PDF Service Repair Manual Komatsu GALEO WA150-5 Wheel Loader - 4 MB
This is the complete service and repair manual for the Komatsu GALEO WA150-5 Wheel Loader, specifically for serial numbers H50051 and up.
It offers comprehensive, step-by-step instructions for every aspect of machine repair, from the engine to the hydraulic systems.
Technicians rely on this manual for detailed specifications, troubleshooting charts, and assembly procedures.
It is the definitive guide for maintaining and repairing your WA150-5.
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--- Page 1 ---
VEBM934100
Shop
Manual
WA150-5
WHEEL LOADER
SERIAL NUMBERS WA150-5 H50051 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 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, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
Copyright 2007 Komatsu
Printed in U.S.A.
Komatsu America Corp.
April 2007
--- Page 3 ---
GENERAL SPECIFICATIONS
Machine model WA150-5H
Serial No. H50051 and up
Type Articulated steering
Steering
control
Control Hydraulic control
Work equipment and Steering pump
• Type Gear type
• Theoretical capacity cm³/rev 63.1
Hydraulic pump
Brake and cooling fan pump
• Type Gear type
• Theoretical capacity cm³/rev 10.5
Transfer lubrication pump
• Type Gear type
• Theoretical capacity cm³/rev 6.4
Type Reciprocating piston type
Steering cylinder
Cylinder inner diameter mm 55
Hydraulic system
Piston rod diameter mm 30
Stroke mm 375
Max. length between pins mm 1,020
Min. length between pins mm 645
Type Reciprocating piston type
Cylinder inner diameter mm 110
Lift cylinder
Cylinder
Piston rod diameter mm 60
Stroke mm 628
Max. length between pins mm 1,659
Min. length between pins mm 1,031
Type Reciprocating piston type
Bucket cylinder
Cylinder inner diameter mm 110
Piston rod diameter mm 55
Stroke mm 452
Max. length between pins mm 1,367
Min. length between pins mm 915
WA150-5H 01-5
--- Page 4 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Engine
2. Damper
3. HST pump
4. 3-gear pump unit
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
WA150-5H 10-5
--- Page 5 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CHARGE PUMP
HST CHARGE PUMP
1. Cover bolt Specifications
2. Pump gear
3. Key Gear pump
Type
4. Coupling (Inscribed type)
5. Drive shaft
6. Plate Theoretical capacity
19.6
7. Charge pump cover (cc/rev)
8. Crescent divider board
Function
Outline • The HST charge pump is connected to drive shaft
• The HST charge pump is built in the HST pump (5) of the HST pump and rotated by coupling (4).
and driven together with the HST pump to supply • The HST charge pump has pump gear (2) and
oil to the HST speed-related valve and low-pres- crescent divider board (8) in it and sucks and dis-
sure relief valve of the HST pump. charges the oil in the direction shown in the
• The HST charge pump sucks in oil from the hy- above figure.
draulic tank.
WA150-5H 10-15
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER
1. HST motor 1 8. Motor 1 gear (Number of teeth: 43)
2. Input shaft 9. Sun gear (Number of teeth: 27)
3. Transfer clutch 10. Parking brake
4. Carrier 11. Rear coupling
5. Ring gear (Number of teeth: 66) 12. Output gear (Number of teeth: 50)
6. Planetary gear (Number of teeth: 19) 13. Output shaft
7. Planetary shaft 14. Front coupling
WA150-5H 10-25
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLUTCH SOLENOID VALVE
CLUTCH SOLENOID VALVE
P: From HST charge pump Operation
A: To transfer clutch • When the current of the input signal is large, the
T: To drain port hydraulic oil of the transfer clutch is drained.
• As the current of the input signal is reduced, the
1. Clutch solenoid valve hydraulic pressure of the transfer clutch is height-
2. Plunger ened.
3. Coil • After the current of the input signal is reduced un-
4. Push pin til the hydraulic pressure of the transfer clutch
5. Spring reaches the hydraulic pressure sent from the
6. Spool HST charge pump, the hydraulic pressure of the
7. Body transfer clutch is kept at the hydraulic pressure
sent from the HST charge pump even if the cur-
rent of the input signal is reduced further.
