjust the compressor belt tension, referenc-
ing to “Testing and adjusting air compressor
belt tension” in “Testing and adjusting.”
[*2]
a When tightening the 2 clamps, set their bolts
180° apart from each other.
2 Hose inserting part:
[*3]
3 Mounting bolt:
26. Lift off engine assembly (25). 455 – 565 Nm {46.5 – 58 kgm}
a Before lifting off the engine, make sure
every necessary harness and piping is [*4]
disconnected. a When connecting the engine to the torque con-
4
verter, adjust height of the torque converter
Engine assembly: 1350 kg shaft and ring gear so that they can be
smoothly inserted.
q Refilling with coolant

Add coolant up to the specified level. Run the
engine to circulate the coolant through the sys-
tem. Then, check the coolant level again.
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 50-200 5

SEN04535-01 Removal and installation of engine hood assembly
Removal and installation of 5. Disconnect connector E33 (4) in the left rear
engine hood assembly 1 frame and remove all the wiring harness
clamps.
Removal
tires.
1. Remove exhaust pipe (1).
6. Remove all the clamps of breather hose (5).
2. Open the right and left engine side covers.
3. Remove air cleaner hose (2).
4. Remove 4 bracket mounting bolts (3).

7. Remove left plate (6).
8. Remove 3 mounting bolts for left side cover (7)

and a mounting bolt for plate (8), and then
remove left side cover (7).
50-200 6 WA470-6, WA480-6

Removal and installation of engine hood assembly SEN04535-01
9. Remove right plate (9). 15. Remove 2 mounting bolts (16) each on the
right and left sides of the engine hood top.
10. Remove right cover (10).
16. Temporarily lift the engine hood assembly.

11. Remove 2 bolts (11) and open radiator grille
(12). 17. Remove the right and left side mounting bolts
and spacers (18) for frame (17).
12. Remove under view mirror stay (13).
13. Remove the 3 mounting bolts of bracket (14).
14. Remove cover (15).
WA470-6, WA480-6 50-200 7

SEN04535-01 Removal and installation of engine hood assembly
18. Lift off hood assembly (19). Installation

4
q Carry out installation in reverse order of
Hood assembly: 310 kg
removal.
50-200 8 WA470-6, WA480-6

Removal and installation of radiator assembly SEN04535-01
Removal and installation of 11. Remove the clamps in 2 places and discon-
radiator assembly 1 nect hose (11) and harness (12).
Removal 12. Remove receiver (13) along with the bracket

k Stop the machine on a level ground and and place them beside the engine.
tires.
1. Drain coolant.
6 Coolant: 61 l

assembly."
13. Remove the aftercooler assembly, referencing
3. Remove the clamps in 2 places and discon- to "Removal and installation of aftercooler
nect hoses (1) and (2). assembly."
4. Remove joint (3) and slide it toward the engine 14. Disconnect hose (14).
side.
5. Disconnect hose (4).
6. Remove joint (5) and slide it toward the engine

side.
7. Disconnect radiator upper hose (6). [*1] [*2]
8. Disconnect radiator connection hose (7).

[*1] [*2]
9. Remove the top mounting bolts in 2 places on

mounting bracket (9) for condenser (8).
10. Disconnect aftercooler inlet hose (10). [*2]

15. Remove the clamps in 2 places and discon-
nect oil cooler hose (15).
WA470-6, WA480-6 50-200 9

SEN04535-01 Removal and installation of radiator assembly
16. Remove condenser (8). 20. Disconnect bottom radiator connection hose
(20). [*1] [*2]
17. Remove the bottom mounting bolt, and then a Disconnect one side alone.
remove bracket (9).
21. Disconnect radiator lower hose (21) on the

18. Remove oil cooler top tube (16) and bottom radiator side. [*1] [*2]
block (17), and then remove oil cooler (18). a When disconnecting the radiator lower
hose, first remove 2 mounting bolts (23)
for oil cooler (22), and then disconnect the
lower hose while sliding the oil cooler left-
wards.
19. Remove bottom bracket (19).
50-200 10 WA470-6, WA480-6

Removal and installation of radiator assembly SEN04535-01
22. Remove top bracket (24). Installation

removal.
[*1]
2 Hose inserting part:
[*2]
23. Remove 2 radiator mounting bolts (25) on

each side.
24. Gradually lift and remove right and left side

radiator core assemblies (26) and (27).
4 Radiator assembly: 25 kg (one side)
WA470-6, WA480-6 50-200 11

SEN04535-01 Removal and installation of aftercooler assembly
Removal and installation of 6. Remove hose joint (5).

aftercooler assembly 1
7. Disconnect aftercooler hose (6). [*1]
Removal
tires.
1. Remove the engine hood assembly, referenc-

ing to "Removal and installation of engine hood
assembly."
2. Remove bracket (1).

8. Remove the clamp of oil cooler hose (7).

9. Remove the clamp of condenser hose (8).
4. Disconnect hose (3) from the aftercooler. [*1]
10. Remove the condenser mounting bolts and fix
5. Remove the clamp of tube (4). condenser (9) to the machine frame.
50-200 12 WA470-6, WA480-6

Removal and installation of aftercooler assembly SEN04535-01
11. Remove bracket (10). Installation

removal.
[*1]
13. Sling the aftercooler (12) then remove it.

4 Aftercooler assembly: 25 kg
WA470-6, WA480-6 50-200 13

SEN04535-01 Removal and installation of oil cooler assembly
Removal and installation of oil 6. Disconnect hose (5) from oil cooler tube (6).
cooler assembly 1
Removal
tires.
1. Open the engine left side cover.
2. Remove side plate (1).

7. Disconnect bottom hose (7) from block (8).
3. Remove left side plate (2).

and a mounting bolt for plate (3), and then
remove left side cover (4).
8. Remove 2 bolts (9) for oil cooler top mounting

plate.
a Another place is at the left of figure.
5. Remove 2 clamps for oil cooler hose (5).
50-200 14 WA470-6, WA480-6

Removal and installation of oil cooler assembly SEN04535-01
9. Remove 2 bolts (10) for oil cooler bottom Installation

mounting plate. q Carry out installation in reverse order of
removal.
10. Gradually draw out and remove oil cooler

assembly (11).
WA470-6, WA480-6 50-200 15

SEN04535-01 Removal and installation of cooling fan and drive motor 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
tires.
tank to release the internal pressure.
1. Open right and left engine side covers.

5. Open the battery cover and remove the bottom
2. Remove 2 bolts (1), and open front grille (2). mounting bolts for right and left side radiator
guards (5) and (6).
3. Remove the mounting bolt for cover (3).

6. Lift top grille assembly (7) and remove right
and left side grilles (4), and then remove the
top grille assembly.
4 Grille assembly: 35 kg
50-200 16 WA470-6, WA480-6

Removal and installation of cooling fan and drive motor assembly SEN04535-01
7. Disconnect rear work light left-connector G04 12. Disconnect fan buzzer connector G10 (12), fan
(8) and right-connector G05 (9). motor solenoid connector G11 (13) and fan
speed sensor connector G12 (25).
8. Remove 3 clamps for harness (10).
13. Remove clamp for harness (10).
14. Remove back buzzer (14).
9. Remove 4 mounting bolts, and then remove

grille (3).
10. Remove 3 right side clamps for harness (10). 15. Remove 3 fan motor hoses (15), (16) and (17).
11. Remove fan motor cover (11). 16. Temporarily lift bracket assembly (18), remove
the mounting bolt, and then remove the
bracket assembly.
4 Bracket assembly: 75 kg
WA470-6, WA480-6 50-200 17

SEN04535-01 Removal and installation of cooling fan and drive motor 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. Remove bolt (26) and nut fixing lock plate (21)
on the fan motor shaft, and then remove the
nut (27). [*1]
19. Remove boss (28) and fan (22) using puller [1].
50-200 18 WA470-6, WA480-6

Removal and installation of cooling fan and drive motor assembly SEN04535-01
Installation [*2]
q Carry out installation in reverse order of a Clean and degrease the shaft of fan motor
removal. assembly (23) and the tapered part of boss
(28) before assembling.
[*1] a Install fan (22) as shown in the figure.
a Install lock plate (21) according to the following a When installing boss (28), match it with fan
procedure. motor shaft key (29).
1. Tighten nut (27).
3 Nut (27): 132 – 157 Nm {13.5 –16 kgm}
2. Set lock plate (21) to nut (27).

a Before retightening nut (27) until either
one of two holes of lock plate (21)
matches to one of two mounting holes,
seek the fitting position of smallest retight-
ening angle first. Since the both sides of
lock plate (21) are usable, check for the
above mentioned fitting position on both
sides and select one with smaller retight-
ening angle. Then set lock plate (21) to
nut (27).
3. Retighten nut (27) and match the hole of lock

plate (21) to the bolt mounting hole.
4. Tighten bolt (26).

2 Bolt: Adhesive (LT-2)
q Bleeding air
Bleed air. For details, see "Bleeding air from
hydraulic driven fan circuit" in Testing and
adjusting.
WA470-6, WA480-6 50-200 19

SEN04535-01 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 4. Remove right side plate (4).

supply pump assembly 1
5. Remove 3 mounting bolts for right side cover
Special tool (5) and a mounting bolt for cover bottom plate
(3), and then remove cover (5).
New/Remodel
Necessity
Sym-
Part No. Part name
bol
Sketch
Q'ty
1 795-630-5500 Standard puller t 1
A1 2 01010-81090 Bolt t 2
3 01643-31032 Washer t 2
Removal
tires.
k Disconnect the cable from the negative (–) 6. Remove bottom plate (3).
1. Open the right and left engine side covers.
2. Remove left side plate (1).

and a mounting bolt for cover bottom plate (3),
and then remove cover (2).
7. Disconnect harness connector PCV1 (6),

PCV2 (7) and connector RES (8) on the supply
pump.
8. Remove clamp (10) and bracket (11) for oil

level gauge guide (9).
50-200 20 WA470-6, WA480-6

Removal and installation of fuel supply pump assembly SEN04535-01
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]
15. Remove lubrication tube (24). [*6]
10. Remove clamps (13) and (14).

a Spacers are used for clamp (13). Take
care not to lose them. [*1] 16. Remove clamps (25), (26), (27) and (28).
a Clamp (28) is located on the backside of
11. Remove fuel tubes (15) and (16). [*2] the oil filler port.
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 spray preven-
tion caps (30) and supply pump side 2 fuel
spray prevention caps (31).
19. Remove high-pressure pipes (32) and (33).
13. Remove 2 clamps (19) and clamp (20). [*4]
WA470-6, WA480-6 50-200 21

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.
23. Tighten nut (37) by 4 – 5 turns so that the fuel

supply pump gear will not collide with the case
when it is removed in the next step.
21. Rotate the crankshaft forward, and align mid-

position "a" between marking 2/5TOP and 3/
4TOP of damper (35) to pointer (36). (Marking
1/6TOP comes almost right below.)
a At this time, check that the forcing tap on
the drive gear is aligned to the bolt hole of
cover (34).
(If not, rotate the crankshaft one more 24. Install tools A1-1, A1-2 and A1-3 and tighten
turn.) bolt [1] to disconnect the gear from the shaft.
a This position is equivalent to the pump
shaft key position after the key has been 25. Remove tools A1-1, A1-2 and A1-3 and then
rotated 15° clockwise from the top face. remove nut (37).
26. Install tool A1-2 again for fixing the gear when
installing.
50-200 22 WA470-6, WA480-6

27. Remove bracket (39). Installation

k The clamp used for fixing a high-pressure
28. Remove 4 fuel supply pump mounting bolts pipe must be a genuine Komatsu part and it
(40) and then remove fuel supply pump must be tightened to the specified torque.
assembly (41). k Never bend a high-pressure pipe for the
convenience sake.
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).
WA470-6, WA480-6 50-200 23

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}
8. Tighten fuel supply pump assembly mounting

bolts (40) permanently.
9. Tighten the mounting bolts on the cylinder

block side of bracket (39) permanently and
then tighten the mounting bolts on the supply
pump side permanently.
3 Mounting bolt on supply pump side:
19.6 – 29.4 Nm {2 – 3 kgm}
10. Install fuel spray prevention caps (30) and (31).

a When installing the caps, set their notches
in the following directions.
q Cap (30): Down
q Cap (31): Cylinder block side
11. Tighten clamp (27) with the fingers.
12. Tighten clamp (20) with the fingers.
13. Tighten clamp (27) permanently.

3 Mounting bolt:
3. Tighten 4 mounting bolts (40) with the fingers.
2 Mounting bolt: Adhesive (LT-2)
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
14. Tighten mounting bolts (44) of bracket (43)

4. Tighten bracket (39) with the fingers.
permanently.
15. Tighten bolt (45) permanently.
16. Tighten the mounting bolts of clamp (26).

3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
17. Tighten the mounting bolts of bracket (29) per-

manently.
18. Tighten nut (46) permanently.
19. Tighten the mounting bolts of clamp (28).

3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
20. Tighten bolt (47) permanently.

21. Tighten clamp (20) permanently.
50-200 24 WA470-6, WA480-6

[*1]
22. Tighten lubrication tube (24) permanently. a Referring to the following, install the spacers
3 Joint bolt: for clamp (13).
9.8 – 12.7 Nm {1.0 – 1.3 kgm} q For fuel tube (15): 14 mm long
q For fuel tube (16): 30 mm long
23. Tighten the mounting bolts of clamp (25) per-
manently. [*2]
3 Mounting bolt: 3 Sleeve nut: 43 – 47 Nm {4.4 – 4.8 kgm}
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
[*3]
a Spacer length: 104.5 mm
[*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.
q Testing fuel leakage

Inspect leakage of fuel referencing to "Testing
leakage in fuel system" in Testing and adjust-
ing.
k Start the engine after making sure the har-
ness is 10 mm or more away from the high-
pressure pipe.
24. Carry out the following installation in the

reverse order to removal.
WA470-6, WA480-6 50-200 25

SEN04535-01 Removal and installation of fuel injector 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
tires.
k Disconnect the negative (–) terminal of the
battery beforehand.

assembly."
2. Loosen air pipe (1) on the turbocharger side

and aftercooler side of hose clamps (2). [*1]
8. Remove clamps (8), (9) and remove tubes
3. Remove bolt of air pipe mounting bracket (3) (10), (11).
and remove air pipe (1). [*2] a A spacer is used on clamp (8). Take care
not to lose the spacer. [*4]
4. Remove 2 clamps (5) for drain pipe (4) and
remove it. 9. Remove fuel pre-filter (12) and filter head
together.
5. Sling muffler assembly (6) temporarily.
10. Loosen 2 clamps (13) and remove tubes (14)
6. Remove the mounting bolts for muffler mount- and (15).
ing bracket.
a Take care not to lose the spacers of the 4 11. Remove fuel filter (16) and filter head together.
mounting bolts of bracket (7).
50-200 26 WA470-6, WA480-6

Removal and installation of fuel injector assembly SEN04535-01
12. Disconnect connector PAMB (18). a Disconnect the connectors by applying a

flat-head screwdriver [1] to the stepped
13. Remove 3 clamps (20) for harness assembly portion (a) and moving it in the X direction
(19). while pushing the stopper (1a).
a A spacer is used for a clamp. Take care
not to lose the spacer. [*6]
14. Remove pre-fuel filter head mounting brackets

(21) and (22).
15. Remove diffuser connector assembly (23).
18. Remove high-pressure pipe clamps (27) and

(28), and then remove fuel spray prevention
cap (29) on the injector side.
16. Remove 6 injector connectors (24) and slide

them toward the hydraulic tank side along with
clamp bar (25).
a Connectors are numbered CN1 to CN6
starting with the fan side.
19. Remove common rail side clamp (30) and

remove fuel spray prevention cap (31).
WA470-6, WA480-6 50-200 27

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).
26. Remove the mounting bolt for holder (40), and

22. Remove cylinder head cover (35). then remove fuel injector assembly (41) along
with holder (40).
a Insert a small L-shaped bar to the bottom
of the fuel injector connector, and then pull
out the fuel injector using the leverage.
a Do not pull out the solenoid valve section
at the top of the fuel injector, using a tool
such as pliers.
23. Fully loosen 2 nuts (36) of the fuel injector

solenoid valve.
24. Remove bolt (37) and move wiring harness

(38) aside.
50-200 28 WA470-6, WA480-6

Installation 5) Insert sleeve nut (47) of high-pressure

1. Install the fuel injector assembly in the follow- pipe through the high-pressure insertion
ing procedure. section, and then tighten it temporarily
1) Check that the mounting hole of fuel injec- along with the inlet connector (48).
tor assembly on the cylinder head side is a Tighten the common rail side sleeve
free from dusts. nut, too.
2) Assemble gasket (42) and O-rings (43)
and (44) to fuel injector assembly (41).
2 O-ring: Engine oil (EO30)
3) Insert holder (40) to fuel injector assembly
(41), and then insert them to the high-
pressure pipe insertion hole on the fuel
injector.
4) Attach the spherical washer (46) to the
bolt (45) and tighten holder (40) tempo-
rarily.
2 Spherical washer:
Engine oil (EO30)
6) Tighten holder (40) permanently.

a While pulling the high-pressure pipe
in the opposite direction to the injec-
tor, tighten mounting bolt (45).
3 Injector holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
a After tightening the holder, remove
the high-pressure pipe.
2. Install the rocker arm and shaft assembly

1) Set rocker arm and shaft assembly (39).
a When installing the rocker arm shaft,
direct its larger mounting hole end
down and its ball plug (49) end forward.
2) Confirm that the ball of adjustment screw
(50) is fitted in push rod socket (51)
securely and tighten mounting bolts (52).
a Before installing, clean the oil holes.
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3) Adjust the valve clearance. For details,
see Testing and adjusting, "Testing and
adjusting valve clearance."
WA470-6, WA480-6 50-200 29

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).
4. Install cylinder head cover (35).

3 Mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
1) Tighten high-pressure pipe (34) with the

fingers.
a Loosen all the high-pressure pipe
clamps.
2) Tighten high-pressure pipe (34) perma-
nently.
3 Sleeve nut (both sides):
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
3) Install fuel spray prevention caps (29) and
(31) to each high-pressure pipe.
a When installing each cover, take care
of the direction of the slit.
q Fuel injector side: Down
q Common rail side: Cylinder block
side
4) Tighten all of 6 high-pressure pipe clamps
(27), 6 brackets (54), and a bracket (26)
with the fingers.
5) Tighten high-pressure pipe clamps (27)
permanently.
3 Mounting bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
6) Tighten brackets (54) permanently.
50-200 30 WA470-6, WA480-6

7) Tighten 4 high-pressure pipe clamps (28) [*1]

with the fingers. a When tightening the 2 clamps on the after-
8) Tighten high-pressure pipe clamp (30) to cooler side, set their bolts 180° apart from
bracket (26) with the fingers, and then each other.
tighten it permanently. 3 Clamp on turbocharger side:
3 Mounting bolt: 9.8 ± 0.5 Nm {1 ± 0.05 kgm}
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
9) Tighten bracket (26) permanently. [*2]
10) Tighten high-pressure pipe clamps (28) 3 Clamp nut: 10.8 – 26.5 Nm {1.1 – 2.7 kgm}
permanently.
3 Mounting bolt: [*3]
11.8 – 14.7 Nm {1.2 – 1.5 kgm} a Spacer length: 18 mm
[*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.
q Testing fuel leakage

Inspect leakage of fuel referencing to "Testing
leakage in fuel system" in Testing and adjust-
ing.
k Start the engine after making sure the har-
ness is 10 mm or more away from the high-
pressure pipe.

WA470-6, WA480-6 50-200 31

SEN04535-01 Removal and installation of cylinder head assembly
Removal and installation of 6) Remove spill tube (8).

cylinder head assembly 1
Special tool
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).
2) Remove clamp (2) for oil filter tube.
3) Remove oil filter tubes (3) and (4). [*1]
4) Remove oil filter (5) along with the filter

head (6).
5) Remove clamp bracket (7).
50-200 32 WA470-6, WA480-6

Removal and installation of cylinder head assembly SEN04535-01
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]
7. Remove clamp (15).

a A spacer is used for the clamp bottom
mounting bolt. Take care not to lose the
spacer. [*4] 12. Remove heat insulation cover (22).
8. Remove the 1 mounting bolt each on the upper

and lower sides of plate (16).
9. Remove 4 mounting bolts of tube (17) on the

EGR valve side and remove plate (16).
WA470-6, WA480-6 50-200 33

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).
18. Remove clamp (32) for EGR lubrication return

tube (31) and remove tube (31).
a A spacer is used for the clamp-mounting
plate. Take care not to lose the spacer.
[*8]
19. Remove 2 clamps (34) for EGR lubrication inlet

tube (33) and remove tube (33). [*9]
a The union type is employed for the front
cover side mounting section of EGR lubri-
cation inlet tube (33).
14. Remove clamp (24) to remove lubrication pipe

(25).
15. Loosen clamp (26) and remove the mounting

bolt for drain pipe (27).
20. Remove 2 mounting bolts and remove EGR

valve assembly (35). [*10]
50-200 34 WA470-6, WA480-6

21. Remove bracket (37) from the engine front 24. Remove water tube (40). [*13]
side lift plate (36). [*11]
25. Disconnect connector TIM (41) and connector

22. Temporarily lift turbocharger assembly (38), PIM (42) from the rear side of the intake mani-
and then remove the mounting bolt for the fold.
exhaust manifold. [*12]
26. Loosen clip (43) on the oil filler port, remove

23. Remove exhaust manifold and turbocharger bracket (44) and slide it downward.
assembly (39).
4 Exhaust manifold and turbocharger
assembly: 45 kg
WA470-6, WA480-6 50-200 35

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 4 Cylinder head assembly: 20 kg
28. Remove push rods (46). [*15]
29. Remove crossheads (47). [*16]
30. Remove 6 mounting bolts and remove rocker

housing (48). [*17]
50-200 36 WA470-6, WA480-6

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.
2. Tighten the cylinder head mounting bolts.

1) Confirm the following items. If any of the
following conditions applies, do not use it
but replace with new one.
q The number of tightening times of the
bolt is six (number of punch marks is
five). a When not using tool A2, paint mark
q Bolt stem length (a): (b) on the cylinder head and bolts,
171.4 mm or longer and then tighten the bolts further by
90° – 120°. (Target 120°)
3) Stamp a punch mark (c), indicating the
number of tightening, in the bolt head.
a When using a new bolt, stamping of a
punch mark is not necessary.
2) Tighten the mounting bolts in the order of

1 to 6 indicated in the figure.
2 Cylinder head mounting bolt:
Lubricant containing
molybdenum disulfide (LM-P)
3 Cylinder head mounting bolt:
1st time: 98 ± 9.8 Nm {10 ± 1 kgm}
2nd time: 166.6 – 176.4 Nm {17 – 18 kgm}
(Target 176.4 Nm {18 kgm})
3rd time: Using tool A2, tighten the bolts
further by 90° to 120°. (Target:
120°)
WA470-6, WA480-6 50-200 37

4) Tighten the cylinder head auxiliary bolt (7). [*1]

3 Auxiliary bolt for mounting cylinder a Oil filter tube installation procedure
head: 1) Temporarily tighten the filter head (6).
58.8 – 73.5 Nm {6.0 – 7.5 kgm} 2) Assemble oil filter tubes (3) and (4).
3) Temporarily tighten tube flange mounting
bolts (54), (55).
4) First tighten the engine cylinder block side
(54) permanently, and then tighten the oil
filter side (55) permanently.
5) Tighten the filter head (6) permanently.
6) Install the cushion (56) on tubes (3) and
(4), and then assemble the clamp.
a Direct the cushion (56) slit position (a)
outward between the clamps.

[*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
50-200 38 WA470-6, WA480-6

[*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 50-200 39

SEN04535-01 Removal and installation of engine front oil seal
Removal and installation of 4. Sling crankshaft pulley (3) temporarily, loosen

engine front oil seal 1 6 mounting bolts (4), then remove the crank-
shaft pulley. [*2]
4
Special tool
Crankshaft pulley: 15 kg
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".
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.
50-200 40 WA470-6, WA480-6

Removal and installation of engine front oil seal SEN04535-01
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 that the seal comes par-
allel with crankshaft, hit the periphery of
the seal 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)
2. Install tool A4-1 and tighten 3 bolts (A4-2) until

they stop to press fit engine front oil seal (5) to
front cover (6).
a Do not fit washers to bolts (A4-2).
3. Remove 3 bolts (A4-2), fit 3 washers (A4-3)

each to them, and tighten them again evenly to
press fit engine front oil seal (5) until the end of
tool A4-1 reaches the end of cover (6).
a Press fitting distance (b) of seal from front
cover end: 16 (+1/0) mm
WA470-6, WA480-6 50-200 41

SEN04535-01 Removal and installation of engine front oil seal

[*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}
50-200 42 WA470-6, WA480-6

Removal and Installation of engine rear oil seal SEN04535-01
Removal and Installation of 3. Remove engine rear oil seal (2).

engine rear oil seal 1 a Before removing the seal, drive in it a little
to separate.
Special tool a Take care not to damage the seal contact
faces of flywheel housing (3) and crank-
New/Remodel
shaft (4).
a If it is difficult to remove the seal, remove it
Necessity
Sym-
Part No. Part name
bol
Sketch
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 01010-61645 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
q A6: Press fitting of standard seal

q A7, A8: Press fitting of sleeved seal Removal of standard seal
1) Drill several holes about 3 mm in diameter
Removal into engine rear oil seal (2).
1. Remove the engine assembly. For details, see a Remove all the chips.
"Removal and installation of engine assembly." 2) Replace the tip of tool A5 with the drill-
type tip and insert it in one of the holes
2. Remove flywheel (1). [*1] drilled in the above step.
3) Pull hammer [1] of tool A5 toward you and
remove the engine rear seal with impact
forces.
a Perform the above procedure at sev-
eral places so that the seal will not
slant.
WA470-6, WA480-6 50-200 43

SEN04535-01 Removal and Installation of engine rear oil seal
Removal of sleeved seal Installation

1) Replace the tip of tool A5 with the hook- Selection of seal
type tip and hitch it to outer case (a) of a Select the “standard” or “sleeved” engine rear
engine rear oil seal (2). oil seal.
2) Pull hammer [1] of tool A5 toward you and a Decide which oil seal to select by feeling the
remove the engine rear seal with impact wear of the oil seal contact surface of the
forces. crankshaft with the finger cushion.
a Perform the above procedure at sev- q If wear (level difference) is not felt:
eral places so that the seal will not Standard seal
slant. q If wear (level difference) is felt:
3) Cut and remove sleeve (5) with a chisel Sleeved seal
and a hammer.
a Take care not to damage crankshaft
(4).
a Remove all the chips.
Procedure for installing standard seal

a Clean, degrease, and dry the contact face
against the flywheel housing.
a Check that the end corners of the crankshaft,
lip sliding surfaces, and housing are free from
flaws, burrs, rust, etc.
a Do not apply oil or grease to the crankshaft
and seal lip (b) of the slash part. Wipe off the
oil from the crankshaft.
a Never remove guide (6) installed to standard
seal (2) before installing the rear seal.
50-200 44 WA470-6, WA480-6

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.
5. Remove 3 bolts (A6-2), fit 1 washer (A6-3)

press fit engine rear oil seal (2) until the end of
tool A6-1 reaches the end of crankshaft (4).
a Press fitting distance (d) of seal from
crankshaft end: 16.3 ± 0.2 mm
a When press fitting the seal, take care not
to damage the seal lip with the tool, etc.
a After press fitting the seal, remove the red
sealant layer from its periphery.
2. Push in the outer case end of engine rear oil

seal (2) evenly.
3. After press fitting engine rear oil seal (2),

remove guide (6).
a When removing the guide, take care not to
damage the seal lip.
WA470-6, WA480-6 50-200 45

SEN04535-01 Removal and Installation of engine rear oil seal
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.
3. Remove tool A7 and interchange with tool A8-

1.
4. Tighten 3 bolts (A8-2) evenly until the end of

tool A8-1 touches the end of crankshaft (4) to
1. Set sleeve and seal assembly (2) to tool A7-1. press fit sleeve and seal assembly (2).
2 Sleeve inside cylinder surface: a Do not fit washers to bolts (A8-2).
5. Remove 3 bolts (A8-2), fit 3 washers (A8-3)
press fit sleeve and seal assembly (2) until the
end of tool A8-1 reaches the end of crankshaft
(4).
a Press fitting distance (e) of sleeve and seal
assembly from crankshaft end:
16.3 ± 0.2mm
a After press fitting the seal, remove the red
sealant layer from its periphery.
50-200 46 WA470-6, WA480-6

a Carry out the following installation in the

[*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}
a After installing the flywheel, measure the facial

runout and radial runout with dial gauge [1].
q Radial runout: Max. 0.30 mm
q Facial runout: Max. 0.30 mm
WA470-6, WA480-6 50-200 47

SEN04535-01 Removal and installation of fuel tank assembly
Removal and installation of fuel 6. Loosen clamp (6) and pull out hose (7).
tank assembly 1
Removal
tires.
battery beforehand.
1. Drain fuel.
5 When fuel tank is full: 413 l
7. Remove 2 clamps (9) for air conditioner hose

2. Open right and left plates (1). (8).
8. Remove clamp (11) of fuel breather hose (10),

remove the clip and disconnect the hose from
the fuel tank assembly.
3. Remove right and left steps (2).
9. Remove 2 clamps (13) on radiator coolant

drain hose (12).
4. Remove clamp (3) and disconnect engine oil

drain valve (4) from the fuel tank.
5. Disconnect radiator coolant drain valve (5)

from the fuel tank.
50-200 48 WA470-6, WA480-6

Removal and installation of fuel tank assembly SEN04535-01
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.
15. Disconnect connector R33 (16) on the

machine left side.
12. Temporarily lift the fuel tank assembly with

nylon sling [2].
a Bottom face of the fuel tank assembly is
inclined. Thus, take the action so that the
nylon sling may not slip off.
16. Disconnect fuel supply hoses (17) and (18) on
the machine right side.
17. Disconnect fuel return hose (19) on the

machine right side.
WA470-6, WA480-6 50-200 49

SEN04535-01 Removal and installation of fuel tank 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
19. Place fuel tank assembly on pallet jack [4] and

pull it out of the machine.
50-200 50 WA470-6, WA480-6

Removal and installation of fuel tank assembly SEN04535-01
WA470-6, WA480-6 50-200 51

SEN04535-01

©2009 KOMATSU
All Rights Reserved
50-200 52
SEN04536-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
50 Disassembly and assembly 50
301 Power train, Part 1

Removal and installation of torque converter and transmission assembly ..................................................... 2
Disassembly and assembly of torque converter and transmission assembly ................................................. 7
Disassembly and assembly of torque converter assembly (Standard specification) .................................... 40
Disassembly and assembly of torque converter assembly (Lockup specification) ....................................... 45
Disassembly and assembly of clutch pack assembly ................................................................................... 53
WA470-6, WA480-6 50-301 1

SEN04536-01 Removal and installation of torque converter and transmission assembly
Removal and installation of

torque converter and
transmission assembly 1
Removal
tires.
battery beforehand.
1. Drain hydraulic oil.

