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WA450-
WA480-
WHEEL LOADER
SERIAL NUMBERS
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
September 2005
Printed in USA
WA450-5L
WA480-5L
WA450-5L WA480-5L
5L
5L
A36001
A37001
Copyright 2005 Komatsu
DataKom Publishing Division
CEBM009605
and UP
00-1
f
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Summary of Contents for Komatsu GALEO WA450-5L
- Page 1 WA480-5L A37001 This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
- Page 2 FOREWORD CONTENTS CONTENTS GENERAL ............. 01-1 STRUCTURE AND FUNCTION .
- Page 3 FOREWORD The affected pages are indicated by using the following Mark Indication Action marks. It is requested that necessary actions be taken to ❍ New page to be added these pages according to the table below. ● Page to be replaced Replace Page to be deleted Discard...
- Page 4 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-73 10-106 10-139 10-172 10-74 10-107 10-140 10-173 10-75 10-108 10-141 10-174 10-76 10-109 10-142 10-175 10-77 10-110 10-143 10-176 10-78 10-111 10-144 10-177 10-79 10-112 10-145 10-178 10-80 10-113 10-146 10-179 10-81 10-114...
- Page 5 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-205 10-238 10-271 10-304 10-206 10-239 10-272 10-305 10-207 10-240 10-273 10-306 10-208 10-241 10-274 10-307 10-209 10-242 10-275 10-308 10-210 10-243 10-276 10-309 10-211 10-244 10-277 10-310 10-212 10-245 10-278 10-311 10-213 10-246...
- Page 6 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● 10-337 20-9 20-42 20-112 ● ● 10-338 20-10 20-43 20-113 ● ● 10-339 20-11 20-44 20-114 ● ● 10-340 20-12 20-45 ● ● ● 10-341 20-13 20-46 20-201 ● ●...
- Page 7 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ❍ ● ● 20-230 20-263 20-327 20-360 ● ❍ ● ● 20-231 20-264 20-328 20-361 ● ❍ ● ● 20-232 20-265 20-329 20-362 ● ❍ ● ● 20-233 20-266 20-330 20-363 ●...
- Page 8 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● ● 20-414 20-447 20-480 20-513 ● ● ● ● 20-415 20-448 20-481 20-514 ● ● ● ● 20-416 20-449 20-482 20-515 ● ● ● ● 20-417 20-450 20-483 20-516 ●...
- Page 9 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ❍ ❍ ❍ 20-546 20-618 20-651 20-684 ● ❍ ❍ ❍ 20-547 20-619 20-652 20-685 ● ❍ ❍ ❍ 20-548 20-620 20-653 20-686 ● ❍ ❍ ❍ 20-549 20-621 20-654 20-687 ●...
- Page 10 FOREWORD Mark Page Mark Page Mark Page Mark Page ❍ ❍ ● ● 20-717 20-750 20-808 20-841 ❍ ❍ ● ● 20-718 20-751 20-809 20-842 ❍ ❍ ● ● 20-719 20-752 20-810 20-843 ❍ ❍ ● ● 20-720 20-753 20-811 20-844 ❍...
- Page 11 FOREWORD Mark Page Mark Page Mark Page Mark Page ● ● ● 20-874 20-907 20-953 20-1007 ● ● ● 20-875 20-908 20-954 20-1008 ● ● ● 20-876 20-909 20-955 20-1009 ● ● ● 20-877 20-910 20-956 20-1010 ● ● ● 20-878 20-911 20-957...
- Page 12 FOREWORD Mark Page Mark Page Mark Page Mark Page ● 20-1040 30-22 30-55 30-88 ● 20-1041 30-23 30-56 30-89 ● 20-1042 30-24 30-57 30-90 ● 20-1043 30-25 30-58 30-91 ● 20-1044 30-26 30-59 30-92 ❍ 20-1045 30-27 30-60 30-93 ❍ 20-1046 30-28 30-61...
