CEBM009605
WHEEL LOADER
SERIAL NUMBERS
and UP
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.
September 2005 Printed in USA
Copyright 2005 Komatsu DataKom Publishing Division 00-1
FOREWORD 12
CONTENTS
CONTENTS
00
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10
STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20
TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
90
OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
WA450-5L WA480-5L
FOREWORD The affected pages are indicated by using the following marks. It is requested that necessary actions be taken to these pages according to the table below.
Mark
( ) Mark
Page
Rev
Mark
Page
Rev
Mark
Indication
Action
New page to be added
Add
Page to be replaced
Replace
Page to be deleted
Discard
Page
Rev
Mark
Page
00-1
00-18
10-15
10-44
00-2
00-19
10-16
10-45
00-2-1
00-20
10-17
10-46
00-2-2
00-21
10-18
10-47
00-2-3
00-22
10-19
10-48
10-20
10-49
00-2-4 00-2-5
01-1
10-21
10-50
00-2-6
01-2
10-22
10-51
00-2-7
01-3
10-23
10-52
00-2-8
01-4
10-24
10-53
00-2-9
01-5
10-25
10-54
00-2-10
01-6
10-26
10-55
00-2-11
01-7
10-27
10-56
00-2-12
01-8
10-28
10-57
10-29
10-58
00-3 00-4
10-1
10-30
10-59
00-5
10-2
10-31
10-60
00-6
10-3
10-32
10-61
00-7
10-4
10-33
10-62
00-8
10-5
10-34
10-63
00-9
10-6
10-35
10-64
00-10
10-7
10-36
10-65
00-11
10-8
10-37
10-66
00-12
10-9
10-38
10-67
00-13
10-10
10-39
10-68
00-14
10-11
10-40
10-69
00-15
10-12
10-41
10-70
00-16
10-13
10-42
10-71
00-17
10-14
10-43
10-72
WA450-5L WA480-5L
WA450-5L WA480-5L
Rev
00-2-1
FOREWORD Mark
00-2-2
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
10-147
10-180
10-82
10-115
10-148
10-181
10-83
10-116
10-149
10-182
10-84
10-117
10-150
10-183
10-85
10-118
10-151
10-184
10-86
10-119
10-152
10-185
10-87
10-120
10-153
10-186
10-88
10-121
10-154
10-187
10-89
10-122
10-155
10-188
10-90
10-123
10-156
10-189
10-91
10-124
10-157
10-190
10-92
10-125
10-158
10-191
10-93
10-126
10-159
10-192
10-94
10-127
10-160
10-193
10-95
10-128
10-161
10-194
10-96
10-129
10-162
10-195
10-97
10-130
10-163
10-196
10-98
10-131
10-164
10-197
10-99
10-132
10-165
10-198
10-100
10-133
10-166
10-199
10-101
10-134
10-167
10-200
10-102
10-135
10-168
10-201
10-103
10-136
10-169
10-202
10-104
10-137
10-170
10-203
10-105
10-138
10-171
10-204
Rev
WA450-5L WA480-5L
FOREWORD Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
10-279
10-312
10-214
10-247
10-280
10-313
10-215
10-248
10-281
10-314
10-216
10-249
10-282
10-315
10-217
10-250
10-283
10-316
10-218
10-251
10-284
10-317
10-219
10-252
10-285
10-318
10-220
10-253
10-286
10-319
10-221
10-254
10-287
10-320
10-222
10-255
10-288
10-321
10-223
10-256
10-289
10-322
10-224
10-257
10-290
10-323
10-225
10-258
10-291
10-324
10-226
10-259
10-292
10-325
10-227
10-260
10-293
10-326
10-228
10-261
10-294
10-327
10-229
10-262
10-295
10-328
10-230
10-263
10-296
10-329
10-231
10-264
10-297
10-330
10-232
10-265
10-298
10-331
10-233
10-266
10-299
10-332
10-234
10-267
10-300
10-333
10-235
10-268
10-301
10-334
10-236
10-269
10-302
10-335
10-237
10-270
10-303
10-336
WA450-5L WA480-5L
00-2-3
FOREWORD Mark
00-2-4
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
10-342
20-14
20-47
20-202
10-343
20-15
20-48
20-203
10-344
20-16
20-49
20-204
10-345
20-17
20-50
20-205
10-346
20-18
20-51
20-206
10-347
20-19
20-52
20-207
10-348
20-20
20-53
20-208
10-349
20-21
20-54
20-209
10-350
20-22
20-55
20-210
10-351
20-23
20-56
20-211
10-352
20-24
20-57
20-212
10-353
20-25
20-58
20-213
10-354
20-26
20-59
20-214
10-355
20-27
20-60
20-215
10-356
20-28
20-61
20-216
10-357
20-29
20-62
20-217
10-358
20-30
10-359
20-31
20-101
20-219
10-360
20-32
20-102
20-220
20-33
20-103
20-221
20-1
20-34
20-104
20-222
20-2
20-35
20-105
20-223
20-3
20-36
20-106
20-224
20-4
20-37
20-107
20-225
20-5
20-38
20-108
20-226
20-6
20-39
20-109
20-227
20-7
20-40
20-110
20-228
20-8
20-41
