Komatsu Wheel Loader WA470-5H, WA480-5H Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA470-5H, WA480-5H, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheel Loader WA470-5H, WA480-5H workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 2,265 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
VEBM180101 - Wheel Loader WA470-5H, WA480-5H Shop Manual.pdf
VEAM180100 - Wheel Loader WA470-5H Operation & Maintenance Manual.pdf
VEAM190100 - Wheel Loader WA480-5H Operation & Maintenance Manual.pdf
VEAM190200 - Wheel Loader WA480-5H Operation & Maintenance Manual.pdf
MAIN SECTIONS
VEAM180100 - Wheel Loader WA470-5H Operation & Maintenance Manual......2
WA470-5......2
FOREWORD......4
FOREWORD......5
SAFETY INFORMATION......7
INTRODUCTION......9
INTENDED USE......9
DIRECTIONS OF MACHINE......9
NECESSARY INFORMATION......10
MACHINE SERIAL NO. PLATE AND POSITION......10
ENGINE SERIAL NO. PLATE AND POSITION......10
ROPS/FOPS-CAB SERIAL NO. PLATE......11
AXLE SERIAL NO. PLATE......11
TRANSMISSION SERIAL NO. PLATE......11
SEAT OPERATOR SERIAL NO. PLATE......11
POSITION OF SERVICE METER......12
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR......12
CONTENTS......13
DIMENSIONS, WEIGHTS AND OPERATING DATA......20
WA470-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA......20
CE-CONFORMING EQUIPMENT......21
CE-CONFORMING EQUIPMENT - PART 1......21
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900......22
SAFETY......26
SAFETY LABELS......28
LOCATION OF SAFETY LABELS......28
SAFETY LABELS......29
GENERAL PRECAUTIONS......30
PRECAUTIONS FOR OPERATION......38
BEFORE STARTING ENGINE......38
OPERATION......39
TRANSPORTATION......46
BATTERY......47
TOWING......49
PRECAUTIONS FOR MAINTENANCE......50
PRECAUTIONS WITH TIRES......57
OPERATION......58
GENERAL VIEW......59
GENERAL VIEW OF MACHINE......59
GENERAL VIEW OF CONTROLS AND GAUGES......60
EXPLANATION OF COMPONENTS......63
MACHINE MONITOR......63
TYPES OF WARNING......64
CENTRAL WARNING LAMP......64
CHARACTER DISPLAY PORTION......65
EMERGENCY STOP ITEM......71
CAUTION ITEMS......74
INSPECTION AND MAINTENANCE ITEM......77
PILOT DISPLAY PORTION......81
METER DISPLAY PORTION......86
OTHER FUNCTIONS OF MACHINE MONITOR......88
SWITCHES......93
CONTROL LEVERS, PEDALS......108
STEERING TILT LOCK LEVER......114
CAP WITH LOCK......115
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)......115
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAURIC TANK FILLER PORT)......116
SAFETY BAR......117
TOWING PIN......117
GREASE PUMP......117
CAB DOOR OPEN LOCK......118
CAB WINDOW OPEN LOCK CANCEL KNOB......118
BACKUP ALARM......118
FUSE......119
FUSE CAPACITY AND NAME OF CIRCUIT......120
SLOW-BLOW FUSE......121
TAKING OFF POWER......121
HANDLING CAB WIPER......122
PREVENTING DAMAGE TO WIPER ARM BRACKET......122
DUST INDICATOR......122
OPERATION......123
CHECK BEFORE STARTING ENGINE, ADJUST......123
WALK-AROUND CHECK......123
CHECK BEFORE STARTING......126
ADJUSTMENT......131
OPERATIONS AND CHECKS BEFORE STARTING ENGINE......136
STARTING ENGINE......138
AUTOMATIC WARMING-UP OPERATION......140
OPERATIONS AND CHECKS AFTER STARTING ENGINE......141
BREAKING IN THE MACHINE......141
NORMAL OPERATION......141
STOPPING ENGINE......143
CHECK AFTER STOPPING ENGINE......143
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING......144
PREPARATIONS FOR MOVING MACHINE......144
CHANGING GEAR SPEED......147
CHANGING DIRECTION......148
STOPPING MACHINE......150
TURNING......153
EMERGENCY STEERING......153
OPERATION OF WORK EQUIPMENT......155
WORK POSSIBLE USING WHEEL LOADER......157
DIGGING OPERATIONS......157
LEVELING OPERATIONS......161
PUSHING OPERATION......161
LOAD AND CARRY OPERATIONS......161
LOADING OPERATIONS......162
PRECAUTIONS FOR OPERATION......164
PERMISSIBLE WATER DEPTH......164
IF WHEEL BRAKE DOES NOT WORK......164
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES......164
PRECAUTIONS REGARDING BRAKE FUNCTION......165
ADJUSTING WORK EQUIPMENT POSTURE......166
ADJUSTING BOOM KICKOUT......166
ADJUSTING BUCKET POSITIONER......168
BUCKET LEVEL INDICATOR......168
PARKING MACHINE......169
CHECKS AFTER COMPLETION OF OPERATION......171
LOCKING......171
HANDLING THE TIRES......172
PRECAUTIONS WHEN HANDLING TIRES......172
TIRE PRESSURE......172
PRECAUTIONS WHEN LOAD AND CARRY METHOD......173
TRANSPORTATION......174
TRANSPORTATION PROCEDURE......174
LOADING, UNLOADING WORK WITH TRAILERS......174
LOADING......174
SECURING MACHINE......175
UNLOADING......175
LIFTING MACHINE......176
POSITION FOR STICKING LIFTING POSITION MARK......177
WEIGHT TABLE......177
LIFTING PROCEDURE......178
COLD WEATHER OPERATION......179
PRECAUTIONS FOR LOW TEMPERATURE......179
FUEL AND LUBRICANTS......179
COOLANT......179
BATTERY......180
PRECAUTIONS AFTER COMPLETION OF WORK......180
AFTER COLD WEATHER......180
WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER......181
LONG-TERM STORAGE......182
BEFORE STORAGE......182
DURING STORAGE......182
AFTER STORAGE......182
TROUBLESHOOTING......183
WHEN MACHINE RUNS OUT OF FUEL......183
TOWING THE MACHINE......184
WHEN ENGINE CAN BE USED......185
WHEN ENGINE CANNOT BE USED......185
RELEASING PARKING BRAKE......185
EMERGENCY TRAVEL OPERATION......187
IF BATTERY IS DISCHARGED......188
REMOVAL AND INSTALLATION OF BATTERY......188
PRECAUTIONS FOR CHARGING BATTERY......189
STARING ENGINE WITH BOOSTER CABLE......189
OTHER TROUBLE......191
ELECTRICAL SYSTEM......191
CHASSIS......192
ENGINE......194
MAINTENANCE......196
GUIDES TO MAINTENANCE......197
OUTLINES OF SERVICE......199
OUTLINE OF OIL, FUEL, COOLANT......199
OIL......199
FUEL......199
COOLANT......199
GREASE......200
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)......200
STORING OIL AND FUEL......201
FILTERS......201
OUTLINE OF ELECTRIC SYSTEM......201
WEAR PARTS LIST......202
THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME......202
LUBRICANTS AND OPERATING MEANS......203
LUBRICATION CHART......203
LUBRICANTS, FUELS AND FILLING CAPACITIES......204
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS......208
TORQUE LIST......208
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......209
MAINTENANCE SCHEDULE CHART......210
MAINTENANCE SCHEDULE CHART......210
SERVICE PROCEDURE......212
INITIAL 250 HOURS SERVICE......212
WHEN REQUIRED......213
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......213
CLEAN INSIDE OF COOLING SYSTEM......216
CHECK TRANSMISSION OIL LEVEL, ADD OIL......219
CHECK AXLE OIL LEVEL, ADD OIL......220
CHECK AXLE CASE BREATHER......221
CLEAN CONDENSER OF AIR CONDENSER......221
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID......222
CLEAN RADIATOR FINS AND COOLER FINS......223
CHECK ELECTRICAL INTAKE AIR HEATER......226
REPLACE BOLT ON CUTTING EDGE......226
REPLACE BUCKET TEETH......227
CHECK AIR CONDITIONER......228
REPLACE SLOW BLOW FUSE......229
SELECTION AND INSPECTION OF TIRES......230
CHECK BEFORE STARTING......232
EVERY 50 HOURS SERVICE......233
DRAIN WATER, SEDIMENT FROM FUEL TANK......233
EVERY 100 HOURS SERVICE......234
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL......234
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER......235
EVERY 250 HOURS SERVICE......236
CHECK ENGINE ELECTROLYTE LEVEL......236
CHECK PARKING BRAKE......237
CHECK ALTERNATOR BELT TENSION, ADJUST......238
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......239
CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN......239
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER......240
EVERY 500 HOURS SERVICE......241
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......241
REPLACE FUEL FILTER CARTRIDGE......242
CLEAN FUEL STRAINER......244
EVERY 1000 HOURS SERVICE......245
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER......245
CLEAN TRANSMISSION CASE BREATHER......246
CHECK TIGTENING PARTS OF TURBOCHARGER......246
CHECK PLAY OF TURBOCHARGER ROTOR......246
REPLACE CORROSION RESISTOR CARTRIDGE......246
EVERY 2000 HOURS SERVICE......247
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT......247
REPLACE HYDRAULIC TANK BREATHER ELEMENT......249
CHANGE AXLE OIL......250
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......250
CLEAN PPC CIRCUIT STRAINER......251
CLEAN ENGINE BREATHER ELEMENT......251
CHEK ALTERNATOR, STARTING MOTOR......251
CHECK ENGINE VALVE CLEARANCE, ADJUST......251
CLEAN AND CHECK TURBOCHARGER......251
CHECK INJECTOR......252
CHECK ACCUMULATOR GAS PRESSURE......252
CHECK VIBRATION DAMPER......252
CHECK BRAKE DISC WEAR......253
EVERY 4000 HOURS SERVICE......254
LUBRICATING......254
CHECK WATER PUMP......254
CHECK AIR CONDITIONER COMPRESSOR, ADJUST......255
CHECK INJECTOR NOZZLE TIP......255
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......255
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......256
EVERY 8000 HOURS SERVICE......257
REPLACE HIGH-PRESSURE PIPING CLAMP......257
REPLACE FUEL SPRAY PREVENTION CAP......257
CHECK INJECTOR NOZZLE TIP, REPLACE IF NECESSARY......257
TECHNICAL DATA......258
TECHNICAL DATA......259
NOISE EMISSION LEVELS......261
VIBRATION LEVEL......261
LIMIT VALUES FOR SLOPES......262
ATTACHMENTS, OPTIONS......264
HANDLING LOAD METER......265
GENERAL LOCATIONS......265
MACHINE MONITOR WITH LOAD METER......265
SWITCHES......266
LOAD METER FUNCTIONS......267
HANDLING LOAD METER DISPLAY......270
SETTING ADDITION MODE......270
SETTING REMAIN MODE......272
TOTAL LOAD DATA DISPLAY......275
STOPPING CALCULATION......277
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY......278
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED......280
SUBTRACTION FUNCTION......283
METHOD OF SETTING TIME ON CLOCK......285
PRINTER OUTPUT......287
PRINTOUT MODE......287
METHOD OF SELECTING PRINTOUT MODE......288
HANDLING TORQUE CONVERTER LOCK-UP......290
GENERAL LOCATIONS......290
METHOD OF OPERATION......291
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED......292
AIR CONDITIONER......293
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL......293
METHOD OF OPERATION......296
PRECAUTIONS WHEN USING......297
HANDLING AUTOMATIC AIR-CONDITIONER......298
GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL......298
METHOD OF OPERATION......302
PRECAUTIONS WHEN USING......304
INSPECTION AND MAINTENANCE......304
CENTRAL LUBRICATION......305
OPERATION......305
DISPLAY AND CONTROL UNIT......306
LED-DISPLAY......306
PUSHBUTTONS......306
CHANGING THE LUBRICATION INTERVAL TIMES......307
HANDLING JOYSTICK STEERING SYSTEM......308
EXPLANATION OF COMPONENTS......308
SHIFT UP, SHIFT DOWN SWITCHES......308
FNR SWITCH......309
JOYSTICK STEERING LEVER......309
JOYSTICK ON/OFF SWITCH......309
HI/LOW SELECTOR SWITCH......309
HORN SWITCH......310
CONSOLE LOCK LEVER......310
HEIGHT ADJUSTMENT LOCK LEVER......310
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER......310
STRUCTURE AND FUNCTION OF JOYSTICK STEERING......310
GETTING IN OR OUT OF OPERATORS CAB......312
ADJUSTMENT OF JOYSTICK CONSOLE......312
OPERATION METHOD OF JOYSTICK STEERING SYSTEM......313
INDEX......316
NOTES......318
NOTES......319
VEAM190100 - Wheel Loader WA480-5H Operation & Maintenance Manual......330
WA480-5H......330
FOREWORD......332
FOREWORD......333
SAFETY INFORMATION......334
INTRODUCTION......336
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE......336
NECESSARY INFORMATION......337
MACHINE SERIAL NO. PLATE AND POSITION......337
ENGINE SERIAL NO. PLATE AND POSITION......337
POSITION OF SERVICE METER......338
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR......338
CONTENTS......339
SAFETY......347
SAFETY......348
SAFETY LABELS......350
LOCATION OF SAFETY LABELS......350
SAFETY LABELS......351
GENERAL PRECAUTIONS......352
PRECAUTIONS FOR OPERATION......360
BEFORE STARTING ENGINE......360
OPERATION......361
TRANSPORTATION......367
BATTERY......368
TOWING......370
PRECAUTIONS FOR MAINTENANCE......371
PRECAUTIONS WITH TIRES......378
OPERATION......379
GENERAL VIEW......380
GENERAL VIEW OF MACHINE......380
GENERAL VIEW OF CONTROLS AND GAUGES......381
EXPLANATION OF COMPONENTS......384
MACHINE MONITOR......384
TYPES OF WARNING......385
CENTRAL WARNING LAMP......385
CHARACTER DISPLAY PORTION......386
EMERGENCY STOP ITEM......392
CAUTION ITEMS......395
INSPECTION AND MAINTENANCE ITEM......398
PILOT DISPLAY PORTION......402
METER DISPLAY PORTION......407
OTHER FUNCTIONS OF MACHINE MONITOR......409
SWITCHES......414
CONTROL LEVERS, PEDALS......429
STEERING TILT LOCK LEVER......435
CAP WITH LOCK......436
METHOD OF OPENING AND CLOSING CAP WITH LOCK(FOR THE FUEL TANK FILLER PORT)......436
METHOD OF OPENING AND CLOSING CAP WITH LOCK(FOR THE HYDRAURIC TANK FILLER PORT)......437
SAFETY BAR......438
TOWING PIN......438
GREASE PUMP......438
CAB DOOR OPEN LOCK......439
CAB WINDOW OPEN LOCK CANCEL KNOB......439
BACKUP ALARM......439
FUSE......440
FUSE CAPACITY AND NAME OF CIRCUIT......441
SLOW-BLOW FUSE......442
TAKING OFF POWER......442
HANDLING CAB WIPER......443
PREVENTING DAMAGE TO WIPER ARM BRACKET......443
DUST INDICATOR......443
OPERATION......444
CHECK BEFORE STARTING ENGINE, ADJUST......444
WALK-AROUND CHECK......444
CHECK BEFORE STARTING......447
ADJUSTMENT......452
OPERATIONS AND CHECKS BEFORE STARTING ENGINE......457
STARTING ENGINE......459
AUTOMATIC WARMING-UP OPERATION......461
OPERATIONS AND CHECKS AFTER STARTING ENGINE......462
BREAKING IN THE MACHINE......462
NORMAL OPERATION......462
STOPPING ENGINE......464
CHECK AFTER STOPPING ENGINE......464
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING......465
PREPARATIONS FOR MOVING MACHINE......465
CHANGING GEAR SPEED......468
CHANGING DIRECTION......469
STOPPING MACHINE......471
TURNING......474
EMERGENCY STEERING......474
OPERATION OF WORK EQUIPMENT......476
WORK POSSIBLE USING WHEEL LOADER......478
DIGGING OPERATIONS......478
LEVELING OPERATIONS......482
PUSHING OPERATION......482
LOAD AND CARRY OPERATIONS......482
LOADING OPERATIONS......483
PRECAUTIONS FOR OPERATION......485
PERMISSIBLE WATER DEPTH......485
IF WHEEL BRAKE DOES NOT WORK......485
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES......485
PRECAUTIONS REGARDING BRAKE FUNCTION......486
ADJUSTING WORK EQUIPMENT POSTURE......487
ADJUSTING BOOM KICKOUT......487
ADJUSTING BUCKET POSITIONER......489
BUCKET LEVEL INDICATOR......489
PARKING MACHINE......490
CHECKS AFTER COMPLETION OF OPERATION......492
LOCKING......492
HANDLING THE TIRES......493
PRECAUTIONS WHEN HANDLING TIRES......493
TIRE PRESSURE......493
PRECAUTIONS WHEN LOAD AND CARRY METHOD......494
TRANSPORTATION......495
TRANSPORTATION PROCEDURE......495
LOADING, UNLOADING WORK WITH TRAILERS......495
LOADING......495
SECURING MACHINE......496
UNLOADING......496
LIFTING MACHINE......497
POSITION FOR STICKING LIFTING POSITION MARK......498
WEIGHT TABLE......498
LIFTING PROCEDURE......499
COLD WEATHER OPERATION......500
