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Komatsu Galeo WA450-6, WA480-6 KA Spec. Wheel Loader Service Manual

1,597 pages · Publication SEN00809-04

$159.71
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Models
Galeo WA450-6, WA480-6 KA Spec.
Serial coverage
WA450-6 66001 and up, WA480-6 85001 and up
Manual type
Service Manual
Pages
1,597
Publication
SEN00809-04
Condition
Brand new
Komatsu Galeo WA450-6, WA480-6 KA Spec. Wheel Loader Service Manual, publication SEN00809-04

What's inside

From the manual's own table of contents: 261 sections, 543 entries. See sample pages (PDF, 1590 KB)

Composition of shop manual
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification and technical data
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine and cooling system
Engine mount and transmission mount
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train system diagram
Drive shaft
Power train piping diagram
Show all 261 sections
Torque converter
Transmission
Flow control valve
Transmission control valve
ECMV
Main relief valve and torque converter relief valve
Axle
Differential
Limited slip differential
Final drive
Steering system
Steering piping diagram
Steering column
Steering pump
Steering valve
Orbit-roll valve44 topics
  • Stop valve
  • Steering relief valve
  • Steering cylinder
  • Emergency steering motor
  • Emergency steering pump
  • Brake system
  • Brake piping diagram
  • Charge valve
  • Brake valve
  • Accumulator (for brake)
  • Slack adjuster
  • Brake
  • Parking brake control
  • Parking brake
  • Parking brake solenoid valve
  • Emergency parking brake release valve
  • Undercarriage and frame
  • Axle mount and center hinge pin
  • Tires
  • Hydraulic piping diagram
  • Work equipment control lever linkage
  • Hydraulic tank
  • Power train pump
  • Work equipment pump
  • Work equipment control valve
  • CLSS
  • Each function and operation of each valve
  • Hydraulic system, Part 2
  • PPC valve
  • Accumulator (for PPC circuit)
  • Accumulator (for ECSS)
  • Work equipment
  • Work equipment linkage
  • Bucket
  • Bucket positioner and boom kick-out
  • Work equipment cylinder
  • Cab and its attachments
  • Air conditioner
  • Electrical system, Part 1
  • Machine monitor system
  • Machine monitor
  • Electrical system, Part 2
  • Electrical system (Transmission controller system)
  • Transmission controller
Electrical system, Part 3
Electric transmission control
Combination switch
Kickdown switch and hold switch
KOMTRAX terminal system
Engine starting circuit
Engine stopping circuit
Preheating circuit
Engine power mode selector circuit
Engine output derating function
Automatic warm-up function
Parking brake circuit
Sensor
Standard service value table
Standard value table for engine
Standard value table for chassis
Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring exhaust gas color
Measuring exhaust temperature
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Measuring intake air (boost) pressure
Handling fuel system equipment
Releasing residual pressure in fuel system
Testing fuel pressure
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Handling controller voltage circuit
Testing and adjusting air conditioner compressor belt tension
Testing and adjusting alternator belt tension
Adjusting transmission speed sensor
Measuring directional lever
Measuring and adjusting power train oil pressure
Procedure for flushing torque converter and transmission hydraulic circuit
Method of moving machine when transmission valve is broken
Testing and adjusting steering stop valve
Testing and adjusting steering wheel
Testing steering oil pressure
Bleeding air from steering circuit
Testing and adjusting, Part 2
Testing hydraulic drive fan
Bleeding air from hydraulic drive fan circuit44 topics
  • Measuring brake pedal
  • Measuring brake performance
  • Testing and adjusting accumulator charge pressure
  • Testing wheel brake oil pressure
  • Measuring wear of wheel brake disc
  • Bleeding air from wheel brake circuit
  • Releasing residual pressure in brake accumulator circuit
  • Testing parking brake performance
  • Measuring parking brake oil pressure
  • Manual release method for parking brake
  • Measuring and adjusting work equipment control lever
  • Measuring and adjusting work equipment PPC oil pressure
  • Measuring and adjusting work equipment oil pressure
  • Bleeding air from work equipment circuit
  • Releasing residual pressure in work equipment circuit
  • Testing and adjusting bucket positioner
  • Testing and adjusting boom kick-out
  • Checking proximity switch operation pilot lamp
  • Procedure for testing diodes
  • Preparation work for troubleshooting for electrical system
  • Starting KOMTRAX terminal operations