WA150-5H 10-35
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
11 Plate thickness 3
± 0.02 2.9
3.1
+0.04
12 Disc thickness 2.5 2.45
-0.03
13 Washer thickness 2 ± 0.05 1.8
Clearance between disc and
14 0.20 – 0.6
plate (Total of both sides)
End play (one end ) of side Replace
15 0.13 – 0.36
gear in axial direction
Backlash between case and
16 0 – 0.5
plate
Backlash between side gear
17 0.13 – 0.32
and disc
Standard Tolerance Standard Clearance
Clearance between spider and size Shaft Hole clearance limit
18
differential pinion gear
-0.110 +0.05 0.110 –
22 —
-0.160 +0 0.210
WA150-5H 10-45
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING PIPING
STEERING PIPING
1. Steering cylinder (right)
2. Orbit-roll valve
3. Hydraulic oil tank
4. Priority valve
5. Work equipment and steering pump
6. Steering cylinder (left)
WA150-5H 10-55
--- Page 10 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE
• If the steering wheel is turned to the left, spool (3) 3. Steering wheel stopped
connected by the drive shaft of the steering col- W h e n t h e o p e r a t io n o f s t e e r i n g w h e e l is
umn turns to the left. stopped, the difference in rotation between the
At this time, since spool (3) and sleeve (5) are spool (3) and sleeve (5) is returned to the neutral
connected by centering spring (12), spool (3) condition by the reaction of centering spring
compresses centering spring. (12).
Accordingly, an angular displacement is made
between spool (3) and sleeve (5) by the com-
pression of centering spring (12).
Then, port A is connected to vertical groove B
first. Next, vertical groove B is connected to port
E, and then port E is connected to vertical
groove C, and vertical groove C is connected to
port G of the left steering circuit at last.
Orifice b of port J to vertical B and priority valve
is kept connected, but port K of sleeve (5) dis-
connects vertical groove M and port L gradually.
When port A is connected to vertical groove B,
port F of the right steering circuit is connected to
vertical groove D.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil from
the pump flows through port A to the vertical
groove B, and then flows to port E to rotate the
gerotor. The oil discharged from the gerotor flows
through port E, vertical groove C, and port G to
the head side of the left steering cylinder.
The hydraulic pressure in vertical groove M is
transmitted through orifice b to port J and used
as the pilot pressure of the priority valve.
The oil from the head side of the right steering
cylinder is drained through port F, vertical groove
D, and port H into the hydraulic tank.
WA150-5H 10-65
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
P1: From HST pump A: To rear brake
T1: To hydraulic tank PB: From accumulator (Front side)
T2: To steering pump (Suction side) B: To front brake
PA: From accumulator (Rear side)
1. Rod 5. Brake valve body (for rear)
2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between inching size Shaft Hole clearance limit
8
valve spool and body
-0.022 +0.033 0.020 –
22.4 0.096
-0.053 +0 0.086
Clearance between inching -0.022 +0.033 0.020 –
9 22.4 0.096
valve guide and body -0.053 +0 0.086
Clearance between inching -0.050 +0.050 0.050 –
10 12 0.157
valve spool and guide -0.093 +0 0.143
Standard size Repair limit
Replace
Free Installed Installed Free Installed
11 Inching valve control spring length length load length load
24.5 N 20.8 N
34.7 16.7 –
{2.5 kg} {2.1 kg}
12 Brake valve control spring 35.6 24.0 113 N – 96 N
{11.5 kg} {9.8 kg}
13 Inching valve return spring 50.0 49.5 19.6 N – 16.7 N
{2.0 kg} {1.7 kg}
14 Brake valve return spring 114.9 52.4 147 N – 125 N
{15.0 kg} {12.7 kg}
WA150-5H 10-75
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
A: From brake valve
B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance
Clearance between piston and size Shaft Hole clearance limit
4
body
-0.065 +0.052 0.065 –
30 0.163
-0.098 +0 0.150
Clearance between check -0.013 +0.015 0.013 –
5 10 0.048
valve and body -0.028 +0 0.043
Replace
Standard size Repair limit
Free Installed Installed Free Installed
6 Piston return spring length length load length load
11.8 N 9.8 N
87.5 48.2 –
{1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25 –
{5.5 kg} {4.7 kg}
WA150-5H 10-85
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING
1. Work equipment control valve Outline
2. Bucket cylinder • The hydraulic system consists of the HST, steer-
3. Hydraulic tank ing, work equipment, brake, cooling fan, and
4. Work equipment PPC valve transfer lubricating circuit. Work equipment cir-
5. Lock valve cuit controls the operation of the lift arm and
6. Oil cooler bucket.
7. Cold relief valve • The oil in hydraulic tank (3) is sent by the work
8. 3-gear pump unit equipment pump of 3-gear pump unit (8) to work
• Work equipment and steering pump equipment control valve (1). If both spools of the
• Brake and cooling fan pump lift arm and bucket of work equipment control
• Transfer lubricating oil pump valve (1) are held, the oil flows through the drain
9. Accumulator (for PPC circuit) circuit of work equipment control valve (1) and is
10. Accumulator (for E.C.S.S.) (If equipped) filtrated by the return filter installed to hydraulic
11. Lift cylinder tank (3) and returns to hydraulic tank (3).
12. E.C.S.S. valve (If equipped) • If the work equipment control lever is operated,
the spool of the lift arm or bucket of work equip-
ment PPC valve (4) operates.
