Komatsu WA470-5, WA470-6, WA480-5, WA480-6 Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA470WA480.zip

A full factory-level service and repair guide, complete with electrical wiring diagrams, for the Komatsu WA470 and WA480 Wheel Loaders — packed with everything needed to service, troubleshoot, fix, and rebuild these machines the way a professional technician would.

Inside the Komatsu WA470 / WA480 Wheel Loader workshop service and repair manual you'll find:

* 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: 9,846 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

CEAM009103 - Wheel Loader WA480-6 Operation & Maintenance Manual.pdf

CEAM023602 - Wheel Loader WA480-6 Operation & Maintenance Manual.pdf

CEBM007102 - Wheel Loader WA470-6, WA480-6 Shop Manual.pdf

CEBM023002 - Wheel Loader WA470-6, WA480-6 Shop Manual.pdf

SEBM024414 - Wheel Loader WA470-5, WA480-5 Shop Manual

SEN00783-07 - Wheel Loader WA470-6, WA480-6 Shop Manual.pdf

SEN04409-06 - Wheel Loader WA470-6, WA480-6 Shop Manual.pdf

VEBM946101 - Wheel Loader WA470-6, WA480-6 Shop Manual.pdf

MAIN SECTIONS

CEAM009103 - Wheel Loader WA480-6 Operation & Maintenance Manual......2

CEAM009103......2

FOREWORD......5

SAFETY INFORMATION......6

APPROVED AND NON-APPROVED USES......7

Approved Functions......7

Non-Approved Functions......7

VISIBILITY STANDARD......8

Visibility in Immediate Area......8

12-M Radius Visibility......8

Front/Rear, Left/Right Directions of Machine......9

Machine Serial Number/Product Identification Number (PIN)......10

Engine Serial Number, EPA Regulations......10

Position of Service Meter......11

Serial Numbers and Dealer Information......12

TABLE OF CONTENTS......13

SAFETY AND WARNING DECALS......27

Location of Safety Decals......27

Safety Labels......28

GENERAL SAFETY RULES AND PRECAUTIONS......35

General Safety Rules......35

General Safety at Job Site......36

Working on Loose Ground......36

Safety Features......37

Personal Protective Equipment......37

Keep Machine Clean......37

Fire and Explosion Prevention......38

Fire Caused by Fuel, Oil, Antifreeze, or Window Washer Fluid......38

Fire Caused by Accumulation of Flammable Material......38

Fire Coming from Electric Wiring......39

Fire Coming from Hydraulic Line......39

Windshield Washer Fluid......39

Action If Fire Occurs......39

Fire Extinguisher and First Aid Kit......39

Fire Prevention and Suppression......40

Fire Prevention Steps......40

Fixed Fire Detection System......40

Fixed Fire Suppression System......40

Fire Prevention Procedures......40

Precautions When Cleaning Cab Glass......41

Dust Hazards Precautions......42

Keep Operator's Cab Clean......42

Unauthorized Modifications......42

Leaving Operators Compartment......43

Mounting and Dismounting......44

Crush or Pinch Point Dangers......44

Inside Operators Compartment......45

Precautions When Using ROPS......45

Emergency Escape From Operator's Cab......45

PRECAUTIONS BEFORE STARTING OPERATIONS......46

Pre-Operational Checks......46

Starting Your Work Operations......46

Seat Belt Inspection......47

Work Site Hazards......48

Avoiding Dangerous Situations......49

Working Clearances......51

Operating on Snow or Icy Surfaces......51

Precautions in Cold Areas......52

Asbestos Hazard Alert......52

RULES FOR ROAD TRAVEL......53

Traveling in Reverse......53

Travel on Slopes......54

Parking the Machine......55

PRECAUTIONS DURING MAINTENANCE OPERATIONS......56

Warning Tags......56

Equipment Storage......56

Working Under the Machine......57

Using Drop Lamps......57

Keeping the Machine Clean......57

HANDLING TIRES......58

Precautions When Storing Tires......58

PERFORMING GENERAL MAINTENANCE PROCEDURES......59

Running the Engine During Maintenance......61

Proper Tools......62

Engine System High-Voltage......62

Welding, Grinding or Cutting......63

When Using Hammer......63

Refueling the Machine......64

Cooling System Precautions......64

Battery Precautions......65

Starting the Machine......66

High-Pressure Hoses......66

Safety Handling High-Pressure Hoses......66

Precaution For High Fuel Pressure......67

High Temperature Areas......67

Disposal of Waste Materials......67

Inflating Tires......68

Accumulator......68

Critical Parts......68

TRANSPORTING THE MACHINE......69

Loading and Unloading a Trailer......69

Loading Machine......70

TOWING THE MACHINE......71

GENERAL VIEW......75

General View Of Machine......75

General View of Controls and Gauges......76

Machine Monitor......77

Switch Panel......79

EXPLANATION OF COMPONENTS......80

Machine Monitor......80

Types of Warnings......81

Emergency Stop......81

Caution......81

Mistaken Operation......81

Inspection and Maintenance......81

Central Warning Lamp......81

Character Display Portion......82

Service Meter......82

Action Code Display......83

Failure Code Display......84

Filter, Oil Replacement Time Display......85

Emergency Stop Items......87

Brake Oil Pressure Caution Lamp......88

Engine Oil Pressure Caution Lamp......88

Battery Charge Circuit Caution Lamp......89

Steering Oil Pressure Caution Lamp (if equipped)......89

Caution Items......90

Brake Oil Temperature Caution Lamp......91

Torque Converter Oil Temperature Caution Lamp......91

Engine Coolant Temperature Caution Lamp......92

Hydraulic Oil Temperature Caution Lamp......92

Fuel Level Caution Lamp......92

Inspection and Maintenance Items......93