PRECAUTIONS FOR LOW TEMPERATURE......500
FUEL AND LUBRICANTS......500
COOLANT......500
BATTERY......501
PRECAUTIONS AFTER COMPLETION OF WORK......501
AFTER COLD WEATHER......501
WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER......502
LONG-TERM STORAGE......503
BEFORE STORAGE......503
DURING STORAGE......503
AFTER STORAGE......503
TROUBLESHOOTING......504
WHEN MACHINE RUNS OUT OF FUEL......504
TOWING THE MACHINE......505
WHEN ENGINE CAN BE USED......506
WHEN ENGINE CANNOT BE USED......506
RELEASING PARKING BRAKE......506
EMERGENCY TRAVEL OPERATION......508
IF BATTERY IS DISCHARGED......509
REMOVAL AND INSTALLATION OF BATTERY......509
PRECAUTIONS FOR CHARGING BATTERY......510
STARING ENGINE WITH BOOSTER CABLE......510
OTHER TROUBLE......512
ELECTRICAL SYSTEM......512
CHASSIS......513
ENGINE......515
MAINTENANCE......517
GUIDES TO MAINTENANCE......518
OUTLINES OF SERVICE......520
OUTLINE OF OIL, FUEL, COOLANT......520
OIL......520
FUEL......520
COOLANT......520
GREASE......521
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)......521
STORING OIL AND FUEL......522
FILTERS......522
OUTLINE OF ELECTRIC SYSTEM......522
WEAR PARTS LIST......523
THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME......523
LUBRICANTS, FUELS AND FILLING CAPACITIES......524
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS......524
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS......528
TORQUE LIST......528
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......529
MAINTENANCE SCHEDULE CHART......531
MAINTENANCE SCHEDULE CHART......531
SERVICE PROCEDURE......533
INITIAL 250 HOURS SERVICE......533
WHEN REQUIRED......534
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......534
CLEAN INSIDE OF COOLING SYSTEM......537
CHECK TRANSMISSION OIL LEVEL, ADD OIL......540
CHECK AXLE OIL LEVEL, ADD OIL......541
CHECK AXLE CASE BREATHER......542
CLEAN CONDENSER OF AIR CONDENSER......542
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID......543
CLEAN RADIATOR FINS AND COOLER FINS......544
CHECK ELECTRICAL INTAKE AIR HEATER......547
REPLACE BOLT ON CUTTING EDGE......547
REPLACE BUCKET TEETH......548
CHECK AIR CONDITIONER......549
REPLACE SLOW BLOW FUSE......550
SELECTION AND INSPECTION OF TIRES......551
CHECK BEFORE STARTING......553
EVERY 50 HOURS SERVICE......554
DRAIN WATER, SEDIMENT FROM FUEL TANK......554
EVERY 100 HOURS SERVICE......555
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL......555
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER......556
EVERY 250 HOURS SERVICE......557
CHECK ENGINE ELECTROLYTE LEVEL......557
CHECK PARKING BRAKE......558
CHECK ALTERNATOR BELT TENSION, ADJUST......559
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......560
CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN......560
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER......561
EVERY 500 HOURS SERVICE......563
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......563
REPLACE FUEL FILTER CARTRIDGE......564
CLEAN FUEL STRAINER......566
EVERY 1000 HOURS SERVICE......567
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER......567
CLEAN TRANSMISSION CASE BREATHER......568
CHECK TIGTENING PARTS OF TURBOCHARGER......568
CHECK PLAY OF TURBOCHARGER ROTOR......568
REPLACE CORROSION RESISTOR CARTRIDGE......568
EVERY 2000 HOURS SERVICE......569
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT......569
REPLACE HYDRAULIC TANK BREATHER ELEMENT......571
CHANGE AXLE OIL......572
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......572
CLEAN PPC CIRCUIT STRAINER......573
CLEAN ENGINE BREATHER ELEMENT......573
CHEK ALTERNATOR, STARTING MOTOR......573
CHECK ENGINE VALVE CLEARANCE, ADJUST......573
CLEAN AND CHECK TURBOCHARGER......573
CHECK INJECTOR......574
CHECK ACCUMULATOR GAS PRESSURE......574
CHECK VIBRATION DAMPER......574
CHECK BRAKE DISC WEAR......575
EVERY 4000 HOURS SERVICE......576
LUBRICATING......576
CHECK WATER PUMP......576
CHECK AIR CONDITIONER COMPRESSOR, ADJUST......577
REPLACE INJECTOR NOZZLE TIP......577
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......577
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......578
EVERY 8000 HOURS SERVICE......579
REPLACE HIGH-PRESSURE PIPING CLAMP......579
REPLACE FUEL SPRAY PREVENTION CAP......579
SPECIFICATIONS......581
SPECIFICATIONS......582
ATTACHMENTS, OPTIONS......583
HANDLING LOAD METER......584
GENERAL LOCATIONS......584
MACHINE MONITOR WITH LOAD METER......584
SWITCHES......585
LOAD METER FUNCTIONS......586
HANDLING LOAD METER DISPLAY......589
SETTING ADDITION MODE......589
SETTING REMAIN MODE......591
TOTAL LOAD DATA DISPLAY......594
STOPPING CALCULATION......596
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY......597
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED......599
SUBTRACTION FUNCTION......602
METHOD OF SETTING TIME ON CLOCK......604
PRINTER OUTPUT......606
PRINTOUT MODE......606
METHOD OF SELECTING PRINTOUT MODE......607
HANDLING TORQUE CONVERTER LOCK-UP......609
GENERAL LOCATIONS......609
METHOD OF OPERATION......610
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED......611
AIR CONDITIONER......612
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL......612
METHOD OF OPERATION......615
PRECAUTIONS WHEN USING......616
HANDLING AUTOMATIC AIR-CONDITIONER......617
GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL......617
METHOD OF OPERATION......621
PRECAUTIONS WHEN USING......623
INSPECTION AND MAINTENANCE......623
HANDLING AUTO-GREASING SYSTEM......624
METHOD OF OPERATING AUTO-GREASING SYSTEM......624
HANDLING JOYSTICK STEERING SYSTEM......625
EXPLANATION OF COMPONENTS......625
SHIFT UP, SHIFT DOWN SWITCHES......625
FNR SWITCH......626
JOYSTICK STEERING LEVER......626
JOYSTICK ON/OFF SWITCH......626
HI/LOW SELECTOR SWITCH......626
HORN SWITCH......627
CONSOLE LOCK LEVER......627
HEIGHT ADJUSTMENT LOCK LEVER......627
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER......627
STRUCTURE AND FUNCTION OF JOYSTICK STEERING......627
GETTING IN OR OUT OF OPERATORS CAB......629
ADJUSTMENT OF JOYSTICK CONSOLE......629
OPERATION METHOD OF JOYSTICK STEERING SYSTEM......630
INDEX......633
INDEX......635
VEAM190200 - Wheel Loader WA480-5H Operation & Maintenance Manual......637
COVER......637
FOREWORD......638
FOREWORD......639
SAFETY INFORMATION......641
INTRODUCTION......643
INTENDED USE......643
DIRECTIONS OF MACHINE......643
NECESSARY INFORMATION......644
PIN/MACHINE SERIAL NO. PLATE AND POSITION......644
ENGINE SERIAL NO. PLATE AND POSITION......644
ROPS/FOPS-CAB SERIAL NO. PLATE......645
AXLE SERIAL NO. PLATE......645
TRANSMISSION SERIAL NO. PLATE......645
SEAT OPERATOR SERIAL NO. PLATE......645
POSITION OF SERVICE METER......646
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR......646
CONTENTS......647
DIMENSIONS, WEIGHTS AND OPERATING DATA......654
WA480-5H: DIMENSIONS, WEIGHTS AND OPERATING DATA......654
CE-CONFORMING EQUIPMENT......655
CE-CONFORMING EQUIPMENT - PART 1......655
MANUFACTURER-SUPPLIED CE-CONFORMING EQUIPMENT, ACCORDING TO DOCUMENT 421-93-H1900......656
SAFETY......660
SAFETY LABELS......662
LOCATION OF SAFETY LABELS......662
SAFETY LABELS......663
GENERAL PRECAUTIONS......664
PRECAUTIONS FOR OPERATION......672
BEFORE STARTING ENGINE......672
OPERATION......673
TRANSPORTATION......680
BATTERY......681
TOWING......683
PRECAUTIONS FOR MAINTENANCE......684
PRECAUTIONS WITH TIRES......691