  • Indicator lamps of KOMTRAX terminal
  • Adjusting machine monitor
  • Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
  • Testing and adjusting, Part 3
  • Special functions of machine monitor (EMMS)
  • Pm-cli ni c inspection table
  • Failure code table and fuse locations
  • Failure code table
  • Fuse locations
  • General information on troubleshooting
  • Points to remember when troubleshooting
  • Sequence of events in troubleshooting
  • Testing before troubleshooting
  • Classification and procedures of troubleshooting
  • Information contained in troubleshooting table
  • Connection table for connector pin numbers
  • T-branch box and T-branch adapter table
  • Troubleshooting by failure code (Display of code), Part 1
  • Failure code [1500L0] (TORQFLOW transmission: Double meshing)
  • Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON)
  • Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF)
  • Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON)
  • Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF)
Failure code [2F00MA] (Parking brake: Malfunction)
Failure code [2G43ZG] (Accumulator: Low oil pressure)
Failure code [44K0L4] (Bucket positioner: ON/OFF signals disagree)
Troubleshooting by failure code (Display of code), Part 2
Failure code [AA1ANX] (Air cleaner: Clogging)
Failure code [AB00L6] (Alternator: Signal disagrees with operating state of engine)
Failure code [AB00MA] (Alternator: Malfunction)
Failure code [B@BAZG] (Rotation derating by low engine oil pressure)
Failure code [B@BAZK] (Engine oil: Low level)
Failure code [B@BCNS] (Coolant: Overheating)
Failure code [B@BCZK] (Coolant: Low level)
Failure code [B@C7NS] (Brake oil: Overheating)
Failure code [b@CENS] (Torque converter oil: Overheating)
Failure code [B@HANS] (Hydraulic oil: Overheating)
Failure code [CA111] (Abnormality in engine controller)
Failure code [CA115] (Engine Ne or Bkup speed sensor error)
Failure code [CA122] (Charge pressure sensor high error)
Failure code [CA123] (Charge pressure sensor low error)
Failure code [CA131] (Throttle sensor high error)
Failure code [CA132] (Throttle sensor low error)
Failure code [CA135] (Engine oil pressure sensor high error)
Failure code [CA141] (Engine oil pressure sensor low error)
Failure code [CA144] (Coolant sensor high error)
Failure code [CA145] (Coolant sensor low error)
Failure code [CA153] (Charge temperature sensor high error)
Failure code [CA154] (Charge temperature sensor low error)
Failure code [CA187] (Sensor power supply 2 low error)
Failure code [CA221] (Atmospheric pressure sensor high error)
Failure code [CA222] (Atmospheric pressure sensor low error)
Failure code [CA227] (Sensor power supply 2 high error)
Failure code [CA234] (Engine overspeed)
Failure code [CA238] (Ne speed sensor power supply error)
Troubleshooting by failure code (Display of code), Part 3
Failure code [CA263] (Fuel temperature sensor high error)
Failure code [CA265] (Fuel temperature sensor low error)
Failure code [CA271] (PCV1 Short circuit)
Failure code [CA272] (PCV1 Disconnection)
Failure code [CA273] (PCV2 Short circuit)
Failure code [CA274] (PCV2 Disconnection)
Failure code [CA322] (Injector #1 (L/B #1) open/short error)
Failure code [CA323] (Injector #5 (L/B #5) open/short error)
Failure code [CA324] (Injector #3 (L/B #3) open/short error)
Failure code [CA325] (Injector #6 (L/B #6) open/short error)
Failure code [CA331] (Injector #2 (L/B #2) open/short error)
Failure code [CA332] (Injector #4 (L/B #4) open/short error)
Failure code [CA342] (Calibration code inconsistency)
Failure code [CA351] (Injectors drive circuit error)
Failure code [CA352] (Sensor power supply 1 low error)
Failure code [CA386] (Sensor power supply 1 high error)
Failure code [CA431] (Idle validation switch error)
Failure code [CA432] (Idle validation action error)
Failure code [CA441] (Battery voltage low error)
Failure code [CA442] (Battery voltage high error)52 topics
  • Failure code [CA449] Common rail pressure high error 2
  • Failure code [CA451] (Common rail pressure sensor high error)
  • Failure code [CA452] (Common rail pressure sensor low error)
  • Failure code [CA553] (Common rail pressure high error 1)
  • Failure code [CA554] (Common rail pressure sensor in-range error)
  • Failure code [CA559] (Supply pump pressure very low error)
  • Failure code [CA689] (Engine Ne speed sensor error)
  • Failure code [CA731] (Engine Bkup speed sensor phase error)
  • Failure code [CA757] (All continuous data lost error)
  • Failure code [CA778] (Engine Bkup speed sensor error)
  • Failure code [CA1228] (EGR valve servo error 1)
  • Failure code [CA1625] (EGR valve servo error 2)
  • Failure code [CA1633] (KOMNET datalink timeout error)
  • Failure code [CA2185] (Throttle sensor supply voltage high error)
