SEBMU4210106 SO IMLAVINTOA\ LL KOMATSU WA470-1 MACHINE MODEL = SERIAL No. WA470-1 10001 and up © This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. © WA470-1 mount the $60125-1 engine, For details of the eingine, see the 6D125-1 Series Engine Shop Manual.CONTENTS 10 ENGINE 12 13 14 TESTING AND ADJUSTINGIN DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD 20 POWER TRAIN 21 22 23 24 ‘STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD 40 STEERING SYSTEM a 42 43 44 STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD - 50 BRAKE AND AIR SYSTEM 51 52 53 54 STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD 60 WORK EQUIPMENT SYSTEM 61 62 63 64 80 ELECTRIC AND ELECTRONIC SYSTEM 81 82 83 ‘STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD STRUCTURE AND FUNCTION TESTING AND ADJUSTING DISASSEMBLY AND ASSEMBLY 90 OTHERS a 93 97 00-2 LOGGING SPECIFICATIONS DISASSEMBLY AND ASSEMBLY GEAR PUMP No. of page 12-4 13-1 14-1 2 2A 2 22-4 23-1 2h-1 ait 42-4 we 43-1 441 61-1 52-1 -. 53-1 541 . 61-1 62-1 63-1 64-1 81-1 82-1 83-1 a4 93-1 97-1 WaA470-1LIST OF REVISED PAGES ‘The affected pages are indicated by the use of the following marks. It is requested that necessary actions be Mark Indication ‘Action required ‘taken to these pages according to the table below. © | Page to be newly added Add © | Page to be replaced Replace (}] Page to be detetes Discard Pages having no marks are those previously revised or made additions. 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a7 © s.51 @ see sitet 2 53.8 + vas © | + ose ® 6137 5119 53.8 sas @ | + sre © 6138 5120 + S10 8 saa10 @ a7 @ e199 sa @ | * st og | © sso © ae @ so) S122 «sua g | + ssa © oa @ or @ 5120 snag ssaa13 © aor © oar 5124 + sna sass @ so @ ora sua so O sa @ eras 53.12 995 @ 12 @ sar 3 sis D 08D. 3 @ 5223 514 93.37 euiss @ a1 ¢ 52.3 53418 a en2 @ a2 9 524 sas D 508) one 8 aa 9 oe 5007 40D ous 2 a4 @ 52.6 se sar D e116 os 9 a7 3 | # Sater 6 5042 ear ae @ 52:8 sis2 @ | + sa © ene a7 ® Oo ee ies) 6 |e cray © 619 as @ 52103 sea @ soa srs @ ee 521013 suet e922 e210 sana 52.20 e120 @ en 3 52.12 so21 mer 6121 e223 5213 5022 st? sa @ ea e214 59.23 5a 3 22 @ ea 8 5215 5226 sa @ a2 @ eos 3 e216 ao 4 565 6123 21s 5217 326 a6 @ e412 e286 e218 5327 a) e132 @ eo 5219 cy 8 @ om @ e218 5220 os ® st 8 61.25 ene 9 52.0 5410 61.26 62204 soa sent 6127 6221 1 t 5392 61.28 2 8 2G $3.33 61.29 WaAa70-1LIST OF REVISED PAGES we ron SSE rete Engst] now roe Tesh] ek tae] a aa as aa @ 63-227, 64.20 = B19 ae F ® 28 © oD e120 2 eo 2 . ® 3229 © 64.22 @ 8121 7 8210 a 6-32 € 63.2210 © 64-23 ®@ 81-22 ® 8241 a 3-33 © 63-23 81-23 2 8212 z 35 © 63241 @ and a 81-25 @ 8214 36 @ 63-25 * 83 e 81-26 2 8215 ® ° 63.37 63-26 e 65 ® 81-27 z 8216 2 4 63.27 - 36 © aD « enr © 65 63-28 2° 81-61 © © 8130 ® © 8218 ® 6.6 63-29 ® ° 862 © 813 2 8219 a 63. 64 63.30 © 2 863 © © 8132 ® 82:20 a 63-62 63:31 oO * 864 © 8133 2 8220-4 ¢ 63.7 a 63.32 ® 2° 365 © 8134 2 82202 2 e741 @ 63:33 ® © 8-68 © 8135 82203 2 72 @ © 6334 © 8693 © © 8136 ° 982204 ® ae co 6 | eee ce _— « os 6 cao | wen « fee ume & ae sar See e tn 63-12 @ ars 8141 82-23 3 a ol as aa = s on G eS ee | 6 oe oo aa el a. G [2 [eS ¢ Seo es el ae = cs ss 63.17 ® 648 2 B52 2 82.28 - ae ee | ee Se | ee 63.19 64-10 S 81-16-41 2 © B22 © 82-30 = 63-20 6411 2 81-16-2 2 82-24 Z 8231 3 oa ee | ae ol mag eee | ee | ee 63222 @ 6416 2 B66 2 82-4 82.35 % ena @ ear? er187 2 82.5 9236 ‘WA470-1 00-2-5LIST OF REVISED PAGES mark Page TE Of| mark Page TIME! | mark Page Mark Page Time ot! mark Page ne Or e383 s24398 3 82-76 aus 2 7 ® e239 e24a39 3 82.78 e210 oe e403 224340 3 279 aan 3 @ ana e24aa1 3 82 80 ar) s10 8) e242 e24342 3 22-81 e213 ao e243 243433 a2 82 ena 2 e243.2 3 e24g4s 3 82-83 = 2212 © 13 ® © e243 6 6243453 82-64 + e212 © a4 9243.4 3 e24348 3 22. 85 se 6 a5 ® 92435 3 2243473 22. 