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Komatsu A45001 Shop Manual
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Komatsu A45001 Shop Manual

Komatsu A45001 Shop Manual

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WA470-
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
recommended that customers contact their distributor for information on the latest revision.
June 2010
Printed in USA
WA470-6 A45001 to A45999
WA480-6 A47001 to A47999
WA470/480-6
6
6
Copyright 2010 Komatsu
DataKom Publishing Division
CEBM007102
00-1
c

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Summary of Contents for Komatsu A45001

  • Page 1 SERIAL NUMBERS WA480-6 A47001 to A47999 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, FUNCTION AND MAINTENANCE STANDARD .
  • 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 Mark...
  • Page 4 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-200 24 10-200 57 10-300 15 10-300 48 10-200 25 10-200 58 10-300 16 10-300 49 10-200 26 10-200 59 10-300 17 10-300 50 10-200 27 10-200 60 10-300 18 10-300 51 10-200 28 10-200 61 10-300 19...
  • Page 5 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-400 28 10-601 21 10-601 54 10-700 7 10-400 29 10-601 22 10-601 55 10-700 8 10-400 30 10-601 23 10-601 56 10-700 9 10-601 24 10-601 57 10-700 10 10-500 1 10-601 25 10-601 58 10-700 11...
  • Page 6 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-901 2 10-901 35 10-902 29 10-903 9 10-901 3 10-901 36 10-902 30 10-903 10 10-901 4 10-901 37 10-902 31 10-903 11 10-901 5 10-901 38 10-902 32 10-903 12 10-901 6 10-902 33 10-903 13...
  • Page 7 FOREWORD Mark Page Mark Page Mark Page Mark Page 20-100 9 30-101 29 30-101 62 30-102 24 20-100 10 30-101 30 30-101 63 30-102 25 20-100 11 30-101 31 30-101 64 30-102 26 20-100 12 30-101 32 30-101 65 30-102 27 30-101 33 30-101 66 30-102 28...
  • Page 8 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-103 6 30-103 39 30-103 72 40-200 13 30-103 7 30-103 40 40-200 14 30-103 8 30-103 41 40-100 1 40-200 15 30-103 9 30-103 42 40-100 2 40-200 16 30-103 10 30-103 43 40-100 3 40-200 17...
  • Page 9 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-200 46 40-301 28 40-302 24 40-302 57 40-200 47 40-301 29 40-302 25 40-302 58 40-200 48 40-301 30 40-302 26 40-302 59 40-200 49 40-301 31 40-302 27 40-302 60 40-200 50 40-301 32 40-302 28...
  • Page 10 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-303 29 40-303 62 40-304 30 40-304 63 40-303 30 40-303 63 40-304 31 40-304 64 40-303 31 40-303 64 40-304 32 40-304 65 40-303 32 40-304 33 40-304 66 40-303 33 40-304 1 40-304 34 40-303 34...
  • Page 11 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-305 29 40-305 62 40-306 30 40-307 6 40-305 30 40-305 63 40-306 31 40-307 7 40-305 31 40-305 64 40-306 32 40-307 8 40-305 32 40-306 33 40-307 9 40-305 33 40-306 1 40-306 34 40-307 10...
  • Page 12 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-307 39 40-308 29 40-309 7 40-309 40 40-307 40 40-308 30 40-309 8 40-309 41 40-307 41 40-308 31 40-309 9 40-309 42 40-307 42 40-308 32 40-309 10 40-309 43 40-308 33 40-309 11 40-309 44...
  • Page 13 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-310 12 40-310 45 40-400 21 40-400 54 40-310 13 40-310 46 40-400 22 40-400 55 40-310 14 40-310 47 40-400 23 40-400 56 40-310 15 40-310 48 40-400 24 40-400 57 40-310 16 40-310 49 40-400 25...
  • Page 14 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-400 87 40-500 23 40-600 13 50-100 17 40-400 88 40-500 24 40-600 14 50-100 18 40-400 89 40-500 25 40-600 15 50-100 19 40-400 90 40-500 26 40-600 16 50-100 20 40-400 91 40-500 27 40-600 17...
  • Page 15 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-200 15 50-200 48 50-301 28 50-301 61 50-200 16 50-200 49 50-301 29 50-301 62 50-200 17 50-200 50 50-301 30 50-301 63 50-200 18 50-200 51 50-301 31 50-301 64 50-200 19 50-200 52 50-301 32...
  • Page 16 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-302 13 50-600 20 50-800 23 50-302 14 50-500 1 50-600 21 50-800 24 50-302 15 50-500 2 50-600 22 50-800 25 50-302 16 50-500 3 50-800 26 50-302 17 50-500 4 50-700 1 50-800 27 50-302 18...
  • Page 17 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-800 56 00-2-19 00-24 10-5 50-800 57 00-2-20 00-25 10-6 50-800 58 00-2-21 00-26 10-7 50-800 59 00-2-22 00-27 10-8 50-800 60 00-2-23 00-28 10-9 00-2-24 00-29 10-10 50-900 1 00-2-25 00-30 10-11 50-900 2...