OPERATION......692
GENERAL VIEW......693
GENERAL VIEW OF MACHINE......693
GENERAL VIEW OF CONTROLS AND GAUGES......694
MACHINE MONITOR WITH ANALOG SPEEDOMETER (STANDARD)......695
MACHINE MONITOR WITH DIGITAL SPEEDOMETER (IF EQUIPPED)......696
EXPLANATION OF COMPONENTS......698
MACHINE MONITOR......698
TYPES OF WARNING......699
CENTRAL WARNING LAMP......699
CHARACTER DISPLAY PORTION......700
EMERGENCY STOP ITEM......706
CAUTION ITEMS......709
INSPECTION AND MAINTENANCE ITEM......712
PILOT DISPLAY PORTION......716
METER DISPLAY PORTION......721
OTHER FUNCTIONS OF MACHINE MONITOR......723
SWITCHES......729
CONTROL LEVERS, PEDALS......743
STEERING TILT LOCK LEVER......749
CAP WITH LOCK......750
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE FUEL TANK FILLER PORT)......750
METHOD OF OPENING AND CLOSING CAP WITH LOCK (FOR THE HYDRAURIC TANK FILLER PORT)......751
SAFETY BAR......752
TOWING PIN......752
GREASE PUMP......752
CAB DOOR OPEN LOCK......753
CAB WINDOW OPEN LOCK CANCEL KNOB......753
BACKUP ALARM......753
FUSE......754
FUSE CAPACITY AND NAME OF CIRCUIT......755
SLOW-BLOW FUSE......756
TAKING OFF POWER......756
HANDLING CAB WIPER......757
PREVENTING DAMAGE TO WIPER ARM BRACKET......757
DUST INDICATOR......757
OPERATION......758
CHECK BEFORE STARTING ENGINE, ADJUST......758
WALK-AROUND CHECK......758
CHECK BEFORE STARTING......761
ADJUSTMENT......766
OPERATIONS AND CHECKS BEFORE STARTING ENGINE......769
STARTING ENGINE......771
AUTOMATIC WARMING-UP OPERATION......773
OPERATIONS AND CHECKS AFTER STARTING ENGINE......774
BREAKING IN THE MACHINE......774
NORMAL OPERATION......774
STOPPING ENGINE......776
CHECK AFTER STOPPING ENGINE......776
MOVING MACHINE OFF (DIRECTIONAL, SPEED), STOPPING......777
PREPARATIONS FOR MOVING MACHINE......777
CHANGING GEAR SPEED......780
CHANGING DIRECTION......781
STOPPING MACHINE......783
TURNING......786
EMERGENCY STEERING......786
OPERATION OF WORK EQUIPMENT......788
WORK POSSIBLE USING WHEEL LOADER......790
DIGGING OPERATIONS......790
LEVELING OPERATIONS......794
PUSHING OPERATION......794
LOAD AND CARRY OPERATIONS......794
LOADING OPERATIONS......795
PRECAUTIONS FOR OPERATION......797
PERMISSIBLE WATER DEPTH......797
IF WHEEL BRAKE DOES NOT WORK......797
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES......797
PRECAUTIONS REGARDING BRAKE FUNCTION......798
ADJUSTING WORK EQUIPMENT POSTURE......799
ADJUSTING BOOM KICKOUT......799
ADJUSTING BUCKET POSITIONER......801
BUCKET LEVEL INDICATOR......801
PARKING MACHINE......802
CHECKS AFTER COMPLETION OF OPERATION......804
LOCKING......804
HANDLING THE TIRES......805
PRECAUTIONS WHEN HANDLING TIRES......805
TIRE PRESSURE......805
PRECAUTIONS WHEN LOAD AND CARRY METHOD......806
TRANSPORTATION......807
TRANSPORTATION PROCEDURE......807
LOADING, UNLOADING WORK WITH TRAILERS......807
LOADING......807
SECURING MACHINE......808
UNLOADING......808
LIFTING MACHINE......809
POSITION FOR STICKING LIFTING POSITION MARK......810
WEIGHT TABLE......810
LIFTING PROCEDURE......811
COLD WEATHER OPERATION......812
PRECAUTIONS FOR LOW TEMPERATURE......812
FUEL AND LUBRICANTS......812
COOLANT......812
BATTERY......813
PRECAUTIONS AFTER COMPLETION OF WORK......813
AFTER COLD WEATHER......813
WARMING-UP OPERATION FOR STEERING HYDRAURIC CIRCUIT IN COLD WEATHER......814
LONG-TERM STORAGE......815
BEFORE STORAGE......815
DURING STORAGE......815
AFTER STORAGE......815
TROUBLESHOOTING......816
WHEN MACHINE RUNS OUT OF FUEL......816
TOWING THE MACHINE......817
WHEN ENGINE CAN BE USED......818
WHEN ENGINE CANNOT BE USED......818
RELEASING PARKING BRAKE......818
EMERGENCY TRAVEL OPERATION......820
IF BATTERY IS DISCHARGED......821
REMOVAL AND INSTALLATION OF BATTERY......821
PRECAUTIONS FOR CHARGING BATTERY......822
STARING ENGINE WITH BOOSTER CABLE......822
OTHER TROUBLE......824
ELECTRICAL SYSTEM......824
CHASSIS......825
ENGINE......827
MAINTENANCE......830
GUIDES TO MAINTENANCE......831
OUTLINES OF SERVICE......833
OUTLINE OF OIL, FUEL, COOLANT......833
OIL......833
FUEL......833
COOLANT......833
GREASE......834
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)......834
STORING OIL AND FUEL......835
FILTERS......835
OUTLINE OF ELECTRIC SYSTEM......835
WEAR PARTS LIST......836
THE PARTS IN PARENTHESES ARE TO BE REPLACED AT THE SAME TIME......836
LUBRICANTS AND OPERATING MEANS......837
LUBRICATION CHART......837
LUBRICANTS, FUELS AND FILLING CAPACITIES......838
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS......842
TORQUE LIST......842
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS......843
MAINTENANCE SCHEDULE CHART......844
MAINTENANCE SCHEDULE CHART......844
SERVICE PROCEDURE......846
INITIAL 250 HOURS SERVICE......846
WHEN REQUIRED......847
CHECK, CLEAN, OR REPLACE AIR CLEANER ELEMENT......847
CLEAN INSIDE OF COOLING SYSTEM......850
CHECK TRANSMISSION OIL LEVEL, ADD OIL......853
CHECK AXLE OIL LEVEL, ADD OIL......854
CHECK AXLE CASE BREATHER......855
CLEAN CONDENSER OF AIR CONDENSER......855
CHECK WINDOW WASHING FLUID LEVEL, ADD FLUID......856
CLEAN RADIATOR FINS AND COOLER FINS......857
CHECK ELECTRICAL INTAKE AIR HEATER......860
REPLACE BOLT ON CUTTING EDGE......860
REPLACE BUCKET TEETH......861
CHECK AIR CONDITIONER......862
REPLACE SLOW BLOW FUSE......863
SELECTION AND INSPECTION OF TIRES......864
CHECK BEFORE STARTING......866
EVERY 50 HOURS SERVICE......867
DRAIN WATER, SEDIMENT FROM FUEL TANK......867
EVERY 100 HOURS SERVICE......868
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL......868
CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER......869
EVERY 250 HOURS SERVICE......870
CHECK ENGINE ELECTROLYTE LEVEL......870
CHECK PARKING BRAKE......871
CHECK ALTERNATOR BELT TENSION, ADJUST......872
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST......873
CHECK FOR LOOSE WHEEL HAB NUTS, TIGHTEN......873
CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER......874
EVERY 500 HOURS SERVICE......875
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE......875
REPLACE FUEL FILTER CARTRIDGE......876
CLEAN FUEL STRAINER......878
EVERY 1000 HOURS SERVICE......879
CHANGE OIL IN TRANSMISSION CASE AND TRANSMISSION OIL FILTER CARTRIDGE, CLEAN STRAINER......879
CLEAN TRANSMISSION CASE BREATHER......880
CHECK TIGTENING PARTS OF TURBOCHARGER......880
CHECK PLAY OF TURBOCHARGER ROTOR......880
REPLACE CORROSION RESISTOR CARTRIDGE......880
EVERY 2000 HOURS SERVICE......881
CHANGE OIL IN HYDRAULIC TANK, REPLACE HYDRAULIC FILTER ELEMENT......881
REPLACE HYDRAULIC TANK BREATHER ELEMENT......883
CHANGE AXLE OIL......884
REPLACE ELEMENT IN AIR CONDITIONER RECIRCULATION AIR FILTER, FRESH AIR FILTER......884
CLEAN PPC CIRCUIT STRAINER......885
CLEAN ENGINE BREATHER ELEMENT......885
CHEK ALTERNATOR, STARTING MOTOR......885
CHECK ENGINE VALVE CLEARANCE, ADJUST......885
CLEAN AND CHECK TURBOCHARGER......885
CHECK INJECTOR......886
CHECK ACCUMULATOR GAS PRESSURE......886
CHECK VIBRATION DAMPER......886
CHECK BRAKE DISC WEAR......887
EVERY 4000 HOURS SERVICE......888
LUBRICATING......888
CHECK WATER PUMP......888
CHECK AIR CONDITIONER COMPRESSOR, ADJUST......889
CHECK INJECTOR NOZZLE TIP......889
CHECKING FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER......889
CHECKING FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER......890
EVERY 8000 HOURS SERVICE......891
REPLACE HIGH-PRESSURE PIPING CLAMP......891
REPLACE FUEL SPRAY PREVENTION CAP......891