7. Remove oil feed pipe (5).
6 Hydraulic oil: 173 l
8. Disconnect center drive shaft (6) on the trans-
2. Drain the transmission oil. mission side. [*1]
a When removing the coupling, put a block
6 Transmission oil: 65 l between the drive shaft and frame.
a Make a counter mark on the coupling and
3. Remove the hood assembly, referencing to drive shaft before removing them.
assembly."
4. Remove the hydraulic tank assembly, referenc-

ing to "Removal and installation of hydraulic
tank assembly."
5. Remove the operator's cab and floor frame

assembly, referencing to "Removal and instal-
lation of operator's cab and floor frame assem-
bly."
6. Remove right and left covers (1), (2), (3) and

(4).
9. Disconnect rear drive shaft (7) on the transmis-
sion side. [*2]
drive shaft before removing them.
50-301 2 WA470-6, WA480-6

Removal and installation of torque converter and transmission assembly SEN04536-01
10. Disconnect hoses (8) and (9) at the rear of the 13. Disconnect hoses (16), (17) and (18).
accumulator.

11. Disconnect connectors R29 (10) and R71 (11)
and hose (12).
12. Remove bracket (13). 16. Remove U-bolt (21) and bracket (22).
WA470-6, WA480-6 50-301 3

18. Remove bracket (24). 22. Disconnect connector R86 (29).
23. Remove hose (30) and block (31) together.
19. Disconnect connector R96 (25) at the bottom

of the steering pump.
24. Disconnect wiring (32) from the emergency
steering motor.
25. Disconnect hoses (33) and (34).
21. Remove tube (28).
26. Disconnect connectors R36 (35), R37 (36),

R40 (37) and remove wiring harness clamp.
50-301 4 WA470-6, WA480-6

Removal and installation of torque converter and transmission assembly SEN04536-01
27. Disconnect hose (38). 32. Loosen locknuts (42) on the machine front side
of the right and left transmission mounting
28. Remove tube (39) and bracket together. brackets and tighten stopper bolts (43) to
increase the clearance to the mounting brack-
ets. [*3]
33. Remove bolt (44), plate (45) and insulator (46).

[*4]
34. Remove mounting bolt (47) and mounting

bracket (48).
a Since mounting bracket (49) on the
machine right side cannot be removed, fix
it to the machine with a rope.
29. Disconnect hoses (40) and (41) at the trans-

mission unit on the right side of the machine.
30. Sling the torque converter and transmission

assembly temporarily.
31. Put block [1] between the flywheel housing and

rear axle top.
a In the figure, the torque converter and
transmission assembly are removed for
explanation.
35. Remove torque converter mounting bolts (50)
on the engine side.
WA470-6, WA480-6 50-301 5

36. Sling torque converter and transmission Installation

assembly (51), then remove it. [*5] q Carry out installation in reverse order of
a Confirm that all the wiring harnesses and removal.
piping are disconnected from the
machine. [*1]
a While taking care of interference with the a Tightening torque is observed strictly.
machine, remove the assembly. 3 Center drive shaft mounting bolt:
4 Torque converter and transmission 98.1 – 122.6 Nm {10 – 12.5 kgm}
assembly: 1,200 kg
[*2]
a Tightening torque is observed strictly.
3 Rear drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
a Adjust clearances (a) between the bracket and
front and rear stopper bolts (43) to the follow-
ing value and tighten locknuts (42).
q Clearance (a): 2 mm
[*4]
3 Transmission mounting bolt:
455 – 565 Nm {46.5 – 58 kgm}
[*5]
a Adjust the height of the torque converter
to allow its shaft and ring gear to easily fit
before connecting.
q Refilling with oil (Transmission)

a Add power line oil up to the specified level.
again.

again.
q Bleeding air
Bleed air from work equipment circuit. For
details, see Testing and adjusting.
50-301 6 WA470-6, WA480-6

Disassembly and assembly of torque converter and transmission assembly SEN04536-01
Disassembly and assembly of torque converter and transmission

assembly 1
Special tools
New/Remodel
New/Remodel
Necessity
Necessity
Sym- Sym-
Part No. Part name Part No. Part name
Sketch
Sketch
bol bol
Q'ty
Q'ty
793T-607-1250 Bracket t 1 R Q 29 796-765-1110 Push tool t 1
1 01051-62240 Bolt t 1 30 790-201-2680 Plate q 1
01643-32260 Washer t 1 31 794T-425-1110 Push tool t 1 Q
793T-607-1260 Plate t 1 N Q 32 793T-607-1410 Push tool t 1 R Q
01016-52045 Bolt t 1 33 791T-630-2410 Push tool t 1 Q
2
01016-51690 Bolt t 1 34 792-822-1430 Plate q 1
01010-81245 Bolt t 4 35 796-630-1110 Plate q 1
3 793T-607-1270 Plate t 1 N Q 36 795-102-2730 Collar q 1
4 790-102-1891 Nut wrench t 1 37 793T-607-1420 Push tool t 1 R Q
793T-607-1220 Lifting tool t 1 Q 38 792-822-1430 Plate q 1
5
793-607-1230 Pin t 1 39 791-100-1260 Sleeve q 1
793T-607-1280 Lifting tool t 2 R Q 40 790-445-3810 Push tool t 1
01016-31245 Bolt t 4 41 790-201-2860 Spacer q 1
B
01580-11210 Nut t 4 790-101-5401 Push tool kit q 1
01017-32050 Bolt t 2 790-101-5421 • Grip 1
6 42
01643-32060 Washer t 4 790-101-5441 • Plate 1
01580-12016 Nut t 4 01010-51240 • Bolt 1
793T-607-1290 Bar t 1 R Q 43 790-434-1470 Push tool q 1
04530-11628 Eye bolt t 1 793T-607-1430 Push tool t 1 R Q
B 793T-607-1310 Plate t 1 N Q 51 790-101-5421 Grip t 1
793T-607-1320 Push tool t 1 N Q 01010-51240 Bolt t 1
7 2989-01-1220 Bolt t 1 52 793T-607-1140 Spacer t 1 Q
01643-33080 Washer t 2 793T-607-1440 Push tool t 1 R Q
01017-31420 Bolt t 8 53 790-101-5421 Grip t 1
793T-607-1330 Bracket t 1 N Q 01010-51240 Bolt t 1
793T-607-1340 Plate t 1 N Q 54 793T-607-1450 Spacer t 1 R Q
8
01010-80820 Bolt t 2
01643-30823 Washer t 2
793T-607-1350 Bolt t 1 N Q
9
04530-11018 Eye bolt t 1
793T-607-1360 Sleeve t 1 R Q
10 01017-52030 Bolt t 1
01643-32060 Washer t 1
23 790-201-2660 Plate q 1
24 792-135-3360 Plate q 1
25 792-822-1430 Plate q 1
26 790-201-2860 Spacer q 1
27 792-822-1430 Plate q 1
28 792T-227-1110 Push tool t 1 Q
WA470-6, WA480-6 50-301 7

SEN04536-01 Disassembly and assembly of torque converter and transmission assembly
Disassembly 2) Remove tube (4) and gauge (5).

1. Place the torque converter and transmission
assembly on a level place and stabilize it with
blocks etc.
2. Remove the steering and power train pump

assembly. For details, see “Removal and
installation of steering and power train pump
assembly.”
3. Remove the work equipment and cooling fan

pump assembly. For details, see “Removal and
installation of work equipment and cooling fan
pump assembly.”
4. Remove emergency steering pump and motor

assembly (1) and bracket (2). 3) Disconnect hose (6) and remove flange
(7).
5. Disconnect all the wiring harness connectors

and remove the wiring harnesses. 4) Remove tube (8) and filter assembly (9).
a For details of the wiring harness connec-
tors, see Electrical diagrams and draw-
ings, “Connector list and stereogram.”
6. Removal of piping, sensors and ECMV

assembly
1) Remove tube (3).
50-301 8 WA470-6, WA480-6

5) Remove tubes (10) and (10a). 10) Using guide bolt [1], remove F ECMV
6) Remove transmission output speed sen- assembly (15), 1st ECMV assembly (16)
sor (11). and 4th ECMV assembly (17) together
with plate (18).
a In the lockup specification, the L/C
ECMV assembly is installed on F
ECMV assembly (15).
7) Remove transmission oil temperature sen-

sor (12).
11) Remove main relief valve (19).
8) Remove torque converter oil temperature

sensor (13).
9) Remove tube (14).
12) Using guide bolt [2], remove R ECMV
assembly (20), 2nd ECMV assembly (21),
3rd ECMV assembly (22), block (23), and
filter (24) together with plate (25).
WA470-6, WA480-6 50-301 9

13) Remove transmission input speed sensor 2) Remove holder (30) and plate (31).
(26).
3) Install the bolt (M20 x 2.5) of tool B2 to

7. Coupling and strainer transfer shaft 1 (68).
Remove coupling (27) and strainer (28).
4) Install tool B2.

8. Preparation work for removal of R and 2nd
clutch pack assembly
a At this time, install the tools for removing
the R and 2nd clutch pack assembly.
1) Remove cage (29).
50-301 10 WA470-6, WA480-6

9. Separation of front case and rear case 5) Reverse the rear case and stabilize it with
1) Place the torque converter and transmis- blocks etc.
sion assembly with the torque converter 6) Remove snap ring (34) and bearing (35).
side up on a level place and stabilize it
with blocks etc.
2) Sling rear case (32) temporarily, then
remove the coupling bolts between the
front case and rear case.
3) Using forcing screw [3] (M12 x 1.75), sep-
arate the front case and rear case.
4) Lift rear case (32), then remove it.
7) Install bolts [5] (M10 x 1.5) to the screw

hole for lifting and remove spacer (36).
10. Separation of torque converter assembly

1) Place the rear case with the torque con-
verter side up on a level place and stabi-
lize it with blocks etc.
2) Remove the mounting bolts of housing
(33).
3) Using forcing screws [4] (M12 x 1.75),
separate the housing and rear case.
4) Lift housing (33), then remove it.
8) Remove thrust plate (37) and snap ring
(38).
WA470-6, WA480-6 50-301 11

9) Remove10 pieces of bolt (39). 11. PTO assembly

a Remove cover (40) as necessary. a Disassemble the right and left PTO
a When removing the cover, install bolts assemblies similarly.
(M10 x 1.5) to the forcing taps. 1) Remove the mounting bolts of PTO
assembly (42).
2) Using forcing screws [7], lift PTO assem-
bly (42), then remove it.
10) Sling and remove rear case (41) and sep-

arate torque converter assembly (41a).
3) Using tool B3, fix gear (43).

4) Using tool B4, remove nut (44).
a For the disassembly and assembly proce-

dure for the torque converter assembly,
see “Disassembly and assembly of torque
converter assembly.” 5) Remove cage (45) and bearing (46).
6) Remove bearing (47) from gear (43).
50-301 12 WA470-6, WA480-6

7) Remove outer races (48), (49) and snap

ring (45a) from cage (45).
3) Remove gear (58).
12. Rear case

Remove outer races (50), (51) and (52) from
the rear case.
4) Remove inner race (58a) from gear (58).
13. Input shaft and gear

1) Remove input shaft (53).
2) Remove seal rings (54), thrust bearing
(55), thrust plate (56), and inner race (57)
from the input shaft.
WA470-6, WA480-6 50-301 13

5) Remove bearing (60) from front case (59). 3) Install tool B6 to R and 2nd clutch pack
assembly (65) and 3rd and 4th clutch pack
assembly (66) and sling them temporarily.
4) While tightening the center bolt of tool B2
installed in step 8-4), lift R and 2nd clutch
pack assembly (65) and 3rd and 4th clutch
pack assembly (66), then remove them.
a Remove the above assemblies by sepa-
rating inner race (67) and transfer shaft
No.1 (68).
2 Threaded portion and end face of tool
B2 center bolt:
Molybdenum disulphide lubricant
14. Clutch pack assembly

1) Remove seal rings (61), (62), and (63)
from each clutch pack assembly.
2) Using tool B5, lift F and 1st clutch pack

assembly (64), then remove it.
a For the disassembly and assembly proce-

dure for the clutch pack assembly, see
“Disassembly and assembly of clutch pack
assembly.”
50-301 14 WA470-6, WA480-6

15. Parking brake 5) Remove 4 bolts (74) and 12 bolts (75).

1) Remove coupling (69). 6) Remove cover (76).
2) Remove the mounting bolts of cage (71). 7) Remove springs (77) and (78).
3) Using forcing screws [8] (M8 x 1.25), 8) Using eyebolts (M12 x 1.75), remove pis-
remove cage (71). ton (79).
4) Remove dust seal (72) and oil seal (73) 9) Remove O-rings (80), (81) and backup
from cage (71). rings (82), (83) from piston (79).
WA470-6, WA480-6 50-301 15

10) Using too B1, push spacer (84) to remove 13) Remove spacer (90).
ring (85). 14) Install a bolt (M10 x 1.5) to the screw hole
lifting, then remove hub (91).
15) Remove plate (92).
11) Install bolts [11] (M8 x 1.25) to the screw

hole lifting, then remove spacer (86).
16) Remove the mounting bolt of retainer (93).
remove retainer (93).
12) Remove 7 plates (87), 6 springs (88) and

6 discs (89).
18) Remove outer race (94) from retainer (93).
50-301 16 WA470-6, WA480-6

19) Remove shim (95). 22) Remove bearing (99), spacer (100), gear
(101), and bearing (102) from shaft (98).
20) Lift housing (96), then remove it.

23) Remove cover (103) and outer race (104).
21) Install an eye bolt (M22 x 1.5) to the screw

hole lifting of the shaft, then remove shaft 16. Transfer shaft No. 2 and transfer gear No. 2
and gear assembly (97). 1) Remove the mounting bolts of cage (105).
remove cage (105).
WA470-6, WA480-6 50-301 17

3) Remove outer race (106) from cage (105). 7) Tighten the peripheral bolts of tool B7 to
separate and remove transfer shaft No. 2
(108) from transfer gear No. 2 (109).
a Tighten all the peripheral bolts evenly.
2 Threaded portion and end face of
peripheral bolt:
Molybdenum disulphide lubricant
8) Remove bearings (108a) and (108b) from
transfer shaft No. 2 (108).
9) Move transfer gear No.2 (109) laterally to
remove.
10) Remove outer race (111) from front case
(110).
4) Remove shims (107).

5) Remove snap ring (107a) and plate
(107b).
6) Install tool B7 to transfer shaft No. 2 (108)

and transfer gear No. 2 (109).
50-301 18 WA470-6, WA480-6

17. Transfer gear No. 1 4) Remove snap ring (116) and remove bear-
a Transfer shaft No. 1 was removed together ing (118) from front case (117).
with the R and 2nd clutch pack assembly.
1) Remove inner race (112) and bearing
(113).
a After removing bearing (113), remove
the remaining plate [a component
part of bearing (113)].
18. Cage
1) Remove cage (118) and shims (119) from
front case (117).
2) Remove transfer gear No.1 (114).
2) Remove outer race (120) from cage (118).
3) Remove spacer (115) from transfer gear

No.1 (114).
WA470-6, WA480-6 50-301 19

19. Retainer Assembly

1) Remove retainer (121) from front case a Press fit each bearing outer race and inner
(117). race until they stop at case or shaft and check
2) Remove dust seal (122) and oil seal (123) that the feeler gauge (Thickness: 0.05 mm)
from retainer (121). cannot be inserted.
a After installing each bearing, apply at least 6 cc
of power line oil (TO10) to it and rotate it at
least 10 turns to lubricate.
1. Retainer
1) Thinly apply gasket sealant (LG-5) to the
oil seal fitting face of retainer (121).
2) Using tool B53, press fit oil seal (123) to
retainer (121) until dimension (a) becomes
as follows.
a Dimension (a) is 18.9 ± 0.2 mm
2 Oil seal lip and end faces:
Grease (G2-LI)
3) Using tools B53 and B54, press fit dust

seal (122).
a Press fit so that dimension (b) will be
9.9 ± 0.2 mm.
2 Dust seal lip: Grease (G2-LI)
50-301 20 WA470-6, WA480-6

4) Install retainer (121) to front case (117). 3. Bearing for transfer shaft No.1
Install snap ring (116) to front case (117).
Using tool B24, press fit bearing (118).
2. Cage
1) Using tool B23, press fit outer race (120)
to cage (118). 4. Transfer shaft No.2 and transfer gear No.2
2 Inside of outer race: 1) Using tools B25 and B26, press fit outer
Power line oil (TO10) race (111) to front case (110).
2 Inside of outer race:
Power line oil (TO10)
2) Install shims (119) and cage (118) to front

case (117) temporarily.
2 Outside of O-ring: Grease (G2-LI) 2) Using tool B27, press fit outer race (106)
a Select shims (119) so that their total to cage (105).
thickness will be 2.2 – 2.5 mm. 2 Inside of outer race:
a After assembling the torque converter Power line oil (TO10)
and transmission assembly, adjust
shims (119).
WA470-6, WA480-6 50-301 21

3) Using tools B28 and B29, press fit bear- 7) Install tool B9 to transfer shaft No.2 (108).
ings (118a) and (108b) to transfer shaft 8) Cool transfer shaft No.2 (108) with tool B8
No.2 (108). installed in a freezer for at least 1 hour.
4) Apply oil to bearings (108a) and (108b) 9) Cool plate (107b) in the freezer.
and rotate them at least 10 turns to lubri- a The plate does not need to be cooled
cate. so long as transfer shaft No.2 (108).
2 Bearing: Power line oil (TO10) 10) Check that the temperature difference
between transfer gear No.2 (109) and
transfer shaft (108) is at least 140°C.
5) Install tool B8 to transfer gear No.2 (109).

6) Heat transfer gear No.2 (109) with tool B8
installed in heating chamber. 11) Set heated transfer gear No.2 (109) and
a Heat the gear at temperature below tool B8 together into front case (110).
145°C for at least 2 hours. 2 Inside of gear:
12) Check that the inside of transfer gear No.2
(109) is aligned with that of outer race
(111).
13) Insert transfer shaft No.2 (108) slowly in
transfer gear No.2 (109).
a Insert the shaft until it stops.
a Once the shaft is positioned, do not
raise it. (At the moment when the
shaft is raised, the temperature differ-
ence may decrease and the shaft and
gear may become stuck.)
50-301 22 WA470-6, WA480-6

14) Check with a depth gauge that level differ- 18) Install plate (107b) and snap ring (107a).
ence (b) between transfer shaft No.2 (108)
and transfer gear No.2 (109) is in the fol-
lowing range.
q Dimension (b): –0.4 to 0.4 mm
a If dimension (b) is out of the standard
range, separate the shaft and gear
immediately. Find out the cause and
then repeat the work from step 6).
15) Leave the shaft and gear until they return
to the normal temperature for at least 20
minutes.
16) Rotate transfer shaft No.2 (108) to check
that it is press fitted to transfer gear No.2
(109) (that it does not slip on the gear).
a Do not raise transfer shaft No. 2 (108).
17) Remove tools B8 and B9. 19) Install cage (105) temporarily.
a Adjust shims in step 5-9) and then
tighten cage (105) permanently.
2 Outside of O-ring: Grease (G2-LI)
WA470-6, WA480-6 50-301 23

5. Parking brake 3) Install gear (101) and spacer (100) to shaft

1) Using tools B30 and B31, press fit outer (98).
race (104) to the front case. a Install gear (101) with lifting tap side
2 Inside of outer race: down as shown.
Power line oil (TO10) 4) Using tools B32 and B33, press fit bear-
2) Install cover (103). ings (99) and (102) to shaft (98).
2 Mounting bolt: Adhesive (LT-2) 2 Bearings (99) and (102):
3 Mounting bolt: Power line oil (TO10)
98 – 123 Nm {10 – 12.5 kgm}
50-301 24 WA470-6, WA480-6

5) Install eye bolt (M22 x 1.5) to the lifting tap 7) Using tool B34, press fit outer race (94) to
of the shaft, sling shaft and gear assembly retainer (93).
(97), lower it and install. 2 Inside of outer race:
6) Sling housing (96), lower it and install.

WA470-6, WA480-6 50-301 25

8) Adjust the output shaft shim according to 6] Using torque wrench [22], measure
the following procedure. starting torque (B) of shaft (98).
1] Install retainer (93) without inserting 7] Confirm that value (B – A) obtained
shim (95). by subtracting starting torque (A) from
3 Mounting bolt: starting torque (B) is as follows.
9.80 ± 0.98 Nm {1 ± 0.1 kgm} q B – A = 0.49 – 2.9 Nm {0.05 –
2] Rotate shaft (98) to the right and left 0.3 kgm}
10 turns each and check that the 8] If value (B – A) is out of the above
tightening torque of the mounting bolt range, adjust shim (95) until the
of retainer (93) has not changed. former is in the range and repeat
a If the tightening torque has steps 5] – 7].
changed more than 0.98 Nm {0.1 a If the shim thickness changes
kgm}, repeat steps 1] and 2]. +0.1 mm, the starting torque
changes –5.88 to –1.96 Nm
{–0.60 to –0.20 kgm}
9) Adjust the shim of transfer shaft No.2

1] Install cage (105) without inserting
shim (107).
2 Outside of O-ring:
Grease (G2-LI)
3 Mounting bolt:
9.80 ± 0.98 Nm {1 ± 0.1 kgm}
2] Rotate shaft (98) to the right and left
10 turns each and check that the
tightening torque of the mounting bolt
of cage (105) has not changed.
3] Loosen the mounting bolt of retainer a If the tightening torque has
(93) and using torque wrench [22], changed more than 0.98 Nm {0.1
measure starting torque (A) of shaft kgm}, repeat steps 1] and 2].
(98). 3] Measure clearance (c) at 3 points
4] Remove retainer (93) and select equally spaced on the periphery and
shims (95) so that their total thickness calculate the average.
will be as follows. a If the difference between the
q Set shim thickness (mm): maximum and minimum of the
0.15, 0.20, 0.50 measured clearances at 3 points
q Total shim thickness (mm): is larger than 0.15 mm, the bear-
1.35 (+0.35/–0.45) ing is not tightened sufficiently or
5] Tighten retainer (93) to the following there is another cause. Find out
torque. the cause and repair.
3 Mounting bolt: 4] Loosen the mounting bolts of cage
98.0 – 122.5 Nm {10 – 12.5 kgm} (105).
50-301 26 WA470-6, WA480-6

5] Select shims (107) so that their total 10) Install plate (92).
thickness will be the value calculated a Install the plate with the level differ-
by adding 0.15 to 0.21 mm to the ence side down.
average of clearance (c) calculated in 11) Install hub (91) and spacer (90).
step 3] and then install them. 2 Both ends of hub and spacer:
6] Tighten the mounting bolts of cage Molybdenum disulphide
(105). lubricant or molybdenum
3 Mounting bolt: disulphide grease (LM-G)
98.0 – 122.5 Nm {10 – 12.5 kgm}
7] Using torque wrench [22], measure
starting torque (C) of shaft (98).
8] Confirm that value (C – B) obtained
by subtracting starting torque (B)
measured in step 8)-6] from starting
torque (C) is as follows.
q C – B = 0.49 – 2.9 Nm {0.05 –
0.3 kgm}
9] If value (C – B) is out of the above
range, adjust shims (107) until the
former is in the range and repeat
steps 6] – 8].
a If the shim thickness changes
+0.1 mm, the starting torque
changes –6.86 to –1.96 Nm 12) Install 7 plates (87), 6 springs (88) and 6
{–0.70 to –0.20 kgm}. discs (89).
a Install in the order shown in the figure
and take care that spring (88) will not
be caught.
WA470-6, WA480-6 50-301 27

13) Install bolts [11] (M8 x 1.25) to the lifting 16) Using eyebolts (M12 x 1.75), install piston
tap and install spacer (86). (79) to housing (96).
2 Outside of O-ring: Grease (G2-LI) a When installing, align the match-
marks (a) on the housing and piston.
14) Using tool B1, push spacer (84) and install

ring (85).
17) Install springs (77) and (78).
15) Install O-rings (80) and (81) and backup

rings (82) and (83) to piston (79).
2 Outside of O-ring and backup ring:
Grease (G2-LI)
50-301 28 WA470-6, WA480-6

18) Install cover (76). 22) Press fit dust seal (72).
19) Tighten 12 bolts (75) and 4 bolts (74) a Using tools B51 and B52, press fit the
gradually and evenly. dust seal so that dimension (b) will be
a Check that the dowel pin on the cover 10 ± 0.2 mm.
side is matched to the hole on the pis-
ton side.
3 Mounting bolt:
98 – 123 Nm {10 –12.5 kgm}
23) Install cage (71).

20) Thinly apply gasket sealant (LG-5) to the

oil seal fitting face of cage (71).
21) Using tool B51, press fit oil seal (73).
a Press fit the oil seal so that dimension
(a) will be 19 ± 0.2 mm.
2 Oil seal lip and end face:
Grease (G2-LI)
24) Install coupling (69).