  • Page 18 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-38 10-71 10-104 10-137 10-39 10-72 10-105 10-138 10-40 10-73 10-106 10-139 10-41 10-74 10-107 10-140 10-42 10-75 10-108 10-141 10-43 10-76 10-109 10-142 10-44 10-77 10-110 10-143 10-45 10-78 10-111 10-144 10-46 10-79...
  • Page 19 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-170 10-203 10-236 10-269 10-171 10-204 10-237 10-270 10-172 10-205 10-238 10-271 10-173 10-206 10-239 10-272 10-174 10-207 10-240 10-273 10-175 10-208 10-241 10-274 10-176 10-209 10-242 10-275 10-177 10-210 10-243 10-276 10-178 10-211...
  • Page 20 FOREWORD Mark Page Mark Page Mark Page Mark Page 10-302 10-335 10-368 30-9 10-303 10-336 10-369 30-10 10-304 10-337 10-370 30-11 10-305 10-338 10-371 30-12 10-306 10-339 10-372 30-13 10-307 10-340 10-373 30-14 10-308 10-341 10-374 30-15 10-309 10-342 10-375 30-16 10-310 10-343...
  • Page 21 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-42 30-75 30-108 30-141 30-43 30-76 30-109 30-142 30-44 30-77 30-110 30-143 30-45 30-78 30-111 30-144 30-46 30-79 30-112 30-145 30-47 30-80 30-113 30-146 30-48 30-81 30-114 30-147 30-49 30-82 30-115 30-148 30-50 30-83...
  • Page 22 FOREWORD Mark Page Mark Page Mark Page Mark Page 30-174 30-207 40-27 40-60 30-175 30-208 40-28 40-61 30-176 30-209 40-29 40-62 30-177 30-210 40-30 40-63 30-178 30-211 40-31 40-64 30-179 30-212 40-32 40-65 30-180 40-33 40-66 30-181 40-1 40-34 40-67 30-182 40-2 40-35...
  • Page 23 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-93 40-126 40-159 40-192 40-94 40-127 40-160 40-193 40-95 40-128 40-161 40-194 40-96 40-129 40-162 40-195 40-97 40-130 40-163 40-196 40-98 40-131 40-164 40-197 40-99 40-132 40-165 40-198 40-100 40-133 40-166 40-199 40-101 40-134...
  • Page 24 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-225 40-258 40-291 40-324 40-226 40-259 40-292 40-325 40-227 40-260 40-293 40-326 40-228 40-261 40-294 40-327 40-229 40-262 40-295 40-328 40-230 40-263 40-296 40-329 40-231 40-264 40-297 40-330 40-232 40-265 40-298 40-331 40-233 40-266...
  • Page 25 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-357 40-390 40-423 40-456 40-358 40-391 40-424 40-457 40-359 40-392 40-425 40-458 40-360 40-393 40-426 40-459 40-361 40-394 40-427 40-460 40-362 40-395 40-428 40-461 40-363 40-396 40-429 40-462 40-364 40-397 40-430 40-463 40-365 40-398...
  • Page 26 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-489 40-522 40-555 40-588 40-490 40-523 40-556 40-589 40-491 40-524 40-557 40-590 40-492 40-525 40-558 40-591 40-493 40-526 40-559 40-592 40-494 40-527 40-560 40-593 40-495 40-528 40-561 40-594 40-496 40-529 40-562 40-595 40-497 40-530...
  • Page 27 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-621 40-654 40-687 40-720 40-622 40-655 40-688 40-721 40-623 40-656 40-689 40-722 40-624 40-657 40-690 40-723 40-625 40-658 40-691 40-724 40-626 40-659 40-692 40-725 40-627 40-660 40-693 40-726 40-628 40-661 40-694 40-727 40-629 40-662...
  • Page 28 FOREWORD Mark Page Mark Page Mark Page Mark Page 40-753 50-21 50-54 50-87 40-754 50-22 50-55 50-88 40-755 50-23 50-56 50-89 40-756 50-24 50-57 50-90 40-757 50-25 50-58 50-91 40-758 50-26 50-59 50-92 40-759 50-27 50-60 50-93 40-760 50-28 50-61 50-94 40-761 50-29...
  • Page 29 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-120 50-153 50-186 50-219 50-121 50-154 50-187 50-220 50-122 50-155 50-188 50-221 50-123 50-156 50-189 50-222 50-124 50-157 50-190 50-223 50-125 50-158 50-191 50-224 50-126 50-159 50-192 50-225 50-127 50-160 50-193 50-226 50-128 50-161...
  • Page 30 FOREWORD Mark Page Mark Page Mark Page Mark Page 50-252 50-285 50-318 50-351 50-253 50-286 50-319 50-352 50-254 50-287 50-320 50-353 50-255 50-288 50-321 50-354 50-256 50-289 50-322 50-355 50-257 50-290 50-323 50-356 50-258 50-291 50-324 50-357 50-259 50-292 50-325 50-358 50-260 50-293...
  • Page 31 FOREWORD Mark Page Mark Page Mark Page Mark Page 90-200 33 90-200 1 90-200 34 90-200 2 90-200 35 90-200 3 90-200 36 90-200 4 90-200 5 90-200 6 90-200 7 90-200 8 90-200 9 90-200 10 90-200 11 90-200 12 90-200 13 90-200 14 90-200 15...
  • Page 32 FOREWORD Mark Page Mark Page Mark Page Mark Page 00-2-30 WA470/480-6...