CHECK INJECTOR NOZZLE TIP, REPLACE IF NECESSARY......891
TECHNICAL DATA......892
TECHNICAL DATA......893
NOISE EMISSION LEVELS......895
VIBRATION LEVEL......895
LIMIT VALUES FOR SLOPES......896
ATTACHMENTS, OPTIONS......898
HANDLING LOAD METER......899
GENERAL LOCATIONS......899
MACHINE MONITOR WITH LOAD METER......899
SWITCHES......900
LOAD METER FUNCTIONS......901
HANDLING LOAD METER DISPLAY......904
SETTING ADDITION MODE......904
SETTING REMAIN MODE......906
TOTAL LOAD DATA DISPLAY......909
STOPPING CALCULATION......911
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN EMPTY......912
CARRYING OUT CALIBRATION (ADJUSTING 0 POINT) WHEN LOADED......914
SUBTRACTION FUNCTION......917
METHOD OF SETTING TIME ON CLOCK......919
PRINTER OUTPUT......921
PRINTOUT MODE......921
METHOD OF SELECTING PRINTOUT MODE......922
HANDLING TORQUE CONVERTER LOCK-UP......924
GENERAL LOCATIONS......924
METHOD OF OPERATION......925
WARNING/LIMIT FUNCTIONS FOR TRAVEL SPEED......926
AIR CONDITIONER......927
GENERAL LOCATIONS AND FUNCTION OF CONTROL PANEL......927
METHOD OF OPERATION......930
PRECAUTIONS WHEN USING......931
AUTOMATIC AIR-CONDITIONER......932
GENERAL LOCATIONS AND FUNCTIONS OF CONTROL PANEL......932
METHOD OF OPERATION......936
PRECAUTIONS WHEN USING......938
INSPECTION AND MAINTENANCE......938
CENTRAL LUBRICATION......939
OPERATION......939
DISPLAY AND CONTROL UNIT......940
LED-DISPLAY......940
PUSHBUTTONS......940
CHANGING THE LUBRICATION INTERVAL TIMES......941
MULTIFUNCTION LEVER......942
EXPLANATION OF COMPONENTS......942
WORK EQUIPMENT LEVER......943
DIRECTIONAL SELECTOR SWITCH ACTUATION......944
DIRECTIONAL SELECTOR PILOT LAMP......945
OPERATION......946
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE......946
KICKDOWN SWITCH......948
HOLD SWITCH......948
JOYSTICK STEERING SYSTEM......949
EXPLANATION OF COMPONENTS......949
SHIFT UP, SHIFT DOWN SWITCHES......949
FNR SWITCH......950
JOYSTICK STEERING LEVER......950
JOYSTICK ON/OFF SWITCH......950
HI/LOW SELECTOR SWITCH......950
HORN SWITCH......951
CONSOLE LOCK LEVER......951
HEIGHT ADJUSTMENT LOCK LEVER......951
ANGLE, FORE/AFT ADJUSTMENT LOCK LEVER......951
STRUCTURE AND FUNCTION OF JOYSTICK STEERING......951
GETTING IN OR OUT OF OPERATORS CAB......953
ADJUSTMENT OF JOYSTICK CONSOLE......953
OPERATION METHOD OF JOYSTICK STEERING SYSTEM......954
INDEX......958
INDEX......960
NOTES......962
NOTES......963
VEBM180101 - Wheel Loader WA470-5H, WA480-5H Shop Manual......965
WA470-5H / WA480-5H......965
CONTENTS......967
SAFETY......977
Safety......978
Safety notice......978
General precautions......978
Preparations for work......979
Precautions during work......979
General......981
General......981
Structure and Function......981
Testing, Adjusting and Troubleshooting......981
Disassembly and Assembly......981
Maintenance Standard......981
How to read the shop manual......982
Volumes......982
Filing method......982
Revised edition mark......982
Revisions......982
Symbols......983
Hoisting instructions......984
Hoisting......984
Coating materials......986
Standard tightening torque......988
Standard tightening torque of bolts and nuts......988
Tightening torque of hose nuts......989
Tightening torque of split flange bolts......989
Tightening torque for flared nuts......989
Tightening torque for 102 engine series (bolts and nuts)......990
Tightening torque for 102 engine series (eye joints)......990
Tightening torque for 102 engine series (tapered screws)......990
Electric wire code......991
Classification by thickness......991
Classification by color and code......991
Conversion tables......992
Method of using the conversion table......992
Temperature......997
Units......998
GENERAL......999
General assembly drawing......1000
Specifications......1001
Weight table......1005
List of lubricant and coolant......1007
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD......1009
Radiator, oil cooler......1010
Engine mount, transmission mount......1011
Power train......1012
Power train system diagram......1013
Without torque converter lock-up clutch......1013
With torque converter lock-up clutch......1014
Drive shaft (propeller shaft)......1016
Torque converter, transmission piping......1017
Torque converter......1018
Without lock-up clutch......1018
Path of power transmission......1021
With lock-up clutch......1022
Path of power transmission......1026
Transmission......1028
F-R clutch (without lock-up clutch)......1035
F-R clutch (with lock-up clutch)......1036
1st-4th clutch......1037
2nd-3rd clutch......1038
Operation of clutch......1039
Forward 1st......1040
Forward 2nd......1041
Forward 3rd......1042
Forward 4th......1043
Reverse 1st......1044
Transmission control valve......1046
Without lock-up clutch......1046
With lock-up clutch......1048
ECMV (Electronic Control Modulation Valve)......1050
ECMV for speed clutch......1051
ECMV for lock-up clutch......1054
Main relief, torque converter relief valve......1056
Flow valve......1058
Axle......1060
Front axle WA470-5......1060
Front axle WA480-5......1061
Rear axle WA470-5......1062
Rear axle WA480-5......1063
Differential......1064
Anti-slip differential......1064
Operation of anti-slip differential......1068
Front differential......1070
Rear differential......1072
Final drive......1076
WA470-5......1076
WA480-5......1077
Axle mounting, center hinge pin......1082
Steering piping......1086
Steering column, orbit-roll......1087
Steering valve......1088
Overload relief valve......1090
Function......1090
Operation......1090
Steering relief valve......1092
Function......1092
Operation of steering relief valve......1093
Operation of demand valve......1094
Flow AMP......1097
Operation of steering valve......1100
Orbit-roll valve......1104
Connection between hand pump and sleeve......1106
Stop valve......1108
Steering pump, switch pump......1110
Emergency steering pump (op)......1112
Emergency steering motor (op)......1113
Steering cylinder......1114
Joystick steering lever (op)......1116
Steering lever (op)......1118
(For joystick steering lever)......1118
Steering switch valve (op)......1120
(For joystick steering lever)......1120
Brake piping......1122
Brake valve......1124
Brake valve (left)......1124
Brake valve (right)......1126
Outline......1128
Operation......1128
Charge valve......1132
Accumulator (for brake)......1136
Slack adjuster......1138
Outline......1139
Operation......1139
Brake......1140
Front......1140
Outline......1141
Rear......1142
Outline......1143
Outline......1144
Parking brake control......1146
Parking brake......1148
Outline......1148
Parking brake solenoid valve......1150
Operation......1151
Parking brake emergency release valve......1152
Outline......1152
Hydraulic piping......1154
Outline......1156
Work equipment control lever......1158
For PPC valve......1158
For EPC valve (op)......1159
Hydraulic tank......1160
Breather......1161
Torque converter charging, work equipment, and PPC pumps......1162
Outline......1162
PPC relief valve......1164
Outline......1164
Operation......1165
Travel damper valve (op)......1166
Work equipment control valve......1168
PPC valve......1188
Work equipment control epc valve (op)......1194
Shut off valve (op)......1197
Cooling fan motor......1198
Model: LMF28......1198
Cooling fan motor drive pump......1204
Model: LPV30......1204
Servo valve......1209
Safety valve......1211
Work equipment linkage......1212
Bucket......1214
Bucket positioner, lift arm kick-out......1215