3 Mounting bolt:
662 – 829 Nm {67.5 – 84.5 kgm}
WA470-6, WA480-6 50-301 29

6. Clutch pack assembly 7. Input shaft and gear

1) Reverse the front case. 1) Using tool B35, press fit bearing (60) to
2) Using tool B6, install R and 2nd clutch front case (59).
pack assembly (65) and 3rd and 4th clutch 2 Bearing: Power line oil (TO10)
pack assembly (66) simultaneously to the
front case.
2) Using tool B36, press fit inner race (58a)

to gear (58).
3) Using tool B5, install F and 1st clutch pack
assembly (64).
3) Install gear (58).

a Check that the level difference
4) Install seal rings (61), (62) and (63) to between the 3 meshed gears is 3 mm
each clutch pack assembly. or less. If gear (140) is higher, F and
a When installing F and 1st clutch pack 1st clutch pack assembly (64) may be
seal rings (62) and R and 2nd clutch stopped at the faucet joint portion.
pack seal rings (63), check that there
are oil grooves on their sides.
2 Outside of seal ring: Grease (G2-LI)
50-301 30 WA470-6, WA480-6

4) Using tool B37, press fit inner race (57) to 8. Rear case
input shaft (53). Using tool B38, press fit outer races (50), (51)
and (52) to the rear case.
a Press fit taper roller bearing outer race
(50) to the part where there is identifica-
tion hole (a).
2 Inside of outer race:
5) Install thrust plate (56), thrust bearing (55)

and seal rings (54).
a When installing seal rings (54), confirm
that there are oil grooves on its sides.
2 Outside of seal ring:
Grease (G2-LI)
9. PTO assembly
a Install the right and left PTO assemblies in
the same way.
a When installing the inner race and outer
race of the bearing, confirm that their
manufacture Nos. and match symbols (A)
or (B) are the same.
6) Install input shaft (53).
WA470-6, WA480-6 50-301 31

1) Install snap ring (45a) to cage (45). 7) Using tool B3, fix gear (43).
2) Using tool B39, press fit outer races (48) 8) Using tool B4, tighten nut (44).
and (49) to cage (45). 2 Nut: Adhesive (LT-2)
2 Inside of outer race: 3 Nut:
Power line oil (TO10) 392.3 – 441.3 Nm {40 – 45 kgm}
3) Using tool B40, press fit bearing (47) to 9) Install PTO assembly (42).
gear (43). 2 Outside of O-ring: Grease (G2-LI)
2 Bearing: Power line oil (TO10)
4) Install cage (45) and bearing (46).
5) Tighten nut (44) with the fingers.
a Direct the chamfered side down.
6) Rotate gear (43) at least 10 turns to lubri-
cate.
10. Installation of torque converter assembly

1) Sling and lower rear case (41) onto torque
converter assembly (41a).
50-301 32 WA470-6, WA480-6

2) Using tool B41, press fit cover (40) and 4) Using tool B42, install spacer (36).
tighten 10 bolts (39).
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
5) Using tool B43, press fit bearing (35) and

install snap ring (34).
3) Install snap ring (38) and thrust plate (37).
WA470-6, WA480-6 50-301 33

6) Reverse the rear case and stabilize it with 2) Using guide bolt [18], lift off and install rear
blocks etc. case (32).
7) Using guide bolts [17], install housing (33). 3 Connecting bolt:
2 Outside of O-ring: Grease (G2-LI) 98 – 123 Nm {10 – 12.5 kgm}
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
12. Transfer gear No.1, bearing and cage

11. Coupling of front case and rear case 1) Place on a level place with the front case
1) Apply gasket sealant to the mating faces side up and stabilize with blocks etc.
of the front case and rear case as shown. 2) Install transfer gear No.1 (114) to transfer
a Mark (A) which shows there is tap for shaft No.1 (68).
disassembly on opposite surface. 3) Using tool B10, install spacer (115) to
2 Mating face of case: transfer gear No.1 (114).
Gasket sealant (LG-8) 2 Both ends of spacer:
Molybdenum disulphide
lubricant or molybdenum
disulphide grease (LM-G)
50-301 34 WA470-6, WA480-6

4) Install bearing inner ring (130). 8) Install holder (30).

a The bearing inner ring is a component 2 Mounting bolt: Adhesive (LT-2)
part of bearing (113). 3 Mounting bolt:
a Install the bearing inner ring with the 245 – 275 Nm {25 – 28 kgm}
round corner side down.
2 Both ends of bearing inner ring:
5) Tighten cage (29) with bolts [19] (M12 x
1.5, Stem length: 80 – 40 mm) until it
touches the front case to press fit bearing
(113).
a Do not install the O-ring to cage (29)
at this time.
6) Remove cage (29).
9) Install cage (29).

7) Using plate [20] (Outside diameter: 100

mm, thickness: Approx. 10 mm) and bolt
[21] (M20 x 2.5, stem length: Approx. 70
mm), press fit inner race (112) and spacer
(31).
WA470-6, WA480-6 50-301 35

13. Adjustment of shim for F and 1st shaft 11) Check that there is not play at each end of
1) Install cage (118) without inserting shim the F and 1st shaft.
(119). a Install a bolt (M12 x 1.75, stem
3 Mounting bolt:
length: Min. 140 mm) to the shaft and
measure the end play with a dial
9.80 ± 0.98 Nm {1 ± 0.1 kgm} gauge.
2) Rotate the F and 1st shaft to the right and
12) Install cover (131).
left 10 turns each and check that the tight-
ening torque of the mounting bolts of cage
(118) has not changed.
a Install a bolt (M12 x 1.75) to the F and
1st shaft to rotate.
a If the tightening torque has changed
more than 0.98 Nm {0.1 kgm}, repeat
steps 1) and 2).
3) Measure clearance (d) at 3 points equally
spaced on the periphery and calculate the
average.
a If the difference between the maxi-
mum and minimum of the measured
clearances at 3 points is larger than
0.15 mm, the bearing is not tightened
sufficiently or there is another cause.
Find out the cause and repair
4) Loosen the mounting bolts of cage (118).
5) Using torque wrench [22], measure start-
ing torque (D). 14. Coupling and strainer
6) Select shims (119) so that their total thick- 1) Place the torque converter and transmis-
ness will be the value obtained by adding sion assembly horizontally and stabilize it
0.18 – 0.24 mm to the average of clear- with blocks, etc.
ance (d) calculated in step 3) and then 2) Install coupling (27) and strainer (28).
install them.
7) Tighten the mounting bolts of cage (118).
3 Mounting bolt:
98.0 – 122.5 Nm {10 – 12.5 kgm}
8) Using torque wrench [22], measure start-
ing torque (E) of the F and 1st shaft.
9) Check that value (E – D) obtained by sub-
tracting starting torque (D) measured in
step 5) from starting torque (E) is as fol-
lows.
q E – D = 0.49 – 2.94 Nm {0.05 – 0.3
kgm}
10) If value (E – D) is out of the above range,
adjust shims (119) until the former is in the
range and repeat steps 7) – 9).
a If the shim thickness changes +0.1
mm, the starting torque changes
–5.88 to –1.96 Nm {–0.60 to –0.20
kgm}.
50-301 36 WA470-6, WA480-6

15. Installation of piping, sensors and ECMV 3) Install main relief valve (19).
assembly 3 Mounting bolt:
1) Install transmission input speed sensor 44.1 – 53.9 Nm {4.5 – 5.5 kgm}
(26).
a Confirm the sensor tip is free from
steel dust and flaw.
2 Threaded part of sensor:
3 Sensor: 39.2 – 49 Nm {4 – 5 kgm}
4) Using guide bolts [1], install F ECMV

assembly (15), 1st ECMV assembly (16)
and 4th ECMV assembly (17) together
with plate (18).
a For the lockup specification, install
the L/C ECMV assembly on F ECMV
assembly (15).
2) Using guide bolt 2 [2], install R ECMV
assembly (20), 2nd ECMV assembly (21),
3rd ECMV assembly (22), block (23) and
filter (24) together with plate (25).
5) Install tube (14).

6) Install torque converter oil temperature
sensor (13).
3 Sensor: 29.4 – 49 Nm {3 – 5 kgm}
WA470-6, WA480-6 50-301 37

7) Install transmission oil temperature sensor

(12).
3 Sensor: 29.4 – 49 Nm {3 – 5 kgm}
10) Install tube (8) and filter assembly (9).
8) Install transmission output speed sensor

(11).
1] Loosen locknut (132).
2] Tighten sensor (11) until its tip lightly
touches the tooth tip of gear (133).
a Confirm that the sensor tip is free
from steel dust and flaw.
3] Return sensor (11) by 1/2 to 1 turn.
a Clearance (a) between the sen-
sor tip and tooth tip of gear (133) 11) Install flange (7) and connect hose (6).
is about 0.75 – 1.5 mm at this
time.
4] Fix sensor (11) with locknut (132).
3 Locknut:
49 – 96 Nm {5.0 – 7.0 kgm}
9) Install tubes (10) and (10a).
3 Joint bolt:
M8: 19.6 – 29.4 Nm {2.0 – 3.0 kgm}
M12: 34.3 – 44.1 Nm {3.5 – 4.5 kgm}
50-301 38 WA470-6, WA480-6

12) Install tube (4) and gauge (5). 18. Install the work equipment and cooling fan
2 Gauge mounting bolt: pump assembly. For details, see “Removal and
Adhesive (LT-2) installation of work equipment and cooling fan
3 Gauge mounting bolt: pump assembly.”
12.7 – 13.7 Nm {1.3 – 1.4 kgm}
19. Install the steering and power train pump
assembly. For details, see “Removal and
installation of steering and power train pump
assembly.”
13) Install tube (3).

3 Tube mounting bolt:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
16. Connect the wiring harness connectors.

a For detail of the wiring harness connec-
tors, see Electrical diagrams and draw-
ings, “Connector list and stereogram”.
17. Install emergency steering pump and motor

assembly (1) and bracket (2).
WA470-6, WA480-6 50-301 39

SEN04536-01 Disassembly and assembly of torque converter assembly (Standard specification)
Disassembly and assembly of 2) Remove snap ring (4) and stator (5) from
torque converter assembly stator shaft (7).
(Standard specification) 1
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
790-501-5000 Unit repair stand q 1
11 790-901-2110 Bracket q 1
790-901-4240 Plate q 1
44 790-201-2670 Plate q 1
B
45 790-201-2750 Spacer q 1
46 790-201-2690 Plate q 1 3) Remove pump (6) from gear (11).
47 790-201-2220 Plate q 1
48 791-830-1770 Push tool q 1
Disassembly
1. Place torque converter assembly (1) on the
block. (Or install it to tool B11.)
2. Stator shaft and pump assembly

1) Install eye bolts to the stator shaft, remove
bolts (2), and remove stator shaft and
pump assembly (3).
4) Using push tool [1], separate stator shaft

(7) and bearing (8).
50-301 40 WA470-6, WA480-6

Disassembly and assembly of torque converter assembly (Standard specification) SEN04536-01
5) Remove seal ring (9) from stator shaft (7). 2) Remove snap ring (13) and plate (14).
6) Remove bearing (10) from gear (11). 3) Using push tool [2], separate bearing (15)
and boss (16).
3. Turbine case assembly

1) Remove pilot (12). 4) Remove the mounting bolts and separate
turbine (17) and boss (16).
WA470-6, WA480-6 50-301 41

5) Remove bearing (15) from case (18). Assembly

1. Turbine and case assembly
1) Using tool B44, install bearing (15) to case
(18).
a After installing the bearing, apply at
least 6 cc of power train oil (TO10) to
it and rotate it at least 10 turns to
lubricate.
2) Install turbine (17) to boss (16).

3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3) Using tool B45, install bearing (15) to boss

(16).
50-301 42 WA470-6, WA480-6

Disassembly and assembly of torque converter assembly (Standard specification) SEN04536-01
4) Install plate (14) and snap ring (13). 2) Install seal ring (9) to stator shaft (7).
2 Periphery of seal ring:
Grease (G2-LI)
5) Install pilot (12).

3 Mounting bolt: 3) Using tools B47 and B48, install stator
98 – 123 Nm {10 – 12.5 kgm} shaft (7) to bearing (8).
a After installing the bearing, apply at
lubricate.

1) Using tool B46, press fit bearing (10) to
gear (11).
4) Install pump (6) to gear (11).

3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
WA470-6, WA480-6 50-301 43

5) Install stator (5) and snap ring (4) to stator

shaft (7).
6) Lower stator shaft and pump assembly (3)

onto the turbine and case assembly and
install.
2 Mounting bolt between pump and
case: Adhesive (LT-2)
3 Mounting bolt between pump and
case:
49.0– 58.8 Nm {5.0 – 6.0 kgm}
50-301 44 WA470-6, WA480-6

Disassembly and assembly of torque converter assembly (Lockup specification) SEN04536-01
Disassembly and assembly of 2) Using tool B12, remove nut (4).

torque converter assembly a Install 2 bolts (M12 x 1.75) to the bot-
tom of stator shaft (5) diagonally and
(Lockup specification) 1
fix them with bar [1].
Special tools
New/Remodel
Necessity
Sketch
Q'ty
11 2 790-901-2110 Bracket q 1
3 790-901-4240 Plate q 1
12 792-213-1110 Wrench t 1
B
47 790-201-2220 Plate q 1
48 791-830-1770 Push tool q 1
49 790-201-2750 Spacer q 1
50 790-201-2680 Plate q 1
Disassembly
1. Place the torque converter assembly (1) on
blocks (or with it secured to tool B1).

1) Install eye bolts to the stator shaft, remove
bolts (2), and remove stator shaft and
pump assembly (3).
3) Remove 12 bolts (6) and pump (7).

.
WA470-6, WA480-6 50-301 45

SEN04536-01 Disassembly and assembly of torque converter assembly (Lockup specification)
4) Using push tool [2], separate stator shaft 3. Stator assembly

(5) and bearing (8). 1) Remove stator assembly (13).
.
2) Remove snap rings (14) from the top and
bottom of the assembly to remove race
and free wheel assembly (15) from stator
(16).
5) Remove seal ring (9) from stator shaft (5).
3) Remove bushings (18) from race and free

wheel assembly (15) and then remove
free wheel (19) from race (20).
a Take care not to lose balls (21).
6) Separate gear (10) and guide (11).

7) Remove bearing (8) from guide (11).
.
4. Turbine and case assembly

1) Remove pilot (22).
50-301 46 WA470-6, WA480-6

2) Remove snap ring (23) to remove plate 5. Complete housing

(24). 1) Remove the mounting bolts and separate
complete housing (28) and case (29).
3) Using push tool [3], separate boss (25)

and bearing (26). 2) Remove piston (30) from complete hous-
ing (28).
3) Remove seal rings (31) from piston (30).
4) Remove seal rings (32) and bearing (33)
from complete housing (28).
4) Remove mounting bolt to separate turbine

(27) and boss (25).
5) Remove 2 discs (34) and plate (35) from

case (29).
WA470-6, WA480-6 50-301 47

Assembly 4. Complete housing assembly

1. Complete turbine 1) Install seal rings (32) to complete housing
Install turbine (27) to boss (25). (28).
2 Mounting bolt: Adhesive (LT-2) a Install seal rings (32) as shown in Fig.
3 Mounting bolt: 2 Periphery of seal ring:
58.8 – 73.5 Nm {6.0 – 7.5 kgm} Grease (G0-LI or G2-LI)
2. Turbine, case 2) Install seal rings (31) to piston (30) and

Install complete turbine (36) to block [4] to then fit them to complete housing (28).
mount case (29). a Install seal rings (31) as shown in
a Height (h) of block [4]: Approx. 100 mm Fig..
2 Periphery of seal ring:
Grease (G0-LI or G2-LI)
3. Disc, plate
Install 2 discs (34) and plate (35) to case (29).
2 Sliding surface of disc:
Power train oil (TO10)
50-301 48 WA470-6, WA480-6

3) Using eye bolts [5] (M12 x 1.75), sling 7. Pilot

complete housing assembly (37) and set it Install pilot (22).
to case (29). 2 Mounting bolt: Adhesive (LT-2)
4) Tighten mounting bolt (38). 3 Mounting bolt:
2 Mounting bolt: Adhesive (LT-2) 98 – 123 Nm {10 – 12.5 kgm}
3 Mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
8. Stator assembly
1) Install freewheel (19) to race (20).
5. Bearing a Install the freewheel so that drag clip
Using tool B49, press fit bearing (33). (39) on the periphery of the freewheel
a After press fitting the bearing, drop 6 cc of will not be hitched in the ball groove
power train oil (TO10) and then turn the of race (20).
bearing 10 turns. 2 Sliding surface of freewheel:
6. Plate and snap ring

Fit spacer (24) and then install snap ring (23).
WA470-6, WA480-6 50-301 49

2) Install balls (21) and bushings (18) together 9. Stator shaft and pump assembly
to race (20) by expansion fit. 1) Using tool B50, press fit bearing (8) into
a Paint a mark on the outside of bush- guide (11).
ing (18) in contact with the side which a Ensure that the manufacture Nos. (P
has rotation direction arrow (a) of Nos.) of the inner and outer races of
freewheel (19). the bearing and match mark (A) are
matched at the position shown in Fig..
a After press fitting the bearing, apply at
lubricate.
3) Install snap ring (14) to one of stators (16).

4) Fit race and free wheel assembly (15) to
stator (16) before installing snap ring (14).
a Install so that the face of the mark
made on the bushing in step 2) will be
on the boss side (input side).
2) Install guide (11) to gear (10).
50-301 50 WA470-6, WA480-6

3) Install seal ring (9) to stator shaft (5). 6) Using tool B12, tighten nut (4).
2 Periphery of seal ring: a Install 2 bolts (M12 x 1.75) diagonally
Grease (G2-LI) to the bottom of stator shaft (5) and fix
them with bar [1].
2 Nut: Adhesive (LT-2)
3 Nut: 441 – 490 Nm {45 – 50 kgm}
4) Using tools B47 and B48, press fit stator

shaft (5) to bearing (8) and gear (10).
5) Install pump (7) and tighten bolts (6). 10. Stator assembly and turbine and case
2 Mounting bolt: Adhesive (LT-2) assembly
3 Mounting bolt: 1) Set stator assembly (13) to stator shaft
58.8 – 73.5 Nm {6.0 – 7.5 kgm} (5).
2) Ensure that the rotation direction of the
stator seen from the boss side (input side:
view A) will be as follows.
q Clockwise: Free rotation
q Counterclockwise: Lock
WA470-6, WA480-6 50-301 51

3) Using eye bolts [9] (M12 x 1.75), sling tur-

bine and case assembly (40) and tempo-
rarily tighten bolts (2).
4) Reverse the torque converter assembly
and tighten bolts (2).
2 Bolt: Adhesive (LT-2)
3 Bolt:
49.0 – 58.8 Nm {5.0 – 6.0 kgm}
50-301 52 WA470-6, WA480-6

Disassembly and assembly of clutch pack assembly SEN04536-01
Disassembly and assembly of 2. Spacer

clutch pack assembly 1
1) Remove snap ring (2).
Special tools
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
13 793-415-1170 Seal holder t 1
14 793T-607-1370 Seal holder t 1 R Q
15 796T-667-1120 Push tool t 1 Q
16 799-301-1500 Oil leak tester kit t 1
17 793T-607-1380 Seal holder t 1 R Q
B
18 796T-467-2160 Push tool t 1 Q
19 792T-446-1150 Push tool t 1 Q 2) Using puller [2], remove spacer (3).
20 793T-607-1390 Seal holder t 1 R Q
21 796T-467-2160 Push tool t 1 Q
22 795-102-2730 Collar t 1
k Degrease the surfaces of the clutch pack

thoroughly so that it will not slip and drop
from your hands when you place it on the
block etc.
Disassembly
Disassembly of F and 1st clutch
[F clutch]
1. Bearing
Using puller [1], remove bearing (1).
3. F clutch gear
1) Remove bearing (4).
WA470-6, WA480-6 50-301 53

SEN04536-01 Disassembly and assembly of clutch pack assembly
2) Remove F clutch gear (5). 5. Plate, disc, and spring

Remove plate (10), disc (11), and spring (12).
3) Remove plate (6) and bearings (7) from F

clutch gear (5). 6. Plate and bearing
Remove plates (13) and bearing (14).
4. End plate
1) Using vises [3], press end plate (8). 7. Piston
2) Remove snap ring (9). 1) Using eye bolts [4] (M8 x 1.25), remove
3) Remove end plate (8). piston (15).
50-301 54 WA470-6, WA480-6

2) Remove snap ring (16) and remove lubri- [1st clutch]

cation piston (17) from piston (15). 8. Bearing and 1st clutch gear
1) Using puller [5], remove bearing (20).
2) Remove spacer (21) and washer (22).
3) Remove seal rings (18) and (19) from pis-

ton (15).
3) Remove 1st clutch gear (23).
WA470-6, WA480-6 50-301 55

4) Remove bearings (24) from 1st clutch 11. Plate, disc, and spring
gear (23). Remove plate (28), disc (29), and spring (30).
9. Washer 12. Piston

Remove washer (25). 1) Using eye bolts [7] (M8 x 1.25), remove
piston (31).
10. End plate

1) Using push tool [6] (Push tool: Approx. 2) Remove seal rings (32) and (33) from pis-
120 mm in diameter, Bolt: M12 x 1.75 and ton (31).
nut), press end plate (26).
3) Remove end plate (26).
50-301 56 WA470-6, WA480-6

Disassembly of R and 2nd clutch pack assembly 3. Bearing and plate

[R clutch] Remove bearing (37) and plate (38).
1. Bearing
Remove bearing (34).
4. R clutch gear
1) Remove R clutch gear (39).
2. Spacer
2) Remove bearings (40) from R clutch gear

(39).
2) Using pullers [8] and [9], remove spacer
(36).
WA470-6, WA480-6 50-301 57

5. Plate and bearing 8. Piston

Remove plates (41) and bearing (42). 1) Using eye bolts [12] (M8 x 1.25), remove
piston (48).
6. End plate
1) Using vise [10] and push tool [11], press 2) Remove snap ring (49), remove lubrica-
end plate (43). tion piston (50) from piston (48).

ton (48).
7. Plate, disc, and spring
Remove plate (45), disc (46), and spring (47).
50-301 58 WA470-6, WA480-6

[2nd clutch] 2) Using puller [13], remove bearing (57) and

9. Transfer shaft No.1 hub (58) together.
1) Remove transfer shaft No.1 (53).
11. End plate

2) Remove inner race (54) from transfer 1) Using push tool [14] (Push tool: Approx.
shaft No.1 (53). 120 mm in diameter, Bolt: M12 x 1.75 and
nut), press end plate (59).
10. Bearing and hub

1) Remove snap ring (55) and ring (56).
WA470-6, WA480-6 50-301 59

12. Plate, disc, and spring Disassembly of 3rd or 4th clutch pack assembly
Remove plate (61), disc (62), and spring (63). [4th clutch]
1. Bearing
1) Remove bearing (67) and plate (68).
13. Piston
1) Using eye bolts [15] (M8 x 1.25), remove
piston (64).
2. Ring, cover and collar
1) Remove ring (70) and cover (71).

ton (64).
2) Remove collars (72) and seal rings (73).
50-301 60 WA470-6, WA480-6

3. Cylinder assembly 5. Plate, disc and spring

Remove cylinder assembly (74) using the eye- Remove plate (77), disc (78), and spring (79).
bolt (M8 x 1.25).
6. Plate, bearing and washer

4. End plate Remove plate (80), bearing (81), and washer
1) Press end plate (75) using the vise [16]. (82).
7. Piston
1) Remove piston (83) using the eye bolts
[17] (M8 x 1.25).
WA470-6, WA480-6 50-301 61

2) Remove seal rings (84) and (85) from pis- [3rd clutch]
ton (83). 9. Bearing, spacer and plate
a Stick a tape etc. to the bearing sliding
surface (a) of the shaft to protect from
being scratched.
2) Remove spacer (90).
8. 4th gear
1) Remove 4th gear (86).
3) Remove spacers (91) and (92).
2) Remove plate (87) and bearing (88) from

4th gear (86).
4) Remove bearing (93) and plate (94).
50-301 62 WA470-6, WA480-6

10. 3rd gear 12. Plate, disc and spring

1) Remove 3rd gear (95). Remove plate (99), disc (100), and spring
(101).
2) Remove bearing (96) from 3rd gear (95).

13. Piston
1) Remove piston (102).
11. End plate

1) Press end plate (97) using the vises [18].
2) Remove snap ring (98). 2) Remove seal rings (103) and (104) from
3) Remove end plate (97). piston (102).
WA470-6, WA480-6 50-301 63

14. Plate, bearing and washer Assembly

Remove plate (105), bearing (106), and a Before assembling the disc, soak it in clean
washer (107). power line oil for 2 minutes or more.
a Press fit each bearing so that no clearance will
be made to the mating part in the axial direc-
tion.
Assembly of 3rd or 4th clutch pack assembly

[3rd clutch]
1. Plate, bearing and washer
Install plate (105), bearing (106), and washer
(107).
a When installing plate (105) or washer
(107), be careful not to mistake them.
(Washer is thinner than plate.)
2. Piston
1) Install seal rings (103) and (104) to piston
(102) in the direction shown in Fig.
2) Adapt seal rings (103) and (104) to piston
(102) by using tool B13.
a In this state leave it for about 2 or 3
minutes.
50-301 64 WA470-6, WA480-6

3) Install piston (102). 5. 3rd gear

2 Contact surface of seal ring: 1) Install bearing (96) to 3rd gear (95).
2) Install 3rd gear (95).

3. Plate, disc and spring
Install in the order of plate (99), disc (100), and
spring (101).
6. Bearing, spacer and plate

1) Install bearing (94) and plate (93).
4. End plate
1) Press end plate (97) using the vises [18].
2) Install snap ring (98).
a Confirm that it is completely stuck in
the groove.
WA470-6, WA480-6 50-301 65

2) Install spacers (92) and (91). 7. Confirming clearance

a After confirming the match marks By moving 3rd gear (95) up and down, confirm
(numbers) punched on both right and that the dimension "a" is within standard value
left surfaces of spacers (91) are the with dial gauge.
same, connect them exactly. q Dimension (a): 0.14 – 1.03 mm
2 Spacer (91):
[4th Clutch]
8. Piston
(83) in the direction shown in Fig.
3) Press fit spacer (90). 2) Adapt seal rings (84) and (85) to piston
a Press fit the spacer with the center (83) by using tool B14.
dented part facing down. a In this state leave it for about 2 or 3 min-
utes.
4) Install bearing (89) and plate (87).
50-301 66 WA470-6, WA480-6

3) Install piston (83) using eye bolts [17] (M8 10. Plate, disc and spring
x 1.25). Install in the order of plate (77), disc (78), and
2 Contact surface of seal ring: spring (79).
11. End plate

9. Plate, bearing and washer 1) Press end plate (75) using the vise [16].
Install washer (82), bearing (81), and plate 2) Install snap ring (76).
(80). a Confirm that it is completely stuck in
a Install the inside convex part of plate (80) the groove.
facing upward.
12. 4th gear

Install 4th gear (86) to cylinder assembly (74).
WA470-6, WA480-6 50-301 67

13. 4th gear/cylinder assembly 2) Install cover (71).