  • Failure code [CA2186] (Throttle sensor power supply low error)
  • Troubleshooting by failure code (Display of code), Part 4
  • Failure code [CA2249] (Supply pump pressure very low error 2)
  • Failure code [CA2271] (EGR valve lift sensor high error)
  • Failure code [CA2272] (EGR valve lift sensor low error)
  • Failure code [CA2351] (EGR valve solenoid operation short circuit)
  • Failure code [CA2352] (EGR valve solenoid operation disconnect)
  • Failure code [CA2555] (Intake heater relay disconnection error)
  • Failure code [CA2556] (Intake heater relay short circuit error)
  • Failure code [D150KA] (Emergency steering relay: Disconnection)
  • Failure code [D150KB] (Emergency steering relay: Short circuit)
  • Failure code [D150KY] (Emergency steering relay: Short circuit with power supply line)
  • Failure code [D160KA] (Backup lamp relay: Disconnection)
  • Failure code [D160KB] (Backup lamp relay: Short circuit)
  • Failure code [D160KZ] (Backup lamp relay: Disconnection or short circuit)
  • Failure code [D191KA] (Joystick steering neutral safety relay: Disconnection)
  • Failure code [D191KB] (Joystick steering neutral safety relay: Short circuit)
    • (Joystick steering neutral safety relay: Short circuit with power supply line)
  • Failure code [D192KA] (ECSS solenoid: Disconnection)
  • Failure code [D192KB] (ECSS solenoid: Short circuit)
  • Failure code [D192KY] (ECSS solenoid: Short circuit with power supply line)
  • Failure code [D193KA] (Joystick steering solenoid cut relay: Disconnection)
  • Failure code [D193KB] (Joystick steering solenoid cut relay: Short circuit)
    • (Joystick steering solenoid cut relay: Short circuit with power supply line)
  • Failure code [D5ZHKA] (Terminal C signal: Disconnection)
  • Failure code [D5ZHKB] (Terminal C signal: Short circuit)
  • Failure code [D5ZHKZ] (Terminal C signal: Disconnection or short circuit)
    • (Terminal C signal: Signal does not match engine running or stopped state)
  • Failure code [DA80L4] (Auto grease controller: ON/OFF signals disagree)
  • Failure code [DAF3KK] (Machine monitor: Low source voltage (input))
  • Failure code [DAF5KP] (Machine monitor: Low output voltage)
    • Defective communication (Abnormality in target component system))
  • Troubleshooting by failure code (Display of code), Part 5
  • Failure code [DAQ0KK] (Transmission controller: Low source voltage)
  • Failure code [DAQ0KT] (Transmission controller: Abnormality in controller)
    • (Transmission controller load power supply line: Low source voltage (input))
  • (Transmission controller model selection: Disagreement of model selection signals)
  • Defective communication (Abnormality in target component system))
Failure code [DAQRMA] (Transmission controller option setting: Malfunction)1 topic
  • Defective communication (Abnormality in target component system)
Failure code [DB90KK] Work equipment controller: Low source voltage (input)
Failure code [DB90KT] Work equipment controller: Abnormality in controller2 topics
  • Work equipment controller load power supply line: Low source voltage (input)
  • Work equipment controller power supply output: Out of input signal range
Failure code [DB9RMA] (Work equipment controller option setting: Malfunction)1 topic
  • (CAN communication with transmission controller: Defective operation)
Failure code [DD15LD] t switch (Panel switch 1): Switch is kept pressed for long time
Failure code [DD16LD] U switch (Panel switch 2): Switch is kept pressed for long time
Failure code [DD17LD] < switch (Panel switch 3): Switch is kept pressed for long time
Failure code [DD18LD] > switch (Panel switch 4): Switch is kept pressed for long time2 topics
  • Remote positioner raise/lower set switch (raise): Switch is kept pressed for long time
  • Remote positioner raise/lower set switch (lower): Switch is kept pressed for long time
Failure code [DD1CLD] Load meter subtotal switch: Switch is kept pressed for long time3 topics
  • Load meter mode selector switch (A/B): Switch is kept pressed for long time
  • Load meter mode selector switch (+/–): Switch is kept pressed for long time
  • (Load meter display selector switch: Switch is kept pressed for long time)
Failure code [DD1NLD] (Fan reverse switch: Switch is kept pressed for long time)
Failure code [DDB6L4] (Parking brake switch (Neutralizer): ON/OFF signals disagree)1 topic
  • (Remote positioner bucket angle set switch: Switch is kept pressed for long time)
Troubleshooting by failure code (Display of code), Part 6
Failure code [DDE5MA] (Emergency steering drive switch: Malfunction)
Failure code [DDK3KA] (Right FNR switch: Disconnection)
Failure code [DDK4KA] (Joystick steering FNR switch: Disconnection)
Failure code [DDK5L4] (Joystick steering shift-up/down switch: ON/OFF signals disagree)