- Page 13 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-121 30-154 30-187 30-220 30-122 30-155 30-188 30-123 30-156 30-189 90-1 30-124 30-157 30-190 90-2 30-125 30-158 30-191 90-3 30-126 30-159 30-192 90-4 30-127 30-160 30-193 90-5 30-128 30-161 30-194 90-6 30-129 30-162 30-195...
- Page 14 FOREWORD Mark Page Mark Page Mark Page Mark Page 00-2-12 WA450-5L WA480-5L...
- Page 15 FOREWORD SAFETY SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose.
- Page 16 FOREWORD SAFETY When raising heavy components, use a hoist or crane. track separates suddenly, so never let anyone stand at Check that the wire rope, chains and hooks are free from either end of the track. damage. Always use lifting equipment which has ample capacity.
- Page 17 FOREWORD GENERAL GENERAL 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.
- Page 18 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL VOLUMES Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. Shop manuals are issued as a guide to carrying out repairs. SYMBOLS They are divided as follows: Chassis volume:...
- Page 19 FOREWORD HOISTING INSTRUCTIONS HOISTING INSTRUCTIONS HOISTING can result. Hooks have maximum strength at the middle portion. WARNING! Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the sym- bol.
- Page 20 FOREWORD PUSH PULL COUPLER PUSH PULL COUPLER WARNING! Before carrying out the following work, re- lease the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. WARNING! Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected.
- Page 21 FOREWORD PUSH PULL COUPLER TYPE 2 DISCONNECTION 1. Hold the mouthpiece of the tightening portion and push body c in straight until sliding prevention ring b contacts contact surface a of the hexagonal portion at the male end. 2. Hold in the condition in Step 1, and turn the lever e to the right - clockwise.
- Page 22 FOREWORD PUSH PULL COUPLER TYPE 3 DISCONNECTION 1. Hold the mouthpiece of the tightening portion and push the body c in straight until sliding prevention ring b contacts contact surface a of the hexagonal portion at the male end. 2. Hold in the condition in Step 1, and push until the cover d contacts contact surface a of the hexagonal portion at the male end.
- Page 23 FOREWORD COATING MATERIALS COATING MATERIALS ★ The recommended coating materials prescribed in the shop manuals are listed below. Category Code Part No. Quantity Container Main applications, features ● Used to prevent rubber gaskets, rubber LT-1A 790-129-9030 150 g Tube cushions and cork plugs from coming out ●...
- Page 24 FOREWORD COATING MATERIALS Category Code Part No. Quantity Container Main applications, features ● Features: Resistance to water, oil ● Used as sealant for flange surface, thread. ● Also possible to use as sealant for flanges LG-4 790-129-9020 200 g Tube with large clearance.
- Page 25 FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND ASSEMBLY. Thread diameter of bolt Width across flats 13.2 ±1.4 1.35 ±0.15 31.4 ±2.9...
- Page 26 FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF HOSE NUTS Use these torques for hose nuts. Thread diameter Width across flat Tightening torque Nominal No. 24.5 ± 4.9 2.5 ± 0.5 49 ± 19.6 5 ± 2 78.5 ± 19.6 8 ± 2 137.3 ±...
- Page 27 FOREWORD ELECTRIC WIRE CODE 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: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Copper wire Nominal num-...
- Page 28 FOREWORD CONVERSION TABLES CONVERSION TABLES METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE ●...
- Page 29 FOREWORD CONVERSION TABLES Millimeters to Inches 1 mm = 0.03937 in 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142 1.181 1.220 1.260...
- Page 30 FOREWORD CONVERSION TABLES Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661 7.925...
- Page 31 FOREWORD CONVERSION TABLES kgm to ft. lb. 1 kgm = 7.233 ft. lb. 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8 217.0 224.2...
- Page 32 FOREWORD CONVERSION TABLES kg/cm to lb/in 1 kg/cm = 14.2233lb/in 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5 426.7 440.9 455.1 469.4...
- Page 33 FOREWORD CONVERSION TABLES Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
- Page 34 FOREWORD CONVERSION TABLES MEMORANDA 00-22 WA450-5L WA480-5L...