1) Install bearing (88) to shaft. 3 Mounting bolt:
27 – 34 Nm {2.8 – 3.5kgm}
3) Install ring (70).
2 Both end surface of ring:
Lubricant containing
molybdenum disulfide (LM-S)
2) Install 4th gear/cylinder assembly (108).
15. Bearing
1) Press fit the bearing (69) using tool B15.
2 Both end surface of bearing:
14. Ring, cover and collar

1) Install seal rings (73) and collars (72).
2 Periphery of seal ring: grease (G2-LI)
50-301 68 WA470-6, WA480-6

2) Install plate (68) and bearing (67). Assembly of R and 2nd clutch pack assembly
[2nd clutch]
1. Piston
(64) with the direction as shown in the fig-
ure.
2) Using tool B17, fit seal rings (65) and (66)
to piston (64).
a Leave the seal rings and piston under
this condition for 2 – 3 minutes.
16. Confirming clearance

By moving 4th gear (86) up and down, confirm
that the dimension (b) is within standard value
with dial gauge.
q Dimension (b): 1.75 – 3.25 mm
3) Using eye bolts [15] (M8 x 1.25), install

piston (64).
2 Seal ring contact face:
17. Confirming operation of clutch

By blowing air through oil hole of shaft using
tool B16, confirm that 3rd and 4th clutch start
operating.
a If the gear in which air has been blown is
being fixed, the operation of clutch proves
to be proper.
WA470-6, WA480-6 50-301 69

2. Plate, disc, and spring 4. Hub

Install plate (61), disc (62) and spring (63) in Install hub (58).
this order.
5. Bearing
3. End plate 1) Using tool B18, press fit bearing (57).
1) Using push tool [14] (Push tool: Outside
diameter about 120 mm, Bolt: M12 x 1.75
and nut), press end plate (59).
a Confirm that the snap ring is fitted to
the groove securely.
2) Install ring (56) and snap ring (55).
50-301 70 WA470-6, WA480-6

6. Transfer shaft No.1 [R clutch]

1) Using tool B19, press fit inner race (54) to 7. Piston
transfer shaft No.1 (53). 1) Install seal rings (51) and (52) to piston
ure.
to piston (48).
2) Install transfer shaft No.1 (53).

3 Mounting bolt:
59 – 74 Nm {6 – 7.5 kgm}
3) Install dowel pin (50a) and lubricating pis-

ton (50) to piston (48).
WA470-6, WA480-6 50-301 71

5) Using eye bolts [12] (M8 x 1.25), install 10. Plate and bearing
piston (48). Install plates (41) and bearing (42).
11. R clutch gear

1) Install bearings (40) to R clutch gear (39).
Install plate (45), disc (46), and spring (47) in
this order.
2) Install R clutch gear (39).
9. End plate
1) Using vise [10] and push tool [11], press
end plate (43).
50-301 72 WA470-6, WA480-6

12. Bearing and plate 14. Bearing

Install plate (38) and bearing (37). Using tool B15, press fit bearing (34).
13. Spacer 15. Confirmation of the clearance

1) Using tool B21, press fit spacer (36). Move R clutch gear (39) up and down and con-
firm with a dial gauge that dimension (c) is in
the standard range.
q Dimension (c): 0.28 – 0.95 mm
WA470-6, WA480-6 50-301 73

16. Confirmation of the clutch operation Assembly of F and 1st clutch pack assembly
Using tool B16, supply air into the oil hole of [1st clutch]
the shaft and confirm that the R clutch and 2nd 1. Piston
clutch operate. 1) Install seal rings (32) and (33) to piston
a If the gear on the side to which the air is (31) with the direction as shown in the fig-
supplied is fixed, the clutches are operat- ure.
ing normally 2) Using tool B17, fit seal rings (32) and (33)
to piston (31).
3) Using eye bolts [7] (M8 x 1.25), install pis-

ton (31).
50-301 74 WA470-6, WA480-6

2. Plate, disc, and spring 5. 1st clutch gear

Install plate (28), disc (29), and spring (30) in 1) Install bearings (24) to 1st clutch gear
this order. (23).
3. End plate 2) Install 1st clutch gear (23).

1) Using push tool [6] (Push tool: Outside
diameter about 120 mm, Bolt: M12 x 1.75
and nut), press end plate (26).
6. Washer and spacer

Install washer (22) and spacer (21).
a Install spacer (21) with the chamfered side
up.
4. Washer
Install washer (25).
WA470-6, WA480-6 50-301 75

7. Bearing [F clutch]
Using tool B22, press fit bearing (20). 9. Piston
ure.
to piston (15).
8. Confirmation of the clearance

Move 1st clutch gear (23) up and down and
confirm with a dial gauge that dimension (d) is
in the standard range.
q Dimension (d): 0.1 – 1.1 mm
3) Install dowel pin (17a) and lubricating pis-

ton (17) to piston (15).
50-301 76 WA470-6, WA480-6

5) Using eye bolts [4] (M8 x 1.25), install pis- 12. End plate
ton (15). 1) Using vises [3], press end plate (8).
2 Seal ring contact face: 2) Install snap ring (9).
Power train oil (TO10) a Confirm that the snap ring is fitted to
10. Plate and bearing

Install plates (13) and bearing (14). 13. F clutch gear
1) Install bearings (7) and plate (6) to F
clutch gear (5) in this order.

Install plate (10), disc (11), and spring (12) in
this order. 2) Install F clutch gear (5).
WA470-6, WA480-6 50-301 77

14. Bearing 16. Bearing

Install bearing (4). Using tool B18, press fit bearing (1).
15. Spacer 17. Confirmation of the clearance

1) Using tool B21, press fit spacer (3). Move F clutch gear (5) up and down and con-
firm with a dial gauge that dimension (e) is in
the standard range.
q Dimension (e): 0.28 – 0.95 mm
18. Confirmation of the clutch operation.

Using tool B16, supply air into the oil hole of
the shaft and confirm that the F clutch and 1st
clutch operate.
a If the gear on the side to which the air is
supplied is fixed, the clutches are operat-
ing normally.
50-301 78 WA470-6, WA480-6

WA470-6, WA480-6 50-301 79

SEN04536-01

©2009 KOMATSU
All Rights Reserved
50-301 80
SEN04537-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Removal and installation of front axle assembly ............................................................................................. 2
Removal and installation of rear axle assembly.............................................................................................. 4
Disassembly and assembly of axle housing assembly ................................................................................. 10
Disassembly and assembly of differential assembly..................................................................................... 19
WA470-6, WA480-6 50-302 1

SEN04537-01 Removal and installation of front axle 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
Stop the machine on a level ground and
1. Attach lock bar (1) to the frame.
4. Remove front frame front side cover (3).
2. Start the engine and set the bucket to the

dumping posture. Then lift the machine gradu-
ally until the front tires are lifted about 5 cm
above the ground, and set stand [1] at the bot-
tom of the front frame.
k Apply the parking brake and put chocks
under the rear tires.
5. Disconnect brake hose (4).
50-302 2 WA470-6, WA480-6

Removal and installation of front axle assembly SEN04537-01
6. Remove the mounting bolt and disconnect Installation

front drive shaft (5). [*2] q Carry out installation in reverse order of
a Make a counter mark on the coupling and removal.
[*1]
3 Front tire mounting bolt:
823 – 1029 Nm {84 – 105 kgm}
[*2]
3 Drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
3 Front axle assembly mounting bolt:
1,617 ± 167 Nm {165 ± 17 kgm}
7. Temporarily lift the front axle assembly and set q Bleeding air
jack [2] at the bottom. Bleed air from the brake circuit, referencing to
"Bleeding air from wheel brake circuit" in Test-
ing and adjusting.
8. Remove mounting bolt (6) of front axle assem-

bly, and then remove front axle assembly (7)
while lowering it gradually using the jack and
hoist. [*3]
4 Front axle assembly (6): 1300 kg
WA470-6, WA480-6 50-302 3

SEN04537-01 Removal and installation of rear axle 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 stands [2] at the bottom of the
k Stop the machine on a level ground and front frame.
1. Attach lock bar (1) to the frame.
5. Tilt the bucket gradually until the front tires

touch the ground completely, and then lift the
rear tires above the ground.
2. Remove right and left fenders (2). 6. Support the rear end of the rear frame by set-
ting jack [3] on the counterweight.
k Apply the parking brake and put
chocks under the front tires.
3. Set blocks [1] between the right and left rear

axles and rear frame.
50-302 4 WA470-6, WA480-6

Removal and installation of rear axle assembly SEN04537-01
7. Wind around the front tire and wheel assembly 11. Remove 3 harness clamps (6).
(3) with the nylon sling and lift it. Then remove a Another place is above figure.
the mounting bolt to remove the rear tires and
wheel assembly. [*1]
4 Rear tire and wheel assembly: 680 kg
12. Disconnect grease tubes (7) and (8).
8. Remove the fuel tank assembly, referencing to

"Removal and installation of fuel tank assem-
bly."
9. Remove left side cover (4).
13. Remove right side step (9).
10. Disconnect harness connector R60 (5) and

harness clamp (5a).
WA470-6, WA480-6 50-302 5

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]
15. Disconnect rear drive shaft (12). [*2]

18. Using chain block [5], fix the right and left sides
of rear support (14) to rear axle assembly (15).
a This is necessary for preventing rotation of
the rear support during removal.
16. Remove emergency steering relay (13).

a This is necessary for preventing detach-
ment of the mounting bolt in the rear left
side of the rear axle.
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.
50-302 6 WA470-6, WA480-6

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
23. Remove packing (19) from retainer (18). [*5]
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.
24. Remove packing (20) and bushing (21) from

the front support. [*6]
WA470-6, WA480-6 50-302 7

25. Temporarily lift rear support (14) and remove Installation

thrust cap (22). [*7] q Carry out installation in reverse order of
removal.
[*1]
3 Rear tire mounting bolt:
823 – 1,029 Nm {84 – 105 kgm}
[*2]
3 Rear drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3]
2 Rear axle assembly mounting bolt:
Engine oil (EO-10)
26. Remove thrust washer (23) from the rear sup- 3 Rear axle assembly mounting nut:
port. 1,180 – 1,470 Nm {120 – 150 kgm}
27. Remove the mounting bolts, and then remove [*4]

thrust plate (24) and thrust washers (23). [*8] 2 Front support retainer mounting bolt:
Adhesive (LT-2)
28. Remove rear support (14). 3 Front support retainer mounting bolt:
4 Rear support assembly: 150 kg 1,180 – 1,470 Nm {120 – 150 kgm}
[*5]
29. Remove packing (25) and bushing (26) from a Direct the lip unit of the packing (19) toward
the rear support. [*9] the machine front side, and then fit it securely
in the groove.
[*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)
50-302 8 WA470-6, WA480-6

[*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 wheel brake circuit" in Test-
ing and adjusting.
WA470-6, WA480-6 50-302 9

SEN04537-01 Disassembly and assembly of axle housing assembly
Disassembly and assembly of 2. Axle assembly

axle housing assembly 1
Place blocks [1] on the axle assembly.
a Place blocks [1] to prevent the housing
Special tools assembly of one side from tilting at
removal.
New/Remodel
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 793T-622-1330 Push tool t 1 Q
D7 2 793T-622-1340 Spacer t 1 Q
3 793T-622-1350 Push tool t 1 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 Q
D9 2 793T-622-1380 Support t 2 Q
3 01016-30860 Bolt t 6 3. Axle housing assembly
D10 793T-622-1510 Holder t 1 Q 1) Temporarily suspend the axle housing
assembly (8) and remove the housing
Disassembly mounting bolt.
a The front axle housing is illustrated for exam- a When removing axle housing assem-
ple in the following photographs and drawings. bly on both sides, place an identifica-
a The internal structure of the front axle housing tion mark on the housing and the
and rear axle housing are identical but different differential case to avoid confusion.
in appearance. 2) Remove the axle housing assembly.
4 Axle housing assembly: 280 kg
1. Draining oil
Remove the plug (1) and drain the oil.
6 Axle oil
WA470-6 (front) : 57 l
(rear) : 56 l
WA480-6 (front) : 59 l
(rear) : 59 l
50-302 10 WA470-6, WA480-6

Disassembly and assembly of axle housing assembly SEN04537-01
3) Change the suspension point and place

the axle housing (8) vertically.
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.
a Take care not to damage washer (9a).
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
2) Remove shim (11).

a Record the thickness of the shim and
use for reference when assembling.
WA470-6, WA480-6 50-302 11

8. Axle housing
Remove the bearing outer races (18) and (19)
and oil seal (17) from the axle housing (14).
7. Axle shaft bearing

k Do not pull out the bearing by applying
heat or remove by fusing.
1) Mount bolt (b) to the bolt hole (a) of the 9. Planetary carrier
bearing puller [4]. 1) Hit in the spring pin (21) of the planetary
carrier (20) into the shaft (22).
a Be careful not to hit in the spring pin
too much.
2) Mount the bearing puller [4] to the lower

part of the bearing (16) and fix securely.
3) Insert washer (c) in between bolt (b) and
flange face and remove the bearing (16)
by turning bolt (b) in the slackening direc- 2) Pull out the shaft (22) using the press.
tion. 3) Pull out the spring pin (21) from the shaft
4) Remove the oil seal (17). (22).
4) Remove the planetary gear (23), holder
(24) and washer (9a) from the planetary
carrier (20).
50-302 12 WA470-6, WA480-6

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).
5) Remove the bearing (25) from the plane-

tary gear (23).
WA470-6, WA480-6 50-302 13

3. Axle housing, shaft 4) Pull out tool D9 horizontally.

1) Mount tool D9-1 (D9-2 for WA480-6) a Pull out tool D9 while pressing it
under oil seal (17). against the end face of housing (14).
a Adjust with tool D9-3 so that the q Clearance (a) = Max. 0.2 mm
upper face of tool D9-1 (D9-2) and a Check to see if oil seal (17) is not tilt-
the oil seal (17) touches each other ing.
lightly and its clearance is even.
4. Selecting shims
2) Suspend the axle housing (14) horizon- 1) Install planetary carrier (20) to the spline
tally, and slowly lower by aligning its posi- of axle shaft (15). Then, install tool D10
tion to 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 a Tightening torque is observed strictly.
WA470-6 rear axle). 3 Bolt:
2 Bearing periphery: Axle oil WA470-6 front and WA480-6
front and rear:
824 – 1,030 Nm {84 – 105 kgm}
WA470-6 rear:
662 – 829 Nm {67.5 – 84.5 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}
50-302 14 WA470-6, WA480-6

4] Perform steps 2) and 3) and check

that the starting torque is in the stan-
dard range.
a If the starting torque is below the standard

value, perform the following work.
1] Remove planetary carrier (20).
2] Referring to steps 3-3), press fit bear- 4) Using a depth micrometer, measure the
ing (26) further. distance (H) from the end surface of tool
3] Perform steps 1) – 3) and check that D10 to the axle shaft end surface.
the starting torque is in the standard 5) Subtract thickness (t) of tool D10 from
range. dimension (H) and set the result as (H – t),
a If the starting torque is above the standard and then decide the shim thickness.
value, perform the following work. q Shim thickness = (H – t) +0.05
+0
1] Loosen bolt (9) by 1 – 2 turns. 6) Remove planetary carrier (20).
2] Hold 2 parts of axle shaft and housing
assembly (8) and sling it by 20 – 30
mm.
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
WA470-6, WA480-6 50-302 15

5. Planetary carrier a Align the shaft (22) and the hole of

1) Install bearings (25) to planetary gear the planetary carrier (20) and hit in
(23). the spring pin (21) until it is flush (j)
with the carrier (20).
2) Install holder (24) and washer (9a) into 5) Make sure the gear slightly revolves, by
planetary carrier (20). pushing back the bearing (25) hitting the
a Apply grease thinly to the mounting edge of the shaft (22) and the side of the
face of the washer on the holder side. gear (23).
3) Install planetary gear (23).
4) Insert the shaft while aligning the shafts

(22) and spring pin holes (22a).
2 Shaft: Oil (Axle oil)
50-302 16 WA470-6, WA480-6

6. Ring gear
Insert the ring gear (12) into the axle housing
(14) and then insert 6 pins (12a).
a When installing the ring gear, direct its
chamfered side down and align its pin
holes with those of the housing.
a Carefully and horizontally insert the ring
gear to avoid tilting.
3) After checking that the bearing is properly

working, check the startup torque at the
drilled hole (h) of the axle housing (14).
a Refer to procedure 4. Selecting shims
page.
q Activation turning force:
29.4 – 54.9 N {3.0 – 5.6 kg}
7. Planetary carrier assembly (WA470-6, Front)
1) Set the shim (11) selected in step 4.-5) to 29.4 – 57.9 N {3.0 – 5.9 kg}
the edge of the axle shaft. (WA470-6, Rear)
2) Mount the planetary carrier assembly (10) 63.7 – 122.6 N {6.5 – 12.5 kg}
and tighten the mounting bolt (9). (WA480-6, Front and Rear)
a Wash and completely degrease the a If the turning force is out the standard
bolt mounting hole of the axle shaft value, return to procedure 4.
and mounting bolt. 4) Mount the dial gauge [4] to the axle hous-
k Be fully careful not to get your fin- ing (14) and measure the planetary carrier
ger in between the gears when set- end play on the edge of the planetary car-
ting the planetary carrier. rier.
2 Mounting bolt: Adhesive (LT-2) q Planetary carrier end play (Reference
a Tightening torque is observed strictly. value): 0 – 0.1mm
3 Mounting bolt:
WA470-6 for front, WA480-6 for
front/rear:
824 – 1,030 Nm {84 – 105 kgm}
WA470-6 for rear:
662 – 829 Nm {67.5 – 84.5 kgm}
a Clean the edge of the shaft and the
planetary carrier spline part before
setting them.
WA470-6, WA480-6 50-302 17

8. Axle housing assembly

1) Wash and degrease the axle housing (14)
and mounting surface of the differential
housing, and wholly apply the gasket seal-
ant.
a Apply gasket sealant (30) in continu-
ous 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)
4) Mount the mounting bolt diagonally and

fix.
3 Housing mounting bolt:
490 – 608 Nm {50 – 62 kgm}
9. Oiling
1) Tighten the drain plug and fill from the fill
opening until the standard level is
reached.
5 Axle oil WA470-6 (front): 57 l
(rear): 56 l
WA480-6 (front): 59 l
2) Install guide bolts [5].
(rear): 59 l
3) Suspend the axle housing assembly (8)
2) Remove the plug of the oil level and check
horizontally and gently set by aligning to
if the oil is filled up close to the lower edge
the spline groove and guide bolts [5].
of the plug hole.
a Set the brake piston surface and plate
surface to avoid damage.
50-302 18 WA470-6, WA480-6

Disassembly and assembly of differential assembly SEN04537-01
Disassembly and assembly of 2. Oil temperature sensor (Rear differential)

differential assembly 1
1) Remove the cover (3).
2) Separate the connector (4) and remove
special tools the oil temperature sensor (5).
New/Remodel
3. Rear support (Rear differential)
Remove the rear support (6) by referring to
Necessity
Sym-
Part No. Part name
“Removal and installation of rear axle assem-
Sketch
bol
bly” section
Q'ty
D1 2 790-901-2110 Bracket q 1
3 790T-901-3440 Plate q 1 Q
1 793T-622-1310 Push tool t 1 Q
D2 2 790-101-5421 Grip t 1
3 01010-51240 Bolt t 1
1 793T-622-1310 Push tool t 1 Q
2 793T-622-1320 Spacer t 1 Q
D3
3 790-101-5421 Grip t 1
4 01010-51240 Bolt t 1
D4 793T-622-1360 Push tool t 1 Q
1 796-765-1110 Push tool t 1
D5
2 790-201-2750 Spacer t 1
790-301-1720 Adapter t 1
1
07002-12034 O-ring t 1
D6 2 799-101-5002 Hydraulic kit t 1
3 793-605-1001 Brake tester 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 4. Axle housing assemblies
photos and illustrations in this manual refers to Remove right and left axle housing assemblies
a front differential unless a distinction is made by referring to “Disassmbly and assembly of
between front and rear differentials. axle housing assembly” section.
a The internal structure of front and rear differen-
tials is identical, excluding the shape in 5. Differential assembly
appearance. Place the differential assembly (7) on the
blocks [1] and ensure stability (or install on tool
1. Brake pipe D1).
1) Disconnect the tubes (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 50-302 19

SEN04537-01 Disassembly and assembly of differential assembly
6. Cover 4) Blow air into the brake oil port (15) and
Remove the cover (8). remove the piston (16).
7. Brake 8. Cage assembly

1) Remove the sun gear shaft (9). 1) Lift the differential case and bring the cage
2) Remove the bolts (10) and then remove assembly to the top.
the outer plate (11). 2) Remove the bolt (17) and remove the cou-
3) Remove the plate (12), wave spring (13), pling (19) together with the protector (18).
and disc (14). a The protector must not be removed
a Mark each part or do in similar man- from the coupling except when the
ner in order to avoid confusion with need arises.
right and left parts.
3) Install the eyebolt [2] and temporarily lift

the cage assembly (20).
a Put mating marks on cage and differ-
ential case.
4) Remove the bolt (21).
5) Screw in the forcing screw and lift the
cage assembly until O-ring appears.
50-302 20 WA470-6, WA480-6

6) Lift cage assembly (20) and remove it. 3) Remove all bearing carrier (24) mounting
4 Cage assembly: 55 kg bolts and attach the guide bolts [3].
4) Screw in the forcing screws [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.
7) Remove shims (22).

a Record the number of shims for the
reference purpose when re-assem-
bling.
5) Remove outer race (24a) and seals (24b)

and (24c) from bearing carrier (24).
9. Bearing carrier
1) Direct the face of the differential case up
from which the cover was removed in step
6.
2) Temporarily lift the differential bearing car-
rier assembly (23).
WA470-6, WA480-6 50-302 21

10. Differential carrier assembly 11. Disassembly of differential carrier assem-

1) Remove the differential carrier assembly bly (Standard specification)
(23) from the differential case (25). 1) Remove case (62).
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
2) Remove bearing (63) from case (62).
2) Remove the gear cover (26) from the dif-

ferential case.
3) Remove washer (64) and side gear (65).

4) Remove spider shaft (66) together with
the pinion gear (67).
50-302 22 WA470-6, WA480-6

5) Remove spherical washer (68), pinion 12. Disassembly of differential carrier assem-
gear (67) and bushing (69) from spider bly (Limited slip differential specification)
shaft (66). a Identify right and left parts to avoid confu-
sion.
1) Remove the cover (28) together with the
bearing (27).
a Put mating marks on the cover (28)
and case (29) for reference purposes
when re-assembling.
6) Remove side gear (70) and washer (71)

from case (72).
a When removing the cover (28), it is

detached with the washer (30) fitted
in a groove at the back.
7) Remove bevel gear (73) and bearing (74)

from case (72).
2) Remove bearing (27) from cover (28).
WA470-6, WA480-6 50-302 23

3) Remove the 2 plates (31) and 2 discs (32). 6) Remove the side gear (37) and pressure
ring (38).
4) Remove the pressure ring (33) and side

gear (34). 7) Remove the 2 discs (39) and 2 plates (40).
8) Remove the washer (41).
5) Remove the pinion gear (35) and spider

shaft (36). 9) Reverse the case (29) and remove the
bolt (42) to detach the bevel gear (43) and
bearing (29a).
50-302 24 WA470-6, WA480-6

13. Pinion gear and cage Assembly

1) Remove the pinion gear (45) from the 1. Pinion gear and cage
cage (44) using a press. 1) Install the outer races (47) and (48) in the
2) Remove the dust seal (49), oil seal (50), cage (44).
bearing (46), and outer races (47) and
(48) from the cage (44).
2) Press fit the bearing inner race (52) into

pinion gear (45) using tool D5.
3) Remove the spacer (51) and bearing inner
race (52) from the pinion gear (45).
3) Install the spacer (51).
WA470-6, WA480-6 50-302 25

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.
8) Press fit the dust seal (49) into cage (44)

using tool D3.
6) To measure starting torque, install a push- 2 Dust seal lip: Grease (G2-LI)
pull gauge at the point marked as [A] in
the following illustration and turn the cage
(44).
a Starting torque
WA470-6 rear: 49.0 N {5 kg} or less
WA470-6 front, WA480-6 front and
rear: 73.5 N {7.5 kg} or less
a If the starting torque exceeds the ref-
erence value or the cage is not turned
by hand easily (heavy rotation),
replace the bearing and spacer and
recheck it.
50-302 26 WA470-6, WA480-6

2. Coupling 3) Place the bevel gear (43) on the blocks [6]

1) Install protector (18) to cage (44). with the gear side down.
2) Install coupling (19), O-ring (19a), shim 4) Install guide bolts [7] to bevel gear (43).
(17a) and holder (17b) to pinion gear (45) 5) Lower the case (29) and install it in the
and tighten mounting bolt (17) temporarily. bevel gear (43) and tighten the bevel gear
a Tighten mounting bolt (17) perma- mounting bolts (42).
nently after installing to the differential 2 Mounting bolt: Adhesive (LT-2)
case. 3 Mounting bolt:
a When inserting the coupling (19), 245 – 309 Nm {25 – 31.5 kgm}
great care should be taken not to
damage the seal.
3. Assembly of differential carrier assembly

(Limited slip differential specification)
a Assemble right and left parts according to
identifications made at the time of taking
them apart.
1) Press fit the bearing (29a) into the case
(29).
2) Press fit the bearing (27) into the cover
(28).
6) Reverse the case (29) and install the

washer (41), plate (40), and disc (39) in
this 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.
WA470-6, WA480-6 50-302 27

q For rear differential of WA470-6: 8) Install the pinion gear (35) and spider
Outside diameter: 185 mm shaft (36).
Thickness: 3.2 mm
q For front differential of WA470-6
and front and rear differentials of
WA480-6:
Outside diameter: 198 mm
Thickness: 3.6 mm
2 Plate and disc: Axle oil
9) Install the side gear (34) and pressure ring

(33).
10) Install the disc (32) and plate (31) in this

order.
a For the installation procedure, see
step 6).
7) Install the pressure ring (38) and side gear
(37).
50-302 28 WA470-6, WA480-6

11) Adjust the clearance (g) between the

cover (28) and plate (31).
1] Using depth gauge [11], measure dis-
tance (d) from the end face of case
(29) to plate (31) end face at weight of
686 N {70 kg} equally.
2] Measure dimension (f) from the end
face of cover (28) to the flange.
3] Calculate clearance (g) as follows
and confirm that it is within the stan-
dard range.
q Clearance (g) = (d) – (f) = 0.2 to
0.75 mm
4] If clearance (g) is out of the standard
range, replace the plate (31) with the
one with proper thickness so that dis- 12) Install the washer (30) on the cover (28).
tance (d – f) will be in the standard a Coat the washer with grease thinly
range. and stick it to the cover.
a Replace the plates on both right
and left sides so that the total
thickness of the 2 plates on each
side will be the same, and then
perform the above procedure
from step 7).
q Thicknesses of plates: 3.1 mm,
3.2 mm
13) Install the cover (28) with the bearing (27)

on the case (29).
a Install them by aligning the mating
marks put when disassembling.
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
WA470-6, WA480-6 50-302 29

14) Adjust the axial clearance of the side gear. 3] Install tool D11 and torque wrench
1] Using clearance gauges, measure [12] to the sun gear shaft on the
clearance (e) between the side gears opposite side to measure the rotation
(34), (37) and washers (30), (41) torque.
through the shaft holes on the right a When measuring, let the case
and left sides of the limited slip differ- turn freely.
ential. q Rotation torque:
q Clearance (e): Rear differential of WA470-6:
Rear differential of WA470-6: Max. 10 Nm {1.0 kgm}
0.15 – 0.35 mm (Both right and Front differential of WA470-6 and
left) front and rear differentials of
Front differential of WA470-6 and WA480-6:
front and rear differentials of Max. 15 Nm {1.5 kgm}
WA480-6: 0.2 – 0.4 mm (Both 4] If the rotation torque exceeds the
right and left) above value, disassemble the differ-
2] If clearance (e) is out of the standard ential carrier again and perform steps
range, replace the washer with the 11) and 14).
one with proper thickness so that the
clearance will be in the standard
range.
a When replacing the washer, per-
form the above procedure from
step 6).
q Thicknesses of washers:
4.0 mm, 4.1 mm
4. Assembly of differential carrier assembly

(Standard specification)
1) Install bearing (74) and bevel gear (73) to
case (72).
2 Bevel gear mounting bolt:
Adhesive (LT-2)
3 Bevel gear mounting bolt:
245 – 309 Nm {25 – 31.5 kgm}
15) Measure the differential torque while no
load is applied.
1] Install sun gear shafts (9) to the right
and left sides of differential carrier
assembly.
2] Fix the sun gear shaft on either one
side.
50-302 30 WA470-6, WA480-6

2) Install washer (71) and side gear (70) to 6) Install bearing (63) to case (62).
case (72).
7) Install case (62).