Bucket positioner......1216
Lift arm kick-out......1217
Operation of proximity switch......1218
Work equipment cylinder......1222
Lift arm cylinder......1222
Bucket cylinder......1222
Cab (op)......1224
Air conditioner (op)......1225
Air conditioner piping......1225
Machine monitoring system......1226
Outline......1226
Individual circuit diagrams of the machine monitor......1228
Starting and lighting functions......1228
Load meter......1228
Sensing functions......1229
Power supply and network......1230
Machine monitor......1234
Load meter specifications (option)......1235
Table of monitor indication items......1236
Setting of the machine monitor......1241
Service mode functions......1245
Items related to the fault history of electric system......1249
Items related to the fault history of machine system......1251
Items related to maintenance monitor......1253
Engine cylinders cut-out function......1256
Real-time monitoring function......1258
Real-time monitoring items......1261
Machine setting......1271
Setting necessary for option mounting......1274
Optional device setting for machine monitor......1275
Transmission control system......1296
System diagram......1296
Control Function......1297
Electric circuit diagram (std)......1316
Electric circuit diagram (op)......1318
Transmission controller......1320
Work equipment control system (op)......1322
System diagram......1322
Electric circuit diagram (op)......1336
Work equipment controller......1338
Electric transmission control......1340
Functions......1341
Combination switch......1342
Overview......1342
Functions......1342
Operation......1343
Kick down, hold switch......1344
Functions......1344
Engine starting circuit......1346
Function......1346
Operation......1347
Engine stop circuit......1348
Operation......1348
Parking brake circuit......1350
Operation......1350
Turn signal, hazard lamp circuit......1354
Operation......1354
Backup lamp, stop lamp circuit......1356
Operation......1356
Small lamp, head lamp circuit......1358
Operation......1358
Working lamp circuit......1359
Operation......1359
Horn circuit......1360
Operation......1360
Windshield wiper/window washer circuit (If equipped with cab)......1362
Sensors......1364
Engine speed sensor......1364
Speed sensor......1364
Engine oil pressure sensor......1365
Engine oil level sensor......1365
Engine water temperature sensor......1366
Torque converter oil temperature sensor......1366
Hydraulic oil temperature sensor......1366
Transmission oil temperature sensor......1366
Brake oil temperature sensor......1366
Transmission cut-off pressure sensor......1367
Radiator water level sensor......1368
Fuel level sensor......1369
Lift arm angle sensor (op)......1370
Air cleaner clogging sensor......1371
Pressure sensor for load meter (op)......1372
Battery liquid sensor (op)......1373
Relay......1374
Standard value table for engine......1376
Standard value table for chassis......1377
TESTING AND ADJUSTING......1375
Measuring engine speed......1386
Measuring exhaust color......1388
Measuring exhaust temperature......1389
Adjusting valve clearance......1390
Measuring compression pressure......1392
Measuring blow-by pressure......1394
Measuring engine oil pressure......1395
Measuring air supply pressure (boost pressure)......1396
Measuring fuel pressure......1396
Adjusting engine speed sensor......1397
Handling equipment in fuel system......1398
Releasing remaining pressure in fuel system......1398
Bleeding air from fuel circuit......1399
Reduced cylinder mode operation for engine......1400
Checking for leakage in fuel system......1401
Adjusting accelerator pedal potentiometer......1402
Adjusting accelerator pedal microswitch......1403
Adjusting transmission speed sensor......1404
Testing and adjusting power train oil pressure......1405
Flushing torque converter, transmission hydraulic circuit......1409
Moving machine when transmission valve fails......1410
Testing and adjusting steering control......1412
Testing and adjusting steering oil pressure......1413
Measuring brake oil pressure......1416
Testing wear of wheel brake disc......1418
Bleeding air from brake circuit......1419
Testing wear of parking brake disc......1420
Manual release method for parking brake......1421
Testing and adjusting accumulator charge pressure......1422
Testing and adjusting ppc oil pressure......1424
Testing and adjusting work equipment hydraulic pressure......1426
Testing and adjusting bucket positioner......1428
Testing and adjusting lift arm kick-out......1429
Checking proximity switch actuation pilot lamp......1430
Adjusting machine monitor......1431
Testing and adjusting load meter......1434
Bleeding air......1435
Releasing remaining pressure in hydraulic circuit......1436
Releasing remaining pressure in travel damper circuit......1436
Handling controller high-voltage circuit......1437
TESTING AND ADJUSTING......1385
Points to remember when troubleshooting......1440
Sequence of events in troubleshooting......1441
Precautions when carrying out maintenance......1442
Checks before troubleshooting......1450
Equipment for troubleshooting electrical system......1451
Special functions of machine monitor......1452
Flow of modes and functions......1453
Categories, procedure, and method of using troubleshooting charts......1489
Connection table for connector pin numbers......1494
TROUBLESHOOTING......1439
Connector types and installation positions......1509
Connectors layout drawing......1518
Engine control system diagram......1524
Error code [A000N1]......1526
Error code [AD00L2]......1527
Error code [AD00MA]......1528
Error code [AD10L3]......1529
Error code [AD10MA]......1531
Error code [AD10MB]......1532
Error code [AD11KA]......1533
Error code [AD11KB]......1534
Error code [AD51KA]......1535
Error code [AD51KB]......1536
Error code [ADA1KA]......1537
Error code [ADAZKB]......1538
Error code [ADB1KA]......1540
Error code [ADC1KA]......1541
Error code [ADD1KA]......1542
Error code [ADDZKB]......1544
Error code [ADE1KA]......1546
Error code [ADF1KA]......1547
Error code [D182KZ]......1548
Error code [D1D0KB]......1550
Error code [DB20KT]......1552
Error code [AB20KT]......1554
Error code [DB22KK]......1556
Error code [DB29KQ]......1558
Error code [DB2AMA]......1560
Error code [DD11KB]......1561
Error code [DGE3L6]......1562
Error code [DGE4KX]......1563
Error code [DH30KX]......1564
Error code [DH40KX]......1565
Error code [DK10KX]......1566
Error code [DLE3LC]......1567
Error code [DLH1LC]......1568
Error code [ENG-1]......1569
TROUBLESHOOTING OF ENGINE CONTROL SYSTEM (ENG MODE)......1507
Connector types and installation positions......1578
Connector layout drawing......1586
Transmission control system diagram......1592
Error code [1500L1]......1595
Error code [15SAL1]......1596
Error code [15SALH]......1597
Error code [15SBL1]......1598
Error code [15SBLH]......1599
Error code [15SEL1]......1600
Error code [15SELH]......1601
Error code [15SFL1]......1602
Error code [15SFLH]......1603
Error code [15SGL1]......1604
Error code [15SGLH]......1605
Error code [15SHL1]......1606
Error code [15SHLH]......1607
Error code [15SJL1]......1608
Error code [15SJLH]......1609
Error code [989F00]......1610
Error code [989G00]......1611
Error code [B@C7NS]......1612
Error code [D150KA]......1613
Error code [D150KB]......1614
Error code [D160KA]......1615
Error code [D160KB]......1616