86 22.128 a8 ® + eae 5 om 2.87 22.129 9243-7 3 9245 82. 88 82.130 a243-8 3 e247 82. 90 e231 a1 a243-9 3 9248 82-91 e232 2 0 a2asi0 3 e249 82. 92 82433 e2aaa1 3 2250 82 93, e2ase e24gi2 3 2251 82.94 82435 97.001 a24343 3 0252 82. 95 © 62136 97.002 624316 3 8253 82 96 e237 97.003 e24345 3 e254 22.97 824138, 97-004 824316 3 9255 22. 98 e239 97-005 824347 3 9258 a2. 99 82.140 97.006 224318 3 9257 22-100 e241 97.007 624319 3 8258 e201 e2142 97-008 924320 3 9259 e201 s2143 97.101 224321 3 8260 82102 2.144 97.102 e24322 3 e261 | e203 82145, 97.103 243233 82-62 82.08 e246 97-108 9243242 82. 69 624105 e2sa7 97.105, 9243253 8264 824106 e248 97.106 924326 3 62. 65 2407 e249 97.107 924327 3 82. 66 © e2109 6 92.150 97108, 924328 3 22.67 e210 3 97.108 9243293 82-68 - an 6 a1 924390 3 22-69 e223 a2 oO e24331 3 8270 e233 oraz 224333 3 62.71 an 4 | 2 1 © o7ai3 s2aasa F 82.72 aus 3 | 6 2 © ora 2433s 3 82.73 e2ne 3 4 971s 224336 3 a2. 74 e273 rs © 97116 2243374 2.78 ee 3 ore oy 00-2-6 WA470-1 ©A\ IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe methods of operation. Some of these operations re- quire the use of tools specially designed by Komatsu for the purpose. To prevent injury to workers, the symbols /\, and as are used to mark safety pre- cautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation, A\ SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1, Before carrying out any gr read all the precautions given on the decals which are fixed to the machine ing or repairs, 2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing « Always wear safety glasses when hitting parts with a hammer. ¢ Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work, 4. When carrying out any operation with two ‘or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. 6.Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking, Never smoke while working. PREPARATIONS FOR WORK 7.Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving, 8.Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them, 9.When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders ‘or steps when getting on or off the machine, Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 00-3PRECAUTIONS DURING WORK 11, When removing the oil filer cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before car- rying out any work on the oil or water circuits. 13. Before starting work, remove the leads from. the battery. Always remove the lead from the negative (—) terminal first. 14,When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under in- ternal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil fon the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts. 00-4 19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. ‘© When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the ma- chine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21. When assembiing or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD: This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections. STRUCTURE AND FUNCTION This 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. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. AS: This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE ns contained in this shop manual are subject to change at any 1e and without any advance notice. Contact your KOMATSU distributor for the latest information. 00-5HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one volume to cover all models Electrical volume Attachments volume ‘These various volumes are designed to avoid du- plicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up- to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume) 21-3 Unit number (2. Power train) Item number (1. Structure and Function) Consecutive page number for each item, Example 2 (Engine volume): 12-410 Unit number (1. Engine tem number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4) 3. Additional pages: Additional pages are indicated by a hyphen () and number after the page number. File as in the example. 