3) Install bushing (69), pinion gear (67) and 3 Mounting bolt:
spherical washer (68) to spider shaft (66). 157 – 196 Nm {16 – 20 kgm}
4) Install pinion gear (67) together with the 5. Gear cover

spider shaft (66). Install the gear cover (26) on differential case.
5) Install side gear (65) and washer (64). 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
98 – 123 Nm {10.0 – 12.5 kgm}
WA470-6, WA480-6 50-302 31

6. Bearing carrier shim adjustment 4) Install right and left bearing carriers (24)
1) Lift the differential carrier assembly (23) and any shims (80) together.
and set the differential case (25) in the a Select shims with reference to the
installation section. 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}
2) Install outer race (24a) and seals (24b),

(24c) in right and left bearing carriers (24).
5) Using push-pull gauge [5], measure the

starting rotation force of the bevel gear.
a Starting torque:
WA470-6 rear differential:
35.3 – 53.0 N {3.6 – 5.4 kg}
WA470-6 front differential, WA480-6
front and rear differential:
34.3 – 51.0 N {3.5 – 5.2 kg}
a If the starting torque is outside the ref-
erence value, adjust it by increasing
or reducing the thickness of shims.
3) Fit the guide bolts [3] into the mounting a The shim thickness on each side will
holes of right and left bearing carriers in be in the range from 0.3 to 1.25 mm.
the differential case. a Set shim thickness:
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
50-302 32 WA470-6, WA480-6

7. Cage assembly 8. Adjusting backlash

1) Fit the O-ring (20a) into groove of the cage 1) Measure the backlash of bevel gear using
assembly (20). dial gauge [7].
2 O-ring: Oil (axle oil) a Reference value of backlash: 0.30 –
a Apply oil lightly. 0.41 mm
a Test the backlash at three points on
the circumference of the bevel gear
and check that variations in measure-
ment values are at 0.1 mm or less.
2) Install the guide bolts [6] in the differential

case (25), insert standard shims (22) (the
number and thickness of shims checked
at the time of disassembly), and install the
cage assembly (20). 2) If the backlash is out of the standard
a Insert the shims with thinner ones on range, adjust the shim according to the
the side of the cage. following procedure.
a After carrying out Procedure 8. a Moving shims must not change the
“Adjusting backlash” and Procedure total thickness of right and left shims.
9. “Testing tooth contact”, determine a If backlash is excessively large:
the number and thickness of shims. Move some shims (a) to shims (b).
3 Mounting bolt: a If backlash is excessively small:
245 – 309 Nm {25 – 31.5 kgm} Move some shims (b) to shims (a).
WA470-6, WA480-6 50-302 33

9. Testing tooth contact If the pinion gear is too far from the bevel gear
1) Apply a thin coat of red lead to the tooth a The tooth contact pattern is as follows.
surfaces of the pinion gear, and turn the 1) Decrease shim (d) to move the pinion
bevel gear to both directions (backward gear in direction (C).
and forward). Then, check the tooth con- 2) Adjust shims (a) and (b) to move bevel
tact pattern on the bevel gear. gear in direction (D).
2) Center of the tooth contact shall be at the
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.
If the pinion gear is too close to the bevel gear

a The tooth contact pattern is as follows.
1) Increase shim (d) to move the pinion gear
in direction (E).
2) Adjust shims (a) and (b) to move bevel
gear in direction (F).
10. Adjusting tooth contact

If the obtained tooth contact pattern is not
proper, adjust the tooth contact according to
the following procedure.
a Adjust the tooth contact by increasing or
decreasing shims (a) and (b) (to move the
bevel gear) and shim (d) (to move the pin-
ion gear).
a Do not change the total thickness of shims
(a) and (b) to prevent a change of the pre-
load on the bearing.
a After adjusting the tooth contact, check
the backlash again.
50-302 34 WA470-6, WA480-6

If the bevel gear is too close to the pinion gear 11. Brake
a The tooth contact pattern is as follows. 1) Install the seal in the piston (16) and install
1) Decrease shim (d) to move the pinion it in the differential carrier assembly.
gear in direction (C). a The number (15) denotes brake oil
2) Adjust shims (a) and (b) to move bevel port.
gear in direction (D).
2) Bleed the inside of the cylinder by install-

If the bevel gear is too far from the pinion gear ing tools D6-1 and 2 to the brake oil port
a The tooth contact pattern is as follows. (15) in the differential case (25).
1) Increase shim (d) to move the pinion gear 3) Increase the pressure to 1.4 MPa {14 kg/
in the direction (E). cm²} by operating tool D6-4.
2) Adjust shims (a) and (b) to move the bevel a Leave the pressure at 1.4 MPa {14
gear in direction (F). kg/cm²} for 5 minutes and check that
a drop in pressure is 0.3 MPa {3.5 kg/
cm²} or less.
4) If there is no leakage of oil as a result of
checking as above, further increase the
pressure to 4.9 MPa {50 kg/cm²}.
a Leave the pressure at 4.9 MPa {50
kg/cm²} for 5 minutes and check that
a drop in pressure is 0.1 MPa {1.0 kg/
cm²} or less.
a If there is leakage of oil, remove the
brake piston and check the O-ring,
seal, etc. for damage before reinstall-
ing it.
WA470-6, WA480-6 50-302 35

6) Install the outer plate (11) and sun gear

shaft (9) and tighten bolts (10).
3 Bolt (10):
27 – 34 Nm {2.8 – 3.5 kgm}
5) Install the disc (12), wave springs (13),

and plate (14) in this order.
a Install wave springs (13) with abut-
ments (a) 120° apart from each other
in the circumferential direction. 7) Using tool D12, blow air into the brake oil
port (15) to conform to the movement of
the piston.
12. Coupling
Retighten coupling mounting bolts that were
temporarily tightened in Procedure 2.
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
50-302 36 WA470-6, WA480-6

13. Cover 17. Brake pipe

Install the cover (8) on the differential case (7). 1) Install the slack adjuster (2). (Front differ-
2 Cover mounting surface: ential)
Liquefied gasket (Loctite 515) a For the rear differential, install the
3 Mounting bolt: slack adjuster of on the rear frame.
157 – 196 Nm {16 – 20 kgm} 2) Install the tubes (1).
14. Axle housing

Install the right and left axle housing assem-
blies by referring to “Disassembly and assem-
bly of axle housing assembly” section.
15. Rear support

Install the rear support (6) by referring to
“Removal and installation of rear axle assem-
bly” section.
16. Oil temperature sensor

1) Install the oil temperature sensor (5) and
connect the connector (4).
2 Oil temperature screw:
Liquefied gasket (LG-5) 18. Lubrication
3 Oil temperature sensor: 1) Feed oil to the specified level through filler
29.4 – 49.0 Nm {3 – 5 kgm} opening with the drain plug tightened.
5
2) Install the cover (3).
WA470-6 (front): 60 l
3 Mounting bolt:
Axle oil
(rear): 56 l
98 – 123 Nm {10 – 12.5 kgm}
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 50-302 37

SEN04537-01

©2009 KOMATSU
All Rights Reserved
50-302 38
SEN04866-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
400 Brake system

Removal and installation of parking brake disc and plate ............................................................................... 2
WA470-6, WA480-6 50-400 1

400 Brake system
SEN04866-01 Removal and installation of parking brake disc and plate

parking brake disc and plate 1
Special tool
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name
793T-607-1250 Bracket t 1 R Q
B1 01051-62240 Bolt t 1
01643-32260 Washer t 1
Removal
fectly to the ground. 6. Remove 2 bolts (6), and tighten to plug mount-
k Install the lock bar on the frame, apply the ing portion (a) in turn.
parking brake and put chocks under the a Remove 2 bolts (6) on opposite sides.
tires. a When bolts (6) are screwed in, piston (7)
is pulled and the parking brake is
1. Drain oil from the transmission case. released.
a Tighten the 2 bolts uniformly a little at a
6 Transmission case: 65 l
time. (Tighten approx. 3 turns after the
bolts contact the seat.)
2. Remove refueling tube (1).
7. Remove remaining 2 bolts (6). [*4]
3. Remove the guard (2), and then disconnect
the center drive shaft (3) at the transmission 8. Remove 10 bolts (8), leaving opposite 2 bolts.
side. [*1] [*5]
a Shrink the center drive shaft.
4. Remove coupling (4). [*2]
5. Remove plugs (5). [*3]
50-400 2 WA470-6, WA480-6

400 Brake system
Removal and installation of parking brake disc and plate SEN04866-01
9. Set jack [1] under cover (9).
10. Install guide bolt [2] and remove the bolts left in
step 8. [*5]
11. Using forcing screws [3] (M12 x 1.75), discon-

nect cover (9) and piston together from hous-
ing (10). [*6]
k When removing cover (9) from guide
bolts [2], hold it securely with another
person and lower jack [1] slowly.
4 Cover and piston assembly: 35 kg
14. Install bolts [4] (M8 x 1.25) to the lifting tap and
remove spacer (11). [*7]
12. To prevent housing (10) from falling, install the

opposite 2 bolts.
13. Using tool B1, push spacer (11) and remove

ring (12). 15. Remove 7 plates (13), 6 springs (14) and 6
discs (15). [*8]
WA470-6, WA480-6 50-400 3

400 Brake system
SEN04866-01 Removal and installation of parking brake disc and plate
Installation q Refilling with oil (Transmission case)

q Carry out installation in the reverse order to Add oil through oil filler to the specified level.
removal. Run the engine to circulate the oil through the
system. Then check the oil level again.
[*1]
a When installing the drive shaft, check that the
spider cap key is perfectly nested in the key
slot of the counter yoke, and then tighten the
bolt.
3 Mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*2]
2 Coupling mounting bolt: Adhesive (LT-2)
3 Coupling mounting bolt:
622 – 829 Nm {67.5 – 84.5 kgm}
[*3]
3 Plug: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*4]
3 Housing mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*5]
3 Cover mounting bolt:
98.1 – 122.6 Nm {10 – 12.5 kgm}
[*6]
2 Piston O-ring: Grease (G2-LI)
[*7]
2 Spacer O-ring: Grease (G2-LI)
[*8]
a Install plates (13), springs (14) and discs (15)
in this order.
a Be careful so that the springs (14) are not
pinched between them.
50-400 4 WA470-6, WA480-6

400 Brake system
Removal and installation of parking brake disc and plate SEN04866-01
WA470-6, WA480-6 50-400 5

SEN04866-01

©2009 KOMATSU
All Rights Reserved
50-400 6
SEN04538-01
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight ................................................................................................... 10
WA470-6, WA480-6 50-500 1

SEN04538-01 Removal and installation of center hinge pin
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 name
Part No.
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
7 790-101-2102 Puller (30 ton) t 1
Removal
k Stop the machine on a level ground and 5. Set jack [4] at the rear counterweight section.
1. Remove the work equipment assembly, refer-

ring to "Removal and installation of work equip-
ment assembly."

assembly. For details, see “Removal and installa-
tion of operator's cab and floor frame assembly”.
3. Jack up rear frame (34) and put blocks [1]

under its right and left portions, while adjusting
its height. 6. Remove the mounting bolt and disconnect
front drive shaft (1). [*1]
50-500 2 WA470-6, WA480-6

Removal and installation of center hinge pin SEN04538-01
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]
8. Disconnect harness connectors FF1 (4), FF2

(5) and FF3 (6), and then remove harness
clamps (7) and (8).
12. Remove 4 bolts (26) and spacer (27). [*4]
13. Remove 6 bolts (28), and then remove retainer

(29). [*5]
9. Disconnect hoses (9), (10), (11), (12), (13) and a Check the number and thickness of shims
(14). used between the retainer and frame.
WA470-6, WA480-6 50-500 3

14. Remove plate (30), and then pull out upper 17. Remove bolts from the upper hinge of front
hinge pin (31). [*6] frame (33), 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.
18. Remove dust seal (37) from the retainer (36).

15. Remove spacer (32). [*9]
16. Carefully pull out front frame (33) forward and

disconnect it from rear frame (34). [*7]
a Take care of the balance at disconnection.
a Confirm whether all the necessary piping
and harnesses are disconnected.
a Check that no point was missed when
separating.
a Remove the frame lock lever.
50-500 4 WA470-6, WA480-6

19. Remove spacer (38) and dust seal (39) from the 23. Remove dust seal (43) from the retainer (42).
bottom of the upper hinge of front frame (33). [*14]
[*10]
20. Remove bearing (40) from the upper hinge of

front frame (33). [*11]
24. Remove dust seal (44) from the lower hinge of

front frame (33), and then remove bearing
(45). [*15]
21. Remove top and bottom bushings (41) from

the lower hinge of rear frame (34). [*12]
22. Remove the mounting bolt from the lower

hinge of front frame (33), and then remove
retainer (42). [*13]
a Check the number and thickness of shims
used between the retainer and frame.
WA470-6, WA480-6 50-500 5

Installation
removal.
[*1]
3 Drive shaft mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*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. 2) Press dust seal (37) in retainer (36).
a At pressing, turn the dust seal lip out-
side.
2 Periphery of dust seal metallic outer
ring: Adhesive (Loctite 601)
[*8][*9][*10][*11]
a Assemble the upper hinge pin in the following
procedure.
1) Assemble tool E1-1 to the top of the upper
hinge of front frame (33), and set bearing
(40) on tool E1-1. Then press the bearing 3) Temporarily tighten retainer (36) using 3
inserting it to the press fitting part from the mounting bolts. Then select the shim so
top. that the clearance (d) between the retainer
a At pressing, use tool E1-4 as a guide. and hinge becomes the specified value.
a Take care so that the bearing may not q Clearance (d):
incline. Max. 0.1 mm (Mean value)
a When replacing bearing (40), spacers 3 Mounting bolt:
(32) and (38) must be replaced along 19.6 ± 2 Nm {2 ± 0.2 kgm}
with it.
a See the previous page for spacers 4) After adjusting the shim, tighten all the
(32) and (38). retainer mounting bolts with the specified
2 Inside bearing: Grease (G2-LI) torque.
2 Mounting bolt:
Adhesive (Loctite 262)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
50-500 6 WA470-6, WA480-6

[*12][*13][*14][*15]
Assemble the lower hinge in the following proce-
dure.
1) Press bearing (45) in front frame (33)
using tool E1.
a At pressing, use tool E1-1 as a guide.
a Take care so that the bearing may not
incline.
2 Inside bearing: Grease (G2-LI)
2) Press dust seal (43) in retainer (42).

side.
5) Assemble dust seal (39) and spacer (38) ring: Adhesive (Loctite 601)
from lower of the front frame (33).
side.
a Assemble spacer (38) from lower so
that the more largely chamfered side
facing to the bearing side.
WA470-6, WA480-6 50-500 7

3) Temporarily tighten retainer (42) using 3 6) Press bushing (41) in the lower hinge of
mounting bolts. Then select the shim so rear frame (34) using the press and the
that the clearance (e) between the retainer like.
and hinge becomes the specified value.
Clearance (e): Max. 0.1 mm (Mean value)
3 Mounting bolt:
19.6 ± 2 Nm {2 ± 0.2 kgm}
4) After adjusting the shim, tighten all the

retainer mounting bolts with the specified
torque.
2 Mounting bolt:
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
[*3][*4][*5][*6][*7]
q Install the front frame and rear frame in the fol-
lowing procedure.
k Use a bar to mach the pin holes. Absolutely
do not insert fingers.
a Be sure to match the pin holes.
1) Insert upper hinge pin (31), and then
assemble spacer (32).
2) Temporarily fit plate (30) to prevent drop of

upper hinge pin (31).
5) Press dust seal (44) from upper of the
front frame.
side.
ring: Adhesive (Loctite 601)
50-500 8 WA470-6, WA480-6

3) Assemble retainer (29) to upper hinge pin 7) Insert lower hinge pin (25) and tighten lock
(31) using spacer (27) and mounting bolt bolt (24).
(26).
3 Pin mounting bolt (26):
19.6 ± 2 Nm {2.0 ± 0.2 kgm}
4) Equally tighten retainer (29) using 3

mounting bolts (28). Then measure clear-
ance (c) between the hinge and retainer at
two places and compute the mean, and
select the shim to be used.
Clearance (c) = 0.2 mm max.
3 Retainer mounting bolt (28):
19.6 ± 2 Nm {2 ± 0.2 kgm}
5) Tighten the mounting bolts (28) for pin

(31) and retainer (29) with the specified
torque.
2 Pin and retainer mounting bolts:
3 Pin mounting bolt:
205.9 ± 2 km {21 ± 0.2 kgm}
3 Retainer mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
6) Tighten the mounting bolt for plate (30)

permanently.
WA470-6, WA480-6 50-500 9

SEN04538-01 Removal and installation of counterweight

counterweight 1
Removal
tires.
battery beforehand.
1. Remove cover (1) in the rear side of the right

and left side tail light boxes.
3. Open the left side battery case cover, remove
5 clamps for harness (4), pull out harness (4)
and place it beside the machine.
4. Disconnect battery cable (5) on the battery

side.
5. Remove 2 mounting bolts for the bottom of top

grille assembly (6).
2. Disconnect connectors (2) and (3) in the right

and left side tail light boxes.
a Machine left side connector (2): R30
Machine right side connector (3): R31
6. Open the right side battery case cover, remove

4 clamps for harness (7), pull out harness (7)
and place it beside the machine.
7. Disconnect ground cable (8) on the machine

side.
50-500 10 WA470-6, WA480-6

Removal and installation of counterweight SEN04538-01
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: 400 kg
9. Open the rear grille and remove stay (9) for the
under mirror.
10. Remove 3 mounting bolts for top bracket (10).
13. Temporarily lift large counter (15), and then

remove 2 mounting bolts (16) to lift off the
counter. [*2]
4 Large counter: 1,950 kg (WA470-6)
3,050 kg (WA480-6)
11. Lift the mounting bolts for side grilles (11) on

both sides and lift off top grille assembly (6).
Installation
removal.
[*1]
3 Weight-adjusting small counter mount-
ing bolt:
1520 – 1912 Nm {155 – 195 kgm}
[*2]
3 Large counter mounting bolt:
1520 – 1912 Nm {155 – 195 kgm}
WA470-6, WA480-6 50-500 11

SEN04538-01

©2009 KOMATSU
All Rights Reserved
50-500 12
SEN04539-00
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
600 Hydraulic system

Removal and installation of steering demand valve assembly ....................................................................... 2
Removal and installation of work equipment valve assembly ......................................................................... 5
Removal and installation of brake charge valve assembly ............................................................................. 8
Removal and installation of hydraulic tank assembly...................................................................................... 9
Removal and installation of steering and power train pump assembly ..........................................................11
Removal and installation of work equipment and cooling fan pump assembly ............................................. 12
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 14
WA470-6, WA480-6 50-600 1

SEN04539-00 Removal and installation of steering demand valve assembly
Removal and installation of 4. Remove left side cover (2).

steering demand valve assembly 1
Removal
1. Raise the lift arm and support it with jack [1].
k The jack must support the lift arm
securely.
5. Take out filter (3) and remove box (4).

chocks under the tires.
k Loosen the oil filler cap of the hydrau-
lic tank to release the internal pressure.
k Disconnect the negative (–) terminal of
the battery beforehand.

6. Remove right side cover (5).
50-600 2 WA470-6, WA480-6

Removal and installation of steering demand valve assembly SEN04539-00
7. Disconnect pilot hose (6). 12. Disconnect tubes (12) and (13).
13. Disconnect pilot hose (14).
14. Disconnect drain hose (15).
8. Disconnect tube (7).
9. Remove 2 clamps (8). [*1]
15. Temporarily lift steering demand valve assem-

bly (16).
a Lead lifting wire [2] through the space
between the front frame and cab.
10. Remove 3 clamps (9). [*2]
11. Disconnect tubes (10) and (11).
16. Remove mounting bolt (17) for steering

demand valve assembly (16).
WA470-6, WA480-6 50-600 3

SEN04539-00 Removal and installation of steering demand valve assembly
17. Pull out steering demand valve assembly (16) Installation

in the front side, and then remove the lifting q Carry out installation in reverse order of
wire. removal.
a When pulling out the assembly, set wood
material [3] on the work equipment valve [*1] [*2]
to protect it from getting damages. 3 Mounting clamp:
10.8 – 26.5 Nm {1.1 – 2.7 kgm}

again.
18. Re-lift steering demand valve assembly (16)

and remove it.
4 Steering demand valve assembly: 35 kg
50-600 4 WA470-6, WA480-6

Removal and installation of work equipment valve assembly SEN04539-00
Removal and installation of work 4. Remove left side cover (2).

equipment valve assembly 1
Removal
1. Raise the lift arm and support it with jack [1].
k The jack must support the lift arm
securely.
5. Take out filter (3) and remove box (4).

chocks under the tires.
k Loosen the oil filler cap of the hydrau-
lic tank to release the internal pressure.
k Disconnect the negative (–) terminal of
the battery beforehand.

WA470-6, WA480-6 50-600 5

SEN04539-00 Removal and installation of work equipment valve assembly
7. Remove 2 clamps (6) and (7), and remove

connectors F12 (8) and F14 (9).
8. Remove clamp bracket (10).
9. Disconnect connector F13 (11).
14. Remove pilot hoses (24) and (25) in the rear

side of the work equipment valve assembly.
10. Disconnect 4 pilot hoses (12), (13), (14) and

(15).
12. Remove clamps (20) and remove tubes (21)

and (22).
a Remove clamps (20) at the top of the front
frame, and then remove tubes (21) and
(22) on both sides. Fix the removed tubes
to the lift cylinder with a piece of string.

16. Remove 4 mounting bolts (28) for mounting
the bottom of the work equipment valve
assembly.
50-600 6 WA470-6, WA480-6

Removal and installation of work equipment valve assembly SEN04539-00
17. 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)
again.
18. Lift off work equipment valve assembly (29).

4 Work equipment assembly: 140 kg
WA470-6, WA480-6 50-600 7

SEN04539-00 Removal and installation of brake charge valve assembly
Removal and installation of brake 4. Disconnect hoses (7), (8), (9) and (10).
charge valve assembly 1
5. Remove the mounting bolts to remove brake
Removal charge valve assembly (11).
k Apply the parking brake and put chocks
under the tires.
tank to release the internal pressure.
battery beforehand.
Installation
removal.

2. Disconnect connectors R52 (2) and R54 (3). again.
3. Disconnect hoses (4), (5) and (6).
50-600 8 WA470-6, WA480-6

Removal and installation of hydraulic tank assembly SEN04539-00
Removal and installation of 8. Remove seat (6).

hydraulic tank assembly 1
Removal
tires.
battery beforehand.
1. Drain hydraulic tank.

5 Hydraulic tank: 173 l
9. Disconnect 3 left side hoses (7), (8) and (9).
"Removal and installation of hood assembly."
4. Remove 2 clamps (2) for the harness.
11. Disconnect 4 right side hoses (11), (12), (13)

and (14).
6. Disconnect connector (4).
7. Remove dust indicator bracket assembly (5).
WA470-6, WA480-6 50-600 9

SEN04539-00 Removal and installation of hydraulic tank 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
14. Remove tubes (20) and (21) at the bottom of

the hydraulic tank.
Installation
removal.

again.
q Bleeding air
Bleed air from the pump circuit, referencing to
"Bleeding air from work equipment circuit" in
50-600 10 WA470-6, WA480-6

Removal and installation of steering and power train pump assembly SEN04539-00
Removal and installation of 7. Sling the steering and power train pump
steering and power train pump assembly temporarily.
assembly 1
8. Remove the mounting bolts, then remove
Removal steering and power train pump assembly (9).
1. Remove the engine hood assembly. For [*1]
details, see "Removal and installation of 4 Steering and power train pump assem-
engine hood assembly." bly: 75 kg
2. Remove the hydraulic tank assembly. For

details, see "Removal and installation of
hydraulic tank assembly."
3. Remove operator cab and floor frame assem-

bly. For details, see "Removal and installation
of operator cab and floor frame assembly."
4. Disconnect hoses (1), (2), (3) and (4).
5. Remove tubes (5) and (6).
Installation
removal.
[*1]
3 Pump assembly mounting bolt:
235 – 285 Nm {23.5 – 29.5 kgm}

6. Disconnect hose (7) and connector R96 (8) at
the bottom of the steering pump.
(Disconnected connector R96 is shown in the
again.
figure.)
q Bleeding air
Bleed air from the steering circuit, referencing
to "Bleeding air from steering circuit" in Testing
and adjusting.
WA470-6, WA480-6 50-600 11

SEN04539-00 Removal and installation of work equipment and cooling fan pump assembly
Removal and installation of work

equipment and cooling fan pump
assembly 1
Removal
assembly."
2. Remove the hydraulic tank assembly, referenc-

ing to "Removal and installation of hydraulic
tank assembly".

assembly, referencing to "Removal and instal-
lation of operator's cab and floor frame assem- 11. Remove brackets (14) and (15) at the bottom
bly." of the work equipment and cooling fan pump
assembly.
4. Remove clamp (1) and disconnect connectors
R71 (2) and R29 (3).
5. Remove clamp (4) and disconnect the hose

(5).
12. Sling the work equipment and cooling fan

pump assembly temporarily.
13. Remove the mounting bolts then remove work

equipment and cooling fan pump assembly
(16). [*1]
4 Work equipment and cooling fan pump
7. Remove hose (7). assembly: 150 kg
8. Remove clamp (8) and disconnect hose (9).
9. Disconnect hoses (10), (11) and (12).
10. Remove tube (13).
50-600 12 WA470-6, WA480-6

Removal and installation of work equipment and cooling fan pump assembly SEN04539-00
Installation
removal.
[*1]
3 Pump assembly mounting bolt:
235 – 285 Nm {23 – 29.5 kgm}

again.
q Bleeding air
Bleed air from the work equipment circuit, ref-
erencing to "Bleeding air from work equipment
circuit" in Testing and adjusting.
WA470-6, WA480-6 50-600 13

SEN04539-00 Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1
1. Disassembly of cylinder head/piston
assembly for steering cylinders
Special tools 1) Set the cylinder assembly (1) for the tool
F1.
New/Remodel
2) Use the tool F3-1 or F3-2 to remove the
cylinder head (2) from the cylinder.
Necessity
Sym-
Part No. Part name
Sketch
bol
Q'ty
1 790-502-1003 Cylinder repair t 1
F1 stand
F2 790-302-1280 Socket t 1
F3
F4
2 790-102-4310 Pin t 1
1 790-720-1000 Expander t 1
2 796-720-1650 Ring t 1
3 07281-01029 Clamp t 1
3) Extract the cylinder head/piston rod
F5 4 796-720-1680 Ring t 1 assembly (3) from the cylinder (4) and
5 07281-01589 Clamp t 1 hang and remove it.
6 796-720-1690 Ring t 1 a Because oil flows out when the piston
rod assembly (3) is extracted from the
7 07281-01919 Clamp t 1
cylinder, prepare an oil receiver.
1 790-201-1500 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-80816 • Bolt 1
F6 4 790-201-1570 • Plate 1
5 790-201-1990 Plate t 1
6 790-201-1660 • Plate 1
7 790-201-1670 • Plate 1
1 790-201-1702 Push tool kit t 1
2 790-101-5021 • Grip 1
3 01010-80816 • Bolt 1
F7 4 790-201-1761 • Push tool 1
5 790-201-1930 • Push tool 1
6 790-201-1851 • Push tool 1
7 790-201-1861 • Push tool 1
50-600 14 WA470-6, WA480-6

Disassembly and assembly of hydraulic cylinder assembly SEN04539-00
4) Set the cylinder head/piston rod assembly 3) Extract the cylinder head/piston rod
(3) for the tool F1. assembly (3) from the cylinder (4) and
5) Use the tool F2 to remove the nut (5). hang and remove it.
a Nut width across flats: 55 mm a Because oil flows out when the piston
6) Remove the piston (6) and remove the rod assembly is extracted from the
cylinder head (2). cylinder, prepare an oil receiver.
2. Disassembly of cylinder head/piston rod 4) Set the cylinder head/piston rod assembly
assembly for lift arm and bucket cylinders (3) for the tool F1.
1) Set the cylinder assembly (1) for the tool 5) Remove the lock screw (7) of the piston
F1. rod assembly from the piston (6).
2) Remove the mounting bolt of the cylinder a Screw size common to the lift and
head (2). bucket cylinders: M12 x 1.75
Bolt width across flats
Cylinder
(mm)
Lift arm cylinder 27
WA470-6 30
Bucket
cylinder
WA480-6 36
WA470-6, WA480-6 50-600 15

a When the caulking of the screw (7) is 3. Fine disassembly of piston rod assembly
strong and the screw is not removed, [Steering cylinder]
thrust the screw into the depth once Remove the wear ring (8) and the piston ring
and apply the tap [1] to the threaded (9) from the piston (6).
portion, then remove the screw.
[Lift arm and bucket cylinder]

Remove wear ring (8), piston ring (9), O-ring,
6) Use the tool F4 to remove the piston rod backup ring (10), and ring (10a) from piston
assembly (6). (6).
a When the tool F4 is not used, use the
drill hole (p) (10 mm in diameter: two
locations) to loosen the piston rod
assembly.
7) Remove the head assembly (2).
50-600 16 WA470-6, WA480-6

4. Fine disassembly of cylinder head assembly Assembly

[Steering cylinder] a Pay attention not to damage the packing, dust
1) Remove the O-ring/backup ring (11). seal, and O-ring.
2) Remove the snap ring (12) and remove a Insert the backup ring after having heated it
the dust seal (13). using warm water of about 50 – 60°C instead
3) Remove the rod packing (14). of forcibly fitting it in.
4) Remove the buffer ring (15). 1. Fine assembly of cylinder head assembly
5) Remove the bushing (16). a Use the tool F6 plate and the F7 push tool
6) Remove the O-ring (17). referring to the following items.
q F6-4, F7-4: Steering cylinder
q F6-5, F7-5: Lift arm cylinder
q F6-6, F7-6: Bucket cylinder (WA470-6)
q F6-7, F7-7: Bucket cylinder (WA480-6)
[Steering cylinder]
1) Use the tool F7 to press-fit the bushing
(16).
2) Build in the buffer ring (15).
3) Build in the rod packing (14).
4) Use the tool F6 to mount the dust seal
(13) and secure it with the snap ring (12).
5) Mount the O-ring/backup ring (11).
6) Mount the O-ring (17).
[Lift arm and bucket cylinder]

1) Remove O-ring and backup ring (11).
2) Remove snap ring (12) and dust seal (13).
3) Remove rod packing (14).
4) Remove buffer ring (15).
5) Remove snap ring (16a) and bushing (16).
WA470-6, WA480-6 50-600 17

[Lift arm and bucket cylinder] 5) Mount the backup ring/O-ring (10) and
1) Using tool F7, press fit bushing (16) and ring (10a).
install snap ring (16a). [Lift arm and bucket cylinders]
2) Install buffer ring (15). a Do not insert the backup ring forcibly,
3) Install rod packing (14). but warm it in water at 50 – 60°C and
4) Using tool F6, install dust seal (13) and then insert it.
secure it with snap ring (12).
5) Install backup ring and O-ring (11).
[Steering cylinder]
2. Fine assembly of piston assembly [Lift arm and bucket cylinder]

1) Use the tool F5-1 to widen the piston ring
(9).
a Rotate the handle eight to ten times
to widen the piston ring.
2) Remove the piston ring (9) from the tool
F5-1 and build it in the piston (6).
3) Set the tool F5 and shorten the piston ring
(9).
a Use the tool F5 ring and clamp refer-
ring to and combining the following
items.
q F5-2, 3: Steering cylinder
q F5-4, 5: Bucket cylinder (WA470-6)
Lift arm cylinder
q F5-6, 7: Bucket cylinder (WA480-6)
4) Build in the wear ring (8).
50-600 18 WA470-6, WA480-6

3. Assembly of cylinder head/piston rod

assembly for steering cylinders
1) Set the piston rod assembly (3) for the tool
F1.
2) Build the cylinder rod (2) and the piston (6)
in the piston rod.
3) Build in the nut (5) and use the tool F2 to
tighten the nut (5).
2 Piston rod threaded portion:
Adhesive (LT-2)
3 Nut:
1.67 ± 0.17 kNm {170 ± 17 kgm}
(Width across flats 55 mm)
4. Assembly of cylinder head/piston rod

assembly for lift arm and bucket cylinders
1) Set the piston rod assembly (3) for the tool
F1.
2) Build in the head assembly (2).
4) Set the cylinder (4) for the tool F1.