• The oil from the PPC valve hydraulically operates
each spool of work equipment control valve (1)
and flows to lift cylinder (11) or bucket cylinder (2)
to move the lift arm or bucket.
• The maximum pressure in the hydraulic circuit is
controlled by the relief valve in work equipment
control valve (1). The bucket cylinder circuit has
a safety valve (safety-suction valve) to protect it-
self.
• Accumulator (for PPC circuit) (9) is installed to
the PPC pilot circuit so that the work equipment
can be lowered to the ground even if the engine
stops.
• Hydraulic tank (3) is pressurized, enclosed, and
equipped with a breather which has a relief valve
and which is also used as an oil filler cap. The
breather pressurizes the tank and prevents gen-
eration of negative pressure and cavitation.
WA150-5H 10-95
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
WA150-5H 10-105
--- Page 15 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
1. Main relief valve 5. Check valve
2. Service spool 6. Suction valve
3. Bucket spool 7. Safety-suction valve
4. Lift arm spool
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit
Free
length x Installed Installed Free Installed
Lift arm raise and bucket tilt
8 Outside length load length load
spool return spring
diameter
92.2 N 87.3 N Replace spring if
42.5 x 27.5 41 40.4
{9.4 kg} {8.9 kg} damaged or
Lift arm lower spool return 55.9 N 53 N deformed
9 58.9 x 26.3 57.3 56
spring {5.7 kg} {5.4 kg}
110.8 N 105 N
10 Lift arm float spool return spring 53.4 x 12 38.5 50.7
{11.3 kg} {10.7 kg}
Bucket dump spool return 72.5 N 68.6 N
11 42 x 27.5 41 39.9
spring {7.4 kg} {7 kg}
WA150-5H 10-113
--- Page 16 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
WORK EQUIPMENT PPC VALVE
a Do not disassemble. If it is disassembled, its set pressure must be adjusted.
Mono-lever type
P: From HST charging pump
T: To hydraulic tank
P1: To bucket TILT valve
P2: To bucket DUMP valve
P3: To lift arm RAISE valve
P4: To lift arm LOWER (FLOAT) valve
WA150-5H 10-123
--- Page 17 ---
BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
1. Bucket positioner proximity switch 4. Bucket cylinder
2. Boom kick-out proximity switch (If equipped) 5. Boom
3. Plate 6. Plate (If equipped)
Unit: mm
No. Check item Criteria Remedy
7 Clearance of bucket positioner 3–5
proximity switch
Adjust
8 Clearance of boom kick-out prox- 3–5
imity switch
WA150-5H 10-133
--- Page 19 ---
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIST OF ITEMS DISPLAYED ON MONITOR
Operation
Engine is stopped Engine is running
Centralized warning
Centralized warning
Individual indication
Individual indication
Indication of failure
Indication of failure
Warning buzzer
Warning buzzer
Condition for Indication
code message
code message
Division No. Item Device Remarks
operation color
Backup Bulb for night When clear-
– Backup lamp ance lamp is – – – – – – – – Orange
lamp light ON
Q Q
Indication of km/h or MPH
Unit 9 LED – – – – – – Green (Selected by setting
meter monitor)
Conversion of If there is error in
Pointer: travel speed communication, con-
5 Travel speed Movement pulse into – – – – – – – – – dition is held until key
travel speed is turned OFF.
Other than
below – – – – – – – – –
w Q Q w Q Q
HST oil tem- Pointer:
1 perature/HST Movement Alarm: Above B@CRNS B@CRNS Red White range: 50 - 110°C
110°C
2 oil tempera- Indicator: Red range: 110 - 135°C
ture caution LED HST oil tem-
perature: – – – DGH1KX – – – DGH1KX –
Above 150°C
Other than – – – – – – – – –
below
Engine water Pointer: Alarm: Above
102°C
– Q – – – Q – – Red
w Q Q w Q Q
3 temperature/ Movement White range: 50 - 102°C