Failure code [DDK6KA] (FNR lever switch: Disconnection)
Failure code [DDK6KB] (FNR lever switch: Short circuit)
Failure code [DDT0L4] (Shift mode selector switch: ON/OFF signals disagree)
Failure code [DDW9LD] (Kick-down switch: Switch is kept pressed for long time)
Failure code [DDWLLD] (Hold switch: Switch is kept pressed for long time)
Failure code [DDY0LD] (Load meter cancel switch: Switch is kept pressed for long time)
Failure code [DF10KA] (Transmission shift lever switch: Disconnected)
Failure code [DF10KB] (Transmission shift lever switch: Short circuit)
Failure code [DGF1KA] (Transmission oil temperature sensor: Disconnected)
Failure code [DGF1KB] (Transmission oil temperature sensor: Short circuit)
Failure code [DGH2KX] (Hydraulic oil temperature sensor: Out of input signal range)39 topics
  • Failure code [DGR2KA] (Rear brake oil temperature sensor: Disconnected)
  • Failure code [DGR2KX] (Rear brake oil temperature sensor: Out of input signal range)
  • Troubleshooting by failure code (Display of code), Part 7
  • Failure code [DHT1KX] (Transmission cut-off pressure sensor: Out of input signal range)
  • Failure code [DHT8KA] (Steering pump pressure sensor: Disconnection)
  • Failure code [DHT8KB] (Steering pump pressure sensor: Short circuit)
  • Failure code [DK59KA] (Lift arm EPC lever potentiometer (Main): Disconnection)
    • (Lift arm EPC lever potentiometer (Main): Short circuit with power supply line)
  • Failure code [DK59L8] (Lift arm EPC lever potentiometer (Main): Analog signals disagree)
  • Failure code [DK5AKA] (Lift arm EPC lever potentiometer (Sub): Disconnection)
    • (Lift arm EPC lever potentiometer (Sub): Short circuit with power supply line)
  • Failure code [DK5BKA] (Bucket EPC lever potentiometer (Main): Disconnection)
    • (Bucket EPC lever potentiometer (Main): Short circuit with power supply line)
  • Failure code [DK5BL8] (Bucket EPC lever potentiometer (Main): Analog signals disagree)
  • Failure code [DK5CKA] (Bucket EPC lever potentiometer (Sub): Disconnection)
    • (Bucket EPC lever potentiometer (Sub): Short circuit with power supply line)
    • (3-spool valve (attachment) EPC lever potentiometer (Main): Disconnection)
    • Short circuit with power supply line)
    • (3-spool valve (attachment) EPC lever potentiometer (Main): Analog signals disagree)
    • (3-spool valve (attachment) EPC lever potentiometer (Sub): Disconnection)
    • (3-spool valve EPC lever potentiometer (Sub): Short circuit with power supply line)
  • Troubleshooting by failure code (Display of code), Part 8
  • Failure code [DK5FKA] (Joystick steering EPC lever potentiometer (Main): Disconnection)
    • (Joystick steering EPC lever potentiometer (Main): Short circuit with power supply line)
  • Failure code [DK5GKA] (Joystick steering EPC lever potentiometer (Sub): Disconnection)
    • (Joystick steering EPC lever potentiometer (Sub): Short circuit with power supply line)
    • (Joystick steering EPC lever potentiometer (Main): Analog signals disagree)
  • Failure code [DKA0KA] (Lift arm angle sensor: Disconnection)
  • Failure code [DKA0KY] (Lift arm angle sensor: Short circuit with power supply line)
  • Failure code [DKA0L0] (Lift arm angle sensor: Double meshing)
  • Failure code [DLT3KA] (Transmission output shaft speed sensor: Disconnection)
  • Failure code [DT20KB] (Transmission cut-off indicator lamp: Short circuit)
  • Failure code [DUM1KB] (Remote positioner raise set indicator lamp: Short circuit)
  • Failure code [DUM2KB] (Remote positioner lower set indicator lamp: Short circuit)
  • Failure code [DV00KB] (Alarm buzzer: Short circuit)
  • Failure code [DW4PKA] (Lift arm raise EPC solenoid: Disconnection)
  • Failure code [DW4PKB] (Lift arm raise EPC solenoid: Short circuit)
  • Failure code [DW4PKY] (Lift arm raise EPC solenoid: Short circuit with power supply line)
  • Failure code [DW4QKA] (Lift arm lower EPC solenoid: Disconnection)
Failure code [DW4QKB] (Lift arm lower EPC solenoid: Short circuit)
Failure code [DW4RKA] (Bucket tilt EPC solenoid: Disconnection)
Failure code [DW4RKB] (Bucket tilt EPC solenoid: Short circuit)
Failure code [DW4RKY] (Bucket tilt EPC solenoid: Short circuit with power supply line)
Troubleshooting by failure code (Display of code), Part 9
Failure code [DW4SKA] (Bucket dump EPC solenoid: Disconnection)
Failure code [DW4SKB] (Bucket dump EPC solenoid: Short circuit)
Failure code [DW4SKY] (Bucket dump EPC solenoid: Short circuit with power supply line)
Failure code [DW7BKA] (Fan reverse solenoid: Disconnection)
Failure code [DW7BKB] (Fan reverse solenoid: Short circuit)
Failure code [DW7BKY] (Fan reverse solenoid: Short circuit with power supply line)
Failure code [DW7DKA] (Hydraulic drive fan neutral solenoid: Disconnection)