5) Hang the cylinder head/piston rod assem-
bly (3) and build it in the cylinder (4).
6) Use the tool F3-1 or F3-2 to mount the cyl-
inder head (2) on the cylinder (4).
3 Cylinder head:
677 ± 67.5 Nm {69 ± 6.9 kgm}
7) Bend the lock of the cylinder head (2) to
the cut-out portion of the cylinder side.
8) Remove the cylinder assembly (1) from
the tool F1.
WA470-6, WA480-6 50-600 19

3) Assemble the piston assembly (6) in the q When using a new product on one side
following procedures. or both sides of the rod and the piston
q When reusing the rod and piston assembly (6):
assembly (6): 1] Screw the piston assembly (6) until it
1] Screw the piston assembly (6) and touches both ends (r) of the rod and
use the tool F4 to tighten the piston use the tool F4 to tighten it.
assembly (6) until the position of the 3 Piston assembly (6):
screw tapped hole is aligned. 294 ± 29.4 Nm {30 ± 3.0 kgm}
a Fully clean them and remove
chips and dust.
a Remove burrs of the threaded
portion with a file, etc.
2] Work one location of the tapped hole

at which the screw (7) is bonded.
a Horizontally work the tapped hole
by aligning a drill to the V-groove
2] Tighten the screw (7). of the threaded portion in the pis-
2 Threaded portion of screw: ton (6) and the rod (3).
Adhesive q Screw work dimensions (mm)
(equivalent to Loctite 262)
3 Screw (7):
Tap drill Tap drill
Tap used Tap depth
diameter depth
58.9 – 73.6 Nm {6 – 7.5 kgm} Bucket 20 (WA470-6)
3] Caulk 4 places on the periphery of 10.3 26 12 x 1.75
cylinder 29 (WA480-6)
threaded portion [2] with a punch. Lift
4] Apply a torque of 41.2 – 88.2 Nm {4.2 10.3 27 12 x 1.75 20
cylinder
– 9 kgm} in the loosening direction of
screw (7) and confirm that the screw
will not be loosened.
50-600 20 WA470-6, WA480-6

3] After having worked the tapped hole,

remove chips and dust and fully clean
it.
4] Tighten the screw (7).
2 Threaded portion of screw:
Adhesive
(equivalent to Loctite 262)
3 Screw (7):
58.9 – 73.6 Nm {6 – 7.5 kgm}
5] Caulk 4 places on the periphery of
threaded portion with a punch.
6] Apply a torque of 41.2 – 88.2 Nm {4.2
– 9 kgm} in the loosening direction of
screw (7) and confirm that the screw
will not be loosened.
4) Set the cylinder (4) for the tool F1.

5) Hang the cylinder head/piston rod assem-
bly (3) and build it in the cylinder (4).
6) Mount the cylinder head (2) on the cylin-
der (4).
3 Mounting bolt:
373 ± 54 Nm {38.0 ± 5.5 kgm}
(Lift arm cylinder)
530 ± 78.5 Nm {54.0 ± 8.0 kgm}
(WA470-6 bucket cylinder)
892 ± 137 Nm {91.0 ± 14 kgm}
(WA480-6 bucket cylinder)
a For the leveler plate (20) of the
bucket cylinder, tighten the bolt to the
following dimensions.
q Dimensions (A): 48.5 ± 1 mm
(B): 140 ± 2 mm
(WA470-6)
150 ± 2 mm
(WA480-6)
7) Remove the cylinder assembly (1) from
the tool F1.
WA470-6, WA480-6 50-600 21

SEN04539-00

©2008 KOMATSU
All Rights Reserved
50-600 22
SEN04540-00
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
700 Work equipment

Removal and installation of work equipment assembly .................................................................................. 2
WA470-6, WA480-6 50-700 1

700 Work equipment
SEN04540-00 Removal and installation of work equipment assembly
Removal and installation of work 6. Install support stands [1] at the lift arm end,
equipment assembly 1
and release the remaining pressure in the
hydraulic piping.
Removal
k Stop the machine on a level ground and 7. Temporarily sling lift cylinder (6) and remove
lower the work equipment and touch per- pin (5). [*4]
fectly to the ground. a When shims are used, check their number
k Install the lock bar on the frame, apply the and thickness.
parking brake and put chocks under the tires. a When lowering the lift cylinder, put the
block [2] into the top of the axle.
4
1. Temporarily lift the bucket link, and remove pin Lift cylinder: 190 kg (WA470-6)
(1). [*1] 200 kg (WA480-6)
a Fix the bucket link using the lever block.
a When shims are used, check their number
and thickness.
2. Remove right and left side pins (2). [*2]

a When shims are used, check their number
and thickness.
3. Move the machine to backward and disconnect

the bucket from the lift arm.
4. Sling bucket cylinder (3) temporarily.
5. Pull out pin (4) and separate the cylinder rod

and bell crank. [*3]
4 Bucket cylinder: 210 kg (WA470-6) 8. Remove 2 bolts, and then remove boom kick
270 kg (WA480-6) out switch assembly (7). [*5]
50-700 2 WA470-6, WA480-6

700 Work equipment
Removal and installation of work equipment assembly SEN04540-00
9. Temporarily sling lift arm, bell crank and bucket 12. Sling bell crank (13) temporarily, pull out pin
link assembly (8). (14), then remove the bell crank. [*7]
a Lift the assembly sandwiching block [3] in
4 Bell crank: 390 kg (WA470-6)
between.
410 kg (WA480-6)
10. Disconnect grease tube (9).

13. Sling bucket link (11) temporarily, pull out pin
11. Pull out pin (10) and remove lift arm, bell crank, (12), then remove the bucket link.
4
and bucket link assembly. [*6]
Bucket link: 90 kg (WA470-6)
a If shims are used, record their number and
110 kg (WA480-6)
thickness.
4 Lift arm, bell crank and bucket link
assembly: 1,950 kg (WA470-6)
2,100 kg (WA480-6)
14. Pull out dust seal (16) and bushing (17) from
lift arm (15). [*8]
WA470-6, WA480-6 50-700 3

700 Work equipment
SEN04540-00 Removal and installation of work equipment assembly
15. Pull out dust seal (18) and bushing (19) from Installation
bell crank (13). [*8] q Carry out installation in reverse order of
removal.
k Use a bar to match the pin holes. Abso-

lutely do not insert fingers.
k When starting the engine, check that the
directional lever is in neutral and the park-
ing brake is applied.
[*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). [*8] 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: 1.5, 3.0 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
q Clearance (b): Max. 1.5 mm
q Set shim thicknesses: 1.5, 3.0 mm
50-700 4 WA470-6, WA480-6

700 Work equipment
Removal and installation of work equipment assembly SEN04540-00
[*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
q Clearance (d): Max. 1.5 mm
q Set shim thicknesses:
1.0 mm, 1.5 mm, 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 50-700 5

SEN04540-00

©2008 KOMATSU
All Rights Reserved
50-700 6
SEN04541-00
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up

Removal and installation of operator's cab and floor frame assembly............................................................ 2
Removal and installation of operator's cab glass (stuck glass)....................................................................... 6
Disassembly and assembly of operator's seat assembly.............................................................................. 14
Removal and installation of air conditioner unit assembly ............................................................................ 56
WA470-6, WA480-6 50-800 1

SEN04541-00 Removal and installation of operator's cab and floor frame assembly
Removal and installation of 5. Take out filter (1a) and remove box (1b).
operator's cab and floor frame
assembly 1
Removal
tires.
battery beforehand.
1. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and 6. Remove right side cove (2).
filling operation of refrigerant.
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 1,250 ± 50 g
2. Drain coolant.
6
7. Disconnect hose (2a) going to the PPC accu-
Coolant: 61 l mulator.

50-800 2 WA470-6, WA480-6

Removal and installation of operator's cab and floor frame assembly SEN04541-00
8. Remove bottom plate (3) on the washer tank

mounting box.
14. Disconnect 2 connectors FL1 (19) and LT1

(20) in the centralized harness box at the lower
9. Remove clamp (4) and disconnect 2 washer left side of the floor frame.
hoses (5).
10. Disconnect connectors R43 (6) and R45 (7).
15. Disconnect connector L09 (21) in the center of

the floor frame.
16. Disconnect brake hose (22) at the booster

11. Disconnect 9 connectors at the lower left side side.
of the lower frame.
17. Disconnect brake hose (23) at the frame side.
• (8) : LR1 • (9) : LR8 • (10): LR4
• (11): LR12 • (12): LR6 • (13): LR5
• (14): LR7 • (15): LR11 • (16): FL2
12. Disconnect connector mounting bracket (17).
13. Disconnect grounding wire (18) situated in the

lower left side of the lower frame.
WA470-6, WA480-6 50-800 3

SEN04541-00 Removal and installation of operator's cab and floor frame 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).
22. Remove the clamp and disconnect air condi-

tioner hoses (35) and (36).
23. Remove hose bracket (37).
19. Disconnect 4 steering hoses (25), (26), (27)

and (28).
24. Remove rear wiper motor cover (38).
26. Remove lunch box (40).
20. Disconnect 4 PPC hoses (29), (30), (31) and

(32) at the rear frame side.
50-800 4 WA470-6, WA480-6

Removal and installation of operator's cab and floor frame assembly SEN04541-00
27. Remove 4 front and rear rubber caps (41). Installation

28. Remove 4 front and rear nuts (42). [*2] removal.
[*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 Refilling with coolant

Add coolant up to the specified level. Run the
29. Lift off operator's cab and floor frame assembly engine to circulate the coolant through the sys-
(43). tem. Then, check the coolant level again.
a Before lifting off, make sure every neces-
sary harness and piping is disconnected. q Refilling with oil (Hydraulic tank)
4 Operator's cab and floor frame a Add hydraulic oil up to the specified level.
assembly: 1,150 kg a Run the engine to circulate the oil through
again.
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 50-800 5

SEN04541-00 Removal and installation of operator's cab glass (stuck glass)
Removal and installation of a If the window glass is broken finely, it may be

operator's cab glass (stuck glass)1 removed with knife [4] and a screwdriver. (If
the screwdriver is applied directly to the normal
Special tools window glass, the glass will be probably bro-
ken.)
Necessity
Symbol
Sketch
Q’ty
N/R
Part number Part name a 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
1. Using seal cutter [1], cut the adhesive between

broken window glass (1) and operator's cab
(2). 2. Remove the window glass.
a If the glass is narrow, you may cut the adhe-

sive by the following method; Insert a fine wire
(piano wire, etc.) [2] in the adhesive and grip
its both ends with pliers [3], etc. (or hold them
by winding them onto something) and cut the
adhesive with the wire.
50-800 6 WA470-6, WA480-6

Removal and installation of operator's cab glass (stuck glass) SEN04541-00
Installation 3. When the adhesive was removed with the

1. Using scraper [5], remove the remaining adhe- scraper, if any paint was flaked off, coat the
sive. bare part with paint.
a Do not scratch the paint. a If the glass is installed without repairing
the bare part, that part will be rusted.
a Do not apply paint to a part which will be
coated with primer.
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (2) and window glass (3) with
white gasoline.
a If the sticking surfaces are not cleaned 4. Stick both-sided adhesive tape (4) along the
well, the glass may not be stuck perfectly. inside edge of the glass sticking section.
a Clean all the black part on the back side of q Size of both-sided adhesive tape: 7 × 4.8 mm
the window glass. a When sticking the both-sided adhesive
a After cleaning the sticking surfaces, leave tape, do not touch the cleaned surface as
them for at least 5 minutes to dry. long as possible.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
WA470-6, WA480-6 50-800 7

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).
a When sticking the both-sided adhesive tape

around a side or a rear window glass, start at
center of the top and make a clearance of
about 5 mm at end joint (c).
3) Using tool X3 (suction cup), place window

glass (3) on tool X2-1 (5 mm spacer) and
match it to the operator's cab.
50-800 8 WA470-6, WA480-6

4) Check the clearance between window

glass (3) and operator's cab (2) on the
right and left sides and adjust it evenly.
5) Stick tape [6] between window glass (3)
and operator's cab (2) and draw position-
ing line (a) on the tape.
6) Cut the tape between window glass (3)
and operator's cab (2) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
3) Evenly apply paint primer (7) to the parts

on the outside of both-sided adhesive tape
on operator's cab (2) which will be coated
with the adhesive.
2 Paint primer:
SUNSTAR PAINT PRIMER 580 SUPER
a Do not apply the primer more than 2
times. (If it is applied more than 2
times, its performance will be low-
ered.)
a Parts to be coated with primer: Apply
the primer all over dimension (d) on
6. Apply primer. the outside of the both-sided adhe-
a The using limit of primer (5) is 4 months sive tape.
after the date of manufacture. Do not use q Dimension to apply primer (d):
the primer after this limit. 23 mm
a Use the primer within 2 hours after unpack- a After applying the primer, leave it for
ing it. at least 5 minutes (within 8 hours) to
a Even if the primer is packed again just dry.
after it is unpacked, use it within 24 hours a If the glass primer is applied by mis-
after it is unpacked for the first time. (Dis- take, wipe it off with white gasoline.
c a r d t h e pr im e r 2 4 ho u r s a fte r i t is (If wrong primer is applied, the glass
packed.) will not be stuck.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it. (If the primer is unpacked
just after taken out of the refrigerator,
water will be condensed. Accordingly,
leave the primer at the room tempera-
ture for a sufficient time.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
WA470-6, WA480-6 50-800 9

4) Evenly apply glass primer (8) to the black 7. Apply adhesive.

part of window glass (3) to be stuck. a Use either of the 2 types of the adhesive,
2 Glass primer: depending on the season.
SUNSTAR GLASS PRIMER 580 SUPER 2 Adhesive (April – October):
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.)
50-800 10 WA470-6, WA480-6

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.
3) Set adhesive cartridge (9) to caulking gun

[7].
a An electric caulking gun is more efficient. a Apply adhesive (12) to dimensions (h)
and (j) of both-sided adhesive tape
(4) of operator's cab (2).
q Dimension (h): 10 mm
a Apply adhesive (12) higher than both-
sided adhesive tape (4).
a Apply the adhesive evenly in height.
4) Remove release tape (13) of the both-

sided adhesive tape on the glass side.
WA470-6, WA480-6 50-800 11

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).
3) After sticking window glass (3), press it

evenly.
a Press all over the window glass to the
degree that the window glass will be
stuck to the both-sided adhesive
tape.
2) Using tool X3, raise and place window a Do not press the window glass too
glass (3) on tool X2-1 (5 mm spacer) and strongly.
stick it to the operator's cab.
a Match the lines of the match tapes
stuck in step 5.
a Stick the glass within 10 minutes after
applying the adhesive.
a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
9. Cure the stuck window glass for a certain time.

a Curing time before removing tool X2-1 (5 mm
spacer) (at temperature of 20°C and humidity
of 60%): 10 hours
a Curing time before operating vehicle after
application of adhesive: 24 hours (1 day)
50-800 12 WA470-6, WA480-6

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.
4) Remove the masking tapes from the win-

dow glass.
11. Remove the primer and adhesive from the

operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it dries.
a When cleaning the glass, do not give an
impact to it.
2) Fill the joint of the glasses with caulking

material (15).
a The using limit of the following caulk-
ing material is 4 months after the date
of manufacture. Do not use the caulk-
ing material after this limit.
2 Caulking material:
SUNSTAR PENGUINE SEAL No. 2505
WA470-6, WA480-6 50-800 13

SEN04541-00 Disassembly and assembly of operator's seat assembly
Disassembly and assembly of operator's seat assembly 1
[Manufactured by ISRING HAUSEN]

a Although the machine of the joystick steering specification is not equipped with the left armrest, its oper-
ator's seat assembly are also disassembled and assembled according to the following procedure.
A: Headrest D: Left-hand armrest

B: Back seat E: Suspension cover
C: Cushion seat F: Rails
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of 2 clips (2) of headrest stay (1) on both
sides.
50-800 14 WA470-6, WA480-6

Disassembly and assembly of operator's seat assembly SEN04541-00
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.
2) Remove back seat hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring back seat (4) down forward.
WA470-6, WA480-6 50-800 15

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.
50-800 16 WA470-6, WA480-6

1) Remove plastic cap (12) from the armrest 6) Remove left-hand armrest (10).
hinge. a There are 2 position adjustment
a Use a flat-head screwdriver, etc. to washers (16) installed to each bolt
remove the cap. between the armrest and back seat.
2) Loosen armrest hinge mounting bolt (13). Take care not to lose them.
3) Remove plastic cap (14), and then remove 5. Suspension cover

lower mounting bolt (15A) (M8 bolt) of left- 1) Remove right-hand hinge cover (17).
hand armrest (10). 2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
4) Turn left-hand armrest (10) up by 180°.

a If the armrest is not turned, you can-
not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B)
WA470-6, WA480-6 50-800 17

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.
4) Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
5) Remove 3 metallic suspension cover clips

(24).
50-800 18 WA470-6, WA480-6

2) Slide rails (28) to the rear end. Assembly

3) Remove 1 hexagon socket head bolt (29) 1. Rails
and 1 lock washer (30) from the front part 1) Put height adjustment washers (31) between
of each rail. [*6] rails (28) and suspension, and then set rails
(28) in position.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29) 2) Set rails (28) to the front end and install 1
and 1 lock washer (30) from the rear part lock washer (30) and 1 hexagon socket
of each rail, and then remove rails (28). head bolt (29) to each rail.
[*7] 3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Take care not to lose height adjust-

ment washers (31) between the rails 3) Set rails (28) to the rear end and install 1
and suspension. lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
WA470-6, WA480-6 50-800 19

2. Suspension cover 3) Set 4 bushings (23) and 2 cushion rails

1) Set suspension cover (27) in position and (22), and then install cushion rear fixing
install 6 plastic suspension cover clips plate (21), and 4 mounting bolts (20).
(small) (25) and 2 plastic suspension 3 Cushion rail mounting bolt:
cover clips (large) (26). 21.4 – 27.6 Nm {2.18 – 2.82 kgm}
a Clips (small):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large):
Front lower part; 2 places
4) Install 4 suspension cover fixing rings

(19).
2) Install 3 metallic suspension cover clips

(24).
5) Install plastic plate (18) to the rear.

6) Install right-hand hinge cover (17).
50-800 20 WA470-6, WA480-6

3. Armrest 6) Tighten armrest hinge mounting bolt (13).

q The procedure for assembling left-hand arm- a Tighten the bolt so that the arm will
rest (10) is shown below. move smoothly.
q Operating effort at armrest end:
49 – 78.4 N {5 – 8 kg}
7) Install plastic cap (12).
1) Install 2 position adjustment washers (16)

for each bolt and set left-hand armrest
(10) in position.
4. Cushion seat
1) Slide in the cushion seat from the front of
the fitting position.
a If cushion seat (8) is slid to the rear, it
is locked by cushion stopper wire (9).
2) Tighten lower mounting bolt (15A) lightly

and turn armrest (10) by 180°.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
5) Install 2 plastic caps (14).
WA470-6, WA480-6 50-800 21

5. Back seat 3) Connect 3 air hoses (5) to the rear left of

1) Insert the left side of back seat (4), and back seat (4).
then lower and set the right side.
6. Headrest
1) Insert headrest (3) in back seat (4).
a Check that 2 clips (2) on both sides
are locked securely.
2) Install back seat hinge mounting bolt (6).

3 Back seat hinge mounting bolt:
21.4 – 27.6 Nm {2.18 – 2.82 kgm}
50-800 22 WA470-6, WA480-6

[ Manufactured by GRAMMER ] 2. Removal and installation of seat pad and

backrest upholstery
a Although the machine of the joystick steering
specification is not equipped with the left arm-
rest, its operator's seat assembly are also dis-
assembled and assembled according to the
I. Upper seat
1. Removal and installation of storage box
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
Removal
1) Connect the connectors (3) and (6).
1) Open the storage box (1).
2) Install the seat pad (5), and fix it with the 5
2) Remove the hook (3).
screws (4).
3) Undo the screws (2) and remove the stor-
3) Install the backrest upholstery (2), and fix
age box (1).
it with the 4 screws (1).
Installation 4) Install the storage box by referring to "1.
1) Set the storage box (1) and fix it with the Removal and installation of storage box".
screws (2).
2) Install the hook (3).
WA470-6, WA480-6 50-800 23

3. Removal and installation of mechanical 4. Removal and installation of armrests

lumbar support (If equipped)
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.
50-800 24 WA470-6, WA480-6

5. Disassembly and assembly of backrest
Removal a Insert the bearing (B/8) into the upper

1) Detach the storage box by referring to "1. hole on the backrest support on the
Removal and installation of storage box". right side (figure B/4).
2) Remove the backrest upholstery by refer- 2) Press the backrest (1) slightly to the left
ring to "2. Removal and installation of seat and install it.
pad and backrest upholstery". a The big cylindrical stamping on the
3) Remove the armrests by referring to "4. backrest adjustment (figure C/2) must
Removal and installation of armrests". (If engage into the big positional bore
equipped) hole on the backrest support on the
4) Disassemble the backrest adjustment by left side (figure C/3).
referring to "6. Disassembly and assembly a The integral catch on the backrest
of backrest adjustment". (figure A/1) must engage into the tor-
5) Unscrew the hexagon nut (5) and remove sion spring (figure A/9).
the washers (6) and (7). 3) Put the washer (10) and tighten the hexa-
6) Remove the hexagon bolt (11) and the gon bolt (11).
washer (10). 4) Put the washers (6) and (7), and tighten
7) Press the backrest (1) slightly to the left the hexagon nut.
and take it off upwards. 3 Hexagon nuts: 25 Nm {2.6 kgm}
8) Remove the bearing (8) and the torsion 5) Assemble the backrest adjustment by
spring (9) from the backrest (1). referring to "6. Disassembly and assembly
of backrest adjustment".
Installation 6) Install the armrests by referring to "4.
1) Install the bearing (8) and the torsion Removal and installation of armrests". (If
spring (9) to the backrest (1). equipped)
a Oil the bearing point (Q) on the back-
rest (1) for the bearing (8) with acid-
free multiple-purpose lubricant.
WA470-6, WA480-6 50-800 25

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
6. Disassembly and assembly of backrest

adjustment
Disassembly
1) Remove the storage box by referring to "1.
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).
Assembly 2] Tilt the switch-plate (2) forwards and
1) Fold the backrest(1) forwards. remove it.
2) Install the handle (6) and the lever (5). 3] Drill off the rivet (3) and remove the
3) Tighten the 3 flat-headed screws (4), seat switch (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
50-800 26 WA470-6, WA480-6

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 50-800 27

Removal
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.
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.
50-800 28 WA470-6, WA480-6

9. Removal and installation of slide rails Installation

1) Install the slide rails (10).
2) Put the nuts (9) and tighten the hexagon
socket screws (8).
a Replace the hexagon socket screws
(8) with new ones.
3 Hexagon socket screws:
25 Nm {2.6 kgm}
3) Install the bellows to the upper part of the
suspension system.
4) Put the washers (7) and install the seat
top assembly (1) and remove.
5) Put the washers (5) and nuts (6), then
tighten the hexagon socket screws (4).
(4) with new ones.
25 Nm {2.6 kgm}
6) Push the seat top assembly (1) as far for-
ward as possible.
7) Put the nuts (3) and tighten the hexagon
socket screws (2).
(2) with new ones.
25 Nm {2.6 kgm}
8) Push the seat top assembly (1) as far
back as possible.
9) Install the seat pad by referring to "2.
Removal
2) Push the seat top assembly (1) as far
back as possible.
3) Unscrew the hexagon socket screws (2)
and remove the nuts (3).
4) Push the seat top assembly (1) as far for-
ward as possible.
5) Unscrew the hexagon socket screws (4),
remove the washers (5) and nuts (6).
6) Remove the seat top assembly (1) and
remove the washers (7).
7) Disconnect the bellows from the upper
part of the suspension system and lay it
down.
8) Unscrew the hexagon socket screws (8)
and remove the nuts (9).
9) Remove the slide rails (10).
WA470-6, WA480-6 50-800 29