20-111
20-229
Rev
20-218
WA450-5L WA480-5L
This is the sample of the manual Click on the download link for complete manual
Download Link
FOREWORD Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
20-234
20-267
20-331
20-364
20-235
20-268
20-332
20-365
20-333
20-366
20-236 20-237
20-301
20-334
20-367
20-238
20-302
20-335
20-368
20-239
20-303
20-336
20-369
20-240
20-304
20-337
20-370
20-241
20-305
20-338
20-371
20-242
20-306
20-339
20-372
20-243
20-307
20-340
20-373
20-244
20-308
20-341
20-374
20-245
20-309
20-342
20-375
20-246
20-310
20-343
20-376
20-247
20-311
20-344
20-377
20-248
20-312
20-345
20-378
20-249
20-313
20-346
20-250
20-314
20-347
20-401
20-251
20-315
20-348
20-402
20-252
20-316
20-349
20-403
20-253
20-317
20-350
20-404
20-254
20-318
20-351
20-405
20-255
20-319
20-352
20-406
20-256
20-320
20-353
20-407
20-257
20-321
20-354
20-408
20-258
20-322
20-355
20-409
20-259
20-323
20-356
20-410
20-260
20-324
20-357
20-411
20-261
20-325
20-358
20-412
20-262
20-326
20-359
20-413
WA450-5L WA480-5L
00-2-5
FOREWORD Mark
00-2-6
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
20-418
20-451
20-484
20-517
20-419
20-452
20-485
20-518
20-420
20-453
20-486
20-519
20-421
20-454
20-487
20-520
20-422
20-455
20-488
20-521
20-423
20-456
20-489
20-522
20-424
20-457
20-490
20-523
20-425
20-458
20-491
20-524
20-426
20-459
20-492
20-525
20-427
20-460
20-493
20-526
20-428
20-461
20-494
20-527
20-429
20-462
20-495
20-528
20-430
20-463
20-496
20-529
20-431
20-464
20-497
20-530
20-432
20-465
20-498
20-531
20-433
20-466
20-499
20-532
20-434
20-467
20-500
20-533
20-435
20-468
20-501
20-534
20-436
20-469
20-502
20-535
20-437
20-470
20-503
20-536
20-438
20-471
20-504
20-537
20-439
20-472
20-505
20-538
20-440
20-473
20-506
20-539
20-441
20-474
20-507
20-540
20-442
20-475
20-508
20-541
20-443
20-476
20-509
20-542
20-444
20-477
20-510
20-543
20-445
20-478
20-511
20-544
20-446
20-479
20-512
20-545
Rev
WA450-5L WA480-5L
FOREWORD Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
20-550
20-622
20-655
20-688
20-551
20-623
20-656
20-689
20-552
20-624
20-657
20-690
20-553
20-625
20-658
20-691
20-554
20-626
20-659
20-692
20-555
20-627
20-660
20-693
20-556
20-628
20-661
20-694
20-557
20-629
20-662
20-695
20-558
20-630
20-663
20-696
20-559
20-631
20-664
20-697
20-560
20-632
20-665
20-698
20-633
20-666
20-699
20-601
20-634
20-667
20-700
20-602
20-635
20-668
20-701
20-603
20-636
20-669
20-702
20-604
20-637
20-670
20-703
20-605
20-638
20-671
20-704
20-606
20-639
20-672
20-705
20-607
20-640
20-673
20-706
20-608
20-641
20-674
20-707
20-609
20-642
20-675
20-708
20-610
20-643
20-676
20-709
20-611
20-644
20-677
20-710
20-612
20-645
20-678
20-711
20-613
20-646
20-679
20-712
20-614
20-647
20-680
20-713
20-615
20-648
20-681
20-714
20-616
20-649
20-682
20-715
20-617
20-650
20-683
20-716
WA450-5L WA480-5L
00-2-7
FOREWORD Mark
Page
Rev
Mark
Page
Mark
Page
Rev
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
20-721
20-754
20-812
20-845
20-722
20-755
20-813
20-846
20-723
20-756
20-814
20-847
20-724
20-757
20-815
20-848
20-725
20-758
20-816
20-849
20-726
20-759
20-817
20-850
20-727
20-760
20-818
20-851
20-728
20-761
20-819
20-852
20-729
20-762
20-820
20-853
20-730
20-763
20-821
20-854
20-731
20-764
20-822
20-855
20-732
20-765
20-823
20-856
20-733
20-766
20-824
20-857
20-734
20-767
20-825
20-858
20-735
20-768
20-826
20-859
20-736
20-769
20-827
20-860
20-737
20-770
20-828
20-861
20-738
20-771
20-829
20-862
20-739
20-772
20-830
20-863
20-740
20-773
20-831
20-864
20-741
20-774
20-832
20-865
20-833
20-866
20-742
00-2-8
Rev
20-743
20-801
20-834
20-867
20-744
20-802
20-835
20-868
20-745
20-803
20-836
20-869
20-746
20-804
20-837
20-870
20-747
20-805
20-838
20-871
20-748
20-806
20-839
20-872
20-749
20-807
20-840
20-873
Rev
WA450-5L WA480-5L
FOREWORD Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