Failure code [DW7DKB] (Hydraulic drive fan neutral solenoid: Short circuit)1 topic
  • (Hydraulic drive fan neutral solenoid: Short circuit with power supply line)
Failure code [DWM1KA] (Work equipment neutral lock solenoid: Disconnection)
Failure code [DWM1KB] (Work equipment neutral lock solenoid: Short circuit)1 topic
  • (Work equipment neutral lock solenoid: Short circuit with power supply line)
Failure code [DWN6KA] (Lift arm raise magnet detent solenoid: Disconnection)
Failure code [DWN6KB] (Lift arm raise magnet detent solenoid: Short circuit)1 topic
  • (Lift arm raise magnet detent solenoid: Short circuit with power supply line)
Failure code [DWN7KA] (Lift arm float magnet detent solenoid: Disconnection)
Failure code [DWN7KB] (Lift arm float magnet detent solenoid: Short circuit)1 topic
  • (Lift arm float magnet detent solenoid: Short circuit with power supply line)
Failure code [DWN8KA] (Bucket tilt magnet detent solenoid: Disconnection)
Failure code [DWN8KB] (Bucket tilt magnet detent solenoid: Short circuit)
Failure code [DX16KA] (Fan pump EPC solenoid: Disconnection)
Failure code [DX16KB] (Fan pump EPC solenoid: Short circuit)
Failure code [DX16KY] (Fan pump EPC solenoid: Short circuit with power supply line)
Failure code [DXH1KA] (Lockup ECMV solenoid: Disconnection)
Failure code [DXH1KB] (Lockup ECMV solenoid: Short circuit)
Failure code [DXH1KY] (Lockup ECMV solenoid: Short circuit with power supply line)
Failure code [DXH4KA] (1st clutch ECMV solenoid: Disconnection)
Failure code [DXH4KB] (1st clutch ECMV solenoid: Short circuit)
Failure code [DXH4KY] (1st clutch ECMV solenoid: Short circuit with power supply line)
Troubleshooting by failure code (Display of code), Part 10
Failure code [DXH5KA] (2nd clutch ECMV solenoid: Disconnection)
Failure code [DXH5KB] (2nd clutch ECMV solenoid: Short circuit)
Failure code [DXH5KY] (2nd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH6KA] (3rd clutch ECMV solenoid: Disconnection)
Failure code [DXH6KB] (3rd clutch ECMV solenoid: Short circuit)
Failure code [DXH6KY] (3rd clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH7KA] (R clutch ECMV solenoid: Disconnection)
Failure code [DXH7KB] (R clutch ECMV solenoid: Short circuit)
Failure code [DXH7KY] (R clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXH8KA] (F clutch ECMV solenoid: Disconnection)
Failure code [DXH8KB] (F clutch ECMV solenoid: Short circuit)
Failure code [DXH8KY] (F clutch ECMV solenoid: Short circuit with power supply line)
Failure code [DXHHKA] (4th clutch ECMV solenoid: Disconnection)
Failure code [DXHHKB] (4th clutch ECMV solenoid: Short circuit)48 topics
  • Failure code [DXHHKY] (4th clutch ECMV solenoid: Short circuit with power supply line)
  • Failure code [DXHJKA] (3-spool valve extend EPC solenoid: Disconnection)
  • Failure code [DXHJKB] (3-spool valve extend EPC solenoid: Short circuit)
    • (3-spool valve extend EPC solenoid: Short circuit with power supply line)
  • Failure code [DXHKKA] (3-spool valve retract EPC solenoid: Disconnection)
  • Failure code [DXHKKB] (3-spool valve retract EPC solenoid: Short circuit)
    • (3-spool valve retract EPC solenoid: Short circuit with power supply line)
  • Failure code [DXHLKA] (Joystick steering right EPC solenoid: Disconnection)
  • Failure code [DXHLKB] (Joystick steering right EPC solenoid: Short circuit)
    • (Joystick steering right EPC solenoid: Short circuit with power supply line)
  • Failure code [DXHMKA] (Joystick steering left EPC solenoid: Disconnection)
  • Failure code [DXHMKB] (Joystick steering left EPC solenoid: Short circuit)
    • (Joystick steering left EPC solenoid: Short circuit with power supply line)
  • Troubleshooting of electrical system (E-mode)
  • Before carrying out troubleshooting for electrical system
  • Information in troubleshooting table
  • Engine does not start
  • Wiper does not operate
  • Windshield washer does not operate
  • Headlamp, clearance lamp, tail lamp, and license lamp do not light up or go off
  • Working lamp does not light up or go off
  • Turn signal lamp and hazard lamp do not light up or go off
  • Brake lamp does not light or it keeps lighting up
  • Backup lamp does not light or it keeps lighting up
  • Backup buzzer does not sound or it keeps sounding
  • Horn does not sound or it keeps sounding
  • Alarm buzzer does not sound or it keeps sounding
  • Air conditioner does not operate or stop
  • The KOMTRAX system does not work properly
  • Troubleshooting of hydraulic and mechanical system (H-mode)
  • Method of using troubleshooting chart
  • Table of failure modes and causes
  • The machine does not start
    • [Machine with lockup clutch (if equipped)]
  • Torque converter lockup is not switched on [Machine with lockup clutch (if equipped)]