II. Suspension 2. Removal and installation of front cover
1. Removal and installation of top cover
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".
50-800 30 WA470-6, WA480-6

3. Removal and installation of bellows
Installation
Removal 6) Install the wire insert (5) to the bellows (2).
1) Remove the upper part of the seat by 7) Install the bellows (2).
referring to "I. Upper seat". 8) 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. 9) 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 10) 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 11) 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 50-800 31

4. Removal and installation of Bowden pull

wire and handle for vertical shock absorber
adjustment
Removal 10) Mark the points where the Bowden pull

1) Remove the upper part of the seat by wire (5) is fastened with the swinging
referring to "I. Upper seat". structure (14) with the cable tie (8) and
2) Remove the top cover by referring to "1. take the cable tie (8) off.
Removal and installation of top cover". 11) Pull the fixation (12) off the vertical shock
3) Take the bellows off by referring to "3. absorber (13).
Removal and installation of bellows". 12) Take the Bowden pull wire (5) off the bear-
4) Move the suspension system to the high- ing (9).
est position. 13) Remove the fixation (12) from the fork
k Risk of crushing! Secure the sus- (11).
pension between the swinging 14) Take the Bowden pull wire (5) off the fork
structure and lower part of the sus- (11), remove the fork (11) and compres-
pension system with suitable spac- sion spring (10).
ers. 15) Mark the location of the mounting hole for
5) Screw out Torx screw (2). the Bowden pull wire (5) in the upper part
6) Pull the handle for vertical shock absorber of the suspension (4), pull the Bowden pull
adjustment (1) off the upper part of the wire (5) out of the upper part of the sus-
suspension (4). pension (4) and then remove it.
7) Remove the Bowden pull wire (5) from the
handle for vertical shock absorber adjust-
ment (1).
8) Push the Bowden pull wire (5) off the
bearing for Bowden pull wire (6).
9) Bore out the rivet head and drive out the
blind rivet (7), and remove the bearing for
Bowden pull wire (6).
50-800 32 WA470-6, WA480-6

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".
WA470-6, WA480-6 50-800 33

5. Removal and installation of vertical shock Installation

absorber 1) Move the suspension system to the high-
est position.
ers.
2) Install the vertical shock absorber (4).
a When re-installing the vertical shock
absorber (4), make sure the labeling
is on top.
3) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (3).
4) Install circlip (5) to the stud (3).
a Apply acid-free multi-purpose lubri-
cant to the entire external surface (F)
of the stud (3).
5) Install the fixation (2) and bearing (1) to
the vertical shock absorber (4).
6) Assemble the vertical shock absorber (4)
to the swinging structure (7) and put the
stud (6).
cant to the entire external surface (F)
of the stud (6).
7) Install the circlip (8) to the stud (6).
Removal
1) Remove the upper part of the seat by
referring to "I. Upper seat".
2) Remove the top cover by referring to "1.
3) Take the bellows off by referring to "3.
est position.
ers.
5) Remove circlip (8) from stud (6).
6) Pull the stud (6) out of swinging structure
(7) and vertical shock absorber (4).
7) Take the fixation (2) and bearing (1) off the
vertical shock absorber (4).
8) Remove circlip (5) from stud (3).
9) Pull the stud (3) out of the swinging struc-
ture (7) and the vertical shock absorber
(4).
10) Remove the vertical shock absorber (4) in
an upward direction.
50-800 34 WA470-6, WA480-6

6. Removal and installation of compressor
Removal 11) Pull the compressed-air hose (7) off the

1) Remove the upper part of the seat by compressor (3).
referring to "I. Upper seat". a Do not use a screwdriver to lift the
2) Remove the top cover by referring to "1. compressed-air hose (7) off the spike
Removal and installation of top cover". of the compressor (3).
3) Take the bellows off by referring to "3. a Heat the compressed-air hose (7) at
Removal and installation of bellows". the head of compressor (3) (e.g.
4) Move the suspension system to the high- using a hot-air blower) and then, pull
est position. it off in one move.
k Risk of crushing! Secure the sus- 12) Pull out the compressor cable (5) in a
pension between the swinging downward direction and remove compres-
structure and lower part of the sus- sor (3) to the front.
pension system with suitable spac- 13) Remove the support (9) from the lower
ers. part of the suspension (2).
5) Mark the points where the compressor
cable (5) is fastened with the 6 cable ties
(6) and remove the cable ties (6).
6) Disconnect the right-angle plug (10) from
the height level control unit (1).
7) Disconnect the electric connector of the
flat plug (11).
8) Mark the points where the compressed-air
hose (7) is fastened with the cable tie (12)
and remove the cable tie (12).
9) Mark the points where the compressor (3)
is fastened with the 2 cable ties (4) and
remove the cable ties (4).
10) Pull the fitting (8) out of the spike of the
compressor (3) and push it backwards off
the compressed-air hose (7).
WA470-6, WA480-6 50-800 35

Installation
est position.
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).
50-800 36 WA470-6, WA480-6

7. Removal and installation of height level

controller
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 50-800 37

18) Pull the Bowden pull wire (3) out of the

attachment for Bowden pull wire (2).
19) Remove the height level controller in an
upward direction.
Installation
est position.
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.
50-800 38 WA470-6, WA480-6

Adjustment 7) Adjust the output level (2) as follows.

1) Remove the upper part of the seat by Adjust the clearance between valve lever
referring to "I. Upper seat". (6) and cam disc (7) by turning the cross-
2) Remove the top cover by referring to "1. head screw (10).
Removal and installation of top cover". q Specified value: The valve lever (6)
3) Take the bellows off by referring to "3. must seat on the cam disc without
Removal and installation of bellows". pressure (7).
4) Move the suspension system to the high- q Turn the cross-head screw (10) to the
est position. left, the valve lever (6) is moving
k Risk of crushing! Secure the sus- towards the cam disc (7). This
pension between the swinging increases the pressure on the valve
structure and lower part of the sus- tappets (4) at the output valve (2) and
pension system with suitable spac- the air escapes the output valve (2)
ers. earlier.
5) Loosen the self-tapping screw (9) a half
q Turn the cross-head screw (10) to the
turn.
right, the valve lever (6) is moving
6) Adjust the micro-switch (3) as follows.
away from the cam disc (7). This
Adjust the clearance between cam switch
decreases the pressure on the valve
(5) and cam disc (7) by turning the cross-
tappets (4) at the output valve (2) and
head screw (8).
the air escapes the output valve (2)
q Specified clearance (A) = 0.5 mm.
q Turn the cross-head screw (8) to the later.
left, the cam switch (5) is moving 8) Tighten the self-tapping screw (9) after the
towards the cam disc (7). adjustment has been completed.
q Turn the cross-head screw (8) to the 9) Install the bellows off by referring to "3.
right, the cam switch (5) is moving Removal and installation of bellows".
away from the cam disc (7). 10) Install the top cover by referring to "1.
q When the cam switch (5) seats on the Removal and installation of top cover".
cam disc (7) under pressure, the 11) Install the upper part of the seat by refer-
compressor (11) turns too early and ring to "I. Upper seat".
runs already during the compression
and expansion of the seat suspen-
sion.
WA470-6, WA480-6 50-800 39

8. Removal and installation of compressed-air

hoses
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.
50-800 40 WA470-6, WA480-6

Installation a Apply pressure to insert the air hose

a Always replace a damaged (marks) hose with with angle (8) into the pneumatic
a new one. It is possible to cut the damaged spring (9) and air tank (10) up to the
part off (about 12 mm) using special tools (14) blue marking.
only once. After the cut off, the blue marking 6) Fix the compressed air hose with angle (8)
should be (arrow) set back by the length of the with cable ties (6), (7) and (12) at the
cut off piece. marked points.
a Do not fix the cable tie (12) at the
1) Move the suspension system to the high- angle.
est position. 7) Install the compressed-air hose (11) to the
k Risk of crushing! Secure the sus- compressor (5). (Refer to "6. Removal and
pension between the swinging installation of compressor")
structure and lower part of the sus- 8) Install the compressed-air hose (11) to the
pension system with suitable spac- pneumatic spring (9).
ers. 9) Fix the compressed-air hose with the
2) Install the height level controller (1) with cable tie (12) at the marked points.
air input hoses (3) and (4). 10) Install the bellows off by referring to "3.
a Cut the air input hose (3) or (4) off at Removal and installation of bellows".
the leaky area and connect the new 11) Install the top cover by referring to "1.
air input hose (3) or (4) to an appro- Removal and installation of top cover".
priate adapter. Subsequently, cut the 12) Install the upper part of the seat by refer-
excess length off. ring to "I. Upper seat".
3) Install the air input hoses (3) and (4) to the
pneumatic spring (9). Hydrostatic test
4) Fix the air input hoses (3) and (4) with the a After the installation of a compressed-air hose,
cable ties (2) and (6) at the marked points. the hydraulic test of the suspension should be
5) Install the compressed-air hose with angle performed.
(8) to the pneumatic spring (9) and then q Apply 60 kg load to the suspension for 24
off the air tank (10). hours.
a To avoid kinking, always install the q The lowering within this time may not
compressed-air hose with angle (8) exceed 15 mm.
first on the pneumatic spring (9). a The compressed-air hoses are locked after
they have been connected.
WA470-6, WA480-6 50-800 41

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 off 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".
50-800 42 WA470-6, WA480-6

Checking and adjustment 5) Check the clearance between the Bowden

a When checking and adjustment is performed wire lever (10) and holder for Bowden wire
through removal and installation, pass proce- end cap (9).
dures 1) and 2) of "Checking". q Specified value: Distance (A)
(Checking) between 1 and 3.5 mm with the han-
1) Remove the upper part of the seat by dle for height adjustment (2) in the up
referring to "I. Upper seat". position.
2) Remove the top cover by referring to "1. q When the specified value exceeds
Removal and installation of top cover". 3.5 mm, the suspension cannot be
3) Operate the handle for height adjustment lifted above the middle position.
(2) several times in both directions and
check the following: (Adjustment)
q Bowden pull wires (1) and (3) for 1) Adjustment of the Bowden pull wire (3):
easy-running. 1] Loosen the counternut (6) and adjust
q Bowden wire lever (10), valve lever the clearance between the Bowden
(14) and valve tappets (13) at the out- wire lever (10) and holder for Bowden
put valve (12) for smoothness of run- wire end cap (9) using the locknut (5).
ning. q Turn the locknut (5) inwards, the
4) Check the neutral position of the handle Bowden pull wire gets longer.
for seat height adjustment (2) and the ten- q Turn the locknut (5) outwards,
sile force of the retracting spring (11) on the Bowden pull wire gets
the height level valve (4): shorter.
q The retracting spring (11) must fix the q Specified value: Clearance (A)
handle for seat height adjustment (2) between 1 and 3.5 mm.
in neutral position. 2] Secure the locknut (5) with the coun-
q The retracting spring (11) must tightly ternut (6) and make sure not to distort
pull the Bowden pull wires (1 and 3) the Bowden pull wire (3).
and keep the Bowden wire lever (10) 3] Operate the handle for seat height
in neutral position. adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
WA470-6, WA480-6 50-800 43

2) Adjustment of the Bowden pull wire (1):

1] Loosen the counternut (7) and adjust
the tension of the Bowden pull wire
(1) on the height valve (4) using the
locknut (8).
q Turn the locknut (8) inwards, the
Bowden pull wire gets longer.
q Turn the locknut (8) outwards,
the Bowden pull wire gets
shorter.
q Specified value: The Bowden
wire (8) must be tightened, but
not distorted on the suspension
device on the height level valve
(4).
2] Secure the locknut (8) with the coun-
ternut (7) and make sure not to distort
the Bowden pull wire (1).
3] Operate the handle for seat height
adjustment (2) several times and
check the specified value, repeat the
adjustment if necessary.
50-800 44 WA470-6, WA480-6

10. Removal and installation of pneumatic

spring
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
pneuma ti c spr ing (6) and rem ove it
of the suspension (2).
together with the washer (4).
4) Tighten the counter sunk screw (7) to the
pneumatic spring (6).
3 Counter sunk screw (6):
est position.
pension between the swinging 6 Nm {0.61 kgm}
structure and lower part of the sus- 5) Turn the spring system by 180° and place
pension system with suitable spac- it onto the upper part (1).
ers. 6) Put the washer (4) to the pneumatic spring
(6) and tighten the counter sunk screw (3).
3 Counter sunk screw (3):
7) Turn the spring system by 180° and place
it onto the upper part (1).
8) Undo the counter sunk screw (7) from the 6 Nm {0.61 kgm}
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 50-800 45

7) Install the 2 air input hoses, compressed-

air hose and air input hose with angle to
the pneumatic spring (6) by referring to "8.
Removal and installation of compressed-
air hoses".
50-800 46 WA470-6, WA480-6

11. Removal and installation of air tank for

additional air supply
2) Remove the top cover by referring to "1. k Risk of crushing! Secure the sus-
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 off 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 50-800 47

12. Removal and installation of cable harness
2) Remove the top cover referring to "1. k Risk of crushing! Secure the sus-
4) Move the suspension system to the high- ers.
est position.
2) Connect the right-angle plug (6) to the
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).
50-800 48 WA470-6, WA480-6


WA470-6, WA480-6 50-800 49

13. Disassembly and assembly of upper part of

the suspension system
Disassembly 8) Move the suspension system to the high-

1) Remove the upper part of the seat by est position.
referring to "I. Upper seat". k Risk of crushing! Secure the sus-
2) Remove the top cover referring to "1. pension between the swinging
Removal and installation of top cover". structure (7) and lower part of the
3) Take the bellows off by referring to "3. suspension system with suitable
Removal and installation of bellows". spacers.
4) Take the Bowden pull wire and handle off 9) Bore out 2 rivet heads and drive out blind
the upper part of the suspension (1) by rivets (10), remove the stops (9).
referring to "4. Removal and installation of 10) Push the upper part of the suspension (1)
Bowden pull wires and handle for vertical forwards until the cut-outs (arrow) on the
shock absorber". left and right sides at the guiding rails (2)
a The Bowden pull wire does not need are located at the same height with the
to be taken off the vertical shock front rollers (8) of the swinging structure
absorber. (7).
5) Remove the vertical shock absorber from 11) Remove the upper part of the suspension
the upper part of the suspension (1) by (1) on the front side over the rollers (8)
referring to "5. Removal and installation of and the back rollers (6) of the swinging
vertical shock absorber". structure (7).
6) Remove the height level controller from
the upper part of the suspension (1) by
referring to "7. Removal and installation of
height level controller".
a Air input hoses do not need to be
taken off the pneumatic spring.
7) Remove Bowden pull wires and handle for
height adjustment by referring to "9.
Removal and installation of Bowden pull
wires and handle for height adjustment".
50-800 50 WA470-6, WA480-6

Assembly
est position.
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).
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.
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".
WA470-6, WA480-6 50-800 51

14. Lower part of the suspension system
Removal 8) Unscrew the 2 hexagon nuts (11), remove

1) Remove the upper part of the seat by washers (10) and counter sunk screws
referring to "I. Upper seat". (9).
2) Remove the top cover by referring to "1. 9) Undo the 2 corrugated-head screws (5)
Removal and installation of top cover". and take the U-shaped profiles (6) off the
3) Take the bellows off by referring to "3. guiding rail (8).
Removal and installation of bellows". 10) Push the upper part of suspension (1) with
4) Remove compressor from the lower part the swinging structure (3) backwards until
of the suspension (7) by referring to "6. the 2 fixed bearings (4) on the swinging
Removal and installation of compressor". structure (3) can be taken out through the
a Compressor cable and compressed- cut-outs (arrows) of the guiding rails (8) on
air hose do not need to be removed. the upper part of suspension (1).
a Protect the compressor against 11) Lift the upper part of the suspension (1)
shocks (impacts) by fixing it on the with the swinging structure (3) out and pull
swinging structure with adhesive it out together with the 2 rollers (2) from
tape. the guiding rails (8) by turning sideways.
5) Remove the webbing from the lower part
of the suspension (7) by referring to "7.
Removal and installation of height level Installation
controller". 1) Install the upper part of the suspension (1)
6) Undo the counter sunk screw from the with the swinging structure (3) together
pneumatic spring by referring to "10. with the 2 rollers (2) to the guiding rails
Removal and installation of pneumatic (8).
spring". a Apply acid-free multi-purpose lubri-
7) Remove the 2 cable ties for the vehicle cant to the bearing surface at the side
power connector cable on the lower part (F) of the 2 guiding rails (8) of the roll-
of suspension(7) by referring to "12. ers (2).
Removal and installation of cable har- 2) Install the U-shaped profile (6) to the guid-
ness". ing rail (8) and tighten the 2 corrugated-
head screws (5).
50-800 52 WA470-6, WA480-6

3) Put the counter sunk screws (9) and the

washers (10), and tighten the 2 hexagon
nuts (11).
4) Install the 2 cable ties for the machine
power connector cable on the lower part
of suspension(7) by referring to "12.
Removal and installation of cable har-
ness".
5) Tighten the counter sunk screw to the
pneumatic spring by referring to "10.
Removal and installation of pneumatic
spring".
6) Install the webbing to the lower part of the
suspension (7) by referring to "7. Removal
and installation of height level controller".
7) Install compressor to the lower part of the
suspension (7) by referring to "6. Removal
and installation of compressor".
WA470-6, WA480-6 50-800 53

15. Swinging structure
Removal 9) Take the Bowden pull wires for height

1) Remove the upper part of the seat by level adjustment off the height level valve
referring to "I. Upper seat". by referring to "9. Removal and installation
2) Remove the top cover by referring to "1. of Bowden pull wire and handle for height
Removal and installation of top cover". adjustment".
3) Take the bellows off by referring to "3. 10) Remove the pneumatic spring by referring
Removal and installation of bellows". to "10. Removal and installation of pneu-
4) Take the Bowden pull wire for vertical matic spring".
11) Remove the air tank for additional air sup-
shock absorber adjustment off the vertical
ply by referring to "11. Removal and instal-
shock absorber by referring to "4.
lation of air tank for additional air supply".
12) Remove the cable harness by referring to
wire and handle for vertival shock
"12. Removal and installation of cable har-
absorber adjustment". ness".
5) Take the vertical shock absorber off the 13) Take the upper part of the suspension off
swinging structure by referring to "5. the swinging structure by referring to "13.
Removal and installation of vertical shock Removal and installation of upper part of
absorber". the suspension".
6) Remove the compressor by referring to "6. 14) Take the lower part of the suspension off
Removal and installation of compressor". the swinging structure by referring to "14.
7) Take the webbing off the lower part of the Removal and installation of lower part of
suspension by referring to "7. Removal the suspension".
and installation of height level controller". 15) Take 4 rollers (5), 2 rollers (6), 2 fixed
8) Remove the cable tie for the air input bearings (9) and 4 felt rings (4) off the
hoses of the height level control and pull swinging structure (1).
the air input hoses off the pneumatic 16) Pull the tube piece (8) out of the fixed
spring by referring to "8. Removal and bearing (9).
installation of compressed-air hoses". 17) Remove the 2 buffers (7) from the swing-
ing structure (1).
18) Remove the edge protection strip (2) from
the swinging structure (1).
50-800 54 WA470-6, WA480-6

Installation 12) Install the Bowden pull wires for height

1) Check: maximum clearance (A) or (B) level adjustment to the height level valve
between the rollers (5) and guiding rails of by referring to "9. Removal and installation
the lower part of the suspension (11) or of Bowden pull wire and handle for height
upper part of the suspension (10) over the adjustment".
complete adjustment length. 13) Install the cable tie for the air input hoses
2) Place the washer compensating for clear- of the height level controller and pull the
ance (2) between the roller (5 or 6) and air input hoses to the pneumatic spring by
axle of the swinging structure (1), if neces- referring to "8. Removal and installation of
sary. compressed-air hoses".
a Clearance spacers (with thickness of 14) Install the webbing to the lower part of the
0.2 mm and 0.5 mm) are included in suspension by referring to "7. Removal
the wear parts set. and installation of height level controller".
3) Install the edge protection strip (2) to the 15) Install the compressor by referring to "6.
swinging structure (1). Removal and installation of compressor".
4) Install the 2 buffers (7) to the swinging 16) Install the vertical shock absorber to the
structure (1). swinging structure by referring to "5.
5) Put the tube piece (8) to the fixed bearing Removal and installation of vertical shock
(9). absorber".
6) Install 4 rollers (5), 2 rollers (6), 2 fixed 17) Install the Bowden pull wire for vertical
bearings (9) and 4 felt rings (4) to the shock absorber adjustment to the vertical
swinging structure (1). shock absorber by referring to "4.
7) Install the lower part of the suspension to Removal and installation of Bowden pull
the swinging structure by referring to "14. wire and handle for vertival shock
Removal and installation of lower part of absorber adjustment".
the suspension". 18) Install the bellows off by referring to "3.
8) Install the upper part of the suspension to Removal and installation of bellows".
the swinging structure by referring to "13. 19) Install the top cover by referring to "1.
Removal and installation of upper part of Removal and installation of top cover".
the suspension". 20) Install the upper part of the seat by refer-
9) Install the cable harness by referring to ring to "I. Upper seat".
"12. Removal and installation of cable har-
ness".
10) Install the air tank for additional air supply
by referring to "11. Removal and installa-
tion of air tank for additional air supply".
11) Install the pneumatic spring by referring to
"10. Removal and installation of pneu-
matic spring".
WA470-6, WA480-6 50-800 55

SEN04541-00 Removal and installation of air conditioner unit assembly
Removal and installation of air 4. Take out filter (2) and remove box (3).
conditioner unit assembly 1
Removal
tires.
battery beforehand.
1. Collect the air conditioner refrigerant (R134a)

from air conditioner circuit in advance. [*1]
a Ask professional traders for collecting and
filling operation of refrigerant. 5. Remove right side cover (4).
a Never release the refrigerant to the atmo-
sphere.
k If refrigerant gets in your eyes, you
may lose your sight. Accordingly, put
on protective goggles, gloves and
working suits with long sleeves while
you are collecting the refrigerant or fill-
ing the air conditioner circuit with the
refrigerant. Collecting and filling work
must be conducted by a qualified per-
son.
q Refrigerant quantity: 1,250 ± 50 g
2. Drain coolant.
6 Coolant: 61 l
6. Disconnect harness connector (6).
3. Remove left side cover (1). 7. Remove blower assembly (7).
50-800 56 WA470-6, WA480-6

Removal and installation of air conditioner unit assembly SEN04541-00
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.
9. Remove left side cover (9) in the operator's

cab.
13. Disconnect connector C10 inside cigar lighter
10. Remove door lock (10), ashtray (11) and (21).
holder (12) at the right side of the operator's
cab, and then remove cover (13). 14. Disconnect front cover (22).
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 50-800 57

SEN04541-00 Removal and installation of air conditioner unit assembly
16. Disconnect connector C12 (24) and remove 20. Disconnect 2 harness clamps (32).
wiper motor (25).
17. Disconnect wiper washer hose (26).
22. Remove covers (34) and (35).

18. Remove ducts (27) and (28).
23. Disconnect 2 heater hoses (36).

19. Remove bracket-mounting bolts (29) and (30)
on both sides, and place handle stand (31) 24. Disconnect harness connector (37).
beside the seat.
25. Disconnect drain hose (38).
50-800 58 WA470-6, WA480-6

Removal and installation of air conditioner unit assembly SEN04541-00
26. Disconnect air conditioner pipes (39) and (40). Installation

removal.
[*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.
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
27. Disconnect 2 drain hoses (41). q Refilling with coolant

Add coolant through the coolant filler to the
28. Disconnect harness connector L17 (42), C50 specified level. Run the engine to circulate the
(43), C49 (44) and AL1 (45). coolant through the system. Then, check the
coolant level again.
29. Remove the mounting bolt and remove fuse
(46).
30. Remove air conditioner unit assembly (47).
WA470-6, WA480-6 50-800 59

SEN04541-00

©2008 KOMATSU
All Rights Reserved
50-800 60
SEN04542-00
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
900 Electrical system

Removal and installation of engine controller assembly ................................................................................. 2
Removal and installation of transmission controller assembly........................................................................ 3
Removal and installation of KOMTRAX terminal assembly ............................................................................ 4
WA470-6, WA480-6 50-900 1

SEN04542-00 Removal and installation of engine controller assembly
Removal and installation of Installation

engine controller assembly 1
removal.
Removal
k Disconnect the negative (–) terminal of the [*1]
battery beforehand. 3 Connectors (2) and (4):
2.54 – 3.01 Nm {0.25 – 0.3 kgm}
1. Open the engine side cover on the right side.
3. Disconnect harness connector EC2 (2), EC3

(3) and ENG (4). [*1]
4. Remove engine controller assembly (5).
50-900 2 WA470-6, WA480-6

Removal and installation of transmission controller assembly SEN04542-00
Removal and installation of Installation

transmission controller assembly1 q Carry out installation in reverse order of
removal.
Removal
k Disconnect the negative (–) terminal of the [*1]
battery beforehand. 2 Connectors (3), (4) and (5):
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
1. Remove the cover (1) in the rear side corner of
the operator's cab.
2. Remove harness clamp (2).
3. Remove harness connector L81 (3), L82 (4)

and L83 (5). [*1]
4. Remove transmission controller assembly (6).

a Remove the mounting bolt through the
bottom of the transmission controller unit
assembly.
WA470-6, WA480-6 50-900 3

SEN04542-00 Removal and installation of KOMTRAX terminal assembly
Removal and installation of 4. Disconnect antenna cables (4) and (5).