20-1011
20-879
20-912
( )
20-958
20-1012
20-880
20-913
( )
20-959
20-1013
20-881
20-914
( )
20-960
20-1014
20-882
20-915
( )
20-961
20-1015
20-883
20-916
( )
20-962
20-1016
20-884
20-917
( )
20-963
20-1017
20-885
20-918
( )
20-964
20-1018
20-886
20-919
( )
20-965
20-1019
20-887
20-920
( )
20-966
20-1020
20-888
20-921
( )
20-967
20-1021
20-889
20-922
( )
20-968
20-1022
20-890
20-923
( )
20-969
20-1023
20-891
20-924
( )
20-970
20-1024
20-892
20-925
( )
20-971
20-1025
20-893
20-926
( )
20-972
20-1026
20-894
20-927
( )
20-973
20-1027
20-895
20-928
( )
20-974
20-1028
20-896
20-929
( )
20-975
20-1029
20-897
20-930
( )
20-976
20-1030
20-898
20-931
( )
20-977
20-1031
20-899
20-932
( )
20-978
20-1032
20-900
20-933
20-901
20-934
20-1001
20-1034
20-902
20-935
20-1002
20-1035
20-903
20-936
20-1003
20-1036
20-1004
20-1037
20-904
20-1033
20-905
( )
20-951
20-1005
20-1038
20-906
( )
20-952
20-1006
20-1039
WA450-5L WA480-5L
00-2-9
FOREWORD Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
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
30-94
20-1047
30-29
30-62
30-95
20-1048
30-30
30-63
30-96
20-1049
30-31
30-64
30-97
20-1050
30-32
30-65
30-98
30-33
30-66
30-99
30-1
30-34
30-67
30-100
30-2
30-35
30-68
30-101
30-3
30-36
30-69
30-102
30-4
30-37
30-70
30-103
30-5
30-38
30-71
30-104
30-6
30-39
30-72
30-105
30-7
30-40
30-73
30-106
30-8
30-41
30-74
30-107
30-9
30-42
30-75
30-108
30-10
30-43
30-76
30-109
30-11
30-44
30-77
30-110
30-12
30-45
30-78
30-111
30-13
30-46
30-79
30-112
30-14
30-47
30-80
30-113
30-15
30-48
30-81
30-114
30-16
30-49
30-82
30-115
30-17
30-50
30-83
30-116
30-18
30-51
30-84
30-117
30-19
30-52
30-85
30-118
30-20
30-53
30-86
30-119
30-21
30-54
30-87
30-120
00-2-10
Rev
WA450-5L WA480-5L
FOREWORD Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
30-121
30-154
30-187
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
90-7
30-130
30-163
30-196
90-8
30-131
30-164
30-197
90-9
30-132
30-165
30-198
90-10
30-133
30-166
30-199
90-11
30-134
30-167
30-200
90-12
30-135
30-168
30-201
90-13
30-136
30-169
30-202
90-14
30-137
30-170
30-203
90-15
30-138
30-171
30-204
90-16
30-139
30-172
30-205
90-17
30-140
30-173
30-206
90-18
30-141
30-174
30-207
90-19
30-142
30-175
30-208
90-20
30-143
30-176
30-209
90-21
30-144
30-177
30-210
90-22
30-145
30-178
30-211
90-23
30-146
30-179
30-212
90-24
30-147
30-180
30-213
90-25
30-148
30-181
30-214
90-26
30-149
30-182
30-215
30-150
30-183
30-216
30-151
30-184
30-217
30-152
30-185
30-218
30-153
30-186
30-219
WA450-5L WA480-5L
Rev
30-220
00-2-11
FOREWORD Mark
Page
00-2-12
Rev
Mark
Page
Rev
Mark
Page
Rev
Mark
Page
Rev
WA450-5L WA480-5L
FOREWORD
SAFETY
12 SAFETY
SAFETY NOTICE
00
00
IMPORTANT SAFETY NOTICE
00
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. To prevent injury to workers, the symbols are used to mark safety precautions 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.
GENERAL PRECAUTIONS
00
PREPARATIONS FOR WORK
00
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
1.
Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1.
Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.
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.
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.
3.
When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
4.
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.
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 operating 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.
WA450-5L WA480-5L
PRECAUTIONS DURING WORK
00
1.
When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
2.
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 carrying out any work on the oil or water circuits.
3.
Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
00-3
This is the sample of the manual Click on the download link for complete manual
Download Link