    • the uphill traveling power is weak, and the gear is not shifted
  • Shocks are large at the times of starting and shifting gear
  • Time lag is large at the times of starting and shifting gear
  • The torque converter oil temperature is high
  • Steering does not turn
  • Steering does not turn [Machine with joystick steering (if equipped)]
  • Steering response is low
  • Turning, response of steering is poor [machine with joystick steering (if equipped)]
  • Steering is heavy
  • When machine turns, it shakes or makes large shocks
    • [machine with joystick steering (if equipped)]
  • The wheel brake does not work or does not work well
  • The wheel brake is not released or it drags
The parking brake does not work or does not work well
The parking brake is not released or it drags (including emergency release system)
Lift arm does not rise
Lift arm speed is low or rising force of lift arm is insufficient
When rising, the lift arm comes to move slowly at specific height
The lift arm cylinder cannot hold down the bucket (Bucket floats)
Hydraulic drifts of the lift arm is large
The lift arm wobbles during operation
Bucket does not tilt back
Bucket speed is low or tilting back force is insufficient
The bucket comes to operate slowly in the midst of tilting-back
The bucket cylinder cannot hold down the bucket
Hydraulic drifts of the bucket is large1 topic
  • (The work equipment valve is set to “HOLD”)
Lift arm and bucket control levers do not move smoothly and are heavy
During operation of the machine, engine speed lowers remarkably or engine stalls
Large shock is made when work equipment starts and stops
When work equipment circuit is relieved singly, other work equipment moves
ECSS does not operate, and pitching, bouncing occur
Troubleshooting of engine (S-mode)
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operation
Engine does not rotate smoothly
Engine lacks output (or lacks power)
Exhaust smoke is black (Incomplete combustion)
Oil is consumed much (or exhaust gas color is blue)
Engine oil becomes contaminated quickly
Fuel consumption is excessive
Coolant contains oil (blows back or reduces)
Oil pressure drops
Oil level rises (Water, fuel in oil)
Coolant temperature rises too high (Overheating)
Abnormal noise is made
Vibration is excessive40 topics
  • General information on disassembly and assembly
  • How to read this manual
  • Coating materials list
  • Special tools list
  • Sketches of special tools
  • Removal and installation of engine assembly
  • Removal and installation of hood
  • Removal and installation of radiator assembly
  • Removal and installation of aftercooler assembly
  • Removal and installation of oil cooler assembly
  • Removal and installation of cooling fan and drive motor assembly
  • Removal and installation of fuel supply pump assembly
  • Removal and installation of fuel injector assembly
  • Removal and installation of cylinder head assembly
  • Removal and installation of fuel tank assembly
  • Power train, Part 1
  • Removal and installation of torque converter and transmission assembly
  • Disassembly and assembly of torque converter assembly (Standard specification)
  • Disassembly and assembly of torque converter assembly (Lockup specification)
  • Disassembly and assembly of transmission assembly
  • Disassembly and assembly of transmission clutch pack assembly
  • Disassembly and assembly of parking brake assembly
  • Power train, Part 2
  • Removal and installation of front axle assembly
  • Removal and installation of rear axle assembly
  • Disassembly and assembly of axle housing assembly
  • Disassembly and assembly of differential assembly
  • Removal and installation of center hinge pin
  • Removal and installation of counterweight
  • Hydraulic system
  • Removal and installation of steering demand valve assembly
  • Removal and installation of work equipment valve assembly
  • Removal and installation of brake charge valve assembly
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of steering and power train pump assembly
  • Removal and installation of work equipment and cooling fan pump assembly
  • Removal and installation of work equipment assembly
  • Removal and installation of operator's cab and floor frame assembly
  • Removal and installation of operator's cab glass (stuck glass)
  • Disassembly and assembly of operator's seat assembly
Electrical system
Removal and installation of air conditioner unit assembly
Removal and installation of engine controller assembly
Removal and installation of transmission controller assembly
Removal and installation of KOMTRAX controller assembly
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram (1/2)
Electrical circuit diagram (2/2)
Connector arrangement diagram