00-6 REVISED EDITION MARK (O@@-~-) When @ manual is revised, an edition mark is recorded on the bottom outside corner of the pages. REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol | Item Remarks Special safety precautions are A a work, Safety Extra special safety precautions are necessary when performing the work because itis under internal pressure. ‘Special technical precautions or other precautions for & | Caution | preserving standards are necessary when performing the work, (Weight of parts or systems. Caution necessary when Weight |selecting hoisting wire, or when working posture is important, ete. Places that require special attention for the tightening torque during assembly. Tighten- ing torque| Places to be coated with Coat Places where oil, water or fuel i, water | must be added, and the [capacity. Places where oil or water must Drain | be drained, and quantity to be drained.HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS AN Heavy parts (25 kg or more) must be lifted with hoist etc, In the Disassembly and As- sembly section, every part weighing 25 kg, or more is indicated clearly with the symbol r= 1. If @ part cannot be smoothly removed from the machine by hoisting, the following checks should be made: © Check for removal of all bolts fastening the part to the relative parts. © Check for existence of another part causing interference with the part to be removed. 2. Wire ropes 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "2" or “S” twist ropes without galvanizing) Rope diameter (mm) | Allowable toad (tons) 10 1.0 112 14 125 16 14 22 16 28 18 36 20 44 224 56 30 100 40 18.0 50 280 60 400 The allowable load value is estimated to be ‘one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, land a serious accident can result. Hooks have ‘maximum strength at the middle portion. 100% = 58% 79% «= T1%—G Fs006e 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. AN Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not siing @ heavy ivad will ropes forming a wide hanging angle from the hook When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the vatiation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°, g 9 g } from = i 30 a a0 o£ Liteing angle : a s0085STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE 1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS ‘The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of “Disassembly and Assembly” weeddaneter | width a of bolt across flat mm) (eam) = kgm | Nm 6 10 1.354015 13.2414 8 13 3.2+03 31.4429 10 7 67407 | 65.7468 12 19 115410 | 112+98 14 22 180420 177#19 16 24 28543 27929 18 27 3924 38339 20 30 5626 549+58 22 32 76=8 745+78 24 38 945+10 927=98 27 a 135415 1320140 30 46 17820 1720490 33 50 22525 2210240 36 55 280+30 2750290 39 60 335435 3280+340 This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are to be used, or which require tightening to otherwise specified torque, * Nm (newton meter): 1Nm & 0.1 kgm 2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter Width Tightening torque ‘of bolt across flats (mm) (om) kgm Nm 10 14 67407 65.7+68 12 7 15+1 | 112298 16 22 28543 27929, 1 00-8STANDARD TIGHTENING TORQUE 3. TIGHTENING TORQUE FOR NUTS OF FLARED Use these torques for nut part of flared. Fs0068 Thread diameter | Width across flats Tightening torque of nut part Ofmut part | pe (mmm) (mm) kgm Nm 4 19 25405 24.5449 18 24 5x2 49+196 22 27 ax2 785+196 24 32 1443 13734294 30 36 18+3 176.5+29.4 33 4 205 196.1249 36 46 2545 245.2+49 42 55 3025 294.2+49 COATING MATERIALS The recommended coating materials prescribed