Komatsu Wheel Loader WA450-5L WA480-5L Galeo service & repair manual

Description Komatsu Wheel Loader WA450-5L WA480-5L Galeo service & repair manual

Komatsu Wheel Loader WA450-5L, WA480-5L Galeo pdf workshop service repair manual + operation & maintenance manual

Serial number WA450-5L A36001 and up, WA480-5L A37001 and up

MANUAL CONTENT:
GENERAL
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS

STRUCTURE AND FUNCTION
RADIATOR AND OIL COOLER
SPECIFICATIONS
ENGINE AND TRANSMISSION MOUNT
POWER TRAIN
OUTLINE
POWER TRAIN SYSTEM DIAGRAM
WITHOUT TORQUE CONVERTER LOCK UP CLUTCH
WITH TORQUE CONVERTER LOCK UP CLUTCH
DRIVE SHAFT
DRIVE TRAIN PIPING
TORQUE CONVERTER
WITHOUT LOCK UP CLUTCH
SPECIFICATIONS
PATH OF POWER TRANSMISSION
WITH LOCK UP CLUTCH
SPECIFICATIONS
PATH OF POWER TRANSMISSION
TRANSMISSION
OUTLINE
CLUTCH AND REDUCTION GEAR RATIO TABLE
F & R CLUTCH WITHOUT LOCK UP CLUTCH
F & R CLUTCH WITH LOCK UP CLUTCH
1ST & 4TH CLUTCH
2ND & 3RD CLUTCH
OPERATION OF CLUTCH
CLUTCH ENGAGED
CLUTCH DISENGAGED
FORWARD 1ST
FORWARD 2ND
FORWARD 3RD
FORWARD 4TH
REVERSE 1ST
TRANSMISSION CONTROL VALVE
WITHOUT LOCK UP CLUTCH
ECMV ACTUATION TABLE
WITH LOCK UP CLUTCH
ECMV ACTUATION TABLE
ECMV - ELECTRONIC CONTROL MODULATION VALVE
ECMV FOR SPEED CLUTCH
ECMV FOR LOCK UP CLUTCH
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
FLOW VALVE
AXLES
FRONT AXLE
REAR AXLE
AXLE MOUNTING
FRONT AXLE
REAR AXLE
DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL
WA450-5L FRONT
WA480-5L FRONT AND REAR
WA450-5L REAR
TRAVELING IN A STRAIGHT LINE
WHEN TURNING
STANDARD DIFFERNTIAL
FRONT DIFFERENTIAL
REAR DIFFERENTIAL
TRAVELING IN A STRAIGHT LINE
TURNING
FINAL DRIVE
CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN
STEERING VALVE
OVERLOAD RELIEF VALVE
STEERING RELIEF VALVE
OPERATION OF STEERING RELIEF VALVE
OPERATION OF DEMAND VALVE
FLOW AMP
OPERATION OF STEERING VALVE
NEUTRAL
TURNING RIGHT
TURNING LEFT
ORBITROL VALVE
CONNECTION BETWEEN HAND PUMP AND SLEEVE
STOP VALVE
STEERING AND SWITCH PUMP
AUXILIARY STEERING PUMP
AUXILIARY STEERING MOTOR
STEERING CYLINDER
MOUNTING
CYLINDER
JOYSTICK STEERING LEVER
LEVER CONNECTIONS
STEERING SWITCH VALVE
STEERING LEVER VALVE
BRAKE SYSTEM
PIPING
BRAKE VALVE
LEFT PEDAL AND VALVE
RIGHT PEDAL AND VALVE
CHARGE VALVE
ACCUMULATOR
BETWEEN CHARGE VALVE AND BRAKE VALVE
BETWEEN BRAKE VALVE AND BRAKE CYLINDER
SLACK ADJUSTER
BRAKES
FRONT
REAR
PARKING BRAKE
CONTROLS
BRAKE PORTION
SOLENOID VALVE
PARKING BRAKE APPLIED
PARKING BRAKE RELEASED
RELEASE VALVE
HYDRAULIC PIPING
WORK EQUIPMENT CONTROL
FOR PPC VALVE
FOR EPC VALVE
HYDRAULIC TANK
SPECIFICATIONS
BREATHER
SPECIFICATIONS
PREVENTION OF NEGATIVE PRESSU
PREVENTION OF PRESSURE RISE IN TANK
CONVERTER, EQUIPMENT AND PPC PUMPS
SAL
PPC RELIEF VALVE
ECSS VALVE
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM
TRAVEL DAMPER
EQUIPMENT CONTROL VALVE
2 SPOOL VALVE
3 SPOOL VALVE
RELIEF VALVE
SAFETY SUCTION VALVE
SUCTION VALVE
SAFETY SUCTION VALVE
CUT OFF VALVE
CUT OFF VALVE OPERATION
FLOAT SELECTOR AND UNLOAD VALVE
BOOM AND BUCKET

TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
ENGINE COMPONENTS
MEASURING EXHAUST SMOKE
MEASURING EXHAUST TEMPERATURE
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING CRANCASE PRESSURE
MEASURING ENGINE OIL PRESSURE
MEASURING BOOST PRESSURE
MEASURING FUEL PRESSURE .
ADJUSTING ENGINE SPEED SENSOR
BLEEDING AIR FROM FUEL SYSTEM
MEASURING ENGINE SPEED
ADJUSTING ACCELERATOR PEDAL
POTENTIOMETER
MICROSWITCH
ADJUSTING TRANSMISSION SPEED SENSOR
POWER TRAIN OIL PRESSURE
FLUSHING
TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT
TRANSMISSION VALVE FAILS
MOVING MACHINE
STEERING CONTROL
STEERING OIL PRESSURE
BRAKE SYSTEM
MEASURING BRAKE OIL PRESSURE
TESTING WEAR OF WHEEL BRAKE DISC
BLEEDING AIR FROM BRAKE CIRCUIT
TESTING WEAR OF PARKING BRAKE DISC
MANUAL RELEASE METHOD FOR PARKING BRAKE
TESTING HYDRAULIC FAN
ACCUMULATOR CHARGE PRESSURE
PPC OIL PRESSURE
WORK EQUIPMENT HYDRAULIC PRESSURE
BUCKET POSITIONER
LIFT ARM KICK-OUT
PROXIMITY SWITCH ACTUATION
ADJUSTING MACHINE MONITOR
LOAD METER
LOAD METER CALIBRATION
NO LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTAL EXPLANATIONS)
LOAD ZERO POINT ADJUSTMENT (SUPPLEMENTARY EXPLANATIONS)
BLEEDING AIR
RELEASING REMAINING PRESSURE
IN HYDRAULIC CIRCUIT
IN TRAVEL DAMPER CIRCUIT
HANDLING CONTROLLER HIGH-VOLTAGE CIRCUIT
PM-CLINIC INSPECTION TABLE

DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
FUEL SUPPLY PUMP ASSEMBLY
SPECIAL TOOLS
SCHEMATIC DRAWINGS OF SPECIAL TOOLS
A1 Remover
A1 Block
A1 Bolt
CYLINDER HEAD ASSEMBLY
SPECIAL TOOL
RADIATOR ASSEMBLY
AIR AFTERCOOLER ASSEMBLY
COOLING FAN DRIVE MOTOR
ENGINE ASSEMBLY
STEERING, SWITCH, COOLING FAN PUMPS
TORQUE CONVERTER CHARGE, WORK EQUIPMENT AND PPC PUMP ASSEMBLY
TORQUE CONVERTER, TRANSMISSION ASSEMBLY
TORQUE CONVERTER ASSEMBLY (standard)
SPECIAL TOOLS
TORQUE CONVERTER ASSEMBLY (lock-up)
SPECIAL TOOLS
TRANSMISSION ASSEMBLY
TRANSMISSION CLUTCH PACK ASSEMBLY
SPECIAL TOOLS
Disassembly of forward-reverse clutch packs
Forward clutch
Reverse clutch
Disassembly of 1^st 4th speed clutch packs
1st speed clutch
4th speed clutch
Disassembly of 2^nd 3rd clutch packs
3rd clutch
2nd speed clutch
Assembly of forward-reverse clutch packs
Reverse clutch
Forward clutch
Assembly of 1^st 4th clutch packs
4th-speed clutch
1st-speed clutch
Assembly of 2^nd 3rd clutch packs
2nd-speed clutch
3rd-speed clutch
SCHEMATIC DIAGRAM OF SPECIAL TOOL
C2 Push tool
PARKING BRAKE ASSEMBLY
SPECIAL TOOLS
SCHEMATIC DRAWING OF SPECIAL TOOLS
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
AXLE HOUSING ASSEMBLY
SPECIAL TOOLS
SCHEMATIC DRAWING OF SPECIAL TOOLS
CENTER HINGE PIN
SPECIAL TOOLS
VALVE ASSEMBLY
TRAVEL DAMPER ASSEMBLY
PARKING BRAKE DISC
SPECIAL TOOLS
SCHEMATIC DRAWING OF SPECIAL TOOLS
Bracket
HYDRAULIC TANK
WORK EQUIPMENT VALVE ASSEMBLY
HYDRAULIC CYLINDER ASSEMBLY
SPECIAL TOOLS
WORK EQUIPMENT ASSEMBLY
COUNTERWEIGHT
FUEL TANK ASSEMBLY
CAB ASSEMBLY
CAB, FLOOR FRAME ASSEMBLY
AIR CONDITIONER UNIT ASSEMBLY

OTHERS
HYDRAULIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM

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