Error code [D191KA]......1618
Error code [D191KB]......1620
Error code [D192KA]......1622
Error code [D192KB]......1623
Error code [DAQ0KK]......1624
Error code [DAQ2KK]......1625
Error code [DAQ9KQ]......1626
Error code [DDK3KA]......1628
Error code [DDK3KB]......1630
Error code [DDK6KA]......1632
Error code [DDK6KB]......1634
Error code [DDS5KA]......1636
Error code [DDS5KB]......1637
Error code [DDT0L4]......1638
Error code [DDT4LD]......1640
Error code [DDW9LD]......1641
Error code [DDWLLD]......1642
Error code [DF10KA]......1644
Error code [DF10KB]......1646
Error code [DGF1KX]......1648
Error code [DGR2KA]......1649
Error code [DGR2KB]......1650
Error code [DHT1KX]......1651
Error code [DLE2KA]......1652
Error code [DLE2LC]......1653
Error code [DLT3KA]......1654
Error code [DT20KB]......1655
Error code [DW7BKA]......1656
Error code [DW7BKB]......1657
Error code [DW7CKA]......1658
Error code [DW7CKB]......1659
Error code [DX16KA]......1660
Error code [DX16KB]......1661
Error code [DXH1KA]......1662
Error code [DXH1KB]......1663
Error code [DXH4KA]......1664
Error code [DXH4KB]......1665
Error code [DXH5KA]......1666
Error code [DXH5KB]......1667
Error code [DXH6KA]......1668
Error code [DXH6KB]......1669
Error code [DXH7KA]......1670
Error code [DXH7KB]......1671
Error code [DXH8KA]......1672
Error code [DXH8KB]......1673
Error code [DXHHKA]......1674
Error code [DXHHKB]......1675
Error code [DY30MA]......1676
Error code [DY30MC]......1678
Action code [TM-1]......1680
Action code [TM-2]......1681
Action code [TM-3]......1682
Action code [TM-4]......1684
Action code [TM-5]......1686
Action code [TM-6]......1688
Action code [TM-7]......1689
Action code [TM-8]......1690
Action code [TM-9]......1691
Action code [TM-10-A]......1692
Action code [TM-10-B]......1694
Action code [TM-11]......1696
Action code [TM-12]......1698
Action code [TM-13]......1699
Action code [TM-14]......1700
Action code [TM-15]......1702
Action code [TM-16]......1704
Action code [TM-17]......1705
Action code [TM-18]......1706
Action code [TM-19]......1707
Action code [TM-20]......1708
Action code [TM-21]......1709
Action code [TM-22]......1710
Action code [TM-23]......1711
Action code [TM-24]......1712
Action code [TM-25]......1713
Action code [TM-26]......1714
Action code [TM-27]......1715
Action code [TM-28]......1716
Action code [TM-29]......1717
TROUBLESHOOTING OF TRANSMISSION CONTROL SYSTEM (TM MODE)......1575
Connector types and installation positions......1721
Connector layout drawing......1730
Work equipment control system diagram......1736
Error code [D193KA]......1739
Error code [D193KB]......1740
Error code [DB90KK]......1741
Error code [DB92KK]......1742
Error code [DB95KX]......1744
Error code [DD1ALD]......1746
Error code [DD1BLD]......1747
Error code [DFAOKM]......1748
Error code [DK59KA]......1749
Error code [DK59KY]......1750
Error code [DK59L8]......1751
Error code [DK5AKA]......1752
Error code [DK5AKY]......1753
Error code [DK5BKA]......1754
Error code [DK5BKY]......1755
Error code [DK5BL8]......1756
Error code [DK5CKA]......1757
Error code [DK5CKY]......1758
Error code [DK5DKA]......1759
Error code [DK5DKY]......1760
Error code [DK5DL8]......1761
Error code [DK5EKA]......1762
Error code [DK5EKY]......1763
Error code [DK5FKA]......1764
Error code [DK5FKY]......1765
Error code [DK5FKM]......1766
Error code [DK5FL8]......1767
Error code [DK5GKA]......1768
Error code [DK5GKY]......1769
Error code [DKAOKA]......1770
Error code [DKAOKY]......1771
Error code [DLE2LC]......1772
Error code [DLT3LC]......1773
Error code [DUM1KA]......1774
Error code [DUM1KB]......1775
Error code [DW4PKA]......1776
Error code [DW4PKB]......1777
Error code [DW4QKA]......1778
Error code [DW4QKB]......1779
Error code [DW4RKA]......1780
Error code [DW4RKB]......1781
Error code [DW4SKA]......1782
Error code [DW4SKB]......1783
Error code [DWM1KA]......1784
Error code [DWM1KB]......1785
Error code [DWN6KA]......1786
Error code [DWN6KB]......1787
Error code [DWN7KA]......1788
Error code [DWN7KB]......1789
Error code [DWN8KA]......1790
Error code [DWN8KB]......1791
Error code [DXHJKA]......1792
Error code [DXHJKB]......1793
Error code [DXHKKA]......1794
Error code [DXHKKB]......1795
Error code [DXHLKA]......1796
Error code [DXHLKB]......1797
Error code [DXHMKA]......1798
Error code [DXHMKB]......1799
Action code [WRK-1]......1800
Action code [WRK-2]......1801
Action code [WRK-3]......1802
Action code [WRK-4]......1804
Action code [WRK-5]......1806
Action code [WRK-6]......1808
Action code [WRK-7]......1810
Action code [WRK-8]......1811
Action code [WRK-9]......1812
Action code [WRK-10]......1814
Action code [WRK-11]......1816
Action code [WRK-12]......1817
Action code [WRK-13]......1818
Action code [WRK-14]......1819
Action code [WRK-15]......1820
Action code [WRK-16]......1821
Action code [WRK-17]......1822
Action code [WRK-18]......1823
Action code [WRK-19]......1824
Action code [WRK-20]......1825
Action code [WRK-21]......1826
Action code [WRK-22]......1827
Action code [WRK-23]......1828
Action code [WRK-24]......1829
Action code [WRK-25]......1830
Action code [WRK-26]......1832
Action code [WRK-27]......1834
Action code [WRK-28]......1836
TROUBLESHOOTING OF WORK EQUIPMENT CONTROL SYSTEM (WORK MODE)......1719
Connector types and installation positions......1841
Connector layout drawing......1848
Monitor system diagram......1854
Error code [2F00KM]......1858
Error code [2G42ZG]......1860
Error code [2G43ZG]......1861
Error code [AA1ANX]......1862
Error code [AB00L6]......1864
Error code [AB00MA]......1865
Error code [B@BAZG]......1866
Error code [B@BAZK]......1867
Error code [B@BCNS]......1868
Error code [B@BCZK]......1869
Error code [B@HANS]......1870
Error code [B@CENS]......1871
Error code [D5ZHL6]......1872
Error code [DA80L4]......1873
Error code [DAF3KK]......1874
Error code [DAF5KP]......1876
Error code [DAF6KP]......1878
Error code [DAFBKM]......1880
Error code [DAFSKQ]......1881
Error code [DAQSKR]......1882
Error code [DBQSKR]......1883
Error code [DB9SKR]......1884
Error code [DD15LD]......1885
Error code [DD16LD]......1886
Error code [DD17LD]......1887
Error code [DD18LD]......1888
Error code [DD1CLD]......1889
Error code [DDK3KM]......1890
Error code [DDK4KM]......1891
Error code [DDK6KM]......1892
Error code [DDS5L6]......1893
Error code [DDY0LD]......1894
Error code [DGE2KX]......1895
Error code [DGH2KX]......1896
Error code [DGT1KX]......1897
Error code [DHE4L6]......1898
Error code [DHPCKX]......1900
Error code [DHPDKX]......1902
Error Code [DKA0KX]......1903
Error code [DV00KB]......1904
Error code [DY30ME]......1906
Action code [MON-1]......1908
Action code [MON-2]......1910
Action code [MON-3]......1911
Action code [MON-4]......1912
Action code [MON-5]......1914
Action code [MON-6]......1915
Action code [MON-7]......1916
Action code [MON-8]......1917
Action code [MON-9]......1918
Action code [MON-10]......1919
Action code [MON-11]......1920
Action code [MON-12]......1921
Action code [MON-13]......1922
Action code [MON-14]......1923
Action code [MON-15]......1924
Action code [MON-16]......1925
Action code [MON-17]......1926
Action code [MON-18]......1927
Action code [MON-19]......1928
Action code [MON-20]......1929
TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE)......1839
H-1......1932
The machine does not start......1932
H-2......1934
The lock-up clutch is not released (The engine stops) (When the lock-up clutch is provided)......1934