- Page 35 GENERAL SPECIFICATIONS ............01-2 WEIGHT TABLE .
- Page 36 GENERAL SPECIFICATIONS SPECIFICATIONS Machine model WA450-5L WA480-5L Serial number A36001 and up A37001 and up Operating weight 21,955 kg (48,402 lb) 24,145 kg (53,231 lb) Distribution (front) 13,360 kg (29,454 lb) 13,360 kg (29,454 lb) Distribution (rear) 15,450 kg (34,061 lb) 15,450 kg (34,061 lb) Bucket capacity (piled) 4.2 m³...
- Page 37 WA480-5L Serial number A36001 and up A37001 and up Model Komatsu SAA6D125E-3 diesel engine Type 4-cycle, water cooled, in-line, 6-cylinder, direct injection with turbocharger, air to air aftercooler No. of cylinders - bore x stroke 6 - 125 mm (4.9 in) x 150 mm (5.9 in) Piston displacement 11 L (673 in³)
- Page 38 GENERAL SPECIFICATIONS Machine model WA450-5L WA480-5L Serial number A36001 and up A37001 and up Type Articulated steering Structure Fully hydraulic power steering Torque converter pump Type Gear type Delivery 251 liters per min. Steering pump Type Gear type Delivery 146 liters per min. Hydraulic pump Type Gear type...
- Page 39 GENERAL SPECIFICATIONS Machine model WA450-5L WA480 Serial number A36001 and up A37001 and up Work equipment control valve 2 or 3-spool type Type 210 kgf/cm (14.2 lbf/in Set pressure Travel control valve 2 or 3-spool type Type 210 kgf/cm (14.2 lbf/in Set pressure Cooling fan motor Type...
- Page 40 GENERAL WEIGHT TABLE WEIGHT TABLE ★ This weight table is a guide for use when transporting or handling components. Unit: kg (lb) Machine model WA450-5L WA480-5L Serial No. A36001 and up A37001 and up Engine (without coolant and oil) 1,200 (2646) 1,200 (2646) Radiator (without coolant) 83 (183)
- Page 41 It is not our policy to approve fuel, coolant and lubricants or to guarantee performance in service. The responsibility for the quality of the fuel, coolant and lubricant must remain with the supplier. When in doubt, consult your Komatsu distributor. The following table shows specified fuel, coolant and lubricants recommended for this machine.
- Page 42 Total amount of oil including oil for components and piping. Refill Capacity: Amount of oil needed to refill system during normal maintenance. Other equipment may be necessary when operating the machine at temperatures below -20°C (-4°F). Consult your Komatsu distributor for your specific needs.
- Page 43 STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER ..........10-9 SPECIFICATIONS .
- Page 44 STRUCTURE AND FUNCTION TABLE OF CONTENTS ECMV FOR SPEED CLUTCH ......... 10-47 ECMV FOR LOCK UP CLUTCH .
- Page 45 STRUCTURE AND FUNCTION TABLE OF CONTENTS OPERATION OF STEERING VALVE ........10-89 NEUTRAL .
- Page 46 STRUCTURE AND FUNCTION TABLE OF CONTENTS OUTLINE ............10-126 SOLENOID VALVE .
- Page 47 STRUCTURE AND FUNCTION TABLE OF CONTENTS BOOM SPOOL RAISE POSITION ........10-154 OPERATION .
- Page 48 STRUCTURE AND FUNCTION TABLE OF CONTENTS BUCKET TILT ........... . 10-191 WORK EQUIPMENT CYLINDER .
- Page 49 STRUCTURE AND FUNCTION TABLE OF CONTENTS STARTING CONDITIONS FOR SEMI AUTO DIG ..... . . 10-324 STARTING SEMI AUTO DIG ........10-324 TERMINATION OF SEMI AUTO DIG .
- Page 50 STRUCTURE AND FUNCTION TABLE OF CONTENTS SENSORS ............. . 10-352 ENGINE AND MACHINE SPEED SENSOR .
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