Radiator Coolant Level Caution Lamp......93

Engine Oil Level Caution Lamp......94

Battery Electrolyte Level Caution Lamp......94

Maintenance Caution Lamp......94

Air Cleaner Clogging Caution Lamp......95

Water Separator Caution Lamp......95

Transmission Oil Filter Clogging Caution Lamp......95

Pilot Display Portion......96

Parking Brake Pilot Lamp......97

Cooling Fan Reverse Rotation Pilot Lamp......97

Emergency Steering Pilot Lamp......97

Power Mode Pilot Lamp (P Mode)......98

Preheating Pilot Lamp......98

Semi-Auto Digging Pilot Lamp......98

Auto-Greasing Pilot Lamp......98

Joystick Pilot Lamp (if equipped)......98

Directional Selector Pilot Lamp......98

Economy Operation Display Lamp......99

Shift Indicator......99

Auto-Shift Pilot Lamp......99

Torque Converter Lockup Pilot Light (if equipped)......99

Shift Hold Pilot Lamp......100

Shift Lever Position Pilot Lamp......100

Turn Signal Pilot Lamp......100

Head Lamp High-Beam Pilot Lamp......100

Meter Display Portion......101

Torque Converter Oil Temperature Gauge......101

Engine Coolant Temperature Gauge......102

Hydraulic Temperature Gauge......102

Fuel Gauge......102

Speedometer......103

Meter Display Pilot Lamp......103

OTHER FUNCTIONS OF MACHINE MONITOR......104

Overall Menu......104

Displaying Odometer......105

Resetting Filter, Oil Replacement Time......105

Entering Telephone Number......106

Selecting Language......107

Adjusting Monitor Brightness......109

Switching Travel Speed/Engine Speed Display......111

Switching Travel Speed/Engine Speed Display/Non-Display......112

SWITCHES AND CONTROLS......113

General View......113

Ignition Switch......114

Power Mode Selector Switch......115

Transmission Shift Mode Selector Switch......115

Transmission Cutoff Switch......116

Transmission Cutoff Set Switch......116

Lamp Switch......117

Turn Signal Lever......117

Dimmer Switch......117

Horn Button......118

Hazard Lamp Switch......118

Parking Brake Switch......119

Front Working Lamp Switch......119

Rear Working Lamp Switch......120

Machine Monitor Mode Selector Switch 1......120

Machine Monitor Mode Selector Switch 2......120

Kickdown Switch......121

Hold Switch......122

Front Wiper Switch......122

Rear Wiper Switch......122

Cigarette Lighter......123

Room Lamp Switch......123

Rear Heated Wire Glass Switch......123

ECSS Switch......124

Emergency Steering Switch (if equipped)......124

Cooling Fan Reverse Rotation Switch (If Equipped)......125

Cooling Fan Auto-Reverse Rotation Switch (If Equipped)......125

Conditions for Switching Fan Rotation......126

Torque Converter Lockup Switch (if equipped)......128

CONTROL LEVERS, PEDALS......129

General View......129

Gearshift Lever......129

Manual Shift......129

Automatic Shift......130

Directional Lever......131

Gearshift Lever Stopper......131

Work Equipment Lock Lever......132

Bucket Control Lever......132

Lift Arm Control Lever......133

Brake Pedals......134

Accelerator Pedal......134

SECURITY LOCKS AND SAFETY FEATURES......135

Steering Tilt Lock Lever......135

Frame Lock Bar......135

Cap with Lock......136

Fuel Tank Filler Port Cap......136

Back-Up Alarm......136

MACHINE FEATURES......137

Towing Pin......137

Grease Pump......137

Cab Door......138

Emergency Escape Right Door......138

Left Cab Door, Door Open Lock......140

Left Cab Door, Knob......141

Left Cab Door, Handle......141

Left Cab Sliding Window (Lock Release Knob)......141

Cab Wiper......142

ELECTRICAL......143

Power Outlet......143

Fuses......143

Fuse Capacity and Name of Circuit......144

Slow-Blow Fuse......145

WORK OPERATIONS......146

Walk-Around Check......146

Precautions Before Starting Work Operations......146

Check Before Starting Engine......150

Check Machine Monitor......150

Check Coolant Level, Add Coolant......151

Check Oil Level in Engine Oil Pan, Add Oil......152

Check Water Separator, Drain Water......153

Check Air Cleaner......154

Electric Air Cleaner Clogging Sensor......154

Check Fuel Level, Add Fuel......155

Check Electric Wiring......156

Check Inflation Pressure of Tires......156

Check Condition of Window Washer Spray......156

Check Wiping Efficiency of Wiper......156

Check Horn......156

Check Defroster Function......157

Check Locks......157

Check Emergency Exit......157

Adjustments......159

Adjusting Seat......159

Removing or Installing Headrest......161

Adjusting Seat Belt......162

Adjusting Lever Stand......163

Adjusting Mirrors......164

Final Checks Before Starting Engine......165

Starting Engine......167

Normal Starting......167

Starting in Cold Weather......169

Automatic Warming-Up Operation......170

Operations and Checks After Starting Engine......171

Checks After Starting Engine......171

Breaking in the Machine......172

Normal Operation......172

Stopping Engine......174

Check After Stopping Engine......174

Moving the Machine (Directional, Speed), Stopping the Machine......175

Moving the Machine......175

Changing Gear Speed......178

Changing Direction......179

Automatic Shift......180

Stopping the Machine......181

Transmission Cut-Off Function......182

Adjusting Transmission Cut-Off Position......183

Canceling Transmission Cut-Off Position......183

Stopping When Transmission Cut-Off Is On......183

Turning......184

Emergency Steering (if equipped)......185

Emergency Steering Self-Check Function......186

Operation of Work Equipment......187