H-3 a......1935
The travel speed is slow, the thrusting force is weak, the uphill traveling power is weak, and th.......1935
H-3 b......1937
The torque converter lock-up clutch is not let in (When the lock-up clutch is provided)......1937
H-4......1938
Shocks are large at the times of starting and shifting gear......1938
H-5......1940
Time lag is large at the times of starting and shifting gear......1940
H-6......1942
The torque converter oil temperature is high......1942
H-7......1943
The steering wheel does not turn......1943
H-8......1944
The steering wheel is heavy......1944
H-9......1945
The steering wheel fluctuates or is strongly shocked......1945
H-10......1945
The steering wheel fluctuates or is strongly shocked......1945
H-11......1945
The right and left swing radii are different......1945
H-12......1946
The brake does not work or does not work well......1946
H-13......1947
The brake is not released or is dragged......1947
H-14......1948
The brake is not released or dragged......1948
H-15......1949
The boom does not rise......1949
H-16......1950
The boom moves slowly or the boom rising force is insufficient......1950
H-17......1951
When rising, the boom comes to move slowly at specific height......1951
H-18......1951
The boom cylinder cannot hold down the bucket (The bucket rises in the air)......1951
H-19......1951
Hydraulic drifts of the boom occur often......1951
H-20......1951
The boom wobbles during operation......1951
H-21......1952
When the control lever is switched from "HOLD" to "RAISE," the boom falls temporarily......1952
H-22......1953
The bucket does not tilt back......1953
H-23......1954
The bucket moves slowly or the tilting-back force is insufficient......1954
H-24......1955
The bucket comes to operate slowly in he midst of tilting-back......1955
H-25......1955
The bucket cylinder cannot hold down the bucket......1955
H-26......1955
Hydraulic drifts of the bucket occur often......1955
H-27......1956
The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD")......1956
H-28......1956
When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily......1956
H-29......1957
The control levers of boom and bucket do not move smoothly and heavy......1957
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)......1931
Connector types and installation positions......1961
Connector layout drawing......1970
Monitor system diagram......1976
Action code [E-1]......1978
Action code [E-2]......1980
Action code [E-3]......1982
Action code [E-4]......1984
Action code [E-5-A]......1985
Action code [E-5-B]......1988
Action code [E-5-C]......1989
Action code [E-6]......1990
Action code [E-7-A]......1993
Action code [E-7-B]......1996
Action code [E-7-C]......1998
Action code [E-7-D]......1999
Action code [E-8]......2001
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)......1959
DISASSEMBLY AND ASSEMBLY......2007
Method of using manual......2009
Precautions when carrying out operation......2010
Fuel supply pump assembly......2014
Special tools......2014
Removal......2014
Installation......2016
Schematic drawings of special tools......2018
A1 Remover......2018
A1 Block......2019
A1 Bolt......2019
Nozzle holder assembly......2020
Removal......2020
Installation......2023
Nozzle tip......2025
Special tool......2025
Removal......2025
Installation......2027
Schematic drawing of special tool......2028
A3 Wrench......2028
Cylinder head assembly......2029
Special tool......2029
Removal......2029
Installation......2035
Radiator assembly......2038
Removal......2038
Installation......2040
Air aftercooler assembly......2041
Removal......2041
Installation......2041
Cooling fan drive motor......2042
Removal......2042
Installation......2042
Engine assembly......2043
Removal......2043
Installation......2049
Steering, switch pump, cooling fan drive pump assembly......2050
Removal......2050
Installation......2051
Torque converter charge, work equipment and PPC pump assembly......2052
Removal......2052
installation......2052
Torque converter, transmission assembly......2053
Removal......2053
Installation......2058
Torque converter assembly (standard specifications)......2059
Special tools......2059
Disassembly......2059
Assembly......2062
Torque converter assembly (lock-up specifications)......2065
Special tools......2065
Disassembly......2065
Assembly......2068
Transmission assembly......2073
Special tools......2073
Disassembly......2073
Assembly......2082
Schematics of special tools......2092
C1 Bracket......2092
C6, C7 Pushing tools......2092
C7 Spacer......2093
C11 Lifting tool......2093
C11 Lifting tool......2094
Transmission clutch pack assembly......2095
Special tools......2095
Disassembly......2095
Disassembly of forward-reverse clutch packs......2095
Disassembly of 1st 4th speed clutch packs......2098
Disassembly of 2nd 3rd clutch packs......2101
Assembly......2104
Assembly of forward-reverse clutch packs......2104
Assembly of 1st 4th clutch packs......2108
Assembly of 2nd 3rd clutch packs......2113
Schematic diagram of special tool......2118
C2 Push tool......2118
Parking brake assembly......2119
Special tools......2119
Disassembly......2119
Assembly......2123
Schematic drawing of special tools......2129
C4, C5 Push tool......2129
C5 Spacer......2129
C8 Push tool......2130
C9 Push tool......2130
C10 Push tool......2131
C13 Bracket......2131
Front axle assembly......2132
Disassembly......2132
Assembly......2134
Rear axle assembly......2135
Removal......2135
Installation......2138
Axle housing assembly......2140
Special tools......2140
Disassembly......2140
Assembly......2145
Schematic drawing of special tools......2151
D7 Pushing tool......2151
D7 Spacer......2151
D7 Pushing tool......2152
D9 Support......2152
D9 Support......2153
Differential assembly......2154
Special tools......2154
Disassembly......2154
Assembly......2160
Schematic drawing of special tools......2172
D1 Plate......2172
D2, D3 Push tool......2172
D3 Spacer......2173
D4 Push tool......2173
D5 Push tool......2174
Center hinge pin......2175
Special tools......2175
Removal......2175
Installation......2181
Steering valve assembly......2185
Removal......2185
Installation......2186
Travel damper assembly......2187
Removal......2187
Installation......2187
Parking brake disc......2188
Special tools......2188
Removal......2188
Installation......2190
Schematic drawing of special tools......2191
C13 Bracket......2191
Hydraulic tank......2192
Removal......2192
Installation......2193
Work equipment valve assembly......2194
Removal......2194
Installation......2195
Hydraulic cylinder assembly (steering, lift, and bucket cylinder assemblies)......2196
Special tools......2196
Disassembly......2197
Assembly......2201
Work equipment assembly......2206
Removal......2206
Installation......2209
Counterweight......2212
Removal......2212
Installation......2213
Fuel tank assembly......2214
Removal......2214
Installation......2215
Cab assembly......2216
Removal......2216
Installation......2218
Cab, floor frame assembly......2219
Removal......2219
Installation......2223
Air conditioner unit assembly......2224
Removal......2224
Installation......2227
Air conditioner compressor assembly......2228
Special tools......2228
Removal......2228
Installation......2229
APPENDIX......2231
Power train oil circuit diagram......2235
Power train oil circuit diagram......2237
Brake oil circuit diagram......2239