  • Page 33: Important Safety Notice

    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 34 FOREWORD SAFETY Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 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.
  • Page 35 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 36 FOREWORD HOW TO READ THE SHOP MANUAL HOW TO READ THE SHOP MANUAL Volumes Revisions Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES They are divided as follows: between the title page and SAFETY page.

  • Page 37: Hoisting Instructions

    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 38 FOREWORD MAINTENANCE STANDARD TERMINOLOGY MAINTENANCE STANDARD TERMINOLOGY The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. Standard size and tolerance • To be accurate, the finishing size of parts is a little different from one to another.
  • Page 39 FOREWORD MAINTENANCE STANDARD TERMINOLOGY Standard clearance and standard value • The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. • When some parts are repaired, the clearance is generally adjusted to the standard clearance. •...
  • Page 40 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs.
  • Page 41 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS C. Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
  • Page 42 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors A. Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart.
  • Page 43 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Connecting connectors A. Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector.
  • Page 44 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Heavy duty wire connector (DT 8-pole, 12-pole) • Disconnection • Connection (example of incomplete setting of (a)) Disconnection (Left figure) While pressing both sides of locks (a) and (b), pull out female con- nector (2).
  • Page 45 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness.
  • Page 46 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Handling controller A. The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. B. Do not place objects on top of the controller. C.
  • Page 47 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
  • Page 48 FOREWORD HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out.
  • Page 49 FOREWORD PUSH PULL COUPLER PUSH PULL COUPLER WARNING! Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pres- sure 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 50 FOREWORD PUSH PULL COUPLER Type 2 Disconnection Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end. Hold in the condition in Step 1, and turn the lever (4) to the right - clockwise.
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

Wa480-6Wa470-6A45999A47001A47999