Inside this manual

Real pages from this service manual (1,597 pages). Open the sample pages (PDF, 1589 KB)

Sample pages from the Komatsu Galeo WA450-6, WA480-6 KA Spec. Wheel Loader Service Manual: Specifications, Diagram, Troubleshooting, Foldout diagram
  • Specifications, page 66: 01 Specification
  • Diagram, page 1,266: Circuit diagram related to brake lamp
  • Troubleshooting, page 1,338: S-6 Engine lacks output (or lacks power)
  • Foldout diagram, page 1,591: WA450-6, WA480-6 (KA SPEC.)

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 1,597 pages

Quantity one is the manual described above.

Fast free USA shipping

Ships in 1 business day.

60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Other editions and similar models

Komatsu WA450-6, WA480-6 with 6D125E-5 EngineService Manual · CEBM018601 · $169.83Komatsu WA450-6Operation & Maintenance Manual · CEAM018204 · $69.85Komatsu WA450-6Operation & Maintenance Manual · TEN00125-05 · $69.59Komatsu WA470-6, WA480-6Operation & Maintenance Manual · VEAM660104 · $69.53Komatsu WA480-6Operation & Maintenance Manual · CEAM009104 · $69.59Komatsu WA480-6Operation & Maintenance Manual · CEAM018404 · $69.97Komatsu WA480-6Operation & Maintenance Manual · CEAM023603 · $69.59Komatsu WA480-6Operation & Maintenance Manual · TEN00124-05 · $69.73

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).