KOMTRAX terminal assembly 1
5. Remove harness connector L80 (6). [*1]
Removal
k Disconnect the negative (–) terminal of the 6. Remove KOMTRAX terminal assembly (7).
battery beforehand.
1. Remove the cover (1) in the rear side of the

operator's cab.
Installation
removal.
[*1]
2 Connectors (6):
3. Remove fuse bracket (3).
2.2 – 2.8 Nm {0.23 – 0.29 kgm}
50-900 4 WA470-6, WA480-6

Removal and installation of KOMTRAX terminal assembly SEN04542-00
WA470-6, WA480-6 50-900 5

SEN04542-00

©2008 KOMATSU
All Rights Reserved
50-900 6
SEN04433-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
90 Diagrams and drawings 1
100 Hydraulic diagrams and drawings

Power train hydraulic circuit diagram .............................................................................................................. 2
Automatic greasing circuit diagram................................................................................................................. 4
Hydraulic circuit diagram................................................................................................................................. 7
WA470-6, 480-6 90-100 1

SEN04433-00 Power train hydraulic circuit diagram
Power train hydraulic circuit diagram 1
Without lockup clutch
90-100 2 WA470-6, 480-6

Power train hydraulic circuit diagram SEN04433-00
With lockup clutch
WA470-6, 480-6 90-100 3

SEN04433-00 Automatic greasing circuit diagram
Automatic greasing circuit diagram 1
(If equipped)
90-100 4 WA470-6, 480-6

Automatic greasing circuit diagram SEN04433-00
A: Automatic greasing pump assembly

B: Feeder 1
C: Feeder 2
D: Feeder 3
E: Feeder 4
Greasing parts
1. Bucket pin (left)
2. Bucket pin (right)
3. Lift arm pivot pin (left)
4. Lift arm pivot pin (right)
5. Bucket link pin (bucket side)
6. Bucket link pin (bell crank side)
7. Bell crank pin
8. Bucket cylinder head pin
9. Bucket cylinder bottom pin
10. Lift cylinder bottom pin (left)
11. Lift cylinder head pin (left)
12. Lift cylinder bottom pin (right)
13. Lift cylinder head pin (right)
14. Drive shaft center support
15. Steering cylinder bottom pin (right)
16. Steering cylinder bottom pin (left)
17. Center hinge pin (upper)
18. Center hinge pin (lower)
19. Steering cylinder head pin (right)
20. Steering cylinder head pin (left)
21. Rear axle pivot pin (front side)
22. Rear axle pivot pin (rear side)
23. Rear axle pivot pin (rear side)
WA470-6, 480-6 90-100 5

SEN04433-00 Automatic greasing circuit diagram
90-100 6 WA470-6, 480-6

Hydraulic circuit diagram
Hydraulic circuit diagram WA470-6, WA480-6
1
WA470-6, WA480-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04433-00
WA470, 480-6
90-100 7
SEN04433-00
WA470-6, 480-6 90-100 9

SEN04433-00

©2008 KOMATSU
All Rights Reserved
90-100 10
SEN04434-00
WHEEL LOADER
WA470-6
WA480-6

WA470-6 90001 and up
WA480-6 90001 and up
90 Diagrams and drawings 1
200 Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Work equipment controller system electrical circuit diagram ........................................................................ 23
Connector list and stereogram...................................................................................................................... 25
WA470-6, 480-6 90-200 1

SEN04434-00
90-200 2 WA470-6, 480-6

Electrical circuit diagram (1/10)
Electrical circuit diagram (1/10) WA470-6, WA480-6
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 3
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 5
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 7
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 9
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 11
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 13
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 15
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 17
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 19
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 21
Work equipment controller system electrical circuit diagram
Work equipment controller system electrical circuit diagram WA470-6, WA480-6
1
WA470-6, WA480-6
SEN04434-00
WA470, 480-6
90-200 23
Connector list and stereogram
WA470-6, WA480-6
Connector list and stereogram 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 AH-2 F03 090 II 2 Horn, Hi C-4 L05 DT-T 2 Steering wheel horn switch S-7 Intermediate connector
LR1 DTHD 1 Y-3
1.SW DT 2 1st ECMV fill switch AH-2 F05 090 II 2 Horn, Lo F-1 L07 SWP 6 Machine monitor mode selector switch 1 T-1 (Floor wiring harness – rear wiring harness)
2.PS DT 2 2nd ECMV solenoid AG-7 F09 DT-T 3 Bucket proximity switch C-3 L08 SWP 6 Machine monitor mode selector switch 2 T-1 Intermediate connector
LR11 DT-T 2 X-2
(Floor wiring harness – rear wiring harness)
2.SW DT 2 2nd ECMV fill switch AG-6 F10 DT-T 3 Boom proximity switch C-5 L09 DT-T 2 Stop lamp switch W-1
Intermediate connector
3.PS DT 2 3rd ECMV solenoid AG-6 F12 DT-T 3 Work equipment pump pressure sensor D-1 L11 DT-T 2 Intermediate connector (Air suspension seat) U-9, AA-6 LR12 DTHD 1 X-2
3.SW DT 2 3rd ECMV fill switch AG-6 F13 DT-T 2 E.C.S.S. solenoid F-1 Right FNR (Directional) switch or multi-function lever Intermediate connector
L12 DT-T 4 P-1 LR13 DT-T 2 X-2
4.PS DT 2 4th ECMV solenoid AH-1 F14 DT-T 2 E.C.S.S. cut-off switch E-1 (if equipped) (Pump bypass solenoid) (if equipped)
4.SW DT 2 4th ECMV fill switch AH-1 F15 DT-T 3 Boom potentiometer C-5 Lift arm neutral lock switch (joystick steering specification) LR2 DT 2 Intermediate connector (Multi-coupler solenoid) —
L13 DT2 2 —
(if equipped)
AL1 DT 6 Intermediate connector (Air conditioner wiring harness) S-1 F16 DT-T 3 Boom bottom pressure sensor G-1 LR3 DT 1 Intermediate connector —
Lift arm kick-down & hold switch or multi-function lever
C01 YAZAKI 9 AM/FM radio G-9 F17 DT-T 3 Boom head pressure sensor G-1 L14 DT-T 4 O-4, P-2 Intermediate connector
(if equipped) LR4 DTHD 1 Y-2
C02 M 2 Speaker, right I-9 Lift arm angle potentiometer L15 DT-T 4 Bucket lever (Load meter specification) (if equipped) O-4, P-2
F18 DT2 2 — Intermediate connector
C03 M 2 Speaker, left J-9 (Lift arm/bucket EPC specification) (if equipped) LR5 DT-T 6 A-2
L17 M 4 DC24V/DC12V converter W-9 (Auto grease wiring harness) (if equipped)
C04 DT-T 2 Front working lamp, right F-8 Bucket positioner
F19 DT2 2 — L18 YAZAKI 2 12VDC socket W-9 Intermediate connector
(Lift arm/bucket EPC specification) (if equipped) LR6 DTHD 1 X-2
C05 DT-T 2 Front working lamp, left J-9 L19 M 4 Flasher unit Z-1 (Floor wiring harness – rear wiring harness)
Lift arm raise EPC
C07 KES1 2 Room lamp J-9 F20 DT2 2 — Intermediate connector
(Lift arm/bucket EPC specification) (if equipped) L20 M 2 Caution buzzer Z-5 LR8 DTHD 1 Y-2
C08 M 1 Door switch, right F-8 Lift arm lower EPC L21 S 10 Intermediate connector (Front/Rear wiper switch) R-7
F21 DT2 2 — LT1 HD30 31 Intermediate connector (Transmission wiring harness) Y-3, AG-8
C09 M 1 Door switch, left J-9 (Lift arm/bucket EPC specification) (if equipped) Bucket dump detent solenoid
L25E DT2 2 — MLT DTM 12 Multi-function lever switch (if equipped) —
C10 YAZAKI 2 Cigarette lighter F-7 Bucket tilt EPC (Joystick steering specification) (if equipped)
F22 DT2 2 —
(Lift arm/bucket EPC specification) (if equipped) L25S DT-T 2 Electrical detent PPC valve P-1 NE FRAMATOME 3 Ne speed sensor AN-2
C12 M 6 Front wiper motor E-7
Bucket dump EPC Lift arm raise detent solenoid PAMB AMP 3 Ambient pressure sensor AM-5
C140 DT-T 4 Tachograph (if equipped) Z-5 F23 DT2 2 — L26E DT2 2 —
(Lift arm/bucket EPC specification) (if equipped) (Joystick steering specification) (if equipped) PB.PS DT 2 Parking brake solenoid AF-5
C141 DT-T 6 Tachograph (if equipped) Z-4 3-spool valve (Attachment) extension EPC
F24 DT2 2 — L26S DT-T 2 Electrical detent PPC valve P-1 PB.SW DT 2 Parking brake indicator switch AE-4
C15 M 4 Rear wiper motor K-9 (Lift arm/bucket EPC specification) (if equipped)
Lift arm lower detent solenoid PCV1 SUMITOMO 2 Supply pump 1 AL-1
C17 SWP 6 Caution lamp, yellow rotary lamp (if equipped) Q-5 3-spool valve (Attachment) retraction EPC L27 DT2 2 —
F25 DT2 2 — (Joystick steering specification) (if equipped)
(Lift arm/bucket EPC specification) (if equipped) PCV2 SUMITOMO 2 Supply pump 2 AL-1
C18 DT 2 Caution lamp (if equipped) — L27S DT-T 2 Electrical detent PPC valve P-1
Lift arm EPC cut-off solenoid PD DT-T 6 Idle validation switch P-5
C18A M 1 Beacon light — F26 DT2 2 — L28 DT2 4 Lift arm EPC lever (Joystick steering specification) (if equipped) —
(Lift arm/bucket EPC specification) (if equipped) PDV 2 Accelerator pedal O-5
C19 SWP 6 Rear glass heater switch H-9 F30 (Terminal) 1 GND (Front frame) H-1 L29 DT2 4 Bucket EPC lever (Joystick steering specification) (if equipped) —
PFUEL AMP 3 Common rail pressure sensor AN-3
C21 SWP 6 Caution lamp, rotary lamp (if equipped) Q-5 F30 (Terminal) 1 GND (Front frame) — 3-spool valve (Attachment) EPC lever
L30 DT2 4 — PIM SUMITOMO 4 Boost pressure sensor AN-4
C22 DT 3 Rotary lamp (if equipped) — (Joystick steering specification) (if equipped)
F31 DT-T 2 Multi-coupler extension solenoid — POIL FRAMATOME 3 Engine oil pressure sensor AN-3
C25 4 Intermediate connector (Caution lamp, rotary lamp) F-8 L31 M 6 Interval wiper timer Z-2
F32 DT-T 2 Diode — R.PS DT 2 R (Reverse) ECMV solenoid AG-7
C29 M 1 Intermediate connector F-9 Joystick steering potentiometer
F33 DT-T 2 Multi-coupler retraction solenoid — L34 DT2 4 —
(Joystick steering specification) (if equipped) R.SW DT 2 R (Reverse) ECMV fill switch AG-7
C33 (Terminal) 1 Rear glass heater I-9 F34 DT-T 2 Diode — Joystick steering right EPC R01 (Terminal) 1 Battery relay N-4
C35 (Terminal) 1 Rear glass heater K-9 L35 DT2 2 —
F35 (Terminal) 1 Fog lamp, right (if equipped) — (Joystick steering specification) (if equipped) R02 (Terminal) 1 Slow blow fuse B-8
C39 (Terminal) 1 GND (Radio body) G-9 F35A (Terminal) 1 Fog lamp (right) (if equipped) — Joystick steering left EPC
L36 DT2 2 — R02 (Terminal) 1 Emergency steering relay N-3
C40 (Terminal) 1 GND() G-9 F36 (Terminal) 1 Fog lamp, left (if equipped) — (Joystick steering specification) (if equipped)
R03 (Terminal) 1 Slow blow fuse A-9
C41 SWP 6 Fog lamp (if equipped) Q-4 F36A (Terminal) 1 Fog lamp (left) (if equipped) — Intermediate connector (Joystick steering EPC)
L36A DT 4 — R04 (Terminal) 1 Battery relay N-4
C47 (Terminal) 1 GND (Beacon) — (Joystick steering specification) (if equipped)
Intermediate wiring harness R04 (Terminal) 1 Slow blow fuse B-8
FF1 DT-T 12 G-1 Joystick steering lever switch
C47 JAE IL-AG5 22 Air conditioner controller H-9 (Front wiring harness – rear wiring harness) L37 DTM 12 —
(Joystick steering specification) (if equipped) R05 (Terminal) 1 Slow blow fuse B-8
C48 JAE IL-AG5 14 Air conditioner controller G-9 Intermediate wiring harness
FF2 DT-T 8 C-2 Joystick steering neutral lock switch R06A (Terminal) 1 Slow blow fuse B-9
C49 DT2(B) 12 Intermediate connector (Air conditioner controller) D-6 (Front wiring harness – rear wiring harness) L38 DT2 3 —
(Joystick steering specification) (if equipped)
Intermediate wiring harness R06B (Terminal) 1 Slow blow fuse A-9
C50 DT2(Gr) 12 Intermediate connector (Air conditioner controller) E-6 FF3 DT-T 6 G-1 Joystick steering ON/OFF switch
(Front wiring harness – rear wiring harness) L39 DT2 6 — R10 (Terminal) 1 Slow blow fuse A-9
C52 S 3 Multi-coupler switch (if equipped) H-9 (Joystick steering specification) (if equipped)
Intermediate connector R11 (Terminal) 1 Slow blow fuse B-9
C60 AMP 2 Daylight sensor F-7 FL1 DRC12 70 Z-3 Joystick steering speed mode switch
(Floor wiring harness – rear wiring harness) L40 DT2 6 —
(Joystick steering specification) (if equipped) R13 (Terminal) 1 Emergency steering relay C-7
C61 SHINAGAWA 5 Caution lamp, yellow rotary lamp relay (if equipped) X-9 Intermediate connector
FL2 DT-T 8 X-2 JIDOSYA Joystick steering cut-off relay R14 (Terminal) 1 Emergency steering relay C-7
JIDOSYA (Floor wiring harness – rear wiring harness) L41 6 —
C62 5 Caution lamp, rotary lamp relay (if equipped) X-9 DENKI KOGYO (Joystick steering specification) (if equipped)
DENKI KOGYO Intermediate connector (Lift arm EPC) R15 (Terminal) 1 Battery relay C-7
FL7 DT2(Br) 8 — L44 M 6 Intermediate connector (Load meter printer wiring harness) V-9
JIDOSYA (Joystick steering specification) (if equipped) R16 (Terminal) 1 Battery relay B-8
C63 6 Caution lamp, rotary lamp relay (if equipped) X-9 L45 D-sub25 25 Printer —
DENKI KOGYO Intermediate connector (Lift arm EPC) R20 DT-T 6 Intermediate connector (Rear combination lamp, left) N-5
FL8 DT2(G) 8 —
C64 SHINAGAWA 6 Fog lamp relay (if equipped) X-9 (Joystick steering specification) (if equipped) L46 HOSHIDEN 4 Printer —
R21 DT-T 6 Intermediate connector (Rear combination lamp, right) M-9
C65 DT 3 Rotary lamp (if equipped) — Intermediate connector (3-spool valve) (Attachment EPC) L51 AMP 070 20 Machine monitor Q-3
FL9 DT2 4 — R22 (Terminal) 1 GND M-9
(Joystick steering specification) (if equipped) L52 AMP 070 18 Machine monitor Q-3
C91 M 1 Intermediate connector (Warning lamp) — R29 DT-T 2 Hydraulic fan EPC L-9
FS1 L 2 Intermediate connector (Fuse box B) Y-1 L53 AMP 070 12 Machine monitor Q-3
CAN1 DT-T 3 Diode AN-3 R30 DT-T 6 Rear combination lamp, left N-6
FS11 X 3 Intermediate connector (Fuse box B) Z-1 L54 AMP 070 18 Machine monitor R-7
CAN2 DT-T 3 CAN terminal resistor Q-2 R31 DT 6 Rear combination lamp, right M-9
FS2 L 2 Intermediate connector (Fuse box A) Y-1 L55 AMP 070 12 Machine monitor Q-6
CHK0 X 1 KOMTRAX test connector Y-8 R32 DT-T 2 Coolant level sensor F-7
FS3 SWP 16 Intermediate connector (Fuse box B) Y-2 L56 AMP 070 12 Machine monitor Q-3
CHK1 X 1 KOMTRAX test connector X-8 R33 DT-T 2 Fuel level sensor N-4
FS4 SWP 12 Intermediate connector (Fuse box A) Y-2 L57 AMP 070 14 Machine monitor Q-6
CL1 SWP 8 Intermediate connector (Cab wiring harness) A-4, O-6 R36 DT-T 2 Pressure switch (Steering pump) I-1
FS5 SWP 6 Intermediate connector (Fuse box A) Y-1 L61 DRC26 24 Transmission controller Y-7
CL2 SWP 12 Intermediate connector (Cab wiring harness) A-5, O-7 R37 DT-T 2 Pressure switch (Emergency steering) I-1
FS6 X 1 Intermediate connector (Fuse box B) Z-1 L62 DRC26 40 Transmission controller Y-8
CL21 SWP 16 Intermediate connector O-7 R38 DT 6 Auto grease controller —
FS7 X 1 Intermediate connector (Fuse box B) Z-1 L63 DRC26 40 Transmission controller Y-8
CL24 X 2 Intermediate connector (Multi-coupler) A-4 R40 X 2 Pressure switch (Steering pump) J-1
G SUMITOMO 3 G sensor AL-1 Work equipment controller
CL26 X 2 Intermediate connector (Cab wiring harness) O-5 L71 DRC26 24 — R43 KES1 2 Front windshield washer L-1
G04 DT-T 2 Left rear working lamp N-9 (Joystick steering specification) (if equipped)
CL26 X 2 Intermediate connector A-3 R45 KES1 2 Rear windshield washer L-2
G05 DT-T 2 Right rear working lamp M-9 Work equipment controller
CL27 SWP 6 Side wiper (if equipped) A-4 L72 DRC26 40 —
G10 DT-T 2 Backup buzzer N-8 (Joystick steering specification) (if equipped) R47 DT-T 2 Hydraulic oil temperature sensor E-7
CN1 DT 2 Injector #1 AJ-3 Work equipment controller R50 (Terminal) 1 GND (Rear frame) N-6
G11 DT-T 2 Fan reverse solenoid N-8 L73 DRC26 40 —
CN2 DT 2 Injector #2 AK-4 (Joystick steering specification) (if equipped) R52 DT-T 2 Emergency brake switch I-1
G12 DT 2 Fan speed sensor N-8
CN3 DT 2 Injector #3 AK-4 L80 DRC26 40 KOMTRAX controller — R54 DT-T 2 Rear brake pressure switch I-1
GR1 DT-T 4 Intermediate connector (Rear working lamp) L-9
CN4 DT 2 Injector #4 AL-5 L100 (Terminal) 1 GND (Floor) Y-3 R60 DT-T 2 Rear brake oil temperature sensor L-2
HEAD DT-T 3 Headlamp, right D-6
CN5 DT 2 Injector #5 AL-5 L101 SWP 16 Intermediate connector (Relay) Z-2 R71 DT-T 2 Loader pump EPC solenoid L-9
HEAD DT-T 3 Headlamp, left H-1
CN6 DT 2 Injector #6 AM-5 L102 SWP 16 Intermediate connector (Relay) Z-2 R73 DT-T 3 Brake oil pressure sensor (For transmission cut-off) K-1
J01 M6409-0073 20 Junction connector V-1
COMBI DT-T 3 Combination lamp, right D-6 L103 SWP 16 Intermediate connector (Relay) Z-3 R86 DT-T 3 Steering pump pressure sensor J-1
COMBI DT-T 3 Combination lamp, left H-1 L104 SWP 16 Intermediate connector (Relay) W-9 R87 DT 2 Intermediate connector A-2
J03 M6409-0071 20 Junction connector U-1
D04 DT-T 2 Diode Z-4 L105 SWP 12 Intermediate connector (Relay) V-9 R90 (Terminal) 1 Heater relay E terminal B-6
D05 DT-T 2 Diode W-1 L106 SWP 16 Intermediate connector (Relay) V-9 R96 DT-T 2 Steering pump EPC solenoid M-2
D06 DT-T 2 Diode Z-4 L107 SWP 12 Intermediate connector (Wiper timer) Z-5 RES DT 2 Intermediate connector AL-5
D07 DT-T 2 Diode Z-4 L111 YAZAKI 5 Relay No. 1 winker & hazard Z-8 REV.INP DT 2 Transmission input speed sensor AG-8
D08 DT-T 2 Diode W-1 L112 YAZAKI 5 Relay No. 2 air cleaner clog (if equipped) Z-8 REV.OUT DT 2 Transmission output speed sensor AH-4
D09 DT-T 2 Diode W-2 L113 YAZAKI 5 Relay No. 3, joystick safety relay Y-8 S1 DT-T 2 Electric detent PPC valve O-3
D11 11 Diode unit — L114 YAZAKI 5 Relay No. 4, start neutral hold Y-8 S01 SWP 6 Front working lamp Q-4
D11 DT-T 2 Diode Z-3 L116 YAZAKI 5 Relay No. 6, neutral safety Z-8 S02 SWP 6 Rear working lamp Q-5
D12 DT-T 2 Diode Z-3 L117 YAZAKI 5 Relay No. 7, backup lamp Z-8 S03 SWP 6 Transmission cut-off switch P-9
D13 YAZAKI 3 Diode X-1 L118 YAZAKI 5 Relay No. 8, stop lamp Z-8 S04 SWP 6 FNR selector switch Q-9
DIODE DT 2 Diode AE-5 L119 YAZAKI 5 Relay No. 9, horn Y-8 S05 SWP 6 Transmission cut-off set switch Q-9
E01 DT-T 2 Starting motor AK-5 L120 YAZAKI 5 Relay No. 10, parking brake Y-9 S06 SWP 6 Torque converter lockup ON/OFF switch P-8
E02 (Terminal) 1 Alternator R terminal AM-8 L123 YAZAKI 5 Relay No. 3, boom detent Y-9 S07 SWP 6 E.C.S.S. switch S-1
J16 M6409-0075 20 Junction connector Q-6
E04 (Terminal) 1 Alternator E terminal AM-7 L124 YAZAKI 5 Relay No. 4, bucket detent Y-9 S14 SWP 6 Upper and lower section remote position ON/OFF switch Q-9
E05 (Terminal) 1 Heater relay C-6 L125 YAZAKI 5 Relay No. 5, boom detent alternate X-9 S15 SWP 6 Automatic digging switch R-9
E06 (Terminal) 1 Heater relay B-8 L126 YAZAKI 5 Relay No. 6, emergency steering X-9 S16 SWP 6 Hydraulic fan selector switch R-9
E06A DT-T 2 Diode N-6 L127 YAZAKI 5 Relay No. 7, front working lamp Y-9 S17 SWP 6 Auto grease switch (if equipped) H-9
E07A (Terminal) 1 Heater relay AL-6 L128 YAZAKI 5 Relay No. 8, rear working lamp Y-9 S19 SWP 6 Emergency steering check switch Q-9
E07B (Terminal) 1 Electrical intake air heater AJ-3 L129 YAZAKI 5 Relay No. 9, rear glass with heater X-9 S21 SWP 6 Engine power mode switch P-8
E10 DT-T 2 Air conditioner compressor magnet clutch AK-1 L130 YAZAKI 5 Relay No. 10, transmission bypass X-9 S22 DT-T 4 Auto-shift mode switch P-8
J41 M6409-0128 20 Junction connector (Joystick steering specification) (if equipped) —
E14A (Terminal) 1 GND (Engine) AN-3 L131 YAZAKI 5 Relay No. 11, headlamp X-9 S3 DT-T 2 Electric detent PPC valve O-3
J42 M6409-0128 20 Junction connector (Joystick steering specification) (if equipped) —
E14B (Terminal) 1 GND (Engine) AN-3 JIDOSYA S31 SWP 6 Load meter mode selector switch (if equipped) T-1
J44 M6409-0071 20 Junction connector (Joystick steering specification) (if equipped) — L141 5 Front washing relay —
DENKI KOGYO
E15 (Terminal) 1 GND (Engine) AL-6 S32 SWP 6 Load meter display selection (if equipped) U-1
J45 DT2(B) 8 Junction connector (Joystick steering specification) (if equipped) — L142 DT 2 Diode —
E26 DT-T 2 Engine oil level sensor AL-5 S33 SWP 6 Remote positioner bucket raise/lower (if equipped) Q-9
J46 DT2 6 Junction connector (Joystick steering specification) (if equipped) — L143 DT 2 Diode —
E33 DT-T 2 Intermediate connector N-3 S34 SWP 6 2-stage idle function switch R-9
J1939 DT 3 CAN AJ-3 L144 DT 2 Diode —
E45 DT-T 2 Dust indicator K-9 S4 DT-T 2 Electric detent PPC valve O-3
JL1 DT2(Gr) 8 Junction connector (Joystick steering specification) (if equipped) AA-4 L145 DT 2 Diode —
EC1 DRC26 60 Engine controller AN-2 S40 DT 4 Starting motor switch T-8
JL2 DTM 12 Joystick lever switch AA-4 L146 DT 2 Diode —
EC2 DRC26 50 Engine controller AN-2 SEGR DT 4 EGR valve position sensor AJ-2
JS1 SWP 6 Joystick ON/OFF switch AB-6 L147 DT 2 Diode —
EC3 DTP 4 Engine controller AM-1 SV DT-T 12 KOM-NET (CAN) SV connector Z-5
JS2 SWP 6 Steering speed mode switch AA-6 L171 YAZAKI 5 Engine controller cut relay Y-8
EGR DT 2 EGR valve AK-1 T21 DT 2 Pump bypass solenoid (if equipped) —
JS3 DT2 4 Joystick lever potentiometer AA-6 L172 YAZAKI 5 Engine controller cut relay Z-8
ER1 DT-T 4 Intermediate connector (Engine controller) M-2, AJ-5 TC.T DT 2 Torque converter oil temperature sensor (Monitor) AG-5
JS4 DT2 2 Joystick neutral lock switch AB-4 L173 X 4 Intermediate connector (Relay) Z-2
ER2 DT-T 12 Intermediate connector (Engine controller) M-2, AK-5 TEL DT-T 12 Intermediate connector (KOMTRAX) U-9
JT1 DT 8 Junction connector AE-4 L175 YAZAKI 6 Brake oil pressure caution, emergency brake relay Y-8
ER3 L 2 Intermediate connector (Engine controller) M-2, AJ-4 TFUEL PACKARD 2 Fuel temperature sensor AN-5
JT2 DT 6 Junction connector AF-5 LL5 DT-T 3 Intermediate connector (Work equipment controller) Z-9
ER4 DT-T 6 Intermediate connector N-5, AL-6 TGN (Terminal) 1 GND (Transmission body) AF-5
L/C.PS DT 2 Torque converter lockup ECMV solenoid AH-3 LL6 DT-T 12 Intermediate connector (Work equipment controller) Z-8
F.PS DT 2 F (Forward) ECMV solenoid AH-2 TIM PACKARD 2 Boost temperature sensor AN-4
L01 SWP 6 Parking brake switch R-7 LL7 DT-T 12 Intermediate connector (Work equipment controller) Z-8
F.SW DT 2 F (Forward) ECMV fill switch AH-2 TM.T DT 2 Transmission lubricating oil temperature sensor AF-1
L02 SWP 6 Lighting switch S-8 Intermediate connector
F01 DT-T 6 Intermediate connector (Headlamp, right) C-5 LL8 DT2(Gr) 8 — TWTR PACKARD 2 Engine coolant temperature sensor AM-7
L03 SWP 6 Turn & Hazard switch S-8 (Joystick steering specification) (if equipped)
F02 DT-T 6 Intermediate connector (Headlamp, left) H-1 W60 SHINAGAWA 5 KOMTRAX engine cut relay X-9
L04 SWP 14 Intermediate connector (Shift switch) T-8
SEN04434-00
WA470-6, 480-6
90-200 25
SEN04434-00
WA470-6, 480-6 90-200 27

SEN04434-00

©2008 KOMATSU
All Rights Reserved
90-200 28

WA470-6 90001 Up

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WA470-6 90001 Up

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SEN04409-02

WHEEL LOADER WA470 -6

Machine model Serial number

00 Index and foreword 00

WA470, 480-6 00-100 1

Composition of shop manual 1

Section Title..................................................................................................................................... Form Number

00 Index and foreword .................................................................................................................... SEN04410-02

01 Specification ............................................................................................................................... SEN04411-00

10 Structure, function and maintenance standard........................................................................... SEN04412-00

20 Standard value table................................................................................................................... SEN04413-01

30 Testing and adjusting ................................................................................................................. SEN04414-01

00-100 2 WA470, 480-6

304 Troubleshooting by failure code (Display of code), Part 4..................................................SEN04524-01 q

50 Disassembly and assembly ........................................................................................................SEN04416-01

90 Diagrams and drawings..............................................................................................................SEN04417-00

WA470, 480-6 00-100 3

00 Index and foreword

10 Structure, function and maintenance standard

00-100 4 WA470, 480-6

Electrical steering lever ................................................................................................................................. 49

WA470, 480-6 00-100 5

Engine power mode selector circuit .............................................................................................................. 16

20 Standard value table

30 Testing and adjusting

00-100 6 WA470, 480-6

Testing brake performance ............................................................................................................................ 10

WA470, 480-6 00-100 7

Failure code [2G43ZG] (Accumulator: Low oil pressure) .............................................................................. 30

00-100 8 WA470, 480-6

Failure code [CA559] (Supply pump pressure very low error)....................................................................... 49

WA470, 480-6 00-100 9

Failure code [DB99KQ] (Work equipment controller model selection:

00-100 10 WA470, 480-6

WA470, 480-6 00-100 11

00-100 12 WA470, 480-6

E-19 FNR switch mode cannot be set or reset.............................................................................................. 66

WA470, 480-6 00-100 13

600 Troubleshooting of engine (S-mode) SEN04533-01

50 Disassembly and assembly

00-100 14 WA470, 480-6

Removal and installation of brake charge valve assembly ............................................................................ 8

90 Diagrams and drawings

WA470, 480-6 00-100 15

WA470-6, WA480-6 Wheel loader

Machine model Serial number

00 Index and foreword 00

200 Foreword and general information

WA470, 480-6 00-200 1

Safety notice (Rev. 2008/08)1

1. General precautions 7) If welding repairs are needed, always

00-200 2 WA470, 480-6

2. Preparations for work 6) When removing a cover which is under

WA470, 480-6 00-200 3

4. Precautions for sling work and making

00-200 4 WA470, 480-6

WA470, 480-6 00-200 5

00-200 6 WA470, 480-6

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table