in Komatsu Shop Manuals are listed below. Nomenciatire Komatsu code ‘Applications uaa Used to appiy rubber pads, uber gaskets and cork plus. a nonmetal bars whe 9 fast song eas needed Adhesives a ura Preventing bolt, nuts and plas from loosening ana ieaking ok = Provides an aright, elgctncaly insulating sea 3 Usedtr alumna sraces ‘Used with gaskets ad packings t inrease sealing effect. Hest-resistnt gasket for precombustion chambers and exhavst piping. Ligue gaset {Used by eet on mounting surfaces on the fina drive and transmission cases ioe [Thveknoss after ughtening 0.07 ~ 0.08 mm a (Used by toot to seal grease fitings, tapered screw fittings and tapered screw i titiogs in hydraulic eveuts of less ton 90 mm in ameter Tanitaction compound fiprscet nets ae [Applic to bearings and taner shafts to facilitate pressing and to rmolycenum cilide) preveat sticking, burning ousting. Grease i “Applied to bearings, sliding pars and ol seals for lubrication, rust {Ui greased cu prevention and foeitation of assembling work. Vaseline — Used for protecting battery electrode terminals from corrosion *LT-28 also called LOCTITE inthe shop manuals 00-9ELECTRIC WIRE CODE (aeeat TH ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: O5WB indicates a cable having a nominal number O5 and white coating with black stripe, CLASSIFICATION BY THICKNESS Copper wire Nominal i cable. | Current rating Applicable ckcuit mer Number | Oa ofstrands | Cross secton | Imm a Sande ir imo or " 032 oss 24 2 Starting, lighting, signal ete 02 26 032 208 34 20 Lighting, signal ot. os 65 sz 523 46 37 Charging and signs! 15 24 os 1336 10 59 Starting (low plug) 40 88 080 4273 118 135 ‘Starting 60 127 080 384 136 178 Starting 100 27 o80 109.1 176 230 Starting CLASSIFICATION BY COLOR AND CODE : creute Pronty a Staring | Chorging Lanting Signal Instrument omer Cisesstieator Code 8 w ® © Y v Color ‘lack Wate ea Yetow Bie cose ew wr aw ow YR ww 2 = Cor | Backs White | Whte&Aed | Rea&Wnite |Green& white | Yellow a Rea | Blue & White cose By we Re oF va iF a ‘color | Black & Yetow | Whitew Block | Rede Black | Green& Red |Velow& Black | Blu0a Red Code BR we RY ey Ye Wy 4 : Color | Bleck &Red | WhteSaiue | Red Vetlow |Green& Yellow |velow& Green | Blue & Yellow Code = wy RG 8 ve 1B 5 Color = |White &vetiow | Rea& Green [Green a Black | Yellow a Bive | Blue & Black Code = we FL ce yw 6 Color = ‘white & Green | Red&siue | Greane Bue [yotiow & White 00-10GENERAL WEIGHT TABLE AX This weight table is a guide for use when transporting or handling components, WEIGHT TABLE Unit: kg Machine model WA470-1 Serial No. 10001 — 20000 20001 and up Engine assembly Radiator assembly Torque converter assembly Transmission assembly Damper Upper drive shaft Center drive shaft Front drive shaft Rear drive shaft Front axle assembly Rear axle assembly Front differential assembly Rear dif sembly Planetary carrier assembly (1 piece) Planetary hub assembly (1 piece} Axle pivot (Rear axle) Wheel (1 piece) Tire (1 piece) Steering valve Steering cylinder (1 piece) Brake (1 piece) Hydraulic tank Hydraulic pump Switch * POC pump Switch * PPC pump, Steering pump POC valve PPC valve Main control valve 1,020 165 195 770 85 10 30 45 30 1,540 1,500 255 238 90 60 70/85 218 335 55 40 110 250 20 12 90 1,020 165 195 770 85 15 30 45 30 1,492 1,443 285 235 90 60 70/85 218 335 24 38 128 314 20 12 13 35 90 WA470-1 00-11GENERAL WEIGHT TABLE Unit: kg Machine model waa7o-1 SerialNo 10001 — 20000 20001 end up Lifteyinder (1 piece) 210 190 Dump eviner 230 220 Engine hood 65 a1 Front frame 1.580 1.749 Rear frame 1.375 1423 Bucket ink 75 80 Titever 330 440 Litt am bth bushing) 1,360 1375 Bucket with teth) 1.760 1,840 Counterweight 870 1,550 Fuel tenk 270 240 Battery (1 piece) 45 a7 Operator's seat 40 40 Floor plate 100 99 00-12 waa7o-1 @